warning MAZDA PROTEGE 1992 Service Manual

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 TRUNK LID
03uosx-04’
HINGE (L.H.)
RIGHT SPRING -1
I
,i I
II
1
k
TRUNK LID
TRUNK LID
SEC.B--8
6 * 1.5 (0.31 * 0.06)
SECA-A mm (in)
03uosx-01
Removal Note
Balance springs
Remove the balance springs from the brackets (LH/RH) with
pliers.
Warning
l Use care when moving the balance spring.
Installation Note
Balance springs
1. Install the hook of each balance spring to the lid hinge as-
sembly.
2. Install the balance spring at the @or @position as shown.
Warning
l Use care when moving the balance spring.
Adjustment Note
Balance spring
Adjust the balance spring tension as described below.
(a) Increase: Set the right spring from standard position @
to @.
(b) Decrease: Set the left spring from standard position @to
03.
Trunk lid
Centering
1. Loosen the hinge bolts and adjust as shown.
2. Tighten the bolts to the specified torque.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 in-lb)
Height
1. Loosen the lid striker installation bolts as shown.
2. Tighten the bolts to the specified torque.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 89-95 in-lb)
s-34

PASSIVE SHOULDER BELT SYSTEM S
PASSIVE SHOULDER BELT SYSTEM
STRLICTURAL VIEW
--
1, Passive shoulder belt control unit
Removal / Installation . . . . . . . . . . . . . . . . page S-l 08
2. Passive shoulder belt retractor
Removal / Installation . . . . . . . . . . . . . . . . page S-l 08
a. Warning switch
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page S-l 07
3. Lap belt
Inspection (Retractor) .,.............. page S-l 02 4. Passive shoulder belt
Removal / Installation . . . . page S-l 08
b. Passive shoulder belt motor
Inspection . . . . . . ,,......... page S-l 06
c. Limit switch (Front)
Inspection ,........,.,..... page S-l 07
d. Limit switch (Rear)
Inspection . . . . ,...,.,.... . . page S-l 07
5. Door catch switch (In door lock assembly)
Removal / Installation . . . . pages S-l 3, 14
Inspection . . . . . . . . . . . . . . . . . . . . . page S-l 07
S-l 03

PASSIVE SHOULDER BELT SYSTEM S
DOOR CATCH SWITCH (in front door lock assembly)
Inspection
1. Disconnect the door catch switch connector.
2. Check for continuity between the terminals with an
ohmmeter.
031JOSX- 19
mm (in) Release
( +<>: lndtcates continuity
LIMIT SWITCH (FRONT/REAR)
Inspection
1. Disconnect the passive shoulder belt and front limit switch
connectors.
2. Position the shoulder belt buckle forward and rearward as
shown with the emergency handle.
3. Check for continuity between the limit switch terminals with
an ohmmeter.
Note
l Verify that the shoulder belt buckle is fully in the
front/rear lock position when checking.
Limit switch
Front
Rear
Buckle posItIon a b f h
Released (Front)
0 0
O---G Indicates continuity
4. If not as specified, replace the passive shoulder belt.
WARNING SWITCH (in passive shoulder belt retractor)
Inspection
1. Disconnect the warning switch connector.
2. Check for continuity between terminals when the lap belt
is pulled out/released.
Lap belt condition R.H. side
L.H. side
a b C d
I
Pulled (more than 80 cm (31.50 in) 1 0
Released
C&---i). Indicates continuity
SPEED SENSOR
Inspection
1. Remove the instrument cluster. (Refer to Section T.)
2. Check for continuity between terminals A and F while rotat-
ing the speedometer cable shaft.
3. If there are not four pulses per shaft rotation, replace the
speedometer. (Refer to Section T.)
S-l 07

1
2.
3.
4.
5. Scuff plate
PASSIVE SHOULDER BELT SYSTEM S
6. Lap belt buckle
97, 98 Inspection (Buckle switch) page S-102
7. Rear console Removal I Installation . . . . . . pages S-
B-pillar lower trim (PROTEGE)/
Quarter trim (Hatchback)
Removal I Installation .,.... pages S-
A-pillar trim
Removal / Installation . . . . . pages S-
Passive shoulder belt
Inspection
(Motor, Limit switch) . . . . . pages S-
Lap belt
Inspection (Retractor) . . . . . . page S- Removal / Installation, . . . . . . . page S- 94
97, 98 8. Passive shoulder belt retractor
Inspection (Retractor, Warning switch)
97, 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pages S-102, 107
9. Front seat (L.H. side)
Removal I installation. . . . . . . . page S-l IO
106, 107 10. Passive shoulder belt control unit
13UOSX-022
102
S-l 09

