MAZDA PROTEGE 1992 Workshop Manual

FRONT SUSPENSION (STRUT) R
DIRECTION INDICATOR
LOWER BRACKET
i’
I
I I
LOWER BRACKET
03UORX-02; 5. Apply the rubber lubricant to the bound stopper and the
upper spring seat contact surfaces.
6. Install the rubber spring seat and the upper spring seat.
7. Install the thrust bearing.
8. install the mounting block, facing the direction indicator as
shown in the figure.
9. Loosely tighten the mounting block nut.
10. Carefully loosen, and remove the
SST.
Caution
l Verify that the coil spring is correctly seated in the
upper and lower seats.
11. Secure the mounting block in a vise.
12. Tighten the mounting block nut to the specified torque.
Tightening torque:
78-l 10 N-m (8.0-l 1.2 m-kg, 58-81 ft-lb)
13. Install the cap over the nut.
R-l 5

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

R FRONT SUSPENSION (STRUT)
FRONT STABILIZER
Removal / Inspection / Installation
1. Jack up the front of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove the undercover.
4. Remove in the order shown in the figure, referring to
Removal Note.
5. Visually inspect each part and replace as necessary.
6. Install in the reverse order of removal, referring to
Installation Note.
Caution
l Retighten the stabilizer bracket bolts to the specified torque after lowering the vehicle (un-
laden condition).
@ 37-52 (3.8-5.3, 27-38)
N.m (m-kg, R-lb:
23UORX-0’
1. Stabilizer nut 5. Stabilizer bracket
Installation Note . . . . . . . . . . . . . . . . . ..*...... page R-19 6. Stabilizer bushing
2. Retainer, washer,
spacer
3. Stabilizer bolt
4. Bolt installation Note .,.....,..,...,........... page 11-19
7. Stabilizer bar
Removal / installation Note . . . . . . . . . page R-l 9
R-l 8

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

R REAR SUSPENSION (STRUT)
REAR SUSPENSION (STRUT)
PREPARATION
SST
49 GO34 1AO
disassembly and
49 GO34 101
R-20

REAR SUSPENSION (STRUT)
REAR SHOCK ABSORBER AND SPRING
Removal / Installation
R
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
5. After installation, measure the rear wheel alignment, if necessary.
Caution
l Retighten the shock absorber lower bolts to the specified torque after lowering the vehicle
(unladen condition).
.
/
2940 (3.0-4.1, 22-30)
‘I I L 93-127 (9.5-12.9, 69-93)
/
N-m (m-kg, R-lb)
23UORX-01’
1. Clip
5. Shock absorber and spring
2. Nut Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page R-22
3. Bolt Inspection ..__._.._ page R-23
4.
Nut Assembly.. . , . , . , , . , . . . . . . . . . . . . . . . . . . . . . . . . . page R-24
R-21

R REAR SUSPENSION (STRUT)
Disassembly / Inspection
1. Reassemble in the order shown in the figure, referring to Disassembly Note.
2. Visually inspect each part and replace as necessary.
1. Cap 6. Bound stopper
2. Nut and washer 7. Coil spring
Disassembly Note .,........,.*,................. Below 8. Lower spring seat
9. Shock absorber
Inspection .,,.,....,.....*..,...........*.... page R-23 3. Retainer
4. Mounting block
5. Stopper seat .-,
.
Disassembly note
Piston rod nut and washer
1. Secure the mounting block in a vise.
Caution
l Use protective plates in the jaws of the vise.
2. Loosen the piston rod nut a few turns. Do not remove it.
Caution _-,
l Do not remove the nut.
R-22

REAR SUSPENSION (STRUT)
03UORX-04
3. Compress the coil spring with the SST.
4. Remove the piston rod nut.
5. Remove the coil spring.
Inspection
Check for the following and replace the shock absorber, if
necessary.
Rear shock absorber function inspection
Secure a handle to the piston rod, and compress and expand
the shock piston at least three times, Verify that the operation-
al force does not change and that there is no unusual noise.
R-23

R REAR SUSPENSION (STRUT)
Assembly
41-50)
N.m (m-kg, f&lb)
03UORX-041
!J ‘6
1. Shock absorber
2. Lower spring seat
3. Coil spring
4. Bound stopper
5. Stopper seat
03UORX.047
R-24
6. Mounting block
7. Retainer
8. Nut and washer
9. Cap
1. Secure the shock absorber in a vise.
Caution
l Use protective plates in the jaws of the vise.
2. Install the lower spring seat.
3. Install the coil spring, fitting the end of the coil into the step
of the lower seat.
4. Compress the coil spring with the SST.
5. Install the bound stopper and the stopper seat.