steering MAZDA PROTEGE 1992 Repair Manual

R OUTLINE
OUTLINE
SPECIFICATIONS
Suspension type Item Specification Strut
Shock absorber Double-acting, oil-filled
Coil spring
Stabilizer Type Front Taper wound
Rear Straight wound
Dimension See coil spring specification below
Type Torsion bar
BP SOHC Front 19.1 (0.75) (Hollow type)
Rear 20.0 (0.79) (Hollow type)
Diameter 22.0 (0.87) (Solid type)
mm (in) BP DOHC ;eTrt
21 .O (0.83) (Solid type)
P ,
-
66 SOHC rronr
Rear 20.0 (0.79) (Hollow type)
Maximum Inner 400 f 20
steering angle
Outer 330 f 20
Total mm (in) 2 f 3 (0.08 f 0.12)
Front toe-in
degree 0.2O f 0.3O
Wheel alignment
(*‘Unladen) Camber angle -0005’ f 45’
Caster angle 1055 * 55’
Kingpin angle 12O25’
Total mm (in) 2 f 3 (0.08 * 0.12)
Rear toe-in
degree 0.2O f 0.3O
Camber angle -0°20’ f 45’
*’ Fuel tank full; radiator coolant and engine oil at specified levels; and spare tire, jack, and tools in designated positions.
23UORX.004
Coil Spring Specifications (See next page for coil spring applications)
I Item Wire diameter Coil center Free lel.=-. .
mm iin1 rliamotor mm [in mm (in 1 coil numbs
Front
nath
1 _ . . *St Identification mark color +l
., . . . . I...,
-*.....-.“, * . . . . . ,..-, -....- I--‘, M iA*=
A 13.1 (0.52) 133.5-159.5 (5.26-6.28)
294.5 (11.59) 3.22 Light green
B 13.3 (0.52) 133.7-159.9 (5.26-6.30) 300.5 (11.83)
3.43 Purple Yellow
C 13.4 (0.53)
132.6-158.6 (5.22-6.24) 301.5 (11.87) 3.49
Light blue
D 13.7 (0.54)
132.9-158.9 (5.23-6.26) 302.0 (11.89) 3.52
Pink White
I F I 12f3 Kl5Al I 1.17 A-l!% 8 f!i PR-Fi 751
I RrIl .5 II 1 6x71 I 3.56 Orange
Blue
3 83 Pink -
Brown - .“._ \“.- .,
. “W.., ~ - -. - \-. -- -. - -, -- .-
\’ .‘-‘I t
F 11 .o (0.43) 129.0 (5.08)
335.0 (13.19) -.--
G 11.2 (0.44) 128.8 (5.07)
334.0 (13.15) 3.94
Rnnr l-4
1 I ? 07 AA 1387 /5n7
.?m !i 113 1% 3 an Blue - I I I I .” \v.-7, I&V., \V.“., ---.., \.-. .-, I 11.5 (0.45) 128.5 (5.06)
333.0 (13.11) i:oi Gray
-
J 11.6 (0.46) 128.4 (5.06)
332.5 (13.09) 4.00 Orange
-
l ’ Main identification mark color: Indicated on second coil from bottom.
*’ Auxiliary identification mark color: Indicated on third coil from bottom. 23UORX-005
R-4

TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem Possible Cause Action Page
Body “rolls” Weak stabilizer Replace R-18, 27
Worn or deteriorated stabilizer bushing Replace R-18, 27
Worn or deteriorated lower arm bushing
Replace R-16
Malfunction of shock absorber
Replace R-11,21
Poor riding comfort Weak coil spring Replace R-12, 22
Malfunction of shock absorber Replace R-11,21
Body leans Weak coil spring Replace R-12, 22
Worn or deteriorated stabilizer bushing
Replace R-18, 27
Worn or deteriorated lower arm bushing Replace R-16
Abnormal noise from Poor lubrication or wear of lower arm ball joint Lubricate or replace R-16
suspension system Looseness of peripheral connections Tighten -
Malfunction of shock absorber Replace R-11, 21
Worn or deteriorated stabilizer bushing Replace R-18, 27
Worn or deteriorated lower arm bushing
Replace R-16
General driving Weak coil spring Replace R-12, 22
Instability Malfunction of shock absorber Replace R-11, 21
Worn or deteriorated lower arm bushing Replace R-16
Worn or deteriorated stabilizer bushing Replace R-18, 27
Improperly adjusted wheel alignment Adjust R- 7
Damaged lower arm ball joint
Replace R-l 6
Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Q
Heavy steering
Poor lubrication or wear of lower arm ball joint Lubricate or replace R-16
Improperly adjusted wheel alignment
Adjust R- 7
Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Q
Steerlng wheel pulls to Weak coil spring
Replace R-12, 22
one side
Worn or deteriorated stabilizer bushing Replace R-18, 27
Worn or deteriorated lower arm bushing Replace R-16
Damaged lower arm ball joint Replace R-16
Improperly adjusted wheel alignment Adjust R- 7
Malfunction of steering system -
Section N
Malfunction of braking system -
Section P
Damaged or unbalanced wheel(s) -
Section Q
“Shimmy” occurs Damaged lower arm ball joint Replace R-16
(Steering wheel vibrates Malfunction of shock absorber
Replace R-11, 21
left/right) Loose shock absorber mounting
Tighten R-11, 21
Worn or deteriorated lower arm bushing
Replace R-16
Worn or deteriorated stabilizer bushing Replace R-18, 27
Improperly adjusted wheel alignment
Adjust R- 7
Damaged or worn wheel bearing Replace Section M
Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Q
Steering wheel doesn’t Stuck or damaged lower arm ball joint
Replace R-16
return properly Improperly adjusted wheel alignment Adjust R- 7
Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Q
_-..--..__
23UUHXJJC
.-_,
.-
R-6

