belt MAZDA PROTEGE 1992 Manual Online

INDEX
ENGINE SPEED SENSING POWER STEERING (ESPS)
FLUID
ATF M STEERING WHEEL PLAY
O-30mm (O-l .18 in)
SPECIFICATION
-IIt or Dexron@lI
I T nFFl FCTIC-IN
--. --w. .-.. NEW: 8.0-9.0mm (0.31-0.35 in)
USED: 9.0-lO.Omm (0.35-0.39 in)
LIMIT: 11.5mm (0.45 in)
23UONX-00
1. Boot
4. Drive belt
Removal / installation
.................. page N- 6 Inspection ................................... page N-41
2. Steering gear and linkage Adjustment .................................
page N-42
Removal / Installation.. ................ page N-30 Replacement .............................. page N-42
Disassembly / Inspection.. ..........
page N-31 5. Power steering fluid
Assembly..
.................................. page N-34 Air bleeding ................................ page N-26
3. Power steering oil pump Inspection.. .................................
page N-27
Removal I Installation
.................. page N-37 6. Steering wheel and column
Disassembly / Inspection I Inspection (On-vehicle).
.............. page N-26
Assembly ..................................
page N-38 Removal / Installation..
................ page N- 9
Disassembly / Assembly ............. page
N-l 0
Inspection ................................... page N-l 1
N-3

N ENGINE SPEED SENSING POWER STEERING
19 1232 670A
Gauge set,
Dower steering
49 HO32 301
wrench
49 8032 304
Adapter
49 8032 307
Wrench, outer
box
49 8032 308
Remover body,
rod seal
49 8032 319
Protector body,
rod seal
49 9200 020
Tension gauge,
V-ribbed belt For
measurement of
fluid pressure
For
removal of
tie-rod
For
measurement of
fluid pressure
For
removal and
installation of
outer box
For
removal of oil
seal
For
installation of
inner guide 81 oil
seal
For
measurement of
drive belt tension 49 1232 673
Valve body
(Part of
49 1232 670A)
49 1232 672
Gauge
(Part of
49 1232 670A)
49 HO02 671
Adapter
49 8032 313
Protector, outer
box
49 8032 318
Guide, rod seal
49 0118 850C
Puller, ball joint
I
-
For
measurement of
fluid pressure
For
measurement of
fluid pressure
For
measurement of
fluid pressure
For
installation of
outer box
For
installation of
inner guide & oil
seal
For
removal of
tie rods end
23UONX-0.
N-24

ENGINE SPEED SENSING POWER STEERING
POWER STEERING OIL PUMP
N
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of remnvnl
. ..-.-..
d 2 19-25 (1.9-2.6, 14-19)
- Nm (m-kg, f&lb)
23UONX-043
1. Bolt
2. Nut
3. Nut
4. Adjusting bolt
5. Drive belt
Replacement .,....,.,.,,,,.,.....,..,,.... page N-42
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page N-42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page N-41 6. Pressure hose
7. Return hose
8. Bolts
9. P/S oil pump assembly
N-37

ENGINE SPEED SENSING POWER STEERING N
P/S
23UONX-04!
PULLEY
P/S AND A/C
23UONX-04
DRIVE BELT
Inspection
1. Check the drive belts for wear, cracks, and fraying. Replace
as necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
3. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
0 A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specification below accordingly.
* Check the belt deflection when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflection
mm (in)
New Used Limit
8-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39) 11.5 (0.45)
4. If the deflection is not within specification, adjust it.
23UONX-047
Drive belt tension check
WHEN SET
I
23UONX-048
Note
l Belt tension can be checked in place of belt
deflection.
aBelt tension can be measured between any two
pulleys.
Using the SST check the belt tension.
Tension
N (kg, lb)
New
491-589
(50-60, 11 O-l 32) Used
422-491
(43-50, 95-l 10) Limit
245
(25, 55)
N-41

