1992 MAZDA PROTEGE oil pressure

MANUAL STEERING N
Disassembly
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
23UONX-017
1. Tie rod end 12. Pinion protector
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-l 6 Disassembly note ,.,..,.............,... page N-16
2. Boot wire
3. Boot clip
4. Boot
5. Tie rod
Disassembly Note . . . . . . . . . . . . . . . . . . . . . .
6. Washer
7. Locknut
8. Adjusting cover
9. Spring
10. Pressure pad plate
11. Pressure pad 13. Oil seal
14. Snap ring cap
15. Snap ring
16. Pinion
page N-16 Disassembly Note ,....,,.............,. page N-l 7
17. Rack
Disassembly
Note . . . . . . . . . . . . . . . . . . . . . . page N-l 7
18. Bushing
19. Mounting bracket and rubber
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-17
20. Gear housing .
N-15

MANUAL STEERING N
Assembly
Assemble in the order shown in the figure, referring to Assembly Note.
REPLACE 1 J REPLACE
REPLACE
N.m (m-kg, ft-lb)
7% lilNXA7
----. .,. --
1. Gear housing 11. Pressure pad plate
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-20 12. Spring
2. Mounting bracket and rubber 13. Adjusting cover
Assembly Note. . . . . . . . . . . ,, ,....,.... ,, . . page N-20 Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
3. Bushing 14. Locknut
4. Rack Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-20 15. Washer
5. Pinion gear Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-22
Assembly Note. . . . . . . . . . . . . . . . . . . . . . . . . . . page N-20 16. Tie rod
6. Snap ring Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page N-21
Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-20 17. Boot
7. Snap ring cap Assembly Note... . . . . . . . . . . . . . . . . . . . . . . . . page N-22
8. Oil seal 18. Boot wire
Assembly Note.. . . . . . . . . . ,.. . . . . . . . . . . . . . page N-20 19. Boot clip
9. Pinion protector 20. Locknut
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page N-21 21. Tie rod end
IO. Pressure pad Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page N-22
Assembly Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page
N-21
N-19

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

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

ENGINE SPEED SENSING POWER STEERING N
Disassembly / Inspection
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. insoect all Darts and reoair or reolace as necessarv.
N.m (m-kg, ft-lb:
L.
311 rnNX.rf
_” _-..,. -39
1. Oil pipe
Disassembly Note ,., ,......... .., ,., ,.. page N-32
2. Tie rod end
3. Locknut
4. Boot clip
5. Boot wire
6. Boot
7. Tie rod
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-32
Inspection for damage
Inspect operation of ball joint
8. Washer
9. Cover
10. Locknut
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-32
11. Adjusting cover
12. Spring
13. Pressure pad
14. Housing cover
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-32
15. Locknut
16. Bearing
17. Plug
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-32
Inspection . . . . . . . . . . . . . . . . . . . . ..*............ page N-33
18. O-ring 19. Oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-33
20. Bearing
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-33
21. Pinion shaft assembly
Inspect for damage and wear
22. Seal ring
23. Outer box assembly
Disassembly note ,....,..,.....,........ page N-33
24. O-ring
25. U-gasket
26. Steering rack
Inspection . . . . . . . . . . ..*...........*.......... page N-33
27. Seal ring
28. O-ring
29. Oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-33
30. Inner guide
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page N-33
31. Bearing
32. Oil seal
33. Mounting rubber
34. Mounting bracket
35. Gear housing
Inspect for damage and crack
N-31

N ENGINE SPEED SENSING POWER STEERING
23UOiX-055
23UONX-057
23UONX-05s
23UONX-05
Assembly
1. Mounting bracket and mounting rubber (gear housing
side)
(1) install the mounting bracket and mounting rubber (gear
housing side) to the gear box. ,
2. Steering rack
(1) Install a new O-ring and new seal ring to the rack’s
piston.
(2) After installing the seal ring, seat it properly at the pis-
ton circumference.
(3) Install the oil seal and inner guide to the
SST.
(4) Using the SST, place the oil seal and inner guide at the
edge of the steering rack’s pinion.
(5) After mounting the steering rack to the gear box, use
a press to install the oil seal and inner guide to the cor-
rect position.
Caution
l When pressing in, do not apply a load pressure of
more than 29,430 kPa (300 kg/cm2, 4,266 psi), be-
cause to do so will damage the oil seal and inner
guide.
l Apply grease to the seal ring, O-ring oil seal and in-
ner guide.
23UONX-056
3. Outer box assembly
(1) Install a new U-gasket and O-ring to the outer box.
(2) After installing the SST to the rack, install the outer box,
and use the
SST to tighten.
Tightening torque:
39-49 N-m (4-S m-kg, 29-36 ft-lb)
4. Cylinder air-tightness check
(1) Install the SST to the cylinder part of the gear housing.
(2) Using a vacuum pump, apply a vacuum of 400 mmHg
and check to be sure that the vacuum is maintained for
30 seconds.
(3) If there is any leakage, replace the oil seal.
5. Oil seal
(1) Use the SST to install a new oil seal to the gear housing.
Note
l Apply grease to the oil seal.
N-34

ENGINE SPEED SENSING POWER STEERING N
23UONX-060
II-...-- -II
1
23UONX-061
I
23UONX-041
23UONX-04
6. Pinion shaft assembly
(1) Use the SST to install new seal rings to the valve part
of the pinion shaft.
(2) After installing them, use the SST to seat it properly.
(3) Install the bearing to the pinion shaft.
Caution
l Apply grease to the bearing.
(4) Use the SST to install the pinion shaft assembly to the
gear housing.
(5) Install the locknut.
Tightening torque:
39-49 N,m (4-5 m-kg, 29-36 ft-lb)
(6) Install the bearing, the housing cover and stake it.
Tightening torque:
39-49 N-m (4-5 m-kg, 29-36 ft-lb)
Caution
l Apply sealant to the housing cover.
l Apply grease to the bearing.
7. Plug, Bearing, Oil seal, O-ring
(1) Use the SST to press in a new oil seal.
(2) Press in by placing the flat plate against the bearing.
Caution
l Apply grease to the oil seal and bearing.
(3) Install the new O-ring.
Caution
l Apply grease to the O-ring.
(4) Use the SST to tighten the plug to the gear housing.
Tightening torque:
29-39 N-m (3-4 m-kg, 22-29 f&lb)
(5) Install the cover.
8. Pressure pad, spring
(1) Install the pressure pad and spring.
9. Adjusting cover
(1) Apply sealant to the adjusting cover and temporarily
tighten it to a torque of 11 N*m (110 cm-kg, 95
in-lb).
(2) Move the rack back and forth approx. 3 times and loos-
en the adjusting cover.
(3) Retighten the adjusting cover to the specified torque and
then loosen it 0-40°.
Tightening torque:
4.4-5.4 N-m (45-55 cm-kg, 39-48 in-lb)
N-35