light MAZDA PROTEGE 1992 Manual PDF

REAR BUMPER
REAR BUMPER
COMPONENTS
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
16- -23 (1.6-2.3, 12-17)
16-23 (1.6-2.3, 12-17)
1 HATCHBACK
A
1’ : PROTEG&
N.m (m-kg, ft-lb)
13uosx-01
1. Trunk end trim 5. Rear bumper assembly
Removal / Installation . . . . . . . . . .
pa
2. Bumper bracket cover (PROTEG ii es S-97, 98 a. Rear bumper retainer
) b. Rear bumper reinforcement
3. Rear reflector light c. Energy absorbing foam
4. Licence plate light (Hatchback) d. License plate light harness (Hatchback)
e. License plate light holder (Hatchback)
f. Rear bumper facia
6. Rear flap
s-40

RADIATOR GRILLE, LOWER GRILLE MOLDING S
RADIATOR GRILLE, LOWER GRILLE MOLDING
COMPONENTS
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal, referring to Installation Note.
1. Radiator grille 3. Lower grille molding
Installation Note. . . . . . . . . . . . . . . . . . . . .
page S-51 4. Clip
2. Front combination light
Removal I Installation ..,.,,...,..,........ Section T
Installation Note
Radiator grille
1. Insert the clips into the grille, and align them with the instal-
lation holes in the body.
2. Press the grille into the body.
s-51

S REAR FINISHER
REAR FINISHER
COMPONENTS
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
HATCHBACK
Hatchback PROTEGE
1. Rear hatch lower trim 4. License plate light
Removal / Installation . . . . . . . . . . . . . . . . . . page S-98 5. Rear finisher 2. Rear finisher 6. Packing
3. Packing
S-52

WINDSHIELD S
PROTECTOR
I SEALANT
mm (in)
.
03uosx-09
GLASS /
SPACER
mm (in
03uosx-1c
PROTEG6
MOLDING MOLDING
SEALANT SEALANT
CROSS-SECTION
mm (in)
03uosx-1c
7. Align the protector on the body, and attach it securely as
shown.
8. Prepare the nozzle of the sealant gun so that it has a flange
that can run along the edge of the glass and a V from which
the sealant can flow. Once the primer is dry, apply the seal-
ant around the entire circumference of the glass to fill the
gap between the dam and the edge of the glass with a ridge
of sealant
12mm (0.47 in) high.
Keep the bead of sealant smooth and even, reshaping it
where necessary with a spatula.
9. Lift the glass into place. Push it in lightly toward the vehicle
to compress the sealant.
Caution
l Open the windows to prevent the glass from being
pushed out by air pressure if a door is closed.
Hardening time of repair seal
I Temperature Surface hardening Time required until car
time can be put into service
I
5% (41 OF) Approx. 1.5 hrs 12 hrs
2ooc (68OF) Approx. 1 hr
4 hrs
35OC (95OF)
Approx. 10 min 2 hrs
10. Align the upper windshield molding on the body as shown,
and push the molding into place along the top.
Note
l Install the molding before the sealant has hardened.
11. Check for water leaks. If a leak is found, wipe the water off
well and add
sealant (BOO1 77 739) where needed.
S-61

REAR WINDOW GLASS S
REAR WINDOW GLASS
PREPARATION
SST
49 0305 870A
1 For
Tool set, window removal and
installation of rear
window glass
COMPONENTS
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. install in the reverse order of removal, referring to Installation Note.
r
I’
PROTEGi:
1. Rear seat cushion
6. Rear header trim
5
Removal I Installation . . . . . . . . . . . . . . . . page S-l 11
Removal / Installation . . . . . . . . . . . . . . . . page S-
97
2. Rear seat back/side
7. C-pillar trim
Removal I Installation . . . . . . . . . . . . . . . . page S-l 11
3. High-mount stoplight (interior mounted)
Removal / Installation . . . . . . . . . . . . . . . . . . . . . Section
T
4. Rear package trim
Removal I Installation . . . . . . . . . . . . . . . . page S-
97
5. Rear seat belt upper anchor
Removal / Installation ..,............. page
S-101
Removal / Installation . . . . . . . . . . . . . . . . page S-
97
8. Rear window molding
Removal I Installation . . . . . . . . . . . . . . . . page S-
43
9. Rear window glass
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . .
page S- 64
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page S-
65
10. Spacer
S-63