BODY ELECTRICAL SYSTEM
INDEX .......................................... T- 2
RELAY ....................................... T- 2
INSTRUMENT CLUSTER AND
SWITCHES ................................ T- 3
EXTERIOR LIGHTS.. ..................... T- 4
INTERIOR LAMPS.. ...................... T- 5
CRUISE CONTROL SYSTEM.. ........ T- 6
AUDIO ....................................... T- 7
OTHER ...................................... T- 8
OUTLINE ...................................... T- 9
HOW TO USE THIS SECTION.. ...... T- 9
ELECTRICAL TROUBLESHOOTING
TOOLS .....................................
ELECTRICAL SYMBOLS - ............... T- 1x
TROUBLESHOOTING GUIDE.. .........
T- 11
FUSE AND JOINT BOX ..................
T- 12
STRUCTURAL VIEW.. ...................
T- 12
FUSES ....................................... T- 13
CIRCUIT BREAKER.. ....................
T- 14
JOINT BOX ................................. T- 15
RELAY .......................................... T- 16
STRUCTURAL VIEW.. ...................
T- 16
.-
FLASHER UNIT ........................... T- 17
DOOR LOCK TIMER UNIT ............
T- 17
HORN RELAY ............................. T- 18
HEADLIGHT RELAY.. ................... T- 18
TNS RELAY ................................ T- 18
DRL RELAY (CANADA). ................ T- 18
SWITCHES .................................... T- 19
STRUCTURAL VIEW.. ................... T- 19
SWITCH ..................................... T- 20
COMBINATION SWITCH ...............
T- 23
EXTERIOR LIGHTING SYSTEM ....... T- 29
STRUCTURAL VIEW.. ...................
T- 29
AIMING ...................................... T- 30
TROUBLESHOOTING.. .................
T- 30
HEADLIGHT AND FRONT
COMBINATION LIGHT.. ..............
T- 41
REAR COMBINATION LIGHT.. ....... T- 43
HIGH-MOUNT STOPLIGHT.. .......... T- 45
DRL RESISTOR ........................... T- 46
STOPLIGHT SWITCH.. .................. T- 47
BACK-UP LIGHT SWITCH ............. T- 47
LICENSE PLATE LIGHT.. ..............
T- 47
REAR SIDE MARKER LIGHT ......... T- 48
INTERIOR LAMP SYSTEM ..............
T- 49
STRUCTURAL VIEW.. ...................
T- 49
TROUBLESHOOTING ...................
T- 50 SPOT LAMP
(IN OVERHEAD CONSOLE) ......... T- 52
INTERIOR LAMP
(WITHOUT SUNROOF). ............... T- 52
INTERIOR LAMP (WITH SUNROOF) T- 53
INTERIOR AND SPOT LAMP
(WITHOUT SUNROOF). ............... T- 53
CARGO COMPARTMENT LAMP.. .. T- 54
TRUNK COMPARTMENT LAMP.. ... T- 54
COURTESY LAMP ....................... T- 54
CENTRAL PROCESSING UNIT (CPU) T- 55
SYSTEM DIAGRAM ...................... T- 55
CPU .......................................... T- 56
WARNING SYSTEM.. ...................... T- 58
WARNING BUZZER AND TIMER .... T- 58
WARNING AND INDICATOR LAMP T- 60
INSTRUMENT CLUSTER.. ............... T- 63
PREPARATION ............................ T- 63
STRUCTURAL VIEW ..................... T- 63
TROUBLESHOOTING ................... T- 64
INSTRUMENT CLUSTER
AND SPEEDOMETER CABLE.. .... T- 89
WATER THERMOSENSOR ............ T- 72
FUEL GAUGE SENDER UNIT.. ...... T- 73
REAR WINDOW DEFROSTER.. ........ T- 74
STRUCTURAL VIEW.. ................... T- 74
TROUBLESHOOTING ................... T- 75
FILAMENT .................................. T- 77
REAR WINDOW DEFROSTER
SWITCH .................................... T- 77
CRUISE CONTROL SYSTEM.. ......... T- 78
STRUCTURAL VIEW.. ................... T- 78
TROUBLESHOOTING GUIDE.. ....... T- 79
SELF-DIAGNOSTIC INSPECTION .... T- 80
TROUBLESHOOTING ................... T- 83
CRUISE CONTROL UNIT .............. T- 85
HORN ........................................... T- 88
HORN AND HORN RELAY.. .......... T- 88
AUDIO .......................................... T- 89
STRUCTURAL VIEW.. ................... T- 89
OUTLINE OF AUDIO.. .................. T- 90
SYSTEM ..................................... T- 91
TROUBLESHOOTING ................... T- 92
CAUSES OF NOISE ..................... T- 96
AUDIO COMPONENT.. ................. T- 98
DOOR SPEAKER .........................
REARSPEAKER .......................... ;-
- !3;
ANTENNA FEEDER ..................... T- 99
23UOTX-001