N ENGINE SPEED SENSING POWER STEERING
13UONX-02
Adjustment
1. Loosen bolt @, nut @J, and locknut 0. Turn adjusting bolt
@? to adjust the belt to the specified tension.
2. Tighten locknut 0, bolt @, and nut @I to the specified
torques.
Tightening torque
Bolt @: 36-54 N-m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut @J : 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Locknut 0:
31-46 Narn (3.2-4.7 m-kg, 23-34 f&lb)
Replacement
1. Loosen bolt @, nut 0, and locknut @.
2. Turn adjusting bolt @ to release the belt tension.
3. Remove the belt.
4. Install a new drive belt and adjust the tension and deflec-
tion. (Refer to above for adjustment.)
N-42

S
BODY
INDEX ........................................................ 2
HOOD ........................................................
COMPONENTS ........................................ t
FRONT FENDER PANEL .............................. ;I
COMPONENTS ........................................ S- ::
FRONT DOOR ............................................. S- 8
COMPONENTS ........................................ S- 8
FRONT SIDE WINDOW REGULATOR AND
GLASS ..................................................... s- 10
COMPONENTS ........................................ s- 10
FRONT DOOR LOCK AND OPENER .............. S- 13
COMPONENTS ........................................ s- 13
REAR DOOR ............................................... s- 15
COMPONENTS ........................................ s- 15
REAR SIDE WINDOW REGULATOR AND
GLASS ..................................................... s- 17
COMPONENTS ........................................ s- 17
REAR DOOR LOCK AND OPENER ...........
.-. ...
S- 19
COMPONENTS ........................................ s- 19
REAR HATCH ............................................. s- 20
COMPONENTS ........................................ s- 20
REAR HATCH LOCK AND OPENER.. .............
S- 22
COMPONENTS ........................................ s- 22
POWER DOOR LOCK SYSTEM.. ................... S- 23
STRUCTURAL VIEW .................................. S- 23
TROUBLESHOOTING GUIDE ...................... S- 24
DOOR LOCK SWITCH ............................... S- 28
DOOR LOCK CONTROL ............................ S- 26
DOOR LOCK TIMER AND RELAY ............... S- 26
POWER WINDOW SYSTEM .......................... S- 27
STRUCTURAL VIEW .................................. S- 27
TROUBLESHOOTING GUIDE.. .................... S- 28
MAIN POWER WINDOW SWITCH.. .............. S- 31
POWER WINDOW SUB-SWITCH.. ................ S- 32
POWER WINDOW MOTOR ......................... S- 32
TRUNK LID .................................................
s- 33
COMPONENTS ........................................ s- 33
TRUNK LID LOCK AND OPENER.. ................ S- 35
COMPONENTS ........................................ s- 35
FUEL FILLER LID AND OPENER ................... S- 37
COMPONENTS ........................................ s- 37
FRONT BUMPER ......................................... s- 39
COMPONENTS ........................................ s- 39
REAR BUMPER ........................................... s- 40
COMPONENTS ........................................ s- 40
REAR SPOILER ........................................... s- 41
COMPONENTS ........................................ s- 41
MOLDING, PROTECTOR, GARNISH .............. S- 42
UPPER WINDSHIELD MOLDING,
A-PILLAR GARNISH ................................ S- 42
REAR WINDOW MOLDING (PROTEGE) ........ S- 43
REAR WINDOW MOLDING (HATCHBACK) ... S- 44
ROOF MOLDING ...................................... S- 46
BELTLINE MOLDING ................................ S- 48
SIDE PROTECTOR.. .................................. S- 49
RADIATOR GRILLE, LOWER GRILLE
MOLDING ................................................. s- 51
COMPONENTS ........................................ S- 51
REAR FINISHER.. ........................................
S- 52
COMPONENTS ........................................ S- 52
COWL GRILLE ............................................ s- 53
COMPONENTS ........................................ s- 53
EXTRACTOR CHAMBER ..............................
COMPONENTS ........................................ g-
- ;; OUTSIDE MIRROR ....................................... s- 54
TROUBLESHOOTING GUIDE.. .................... S- 54
POWER OUTSIDE MIRROR SWITCH ............ S- 55
POWER OUTSIDE MIRROR.. ...................... S- 56
COMPONENTS ........................................ s- 66
WINDSHIELD .............................................. S- 58
PREPARATION ......................................... S- 58
COMPONENTS ........................................ S- 58
QUARTER WINDOW GLASS ......................... S- 62
COMPONENTS .................. ..T ................... S- 82
REAR WINDOW GLASS ............................... S- 63
PREPARATION ......................................... S- 63
COMPONENTS ........................................ S- 63
WINDSHIELD WIPER AND WASHER ............. S- 87
TROUBLESHOOTING GUIDE.. .................... S- 67
WIPER MOTOR ........................................ s- 70
WASHER MOTOR ..................................... s- 71
WINDSHIELD WIPER AND WASHER
SWITCH ................................................ s- 71
COMPONENTS ........................................ S- 72
REAR WIPER AND WASHER ........................ S- 74
TROUBLESHOOTING GUIDE.. .................... S- 74
REAR WIPER MOTOR ............................... s- 77
REAR WASHER MOTOR ............................ s- 77
REAR WIPER AND WASHER SWITCH.. ........ S- 77
COMPONENTS ........................................ S- 78
SLIDING SUNROOF ..................................... S- 80
TROUBLESHOOTING GUIDE.. .................... S- 80
MOTOR ASSEMBLY .................................. S- 81
SUNROOF RELAY .................................... S- 82
SUNROOF SWITCH
(OVERHEAD CONSOLE) .......................... S- 82
COMPONENTS ........................................ S- 83
HEADLINER ................................................ S- 89
COMPONENTS ........................................ S- 89
DASHBOARD .............................................. s- 94
COMPONENTS ........................................ s- 94
TRIM .......................................................... s- 97
COMPONENTS ........................................ s- 97
FLOORMAT ................................................ s- 99
COMPONENTS ........................................ s- 99
SEAT BELT ................................................ S-l 00
COMPONENTS ........................................ S-l 00
SEAT BELT .............................................. S-l 02
BUCKLE SWITCH ..................................... s-102
PASSIVE SHOULDER BELT SYSTEM.. .......... S-103
STRUCTURAL VIEW .................................. s-103
TROUBLESHOOTING GUIDE.. .................... S-104
PASSIVE SHOULDER BELT MOTOR.. .......... S-106
DOOR CATCH SWITCH ............................. S-l 07
LIMIT SWITCH (FRONT/REAR)
WARNING SWITCH ....................................................... z-:X;
-
SPEED SENSOR ....................................... s-i 07
COMPONENTS ........................................ S-l 08
SEAT ......................................................... s-110
COMPONENTS ........................................ s-110
SEAT ASSEMBLY ..................................... S-l 13
UNDERBODY DIMENSIONS .............. ..: ......... S-116
PROJECTED DIMENSIONS (PROTEGE) ........ S-116
PROJECTED DIMENSIONS (HATCHBACK). .. S-117
STRAIGHT-LINE DIMENSIONS (PROTEGE). .. S-118
STRAIGHT-LINE DIMENSIONS
(HATCHBACK) ........................................ s-119
23UOSX.001

