1992 MAZDA PROTEGE fuel

CONTROL SYSTEM F
VB: Battery voltage
Incorrect voltage Possible cause
Always OV l ROOM 10A fuse burned l Open circuit in wiring from ROOM 10A fuse to ECU terminal 1A
Always OV
l Main relay malfunction (Refer to page F-171) l Open or short circuit in wiring from main relay to ECU terminal 1B
Always OV (Starter turns)
l Open or short circuit in wiring from or inhibitor switch (ATX) to ECU termi-
nal 1C
Always OV
Always Ve
Always 4.5~5.5U
l Main relay (FUEL INJ relay) malfunction (Refer to page F-171) l Open circuit in wiring from main relay to diagnosis connector terminal +B l Open or short circuit in wiring from diagnosis connector terminal MEN to
ECU terminal 1D
l Poor connection at ECU connector l ECU malfunction
l ECU malfunction
Always below
25v
Always Va MIL always ON
MIL never ON
l Short circuit in wiring from combination meter to ECU terminal 1E l ECU malfunction
l Open circuit in wiring from combination meter to ECU terminal 1E
l Poor connection at ECU connector l ECU malfunction
Always below
2.5V
Always VB No display on Self- * Main relay (FUEL INJ relay) malfunction (Refer to page F-171)
Diagnosis Checker
l Open circuit in wiring from main relay to diagnosis connector terminal +B
“88” displayed and
l Open or short circuit in wiring from diagnosis connector terminal FEN to
buzzer sounds con- ECU terminal 1F
tinuously
l Poor connection at ECU connector l ECU malfunction
Always OV
l Short circuit in wiring from igniter to ECU terminal 1G
Always below 1 .OV (Headlights OK)
l Open or short circuit in wiring from headlight relay to ECU terminal 1H
(Refer to page F-171)
Always OV
Always VB
Always OV Illumination lamp
ON when rear
window defroster
switch ON
Illumination lamp
never ON
Approx. 5V (California)
Always OV (Canada)
l Short circuit in wiring from diagnosis connector terminal TEN to ECU termi-
nal II
l Open circuit in wiring from diagnosis connector terminal TEN to ECU termi-
nal II
l Open circuit in wiring from diagnosis connector terminal GND to ground
l Open or short circuit in wiring from rear window defroster switch to ECU
terminal 1 J
l Open circuit in wiring from ignition switch to rear window defroster switch l Rear window defroster switch malfunction (Refer to page T-21)
l Open circuit in wiring from ECU terminal 1K to ground
l Short circuit in wiring from ECU terminal 1K to main relay (FUEL INJ relay)
23UOFX-14: 2
f-1 59

CONTROL SYSTEM
Ve: Betterv voltaae
Incorrect voltage Possible csuse
Always OV l Main relay (FUEL INJ relay) malfunction (Refer to page F-172) l Open or short circuit in wiring from injector to ECU terminal 3U or 3V
Always Ve
l ECU malfunction
Always OV
Always Ve
l 1-2 shift solenoid valve malfunction (Refer to page K-143) l Short circuit in wiring from solenoid valve to ECU terminal 3W
I
l l-2 shift solenoid valve malfunction (Refer to page K-143) l Ooen circuit in wiring from solenoid valve to ECU terminal 3W
Always OV
l 2-3 shift solenoid valve malfunction (Refer to page K-143) l Short circuit in wirino from solenoid valve to ECU terminal 3X
Always VB
Always OV
l 2-3 shift solenoid valve malfunction (Refer to page K-143) l Open circuit in wiring from solenoid valve to ECU terminal 3X
l 3-4 shift solenoid valve malfunction (Refer to page K-143) l Short circuit in wiring from solenoid valve to ECU terminal 3Y
Always
VB l 3-4 shift solenoid valve malfunction (Refer to page K-143) l Open circuit in wiring from solenoid valve to ECU terminal 3Y
Always OV
l Lockup solenoid valve malfunction (Refer to page K-143) l Short circuit in wiring from solenoid valve to ECU terminal 32
Always Ve
l Lockup solenoid valve malfunction (Refer to page K-143) l Open circuit in wiring from solenoid valve to ECU terminal 32
23UOFX-1 E i0
F-l 67

