Mazda 1996 Protege Instruction manual

WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury and property damage
increase. The recommended servicing procedures for the
vehicle in this workshop manual were developed with Mazda-
trained technicians in mind. This manual may be useful to non-
Mazda trained technicians, but a technician with our service-re-
lated training and experience will beatless risk when performing
servicing operations. However, all users of this manual are
expected to know general safety procedures.
This manual contains "Warnings" and "Cautions" applicable to
risks not normally encountered in a general technician's experi-
ence. Theyshould befollowed to reduce the risk of injuryand the
risk that improper service or repair may damage the vehicle or
render it unsafe. It is also important to understand that the
"Warnings" and "Cautions"are notexhaustive. It is impossible to
warn of all the hazardous consequences that might result from
failure to follow the procedures.
The procedures recommended and described in this manual are
effective methods of performing service and repair. Some
require tools specifically designedfora specific purpose. Nonre-
commended procedures and tools should include consideration
for safety of the technician and continued safe operation of the
vehicle.
Parts should be replaced with genuine Mazda replacement
parts, not parts of lesser quality. Use of a nonrecommended
replacement part should include consideration for safety of the
technician and continued safe operation of the vehicle.

1996
Mazda
Protege
Workshop
Manual
FOREWORD
A thorough familiarization with this
manual
is important for proper repair and
maintenance.
It should always be kept in
a handy place for quick and easy refer-
ence.
The contents of this manual, including
drawings and specifications, are the latest
available at the time of printing. As modifi-
cations 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 con-
tents 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 mechani-
cal-including photocopying and record-
ing, and the use of any kind of information
storage and retrieval
system-without per-
mission
in writing.
WARRANTY
The manufacturer's warranty
on Mazda
vehicles and engines can
be voided if
improper service or repairs are performed
by persons other than those at
an Autho-
rized Mazda Dealer.
APPLICATION:
Mazda Motor Corporation
HIROSHIMA, JAPAN
This manual
is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials
shown
on the following page.
CONTENTS Title
General Information
Engine
Lubrication System
Cooling System
Fuel and Emission Control
Systems
Engine Electrical System
Clutch
Manual Transaxle
Automatic Transaxle
Front and Rear Axles
Steering System
Braking System
Wheels and Tires
Suspension
Z5
BP
Z5
BP
F25M-R
FA4A-EL
Body 4SD
Body Electrical System 4SD
Heater and Air Conditioner Systems
© 1995 Mazda Motor Corporation
PRINTED IN U.S.A., JULY '95
Form No. 1495-10-95G
Part No. 9999-95-017B-96

VEHICLE IDENTIFICATION NUMBERS {VIN)
JM1 BB141*TO 300001-
JM1 BB142*TO 300001-
JM1 BB143*TO 300001-
JM1 BB144*TO 300001-
RELATED MATERIALS
1995 323/Protege Service Highlights ................. 9999-95-064F-95
1996 Protege, MX-3, MX-5, 626/MX-6, 929,
MPV, Millenia
Service
Highlights .................................. 9999-95-MODL-96
Engine
Workshop Manual Z5-DOHC . . . . . . . . . . . . . . . . . 9999-95-EWZ5-95
Engine
Workshop Manual 86, BP-DOHC ............ 9999-95-EWBP-95
Manual Transaxle Workshop Manual F25M-R ........ 9999-95-F25M-95
Automatic Transaxle
Workshop Manual FA4A-EL .... 9999-95-FA4A-95
1996 Protege Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 9999-95-019G-96

GENERAL INFORMATION
SAFETY INFORMATION ...................... Gl- 2
LUBRICANTS .•••••••...................... Gl- 2
JACKING POSITIONS ...................... Gl- 2
SAFETY STAND POSITIONS . . . . . . . . . . . . . . . . Gl- 2
VEHICLE LIFT POSITIONS •.•............... Gl- 3
DYNAMOMETER . . . . . . . . . . . . . . . . . . •••. . . . . .
Gl- 3
COMPRESSED AIR ...........•••.......... Gl- 3
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . Gl- 4
ADVISORY MESSAGES ...................• Gl- 4
PREPARATION ...••••••................... Gl- 4
REPAIR PROCEDURE .•.................... Gl- 4
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gl- 5
IDENTIFICATION NUMBER LOCATIONS . . . . . . . Gl- 6
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . •. . Gl- 7
UNITS ..................•................... Gl- 8
SAE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . Gl- 9
FUNDAMENTAL PROCEDURES
............... Gl-11
PROTECTION OF THE VEHICLE ...........• Gl-11
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT
........•.................... Gl-11
SPECIAL TOOLS ............•.•............ Gl-11
REMOVAL OF PARTS .....................• Gl-11
DISASSEMBLY ..........•................. Gl-11
REASSEMBLY .................•........... Gl-12
ADJUSTMENTS ......•••............•.••... Gl-13
RUBBER PARTS AND TUBING .............• Gl-13
HOSE CLAMPS ............................ Gl-13
TORQUE FORMULAS .....•................ Gl-13
VISE ........•............................. Gl-13
ELECTRICAL TROUBLESHOOTING TOOLS ... Gl-14
TEST LIGHT ....................•.......... Gl-14
JUMPER WIRE •..•........................ Gl-14
VOLTMETER ....................•......... Gl-14
OHMMETER •................••••.......... Gl-14
ELECTRICAL PARTS . . . . . . . . . . . . . . . . . •. . . . . . . Gl-15
BATTERY CABLE .....••..•• o •••••••••••••• Gl-15
CONNECTORS ............................ Gl-15
TERMINALS ........ o. o •••••••••••••••••••• Gl-16
SENSORS, SWITCHES, AND RELAYS ..•••.. Gl-16
WIRING HARNESS o •••••••••••••• o o •••••••• Gl-17
FUSE ...• o •••••••••••••••••••••••••••••••• Gl-17
INSTALLATION OF RADIO SYSTEM ........... Gl-17
TOWING .................................... Gl-18
PRE-DELIVERY INSPECTION ................. Gl-19
PRE-DELIVERY INSPECTION TABLE ........ Gl-19
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . Gl-20
SCHEDULED MAINTENANCE TABLE
(EXCEPT CANADA) . . . . . . . . . . . . . . . . . . . . . . . Gl-20
SCHEDULED MAINTENANCE TABLE
(CANADA) . . . . . . . . . . . . . . . . . . . . . •. . . . . . . . . .
Gl-23
Gl