INDEX T
INSTRUMENT CLUSTER AND SWITCHES
23UOTX-00
1. Rear window defroster switch
7. Fuel gauge sender unit
Inspection
........................... page T-21 Removal / Installation ..................
page T-73
2. Remote control door mirror switch
Inspection ................................... page T-73
Inspection
........................... page T-20 8. Hazard warning switch
3. Ignition switch
Removal / installation .................. page T-20
Removal / Installation..
........ page T-20 Inspection ................................... page T-21
Inspection ........................... page
T-2 1 9. Cruise control main switch
4. Combination switch Inspection ...................................
page T-21
Removal / installation
.......... pages T-23, 25 10. Cruise control switch
Disassembly / Assembly ..... pages T-24, 26 Removal / Installation ..................
page T-20
Inspection
........................... pages T-27, 28 Inspection ................................... page T-21
5. Instrument cluster 11. Power window main switch
Troubleshooting..
................ page T-65 Inspection ................................... page T-22
Removal / Installation
.......... page T-69 12. Power window switch
Disassembly I Assembly ..... page T-70 Inspection ................................... page T-22
Inspection
........................... page T-71 13. Panel lamp control switch
6. Water thermosensor
Inspection ................................... page T-22
Removal / Installation..
........ page T-72
Inspection ........................... page T-72
T-3

T INDEX
EXTERIOR LIGHTS
1. Headlight
Troubleshooting .......................... page T-30
Removal / Installation .................. page T-41
Aiming ......................................... page T-30
2. Front combination light
Removal / Installation .................. page T-41
(1) Turn and hazard warning light
Troubleshooting .................. page T-34
(2) Small light control system
Troubleshooting .................. page T-37
3. Rear combination light
Removal / Installation .................. page T-43
Disassembly / Assembly ............. page T-44
(1) Turn and hazard warning light
Troubleshooting .................. page T-34
(2) Parking light control system
Troubleshooting .................. page T-37
(3) Stoplight
Troubleshooting .................. page T-39
4. Stoplight switch
Inspection ................................... page T-47
T-4
5. License plate light
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . page T-37
Removal I Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-47
6. Back-up light switch
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-47
7. Flasher unit
Inspection . . . . . . . . . . . . . . . . . ,.. . . . . . . . . . . page T-42
8. High-mount stoplight
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-45
9. Rear side marker light
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-48
0. Daytime running light (DRL) system
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . page T-33
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-42
1. DRL resistor
Removal I Installation . . . . . . . . . . . . . . . . . . page T-46
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-46

TROUBLESHOOTING GUIDE T
TROUBLESHOOTING GUIDE
System
Exterior lighting system
Interior lamp system
Warning system
Instrument cluster
Rear window defroster
Cruise control system
Audio system Symptom Reference page
Headlights do not operate T-32
Headlights either do not operate or are dim T-33
Low-High beam or passing flasher does not operate T-33
Daytime running lights (DRL) do not operate T-33
Turn signal lights do not operate T-35
Only hazard function does not operate T-36
Only one side of signal operates
T-36
TNS system (side marker, license, tail, illumination light) does not operate T-38
Both stoplights do not operate when brake pedal is depressed T-40
One stoplight does not come on T-40
IG key illumination does not operate
T-51
Key reminder alarm does not sound
Light-off reminder alarm does not sound
Seat belt alarm does not sound
Seat belt timer does not operate
Passive shoulder belt alarm does not sound
IG key illumination timer does not operate T-58
T-59
T-59
T-59
T-59
T-59
Speedometer does not operate or indication is not correct
Tachometer does not operate
Water temperature gauge does not operate
Fuel gauge does not operate
Defroster does not operate
Can’t set or control the speed T-65
T-66
T-67
T-68
T-76
T-84
No sound
Sound is partial
Bad sound quality of radio
Bad sound quality of tape
Noise
Scan or tuning does not stop T-93
T-93
T-94
T-94
T-95
T-95
T-l 1

FUSE AND JOINT BOX
FUSES
Specifications
Main fuse block
Fuse Color
FUEL INJ 30A Pink
HEAD 30A Pink
MAIN 80A Black
BTN 60A Green
AD FAN 30A Pink
ST SIG 10A Red
ELEC FAN 30A Pink Protected circuit
EGI system
Headlight
Cooling fan, Power window, Sunroof, Wiper and washer, Air conditioner
Door lock, Charging system
Additional cooling fan
Fuel pump
Cooling fan
Fuse box
23UOTX-001
Specifications
Fuse
REAR WIPER 10A
HAZARD 15A
ROOM IOA
ENGINE 15A
RADIO 15A
DOOR LOCK 30A
BELT 30A
POWER WINDOW 30A Color
Red
Blue
Red
Blue
Blue
Green
Green
Green Protected circuit
Rear wiper and washer
Hazard warning
Clock, interior lamp, Cargo compartment lamp, Trunk compartment lamp
Alternator
Audio
Power door lock
Passive shoulder belt
Power window
1
T-13