F CONTROL SYSTEM
23UOFX-15
23UOFX-15
23UOFX-15
LOCK
4
I
13UOFX-oc
F-l 72
6. Turn the ignition switch OFF.
7. Disconnect the negative battery terminal for
at least 20 sec.
to eliminate the malfunction code that was created during
inspection from the control unit memory.
Replacetnent
1. Disconnect the oxygen sensor connector.
2. Remove the oxygen sensor.
3. Install in the reverse order of removal.
Tightening torque:
29-49 N-m (3-5 m-kg, 22-36 ft-lb)
MAIN RELAY (FUEL INJ RELAY)
Inspection
1. Verify that the main relay clicks when turning the ignition
switch ON and OFF.
2. Apply battery voltage to terminal A and ground terminal E3
of the main relay.
3. Check continuity of the terminals as shown.
VB: Battery voltage
Terminals 1 Ve not applied VB applied
C-D No continuity Continuity
4. If not as specified, replace the main relay.
CLUTCH SWITCH (MTX)
Inspection
1, Disconnect the clutch switch connector.
2. Connect an ohmmeter to the switch.
3. Check continuity of the switch.
Pedal Continuity
Depressed Yes
Released No
4. If not as specified, replace the clutch switch. ,
Replacement
1. Disconnect the clutch switch connector.
2. Loosen the locknuts.
3. Remove the clutch switch.
4. Install in the reverse order of removal.
5. Adjust the pedal height. (Refer to page H-6.)

R OUTLINE
OUTLINE
SPECIFICATIONS
Suspension type Item Specification Strut
Shock absorber Double-acting, oil-filled
Coil spring
Stabilizer Type Front Taper wound
Rear Straight wound
Dimension See coil spring specification below
Type Torsion bar
BP SOHC Front 19.1 (0.75) (Hollow type)
Rear 20.0 (0.79) (Hollow type)
Diameter 22.0 (0.87) (Solid type)
mm (in) BP DOHC ;eTrt
21 .O (0.83) (Solid type)
P ,
-
66 SOHC rronr
Rear 20.0 (0.79) (Hollow type)
Maximum Inner 400 f 20
steering angle
Outer 330 f 20
Total mm (in) 2 f 3 (0.08 f 0.12)
Front toe-in
degree 0.2O f 0.3O
Wheel alignment
(*‘Unladen) Camber angle -0005’ f 45’
Caster angle 1055 * 55’
Kingpin angle 12O25’
Total mm (in) 2 f 3 (0.08 * 0.12)
Rear toe-in
degree 0.2O f 0.3O
Camber angle -0°20’ f 45’
*’ Fuel tank full; radiator coolant and engine oil at specified levels; and spare tire, jack, and tools in designated positions.
23UORX.004
Coil Spring Specifications (See next page for coil spring applications)
I Item Wire diameter Coil center Free lel.=-. .
mm iin1 rliamotor mm [in mm (in 1 coil numbs
Front
nath
1 _ . . *St Identification mark color +l
., . . . . I...,
-*.....-.“, * . . . . . ,..-, -....- I--‘, M iA*=
A 13.1 (0.52) 133.5-159.5 (5.26-6.28)
294.5 (11.59) 3.22 Light green
B 13.3 (0.52) 133.7-159.9 (5.26-6.30) 300.5 (11.83)
3.43 Purple Yellow
C 13.4 (0.53)
132.6-158.6 (5.22-6.24) 301.5 (11.87) 3.49
Light blue
D 13.7 (0.54)
132.9-158.9 (5.23-6.26) 302.0 (11.89) 3.52
Pink White
I F I 12f3 Kl5Al I 1.17 A-l!% 8 f!i PR-Fi 751
I RrIl .5 II 1 6x71 I 3.56 Orange
Blue
3 83 Pink -
Brown - .“._ \“.- .,
. “W.., ~ - -. - \-. -- -. - -, -- .-
\’ .‘-‘I t
F 11 .o (0.43) 129.0 (5.08)
335.0 (13.19) -.--
G 11.2 (0.44) 128.8 (5.07)
334.0 (13.15) 3.94
Rnnr l-4
1 I ? 07 AA 1387 /5n7
.?m !i 113 1% 3 an Blue - I I I I .” \v.-7, I&V., \V.“., ---.., \.-. .-, I 11.5 (0.45) 128.5 (5.06)
333.0 (13.11) i:oi Gray
-
J 11.6 (0.46) 128.4 (5.06)
332.5 (13.09) 4.00 Orange
-
l ’ Main identification mark color: Indicated on second coil from bottom.
*’ Auxiliary identification mark color: Indicated on third coil from bottom. 23UORX-005
R-4

