engine MAZDA 626 1987 Workshop Manual

10
STEERING SYSTEM
OUTLINE 10— 2
STRUCTURAL VIEW 10— 2 SPECIFICATIONS 10— 6
TROUBLESHOOTING GUIDE 10— 7
MANUAL STEERING 10— 7
POWER STEERING 10— 8
4WS 10— 9
ON-VEHICLE MAINTENANCE 10— 10
STEERING WHEEL PLAY 10— 10
LOOSENESS OR PLAY OF THE
STEERING WHEEL 10— 10
STEERING WHEEL EFFORT 10— 10
POWER STEERING FLUID LEVEL 1 fl-11
LOOSE OR DAMAGED
OIL PUMP BELT IC— 12
REAR STEERING GEAR OIL 10— 12 LEAKAGE OF POWER STEERING
FLUID 10— 13
INSPECTION AND ADJUSTMENT. 10— 15
BLEEDING OF POWER STEERING
SYSTEM 10— 15
POWER STEERING PRESSURE ... 10— 16
TIE-ROD END BOOTS 10— 18
REMOVAL AND INSTALLATION .. 10— 18
STEERING WHEEL AND COLUMN 10— 21
STRUCTURAL VIEW 10— 21
REMOVAL 10— 22
DISASSEMBLY AND ASSEMBLY.. 10— 24
INSPECTION 10— 25
INSTALLATION 1 fl-27
STEERING GEAR AND LINKAGE .. IC— 28
STRUCTURAL VIEW 10— 28
REMOVAL 10— 29
INSTALLATION 10— 30
4-WHEEL STEERING GEAR AND
LINKAGE 10— 31
STRUCTURAL VIEW 10— 31 4WS PERFORMANCE INSPECTION 10— 32
ADJUSTMENT OF STEERING
ANGLE TRASFER SHAFT 10— 35
REMOVAL AND INSTALLATION .. 10— 37
INSPECTION 10— 44
MANUAL STEERING 10— 48
DISASSEMBLY 10— 48
INSPECTION 10— 51
ASSEMBLY 10— 52
ENGINE SPEED SENSING POWER
STEERING 10— 58
DISASSEMBLY 10— 58
INSPECTION 10— 62
ASSEMBLY 10— 64
ELECTRONICALLY-CONTROLLED
POWER STEERING 10— 75
DISASSEMBLY 10— 75
INSPECTION 10— 78
ASSEMBLY 10— 79
OIL PUMP 10— 83
REMOVAL AND INSTALLATION .. 10— 83
ELECTRICAL COMPONENTS OF
ELECTRONICALLY-CONTROLLED
POWER STEERING 10— 87
CIRCUIT DIAGRAM 10— 87
TROUBLESHOOTING GUIDE 10— 87
TROUBLESHOOTING 10— 87
ELECTRICAL COMPONENTS OF
4 WHEEL STEERING 10— 94
CIRCUIT DIAGRAM 10— 94
TROUBLESHOOTING GUIDE 10— 95
TROUBLESHOOTING 10— 95
4WS WARNING LIGHT 10—102
SPEED SENSOR (IN METER) 10—103
SPEED SENSOR (AT TRANSAXLE) 10—103
REAR-TO-FRONT STEERING
RATIO SENSOR 10—103
OIL LEVEL SWITCH
(IN P/S RESERVOIR) 10—103
RELAY AND TIMER 10—104 76G10X-001

OUTLINE 10
1. Steering wheel
2. Steering shaft
3. Intermediate shaft
4. Steering gear assembly
5. Pressure hose
6. Return hose
7. Oil pump
8. Reserve tank
86U10X-003
Note
Engine speed sensing power steering is abbreviated ESPS.
10—3

