steering MAZDA PROTEGE 1992 User Guide

CONTROL SYSTEM F
23UOFX-151
WASHER,
REPLACE
9MUOF2-24
05UOFX-25

9MUOF2-24
NEUTRAL SWITCH (MTX)
Inspection
1. Disconnect the neutral switch connector.
2. Connect an ohmmeter to the switch.
3. Check continuity of the switch.
Transmission Continuity
Neutral Yes
Other ranges No
4. If not as specified, replace the neutral switch.
Replacement
Replace the neutral switch as shown in the figure.
POWER STEERING PRESSURE SWITCH
Inspection
1. Disconnect the P/S pressure switch connector.
2. Connect an ohmmeter to the switch.
3. Start the engine and let it idle. Check continuity of the switch
while turning the steering wheel.
P/S
Turning
Not turning Continuity
Yes
No
4. If not as specified, replace the P/S pressure switch.
Replacement
Replace the P/S pressure switch as shown in the figure.
F-l 73

M’
FRONT AND REAR AXLES
INDEX .....................................................
OUTLINE .................................................
SPECIFICATIONS ....................................
TROUBLESHOOTING GUIDE.. .................... ;I ;
FRONT AXLE ......................................... M- 3
REAR AXLE ........................................... M- 3
FRONT AXLE ........................................... M- 4
PREPARATION .......................................
WHEEL HUB, STEERING KNUCKLE.. ........ ii- d
-
REAR AXLE ............................................. M-10
PREPARATION ....................................... M-10
DRUM BRAKE TYPE ............................... M-l 1
DISC BRAKE TYPE ................................. M-14
DRIVE SHAFT .......................................... M-17
PREPARATION ....................................... M-17
JOINT SHAFT (BP DOHC). ....................... M-18
DRIVE SHAFT (TRIPOD JOINT). ................ M-21
23UOMX-001

OUTLINE, TROUBLESHOOTING GUIDE M
OUTLINE
SPECIFICATIONS
Engine/Transaxle
86 SOHC
I BP SOHC BP DOHC
MTX 1 ATX 1 MTX 1 ATX
Front axle
Bearing play axial direction Rear axle
Bearina olav axial direction I
mm (in) 0.05 (0.002)
mm (in) I 0.05 (0.002) Drive shaft
j Inside Tripod ioint
I Joint type I -
Outside I Ball ioint 1
Right side 919.3 (36.19)
918.7 (36.17) 630.7 (24.83)
Length of shaft
mm (in)
Left side 637.8 (25.11)
640.2 (25.20) 621.2 637.1
(24.46) (25.08)
Shaft diameter mm (in) Right side 21.5 (0.85) 23.0 (0.91)
Left side
21.5 (0.85)
23.0 (0.91)
23UOMX-003
TROUBLESHOOTING GUIDE
FRONT AXLE Problem
Steering wheel
vibration
Steering wheel pulls
or one-sided braking
Excessive steering
wheel play
Abnormal noise
Grease leakage from
boot Possible Cause Action
Worn or damaged wheel bearing
Excessive wheel bearing play
Worn or damaged wheel bearing
Excessive wheel bearing play
Excessive wheel bearing play Replace
Tighten or replace
Replace
Tighten or replace
Tighten or replace
Bent drive shaft or joint shaft
Worn or damaged wheel bearing
Worn drive shaft or joint shaft splines
Insufficient grease in joint or on splines of drive shaft
insufficient grease in joint or splines of joint shaft
Nom drive shaft tripod joint Replace
Replace
Replace
Replenish or replace
Add or replace
Replace
Damaged or broken boot
Faulty boot band
Excessive grease Replace
Replace
Reoair Page M- 7
M- 5,7
M- 7
M- 5,7
M- 57
M-18, 22
M- 7
M-18, 22
M-22, 25
M-18
M-25
M-25
M-25
M-25
23UOMX-004
REAR AXLE Problem Possible Cause Action Page
Steering wheel
Worn or damaged wheel bearing
Replace M-11, 14 vibration
Excessive wheel bearing play Tighten or replace M-11, 14 Steering wheel pulls
Worn or damaged wheel bearing Replace M-11, 14 or one-sided braking Excessive wheel bearing play Tighten or replace M-11, 14 Excessive steering
Excessive wheel bearing play Tighten or replace M-11, 14 wheel olav
Abnormal noise
Worn or damaged wheel bearing Replace M-11, 14
23UOMX-005
M-3

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

N
STEERING SYSTEM
INDEX ......................................................
MANUAL STEERING ............................... ;I g
ENGINE SPEED SENSING POWER
STEERING (ESPS) ................................. N- 3
OUTLINE ..................................................
SPECIFICATIONS .................................... ;I ::
MANUAL STEERING ..................................
PREPARATION ....................................... ;I ;
TROUBLESHOOTING GUIDE.. .................. N- 5
BOOT ................................................... N- 6
STEERING WHEEL AND COLUMN.. .......... N- 6
STEERING GEAR AND LINKAGE .............. N-13
ENGINE SPEED SENSING POWER
STEERING .............................................. N-23
PREPARATION ....................................... N-23
TROUBLESHOOTING GUIDE.. .................. N-25
AIR BLEEDING ....................................... N-26
STEERING WHEEL AND COLUMN.. .......... N-26
POWER STEERING FLUID.. ...................... N-27
STEERING GEAR AND LINKAGE .............. N-30
POWER STEERING OIL PUMP.. ................ N-37
DRIVE BELT ........................................... N-41
23UONX-001

