lock MAZDA PROTEGE 1992 Workshop Manual

MANUAL STEERING N
93GONX-018
23UONX-02
I 23UONX-02
23UONX-026
23UONX-02
Pinion protector
1. Press the pinion protector onto the gear housing with the
SST as shown in the figure.
Pressure pad and adjustment cover
1. Install so that the pressure pad correctly contacts the rack.
2. Apply a coat of sealant to the threads of the adjusting cover.
Adjusting cover and locknut
1. Apply sealant to the adjusting cover.
2. After tightening the adjusting cover to a torque of 4.4-6.4
N-m (45-65 cm-kg, 39-56 ft-lb), loosen it about
5O -35” from that position. Add then tighten the locknut
securely.
Locknut tightening torque:
39-49 N-m (4.0-5.0 m-kg, 29-36 ft-lb)
2. Measure the pinion torque with the SST.
Pinion torque: Neutral position f 90’
0.9-l .3 N*m (9-13 cm-kg, 7.6-l 1.3 in-lb)
[Pull scale reading: 900-1,300 g, 31.6-45.9 oz]
Any other position
1.5 N-m or less (15 cm-kg, 13 in-lb or less)
[Pull scale reading:
1,500 g or less (52.95 02 or less)]
Tie rod
1. Attach new washers to the left and right tie rods, and then
screw them onto the rack.
2. Using a wrench, tighten the left and right tie rod to the speci-
fied torque.
Tightening torque:
108-128 N-m (1 l-13 m-kg, 80-94 ft-lb)
N-21

ENGINE SPEED SENSING POWER STEERING N
ENGINE SPEED SENSING POWER STEERING
PREPARATION
SST
19 6032 306
Nrench, plug For
removal and
installation of
Plug 49 8032 312
Protector, slipper
seal For
installation of seal
ring
$9 B032 314
Yipper seal
ormer For
form of seal ring 49 F032 303
Handle
19 8032 315
nstaller, oil seal For
installation of oil
seal 49 8032 309
Installer body,
pinion seal For
installation of
oil seal
49 B032 316
Support block,
Pul For
removal of oil
seal & bearing 49 8032 310
Protector, pinion
seal For
installation of
oil seal
49 8032 317
Remover, bearing
& oil seal For
removal of oil
seal & bearing 49 8032 311
Protector, slipper
seal For
installation of
pinion shaft
49 GO30 797
Handle For
installation of
pinion seal 49 8032 320
Wrench For
removal and
installation of
adjustment cover
locknut
49 0180 5108 For 49 8032 321 For
measurement of hermetic
Attachment,
preload ,+&--I pinion torque Adapter
Q inspection
^
49 8032 305
Holder, power
steering pump For
installation of oil
N-23

ENGINE SPEED SENSING POWER STEERING N
Disassembly / Inspection
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. insoect all Darts and reoair or reolace as necessarv.
N.m (m-kg, ft-lb:
L.
311 rnNX.rf
_” _-..,. -39
1. Oil pipe
Disassembly Note ,., ,......... .., ,., ,.. page N-32
2. Tie rod end
3. Locknut
4. Boot clip
5. Boot wire
6. Boot
7. Tie rod
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-32
Inspection for damage
Inspect operation of ball joint
8. Washer
9. Cover
10. Locknut
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-32
11. Adjusting cover
12. Spring
13. Pressure pad
14. Housing cover
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-32
15. Locknut
16. Bearing
17. Plug
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-32
Inspection . . . . . . . . . . . . . . . . . . . . ..*............ page N-33
18. O-ring 19. Oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-33
20. Bearing
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-33
21. Pinion shaft assembly
Inspect for damage and wear
22. Seal ring
23. Outer box assembly
Disassembly note ,....,..,.....,........ page N-33
24. O-ring
25. U-gasket
26. Steering rack
Inspection . . . . . . . . . . ..*...........*.......... page N-33
27. Seal ring
28. O-ring
29. Oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-33
30. Inner guide
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-33
31. Bearing
32. Oil seal
33. Mounting rubber
34. Mounting bracket
35. Gear housing
Inspect for damage and crack
N-31

