service MAZDA PROTEGE 1992 Service Manual

H INDEX
NDEX
CLUTCH SWITCH
SERVICE, SECTION F
23UOHX-00:
2
5. Clutch release fork
Removal / Installation . . . . . . . . . . . . . . . . . . page
H-l 5
6. Clutch cover 1. Clutch pedal
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H- 5
Removal / Inspection /
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H- 6
2. Clutch master cylinder
Removal I Inspection I
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H- 7
Air bleeding ,............,..... I ,.,........, page H- 8
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . I ,,.,........
page H-10
3. Clutch release cylinder
Removal / Installation.. . . . . . . . . . . . . . . . . page
H-l 2
Air bleeding . . . . . . . . . . . ..*..................
page H- 8
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page
H-l 3
4. Release bearing
Removal / installation . . . . . . . . . . . . . . . . . . page
H-l 5
Inspection ,.....,..,.,~.,..........,.,,..,,.. page H-l 7
H-2
Removal / Installation .,.......,..,..... page H-l 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H-l 7
7. Clutch disc
Removal I Installation . . . . . . . . . . . . . . . . . . page
H-l 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H-l 7
8. Pilot bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H-l 8
Removal / Installation.. . . . . . . . . . . . . . . .
page H-l 5
9. Flywheel
Removal I Installation . . . . . . . . . . . . . . . . . . page
H-l 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-18

CLUTCH UNIT
REMOVAL / INSTALLATION
Note
l Remove the clutch release cylinder with the clutch pipe connected.
l Do not remove the pilot bearing if not necessary.
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
96-l 03
Kt.6-10.5. 71-761
(MOLYBDENUM SULFIDE)
N-m (m-kg, R-lb:
911 Im-4Y.fi,r
1. Clutch release cylinder
2. Transaxle
Service . . . . . . . . . . . . . . . . . . . . . . . . . ,....... Sections Jl , J2
3. Boot
4. Release bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-l 7
5. Clutch release fork
6. Clutch cover
Removal Note ..,...........,,,.........,, page H-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-l 7
Installation Note .,......................., page
H-l 7
7. Clutch disc
Removal Note ............................ page H-16
Inspection.. ................................. page H-l 7
Installation Note .......................... page H-l 7
8. Pilot bearing
Inspection ................................... page H-18
Removal Note ............................ page H-16
Installation Note.. ........................ page H-16
9. Flywheel
Removal Note ............................ page H-16
Inspection ................................... page H-18
Installation Note .......................... page H-16
H-15

Jl INDEX
INDEX
BACK-UP LdHT SWITCH
SERVICE, SECTION T VISCOSITY: SAE 75W-90
CAPACITY : 2.68 liters (2.83 US qt, 2.36 Imp qt)
03UOJl-00
1, Transaxle 2. Differential
Removal.. ..................................
page Jl-IO Disassembly I Inspection I
Disassembly ................................ .............................. page Jl-14 Assembly page Jl-53
Inspection ..................................
page J 1-27 3. Shift mechanism
Assembly .................................. page J l-30 Overhaul ...................................
page Jl-56
Installation ................................. page Jl -48 4. Transaxle oil
Inspection. .................................
page Jl- 7
Replacement ............................. page Jl- 7

OUTLINE Jl
OUTLINE
SPECIFICATIONS
c EnginelTransaxle
B6 SOHC BP SOHC
Item FSM-R
I
Transaxle control
I Floor shift
Synchromesh system Forward: Synchromesh
Reverse: Selective sliding
1 1st
I 3.416
2nd 1.842
I
Gear ratio
4th
Final aear ratio 5th
Reverse I
0.918
0.731
3.214
4.105 3.619
Grade
I API service GL-4
Oil Viscosity
I SAE 75W-90
Capacity liters (US qt, Imp qt) 2.68 (2.83, 2.36)
13UOJl-00
Jl-3

TRANSAXLE OIL Jl
/
03UOJl-00
03UOJl-O(
TRANSAXLE OIL
INSPECTION
Note
l Park the vehicle on level ground.
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Verify that the oil level is between the F and L.
3. Install the speedometer driven gear.
Tightening torque:
7.8-12 N,m (80-120 cm-kg, 89-l 04 in-lb)
4. Connect the speedometer cable.
REPLACEMENT
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Remove the drain plug and washer. Drain the oil into a suita-
ble container.
3. Install a new washer and the drain plug.
Tightening torque:
39-54 N#rn (4.0-5.5 m-kg, 29-40 ft-lb)
4. Add the necessary amount of the specified oil through the
speedometer driven gear mounting.
Specified oil
Grade: API service GL-4
Viscosity: SAE 75W-90
Capacity: 2.88 liters (2.83 US qt, 2.38 Imp qt)
5. Verify the oil level.
6. Install the speedometer driven gear and connect the
speedometer cable.
Jl-7

