wheel MAZDA PROTEGE 1992 Workshop Manual

1992
Mazda
CONTENTS
Protege
Workshop
Manual
FOREWORD
This workshop manual is intended for use
by service technicians of Authorized Mazda
Dealers to help them service Mazda vehicles.
For proper repair and maintenance, a
thorough familiarization with this manual is im-
portant, and it should always be kept in a han-
dy place for quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest avail-
able at the time of printing. As modifications
affecting repair or maintenance occur, relevant
information supplementary to this volume will
be made available at Mazda dealers. This
manual should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of this
manual without obligation or advance notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by any
means, electronic or mechanical-including
photocopying and recording and the use of
any kind of information storage and retrieval
system-without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN)
shown on the following page.
Title
General Information Section
Pre-Delivery Inspection and
Scheduled Maintenance Services
SOHC
Engine
DOHC
Lubrication System
Cooling System
Fuel and Emission Control System
Engine Electrical System
Clutch
FSM-R
Manual Transaxle
GSM-R
Automatic Transaxle
Front and Rear Axles
Steering System
Braking System
Wheels and Tires
Suspension
Body
--
Body Electrical System
Heater and Air Conditioner Systems
Technical Data
Special Tools
Parts Index
Wiring DNvam
I Part No. 5209-10-91 F)
9999~95-019(3-92)
o 1991 Mazda Motor Corporation
PRINTED IN USA, JUL. ‘91
1270-l O-91 G
(9999-95-0178-92)

FUNDAMENTALPROCEDURES GI
SMUGIX-0: B
47UOGX-00 5 ‘3
16
A WORD ABOUT SAFETY
The following precautions must be followed when jacking up
the vehicle.
1. Block the wheels.
2. Use only the specified jacking positions.
3. Support the vehicle with safety stands.
Start the engine only after making certain the engine compart-
ment is clear of tools and people.
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT
Be sure that all necessary tools and measuring equipment are
available before starting any work.
SPECIAL TOOLS
Use special tools when they are required.
REMOVAL OF PARTS
While correcting a problem, try also to determine its cause.
Begin work only after first learning which parts and subassem-
blies must be removed and disassembled for replacement or
repair.
DISASSEMBLY
If the disassembly procedure is complex, requiring many parts
to be disassembled, all parts should be disassembled in a way
that will not affect their performance or external appearance
and identified so that reassembly can be performed easily and
efficiently.
GI-5

TOWING
.-
WHEEL dOLLlES
03UGIX-00
TOWING
Proper towing equipment is necessary to prevent damage to
the vehicle.
Y
Laws and regulations applicable to vehicles in tow must al-
ways be observed.
As a general rule, towed vehicles should be pulled with the
driving wheels off the ground. If excessive damage or other
conditions prevent towing the vehicle with the driving wheels
off the ground, use wheel dollies.
With either automatic or manual transaxle:
1. Set the ignition switch in the ACC position;
2. Place the selector lever or shift lever in N (Neutral);
3. Release the parking brake.
Caution
l Do not tow the vehicle backward with driving wheels
on the ground. This may cause internal damage to
the transaxles.
l Do not use the hook loops under the front and rear
of the vehicle for towing purposes. These hook
loops are designed ONLY for transport tie-down. If
tie-down hook loops are used for towing, the
front/rear bumper will be damaged.
TIE-DOWN HOOKS - FRONT
TIE-DOWN HOOKS - REAR (HATCHBACK) TIE-DOWN HOOKS - REAR (PROTEGk)
GI-9

