1992 MAZDA PROTEGE power steering

ENGINE SPEED SENSING POWER STEERING
POWER STEERING OIL PUMP
N
Removal / Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of remnvnl
. ..-.-..
d 2 19-25 (1.9-2.6, 14-19)
- Nm (m-kg, f&lb)
23UONX-043
1. Bolt
2. Nut
3. Nut
4. Adjusting bolt
5. Drive belt
Replacement .,....,.,.,,,,.,.....,..,,.... page N-42
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page N-42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page N-41 6. Pressure hose
7. Return hose
8. Bolts
9. P/S oil pump assembly
N-37

N ENGINE SPEED SENSING POWER STEERING
Disassembly / Inspection / Assembly
1. The following procedures show replacement of the O-rings. If a problem is found in other parts, replace
the oil pump assembly.
2. Disassemble in the order shown in the figure, referring to
Disassembly Note.
3. Inspect all parts and replace as necessary.
4. Assemble in the reverse order of disassembly, referring to
Assembly Note,
1. Suction pipe
2. O-ring
3. Pressure-switch assembly
4. O-ring
5. Connector
6. O-ring
7. Control valve
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
8. Spring
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
9. Bracket
10. Pump body (rear)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Il. O-ring _,
12. Cam ring
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
13. Vane
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
14. Rotor
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
15. Side plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-40
16. O-ring
17. O-ring
18. Pin
19. Pump body (front)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-39
N-38

ENGINE SPEED SENSING POWER STEERING
93GONX-05:

93GONX-056

93GONX-O!
93GONX-05
Disassembly note
Oil pump
Note
l As shown in the figure, when securing the oil pump
in a vise, be sure to use the SST so that force is not
applied to the pulley or shaft.
Assembly note
Rotor
1. Install the rotor to the shaft with the rotor’s identification mark
facing upward.
Cam ring
1. Install the cam ring so that its identification mark is facing
downward.
Vane
1. Install the vanes (10 pieces) to the rotor, with the R part of
the vanes facing outward.
Inspection
Note
l Replace the pump assembly if necessary.
Pump body
1. Check the front and rear pump bodies for cracking or oth-
er damage and for abnormal wear of the moving surface
of the rotor.
N-39

N ENGINE SPEED SENSING POWER STEERING
93GONX-05
I 93GONX-05!
Cam ring, rotor, vanes, side plate
1. Check the moving surface of the cam ring’s vanes for ab-
normal wear.
2. Check the moving surface of the side plate and the pump
bodies for abnormal wear.
3. Check the moving surface of the vane cam ring for abnor-
mal wear.
4. Check the clearance of the rotor and vanes.
4
Control valve and spring
1. Check the control valve for cracking and other damage, for
clogging, and for abnormal wear of the moving part.
2. Check the spring for damage.

ENGINE SPEED SENSING POWER STEERING N
P/S
23UONX-04!
PULLEY
P/S AND A/C
23UONX-04
DRIVE BELT
Inspection
1. Check the drive belts for wear, cracks, and fraying. Replace
as necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
3. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
0 A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specification below accordingly.
* Check the belt deflection when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflection
mm (in)
New Used Limit
8-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39) 11.5 (0.45)
4. If the deflection is not within specification, adjust it.
23UONX-047
Drive belt tension check
WHEN SET
I
23UONX-048
Note
l Belt tension can be checked in place of belt
deflection.
aBelt tension can be measured between any two
pulleys.
Using the SST check the belt tension.
Tension
N (kg, lb)
New
491-589
(50-60, 11 O-l 32) Used
422-491
(43-50, 95-l 10) Limit
245
(25, 55)
N-41

N ENGINE SPEED SENSING POWER STEERING
13UONX-02
Adjustment
1. Loosen bolt @, nut @J, and locknut 0. Turn adjusting bolt
@? to adjust the belt to the specified tension.
2. Tighten locknut 0, bolt @, and nut @I to the specified
torques.
Tightening torque
Bolt @: 36-54 N-m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut @J : 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Locknut 0:
31-46 Narn (3.2-4.7 m-kg, 23-34 f&lb)
Replacement
1. Loosen bolt @, nut 0, and locknut @.
2. Turn adjusting bolt @ to release the belt tension.
3. Remove the belt.
4. Install a new drive belt and adjust the tension and deflec-
tion. (Refer to above for adjustment.)
N-42

CONVENTIONAL BRAKE SYSTEM
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Poor braking
Leakage of brake fluid Repair P- 7
Air in system Bleed air P- 6
Worn pad or lining Replace P-l 8,23,28
Brake fluid, grease, oil, or water on pad or lining Clean or replace P-18,23,28
Hardening of pad or lining surface or poor contact Grind or replace P-l 8,23,28
Malfunction of disc brake piston Replace P-l 9,24
Malfunction of master cylinder or wheel cylinder Repair or replace P-l 0,21,26,
28,30
Malfunction of power brake unit Repair or replace P-16
Malfunction of check valve (vacuum hose) Replace P-15
Damaged vacuum hose Replace -
Deterioration of flexible hose Replace -
Malfunction of dual proportioning valve Replace P-17 Brakes pull to one
Worn pad or lining Replace P-l 8,23,28 side Brake fluid, grease, oil, or water on pad or lining Clean or replace -
Hardening of pad or lining surface or poor contact Grind or replace
Abnormal wear or distortion of disc, drum, pad, or lining Repair or replace P-l 8;3,28
Malfunction of automatic adjuster Repair or replace -
Looseness of backing plate I dust cover mounting bolts Tighten Section M
Malfunction of wheel cylinder Repair or replace P-21,26,30
Improperly adjusted wheel alignment Adjust Section R
Unequal tire air pressures
Adjust Section Q Brakes do not
No brake pedal play Adjust P- 9 release Improperly adjusted push rod clearance Adjust P-11
Clogged master cylinder return port Clean -
Weak brake pad or shoe return spring Replace -
Wheel cylinder not returning properly
Clean or replace
Malfunction of piston seal of disc brake Replace P-l;,24
Excessive runout of disc plate
Replace P-20,25 Pedal goes too far
Improperly adjusted pedal play Adjust P- 9 (too much pedal Worn pad or lining
Replace P-18,23,28 stroke) Air in system
Bleed air P- 6 Abnormal noise or
Worn pad or lining
Replace P-18,23,28 vibration during Deteriorated pad or lining Grind or replace - braking Brakes do not release Repair -
Foreign material or scratches on disc plate or drum con- Clean -
tact surface
Looseness of backing plate / dust cover or caliper Tighten
Section M,
mounting bolts P-l 9,24
Damaged disc or drum contact surface Replace -
Poor contact of pad or fining Repair or replace
P-18,23,28
Insufficient grease on sliding parts Grease - Steering wheel pulls
Dragging brake Repair - to one side Malfunction of steering system -
Section N
Damaged or unbalanced wheel(s) -
Section Cl
Incorrect tire pressure -
Section Q
Malfunction of suspension -
Section R
mm> IAn\, ,.e
P-5

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