steering wheel MAZDA PROTEGE 1992 Owner's Manual

ENGINE SPEED SENSING POWER STEERING
23UONX-03
03UONX-032
AIR BLEEDING
Caution
l Do not start the engine.
l Jack up the front of the vehicle.
1. Check the fluid level. (Refer to page N-27.)
2. Turn the steering wheel fully to the left and right several times
with the engine not running.
3. Recheck the fluid level. If the level has lowered, add fluid.
4. Repeat steps 2 and 3 until the fluid level stabilizes.
5. Start the engine and let it idle.
6. Turn the steering wheel fully to the left and right several
times.
7. Check that the fluid is not foamy and that the fluid level has
not dropped.
8. Add fluid if necessary and repeat steps 6 and 7.
STEERING WHEEL AND COLUMN
Inspection (On-vehicle)
Steering wheel effort
1. With the vehicle on a hard, level surface, put the wheels
in the straight-ahead position.
2. Start the engine and warm the power steering fluid to
50-60°C
(122-14OOF) by turning the steering: wheel fully
left and right several times.
3. With the engine running at idle speed, attach a pull scale
to the outermost point of the steering wheel spoke. 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.
4. If the measured effort exceeds specification, check the fol-
lowing: fluid level, air in system, fluid leakage at hose or con-
nections, function of P/S oil pump and gearbox, and tire
pressures.
Steering wheel effort: 29 N (3.0 kg, 6.6 lb) or less 03UONX-033
N-26

ENGINE SPEED SENSING POWER STEERING N
r-
-l
03UONX-034
POWER STEERING FLUID
On-vehicle Inspection
Inspection of fluid level
Caution
l Add only the specified power steering fluid.
1. Verify that the fluid level is between the H and L marks.
2. Add or remove fluid if not within specification.
Inspection of fluid leakage
Start the engine. Turn the steering wheel fully left and right to apply fluid pressure; then check for fluid leakage.
Caution
+ To prevent damage, do not keep the steering wheel in the fully turned position for more than
15 seconds.
Note
l The points where fluid leakage may occur are indicated by the arrows in the figure.
03UONX-035
N-27

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

N ENGINE SPEED SENSING POWER STEERING
STEERING GEAR AND LINKAGE
Removal / Installation
1. Loosen the wheel lug nuts.
2. Jack up the front of the vehicle and support it with safety stands.
3. Remove the wheels.
4. Remove in the order shown in the figure, referring to
Removal Note.
5. Install in the reverse order of removal, referring to Installation Note.
6. After installation, bleed air from the steering system and adjust the toe-in if necessary. (Refer to Section R.)
2.0-5.9 N.m (20-60 cm-kg, 17-52 In-lb) _
(4.3-5.5, 31-42)
31-L46
(3.2-4.7, 23-34;>
16-23
(1.6-2.3, 12-17)
Y
N.m (m-kg, ft-lb)
23UONX-02
Note
l Use a container or rags to collect the power steering fluid when disconnecting the pressure
pipe and return hose.
l Lower the steering brackets and steerlng gear and linkage as an assembly; then separate the
steering gear and linkage.
1. Cotter pin 8. Extension bar/Control rod (MTX)
2. Nut 9. Nut (Steering gear mounting bolt)
3. Tie rod end/Steering knuckle Installation note .,,...*................... page N-14
Removal note . . . . . . . . . . . . . . . . . . . . . . . . . ,. page N- 6 10. Steering gear and linkage
4. Pressure pipe Removal note . . . . . . . . . . . . . . . . . . . . . . . ..a... page N-14
5. Return hose Disassembly / Inspection . . . . . . . . . . . . page N-31
6. Set plate Assembly . . . . . . . . . . . . . . . ..*.................. page N-34 .li;
7. Fixing bolt (intermediate shaft/pinion shaft)
Installation note . . . . . . . . . . . . . . . . . . . . . . . . . . page N-14
N-30

