1992 MAZDA PROTEGE Workshop Manual

SLIDING SUNROOF
Sliding sunroof does not operate
NG
Check SUNROOF 15A fuse = Repair harness and replace fuse OK
Turn ignition switch ON t
Check for battery voltage at terminal-wire (G/O) of sun-
roof switch connector NG-
_ Repair harness (Fuse box - Sunroof switch)
I OK
Check for battery voltage at terminal-wire (G) of sunroof
relay connector NG
- Repair harness (Sunroof switch-Sunroof relay) OK
Disconnect sunroof relay; check for continuity terminal-
wire (B) to ground NG
Repair harness (Sunroof relay - Motor body ground)
1 OK
Check sunroof relay (Refer to page S-82)
I Replace sunroof relay (Refer to page S-82)
1 OK
Disconnect motor connector; check for continuity be-
tween terminal-wires (L, Y, Y/R, Y/G) of sunroof relay
and motor connectors
I NG
- Repair harness (Sunroof relay - Motor) OK
Check motor assembly (Refer
I NG - Replace motor assembly (Refer to page S-81)
1 OK
Disconnect sunroof switch connectors; check for con-
tinuity between terminal-wires (L, L/W, L/G, L/Y, B) of
sunroof switch and motor connectors Repair harness (Sunroof switch - Motor)
23UOSX-033
MOTOR ASSEMBLY
Inspection
Motor
1. Disconnect the motor connector.
2. Verify that the motor operates when battery voltage is con-
nected to terminal (i) and a ground is connected to termi-
nal (j).
3. Reverse the above connections and verify reverse opera-
tion of the motor.
I I
23UOSX-034
S-81

S SLIDING SUNROOF
I c a
I
jh f db jht; a
23UOSX-035
a
a ACE
ftE-3
b ii ItI i:
(FRONT VIEW)
03uosx-14
Limit switch
Using the sunroof emergency handle (hex-head wrench) set
the roof panel in the positions shown, and check for continui-
ty between terminals of the motor assembly connector.
O----O: Indicates continuity
SUNROOF RELAY
Inspection
1. Disconnect the sunroof relay connector.
2. Check for continuity between terminals.
O---O: Indicates continuity
3. Check for continuity between terminals (c) and (i) when bat-
tery voltage is connected to terminal (f) and a ground is con-
nected to terminal (j).
SUNROOF SWITCH (OVERHEAD CONSOLE)
Inspection
1. Disconnect the sunroof switch connector.
2. Check for continuity between terminals.
m: Indicates continuity

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

SLIDING SUNROOF
_________- -- J
03uosx-149
03uosx-150
-___-
SLIDING ROOF
/ EMERGENCY HANDLE
Removal Note
Decoration cover, Lower panel cover
1. Slide the sunshade all the way to the rear.
2. Fully close the sliding panel.
3. Remove the decoration covers and lower panel cover in
the order shown.
Sliding roof trim
1. Open the slide panel approx. 10 cm (4 in).
2. Remove the sliding roof trim.
(1) Pull down the front.
(2) Pull the trim forward.
(3) Remove the trim, lifting it up, and out of the vehicle.
Sliding panel assembly
1. Close the sliding panel fully, and remove the installation nuts
from the sliding panel and the lower panel.
2. Remove the sliding panel by pushing it upward from inside
the vehicle.
Sunshade
1. Fully close the sunshade.
2. Turn the sliding roof emergency handle and move the sun-
shade
5-10mm (0.19-0.39 in) to the rear.

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

S SLIDING SUNROOF
DRIVE CABLE
o3uosx15
I-- _-_- ~_..___ -~--
BRACKET

- 031JOSX-1E 1 i0
FRONT
03uoti ----1
03uosx 163
S-86
TILTING GUIDE
GUID! ROLLER
Rear guide assembly
Pull out the drive cable.
installation Note
Rear guide assembly
1, Insert the drive cable into the tube.
Note
l Apply a liberal coat of grease to the drive cable and
friction surface of the rear guide assembly.
2. Adjust the left and right sides of the drive cable.
Note
l Insert the guide rail assembly into the guide rail and
match the rear end of the bracket into the notch at
the rear of the rail.
Motor assembly
Verify that the limit switches (LSI and LS2) of the motor are
as shown in the OFF position, and install the motor assembly.
Note
l Be certain of the cam position.
l Use the handle to position the cam correctly if
necessary.
l There are two lengths of motor assembly installa-
tion screws, long and short. Be sure to use the cor-
rect ones.
Guide rail cover, Set plate
1. Using the sliding roof emergency handle, turn the motor
to fully open the lower panel.
Note
l Because the roof panel and lower panel might in-
terfere with each other when the lower panel is ’
opened, check that the guide roller is correctly fitted
into the guide rail as shown. ..J
l Turn the motor while pushing the cable.

SLIDING SUNROOF S
03UOSX-16d
(SUNROOF) (MOONROOF)
03UOSX-16!
ADJUSTING SCREW
SECA-A
D
__--__..-- ---__.-__
031JOSX 16
__-__
-~-
03UOSX-16
2. Install the guide rail cover and set plate.
3. Turn the motor using the emergency handle, and visually
check the sliding, tilt-down and tilt-up operations.
Adjustment Note
Sliding panel assembly
Height
Adjust so that the height difference between the sliding panel
and the roof panel is
1.5mm (0.06 in) max, referring to below.
(Front portion)
1. Loosen installation screws (1) and (2).
If the adjustment is only about
2mm (0.08 in) don’t loosen
screw (1).
2. Turn the screws to adjust.
Turning to the right raises; to the left lowers.
3. Tighten installation screws (1) and (2).
(Rear portion)
1. Loosen the adjusting screw.
2. Adjust by moving the sliding panel.
3. Tighten the adjusting screw.
S-987

S SLIDING SUNROOF
SET--PLATE
5.8 f 0.3 (0.23 f 0.01)
D5.8U.3& (0.23 f 0.01
SEC. A-A
13uosx.030 mm (in)
03UOSX-16
TORQUE ADJUSTING NUT
PAWL WASHER
Gap 1, Verify that the sliding panel does not interfere with the roof
panel when opened.
2. Open the sliding panel fully and move the set plate forward
if necessary.
Caution
l If the set plate is moved too far forward, there may
be a malfunction or leakage.
Moving load
1. Measure the operation time of the sliding panel.
(From fully opened to fully closed or reverse operation.)
Specified time: 4-7 sec.
2. If not as specified, adjust the torque adjusting nut on the
motor.
Tightening torque:
3.9-4.9 N-m (40-50 cm-kg, 35-43 in-lb)
Caution
l Lock the nut with the paw1 washer after adjustment.