INDEX
MANUAL STEERING
STEERING WHEEL PLAY
NON-TILT
23UONX-00.
1. Boot 3. Steering gear and linkage
Removal / Installation page N- 6 Removal / Installation..
................ page N-l 3 ..................
2. Steering wheel and column Disassembly ............................... page N-15
Inspection (On-vehicle)
............... page N- 8 Inspection ................................... page N-17
Removal I Installation.. ................
page N- 9 Assembly .................................... page N-19
Disassembly / Assembly.. ........... page
N-l 0
Inspection ...................................
page N-l 1
_’
N-2

INDEX
ENGINE SPEED SENSING POWER STEERING (ESPS)
FLUID
ATF M STEERING WHEEL PLAY
O-30mm (O-l .18 in)
SPECIFICATION
-IIt or Dexron@lI
I T nFFl FCTIC-IN
--. --w. .-.. NEW: 8.0-9.0mm (0.31-0.35 in)
USED: 9.0-lO.Omm (0.35-0.39 in)
LIMIT: 11.5mm (0.45 in)
23UONX-00
1. Boot
4. Drive belt
Removal / installation
.................. page N- 6 Inspection ................................... page N-41
2. Steering gear and linkage Adjustment .................................
page N-42
Removal / Installation.. ................ page N-30 Replacement .............................. page N-42
Disassembly / Inspection.. ..........
page N-31 5. Power steering fluid
Assembly..
.................................. page N-34 Air bleeding ................................ page N-26
3. Power steering oil pump Inspection.. .................................
page N-27
Removal I Installation
.................. page N-37 6. Steering wheel and column
Disassembly / Inspection I Inspection (On-vehicle).
.............. page N-26
Assembly ..................................
page N-38 Removal / Installation..
................ page N- 9
Disassembly / Assembly ............. page
N-l 0
Inspection ................................... page N-l 1
N-3

OUTLINE, MANUAL STEERING
OUTLINE
SPECIFICATIONS
Item
Steering wheel
Steering shaft and joint
Steering gear Outer diameter mm (in)
Lock-to-lock turns
Shaft
Joint
Power assist
Gear
Gear ratio
Rack stroke mm (in)
Power steering fluid
Fluid capacity liter (US qt, Imp qt) Manual steering Power steering 370 (14.6)
4.3 3.0
Collapsible
2cross joint
-
Engine speed sensing
Rack-and-pinion
a0 (infinite)
140 (5.51)
-
ATF Dexron@lI or M-III
-
0.8 (0.85, 0.70)
23UONX-00
MANUAL STEERING
PREPARATION
SST
49 0118 850C
Puller, ball joint For 49 1243 785
removal of tie rod
end Installer, dust
boot
49 0180 5108
Attachment,
steering worm
bearing preload
measuring For
measurement of
pinion preload 49 F032 308
Installer For
installation of dust
boot
For
installation of
oil seal
93GONX-OC
N-94

MANUAL STEERING N
TROUBLESHOOTING GUIDE
Problem
Possible cause Action PagelSectio
Steering feels heavy
Poor lubrication, foreign material in mechanism, stuck or Lubricate or replace N- 6
(Vehicle jacked up) damage of steering ball joint
Improper steering gear preload
Replace gear -
Damaged steering gear
Replace N-13
Malfunction of steering shaft joint
Replace N-10
Malfunction of steering gear Replace N-13
Cracked or worn steering gear mounting rubber Replace N- 6
Malfunction of suspension -
Section R Steering wheel pulls
Damaged steering linkage
Replace N-13 to one side Damaged wheel or tire -
Section Q
Malfunction of braking system -
Section P
Malfunction of suspension -
Section R General instability
Worn or damaged steering joints Replace N- 6 while drlvlng Improper steering gear preload Adjust
Damaged steering linkage
Replace N-13
Damaged wheel or tire -
Section Q
Malfunction of suspension -
Section R Steering feels
Malfunction of steering gear
Replace N-13 unstable Malfunction of steering joints
Replace N- 6
Malfunction of steering linkage
Replace N-13
Excessive steering
Worn steering gear
Replace N-13 wheel play Worn or damaged steering joints
Replace N- 6 Loose steering gear mounting bolts
Replace N-13 Poor steering wheel
Stuck or damaged steering joints
Replace N- 6
return Improper steering gear preload
Replace gear
Damaged wheel or tire -
Section Q
Malfunction of suspension -
Section R Shimmy
Damaged steering linkage Replace N-13 (Steering wheel Loose steering gear mounting bolts Tighten N-13 vibrates left/right) Stuck or damaged steering joints Replace N- 6
Damaged or worn front wheel bearing Replace Section M
Damaged wheel or tire -
Section Q
Malfunction of suspension -
Section R Abnormal noise from
Loose steering gear mounting bolts
Tighten N-13 steering system Malfunction of steering gear Replace N-13
Obstruction near steering column Replace -
Loose steering linkage Tighten N-13
Worn steering joints Replace N- 6
23UONX-OC
N-5

MANUAL STEERING
BOOT
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referrino to Installation Note.
N.m (m-kg, ft-lb) 7 (4.3-d&31-42)
23UONX-006
1. Cotter pin, nut
5. Tie rod end boot
2. Tie rod end/Steering knuckle
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7
3. Locknut
6. Boot clip
Removal Note . . . . . . . . . . . . . . . . . . . . . page N- 7 7. Boot wire
4. Tie rod end
23UONX-00
8. Rack boot
Removal note
Tie rod end/Steering knuckle
1. Pull out the cotter pin, and loosen the nuts until the nut con-
tacts with the hole stud face.
Caution
l Leave the nuts temporarily tight not to damage the
screw thread.
2. Remove the tie rod from the knuckle arm with the SST.