CONVENTIONAL BRAKE SYSTEM
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Poor braking
Leakage of brake fluid Repair P- 7
Air in system Bleed air P- 6
Worn pad or lining Replace P-l 8,23,28
Brake fluid, grease, oil, or water on pad or lining Clean or replace P-18,23,28
Hardening of pad or lining surface or poor contact Grind or replace P-l 8,23,28
Malfunction of disc brake piston Replace P-l 9,24
Malfunction of master cylinder or wheel cylinder Repair or replace P-l 0,21,26,
28,30
Malfunction of power brake unit Repair or replace P-16
Malfunction of check valve (vacuum hose) Replace P-15
Damaged vacuum hose Replace -
Deterioration of flexible hose Replace -
Malfunction of dual proportioning valve Replace P-17 Brakes pull to one
Worn pad or lining Replace P-l 8,23,28 side Brake fluid, grease, oil, or water on pad or lining Clean or replace -
Hardening of pad or lining surface or poor contact Grind or replace
Abnormal wear or distortion of disc, drum, pad, or lining Repair or replace P-l 8;3,28
Malfunction of automatic adjuster Repair or replace -
Looseness of backing plate I dust cover mounting bolts Tighten Section M
Malfunction of wheel cylinder Repair or replace P-21,26,30
Improperly adjusted wheel alignment Adjust Section R
Unequal tire air pressures
Adjust Section Q Brakes do not
No brake pedal play Adjust P- 9 release Improperly adjusted push rod clearance Adjust P-11
Clogged master cylinder return port Clean -
Weak brake pad or shoe return spring Replace -
Wheel cylinder not returning properly
Clean or replace
Malfunction of piston seal of disc brake Replace P-l;,24
Excessive runout of disc plate
Replace P-20,25 Pedal goes too far
Improperly adjusted pedal play Adjust P- 9 (too much pedal Worn pad or lining
Replace P-18,23,28 stroke) Air in system
Bleed air P- 6 Abnormal noise or
Worn pad or lining
Replace P-18,23,28 vibration during Deteriorated pad or lining Grind or replace - braking Brakes do not release Repair -
Foreign material or scratches on disc plate or drum con- Clean -
tact surface
Looseness of backing plate / dust cover or caliper Tighten
Section M,
mounting bolts P-l 9,24
Damaged disc or drum contact surface Replace -
Poor contact of pad or fining Repair or replace
P-18,23,28
Insufficient grease on sliding parts Grease - Steering wheel pulls
Dragging brake Repair - to one side Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Cl
Incorrect tire pressure -
Section Q
Malfunction of suspension -
Section R
mm> IAn\, ,.e
P-5

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

Q OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
Wheels
Tires Standard Temporary spare __/
Size 13x5-J 14x5 l/2-JJ l4x4T
Offset mm (in)
45 (1.77)
Pitch circle diameter mm (in)
100 (3.94)
Material Steel or aluminum alloy Steel
Size P155/80R13’P175/70R131
PI 85/60Rl4 82H Tll5/70D14
79s 82s
Air pressure kPa (kgflcm’, psi)
216 (2.2, 32) 415 (4.2, 60)
23UOQX-001
TROUBLESHOOTING GUIDE _____ -_- ____ _ __.- -. -.-.--
Problem Possible Cause Remedy Page
Excessive or ir-
regular tire wear Refer to page Q-5 for details
Premature tire incorrect tire pressure Adjust Q-3
wear
Tire squeal Incorrect tire pressure Adjust Q-3
Tire deterioration Replace -
Road noise or Insufficient tire pressure Adjust Q-3
body vibration
Unbalanced wheel(s) Adjust Q-6
Deformed wheel(s) or tire(s) Repair or replace
Irregular tire wear Replace Q-5
“Shake” occurs Excessive tire and wheel runout
Replace
(Steering wheel Loose lug nuts
Tighten a-4
vibrates up/down) Unbalanced wheel(s)
Adjust Q-6
Cracked or worn engine mount rubber
Replace Sections Bl, B:
Cracked or worn transaxle mount rubber
Replace Sections Jl, J2
“Shimmy” occurs Excessive tire and wheel runout
Replace
(Steering wheel
Loose lug nuts Tighten a-4
vibrates left/right) Unbalanced wheel(s)
Adjust Q-6
irregular tire wear -
Q-5
insufficient tire pressure
Adjust Q-3
Damaged or worn front wheel bearing
Replace Section M
Malfunction of steering system -
Section N
Malfunction of suspension -
Section R
Steering wheel Incorrect tire pressure Adjust Q-3
pulls to one side Excessive or irregular tire wear -
Q-5
Malfunction of steering system -
Section N
Malfunction of braking system -
Section P
Malfunction of suspension -
Section R
General driving Unequal tire pressures Adjust Q-3
instability Deformed wheel(s) or tire(s) Repair or replace
Loose lug nuts Tighten Q-4
Malfunction of steering system -
Section N
Malfunction of suspension -
Section R
Uneven (one-sided) Unequal tire pressures
Adjust Q-3
braking Malfunction of braking system -
Section P
Heavy handling Insufficient tire pressures Adjust Q-3
Malfunction of steering system -
Section N
Malfunction of suspension -
Section R
Steering wheel Insufficient tire pressures Adjust Q-3
does’t return Malfunction of steering system -
Section N
properly Malfunction of suspension -
Section R
731100x-or . _. -,
Q-2

