MAZDA 626 1987 Workshop Manual

ENGINE SPEED SENSING POWER STEERING 1 0
3. Tap in a new roll pin.
86U10X-175
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Boot
1. Apply grease to the inner surface of the small end
of the boot.
2. Install the boot. Wrap a new wire around the large
end of the boot two times and then twist it 4 to 4.5
times. Bend the twisted part toward the mounting
bracket.
Note
Be careful not to break the boot wire.
3. Install the spring clip on the small end of the boot.
86U10X-176
Tie-rod end
Align with the mark made before disassembly, and
then tighten the nut.
86U10X-177
Oil pipe
Secure the mounting bracket in a vise so that the oil
pipe connections face upward.
86U10X-178
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1 0 ENGINE SPEED SENSING POWER STEERING
Oil pressure switch
1. Install the pressure switch O-ring in the gear
housing.
2. Install the oil pressure switch.
Tightening torque:
31—36 N-m (3.2—3.7 m-kg, 23—27 ft-lb)
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ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
ELECTRONICALLY-CONTROLLED POWER STEERING
DISASSEMBLY
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
parts.
Caution
a) Because adjustment of the spool valve is not possible, do not disassemble the gear box
for spool valve repairs. If repairs are necessary, replace the gear box assembly.
b) In order to prevent the entrance of dirt, all disassembly and assembly should be done
in a clean area.
c) Before disassembly, plug the openings of all pipe installation fittings; then thoroughly
clean the steering gear and linkage.
86U10X-180
1. Pipe
2. Solenoid valve
3. Tie-rod end
4. Tie-rod end locknut
5. Spring clip
6. Boot wire
7. Boot
8. Tie-rod
9. Adjust cover locknut
10. Adjust cover
11. Spring
12. Pressure pad
13. Outer box assembly
14. Oil seal
15. Mounting bracket
16. Mounting rubber
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1 0 ELECTRONICALLY-CONTROLLED POWER STEERING
Disassembly Note
Steering gear and linkage
Secure the mount part of the removed gear and link-
age in a vise.
Caution
Insert protective material (such as copper
plates) in the jaws of the vise.
86U10X-181
Tie-rod ends
Before removing the tie-rod ends, make a mark for
proper installation.
86U10X-182
Oil pipe
Mark the pressure and return pipes and the valve
case for proper installation. Remove the pipes.
86U10X-183
Solenoid valve
Remove the solenoid valve.
86U10X-184
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ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
/
I I
86U10X-185
63U10X-127
86U10X-186
Tie-rods
1. Uncrimp the washer as shown in the figure.
2. Remove the tie-rod from the rack.
Locknut and adjust cover
Loosen the locknut and remove the adjust cover,
spring, and pressure pad.
Outer box
Protect the outer box with cloth and remove it with
a pipe wrench.
86U10X-187
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1 0 ELECTRONICALLY-CONTROLLED POWER STEERING
Oil seal
Remove the oil seal with a screwdriver.
86U10X-188
INSPECTION
Check the following and replace any faulty parts.
1. Cracked, damaged, or deteriorated boots
2. Worn pressure pad friction surface
3. Loose or sticking tie-rod ball joint
4. Bent or damaged tie-rod or tie-rod end
86U10X-189
5. Worn outer box bushing
86U10X-190
6. Cracked or damaged gear housing
7. Steering gear oil leakage
86! I10X-191
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ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
ASSEMBLY
Torque Specifications
29—39 N-m (3.0-4.0 m-kg, 22-29 ft-lb)
29—39 N m
(3.0—4.0 m-kg, 22—29 ft-lb)
29—39 N m
(3.0—4.0 m-kg, 22—29 ft-lb) 29—39 N-m (3.0—4.0 m-kg, 22—29 ft-lb)
15—25 N m (1.5—2.5 m-kg
3.9—4.9 N m (0.4—0.5 m-kg,
39—49 N-m (4.0—5.0 m-kg, 29—36 ft-lb) 78—98 N-m (8.0—10.0 m-kg, 58—72 ft-lb)
34—44 N m 34—44 N-m (3.5—4.5 m-kg, 25—33 ft-lb) (3.5-4.5 m-kg, 25—33 ft-lb) (7.0—ID, 0 m-kg, 51—72 ft-lb)
86U10X-252
1. Install the outer box in the rack housing.
Note
Coat the seals and O-rings with ATF.
86U10X-192
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1 0 ELECTRONICALLY-CONTROLLED POWER STEERING
2. Protect the outer box with cloth and tighten it with
a pipe wrench.
86U10X-193
3. Stake between the outer box and the rack hous-
ing with a center punch.
B6U10X-194
4. Install the oil seal with a suitable pipe.
86U10X-195
5. Install the pressure pad and spring in the gear
housing.
86U10X-196
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ELECTRONICALLY-CONTROLLED POWER STEERING 1 0
86U10X-197
86U10X-198
86U10X-199
6. Apply thread sealant to the threads of the adjust
cover.
7. Install the adjust cover to the gear housing and
tighten it as specified; then loosen it 35°.
Tightening torque:
4.5—5.5 Nm
(45—55 cm-kg, 39—48 in-lb)
8. Measure the pinion torque with the SST.
Pull scale: 1,000—1,400 g (35.3—49.4 oz)
9. If the pinion torque is not within specification, read-
just the adjust cover.
10. Lock the adjust cover with the locknut.
Tightening torque:
40—50
N
m
(4—5 m-kg, 29—36 ft-lb)
11. Set the rack in a vise and install the washer. Tight-
en the tie-rod.
Tightening torque:
60—80 N-m
(6—8 m-kg, 43—58 ft-lb)
Caution
Insert protective material (such as copper
plates) in the jaws of the vise.
76G10X-040
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1 0 ELECTRONICALLY-CONTROLLED POWER STEERING
12. Stake the washer in two places with a punch.
86U10X-201
13. Install the boot. Wrap a new wire around it two
times and twist it 4 to 4.5 times.
Caution
Be sure that the boot is not twisted or dented.
86U10X-202
14. Install the tie-rod ends, aligning them with the marks
made before disassembly.
86U10X-203
15. Install the solenoid valve and pressure switch.
16. Align the oil pipes with the marks made before dis-
assembly, then tighten them.
86U10X-204
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