power steering fluid MAZDA PROTEGE 1992 Workshop Manual

GI IDENTIFICATION NUMBER LOCATIONS/UNITS/ABBREVlATlONS
VEHICLE IDENTIFICATION NUMBER (VIN) AUTOMATIC TRANSAXLE MODEL AND NUMBER
ENGINE MODEL AND NUMBER
B6 ENGINE
IDENTIFICATION NUMBER LOCATIONS
UNITS
I
N.m (m-kg or cm-kg,
ft-lb or in-lb) . . . . . . . . . . . . . . . . . . Torque
rpm ._..,,,.............,.......... Revolutions per minute
A . . . . . . . . . . . . . . . . . Ampere(s)
v, . . . . . . . . . . . . . .
Volt(s)
$2 _....._..,......................... Ohm(s) (resistance)
kPa (kg/cm2,
psi) . . . . . . . . . . Pressure
(usually positive)
mmHg (inHg) . . . . . . . . . . . . . . . Pressure
(usually negative)
W.. . . . . . . . . . . .
Watt
liters (US qt, Imp qt) ,... Volume
mm (in) ..,......,...,........... Length
89UOGX-00
ABBREVIATIONS
ABDC . . . . . . . . . . . . . . . . . . . . .
After bottom dead
center
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air conditioner
ACC ..,.,...... 3 . . . . . . . . . . . . . . . . . Accessories
ATX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transaxle
ATDC ..,,...,...,............... After top dead center
ATF . . . . . . . . . . . . . . . . . Automatic transaxle
fluid
BBDC ,,..,.......,...,......,... Before bottom dead
center
BTDC .,......,...............,.. Before top dead center
CPU ..,,.......,...,..........,.. Central processing unit
DOHC ..,...,..,............,,.. Double overhead
camshaft
DRL ____.......................... Daytime running lights
EC-AT .,_.......,............,,.. Electronically-controlled
automatic transaxle
L
GI-10
ECU ............................. Engine control unit
EGI ............................... Electronic gasoline
injection
E/L.. .............................. Electrical load
EX ................................ Exhaust
GND.. ........................... Ground
HLA.. ............................ Hydraulic lash adjuster
IGN ............................... Ignition
IN ................................. Intake
INT ............................... Intermittent
ISC
............................... idle speed control
LH ................................ Left hand
M..
................................ Motor
MIL..
............................. Malfunction indicator
lamp
M/S..
............................. Manual steering
MTX.. ............................ Manual transaxle
OD ................................ Overdrive
OFF.. ............................ Switch off
ON.. .............................. Switch on
PCV.. ............................ Positive crankcase
ventilation
PRC..
............................ Pressure regulator
control
PIS ................................ Power steering
RH..
.............................. Right hand
SOHC.. .........................
z;;kiprhead
SST ............................... Special service tool
SW.. .............................. Switch
TNS
.............................. Tail number side
VICS
............................. Variable inertia charging
system
23UGIX-00

PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Following items may be done at any time prior to delivery to your customer.
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Glass, exterior bright metal and paint for damage
Cl Wheel lug nuts, and locks (if equipped)
88-118 N.m (9-12 m-kg, 65-87 ft-lb)
q All weatherstrips for damage or detachment
0 Operation of hood release and lock
0 Operation of trunk lid, rear hatch, and fuel lid opener
Cl With trunk open, check for spare jack, tire, tools, and
fasteners securing these items in place.
Cl Door operation and alignment
Cl Headlight aim
INSTALL the following parts:
Cl Wheel caps or rings (if equipped)
q Outside rearview mirror(s)
1 UNDER HOOD-ENGINE OFF )
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
Cl Engine oil level
0 Power steering fluid level
0 Brake and clutch master cylinder fluid level
El Windshield washer reservoir fluid level
Cl Radiator coolant level
Cl Tightness of battery terminals
Cl Manual transaxle oil level
riizmiq
INSTALL the following parts:
Cl Rubber stopper for inside rearview mirror
CHECK operation of the following items:
0 Seat controls (sliding and reclining) and head restraint
Cl Folding rear seat
0 Door locks, including childproof door locks (if equipped)
Seat belts and warning system
Cl Ignition switch and steering lock
0 Inhibitor switch (ATX only)
U Starter interlock switch (clutch pedal, MTX only)
Cl All lights, including warning and indicator lamps
Cl Sound warning system
Cl Horn, wipers and washers (front and rear, if equipped)
0 Audio system (if equipped) 0 Cigarette lighter and clock
0 Sunroof (if equipped)
II Remote control outside rearview mirrors (if equipped)
Cl Power windows (if equipped)
q Heater, defroster and air conditioner at various mode
selections (if equipped)
CHECK the following items:
Cl Presence of spare fuse
0 Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
0 Pedal height and free play of brake and clutch pedal
Pedal height mm (in) Free play mm (in)
0 Parking brake
5-7 notches/98 N (10 kg, 22lb)
UNDER HOOD-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
q Automatic transaxle fluid level
[I
CHECK the following items:
Cl Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
0 Tires for cuts or bruises
0 Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
[I
CHECK the following items:
0 Brake operation
0 Clutch operation
Cl Steering control
Cl Operation of gauges
q Squeaks, rattles or unusual noise
Cl Emergency locking retractors
0 Cruise control system (if equipped)
1 AFTER ROAD TEST (
CHECK for necessary owner information materials.
Following items must be done just before the delivery to your customer.
q Load test battery and charge if necessary
1 Volts 1 0 Install fuses for accessories
i.. _
0 Adjust tire pressure to the specification
Load test result cl Remove seat and floor mat protective covers
(Refer to door label) 0 Vacuum and clean interior of vehicle
0 Clean outside of vehicle q Inspect installation of option parts with invoice
23UOAX-002
A-2

7 Schedule (Cont’d)
rile
iii
48
30
-
R
I
R !rs
25
40
25
-
-i- , whichever comes first
OPERATION MAINTENANCE Number of m
INTERVALS Months
x 1,000 km
x 1,000 miles
ii
is
G
-
i-
-
-
I
5-
T
-
-
-
-
-
-
- ii
z
ro
-
I-
-
-
I
- 45
72
45
-
-i-
-
-
I
-
ry 15 month:
I I I
A
t
A
j
milt Service data and inspection points Page
l Capacity
MTX B6, BP SOHC:
2.68 liters (2.83 US qt, 2.36 Imp qt)
BP DOHC
3.35 liters (3.55 US qt, 2.96 Imp qt)
ATX: 6.3 liters (6.7 US qt, 5.5 Imp qt)
l Level and condition
- Jl-7
J2-7
- Transaxle oil
l Wear and damaae -i- -i- -i- -
Brake fluid, clutch fluid
Brake fluid*3 -
Q-3, 5
Q-6
N-27
P-28
P-29 I I
- I
1,oo
-i
-
-
-
-
-
-
- I
G
T
-
-
-
-
-
-
- I
15,(
I Tire inflation pressure and wear l Proper pressure-
-
l Level and condition
l Wheel cylinder operation and leakage l Lining for wear or damage l Lining thickness:
Minimum 1 .Omm (0.04 in)
l Drum inner diameter. 3s) or f
I I
I
:t r
- Rotate tires
Power steering fluid
Drum brake ? every
I I
Disc brake I I
Maximum 201mm (7.91 in)
l Caliper operation l Disd plate thickness:
Minimum Front.... 20mm (0.79 in)
Rear . . . . . 7.0mm (0.28 in)
l Pad thickness:
Minimum Front.... 2.0mm (0.08 in) P-20
P-25
P-l 8
P-25
N-27
N-8 Rear . . . . . 1 .Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozina
l Free play.... O--3OmmjO-1.18 in)
l Damage looseness and grease leakage
l Cracking and damage
l Insulator clearawp .-v
-
Steering operation and linkage
I
-i-
-I-
-i- Front suspension ball joint
Drive shaft dust boots
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor
Suspension components (front and rear)
All chassis and body nuts and bolts
All locks and hinaes
Washer fluid -
M-21
F-136
u-35
u-39
-
- IY efrigerant amount ann
*. I# mspec
Inspect operation annualry -
l Damaae
l Retighten all loose nuts and bolts
l Lubricate all locks and hinges
l Level
l ODeration - Function of all lights l !%t and damage -