WHEEL ALIGNMENT
WHEEL ALIGNMENT
PRE-INSPECTION
1. Check the tire inflations and set to the recommended pressure, if necessary.
2. Inspect the front wheel bearing play; replace the bearing if necessary.
3. inspect the wheel and tire runout.
4. Inspect the ball joints and steering linkage for any excessive looseness.
5. The vehicle must be on level ground and have no luggage or passenger load.
6. The difference in height between the left and right sides from the center of the wheel to the fender brim
must not exceed
10mm (0.39 in).
7. Shake the vehicle to check operation of the shock absorbers.
03UORX.007
FRONT WHEEL ALIGNMENT
Specifications
item
Specifications
Maximum Inner 4o” f: 2O
steering angle Outer
33O f 2O
Total mm (in) 2 f 3 (0.08 f 0.12)
toe-in dearee 0.20 f 0.30 Wheel alignment
(*‘Unladen) Front
*I Fuel tank full; radiator coolant and Camber angle -0005 * 45’
Caster angle 1°55’ f 55’
Kingpin angle 12O25’
engine oil at specified level; and spare tire, jack, and tools in designated positions.
23UORX-008
I
I 23UORX-023
Adjustments
Maximum steering angle
1. Loosen the left and right tie rod locknuts, then turn the tie
rods equally.
Maximum left/right difference: 3mm (0.12 in)
2. Tighten the tie rod locknuts.
Tightening torque:
34-50 N-m (3.5-5.1 m-kg, 25-37 ft-lb)
3. Adjust the toe-in after adjusting the steering angle.
4. Inspect and adjust the toe-in after adjusting the turning angle.
I 23UORX-024
R-7

WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT
Specifications
kern Specifications
Total mm (in) 2 f 3 (0.08 f 0.12)
Wheel alignment
(*‘Unladen) Rear toe-in
degree 0.2O f 0.3O
Camber angle -0020’ f 45’
*I Fuel tank full; radiator coolant and engine oil at specified level; and spare tire, jack, and tools in designated positions.
13UORX-012
Adjustment
Total toe-in
1. Loosen the lateral link locknuts.
2. Turn the lateral link adjustment link to adjust.
Note
l One turn of the link changes 11.3mm (0.44 in).
3. Tighten the lateral link locknuts to the specified torque.
Tightening torque:
55-64 N,m (5.6-6.5 m-kg, 41-47 ft-lb)
R-9

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
NDEX
1. Hood
Components ............................... page S- 5
2. Front fender panel
Components ............................... page S- 7
3. Front door
Components ............................... page S- 8
4. Front side window regulator and glass
Components ............................... page S-l 0
5. Front door lock and opener
Components ............................... page S-l 3
6. Power door lock system
Structural view.. .......................... page S-23
Troubleshooting guide.. .............. page S-24
Door lock switch.. ....................... page S-26
Door lock control.. ...................... page S-26
Door lock timer and relay ........... page S-26
7. Power window system
Structural view ............................ page S-27
Troubleshooting guide.. .............. page S-28
Main power window switch.. ...... page S-31
Power window sub-switch .......... page S-32
Power window motor .................. page S-32
8. Fuel filler lid and opener
Components ............................... page S-37
9. Front bumper
Components ............................... page S-39
23UOSX-03
10. Molding, protector, garnish
Upper windshield molding,
A-pillar garnish.. ........................ page S-42
Roof molding .............................. page S-46
Beltline molding.. ........................ page S-48
Side protector.. ...........................
page S-49
11. Radiator grille, lower grille molding
Components ....................... . ....... page S-51
12. Cowl grille
Components ............................... page S-53
13. Outside mirror
Troubleshooting guide ................ page S-54
Power outside mirror switch.. ..... page S-55
Power outside mirror.. ................ page S-56
Components ............................... page S-56
14. Windshield
Components ...............................
page S-58
15. Windshield wiper and washer
Troubleshooting guide.. .............. page S-67
Wiper motor ................................ page S-70
Washer motor.. ........................... page S-71
Windshield wiper and
washer switch ........................... page S-71
Components ............................... page S-72
16. Sliding sunroof
Troubleshooting guide ................ page S-80
Motor assembly.. ........................ page S-81
Sunroof relay ..............................
page S-82 .--‘-
Sunroof switch ............................ page S-82
Components ............................... page S-83
s-2