ON-VEHICLE MAINTENANCE 1 0
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^A-X
Power Steering
1.
86U10X-014
86U10X-015
With the vehicle on a hard level surface, move the
steering wheel to put the wheels in the straight
ahead position.
Start the engine and warm the power steering flu-
id to 50—60°C (122—140°F), pull scale.
Attach a pull scale to the outer circumference of
the steering wheel. 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.
If the measured value exceeds specification, check
the following: fluid level, air in system, fluid leak-
age at hose or connections, function of oil pump
and gear box, and tire pressure.
Steering wheel effort:
ESPS Type
25—31N (2.6—3.2 kg, 6—7 lb)
ECPS Type
15—23 N (1.7—2.3 kg, 3—5 lb)
4WS Type
25—35N (2.5—3.5 kg, 6—8 lb)
[during one turn of the steering wheel]
Note (4WS)
1)lf not within specification, separate the
transfer shaft from the front steering gear
and check again.
2) If still not within specification, there is a
malfunction of the front steering gear.
3) If the measured value is now within specifi-
cation, check the transfer shaft and rear
steering gear. (Refer to Page 10—45.)
86U10X-016
POWER STEERING FLUID LEVEL
Check the power steering fluid level, and add fluid
to the specified level if necessary.
Caution
Use only the specified power steering fluid.
86U10X-017
10—11

1 0 ON-VEHICLE MAINTENANCE
Gasoline engine Adjust bolt
Idler pulley fM ,.. Lock nut
1 / I
Drive pulley Power steering oil
pump pulley
76G10X-004
Diesel engine
Vacuum pump
Rear
camshaft
pulley
Power steering oil
pump pulley
76G10X-005
86U10X-019
LOOSE OR DAMAGED OIL PUMP BELT
Inspection
Inspect the oil pump belt for looseness or damage.

Power steering
oil

pump drive belt
Deflection Power steering
oil

pump drive belt New Used
Gasoline engine 8—10
mm

(0.31-0.39
in)

9—11
mm

(0.35—0.43
in)

Diesel engine 6.5—7.5
mm
(0.26—0.30
in)

7—8
mm

(0.28—0.31
in)
[When depressed with a force of 98 N (10 kg,
22 lb)]
Adjustment
Gasoline engine
1. Loosen the lock nut on the idler pulley.
2. Turn the adjust bolt on the idler pulley until the cor-
rect tension is obtained.
3. Tighten the lock nut and recheck the tension.
Tightening torque:
49—59 Nm (5—6 m-kg, 36—43 ft-lb)
Diesel engine
1. Loosen the vacuum pump bolt ©and (B).
2. Lever the vacuum pump outward and apply ten-
sion to the belt.
3. Tighten the adjust bolt (|).
Tightening torque:
49—59
N
m (5—6 m-kg, 36—43 ft-lb)
4. Tighten the mounting bolt
Tightening torque:
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
REAR STEERING GEAR OIL
Fluid Level (4WS)
Remove the bleeder valve, and check the fluid level
with a wire.
Caution
Be careful not to let dirt in.
Fluid level
44 ± 3 mm (1.7 ± 0.1 in)
0.9 ± 0.1 liters (1.0 ± 0.1 US qt,
0.8 ± 0.1 Imp qt)
86U10X-250
10-12

ON-VEHICLE MAINTENANCE 1 0
LEAKAGE OF POWER STEERING FLUID
Check the following points for fluid leakage:
1. Gear
2. Oil pump
3. All fluid pipes and connections
4. Solenoid valve (ECPS Type, 4WS Type)
Note
a) Start the engine, and check for fluid leakage after turning the steering wheel completely
to the left and right to apply fluid pressure. Do not, however, keep the steering wheel
in the fully turned position for more than 15 seconds.
b)The points where fluid leakage may occur are indicated by the arrows in the figure.
Power Steering (2WS)
86U10X-020
10-13

INSPECTION AND ADJUSTMENT 1 0
INSPECTION AND ADJUSTMENT
BLEEDING OF POWER STEERING SYSTEM
1. Check the fluid level, and add fluid if necessary.
2. Turn the steering wheel fully in both directions 5
times (engine not running).
3. Recheck the fluid level. If the level has lowered,
add fluid, and repeat from step 1.
86U10X-021
4. Start the engine, and run it at idle.
5. Turn the steering wheel fully in both directions 5
times to bleed air from the system.
6. Check that the fluid is not foamy and the fluid lev-
el has not lowered.
If a problem is found, add fluid as necessary and
repeat from step 5.
Note
If bleeding is not done completely, the follow-
ing problems may appear:
• Foamy fluid on level gauge.
• Noise from power steering oil pump.
86U10X-022
10—15

