1992 MAZDA PROTEGE engine

J2 TRANSAXLE
03UOJZ018
Driveshaft
Caution
l Do not shock the tripod joint when removing the
driveshaft.
1. Separate the driveshaft from the transaxle by prying with
a bar inserted between the outer ring and the transaxle.
2. Suspend the driveshaft with a rope.
Transaxle
1. Lean the engine toward the transaxle.
2. Support the transaxle with a jack.
3. Remove the transaxle mounting bolts.
4. Remove the transaxle.
DISASSEMBLY
Precaution
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry
with compressed air. Clean out all holes and passages with compressed air, and verify that there are no
obstructions.
3. Wear eye protection when using compressed air to clean components.
03UOJ2-020
J2-12

TRANSAXLE J2
INSTALLATION
1. Raise the vehicle and support it with safety stands.
2. Install in the order shown in the figure, referring to
Installation Note,
3. Fill the transaxle with the specified amount of the specified transaxle oil after installation.
4. Warm up the engine and transaxle, and inspect for oil leakaae and transaxle ooeration.
37-52 (3.8-5.3, 27-38) 37-52 (3.8-5.3, 27-38)
9.8-12 (1.0-1.2, 7.2-8.7)
7.8-l 2 (0.8-l .2, 5.8-8.7)
1. Transaxle
6. Tie-rod end
2. Engine mount No.4 7. Clutch release cylinder
3. Joint shaft
8. Engine mount No.2
4. Driveshaft
9. Exhaust pipe
Installation Note
10. Engine mount member
. . . . . . . . . . . . . . . . . . . . .
page J2-42 11. Control rod
5. Stabilizer
12. Extension bar
Installation Note 13. Starter
. . . . . . . . . . . . ..______. page J2-42 14. Ground
31-48 (3.2-4. ‘8
88-l 18 (g-12,65-87)
(6.5-9.1, 47-88)
37-52 (3.8-5.3, 27-38)
N.m (m-kg, Mb)
15. Neutral switch connector
16. Back-up light switch
connector
17. Speedometer
cable
18. Battery carrier
19. Battery
20. Air hose and resonance
chamber
21. Splash shield
22. Wheel and tire
52-41

OUTLINE, TROUBLESHOOTING GUIDE M
OUTLINE
SPECIFICATIONS
Engine/Transaxle
86 SOHC
I BP SOHC BP DOHC
MTX 1 ATX 1 MTX 1 ATX
Front axle
Bearing play axial direction Rear axle
Bearina olav axial direction I
mm (in) 0.05 (0.002)
mm (in) I 0.05 (0.002) Drive shaft
j Inside Tripod ioint
I Joint type I -
Outside I Ball ioint 1
Right side 919.3 (36.19)
918.7 (36.17) 630.7 (24.83)
Length of shaft
mm (in)
Left side 637.8 (25.11)
640.2 (25.20) 621.2 637.1
(24.46) (25.08)
Shaft diameter mm (in) Right side 21.5 (0.85) 23.0 (0.91)
Left side
21.5 (0.85)
23.0 (0.91)
23UOMX-003
TROUBLESHOOTING GUIDE
FRONT AXLE Problem
Steering wheel
vibration
Steering wheel pulls
or one-sided braking
Excessive steering
wheel play
Abnormal noise
Grease leakage from
boot Possible Cause Action
Worn or damaged wheel bearing
Excessive wheel bearing play
Worn or damaged wheel bearing
Excessive wheel bearing play
Excessive wheel bearing play Replace
Tighten or replace
Replace
Tighten or replace
Tighten or replace
Bent drive shaft or joint shaft
Worn or damaged wheel bearing
Worn drive shaft or joint shaft splines
Insufficient grease in joint or on splines of drive shaft
insufficient grease in joint or splines of joint shaft
Nom drive shaft tripod joint Replace
Replace
Replace
Replenish or replace
Add or replace
Replace
Damaged or broken boot
Faulty boot band
Excessive grease Replace
Replace
Reoair Page M- 7
M- 5,7
M- 7
M- 5,7
M- 57
M-18, 22
M- 7
M-18, 22
M-22, 25
M-18
M-25
M-25
M-25
M-25
23UOMX-004
REAR AXLE Problem Possible Cause Action Page
Steering wheel
Worn or damaged wheel bearing
Replace M-11, 14 vibration
Excessive wheel bearing play Tighten or replace M-11, 14 Steering wheel pulls
Worn or damaged wheel bearing Replace M-11, 14 or one-sided braking Excessive wheel bearing play Tighten or replace M-11, 14 Excessive steering
Excessive wheel bearing play Tighten or replace M-11, 14 wheel olav
Abnormal noise
Worn or damaged wheel bearing Replace M-11, 14
23UOMX-005
M-3

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

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