1992 MAZDA PROTEGE suspension

REAR CROSSMEMBER
Removal / Installation
REAR SUSPENSION (STRUT) R
1. Jack up the vehicle and support it with safety stands.
2. Remove the wheels and tires.
3. Remove the brake pipe holder.
4. Remove in the order shown in the figure.
5. Inspect all parts and repair or replace as necessary.
6. Install in the reverse order of removal, referring to
Installation Note.
7. After installation, check the rear wheel alignment and adjust it if necessary.
Caution
l Loosely tighten the lateral link and trailing link bolts and nuts when installing. Lower the vehi-
cle and tighten all nuts and bolts to the specified torques with the vehicle unladen.
46-63 (4.7-6.4, 34-46)
66-117 (6.7-11.9, 63-66)
I
66-95 (W-9.7,
43-59 (4.4-6.0, 32-43)
63-93 (6.4-9.5, 46-69)
N.m (m-kg, ft-lb)
‘)‘)I ano” n,
1. Nut (Stabilizer)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Bushing and retainer
3. Bolt, retainer and bushing
4. Retainer, bushing and spacer
5. Bolt (Lateral link)
6. Bolt (Trailing link)
7. Bolt (Trailing link) 8. Trailing link
page R-28 9. Bolt (Lateral link)
10. Lateral link (front and rear)
Il. Bolt
12. Rear stabilizer
13. Bolt and washer
14. Rear crossmember
R-29

E F G H I J
-
A: CROSSMEMBER REFERENCE HOLE $12 (0.47) G: FRONT FRAME B REFERENCE HOLE 914 (0.55)
B: CROSSMEMBER REFERENCE HOLE 412 (0.47) H: FRONT FRAME B REFERENCE HOLE 412 (0.47)
C: FRONT FRAME REFERENCE HOLE $16 (0.63) I: TRAILING LINK BRACKET REFERENCE HOLE 410 (0.39)
2 E: CROSSMEMBER MOUNTING BOLT J: REAR SUSPENSION MOUNTING NUT
is F: CROSSMEMBER MOUNTING NUT L: REAR SIDE FRAME REFERENCE HOLE 16x22 (0.63x0.87)
2 mm (in)
& ,

TD
TECHNICAL DATA
MEASUREMENTS .................................... TD- 2
ENGINE (B6 AND BP SOHC)
ENGINE (BP DOHC) ... .................................................. ;;- f
LUBRICATION SYSTEM ........................... TDI 6
COOLING SYSTEM .................................. TD- 6
FUEL AND EMISSION CONTROL
SYSTEMS ............................................. TD- 9
ENGINE ELECTRICAL SYSTEM ................ TD-10
CLUTCH ................................................. TD-11
MANUAL TRANSAXLE (F5M-R) ................ TD-12
MANUAL TRANSAXLE (GSM-R) ................ TD-13
AUTOMATIC TRANSAXLE ....................... TD-14
FRONT AND REAR AXLES.. .....................
STEERING SYSTEM ................................ ;;-;;
-
BRAKING SYSTEM .................................. TD-16
WHEELS AND TIRES ............................... TD-19
SUSPENSION ......................................... TD-19
BODY ELECTRICAL SYSTEM ................... TD-20
HEATER AND AIR CONDITIONER
SYSTEMS ............................................. TD-21
STANDARD BOLT AND NUT TIGHTENING
TORQUE .............................................. TD-21
23UTDX-001

