1992 MAZDA PROTEGE Workshop Manual

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

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 INDEX
1. Headliner
Components .............................
page S- 89 Components ............................. page S-l 10
2. Dashboard Seat assembly ..........................
page S-l 13
Components
............................. page S- 94 8. Underbody dimensions
3. Trim
Projected djmensions
Components
............................. page S- 97 (PROTEGE). ............................
page S-l 16
4. Floormat
Projected dimensions
Components ............................. page
S- 99 (Hatchback) ............................
page S-l 17
5. Seat belt
Straight-line, dimensions
Components ............................. page S-i 00 (PROTEGE). ............................ page
S-l 18
Seat belt ...................................
page S-102 Straight-line dimensions
Buckle switch.. .......................... page
S-102 (Hatchback) ............................
page S-l 19
6. Passive shoulder belt system
Structural view.. ........................
page S-103
Troubleshooting guide.. ............ page S-l 04
Passive shoulder belt motor..
... page S-l 06
Door catch switch..
................... page S-l 07
Limit switch.. ............................. page S-107
Warning switch
......................... page S-l 07
Speed sensor ........................... page
S-l 07
Components .............................
page S-l 08
s-4

HOOD
. COMPONENTS
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
Note
l Remove the radiator grille for removal of the hood lock. (Refer to page S-51.)
19-25
(1.9-2.6, 19-25 11.9-2.6s
[80-110 cm-kg, 69-96 in-lb) 7.8-11 N.m L mfj

N.m (m-kg, ft-lb
p ,mx.nnE.
1. Washer pipe 6. Weatherstrip
2. Hood hinge 7. Hood stay
3. Hood 8. Hood lock
Adjustment Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page S-6 Adjustment Note ..,.,...................... page S-6
4. Hood insulator 9. Release wire
5. Hood deflector
S-5

HOOD
Adjustment Note
Hood
9*2
(0.35 * 0.08)’
“ I
>
P SEC.A-A
;; ‘, Adjust the hood laterally and vertically by loosening the hood-
to-hinge mounting bolts and repositioning the hood. .-
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
ii1
‘ -~ 1. J -I SEC.B-B
03uosx-oc 16
Hood lock
Adjust the hood lock after the hood has been aligned. Loos-
en the hood lock mounting bolts and nut and align the lock
with the striker on the hood.
Tightening torque
Bolts: 7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
Nut: 19-25 N,rn (1.9-2.6 m-kg, 14-19 ft-lb)
S-6

FRONT FENDER PANEL S
FRONT FENDER PANEL
COMPONENTS
Removal / Installation
1, Remove in the order shown in the figure.
7 Install in the reverse order of removal.
-. . . .-.-*. . .
6.9-9.6 N.m (70-100
13uosx-004
1. Front combination light
Removal I Installation . . . . . . . . . . . . . . . . . . . . . Section T
2. Radiator grille
Removal I Installation .,................ page S-51
3. Headlight, lower grille molding
Removal / Installation .,,.,......,......... Section T 4. Front flap
5. Mud guard
6. Front fender panel
s-7

FRONT DOOR
FRONT DOOR
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 front door trim and door screen for removal of the checker.
(Refer to pages S-10, 11.)
\
J
N.m (m-kg, ft-lb)
1. Harness connector
5. Door lock striker
2. Checker pin
Adjustment Note .,......................... page S-9
3. Hinge
6. Checker 4.
Front door
Adjustment Note . . . . . . . . . . . . . . . . . . . . . . . . . . .
page S-9
S-8