oil MAZDA PROTEGE 1992 Workshop Manual

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

N ENGINE SPEED SENSING POWER STEERING
19 1232 670A
Gauge set,
Dower steering
49 HO32 301
wrench
49 8032 304
Adapter
49 8032 307
Wrench, outer
box
49 8032 308
Remover body,
rod seal
49 8032 319
Protector body,
rod seal
49 9200 020
Tension gauge,
V-ribbed belt For
measurement of
fluid pressure
For
removal of
tie-rod
For
measurement of
fluid pressure
For
removal and
installation of
outer box
For
removal of oil
seal
For
installation of
inner guide 81 oil
seal
For
measurement of
drive belt tension 49 1232 673
Valve body
(Part of
49 1232 670A)
49 1232 672
Gauge
(Part of
49 1232 670A)
49 HO02 671
Adapter
49 8032 313
Protector, outer
box
49 8032 318
Guide, rod seal
49 0118 850C
Puller, ball joint
I
-
For
measurement of
fluid pressure
For
measurement of
fluid pressure
For
measurement of
fluid pressure
For
installation of
outer box
For
installation of
inner guide & oil
seal
For
removal of
tie rods end
23UONX-0.
N-24

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

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

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.

N ENGINE SPEED SENSING POWER STEERING
23UOiX-055
23UONX-057
23UONX-05s
23UONX-05
Assembly
1. Mounting bracket and mounting rubber (gear housing
side)
(1) install the mounting bracket and mounting rubber (gear
housing side) to the gear box. ,
2. Steering rack
(1) Install a new O-ring and new seal ring to the rack’s
piston.
(2) After installing the seal ring, seat it properly at the pis-
ton circumference.
(3) Install the oil seal and inner guide to the
SST.
(4) Using the SST, place the oil seal and inner guide at the
edge of the steering rack’s pinion.
(5) After mounting the steering rack to the gear box, use
a press to install the oil seal and inner guide to the cor-
rect position.
Caution
l When pressing in, do not apply a load pressure of
more than 29,430 kPa (300 kg/cm2, 4,266 psi), be-
cause to do so will damage the oil seal and inner
guide.
l Apply grease to the seal ring, O-ring oil seal and in-
ner guide.
23UONX-056
3. Outer box assembly
(1) Install a new U-gasket and O-ring to the outer box.
(2) After installing the SST to the rack, install the outer box,
and use the
SST to tighten.
Tightening torque:
39-49 N-m (4-S m-kg, 29-36 ft-lb)
4. Cylinder air-tightness check
(1) Install the SST to the cylinder part of the gear housing.
(2) Using a vacuum pump, apply a vacuum of 400 mmHg
and check to be sure that the vacuum is maintained for
30 seconds.
(3) If there is any leakage, replace the oil seal.
5. Oil seal
(1) Use the SST to install a new oil seal to the gear housing.
Note
l Apply grease to the oil seal.
N-34

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