engine MAZDA PROTEGE 1992 Workshop Manual

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

ENGINE SPEED SENSING POWER STEERING
POWER STEERING OIL PUMP
N
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of remnvnl
. ..-.-..
d 2 19-25 (1.9-2.6, 14-19)
- Nm (m-kg, f&lb)
23UONX-043
1. Bolt
2. Nut
3. Nut
4. Adjusting bolt
5. Drive belt
Replacement .,....,.,.,,,,.,.....,..,,.... page N-42
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page N-42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page N-41 6. Pressure hose
7. Return hose
8. Bolts
9. P/S oil pump assembly
N-37

N ENGINE SPEED SENSING POWER STEERING
Disassembly / Inspection / Assembly
1. The following procedures show replacement of the O-rings. If a problem is found in other parts, replace
the oil pump assembly.
2. Disassemble in the order shown in the figure, referring to
Disassembly Note.
3. Inspect all parts and replace as necessary.
4. Assemble in the reverse order of disassembly, referring to
Assembly Note,
1. Suction pipe
2. O-ring
3. Pressure-switch assembly
4. O-ring
5. Connector
6. O-ring
7. Control valve
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
8. Spring
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
9. Bracket
10. Pump body (rear)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Il. O-ring _,
12. Cam ring
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
13. Vane
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
14. Rotor
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
15. Side plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
16. O-ring
17. O-ring
18. Pin
19. Pump body (front)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
N-38

ENGINE SPEED SENSING POWER STEERING
93GONX-05:

93GONX-056

93GONX-O!
93GONX-05
Disassembly note
Oil pump
Note
l As shown in the figure, when securing the oil pump
in a vise, be sure to use the SST so that force is not
applied to the pulley or shaft.
Assembly note
Rotor
1. Install the rotor to the shaft with the rotor’s identification mark
facing upward.
Cam ring
1. Install the cam ring so that its identification mark is facing
downward.
Vane
1. Install the vanes (10 pieces) to the rotor, with the R part of
the vanes facing outward.
Inspection
Note
l Replace the pump assembly if necessary.
Pump body
1. Check the front and rear pump bodies for cracking or oth-
er damage and for abnormal wear of the moving surface
of the rotor.
N-39

N ENGINE SPEED SENSING POWER STEERING
93GONX-05
I 93GONX-05!
Cam ring, rotor, vanes, side plate
1. Check the moving surface of the cam ring’s vanes for ab-
normal wear.
2. Check the moving surface of the side plate and the pump
bodies for abnormal wear.
3. Check the moving surface of the vane cam ring for abnor-
mal wear.
4. Check the clearance of the rotor and vanes.
4
Control valve and spring
1. Check the control valve for cracking and other damage, for
clogging, and for abnormal wear of the moving part.
2. Check the spring for damage.

ENGINE SPEED SENSING POWER STEERING N
P/S
23UONX-04!
PULLEY
P/S AND A/C
23UONX-04
DRIVE BELT
Inspection
1. Check the drive belts for wear, cracks, and fraying. Replace
as necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
3. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
0 A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specification below accordingly.
* Check the belt deflection when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflection
mm (in)
New Used Limit
8-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39) 11.5 (0.45)
4. If the deflection is not within specification, adjust it.
23UONX-047
Drive belt tension check
WHEN SET
I
23UONX-048
Note
l Belt tension can be checked in place of belt
deflection.
aBelt tension can be measured between any two
pulleys.
Using the SST check the belt tension.
Tension
N (kg, lb)
New
491-589
(50-60, 11 O-l 32) Used
422-491
(43-50, 95-l 10) Limit
245
(25, 55)
N-41

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