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

7 Schedule 1 (Normal Driving Conditions) (Cont’d)
MAINTENANCE
INTERVALS 1 ::::“’ rths ’ 7.5
DPERATION x 1,000 miles
x 1,000 km 3r mi
15
15
24
1
Page
l- . whichever comes first s (kilometer!
37.5
37.5
60 52.5
52.5
64 60
60
96
I
l-7
Service data and inspection points
l Hoses for cracks or wear l Coolant level E-5
Zooling system
Engine coolant
Fuel filter
‘die speed
Fuel lines
Brake lines, hoses and connections
l Coolant capacity:
5.0 liters (5.3 US qt, 4.4 Imp qt) . . . . . . . . . . MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) . . . . . . . . . . ATX
I E-6 -
F-l 24
l ATX: P range, MTX: Neutral
700-800 rpm (with parking brake applied)
l Fittings, connections, and components for F-80
F-120
-
H-6
P-28
P-29
P-20
P-25
P-18
P-25
---
N-27
N-8
-
M-21
-
F-136
u-35
u-39 leaks
0 Proper attachment and connections
l Operation l Pedal height (with carpet):
196-204mm (7.72-8.03 in)
l Free play:
5--13mm 10.197-0.512 in) Clutch pedal
l Wheel cylinder operation and leakage
l Lining for wear or damage l Lining thickness:
Minimum . . . . . 1 .Omm (0.04 in)
l Drum inner diameter
Maximum..... 201mm (7.91 in) Drum brake
l Caliper operation l Disc plate thickness:
Minimum.... Front 20mm (0.79 in)
Rear 7.0mm (0.28 in)
l Pad thickness:
Minimum.... Front 2.0mm (0.08 in)
Rear l.Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozing l Free play.... O-30mm (O-l .18 in)
l Damage, looseness, and grease leakage
l Cracking and damage
l Retighten all loose nuts and bolts I
1
Disc brake
I
---l-T
Steering operation and linkage
Front suspension ball joints
Drive shaft dust boots
Bolts and nuts on chassis and body
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor am01 anni I
l Insulation clearance
- ,.
Inspect rerrlgerar
Inspect operation annually -

I
Schedule 2 (Unique Driving Conditions) (Cont’d)
(kil
I :
I :
’ 1 iii ichever comes first lometers), Y
25 30 35
25 30 35
40 48 58
I
45
45
72 50
50
80
-
-
I
I
I
I
I
T
I
,
40
iii
i5i
-
-
-
-
-
-
-
-
-
I
-
-
T -
-
-
- -
1 nspec L :t rerngeranr amount annually
Inspect operation annually m
rs
E
24
-
-
-
I
-
-
-
T
-
T fn
iiF
is
w
-
-
-
-
-
-
-
-
- iii
iii
,s
-
I
-
I
-
I
-
I
T
I-
r
T
-
T7
Service data and inspection points Page l
Operation l Pedal height (with carpet):
196-204mm (7.72-8.03 in) l
Free play
5-13mm (0.197-0.512 in) l
Wheel cylinder operation and leakage l Lining for wear or damage l Lining thickness:
Minimum l.Omm (0.04 in) l
Drum inner diameter: H-6
Clutch pedal
P-28
P-29 Drum brake
Maximum 201mm (7.91 in) l
Caliper operation l Disc plate thickness:
Minimum Front.... 20mm (0.79 in)
Rear . . . . . 7.0mm (0.28 in) l
Pad thickness:
Minimum Front.... 2.0mm (0.08 in)
Rear . . . . . 1 .Omm (0.04 in) l
Operation and looseness l Fluid leakage or oozing l Free play.... O-30mm (O-l.18 in) l
Damage looseness and grease leakage l
Cracking and damage l
Retighten all loose nuts and bolts l
Insulator clearance
-
- P-20
P-25
P-18
P-25
N-27
N-8 Disc brake
Steering operation and linkage
Front suspension ball joint
Drive shaft dust boots
Bolts and nuts on chassis and body
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor -
M-21
-
F-136
u-35
u-39

