trunk 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

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 REAR HATCH
REAR HATCH
COMPONENTS
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal.
Note
l Remove the trunk end trim, trunk side cover, trunk side trim, rear header trim, rear seat belt
upper anchor, and C-pillar trim for removal of rear harness No.2. (Refer to pages S-98, 101.)
l Remove the rear portion of the headliner for removal of the rear hatch hinge and washer pipe.
(Refer to page S-91.)
I
I
\/ 8.8-13 N.m f60-130 cm-ka. 78-l 13 In-lb)
18-23 (1.8-2.3, 12-17)
7.8-12 N-m (80-120 cm-kg, 89-104 In-lb)
=?.3, 12-17)
7.8-12 Nin
(80-120 cm-kg,
89-l 04 in-lb)
Rear hatch
Rear hatch striker
1. Rear harness No.2
6. Trunk end trim
2. Washer pipe
Removal I Installation . . . . . . . . . . . . . . . . . . page S-98
3. Stay damper 7. Rear hatch striker
4. Rear hatch Adjustment Note . . . . . . . . . . . . . . . . . . . . . . . . . page S-21
Adjustment Note . . . . . . . . . . . . . . . . . . . . . . . . . page S-21 8. Rear hatch opener cable
5. Rear hatch hinge
s-20

S REARHATCH LOCKANDOPENER
REARHATCH LOCKANDOPENER
COMPONENTS
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
2 lnctall in the rpvprs~! order of rwnoval.
2.3, 12-17)
N.m (m-kg, ft-lb
_____-
0.1UOSX-C’
Rear hatch lock Rear hatch opener, opener cable
1. Rear hatch lower trim 5. Trunk end trim
Removal / Installation .,......,,...... page S- 98 Removal / Installation .,,......,,._... page S- 98
2. Lock cylinder retainer 6. Rear hatch striker
3. Lock cylinder assembly Adjustment Note ,.,,,,,,,......,,,,,... page S- 21
4. Rear hatch lock assembly 7. Scuff plate, Trunk side cover, Trunk side trim,
Quarter trim (R.H. side)
Removal / Installation ,.........,..... page S- 98
8. Opener lever
9. Rear seat cushion
Removal / Installation . . . . . . . . . . . . . . . . page S-l 12
10. Rear hatch opener cable
s-22

TRUNK LID S
TRUNK LID
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, referrina to Installation Note.
m-kg, 69-95 in-lb)
1. Lid lock protector 6. High-mount stoplight (Interior mounted)
2. Trunk ooener cable Removal / Installation . . . . . . . . . . . . . . . . . . . . . Section T
3. Rear harness
4. Trunk lid
Adjustment Note . . . . . . . . . . . . . . . . . . . . . . . . . page S-34
5. Balance spring
Removal Note.. . . . . . . . . . . . . . . page S-34
Installation Note . .._. ._._.._.____...r..__ page S-34
Adjustment Note.. . . . . . . . . page S-34 7. Rear package trim
Removal / Installation . . . . . . . . . . . . . . . . . . page S-97
8. Lid hinge assembly
s-33

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

TRUNK LID LOCK AND OPENER S
TRUNK LID LOCK AND OPENER
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.
-.
*--
7.8-11 N-m
(60-110 cm-kg,
69-95 in-lb)
7.6-l 1 N.m (80-l 10 cm-kg, 69-95 in-lb)
03uosx-04
Trunk lid lock, Striker
Trunk lid opener, Opener cable
1. Trunk lid protector
5. Trunk lid protector
2. Trunk lid lock cylinder, Retainer
6. Scuff plate, B-pillar lower trim (L.H. side)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page S-
36
Removal I Installation . . . . . . . :.. page S-
97
3. Trunk lid lock assembly
7. Opener lever
4. Trunk lid striker
8. Rear seat
Removal / Installation . . . . . . . . . . . . . . . . page S-l 11
9. Trunk lid opener cable
s-35

S TRUNK LID LOCK AND OPENER
Removal Note
Trunk lid lock cylinder
1. Disconnect the opening rod from the trunk lid lock assembly.
2. Remove the retainer and the trunk lid lock cylinder and
-/
opening rod.
S-36

FUEL FILLER LID AND OPENER s
FUEL FILLER LID AND OPENER
COMPONENTS
Removal / Installation
1, Remove in the order shown in the figure.
2. Install in the reverse order of removal.
Note
l Remove the rear seat belt retractor for removal of the trunk side trim (PROTEGe).
(Refer to page S-101 .)
Filler lid Filler lid opener, Opener lever, Opener cable
1 . Filler lid 5. Trunk end trim
2.
3.
4. Lift spring (With opener) Removal / Installation . . . . . . . . . . . . . . . . page S- 97
Lock cylinder retainer (Without opener) 6. Trunk side trim (L.H. side)
Filler lid lock (Without opener) Removal I Installation . . . . . . . . . . . . . . . . page S- 97
7. Filler lid opener
8. Scuff plate (L.H. side)
Removal / Installation . . . . . . . . . . . . . . . . page S- 97
9. B-pillar lower trim (L.H. side)
Removal / Installation . . . . . . . . . . . . . . . . page S- 97
10. Rear seat
Removal I Installation .,.............. page S-l 11
11. Opener lever
12. Opener cable
s-37