wheel torque MAZDA PROTEGE 1992 User Guide

TRANSAXLE Jl
1. Transaxle
Installation Note ..,......,.............. page Jl-49
2. Engine mount No.4
3. Driveshaft
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
4. Stabilizer (BP SOHC)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
5. Tie-rod end
Installation Note ,........,..,........... page Jl-50
6. Clutch release cylinder
7. Engine mount No.2
8. Exhaust pipe
9. Engine mounting member
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-50
10. Control rod
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51 11. Extension bar
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51
1 12. Starter
13. Ground
Installation Note .,..,...,......,........ page Jl-5
14. Neutral switch connector
15. Back-up light switch connector
16. Speedometer cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-5
17. Battery carrier
18. Battery
19. Air hose and resonance chamber
20. Splash shield
21. Wheel and tire 1
Installation Note
Transaxle
1. Set the transaxle on a jack and lift it into place.
Install tne transaxle oorts.
Tightening torque:
64-69 N*rn (6.5-9.1 m-kg, 47-66 ft-lb)
Loosely tighten engine mount No.4 bolts.
Jl-49

FRONT AXLE M
WHEEL HUB, STEERING KNUCKLE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Remove the brake caliper assembly and disc plate.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and meas-
ure the wheel bearing play.
4. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
Removal / Installation
d Maximum wheel bearing play: 0.05mm (0.002 in)
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation, check the front wheel alignment. (Refer to Section R.)
SERVIC\E, SECTION R

7 93--12? W.-L%” COTiER PIN, REPLACE
(9.5-12.9, 69-S
39-54
(4.0-5.6, 29-40) 39-64 ’ 236-319 (24.0-32.5, 174-235)
(4.4-6.0, 32-43)
66-67)
N.m (m-kg, it-lb)
23UOMX-006
1. Wheel and tire
2. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6
3. Brake caliper assembly
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
4. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
5. Tie rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6 6. Lower ball joint
7. Knuckle, wheel hub, and dust cover
Inspect wheel hub for cracks and damage
Inspect knuckle spindle for cracks and
damage
Inspect dust cover for damage and dis-
tortion
Disassembly / Inspection I
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M- 7
M-5

REAR AXLE M
L.3”“I”lh-” I
Removal / Inspection / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation, bleed the brake system, adjust the parking brake lever stroke (Refer to Section P.) and
DRUM BRAKE TYPE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Position a dial indicator against the brake drum. Push and
pull the rear brake assembly by hand in the axial direction
and measure the wheel bearing play.
3. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
Maximum wheel bearing play: 0.05mm (0.002 in)
66-l 17 (6.7-l 1.9, 63-66)
45-59
(4.6:6.0, 33-43)
check the rear wheel alignment (Refer to Section R.)
SEiWICE, SECTION R /
I
GA
19-26 (1.9-2.6, 14-19)
177-235
(16.0-24.0, 130-174) d
REPLACE REPLACE
(9.0-12.0,
65-67)
N.m (m-kg, ft-lb)
7RI ImAX-ni
J 3
1. Wheel and tire
2. Hub cap
3. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-l 2
4. Brake drum
5. Hub bearing assembly
Inspect for cracks and damage
Disassembly I Assembly . . . . . . . . . . . . page M-l 3 6. Parking brake cable
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
7. Brake pipe
Removal Note .,.......................... page M-12
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-l 2
8. Rear brake assembly
Service ,,........................................ Section P
9. Rear spindle
Inspect for cracks and damage
M-l 1

M REAR AXLE
DISC BRAKE TYPE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Remove the brake caliper assembly.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and meas-
ure the wheel bearing play.
4. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
-I 5 Maximum wheel bearing play: 0.05mm (0.002 in)
Removal / Inspection / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation. check the rear wheel alianment (Refer to Section R.)
45-61
(4.6-6.2, 33-45)
-118
-12.0,
-87)
REPLACE
16-23
(1.6-2.3, 12-17)
N-m (m-kg, ft-lb]
311 InMY-nif4
1. Wheel and tire
2. Hub cap
3. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-15
4. Brake caliper assembly
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~ Section P
5. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P 6. Hub bearing assembly
Inspect for cracks and damage
Disassembly I Assembly . . . . . . . . . . . . page M-l 5
7. Dust cover
8. Rear spindle
Inspect for cracks and damage
M-14

DRIVE SHAFT M
23UOMX-04
23UOMX-02
I
23UOMX-02
/
I
23UOMX-029
23UOMX-04
Removal note
Tie rod end
Caution
l Do not damage the dust boot.
1. Loosen the nut and disconnect the tie rod end with the SST.
Drive shaft
Caution
l Do not damage the dust cover or oil seal.
1. Remove the drive shaft from the transaxle with a pry bar.
Note
l If the drive shaft is stuck in the front wheel hub, in-
stall a miscellaneous nut until it is flush with the end
of the shaft. Tap the nut with a copper hammer to
remove the drive shaft.
Installation note
Drive shaft
Caution
l Do not damage the dust cover or oil seal.
1. install the drive shaft with the end-gap of clip facing upward.
Tie rod end
Caution
l Do not damage the dust boot.
1, Install the nut and secure it with the new cotter pin.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
M-23

N MANUAL STEERING
03UONX-01:
03UONX-01
23UONX-010
STEERING WHEEL AND COLUMN
On-vehicle inspection
Steering wheel play
With the wheels in the straight-ahead position, gently turn the
steering wheel to the left and right to determine if play is with-
in specification.
Play: O-30mm (O-l. 18 in)
Note
l if play exceeds specification, either the steering
joints are worn or the backlash of the steering gear
is excessive.
Looseness of steering wheel and column
Move the steering wheel in directions @ , @ , and @ to check
for column bearing wear, steering shaft joint play, steering
wheel looseness. and column looseness.
Steering wheel effort
1. With the vehicle on a hard level surface, move the steering
wheel to put the wheels in the straight-ahead position.
2. Attach a pull scale to the outer of the steering wheel, and
then starting with the wheels in the straight-ahead position,
check the steering effort required to turn the steering wheel
to the left and to the right.
3. If the measured effort exceeds specification, check the fol-
lowing: rotation-starting torque of the pinion, rotation torque
of each ball joint, and seizure of each joint.
Steering wheel effort: 108 N (11 kg, 24.2 lb) or less
Note
l Measure after turning the steering wheel to the left
and right 5 times or more.