ENGINE SPEED SENSING POWER STEERING
i
93GONX-02t
93GONX-02 ‘8
93GONX-029
I I
93GONX-030
N-32
Disassembly note
Oil pipe
Caution
l After disconnecting the pipes, use a plug or adhe-
sive type tape to seal each port to prevent the en-
try of foreign materials.
Tie rod
1. Use the SST to remove the tie rod.
Caution
l To avoid scratching the rack, secure the rack in a
vise protected with brass pads or cloth.
Locknut
1, Use the SST to remove the locknut.
Housing cover
1. Use a drill @1.5mm (0.06 in)) to make a recessed area (ap-
prox. 1.5mm (0.06 in)) at the punch-crimped part of the
threaded part.
Caution
l if the drill diameter and/or the depth of the recess
are excessive, the threads will be too loose when
the plug is reused.
Plug
1. Use the SST to remove the plug.

ENGINE SPEED SENSING POWER STEERING N
I I
-.
* :I
-3==T
I
, 93GONX-031
93GONX-03 2
I
93GONX-03 3
I
03UONX-822
t
~ t
93WJNX-03
Oil seal and bearing
1. Use the SST to remove the bearing and the oil seal from
the plug.
Caution
l The oil seal can not be reused.
Outer box assembly
1. Use the SST to remove the outer box.
Oil seal and inner guide
1, Use the SST to remove the oil seal and inner guide toward
the cylinder side.
Caution
l The oil seal can not be reused.
lnspectlon
Steerlng rack
1. Check the rack for cracking or other damage or for abnor-
mal wear of the teeth; replace it if necessary.
2. Check the seal ring installation part of the rack for abnor-
mal wear or damage; replace it if necessary.
3. Use V blocks to support both ends of the large-diameter
part of the rack; check for excessive bending; replace it if
necessary.
Bending limit: 0.15mm (0.006 In) (near rack center)
Plug
1. Check for scratches or other damage at the oil seal instal-
lation inner diameter; replace it if necessary.

ENGINE SPEED SENSING POWER STEERING N
23UONX-060
II-...-- -II
1
23UONX-061
I
23UONX-041
23UONX-04
6. Pinion shaft assembly
(1) Use the SST to install new seal rings to the valve part
of the pinion shaft.
(2) After installing them, use the SST to seat it properly.
(3) Install the bearing to the pinion shaft.
Caution
l Apply grease to the bearing.
(4) Use the SST to install the pinion shaft assembly to the
gear housing.
(5) Install the locknut.
Tightening torque:
39-49 N,m (4-5 m-kg, 29-36 ft-lb)
(6) Install the bearing, the housing cover and stake it.
Tightening torque:
39-49 N-m (4-5 m-kg, 29-36 ft-lb)
Caution
l Apply sealant to the housing cover.
l Apply grease to the bearing.
7. Plug, Bearing, Oil seal, O-ring
(1) Use the SST to press in a new oil seal.
(2) Press in by placing the flat plate against the bearing.
Caution
l Apply grease to the oil seal and bearing.
(3) Install the new O-ring.
Caution
l Apply grease to the O-ring.
(4) Use the SST to tighten the plug to the gear housing.
Tightening torque:
29-39 N-m (3-4 m-kg, 22-29 f&lb)
(5) Install the cover.
8. Pressure pad, spring
(1) Install the pressure pad and spring.
9. Adjusting cover
(1) Apply sealant to the adjusting cover and temporarily
tighten it to a torque of 11 N*m (110 cm-kg, 95
in-lb).
(2) Move the rack back and forth approx. 3 times and loos-
en the adjusting cover.
(3) Retighten the adjusting cover to the specified torque and
then loosen it 0-40°.
Tightening torque:
4.4-5.4 N-m (45-55 cm-kg, 39-48 in-lb)
N-35

