rear view mirror MAZDA PROTEGE 1992 Workshop Manual

PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Following items may be done at any time prior to delivery to your customer.
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Glass, exterior bright metal and paint for damage
Cl Wheel lug nuts, and locks (if equipped)
88-118 N.m (9-12 m-kg, 65-87 ft-lb)
q All weatherstrips for damage or detachment
0 Operation of hood release and lock
0 Operation of trunk lid, rear hatch, and fuel lid opener
Cl With trunk open, check for spare jack, tire, tools, and
fasteners securing these items in place.
Cl Door operation and alignment
Cl Headlight aim
INSTALL the following parts:
Cl Wheel caps or rings (if equipped)
q Outside rearview mirror(s)
1 UNDER HOOD-ENGINE OFF )
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
Cl Engine oil level
0 Power steering fluid level
0 Brake and clutch master cylinder fluid level
El Windshield washer reservoir fluid level
Cl Radiator coolant level
Cl Tightness of battery terminals
Cl Manual transaxle oil level
riizmiq
INSTALL the following parts:
Cl Rubber stopper for inside rearview mirror
CHECK operation of the following items:
0 Seat controls (sliding and reclining) and head restraint
Cl Folding rear seat
0 Door locks, including childproof door locks (if equipped)
Seat belts and warning system
Cl Ignition switch and steering lock
0 Inhibitor switch (ATX only)
U Starter interlock switch (clutch pedal, MTX only)
Cl All lights, including warning and indicator lamps
Cl Sound warning system
Cl Horn, wipers and washers (front and rear, if equipped)
0 Audio system (if equipped) 0 Cigarette lighter and clock
0 Sunroof (if equipped)
II Remote control outside rearview mirrors (if equipped)
Cl Power windows (if equipped)
q Heater, defroster and air conditioner at various mode
selections (if equipped)
CHECK the following items:
Cl Presence of spare fuse
0 Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
0 Pedal height and free play of brake and clutch pedal
Pedal height mm (in) Free play mm (in)
0 Parking brake
5-7 notches/98 N (10 kg, 22lb)
UNDER HOOD-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
q Automatic transaxle fluid level
[I
CHECK the following items:
Cl Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
0 Tires for cuts or bruises
0 Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
[I
CHECK the following items:
0 Brake operation
0 Clutch operation
Cl Steering control
Cl Operation of gauges
q Squeaks, rattles or unusual noise
Cl Emergency locking retractors
0 Cruise control system (if equipped)
1 AFTER ROAD TEST (
CHECK for necessary owner information materials.
Following items must be done just before the delivery to your customer.
q Load test battery and charge if necessary
1 Volts 1 0 Install fuses for accessories
i.. _
0 Adjust tire pressure to the specification
Load test result cl Remove seat and floor mat protective covers
(Refer to door label) 0 Vacuum and clean interior of vehicle
0 Clean outside of vehicle q Inspect installation of option parts with invoice
23UOAX-002
A-2

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

OUTSIDE MIRROR S
Rearview mirror
1. Knob cover
2. Knob
3. Inner garnish
4. Outside mirror
Inspection (Remote control) . page S-56
Disassembly . . .., ,.,...... ,., ,. . . . . . . page S-57
Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . page S-57
5. Front door trim, Door screen Power outside mirror switch
7. Meter hood
Removal / installation . . . . . . . . . . . . . . . . . . page S-94
8. Power outside mirror switch
Inspection .,,....,..,...,..........., . . . . . . . . page S-55
23UOSX-044
Removal / Installation . . . . . . . . . . pages S-l 0, 11
6. Power outside mirror harness
. .
23UOSX-04
Disassembly of Door Mirror
1. Warm the frame and the mirror glass with a hot air blower.
2. Insert a scraper between the mirror glass and the frame.
Pry the mirror loose.
3. Remove the remaining adhesive.
Assembly of Outside Mirror
1. Warm the frame with a hot air blower.
2. Install the glass in the frame. Gently press it in to secure it.
s-57

WINDSHIELD S
1. Sun visor and adaptor 7. Glass stopper
2. Inside rearview mirror, overhead console 8. A-pillar garnish (Hatchback)
(With sliding sunroof) Removal / Installation . . . . . . . . . . . . . . . . . . page S-42
3. A-pillar trim 9. Upper windshield molding
Removal / Installation ..,.,..... pages S-97, 98 Removal / Installation . . . . . . . . . . . . . . . . . . page S-42
4. Upper garnish 10. Windshield
5. Wiper arm and blade Removal Note .,.....*.........*........... page S-59
Removal / Installation . . . . . . . . . . . . page S-72 Installation Note ..,......*................ page S-60
6. Cowl arille 11. Spacer
Removal I Installation . . . . . . . . . . . . page S-53 12. Protector
1 HEADLINER
Gsi?i==
SiX.A-A
03uosx-08
PROTECTIVE TAPE -I
9 03UOSX-088
Removal Note
Windshield
1, Use protective tape or cloth along the front edge of the head-
liner to protect it from damage.
2. Apply protective tape along the edge of the body.
3. Using an awl, make a hole through the sealant from the in-
side of the vehicle.
4. Pass piano wire through the hole.
5. Wind each end of the wire around a bar.
6. Working with another person, saw through the sealant
around the edge of the glass. Then remove the glass.
Caution
l Use a long sawing action to spread the work over
the whole length of wire to prevent if from breaking.
l Be careful that the wire does not rub on the body
or dash panel.
Note
l If the glass is not to be reused, a tool like that shown
in the figure may be used.
Insert the blade in the sealant, and pull on the bars.
s-59