1 0 INSPECTION AND ADJUSTMENT
86U10X023
2WS
To oil pump
Si£r To gear housing
86U10X-024
86U10X-025
Thermometer [50—60°C (122—140°C)]
ii ^
Gauge
Close valve
completely
POWER STEERING PRESSURE
1. Disconnect the high-pressure hose of the gear
housing side, and attach the SST.
Tightening torque:
39—49 N-m (4.0—5.0 m-kg, 29—36 ft-lb)
2. Bleed air from the system.
3. Open the gauge valve fully, then start the engine
and turn the steering wheel fully left and right to
raise the fluid temperature to 50—60°C
(122—140°F)
4. To measure the fluid pressure generated by the
oil pump, close the gauge valve completely and
increase the engine speed to 1,000—1,500 rpm.
If the fluid pressure is low, replace the oil pump
assembly.
Warning
If the valve is left closed for more than 15 sec-
onds, the fluid temperature will increase ex-
cessively and adversely affect the oil pump.
Oil pump fluid pressure
2WS
7,355—7,846 kPa
(75—80 kg/cm2, 1,066—1,138 psi)
4WS
Front 8,093—8,829 kPa
(82.5—90.0 kg/cm2, 1,173—1,280 psi)
Rear 7,112—7,848 kPa
(72.5—80.0 kg/cm2, 1,031—1,138 psi)
To measure the fluid pressure generated at the
gear housing, first open the gauge valve complete-
ly, increase the engine speed to 1,000—1,500
rpm, and then turn the steering wheel fully to the
left and right.
Warning
If the steering wheel is kept in the fully turned
position for more than 15 seconds, the fluid
temperature will rise excessively.
80U10X-026
10—16

1 0 4-WHEEL STEERING GEAR AND LINKAGE
86U10X-301
86U10X-302
86U10X-303
4WS PERFORMANCE INSPECTION
1. Steering Angle Transfer Shaft Alignement
(Simple inspection)
(1) Put masking tape on the steering wheel and
column cover.
(2) Drive the vehicle on a straight, flat road for at
least 30 m (18.6 ft) and note the steering wheel
position. Stop and mark the straight-ahead po-
sition on the steering wheel and column cover
tape. Drive the vehicle again and check the
marks.
(3) With the marks between the steering wheel and
column cover aligned, check that the rear
wheels do not turn off center when the engine
is started.
(4) If the rear wheels move, adjust the steering an-
gle transfer shaft.
(Inspection by dial indicator)
(1) Mark between the steering wheel and column
cover as shown above.
(2) Attach a scale on the column cover as shown
in the illustration.
86U10X-304
10-32

4-WHEEL STEERING GEAR AND LINKAGE 1 0
(3) Raise the vehicle on a lift or safety stands.
(4) Set a dial indicator against one rear tire. Set
the pointer to 0.
86U10X-305
(5) With the marks on the steering wheel and
column cover aligned, start the engine and turn
the steering wheel slowly to the right. Using the
scale on the column cover, note the rotation
of the steering wheel at the point where the rear
wheels begin to turn (dial indicator begins to
move).
86U10X-306
(6) Turn the steering wheel left and right a few
times to equalize the hydraulic pressure. Re-
align the marks between the steering wheel
and column cover.
86U10X-307
(7) Reset the dial indicator to 0 and turn the steer-
ing wheel slowly to the left. Using the scale on
column cover, again note the rotation of the
steering wheel at the point where the rear
wheels begin to turn (dial indicator begins to
move).
86U10X-308
10-33

1 0 4-WHEEL STEERING GEAR AND LINKAGE
(Example) ^"in)
-I
8 mm (0.31 in)
1 1111111
- ^Center
10 mm (0.39 in)
86U10X-309
(8) The center position can be determined from
the left/right measurements in (5) and (7) above.
Example:
Right rotation.... 10 mm (0.39 in)
Left rotation....8 mm (0.31 in)
Center = Right 1 mm (0.04 in)
(9) Check that the center is within specification.
Specification
= R 5 mm (0.4 in ) to L 5 mm (0.4 in)
(10) If not correct, adjust the steering angle trans-
fer shaft.
2. Steering Inspection
With the vehicle stopped and the engine running,
check that the rear wheels turn in the opposite
direction when the steering wheel is turned and that
there is no abnormal noise.
86U10X-310
3.4WS Electric System Inspection
Drive the vehicle and check that the 4WS warning
light does not come on at over 40 km/h (25mph).
86U10X-311
10—34