Gl
SAFETY INFORMATION
SAFETY INFORMATION
LUBRICANTS
Avoid prolonged and repeated contact with petroleum-based oils. Used oil may irritate the skin, and can
cause skin cancer and other skin disorders.
Wash thoroughly after working with oil. We recommend water-soluble hand cleaners. Do not use kero-
sene, gasoline, or any other solvent to remove oil from your skin.
If repeated or prolonged contact with oil is necessary, wear protective clothing. Soiled clothing, particu-
larly those soiled with used oils and greases containing lead, should be cleaned at regular intervals.
JACKING POSITIONS
Warning
• Improperly jacking a vehicle is dangerous. The vehicle can slip offthe jack and cause serious
injury. Use only the correct front and rear jacking positions and block the wheels.
Use safety stands to support the vehicle after it has been lifted.
Front
At the front of the engine mount member
LJ
SAFETY STAND POSITIONS
Front
Both sides of the side sill
Gl-2
Rear
At the center of the crossmember
Rear
Both sides of the side sill

SAFETY INFORMATION
Gl
VEHICLE LIFT POSITIONS •
Front Rear
Both sides of the side sill Both sides of the side sill
---
DYNAMOMETER
When test-running a vehicle on a dynamometer:
• Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
• Connect an exhaust gas ventilation unit.
• Cool the exhaust pipes with a fan.
• Keep the area around the vehicle uncluttered.
• Watch the water temperature gauge.
COMPRESSED AIR
When using compressed air to clean or remove parts:
• Wear protective eye wear.
• Hold a rag over the opening to prevent parts from shooting out.
• Take precautions so that people around you are not struck by flying debris.
Gl-3

Gl HOW
TO USE THIS MANUAL
HOW TO USE THIS MANUAL
ADVISORY MESSAGES
You'll find several Warnings, Cautions, and Notes
in this manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is
ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle could result if the caution is
ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
PREPARATION
This points out the needed SSTs for the service operation. It is best to gatherall necessary SSTs before
beginning work.
Example:
FRONT AXLE
PREPARATION
SST
49 0118 850C
Puller. ball joint
REPAIR PROCEDURE
For
removal of tie rod
end
SST NUMBER USAGE
SST ILLUSTRATION
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the
parts fit together, and describes visual part inspection. If a damaged or worn part is found, repair or
replace it as necessary.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the over-
view illustration.
3. Pages related to service procedures are shown under the illustration. Refer to this information when
servicing the related part.
Gl-4

HOW TO USE THIS MANUAL
Example:
SHOWSSPECIALrr=============================================~
SERVICE TOOL 71
{SST) FOR SER-
VICE OPERATION
SHOWS
EXPENDABLE
PARTS
SHOWS
APPLICATION
POINT
OF OIL,
ETC.
SHOWS
RELATED
PAGE FOR
SERVICE
·~f SELECTIVE
1. Bolt 16. Bearing inner race
!: ~~1£i~~~rew ~·~·~;:~:~~:~~~: :=::
5. Bearing outer race 17. Spacer
6. Locknut 18. Drive pinion
7. Washer Removal....... . ................ page M-21
8. Com anion Inspect splines and teeth for wear or damage
t
:i!~!±~~~§l@~~~~;m Adjustment of height................. page M-22
~----A..-· aae M-
*1: The numbers (CD, etc.) refer to part identification and servicing procedures.
SYMBOLS
Gl
SHOWS
TIGHTENING
TORQUE
SPECIFICATIONS
SHOWS
TIGHTENING
TORQUE UNITS
SHOWS VISUAL
INSPECTION
INFORMATION
There are seven symbols indicating oil, grease, and sealant. These symbols show the points of applying
such materials during service.
Symbol
Meaning
Kind
..,__.....
I Apply oil New engine oil or gear oil as appropriate
• Apply brake fluid FMVSS116: DOT
-3
• Apply automatic transaxle fluid
M-Ill or Dexron®u
1 Apply grease Appropriate grease
....
Apply sealant Appropriate sealant
C) Apply petroleum jelly Appropriate petroleum jelly
• Replace part 0-ring, gasket, etc.
Gl-5
•

GI IDENTIFICATION NUMBER LOCATIONS
IDENTIFICATION NUMBER LOCATIONS
VEHICLE IDENTIFICATION NUMBER (VIN)
ENGINE MODEL AND NUMBER
Z5 ENGINE BP ENGINE
Gl-6