oil MAZDA PROTEGE 1992 Workshop Manual

DRIVE SHAFT
JOINT SHAFT (BP DOHC)
Preinspection
Joint shaft
1. Verify that the joint shaft is not twisted or cracked. Replace
it if necessary.
2. Turn the joint shaft by hand and verify that the bearing ro-
tates smoothly and freely. Replace it if necessary. .___,
23UOMX-019
Removal / Installation
Note
l Drain the transaxle oil before removal.
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
r
1
vi5
42-62
7.8-11 N.m
(80-l 10 cm-kg,
69-95 in-lb)
4L59
I (9.0-12.0, 66-87)
(4.4-6.0, 3243)
0
N.m (m-kg, ft-lb)
311 Inh.4Y.A’
1. Wheel and tire
2. Splash shield
3. Stabilizer (BP SOHC, BP DOHC)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-19
4. Tie rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M-19
Installation Note ..,...................... page M-19 5. Lower ball joint
6. Right drive shaft and axle
7. Joint shaft
Removal Note .,.,...,....,,.,.,..,..,..,. page M-19
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-19
Overhaul . . . . . . . . . . . . . . . .,......*...
. . . . . . . . . page M-m .
M-18

DRIVE SHAFT M
r
I
23UOMX-039
03UOMX-030
I
03UOMX-03
ii I I
23UOMX-04
03UOMX-03
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.
Joint shaft
Caution
l Do not damage the oil seal.
1. Remove the joint shaft.
Installation note
Joint shaft
Caution
l Do not damage the oil seal.
1. Install the joint shaft.
2. Tighten the bolts in the order shown.
Tightening torque:
42-62 N*m (4.3-6.3 m-kg, 31-46 ft-lb)
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)
Stabilizer
1. Install the stabilizer bolt.
Dimension A: 17-19mm (0.67-0.75 in)
M-19

M
Removal / Installation
DRIVE SHAFT
Note
l Drain the transaxle oil before removal.
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
7.8-11 N-m
(80-I 10 cm-kg,
N.m (m-kg, ft-lb]
011 InhdYJwG
1. Wheel and tire
2. Splash shield
3. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-24
4. Stabilizer
Installation Note ..,,.....,...,........... page M-24
5. Tie rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M-23
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-23 6. Lower ball joint
7. Drive shaft (Left)
Removal Note ,....,., . . . . . . . . . . . . . . . . . . . . page M-23
Installation Note . .., . . . . . . . . . . . . . . . . . . . . . page M-23
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M-25
8. Drive shaft (Right)
Removal Note .,.. ,., ,.... . . . . . . . . . . . . . . . . page M-23
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . .
page M-23
Overhaul . ,...................... . . . . . . . . . . . . page M-25
M-22

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
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
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
Disassembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
23UONX-017
1. Tie rod end 12. Pinion protector
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-l 6 Disassembly note ,.,..,.............,... page N-16
2. Boot wire
3. Boot clip
4. Boot
5. Tie rod
Disassembly Note . . . . . . . . . . . . . . . . . . . . . .
6. Washer
7. Locknut
8. Adjusting cover
9. Spring
10. Pressure pad plate
11. Pressure pad 13. Oil seal
14. Snap ring cap
15. Snap ring
16. Pinion
page N-16 Disassembly Note ,....,,.............,. page N-l 7
17. Rack
Disassembly
Note . . . . . . . . . . . . . . . . . . . . . . page N-l 7
18. Bushing
19. Mounting bracket and rubber
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-17
20. Gear housing .
N-15

MANUAL STEERING N
Assembly
Assemble in the order shown in the figure, referring to Assembly Note.
REPLACE 1 J REPLACE
REPLACE
N.m (m-kg, ft-lb)
7% lilNXA7
----. .,. --
1. Gear housing 11. Pressure pad plate
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-20 12. Spring
2. Mounting bracket and rubber 13. Adjusting cover
Assembly Note. . . . . . . . . . . ,, ,....,.... ,, . . page N-20 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
3. Bushing 14. Locknut
4. Rack Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-20 15. Washer
5. Pinion gear Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-22
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . . . page N-20 16. Tie rod
6. Snap ring Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-20 17. Boot
7. Snap ring cap Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-22
8. Oil seal 18. Boot wire
Assembly Note.. . . . . . . . . . ,.. . . . . . . . . . . . . . page N-20 19. Boot clip
9. Pinion protector 20. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21 21. Tie rod end
IO. Pressure pad Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page N-22
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page
N-21
N-19

MANUAL STEERING
Assembly note
Pinion gear and gear housing
1. Fill or coat with grease.
Before assembly, coat (of fill) the following parts with grease
(lithium base, NLGI No.2).
(1) Pinion bearing and teeth
(2) Inside the gear housing
1 93GONX-013
23UONX-05 3
93GONX-015
N-20
23UONX-02:
23UONX-02:
Mounting bracket and rubber
1. Push the mounting rubber on until it just contacts the end
of the housing.
Rack
1. Carefully install the rack in the direction of the arrow.
Caution
l If the rack is installed from the opposite direction,
the inner surface of the rack bushing might be
damaged by the edge of the rack gear.
Snap ring
1. Install the new snap ring with facing the chamfer side of the
snap ring upward.
Oil seal
1. Press the new oil seal with the SST as shown in the figure.
Note
l Before installing, apply a coating of general purpose
grease to the oil seal.