wheel MAZDA PROTEGE 1992 Repair Manual

N MANUAL STEERING
03UONX-01:
03UONX-01
23UONX-010
STEERING WHEEL AND COLUMN
On-vehicle inspection
Steering wheel play
With the wheels in the straight-ahead position, gently turn the
steering wheel to the left and right to determine if play is with-
in specification.
Play: O-30mm (O-l. 18 in)
Note
l if play exceeds specification, either the steering
joints are worn or the backlash of the steering gear
is excessive.
Looseness of steering wheel and column
Move the steering wheel in directions @ , @ , and @ to check
for column bearing wear, steering shaft joint play, steering
wheel looseness. and column looseness.
Steering wheel effort
1. With the vehicle on a hard level surface, move the steering
wheel to put the wheels in the straight-ahead position.
2. Attach a pull scale to the outer of the steering wheel, and
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.
3. If the measured effort exceeds specification, check the fol-
lowing: rotation-starting torque of the pinion, rotation torque
of each ball joint, and seizure of each joint.
Steering wheel effort: 108 N (11 kg, 24.2 lb) or less
Note
l Measure after turning the steering wheel to the left
and right 5 times or more.

MANUAL STEERING N
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal.
39-49 (4-5, 29-36)
Q
3-2.7, 13-20)
2.0-5.9 N.m (20-60 cm-kg, 17-52 In
N.m (m-kg. Mb)
1. Horn cap 6. Undercover
2. Locknut 7. Dust cover
3. Steering wheel 8. Fixing bolt (Intermediate shaft/Pinion shaft)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-10 9. Interlock cable (ATX only)
4. Column cover 10. Steering shaft assembly
5. Combination switch Disassembly / Assembly . . . . . . . . . . . . . page N-l 0
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section T Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
N-9

N MANUAL STEERING
Removal note
Steering wheel
Remove the steering wheel with a suitable puller.
Caution
l Do not try to remove the steering wheel by hitting
the shaft with a hammer. The column will collapse.
I
03UONX-011
Disassembly / Assembly
1. Reassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.
REPLACE
22-27 (2.2-2.8, 18-20)
@ 18-27 (1.8-2.7, 13-20)
N.m (m-kg, &lb)
311 I”hlY.nl’ L”““l .,. “,
2
1, Steering lock assembly 7. Tilt lever bracket
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-l 1 8. Fixing bolt (Universal joint/Intermediate shaft)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 2 9. Intermediate shaft
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
2. Coating plate 10. Fixing bolt (Steering shaft/Universal joint)
3. Bolt 11. Universal joint
4. Adjusting bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
5. Adjusting lever
12. Steering shaft assembly
6. Adjusting nut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-l 1
N-10

MANUAL STEERING N
STEERING GEAR AND LINKAGE
Removal / Installation
1. Loosen the wheel lug nuts.
2. Jack up the front of the vehicle and support it with safety stands.
3. Remove the wheels.
4. Remove in the order shown in the figure, referring to
Removal Note.
5. install in the reverse order of removal, referring to Installation Note.
6. Adjust the toe-in (Refer to Section R).
/
37-52 (3.8-5.3, 27-38)
REPLACE 31-42)
N-m (m-kg, ft-lb)
23UONX-01,
1. Cotter pin 6. Nut
2. Nut Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N-14
3. Steering knuckle 7. Steering gear and linkage
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N- 7 Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-14
4. Set plate
5. Fixing bolt (Intermediate shaft/Pinion shaft)
installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page
N-14
N-13

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

ENGINE SPEED SENSING POWER STEERING N
r-
-l
03UONX-034
POWER STEERING FLUID
On-vehicle Inspection
Inspection of fluid level
Caution
l Add only the specified power steering fluid.
1. Verify that the fluid level is between the H and L marks.
2. Add or remove fluid if not within specification.
Inspection of fluid leakage
Start the engine. Turn the steering wheel fully left and right to apply fluid pressure; then check for fluid leakage.
Caution
+ To prevent damage, do not keep the steering wheel in the fully turned position for more than
15 seconds.
Note
l The points where fluid leakage may occur are indicated by the arrows in the figure.
03UONX-035
N-27

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

N ENGINE SPEED SENSING POWER STEERING
STEERING GEAR AND LINKAGE
Removal / Installation
1. Loosen the wheel lug nuts.
2. Jack up the front of the vehicle and support it with safety stands.
3. Remove the wheels.
4. Remove in the order shown in the figure, referring to
Removal Note.
5. Install in the reverse order of removal, referring to Installation Note.
6. After installation, bleed air from the steering system and adjust the toe-in if necessary. (Refer to Section R.)
2.0-5.9 N.m (20-60 cm-kg, 17-52 In-lb) _
(4.3-5.5, 31-42)
31-L46
(3.2-4.7, 23-34;>
16-23
(1.6-2.3, 12-17)
Y
N.m (m-kg, ft-lb)
23UONX-02
Note
l Use a container or rags to collect the power steering fluid when disconnecting the pressure
pipe and return hose.
l Lower the steering brackets and steerlng gear and linkage as an assembly; then separate the
steering gear and linkage.
1. Cotter pin 8. Extension bar/Control rod (MTX)
2. Nut 9. Nut (Steering gear mounting bolt)
3. Tie rod end/Steering knuckle Installation note .,,...*................... page N-14
Removal note . . . . . . . . . . . . . . . . . . . . . . . . . ,. page N- 6 10. Steering gear and linkage
4. Pressure pipe Removal note . . . . . . . . . . . . . . . . . . . . . . . ..a... page N-14
5. Return hose Disassembly / Inspection . . . . . . . . . . . . page N-31
6. Set plate Assembly . . . . . . . . . . . . . . . ..*.................. page N-34 .li;
7. Fixing bolt (intermediate shaft/pinion shaft)
Installation note . . . . . . . . . . . . . . . . . . . . . . . . . . page N-14
N-30

P
BRAKING SYSTEM
INDEX ......................................................
OUTLINE .................................................. ;I g
SPECIFICATIONS .................................... P- 3
CONVENTIONAL BRAKING SYSTEM.. ......... P- 4
PREPARATION ....................................... P- 4
TROUBLESHOOTING GUIDE .................... P- 5
AIR BLEEDING .......................................
BRAKE HYDRAULIC LINE.. -
...................... F- t
BRAKE FLUID ........................................
BRAKE PEDAL ....................................... ;I ;
MASTER CYLINDER ................................ P-l 0
POWER BRAKE UNIT .............................. P-13
DUAL PROPORTIONING VALVE.. .............. P-l 6
FRONT BRAKE (DISC) ............................. P-16
CALIPER ............................................... P-21
REAR BRAKE (DISC) ............................... P-23
CALIPER ............................................... P-26
REAR BRAKE (DRUM) ............................. P-28
WHEEL CYLINDER .................................. P-30
PARKING BRAKE SYSTEM ........................ P-31
TROUBLESHOOTING GUIDE .................... P-31
PARKING BRAKE SHOE .......................... P-31
PARKING BRAKE (LEVER TYPE) ............... P-31
PARKING BRAKE CABLE.. ....................... P-32
PARKING BRAKE LEVER ......................... P-33
13UOPX-001