WHEEL ALIGNMENT
WHEEL ALIGNMENT
PRE-INSPECTION
1. Check the tire inflations and set to the recommended pressure, if necessary.
2. Inspect the front wheel bearing play; replace the bearing if necessary.
3. inspect the wheel and tire runout.
4. Inspect the ball joints and steering linkage for any excessive looseness.
5. The vehicle must be on level ground and have no luggage or passenger load.
6. The difference in height between the left and right sides from the center of the wheel to the fender brim
must not exceed
10mm (0.39 in).
7. Shake the vehicle to check operation of the shock absorbers.
03UORX.007
FRONT WHEEL ALIGNMENT
Specifications
item
Specifications
Maximum Inner 4o” f: 2O
steering angle Outer
33O f 2O
Total mm (in) 2 f 3 (0.08 f 0.12)
toe-in dearee 0.20 f 0.30 Wheel alignment
(*‘Unladen) Front
*I Fuel tank full; radiator coolant and Camber angle -0005 * 45’
Caster angle 1°55’ f 55’
Kingpin angle 12O25’
engine oil at specified level; and spare tire, jack, and tools in designated positions.
23UORX-008
I
I 23UORX-023
Adjustments
Maximum steering angle
1. Loosen the left and right tie rod locknuts, then turn the tie
rods equally.
Maximum left/right difference: 3mm (0.12 in)
2. Tighten the tie rod locknuts.
Tightening torque:
34-50 N-m (3.5-5.1 m-kg, 25-37 ft-lb)
3. Adjust the toe-in after adjusting the steering angle.
4. Inspect and adjust the toe-in after adjusting the turning angle.
I 23UORX-024
R-7

FRONT SUSPENSION (STRUT) R
r
03UORX-03
STABILl2;ER BAR
I
Removal note
Stabilizer bar
1. Remove the nuts of the steering gear box mounting brack-
et, and move the gear box forward.
2. Support the engine with the
SST, and remove the cross-
member mounting bolts.
3. Lower the crossmember slowly, and remove the stabilizer
bar from the crossmember.
Installation note
Stabilizer bushing
Align the bushing with the installation position line painted on
the stabilizer bar.
Stabilizer nut
1. Tighten the stabilizer nut so that the specified thread is ex-
posed at the end of the bolt.
Specification: 17-l 9mm (0.67-0.75 in)
Stabilizer bar
1. Install the stabilizer bar to the crossmember.
2. Install the crossmember and tighten the mounting bolts to
the specified torque.
Tightening torque:
93-127 N#m (9.5-12.9 m-kg, 69-93 ft-lb)
3. Tighten the nuts of the steering gear box mounting bracket
to the specified torque.
Tightening torque:
37-52 N*m (3.6-5.3 m-kg, 27-36 ft-lb)
R-19

DASHBOARD S
1, Rear ashtray (Without passive IO. Combination switch 18. Glove box lid
shoulder belt) Removal / Installation 19. Lower panel (R.H.)
2. Rear console ,..,,.,......,,.,.,....... Section T 20. Front ashtray
3. Front console 11. Center upper hole cover 21. Lower panel (Center)
4. Control box center cover 12. Upper garnish
22. Glove box cover
(With small front console) 13. Side panel 23. Dash board
5. Side walls 14. Hood release knob Removal Note . . page S-95
6. Undercover 15. Lower panel (L.H.) Installation Note page S-96
7. Steering column 16. Meter hood 24. Pipe frame (Lower)
Removal / Installation 17. Instrument cluster 25. Pipe frame (Upper)
. . . . . . . . ...*. . . . . ..n..... Section N Removal I Installation
1 suosx-017
8. Key cylinder set ring
9. Column cover
JOINT BOX
. . . . . . . . . . . . . . . . . . . . . . . . . . Section T
Removal Note
Dashboard
1, Remove the control wires of the heater unit and blower unit.
2. Disconnect the necessary harness connectors.
s-95