7 Schedule (Cont’d)
rile
iii
48
30
-
R
I
R !rs
25
40
25
-
-i- , whichever comes first
OPERATION MAINTENANCE Number of m
INTERVALS Months
x 1,000 km
x 1,000 miles
ii
is
G
-
i-
-
-
I
5-
T
-
-
-
-
-
-
- ii
z
ro
-
I-
-
-
I
- 45
72
45
-
-i-
-
-
I
-
ry 15 month:
I I I
A
t
A
j
milt Service data and inspection points Page
l Capacity
MTX B6, BP SOHC:
2.68 liters (2.83 US qt, 2.36 Imp qt)
BP DOHC
3.35 liters (3.55 US qt, 2.96 Imp qt)
ATX: 6.3 liters (6.7 US qt, 5.5 Imp qt)
l Level and condition
- Jl-7
J2-7
- Transaxle oil
l Wear and damaae -i- -i- -i- -
Brake fluid, clutch fluid
Brake fluid*3 -
Q-3, 5
Q-6
N-27
P-28
P-29 I I
- I
1,oo
-i
-
-
-
-
-
-
- I
G
T
-
-
-
-
-
-
- I
15,(
I Tire inflation pressure and wear l Proper pressure-
-
l Level and condition
l Wheel cylinder operation and leakage l Lining for wear or damage l Lining thickness:
Minimum 1 .Omm (0.04 in)
l Drum inner diameter. 3s) or f
I I
I
:t r
- Rotate tires
Power steering fluid
Drum brake ? every
I I
Disc brake I I
Maximum 201mm (7.91 in)
l Caliper operation l Disd plate thickness:
Minimum Front.... 20mm (0.79 in)
Rear . . . . . 7.0mm (0.28 in)
l Pad thickness:
Minimum Front.... 2.0mm (0.08 in) P-20
P-25
P-l 8
P-25
N-27
N-8 Rear . . . . . 1 .Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozina
l Free play.... O--3OmmjO-1.18 in)
l Damage looseness and grease leakage
l Cracking and damage
l Insulator clearawp .-v
-
Steering operation and linkage
I
-i-
-I-
-i- Front suspension ball joint
Drive shaft dust boots
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor
Suspension components (front and rear)
All chassis and body nuts and bolts
All locks and hinaes
Washer fluid -
M-21
F-136
u-35
u-39
-
- IY efrigerant amount ann
*. I# mspec
Inspect operation annualry -
l Damaae
l Retighten all loose nuts and bolts
l Lubricate all locks and hinges
l Level
l ODeration - Function of all lights l !%t and damage -

Bl ON-VEHICLE MAINTENANCE
TIMING BELT
Removal / Installation
1. Disconnect the negative battery cable.
2. Raise the vehicle on a lift and remove the right front wheel.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referrina to Installation Note.
7.6-11 N.m
[SO-110 cm-kg, 69-95 in-lb)

7.6-11 N.m
(60-l 10 cm-kg,
0 69-95 in-lb)
, .v- I . (60-110 cm-kg, 69-95 in-lb)
157-167 (16-17, 116-123) /@ 7.i11 N.m
(60-110 cm-kg,
69-95 in-lb)
N.m (m-kg, ft-lb]
23UOBl-01
1. Under cover and side cover 10. Timing belt cover, lower
2. P/S and/or A/C drive belt 11. High-tension leads
3. Alternator drive belt 12. Spark plugs
4. Water pump pulley 13. Timing belt
5. Plate Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-13
6. Pulley lock bolt Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-13
Removal Note ..,.,,.,....,....,...,...,, page Bl-13 14. Tensioner
installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-14 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 81-13
7. Crankshaft pulley 15. Tensioner spring .__
8. Pulley boss Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 61-13
9. Timing belt cover, upper
131-12

-.
ON-VEHICLE MAINTENANCE Bl
REAR OIL SEAL
Replacement
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 !.
I
16-26 (1.6-2.7, 13-20) I HTX
ATX
N.m (m-kg, R-lb)
23UOBl-027
1. Transaxle
MTX
Service.. ............................... Sections Jl , J2
ATX
Service .......................................... Section K
2. Clutch cover, clutch disc
Service .......................................... Section H 3. Flywheel (MTX)
Removal Note ..................................... below
Installation Note ........................ page 81-26
4. Drive plate (ATX)
Removal Note.. ......................... page Bl-26
Installation Note.. ...................... page Bl-27
5. Oil seal
Removal Note.. ......................... page 81-26
Installation Note ........................ page 81-26
Removal note
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
Bl-25

Bl ON-VEHICLE MAINTENANCE
OIL SEAL LIP
L I I
OWOBX-063
05UOBX-069
Drive plate (ATX)
1. Hold the drive plate with the SST or equivalent.
2. Remove the drive plate lock bolts.
3. Remove the backing plate, drive plate, and adapter.
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
Installation note
Oil seal
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. Push the oil seal slightly in by hand.
Caution
l The oil seal must be tapped in until it is flush with
the edge of the rear cover.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 1OOmm (3.94 in)
Flywheel (MTX)
1. Remove the sealant from the flywheel bolt holes in the crank-
shaft and from the flywheel bolts.
Caution
l If all the previous sealant cannot be removed from
a bolt, replace the bolt.
l Do not apply sealant if a new bolt is used.
2. Set the flywheel onto the crankshaft.
3. Apply sealant to the flywheel bolts and install them.
4. Hold the flywheel with the SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown
in the figure.
Tightening torque:
96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)