J2 INDEX
IN
new IYLA
BACK-lx LIU, 1, w.., 1 vm q
SERVICE, SECTION
F
k’c’ 1T6AL SWITCH 8.L”
SERI /ICE, SECTION T VISCOSITY: ALL-SEASON ATF DEXRON-II,
M2C33F OR SAE75W-80
ABOVE -18% (OOF) API SERVICE
GL-4 SAE80W-90
CAPACITY: 3.35 liters (3.55 US at. 2.98 ho 41)
1. Transaxle
Removal ..,.....,.,..,....,..,.........,.... page J2-10
Disassembly ,., ,..,., . ,,...., ,.. .., .., page J2-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-22
Assembly . . . . . . . . . ,.,...................... page J2-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page J2-41
52-2
2. Differential
Disassembly / Inspection I
Assembly ,..,.,.,, ,_, ,. .,. ,_. ,_. . . . page J2-44
3. Shift mechanism
Overhaul ,....,.......,..... ,........, . . . . . . page J2-46
4. Transaxle oil
inspection . . . . . . . . ..,........I....I.,..... page J2- 7
Replacement .,.,.., ,.,...,...,.. . . . . . . . . . page J2- 7 .___I’

OUTLINE J2
OUTLINE
SPECIFICATIONS
Item
Transaxle control
Synchromesh system EnginelTransaxle
BP DOHC
GSM-R Floor shift
Forward: Synchromesh
Reverse: Selective sliding and synchromesh
T- I-
Gear ratio
I
1 st 3.307
2nd 1.833
3rd 1.310
4th 1.030
5th 0.795
Reverse 3.166
Final gear ratio 4.105
q
Oil Viscosity All-season
Above -18OC (OOF) ATF DexronYI, M2C33F or SAE75W-80
API service GL-4 SAE80W-90
Capacity liters (US qt, Imp qt) 3.35 (3.55, 2.96)
23UOJ2-001
52-3

TRANSAXLE OIL 52
03UOJ2-00’
03UOJ2-008
03UOJ2-00
1 9
23UOJ2-002
TRANSAXLE OIL
INSPECTION
Note
l Park the vehicle on level ground.
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Verify that the oil level is between F and L.
3. Install the speedometer driven gear.
Tightening torque:
7.8-12 Nmrn (80-120 cm-kg, 89-104 in-lb)
4. Connect the speedometer cable.
REPLACEMENT
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Remove the drain plug and washer. Drain the oil into a suit-
able container.
3. Install a new washer and the drain plug.
Tightening torque:
39-59 N*m (4.0-8.0 m-kg, 29-43 ft-lb)
4. Add the necessary amount of the specified oil through the
speedometer gear case hole.
Specified oil
Viscosity: All-season ATF Dexron@lI, M2C33F or
SAE75W-80
Above -18*C (O*F) API service GL-4
SAE 8OW-90
Capacity: 3.35 liters (3.55 US qt, 2.96 Imp qt)
5. Verify the oil level.
6. Install the speedometer driven gear and connect the
speedometer cable.
03UOJ2-011
J2-7

FRONT AXLE M
WHEEL HUB, STEERING KNUCKLE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Remove the brake caliper assembly and disc plate.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and meas-
ure the wheel bearing play.
4. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
Removal / Installation
d Maximum wheel bearing play: 0.05mm (0.002 in)
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation, check the front wheel alignment. (Refer to Section R.)
SERVIC\E, SECTION R

7 93--12? W.-L%” COTiER PIN, REPLACE
(9.5-12.9, 69-S
39-54
(4.0-5.6, 29-40) 39-64 ’ 236-319 (24.0-32.5, 174-235)
(4.4-6.0, 32-43)
66-67)
N.m (m-kg, it-lb)
23UOMX-006
1. Wheel and tire
2. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6
3. Brake caliper assembly
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
4. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
5. Tie rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6 6. Lower ball joint
7. Knuckle, wheel hub, and dust cover
Inspect wheel hub for cracks and damage
Inspect knuckle spindle for cracks and
damage
Inspect dust cover for damage and dis-
tortion
Disassembly / Inspection I
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M- 7
M-5

REAR AXLE M
L.3”“I”lh-” I
Removal / Inspection / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation, bleed the brake system, adjust the parking brake lever stroke (Refer to Section P.) and
DRUM BRAKE TYPE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Position a dial indicator against the brake drum. Push and
pull the rear brake assembly by hand in the axial direction
and measure the wheel bearing play.
3. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
Maximum wheel bearing play: 0.05mm (0.002 in)
66-l 17 (6.7-l 1.9, 63-66)
45-59
(4.6:6.0, 33-43)
check the rear wheel alignment (Refer to Section R.)
SEiWICE, SECTION R /
I
GA
19-26 (1.9-2.6, 14-19)
177-235
(16.0-24.0, 130-174) d
REPLACE REPLACE
(9.0-12.0,
65-67)
N.m (m-kg, ft-lb)
7RI ImAX-ni
J 3
1. Wheel and tire
2. Hub cap
3. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-l 2
4. Brake drum
5. Hub bearing assembly
Inspect for cracks and damage
Disassembly I Assembly . . . . . . . . . . . . page M-l 3 6. Parking brake cable
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
7. Brake pipe
Removal Note .,.......................... page M-12
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-l 2
8. Rear brake assembly
Service ,,........................................ Section P
9. Rear spindle
Inspect for cracks and damage
M-l 1