S REAR WINDOW GLASS
03uosx-11
WOTEGk GLASS
SPACER
-lATCHBACk
GLASS
SPACER
mm (in
03uosx-11
6. Prepare the nozzle of the sealant gun so that it has a flange
that can run along the edge of the glass and a V from which
the sealant can flow. Once the primer is dry, apply the seal-
ant around the entire circumference of the glass to fill the
gap between the dam and the edge of the glass with a ridge
of sealant
12mm (0.47 in) high.
Keep the bead of sealant smooth and even, reshaping it
where necessary with a spatula.
7. Lift the glass into place. Push it in lightly toward the vehicle
to compress the sealant.
Caution
l Open the windows to prevent the glass from being
pushed out by air pressure if a door is closed.
Hardening time of repair seal
Temperature Surface hardening Time required until car
time can be put into service
5T (41 OF) Approx. 1.5 hrs 12 hrs
2o”c (6WF) Approx. 1 hr 4 hrs
35% (95OF) Approx. 10 min 2 hrs
8. Use a scraper to smooth away any sealant that oozes out.
Add more sealant to any points of poor contact.
9. Check for water leaks. If a leak is found, wipe the water off
well and add
sealant (BOO1 77 739) where needed.
S-66

SLIDING SUNROOF
‘SET PLATE
I
GUIDE RAIL
DEFLECTOR LINK \
v 03uosx-15 03UOSX-156
7
3. Release the sunshade stop at the rear of the cable holder,
and move the sunshade forward.
4. Turn the handle to fully open the lower panel. (Leave the
sunshade fully closed.)
5. Remove the set plate and guide rail cover.
6. Pull out the sunshade.
Deflector
1. Hold the deflector down slightly. Pry up the connector at
the rear of the deflector link, and remove the deflector link.
2. Remove the screws and remove the deflector.
Caution
l Do not damage the deflector link or connector.
Lower panel
1. Fully close the lower panel.
2. Remove the lower panel and rear guide screw and nuts.
3. Remove the installation screw from the drip rail link.
S-85

SEAT BELT
38-78 (3.9-8.0, 28-58)
IEAR
PROTEGt
38-78 (3.9-8.0, 2848)
HATCHBACK
38-78 (3.9-8.0, 28-58)
N.m (m-kg, fl-lb)
13uosx-0:
PROTEGC Hatchback
1. Rear seat cushion
Removal I Installation . . . . . . . . . . . . . . . . page S-l 11
2. High-mount stoplight (Interior mounted)
Removal I Installation ..,.................. Section T
3. Rear package trim
Removal / Installation . . . . . . . . . . . . . . . . page S- 97
4. Rear seat belt
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page S-102 5. Rear seat cushion
Removal / Installation . . . . . . . . . . . . . . . . page S-l 12
6. Trunk end trim
Removal / Installation . . . . . . . . . . . . . . . . page S- 98
7. Trunk side cover
Removal / Installation . . . . . . . . . . . . . . . . page S- 98
8. Trunk side trim
Removal I Installation . . . . . . . . . . . . . . . . page S- 98
9. Rear seat belt inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page S-l 02
s-1 01

SEAT S
REAR (PROTEGa
ONE-PIECE TYPE
1
8.8-12 N-m
(90-l 20 cm-kg, 22-30 (2.2-3.1, 16-22)
22-30 (2.2-3.1, 16-21
.kg, 76-104 in-lb)
N.m (m-kg, Mb)
03uosx-2
Rear seat
1. Rear seat cushion
2. Rear seat side cushion
(With split-folding seatback)
3. Seat back Rear seat back striker
(With split-folding seat back)
4. High-mount stoplight (interior mounted)
Removal / Installation . . . . . . . . . . . . . . . . . . . . . Section T
5. Rear package trim
Removal I Installation ,.. ..,., . . . . . . . . . . page S-97
6. Rear package edge trim
Removal / Installation ,.....,........... page S-97
7. Seat back striker
S-III

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