TECHNICAL DATA
Q. WHEELS AND TIRES
Item Specifications
Wheel
Size
Off set Standard: 13x5-J, 14x5 l/2-JJ
Temporary
mm (in) 1 _ spare: 14x4-T
45 (1.77)
I Diameter of oitch circle
mm (in) I 100 (3.94)
r I Pl
-
Inflation pressure kPa (kg/cm*, psi) Front 1 8
I 9
Runout limit
Unbalance limit mm (in) ;lii.raltLa’
a (02) ’
13 inch wheel: 11 (0.
R. SUSPENSION Item Specifications
Suspension type Strut
)e Double-acting, oil-filled
I Shock absorber tyf
Coil spring
Type
Dimension
Type Front Taper wound
Rear Straight wound
See next page
Torsion bar
I
I C.rrn,
19.1 (0.75)
20.0 (0.79)
22.0 (0.87)
21 .O f0.83)
Wheel alignment
(“‘Unladened) BP SOHC ;;a;
Diameter
mm (in) BP DOHC - ;la;t
Front -
B6 SOHC
Rear 20.0 (0.79)
Maximum Inner 4o” f 2O
steering angle Outer
Total mm (in) 2 f 3 (0.08 j
Front toe-in
dearee
.-.._
Rear
.--. I --- ~~
Camber angle
Caster angle
Kingpin angle
I Total
I mm OnI I I toe-in
1 dearee I , --U’-- 1
Camber angle
I 33O * 2O
: 0.12)
0.2O f 0.3O
-0OO5’ * 45’
1055’ * 55’
12O25’
2 f 3 (0.08 f 0.12)
0.2O f 0.3O
-0°20’ f 45’
l ’ Fuel tank full; radiator coolant and engine ail at specified level; and spare tire, jack, and tools in designated posmons.
TD-19

SPECIAL TOOLS
GENERAL INFORMATION ........................
ENGINE .................................................. i;-
- ‘3
CLUTCH AND MANUAL TRANSAXLE.. ...... ST- 4
AUTOMATIC TRANSAXLE.. ...................... ST- 5
FRONT AND REAR AXLES.. ..................... ST- 7
STEERING SYSTEM ................................ ST- 8
BRAKING SYSTEM .................................. ST- 9
FRONT AND REAR SUSPENSIONS.. ......... ST-10
HEATER AND AIR CONDITIONER
SYSTEMS ............................................. ST-l 0
CHECKER AND OTHER EQUIPMENT.. ....... ST-10
23USTX-001

ST SPECIAL TOOLS
FRONT AND REAR SUSPENSIONS
TOOL NUMBER
& DESCRIPTION PRIORITY ILLUSTRATION
49 8034 2A0
Replacer set,
rubber bush A
49 1243 785
Installer, dust
boot A TOOL NUMBER
81 DESCRIPTION PRIORITY ILLUSTRATION
49 GO34 1AO
Compressor, coil A
spring
49 0208 701A
Air-out tool, boot B
HEATER AND AIR CONDITIONER SYSTEMS
TOOL NUMBER
PRIORITY ILLUSTRATION TOOL NUMBER
i? DESCRIPTION & DESCRIPTION PRIORITY ILLUSTRATION
49 BO61 005
Replacer, seal
plate A 0000-41-0809-06
Remover &
installer, seal
CHECKER AND OTHER EQUIPMENT
TOOL NUMBER
81 DESCRIPTION
49 0839 285
Checker, fuel &
thermometer
49 GO19 901A
EC-AT tester
49 BO19 904
Panel
(EC-AT tester) PRIORITY
A
A ILLUSTRATION
49 GO19 901
EC-AT tester
49 HO19 902
(EC-AT tester)
49 BO19 905
ST-10

