lock MAZDA PROTEGE 1992 Workshop Manual

WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT
Specifications
kern Specifications
Total mm (in) 2 f 3 (0.08 f 0.12)
Wheel alignment
(*‘Unladen) Rear toe-in
degree 0.2O f 0.3O
Camber angle -0020’ f 45’
*I Fuel tank full; radiator coolant and engine oil at specified level; and spare tire, jack, and tools in designated positions.
13UORX-012
Adjustment
Total toe-in
1. Loosen the lateral link locknuts.
2. Turn the lateral link adjustment link to adjust.
Note
l One turn of the link changes 11.3mm (0.44 in).
3. Tighten the lateral link locknuts to the specified torque.
Tightening torque:
55-64 N,m (5.6-6.5 m-kg, 41-47 ft-lb)
R-9

FRONT SUSPENSION (STRUT)
Installation note
Shock absorber and spring
1. Face the direction indicator of the mounting block inboard,
and install the shock absorber and spring.
Note
l When facing the indicator to other position, the cam-
ber and caster are changed as shown in the page
R-8. -’
23UORX-017
Disassembly / Inspection
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Visuallv inspect each part and replace as necessary.
1. Cap
2. Piston rod nut
Disassembly Note ,..........,.....,.... page R-13
3. Mounting block
4. Thrust bearing 5. Upper spring seat
6. Rubber spring seat
7. Bound stopper
8. Coil spring
9. Shock absorber
Inspection . . . . . . . . . , . . . . , . . . . . . . . . . . . . . . . . . . . page R-l 3
R-l 2

FRONT SUSPENSION (STRUT)
R
03UORX-022
.
.
H 03UOAX-02:
03UORX-02r
Disassembly note
Piston rod nut
1. Secure the mounting block in a vise.
Caution
l Use protective plates in the jaws of the vise.
2. Loosen the piston rod nut a few turns. Do not remove it.
Caution
l Do not remove the nut.
3. Compress the coil spring with the SST.
4. Remove the piston rod nut.
5. Remove the coil spring.
Inspection
Check for the following and replace the shock absorber if
necessary.
Secure a handle to the piston rod, and compress and expand
the shock piston at least three times. Verify that the operation-
al force does not change and that there is no unusual noise.
R-13

R
Assembly FRONT SUSPENSION (STRUT)
N.m (m-kg, ft-lb]
03UORX-02
1. Shock absorber
2. Coil spring
3. Bound stopper
4. Rubber spring seat
5. Upper spring seat
R-14
--
6. Thrust bearing
7. Mounting block
8. Piston rod nut
9. Cap
1. Secure the shock absorber in a vise.
Caution
l Use protective plates in the jaws of the vise.
2. Compress the coil spring with the SST.
3. Install the coil spring, fitting the end of the coil into the step
of the lower seat.
4. Install the bound stopper. ..l

FRONT SUSPENSION (STRUT) R
DIRECTION INDICATOR
LOWER BRACKET
i’
I
I I
LOWER BRACKET
03UORX-02; 5. Apply the rubber lubricant to the bound stopper and the
upper spring seat contact surfaces.
6. Install the rubber spring seat and the upper spring seat.
7. Install the thrust bearing.
8. install the mounting block, facing the direction indicator as
shown in the figure.
9. Loosely tighten the mounting block nut.
10. Carefully loosen, and remove the
SST.
Caution
l Verify that the coil spring is correctly seated in the
upper and lower seats.
11. Secure the mounting block in a vise.
12. Tighten the mounting block nut to the specified torque.
Tightening torque:
78-l 10 N-m (8.0-l 1.2 m-kg, 58-81 ft-lb)
13. Install the cap over the nut.
R-l 5

R REAR SUSPENSION (STRUT)
Disassembly / Inspection
1. Reassemble in the order shown in the figure, referring to Disassembly Note.
2. Visually inspect each part and replace as necessary.
1. Cap 6. Bound stopper
2. Nut and washer 7. Coil spring
Disassembly Note .,........,.*,................. Below 8. Lower spring seat
9. Shock absorber
Inspection .,,.,....,.....*..,...........*.... page R-23 3. Retainer
4. Mounting block
5. Stopper seat .-,
.
Disassembly note
Piston rod nut and washer
1. Secure the mounting block in a vise.
Caution
l Use protective plates in the jaws of the vise.
2. Loosen the piston rod nut a few turns. Do not remove it.
Caution _-,
l Do not remove the nut.
R-22

R REAR SUSPENSION (STRUT)
Assembly
41-50)
N.m (m-kg, f&lb)
03UORX-041
!J ‘6
1. Shock absorber
2. Lower spring seat
3. Coil spring
4. Bound stopper
5. Stopper seat
03UORX.047
R-24
6. Mounting block
7. Retainer
8. Nut and washer
9. Cap
1. Secure the shock absorber in a vise.
Caution
l Use protective plates in the jaws of the vise.
2. Install the lower spring seat.
3. Install the coil spring, fitting the end of the coil into the step
of the lower seat.
4. Compress the coil spring with the SST.
5. Install the bound stopper and the stopper seat.

REAR SUSPENSION ~STRUT~
T LbWER BRACKET
LOWER BRACKET
23UQRX-02
6. Install the mounting block, aligning the studs of the mount-
ing block and the lower bracket of the shock absorber as
shown in the figure.
7. Install the retainer.
8. Loosely tighten the piston nut.
9. Carefully loosen and remove the
SST.
Caution
l Verify that the coil spring is correctly seated In the
mounting block and lower spring seat.
IO. Secure the mounting block in a vise.
11. Install the retainer and washer.
12. Tighten the mounting block nut to the specified torque.
Tightening torque:
55-66 Narn (5.6-6.9 m-kg, 41-50 ft-lb)
13. Install the cap over the nut.
R-25

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