T SWITCHES
03UOTX-026
H&N CAP
03UOTX-02 8
03UOTX-02s
SWITCH
Removal / Installation
Ignition switch
1. Remove the negative battery cable.
2. Remove the steering column cover.
3. Remove the screw and the ignition switch.
4. Install in the reverse order of removal.
Hazard warning switch
1. Remove the meter hood.
2. Remove the screws and the hazard switch.
3. Install in the reverse order of removal.
Cruise control switch
(set/coast and resume/accel switch)
1. Remove the steering wheel cap.
2. Remove the cruise control switch as shown in the figure.
3. Install in the reverse order of removal.
Inspection
1. Check for continuity between the terminals with an
ohmmeter.
Remote control door mirror switch
CLASS DIRECTION a b c d i k I
UP o---o
0 0
1 UP
I I lo! I-l7ol
o----O: Indicates continuity
T-20

SWITCHES T
COMBINATION SWITCH
Removal / Installation (Except Canada without cruise control system)
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
1. Horn cap
2. Steering wheel
3. Steering column cover 4. Combination switch
Disassembly I Assembly , . , . . . . . . . . . . page T-24
Inspection .,......,.,....,.*..*..,.,......... page T-27
T-23

SWITCHES T
Removal / Installation (Canada without cruise control system)
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
1. Horn cap
2. Steering wheel
3. Steering column cover 4. Combination switch
13UOTX-01;
Disassembly / Assembly . . . . . . . . . . . . . page T-26
Inspection . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . ,. . , . page T-28
T-25

U AIR CONDITIONER
-0
1 03UOUX-066
23UOUX-02 16
1 13UOUX-027
.ECTION
Removal note
Drive belt
Remove the drive belt as follows.
Vehicle with power steering.
1) Loosen bolt A.
2) Loosen nut C.
3) Loosen nut B.
4) Loosen bolt D.
5) Remove the drive belt.
Vehicle without power steering
1) Loosen nut A.
2) Loosen bolt B.
3) Remove the drive belt.
Installation note
Vehicle with power steering
Drive belt
Adjust the deflection of the drive belt as follows.
Vehicle with power steering
1) Loosen bolt A and nuts B and C.
2) Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.
Belt Deflection: When applying moderate pressure 98 N (IO kg, 22 lb)
New 8-Qmm (0.31-0.35 in)
Used Q-IOmm (0.35-0.39 in)
3) Tighten bolt A and nuts B and C.
Tightening torque
Bolt A: 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut B : 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
Nut C : 32-46 N,m (3.2-4.7 m-kg, 24-34 ft-lb)
Vehicle without power steering
1) Loosen nut A.
2) Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.
Belt Deflection: When applying moderate pressure 98 N (10 kg, 22 lb)
New 8-Qmm (0.31-0.35 in)
Used Q-10mm (0.35-0.39 in)
3) Tighten nut A. Tightening torque
Nut A: 31-34 N.m (3.2-3.6 m-kg, 23-25 ft-lb)
U-42

AIR CONDITIONER
Adjustment
Drive belt
Vehicle with power steering
1. Loosen bolt A and nuts B and C.
2. Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.
23UOUX-045
Belt Deflection: When applying moderate pressure
98 N (IO kg, 22 lb)
New 8-9mm (0.31-0.35 in)
Used 9-l Omm (0.35-0.39 in)
3. Tighten bolt A and nuts B and C.
Tightening torque
Bolt A: 36-54 N-m (3.7-U m-kg, 27-40 ft-lb)
Nut B : 36-51 N-m (3.8-5.3 m-kg, 28-38 ft-lb)
Nut C : 32-46 N-m (3.2-4.7 m-kg, 24-34 ft-lb)
DEFLECTION
03uoux-087
Vehicle without power steering
1. Loosen nut A.
2. Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.
Belt
New
Used Deflection: When applying moderate pressure
98 N (10 kg, 22 lb)
8-9mm (0.31-0.35 in)
9-l Omm (0.35-0.39 in)
3 *Tighten nut A. .-,
Tightening torque:
32-34 N*m (3.2-3.5 m-kg, 24-25 Mb)
u-50