MAZDA PROTEGE 1992 Workshop Manual

MANUAL STEERING N
93GONX-OO! 3
63U 10X-09,
3
23UONX-052
13UOKX-01:
93GONX-01
Pinion
1. Gently grasp the serrated part of the pinion, and pull it out.
Rack
1. Remove the rack by taking it out in the direction indicated
by the arrow.
Caution
l If the rack is taken out in the opposite direction, the
inside surface of the rack bushing might be
damaged by the edge of the rack gear.
Mounting bracket and rubber
1. Remove the mounting bracket and rubber from the housing.
Inspection
Check the following points, replace the part if a problem is
found.
1. Cracking, damage, or deterioration of boots
2. Cracking, worn teeth, or damage to rack and pinion
3. Looseness, abnormal noise, or poor bearing operation in-
side the gear housing
4. Worn rack bushing inside the gear housing. Wear, normal
noise, or rough movement of the bearing on the pinon shaft.
Caution
l If replacement is necessary, replace the entire gear
housing assembly.
l Abnormal noise or rough movement of the bearing.
l If replacement is necessary, replace the entire pin-
ion and bearing assembly.
N-17

N MANUAL STEERING
5. Wear of sliding surface of pressure pad which contacts rack
6. Cracking or deformation of gear housing
7. Looseness or lack of smoothness in tie rod ball-joint
operation
8. Bent tie rod or tie rod ends
9. Damage to tie rod or tie rod end
23UONX-020
N-18

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.

MANUAL STEERING N
93GONX-018
23UONX-02
I 23UONX-02
23UONX-026
23UONX-02
Pinion protector
1. Press the pinion protector onto the gear housing with the
SST as shown in the figure.
Pressure pad and adjustment cover
1. Install so that the pressure pad correctly contacts the rack.
2. Apply a coat of sealant to the threads of the adjusting cover.
Adjusting cover and locknut
1. Apply sealant to the adjusting cover.
2. After tightening the adjusting cover to a torque of 4.4-6.4
N-m (45-65 cm-kg, 39-56 ft-lb), loosen it about
5O -35” from that position. Add then tighten the locknut
securely.
Locknut tightening torque:
39-49 N-m (4.0-5.0 m-kg, 29-36 ft-lb)
2. Measure the pinion torque with the SST.
Pinion torque: Neutral position f 90’
0.9-l .3 N*m (9-13 cm-kg, 7.6-l 1.3 in-lb)
[Pull scale reading: 900-1,300 g, 31.6-45.9 oz]
Any other position
1.5 N-m or less (15 cm-kg, 13 in-lb or less)
[Pull scale reading:
1,500 g or less (52.95 02 or less)]
Tie rod
1. Attach new washers to the left and right tie rods, and then
screw them onto the rack.
2. Using a wrench, tighten the left and right tie rod to the speci-
fied torque.
Tightening torque:
108-128 N-m (1 l-13 m-kg, 80-94 ft-lb)
N-21

MANUAL STEERING
Washer
1. Align the washer with the rack groove, and then crimp the
washer.
93GONX-07
23UONX-02
23UONX-03
Boot
1. Install the boot and then wrap a new wire two times around
it and twist it 4 or 4.5 times.
Caution
l Be sure that the boot is not twisted or dented.
Tie rod end
1. Install the tie rod ends and align them with the marks made
before disassembly.
N-22

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 N
TROUBLESHOOTING GUIDE
Adjust or replace
Repair or replace Shimmy (Steering
wheel vibrates
left/right)
N-25

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