PARTS INDEX
I
CRANKSHAFT.. ....................................
I31 -64
CYLINDER BLOCK .............................. 61-60
CYLINDER HEAD..
............................... 81-54
CYLINDER HEAD GASKET .................
Bl-16
DRIVE BELT(S). ...................................... 81-5
FRONT OIL SEAL ................................ 81-23
HLA .............................................. Bl-7,20,60
OIL JET ................................................ 81-61
PISTON.. ...............................................
Bl-62
PISTON PIN..
........................................ 81-62
PISTON RING
....................................... 81-62
REAR
OIL SEAL..
................................. 81-25
TENSIONER, IDLER ............................. Bl-65
TENSIONER
SPRING ...........................
Bl-65
TIMING BELT ..................................
Bl-12,65
TIMING BELT PULLEY ........................
Bl-65
VALVE MECHANISM ........................... Bl-55
ENGINE
(BP DOHC) .................................... B2-2
CAMSHAFT ..........................................
82-58
CAMSHAFT PULLEY ...........................
B2-65
CONNECTING ROD..
........................... 82-63
CRANKSHAFT ......................................
B2-64
CYLINDER BLOCK ..............................
82-60
CYLINDER
HEAD.. ............................... B2-54
CYLINDER HEAD GASKET .................
82-16
DRIVE
BELTS.. .......................................
B2-5
FRONT
OIL SEAL ................................
82-26
H LA ..............................................
OIL JET .......................... B2-7iyL;;
......................
PISTON .................................................
B2-62
PISTON PIN ..........................................
82-62
PISTON RING..
..................................... 82-62
REAR OIL SEAL ................................... B2-28
TENSIONER, IDLER ............................. B2-65
TENSIONER SPRING ........................... B2-65
TIMING
BELT.. ................................
B2-12,65
TIMING BELT PULLEY ........................ 82-65
VALVE MECHANISM ........................... 82-55
ENGINE CONTROL UNIT (ECU) ............... F-149
ENGINE COOLANT
........................................ E-5
ENGINE OIL.. .................................................
D-7
ENGINE OIL FILTER.. .................................... D-8
’ EXHAUST SYSTEM. ...................................
F-136
EXTRACTOR CHAMBER .............................. S-53
F
FAN MOTOR (COOLING FAN). ................... E-14
FAN RELAY (COOLING FAN). ..................... E-18
FLASHER UNIT ............................................
T-17
FLOORMAT ..................................................
S-99
FLYWHEEL ..................................................
H-18
FRONT AXLE .................................................
M-4
FRONT BRAKE ............................................
P-l 8
FRONT BUMPER ......................................... S-39
FRONT DOOR ................................................
S-8
FRONT DOOR LOCK AND OPENER ..........
S-13
PI-2
FRONT FENDER PANEL ............................... S-7
FRONT LOWER ARM .................................. R-16
FRONT SHOCK ABSORBER AND SPRING R-11
FRONT SIDE WINDOW REGULATOR AND
GLASS ........................................................ S-10
FRONT STABILIZER..
................................... R-l 8
FRONT SUSPENSION .................................. R-l 0
FUEL FILLER LID AND OPENER..
.............. S-37
FUEL FILTER .............................................. F-l 24
FUEL GAUGE SENDER UNIT ..................... T-73
FUEL PUMP ............................................... F-125
FUEL TANK
................................................ F-123
FUSE AND JOINT BOX.. .............................. T-12
H
HEADLIGHT AND
FRONT COMBINATION LIGHT..
................ T-41
HEADLIGHT RELAY ..................................... T-l 8
HEADLINER ................................................. S-89
HEATER CONTROL UNIT.. ......................... U-26
HEATER UNIT
.............................................. U-21
HIGH-MOUNT STOPLIGHT
.......................... T-45
HIGH-TENSION LEAD ................................. G-l 7
HOOD ............................................................. S-5
HORN T-88
...........................................................
HORN RELAY
.......................................... T-18,88
.__. ’
I I
IGNITER .......................................................
G-23
IGNITION COIL.. .......................................... G-19
INJECTOR .................................................. F-l 31
INSTRUMENT CLUSTER
AND SPEEDOMETER CABLE
.................... T-69
INTAKE MANIFOLD ................................... F-113
INTERIOR LAMP ..................................... T-52,53
ISC VALVE.. ................................................ F-l 16
J
JOINT SHAFT (FRONT AXLE) .................... M-18
L
LATERAL LINK AND TRAILING LINK.. ....... R-26
LICENSE PLATE LIGHT.. ............................. T-47
i
M
I
---
MAIN RELAY (FUEL INJ. RELAY). ............ F-172
MANUAL STEERING ..................................... N-4
MANUAL TRANSAXLE (F5M-R). .................. Jl-2