INDEX
NDEX
1. Hood
Components ............................... page S- 5
2. Front fender panel
Components ............................... page S- 7
3. Front door
Components ............................... page S- 8
4. Front side window regulator and glass
Components ............................... page S-l 0
5. Front door lock and opener
Components ............................... page S-l 3
6. Power door lock system
Structural view.. .......................... page S-23
Troubleshooting guide.. .............. page S-24
Door lock switch.. ....................... page S-26
Door lock control.. ...................... page S-26
Door lock timer and relay ........... page S-26
7. Power window system
Structural view ............................ page S-27
Troubleshooting guide.. .............. page S-28
Main power window switch.. ...... page S-31
Power window sub-switch .......... page S-32
Power window motor .................. page S-32
8. Fuel filler lid and opener
Components ............................... page S-37
9. Front bumper
Components ............................... page S-39
23UOSX-03
10. Molding, protector, garnish
Upper windshield molding,
A-pillar garnish.. ........................ page S-42
Roof molding .............................. page S-46
Beltline molding.. ........................ page S-48
Side protector.. ...........................
page S-49
11. Radiator grille, lower grille molding
Components ....................... . ....... page S-51
12. Cowl grille
Components ............................... page S-53
13. Outside mirror
Troubleshooting guide ................ page S-54
Power outside mirror switch.. ..... page S-55
Power outside mirror.. ................ page S-56
Components ............................... page S-56
14. Windshield
Components ...............................
page S-58
15. Windshield wiper and washer
Troubleshooting guide.. .............. page S-67
Wiper motor ................................ page S-70
Washer motor.. ........................... page S-71
Windshield wiper and
washer switch ........................... page S-71
Components ............................... page S-72
16. Sliding sunroof
Troubleshooting guide ................ page S-80
Motor assembly.. ........................ page S-81
Sunroof relay ..............................
page S-82 .--‘-
Sunroof switch ............................ page S-82
Components ............................... page S-83
s-2

