MAZDA PROTEGE 1992 Workshop Manual

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

R REAR SUSPENSION (STRUT)
LATERAL LINK AND TRAILING LINK
Removal / Inspection / Installation
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove in the order shown in the figure.
4. Visually inspect each part and replace as necessary.
5. Install in the reverse order of removal, referring to
Installation Note.
6. After installation, measure the rear wheel alignment, and adjust it if necessary.
Caution
0 Retighten the lateral link and trailing link mounting bolts and nuts to the specified torque af-
ter lowering the vehicle (unladen condition). -
63-93 (6.4
65-l 17 (6.7-l
93-127 (9.5-12.9, 69-93)
N-m (m-kg, R-lb
-^. .^-.. ^
1. Stabilizer nut 4. Cap
Installation Note 5. Nut
. . . . . . . . . . . . . . . . ...‘... page R-27 6. Washer
2. Retainer, bushing, spacer 7. Bolt
3. Stabilizer bolt 8. Retainer 9. Lateral link (front)
10. Lateral link (rear)
11. Bolt, washer
12. Trailing link
x?AJuux-u
R-26

REAR SUSPENSION (STRUT) R
Installation note
Stabilizer nut
Tighten the stabilizer nuts so that the specified thread is ex,
posed at the end of the bolt.
Specification: 16.2-18.2mm (0.84-0.72 in)
REAR STABILIZER
Removal / Inspection / Installation
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove in the order shown in the figure.
4. Visually inspect each part and replace as necessary.
5. Install in the reverse order of removal, referring to
Installation Note.
Caution
l Retighten the stabilizer bracket bolts to the specified torque after lowering the vehicle (un-
laden condition).
43-59 (4.4-6.0, 32-4
N-m (m-kg, ft-lb)
731KmX.01
---_
1. Stabilizer nut 5. Stabilizer bracket
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page R-28 6. Stabilizer bushing
2. Bushing, retainer, spacer Inspect for damage and wear
3. Stabilizer bolt Installation Note .,,,,,.................... page R-28
4. Bolt 7. Stabilizer bar
R-27

REAR SUSPENSION (STRUT)
I 03UORX-053
Installation note
Stabilizer bushing
Align the bushing with the installation position line painted on
the stabilizer bar.
Stabilizer nut
Tighten the stabilizer nuts so that the specified thread is ex-
posed at the end of the bolt.
Specification: l&2-18.2mm (0.64-0.72 in)
R-28

REAR CROSSMEMBER
Removal / Installation
REAR SUSPENSION (STRUT) R
1. Jack up the vehicle and support it with safety stands.
2. Remove the wheels and tires.
3. Remove the brake pipe holder.
4. Remove in the order shown in the figure.
5. Inspect all parts and repair or replace as necessary.
6. Install in the reverse order of removal, referring to
Installation Note.
7. After installation, check the rear wheel alignment and adjust it if necessary.
Caution
l Loosely tighten the lateral link and trailing link bolts and nuts when installing. Lower the vehi-
cle and tighten all nuts and bolts to the specified torques with the vehicle unladen.
46-63 (4.7-6.4, 34-46)
66-117 (6.7-11.9, 63-66)
I
66-95 (W-9.7,
43-59 (4.4-6.0, 32-43)
63-93 (6.4-9.5, 46-69)
N.m (m-kg, ft-lb)
‘)‘)I ano” n,
1. Nut (Stabilizer)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Bushing and retainer
3. Bolt, retainer and bushing
4. Retainer, bushing and spacer
5. Bolt (Lateral link)
6. Bolt (Trailing link)
7. Bolt (Trailing link) 8. Trailing link
page R-28 9. Bolt (Lateral link)
10. Lateral link (front and rear)
Il. Bolt
12. Rear stabilizer
13. Bolt and washer
14. Rear crossmember
R-29

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

INDEX
1. Rear door
10. Rear bumper
Components ...............................
page S-l 5 Components ............................... page S-40
q 2. Rear side window regulator and glass
11. Rear spoiler
Components ...............................
page S-i 7 Components ............................... page S-41
3. Rear door lock and opener 12. Molding, protector, garnish
Components ...............................
page S-l 9 Rear window molding
4. Rear hatch (PROTEGE) ............................... page S-43
Components ............................... page S-20 Rear window molding
5. Rear hatch lock and opener (Hatchback) .............................. page S-44
Components ...............................
page S-22 Side protector ............................. page S-49
6. Power door lock system 13. Rear finisher
Structural view ............................
page S-23 Components ............................... page S-52
Troubleshooting guide.. .............. page S-24 14. Extractor chamber
Door lock switch.. .......................
page S-26 Components ................................ page S-53
Door lock control.. ...................... page S-26 15. Quarter window glass
Door lock timer and relay ...........
page S-26 Components ............................... page S-62
7. Power window system
16. Rear window glass
Structural view ............................
page S-27 Components ............................... page S-63
Troubleshooting guide.. .............. page S-28 17. Rear wiper and washer
Main power window switch.. ...... page S-31 Troubleshooting
guide.. .............. page S-74
Power window sub-switch ..........
page S-32 Rear wiper motor.. ...................... page S-77
Power window motor.. ................
page S-32 Rear washer motor.. ................... page S-77
8. Trunk lid Rear wiper and washer switch..
. page S-77
Components ...............................
page S-33 Components
............................... page S-78
9. Trunk lid lock and opener
Components ...............................
page
S-35
s-3

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