R INDEX
INDEX
FRONT WHEEL ALIGNMENT
TOTAL TOE-IN: 2 -1: 3mm (0.08 f 0.12 in, 0.2’ * 0.3’)
MAXIMUM STEERING ANGLE: 40=’ * 2’ (INNER)
33“ f 2O (OUTER)
CAMBER ANGLE: -O”05’ * 45’
CASTER ANGLE: lo55 f 55
KINGPIN ANGLE: 12“25 FRONT
irr
FRONT SUSPENSION
1. Front shock absorber and spring
Removal I Installation . . . . . . . . . . . . . . . . . . page R-l 1
Disassembly / Inspection . . . . . . . . . . . . page R-l 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page R-l 3
Assembly . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page R-l 4
2. Front lower arm
Removal / Inspection I
Installation ,,...,.......,...........,.._..,. page R-l 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page R-l 7
R-2
3. Front stabilizer
Removal / Inspection /
Installation, . . . . . . ,. . . . . . . . . . . . . . . . . . . . . . . . . page R-l 8

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

TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem Possible Cause Action Page
Body “rolls” Weak stabilizer Replace R-18, 27
Worn or deteriorated stabilizer bushing Replace R-18, 27
Worn or deteriorated lower arm bushing
Replace R-16
Malfunction of shock absorber
Replace R-11,21
Poor riding comfort Weak coil spring Replace R-12, 22
Malfunction of shock absorber Replace R-11,21
Body leans Weak coil spring Replace R-12, 22
Worn or deteriorated stabilizer bushing
Replace R-18, 27
Worn or deteriorated lower arm bushing Replace R-16
Abnormal noise from Poor lubrication or wear of lower arm ball joint Lubricate or replace R-16
suspension system Looseness of peripheral connections Tighten -
Malfunction of shock absorber Replace R-11, 21
Worn or deteriorated stabilizer bushing Replace R-18, 27
Worn or deteriorated lower arm bushing
Replace R-16
General driving Weak coil spring Replace R-12, 22
Instability Malfunction of shock absorber Replace R-11, 21
Worn or deteriorated lower arm bushing Replace R-16
Worn or deteriorated stabilizer bushing Replace R-18, 27
Improperly adjusted wheel alignment Adjust R- 7
Damaged lower arm ball joint
Replace R-l 6
Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Q
Heavy steering
Poor lubrication or wear of lower arm ball joint Lubricate or replace R-16
Improperly adjusted wheel alignment
Adjust R- 7
Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Q
Steerlng wheel pulls to Weak coil spring
Replace R-12, 22
one side
Worn or deteriorated stabilizer bushing Replace R-18, 27
Worn or deteriorated lower arm bushing Replace R-16
Damaged lower arm ball joint Replace R-16
Improperly adjusted wheel alignment Adjust R- 7
Malfunction of steering system -
Section N
Malfunction of braking system -
Section P
Damaged or unbalanced wheel(s) -
Section Q
“Shimmy” occurs Damaged lower arm ball joint Replace R-16
(Steering wheel vibrates Malfunction of shock absorber
Replace R-11, 21
left/right) Loose shock absorber mounting
Tighten R-11, 21
Worn or deteriorated lower arm bushing
Replace R-16
Worn or deteriorated stabilizer bushing Replace R-18, 27
Improperly adjusted wheel alignment
Adjust R- 7
Damaged or worn wheel bearing Replace Section M
Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Q
Steering wheel doesn’t Stuck or damaged lower arm ball joint
Replace R-16
return properly Improperly adjusted wheel alignment Adjust R- 7
Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Q
_-..--..__
23UUHXJJC
.-_,
.-
R-6