SLIDING SUNROOF
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.
Note
l Remove the headliner for removal of the sunroof harness, sunroof relay, drive unit assembly,
and sunroof frame and
packing. (Refer to page S-89.)
SUNROOF (STEEL)
031JOSX.1,
1. Decoration cover (Moonroof) 7. Set plate 14. Motor assembly
Removal Note . . page S-84 Installation Installation
2. Lower panel cover (Moonroof) Note . . . . . . . . . . . . . . . page S-86 Note . . . . . . . . . . . . . . . page S-86
Removal Note . . page S-84 8. Guide rail cover Inspection
3. Sliding roof trim (Sunroof) Installation 15. Rear guide assembly
Removal Note . . page S-84 Note . . . . . . . . . . .
page S-86 Removal Note page S-86
4. Sliding panel assembly 9. Sunshade (Moonroof) Installation
Removal Note . page S-84 Removal Note . . page S-84 Note . . . . . . . . . . . . . page S-86
Adjustment 10. Deflector 16. Sliding roof harness
Note . . . . . . . . . . . . . page S-87 Removal Note . . page S-85 17. Sliding roof relay
a. Sliding panel 11. Lower panel Inspection.. . . . . . . page S-82
b. Glass (Moonroof) Removal Note ,. page S-85 18. Drive unit assembly
c. Weatherstrip 12. Front guide 19. Sliding roof frame
5. Rearview mirror 13. Drip rail assembly 20. Guide rail assembly
6. Overhead console 21. Packing
Inspection . . . . . . . . . page S-82
S-83

S HEADLINER
Y
PROTEGfi
(WITHOUT PASSIVE SHOULDER BELT)
1. Assist handle
2. Interior lamp
3. Seaming welt (With sliding
sunroof)
4. Sunvisor
IJ”“DA-“oC
5. Sunvisor adapter
9. Headliner
6. Rearview mirror Removal Note . . page S-93
7. Overhead console (With slid- Installation Note page S-93
ing sunroof)
IO. Front top bracket
8. Seaming welt (Pillar)
s-90

HEADLINER S
HATCHBACK
(WITH
PASSIVE SHOULDER BELT)
I
R.H. SIDE I
1. Assist handle 5. Rearview mirror
2. Interior lamp 6. Headliner
3. Sunvisor Removal Note .,.,,.,,.......*........,.*.* page S-93
4. Sunvisor adapter
Installation Note ..,.............*......... page S-93
s-91

s HEADLINER
HATCHBACK
(WITHOUT PASSIVE SHOULDER BELT)
R.H. SIDE
1. Assist handle
2. Interior lamp
3. Seaming welt (With sliding sunroof)
4. Sunvisor
5. Sunvisor adapter
6. Rearview mirror
13uosx-03
7. Overhead console (With sliding sunroof)
8. Seaming welt (Pillar)
9. Headliner
Removal Note ,..........,,,....,..,....... page S-93
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page S-93
10. Front top bracket ---
S-92

SWITCHES T
SWITCHES
STRUCTURAL VIEW
13UOfX-0'
1. Rear window defroster switch 6. Power window main switch
Inspection . . . . #. . . . . . . . . . . . . . . ..,. . . . . . . . . . . . page T-21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-22
2. Remote control door mirror switch
7. Power window switch
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page T-20 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-22
3. Ignition switch
8. Cruise control switch
Removal I Installation . . . . . . . . . . . . . . . . . . page T-20 Removal / Installation . . . . . . . . . . page T-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-21
4. Cruise control main switch 9. Combination switch
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-21 Removal / Installation . . . . . . . . . . pages T-23, 25
5. Hazard warning switch Disassem biy / Assembly . . . . . pages T-24, 26
Removal / Installation . . . . . . . . . . . . . . . . . . page T-20 Inspection ,...,.,.,.................. pages T-27, 28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-21 10. Panel lamp control switch
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .
page T-22
T-l 9

.T INTERIOR LAMP SYSTEM
SPOT LAMP (IN OVERHEAD CONSOLE)
Removal / Inspection / Installation
1. Remove in the order shown in the figure.
2. lnsoect all parts and repair or replace as necessary.
3. Install in the reverse order of removal.
1. Rearview mirror
2. Cover
LENS
3. Lens
4. Bulb
Visual inspection
INTERIOR LAMP (WITHOUT SUNROOF)
Removal / Inspection / Installation
1. Remove the lens.
2. Remove the bulb.
3. Remove the screws and cover.
4. Inspect all parts and repair or replace as necessary.
5. Install in the reverse order of removal.
T-52