N
STEERING SYSTEM
INDEX ......................................................
MANUAL STEERING ............................... ;I g
ENGINE SPEED SENSING POWER
STEERING (ESPS) ................................. N- 3
OUTLINE ..................................................
SPECIFICATIONS .................................... ;I ::
MANUAL STEERING ..................................
PREPARATION ....................................... ;I ;
TROUBLESHOOTING GUIDE.. .................. N- 5
BOOT ................................................... N- 6
STEERING WHEEL AND COLUMN.. .......... N- 6
STEERING GEAR AND LINKAGE .............. N-13
ENGINE SPEED SENSING POWER
STEERING .............................................. N-23
PREPARATION ....................................... N-23
TROUBLESHOOTING GUIDE.. .................. N-25
AIR BLEEDING ....................................... N-26
STEERING WHEEL AND COLUMN.. .......... N-26
POWER STEERING FLUID.. ...................... N-27
STEERING GEAR AND LINKAGE .............. N-30
POWER STEERING OIL PUMP.. ................ N-37
DRIVE BELT ........................................... N-41
23UONX-001

INDEX
ENGINE SPEED SENSING POWER STEERING (ESPS)
FLUID
ATF M STEERING WHEEL PLAY
O-30mm (O-l .18 in)
SPECIFICATION
-IIt or Dexron@lI
I T nFFl FCTIC-IN
--. --w. .-.. NEW: 8.0-9.0mm (0.31-0.35 in)
USED: 9.0-lO.Omm (0.35-0.39 in)
LIMIT: 11.5mm (0.45 in)
23UONX-00
1. Boot
4. Drive belt
Removal / installation
.................. page N- 6 Inspection ................................... page N-41
2. Steering gear and linkage Adjustment .................................
page N-42
Removal / Installation.. ................ page N-30 Replacement .............................. page N-42
Disassembly / Inspection.. ..........
page N-31 5. Power steering fluid
Assembly..
.................................. page N-34 Air bleeding ................................ page N-26
3. Power steering oil pump Inspection.. .................................
page N-27
Removal I Installation
.................. page N-37 6. Steering wheel and column
Disassembly / Inspection I Inspection (On-vehicle).
.............. page N-26
Assembly ..................................
page N-38 Removal / Installation..
................ page N- 9
Disassembly / Assembly ............. page
N-l 0
Inspection ................................... page N-l 1
N-3

OUTLINE, MANUAL STEERING
OUTLINE
SPECIFICATIONS
Item
Steering wheel
Steering shaft and joint
Steering gear Outer diameter mm (in)
Lock-to-lock turns
Shaft
Joint
Power assist
Gear
Gear ratio
Rack stroke mm (in)
Power steering fluid
Fluid capacity liter (US qt, Imp qt) Manual steering Power steering 370 (14.6)
4.3 3.0
Collapsible
2cross joint
-
Engine speed sensing
Rack-and-pinion
a0 (infinite)
140 (5.51)
-
ATF Dexron@lI or M-III
-
0.8 (0.85, 0.70)
23UONX-00
MANUAL STEERING
PREPARATION
SST
49 0118 850C
Puller, ball joint For 49 1243 785
removal of tie rod
end Installer, dust
boot
49 0180 5108
Attachment,
steering worm
bearing preload
measuring For
measurement of
pinion preload 49 F032 308
Installer For
installation of dust
boot
For
installation of
oil seal
93GONX-OC
N-94

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
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