N ENGINE SPEED SENSING POWER STEERING
03UONXGI
23UONX-03
23UONX-OZ
THERMOMETER
-Y
23UONX-03
Inspection of fluid pressure
1. Assemble the SST as shown in the figure.
Tightening torque:
39-49 Nern (4.0-5.0 m-kg, 29-36 ft-lb)
2. Disconnect the pressure hose on the oil pump side, and
attach the SST.
Note
l Before disconnecting the hose, make marks at the
connections for proper reinstallation.
3. Bleed the air from the system. (Refer to page N-26.)
4. Open the gauge valve fully. Start the engine and turn the
steering wheel fully left and right to raise the fluid tempera-
ture to 50-60°C (122-14OOP).
5. Close the gauge valve completely. Increase the engine
speed to 1,000-l ,500 rpm and measure the fluid pres-
sure generated by the oil pump. If the pressure is below
specification, replace the oil pump assembly.
Oil pump fluid pressure:
7,356 kPa (75 kg/cm2, 1,067 psi)
Caution
l If the valve Is left closed for more than 15 seconds,
the fluid temperature will increase excessively and
adversely affect the oil pump.
6. Open the gauge valve fully again and increase the engine
speed to l,OOO-1,500 rpm.
7. Turn the steering wheel fully to the left and right and meas-
ure the fluid pressure generated by the gear housing. If the
pressure is below specification, replace the gear housing
assembly.
Gear housing fluid pressure:
7,356 kPa (75 kg/cm2, 1,067 psi)
Caution
l If the steering wheel is kept in the fully turned po-
sition for more than 15 seconds, the fluid tempera-
ture will rise excessively.
N-28

CONVENTIONAL BRAKE SYSTEM
G ‘lW /
03UOPX-01
03UOPX-01’
03UOPX-01,
23UOPX-00
Inspection, on-vehicle
Brake pipe
Check for cracks, damage, and corrosion of the brake pipe.
Replace the pipe or flare nut(s) if necessary.
Flexible hose
Check for scars, cracks, and swelling of flexible hose. Replace
the hose if necessary.
Removal
1. Remove the brake pipe with the SST.
2. Disconnect the clip and remove the flexible hose from the
bracket.
Installation
1. Fix the flexible hose in the bracket and connect the clip to it.
2. Connect the flexible hose to the brake pipe and tighten the
flare nut with the SST.
Caution
l Verify that the hose is not twisted.
l Verify that the hose does not contact other parts
when the vehicle bounces or when the steering
wheel is turned fully right or left.
Tightening torque:
13-22 N*m (1.3-2.2 m-kg, 9.4-16 ft-lb)
P-7

CONVENTIONAL BRAKE SYSTEM
Installation note
Manual adjustment gear
1. Turn the manual adjustment gear clockwise until the brake
pads just touch the disc pIaTe.
2. Return the manual adjustment gear l/3-turn
Removal / Installation
Caliper
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referring to Installation Note.
5. Tighten all nuts and bolts to the specified torques, referring to the figure.
@ 22-29 (2.2-3.0, 16-22)

23-30 (2.2-3.1, 16-
N.m (m-kg, R-lb)
23UOPX-00
1. Parking cable 7. Caliper
Removal I Inspection / Disassembly / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . ,.,........ page P-32 Assembly ,.....*........................... page P-26
2. Connecting bolt 8. Disc pad assembly
3. Brake hose Replacement ,...,.,.,.,........*........... page P-23
4. Screw plug Inspection . . . . . . . ..*......................... page P-25
5. Manual adjustment gear 9. Bolt
Removal Note . . . . . . . . . . . . . . . ,,..,.,....... page P-23 10. Mounting support
Installation Note ,....,.,..,.,...,., ,...,., page P-24 11, Disc plate
6. Lock bolt Inspection .,...........*..................... page P-25
After installation:
(1) Add brake fluid and bleed air. (Refer to page P-6.)
(2) Adjust the parking brake lever stroke. (Refer to page P-31 .)
(3) Depress the brake pedal a few times and check that the rear brakes do not drag excessively while
rotating the wheel by hand.
P-24

CONVENTIONAL BRAKE SYSTEM P
23UOPX-025
03UOPX-071
13UOPX-01
Removal note
Brake pipe
Disconnect or connect the brake pipe from/to the wheel cyl-
inder with the
SST.
Tightening torque:
16-22 N.m (1.6-2.2 m-kg, 12-16 ft-lb)
Grease points
(1) Piston of wheel cylinder
(2) Anchor sliding parts
(3) Projection of backing plate
(4) Adjusting screw
(5) Adjusting sleeve contact surfaces
Inspection
Check for the following and repair or replace parts as
necessary.
Brake drum
1. Drum inner diameter
Standard ‘diameter: 200mm (7.90 in)
Diameter limit : 201mm (7.91 in)
Caution
l When repairing or replacing the drum, check the
contact with the shoe.
2. Scratches, uneven or abnormal wear inside drum
Note
l Repair if the problem is minor.
Installation note
Brake drum
Before installing the brake drum, depress the brake pedal to
verify operation of the automatic adjuster.
P-29