S INDEX
1. Headliner
Components .............................
page S- 89 Components ............................. page S-l 10
2. Dashboard Seat assembly ..........................
page S-l 13
Components
............................. page S- 94 8. Underbody dimensions
3. Trim
Projected djmensions
Components
............................. page S- 97 (PROTEGE). ............................
page S-l 16
4. Floormat
Projected dimensions
Components ............................. page
S- 99 (Hatchback) ............................
page S-l 17
5. Seat belt
Straight-line, dimensions
Components ............................. page S-i 00 (PROTEGE). ............................ page
S-l 18
Seat belt ...................................
page S-102 Straight-line dimensions
Buckle switch.. .......................... page
S-102 (Hatchback) ............................
page S-l 19
6. Passive shoulder belt system
Structural view.. ........................
page S-103
Troubleshooting guide.. ............ page S-l 04
Passive shoulder belt motor..
... page S-l 06
Door catch switch..
................... page S-l 07
Limit switch.. ............................. page S-107
Warning switch
......................... page S-l 07
Speed sensor ........................... page
S-l 07
Components .............................
page S-l 08
s-4

S REAR HATCH
REAR HATCH
COMPONENTS
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal.
Note
l Remove the trunk end trim, trunk side cover, trunk side trim, rear header trim, rear seat belt
upper anchor, and C-pillar trim for removal of rear harness No.2. (Refer to pages S-98, 101.)
l Remove the rear portion of the headliner for removal of the rear hatch hinge and washer pipe.
(Refer to page S-91.)
I
I
\/ 8.8-13 N.m f60-130 cm-ka. 78-l 13 In-lb)
18-23 (1.8-2.3, 12-17)
7.8-12 N-m (80-120 cm-kg, 89-104 In-lb)
=?.3, 12-17)
7.8-12 Nin
(80-120 cm-kg,
89-l 04 in-lb)
Rear hatch
Rear hatch striker
1. Rear harness No.2
6. Trunk end trim
2. Washer pipe
Removal I Installation . . . . . . . . . . . . . . . . . . page S-98
3. Stay damper 7. Rear hatch striker
4. Rear hatch Adjustment Note . . . . . . . . . . . . . . . . . . . . . . . . . page S-21
Adjustment Note . . . . . . . . . . . . . . . . . . . . . . . . . page S-21 8. Rear hatch opener cable
5. Rear hatch hinge
s-20

FUEL FILLER LID AND OPENER s
FUEL FILLER LID AND OPENER
COMPONENTS
Removal / Installation
1, Remove in the order shown in the figure.
2. Install in the reverse order of removal.
Note
l Remove the rear seat belt retractor for removal of the trunk side trim (PROTEGe).
(Refer to page S-101 .)
Filler lid Filler lid opener, Opener lever, Opener cable
1 . Filler lid 5. Trunk end trim
2.
3.
4. Lift spring (With opener) Removal / Installation . . . . . . . . . . . . . . . . page S- 97
Lock cylinder retainer (Without opener) 6. Trunk side trim (L.H. side)
Filler lid lock (Without opener) Removal I Installation . . . . . . . . . . . . . . . . page S- 97
7. Filler lid opener
8. Scuff plate (L.H. side)
Removal / Installation . . . . . . . . . . . . . . . . page S- 97
9. B-pillar lower trim (L.H. side)
Removal / Installation . . . . . . . . . . . . . . . . page S- 97
10. Rear seat
Removal I Installation .,.............. page S-l 11
11. Opener lever
12. Opener cable
s-37