PARTS
DIFFERENTIAL ..................................... Jl-52
SHIFT MECHANISM ............................. Jl-56
TRANSAXLE ............................................ Jl-8
TRANSAXLE OIL .................................... Jl-7
MANUAL TRANSAXLE (G5M-R) .................. J2-2
DIFFERENTIAL ..................................... J2-43
SHIFT MECHANISM ............................. J2-46
TRANSAXLE.. .......................................... J2-8
TRANSAXLE OIL .................................... J2-7
MOLDING, PROTECTOR, GARNISH ...........
S-42
BELTLINE MOLDING ............................. S-48
REAR WINDOW MOLDING.. ............. S-43,44
ROOF MOLDING.. .................................. S-46
SIDE PROTECTOR ................................. S-49
UPPER WINDSHIELD MOLDING,
A-PILLAR GARNISH ............................ S-42
NEUTRAL SWITCH (MTX) . . . . . . . . . . . . . . . . . . . . . . . . . . F-l 73
0
1
\_ OIL COOLER (ENGINE). ................................ D-8
OIL PAN (ENGINE) ........................................ D-9
OIL PUMP (ENGINE) ................................... D-l 3
..................................... F-l 71
OXYGEN SENSOR
P
PARKING BRAKE ......................................... P-31
PARKING BRAKE CABLE ............................ P-32
PARKING BRAKE LEVER ............................ P-33
PARKING BRAKE SHOE ............................. P-31
PASSIVE SHOULDER BELT SYSTEM.. ..... S-103
DOOR CATCH SWITCH ....................... S-l 07
LIMIT SWITCH ...................................... S-l 07
PASSIVE SHOULDER BELT MOTOR.. S-106
SPEED SENSOR ................................... S-l 07
WARNING SWITCH .............................. S-l 07
PCV VALVE ................................................
POWER BRAKE UNIT ‘;--=I;;
..................................
POWER DOOR LOCK SYSTEM ................... S-23
DOOR LOCK CONTROL.. ...................... S-26
DOOR LOCK SWITCH.. .......................... S-26
DOOR LOCK TIMER AND RELAY.. ....... S-26
POWER STEERING.. .................................... N-23
POWER STEERING FLUID .......................... N-27
POWER STEERING OIL PUMP.. ................. N-37
POWER STEERING PRESSURE SWITCH . . F-l 73
POWER WINDOW SYSTEM.. .......................
S-27
MAIN POWER WINDOW SWITCH.. .......
S-31
POWER WINDOW MOTOR.. ..................
S-32
POWER WINDOW SUB-SWITCH ........... S-32
PRESSURE REGULATOR (FUEL). ............. F-l 29 . . . . . . . . , . . . . . , . RADIATOR CAP .............................................
E-7
RADIATOR GRILLE,
I
LOWER GRILLE MOLDING ....................... S-51 fl
RADIATOR THERMOSWITCH ...................... E-17 t
REAR AXLE ................................................. M-10
REAR BRAKE (DISC) ................................... P-23
REAR BRAKE (DRUM) ................................. P-28
REAR BUMPER ............................................ s-40
REAR COMBINATION LIGHT.. ....
REAR CROSSMEMBER ............................... R-29
REAR DOOR ................................................ S-l 5
REAR DOOR LOCK AND OPENER.. .
REAR FINISHER ........................................... s-52
REAR HATCH ............................................... s-20
REAR HATCH LOCK AND OPENER.. ......... S-22
REAR SHOCK ABSORBER AND SPRING.. R-21
REAR SIDE MARKER LIGHT ....................... T-48
REAR SIDE WINDOW REGULATOR AND . . . . . . . . .
AI .,.n
INDEX
Q
QUARTER WINDOW GLASS . . . . . . . . . . . . ..a........ S-62
R
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kiLA33 ........................................................ a-- I I
REAR SPEAKER ........................................... T-99
REAR SPOILER ............................................ s-41
REAR STABILIZER.. ..................................... R-27
REAR SUSPENSION .................................... R-20
REAR WINDOW GLASS ............................... S-63
REAR WINDOW DEFROSTER.. .................... T-74
REAR WINDOW DEFROSTER SWITCH ....... T-77
REAR WIPER AND WASHER ...................... S-74
REAR WASHER MOTOF
REAR WIPER AND WASHER SWITCH . . S-77
REAR WIPER MOTOR ............................ s-77
RELEASE BEARING (CLUTCH). . . . . . . . . . ..s..... H-17 I . . . . . . . . ...*. .*......*..
SEAT BELT.. ........................................ S-100,102
BUCKLE SWITCH.. ............................... S-l 02
SEAT ........................................................... s-110
SEPARATOR (FUEL) .................................. F-l 40
SHUTTER VALVE ACTUATOR (VICS) ........ F-l 18
SLIDING SUNROOF ..................................... S-80
MOTOR ASSEMBLY ............................... S-81
SUNROOF RELAY.. ................................ S-82
SUNROOF SWITCH.. .............................. S-82
SOLENOID VALVE
(PRESSURE REGULATOR CONTROL) .... F-135
SOLENOID VALVE (PURGE CONTROL). .. F-140
SOLENOID VALVE (VICS) .......................... F-l 18
SPARK PLUGS ............................................ G-18
-II__