ENGINE SPEED SENSING POWER STEERING
23UONX-06:
23UONX-06
(4) Tighten the locknut with the SST.
(5) Measure the pinion starting torque with the SST and
a pull scale.
Starting torque .-/
At f 90° from the straight-ahead position:
1.0-l .3 N-m (lo-14 cm-kg, 8.7-12 in-lb)
(Pull scale reading: 1.0-l .4 kg [35.3-49.4 oz])
At other position:
1.6 N,m (17 cm-kg, 14.7 in-lb) max.
(Pull scale reading: 1.7 kg [3.7 lb] max.)
(6) If not as specified, repeat Steps (3) to (5).
10. Tie rod
(1) Install the new washers to the tie rods.
(2) Install the tie rods with the
SST.
Tightening torque:
59-78 N,m (6-6 m-kg, 43-58 ft-lb)
(3) Band the washers.
Note
l Install the tie rod (with air bled out) at the rack hous-
ing side.
ll.Boot
(1) Install the boot, boot wire and boot clip.
12. Tie rod end
(1) Install the locknut and the tie rod end.
13. Oil pipe
(1) Install the oil pipes.
Tightening torque
Cylinder pipe: 20-29 N.m
(2-3 m-kg, 14-22 ft-lb)
Pressure and return pipe:
29-39 N.m (3-4 m-kg, 22-29 ft-lb)
14. Mounting bracket and mounting rubber (tube side)
(1) Install the mounting rubber and the bracket (tube side)
to the gear housing.
N-36

N ENGINE SPEED SENSING POWER STEERING
13UONX-02
Adjustment
1. Loosen bolt @, nut @J, and locknut 0. Turn adjusting bolt
@? to adjust the belt to the specified tension.
2. Tighten locknut 0, bolt @, and nut @I to the specified
torques.
Tightening torque
Bolt @: 36-54 N-m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut @J : 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Locknut 0:
31-46 Narn (3.2-4.7 m-kg, 23-34 f&lb)
Replacement
1. Loosen bolt @, nut 0, and locknut @.
2. Turn adjusting bolt @ to release the belt tension.
3. Remove the belt.
4. Install a new drive belt and adjust the tension and deflec-
tion. (Refer to above for adjustment.)
N-42

P CONVENTIONAL BRAKE SYSTEM
03UOPX.01
03UOPX-01
03UOPX-01
23UOPX-0
BRAKE FLUID
Inspection
Leakage inspection
Depress the brake pedal several times, and inspect for leak-
age of the brake line system. __,
Brake Fluid Level
Leakage check
Verify that the fluid level in the reservoir is between the MAX
and MIN lines on the reservoir.
Add fluid if it is below MAX.
Replacement
1. Follow the procedure outlined in Air Bleeding.
(Refer to page P-6).
2. Continue bleeding and replacing the brake fluid until only
clean fluid is expelled.
3. Fill the reservoir to the MAX level.
BRAKEPEDAL
Inspection, On-vehicle
Brake pedal height
Inspection
Verify that the distance from the center on the pedal pad to
the floor mat is as specified.
Specification: 193-196mm (7.60-7.72 in)
Adjustment
1. Disconnect the stoplight switch connector.
2. Loosen locknuts @J and turn switch @ until it does not con-
tact the pedal.
3. Loosen locknuts (I?J and turn rod @ to adjust the height
of the brake pedal.
4. Tighten the stoplight switch until it contacts the pedal; then
turn it an additional 112 turn. Tighten locknuts @ and @I.
5. Connect the stoplight switch connector.
6. Verify operation of the stoplights.
P-8

CONVENTIONAL BRAKE SYSTEM
03UOPX-021
PEDAL-TO-FLOOR
CLEARANCE

03UOPX-02
Pedal Play
Inspection
1. Depress the pedal a few times to eliminate the vacuum in
the system.
2. Gently depress the pedal by hand and check the free play
(until resistance is felt).
Pedal play: 4-7mm (0.16-0.26 in)
Adjustment
1. Loosen locknut @and turn rod @to adjust the free play.
2. Verify the pedal height and the stoplight operation.
Pedal-To-Floor Clearance
Inspection
Verifv that the distance from the floor panel to the center of
the pedal pad is as specified when the pedal is depressed
with a force of 569 N (60
kg, 132 lb).
Pedal-to-floor clearance: 70mm (2.76 in) min.
If the distance is less than specified, check for the following
problems:
1. Air in brake system
2. Malfunction of automatic adjuster (Rear drum brakes)
3. Worn shoes or pads
P-9