boot MAZDA PROTEGE 1992 Service Manual

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
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

CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM
PREPARATION
SST
49 0259 770B
For 49 F043 001
For
removal of
adjustment of
Wrench, flare nut
w brake pipe Adjust gauge
piston-to-push
rod clearance
49 0208 701A
For 49 0221 600C For
removal of
installation of
Air-out tool, boot 471 piston seal
Expand tool, disc brake pads
brake (Front disc brake)
._’
P-4

CONVENTIONAL BRAKE SYSTEM P
CALIPER
Disassembly / Inspection / Assembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and depair or replace as necessary.
3. Assemble in the reverse order of disassembly.
1. Sleeve pin
2. Boot
3. Rubber cap and bleeder screw ..,.......... Below
4. Retaining ring
5. Dust seal
6. Piston
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . page P-22
Inspect for damage, wear and rust 7. Piston seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . page P-22
8. Caliper body
Inspect for damage, wear and rust
Disassembly note
Rubber cap and bleeder screw
Remove the rubber cap and remove the bleeder screw from
the brake caliper with the
SST.
P-21

P CONVENTIONAL BRAKE SYSTEM
CALIPER
Disassembly / Inspection / Assembly
Caution
l Replace the caliper assembly if a problem is found.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassemblv, referrina to
Assembly Note.
(3.7-5.5, 27-40)
5.9~Sh N-m
REPLACE (60-90 cm-kg, 52-78 in-lb)
@ REPLACE
N-m (m-kg, Mb)
23UOPX-01
1. Dust seal 8. Piston seal
Inspect for damage and poor sealing Disassembly Note . . . . . . . . . . . . . . . . . . . . . . .
page P-22
2. Piston 9. Spring
Disassembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Below 10. Operating lever
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-27 11. Boot
Inspect for wear and rust
3. Manual adjustment gear
4. Snap ring
5. Adjusting bolt
6. O-ring
7. Connecting link 12. Rubber cup and bleeder screw
13. Boot
14. Boot
15. Caliper body
Inspect for damage and cracks
Dlsassembly note
Piston
1. Turn the adjustment gear clockwise with an Allen wrench
to remove the piston from the adjustment gear. (Turn the
adjustment gear until it becomes easy to turn.)

P CONVENTIONAL BRAKE SYSTEM
23UOPX-02
WHEEL CYLINDER
Disassembly / inspection / Assembly Caution
Take the following steps after installation:
l Add fluid and bleed the air. (Refer to page P-6.)
l Check for fluid leakage. (Refer to page P-6.)
l Depress the brake pedal a few times and check that
the rear brakes do not drag while rotating the wheel.
l Check the parking brake lever stroke.
(Refer to page P-31.)
Caution
l if a problem is found in the wheel cylinder or the piston, replace the wheel cylinder as an as-
sembly.
1. Disassemble the wheel cylinder in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly.
5.9-8.8 N-m
1. Dust boot
2. Piston
Inspect for corrosion and damage
3. Piston cup
4. Spring and caps
23UOPX-02
5. Rubber cup and bleeder screw
6. Steel ball
7. Wheel cylinder body
Inspect for corrosion and damage
P-30

FRONT SUSPENSION (STRUT)
FRONT SUSPENSION (STRUT)
PREPARATION
SST
19 GO17 5A0
support of engine
19 GO17
502
Part of
19 GO17 5AO)
19 GO34 1AO
Zompressor coil support of engine support of engine
49 GO34 102
49 GO34 1AO)
49 1243 785
Installer boot 49
0180 51oB installation of ball measurement of
R-l 0

FRONT SUSPENSION (STRUT)
FRONT LOWER ARM
Removal / Inspection / Installation
1. Jack up the front of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Visually inspect each part and replace as necessary.
5. Install in the reverse order of removal, referring to
Installation Note.
6. After installation, measure the front wheel alignment, and adjust it, if necessary.
Caution
l Retighten the lower arm bolt and nuts to the specified torque after lowering the vehicle (un-
laden condition).
@G-l27 (SE,-12.9, M-93) @
I ‘&43h (4.4-6.0, 32-43)
b 93-127 (9.6-12.9, W-93)
N-m (m-kg, It-lb:
23UORX-O(
1. Stabilizer nut 9. Lower arm bushing (Rear)
Installation Note . . . . . . . . . . ..I............. page R-17 10. Nut
2. Retainer, bushing, spacer 11. Bolt
3. Stabilizer bolt 12. Lower arm ball joint
4. Bolt, washer Inspection . . . . . . . . . . . . . . . . . . ..*..*..........* page R-17
5. Bolt 13. Ball joint dust boot
6. Bolt, nut Removal I Installation Note......... page R-17 .--
7. Nut 14. Lower arm bushing (Front)
8. Washer 15. Lower arm
R-16

FRONT SUSPENSION (STRUT) R
03UORX-03
23UORX-01
Removal note
Ball joint dust boot
1. Secure the ball joint in a vise.
2. Use a chisel to remove the dust boot from the ball joint.
Caution
l Do not damage the ball joint.
Installation note
Ball joint dust boot
1. Apply general-purpose grease to the new dust boot.
2. Install the dust boot to the ball joint, and press it on with
the
SST.
Stabilizer nut
1. Tighten the stabilizer nut so that the specified thread is ex-
posed at the end of the bolt.
Specification: 17-19mm (0.67-0.75 in)
Inspection
Lower arm ball joint
Check the following and replace the ball joint if necessary.
Attach the
SST to the ball stud and measure the torque with
a pull scale.
Rotation torque:
2.0-3.4 N-m (20-35 cm-kg, 17-30 In-lb)
Pull scale readlng:
20-34 N (2.0-3.5 kg, 4.4-7.7 lb)
(while ball stud is rotating)
R-17

ST SPECIAL TOOLS
AUTOMATIC TRANSAXLE (CONT’D)
ILLUSTRATION
ILLUSTRATION rOOL NUMBER
L DESCRIPTION 1
&
4
S
4
E
4
E
L
I
1
I
(
(
I rOOL NUMBER
k DESCRIPTION ‘RIORITY
A
A
A
A
A
A
A
A PRIORITY
A
A
A
A
A
A
A
A 9 F401 3818
elector 460 19 DO19 001
30tt
9 GO19 019
lolt set 19 FTOl 439
iolder,
die gear shaft
I9 GO19 021
SoIt set 19 GO19 013
qemover, bearing
19 GO19 017
nstaller, oil seal 49 FTOl 384
Zollar
I
$9 S120 785
nstaller,
dust boot 49 GO19 OA2
Holder,
turbine shatt
$9 GO19 OA7A
Compressor set,
return spring 49 BO19 004
Adapter
(B6 eng.)
49 BO19 901
Gauge, oil 49 6019 005
Adapter
(BP eng.)
49 F401 385
Bar 49 F401 384
Collar
ST-6