engine MAZDA 626 1987 Workshop Manual

ENGINE SPEED SENSING POWER STEERING 1 0
Spacer and pinion housing side oil seal
1. Apply grease to flat surface of the spacer.
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2. Connect the oil seal to the grease coated surface
of the spacer.
3. Apply ATF to the inside and outside of the spacer
and oil seal.
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4. Set the spacer and oil seal on the SST.
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5. Insert the SST from the tube side.
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1 0 ENGINE SPEED SENSING POWER STEERING
6. Install and tighten the SST nut against the tube.
7. Turn the SST shaft in as far as it will go to push
in the seal and spacer.
8. Remove the SST.
86U10X-155
Rack
1. Apply grease (lithium base, NLGI No.2) to the fric-
tion surface and teeth of the rack.
2. Slide the SST over tne rack and slide it in from the
tube side.
3. Remove the SST.
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Oil seal (Rack)
1. Apply ATF to the oil seal and slide it onto the rack.
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Set the SST on the rack.
Turn the SST as far as it will go, and push the oil
seal into the tube.
Remove the SST.
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ENGINE SPEED SENSING POWER STEERING 1 0
Rack bushing
1. Install the rack bushing assembly in the rack
housing.
Tightening torque:
88—98 N m (9—10 m-kg, 65—72 ft-lb)
Note
The oil seal is pushed to the correct position
in the rack housing by the tightening of the
rack bushing.
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2. Stake the rack housing at two points approx 1.5
mm (0.06 in) from the end with a hammer and
center punch.
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Hermetic inspection
1. Connect the SST to the cylinder housing.
2. Connect a vacuum pump to the SST.
3. Apply 400 mmHg (15.7 inHg) vacuum.
4. Verify that vacuum is held for at least 30 sec. If
not, check the seal and assembly.
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Lower bearing
1. Secure the gear housing in a vise so that the low-
er bearing bore faces upward.
2. Apply ATF to the lower bearing, then install it in
the housing.
3. Press the bearing into the gear housing with the
housing cover. Tighten the cover until the tighten-
ing force suddenly increases.
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1 0 ENGINE SPEED SENSING POWER STEERING
Pinion shaft assembly
1. Apply grease (lithium base, NLGI No. 2) to the teeth
of the pinion shaft.
2. Apply ATF to the seal ring and the friction surface
of the control valve.
3. Install the pinion shaft in the housing.
Note
a) Be careful not to damage the oil seal by the
teeth of the pinion.
b) Be careful not to damage the edge of the
seal ring and control valve.
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86U10X-165
Upper bearing
Apply ATF to the upper bearing, and then install it.
Oil seal
1. Apply ATF to the oil seal, and fill inside the lip with
grease (lithium base, NLGI No. 2).
2. Slide the SST over the serrations of the pinion shaft
assembly.
3. Slide the oil seal over the SST and position it in
the housing.
4. Tap the oil seal in with the SST until the snap ring
installation groove in the housing is just visible.
Note
Apply uniform force to the oil seal when in-
stalling.
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ENGINE SPEED SENSING POWER STEERING 1 0
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86u10x-168
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Snap ring
Install the snap ring.
Note
Verify that the snap ring is correctly seated
in the ring groove of the housing.
Locknut
1. Temporarily install the tie-rod on the tube side of
the rack.
2. Install the locknut and turn it until the tie-rod con-
tacts the tube.
3. Tighten the locknut.
Tightening torque:
39—49 N
m
(4.0—5.0 m-kg, 29—36 ft-lb)
Housing cover
1. Apply thread sealant to the housing cover threads.
2. Install the housing cover.
Tightening torque:
44—54 N-m (4.5—5.5 m-kg, 33—40 ft-lb)
3. Stake between the rack housing and housing cover
at two points with a center punch.
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1 0 ENGINE SPEED SENSING POWER STEERING
Pressure pad
1. Secure the gear housing in a vise so that the pres-
sure pad position faces upward.
2. Apply grease (lithium base NLGI No. 2) to the rack
sliding surface of the pressure pad; then install it
in the housing.
3. Install the pressure pad.
86U1OX-171
Adjust cover
1. Set the rack in the center position.
2. Tighten the adjust cover to 9.8 N-m (100 cm-
kg, 7.2 ft-lb) then loosen it.
3. Tighten again to 4.9 ± 0.5 N-m (50 ± 5 cm-
kg, 3.6 ± 0.4 ft-lb), and then return it 45°.
4. Apply thread sealant to the exposed threads of ad-
just cover.
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5. Install and tighten the locknut.
Tightening torque:
49—59 N-m (5.0—6.0 m-kg, 36—43 ft-lb)
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Tie-rod
1. Secure the rack in a vise.
2. Install the tie rod on the rack.
Tightening torque:
123—143 N-m
(12.5—14.5 m-kg, 90.6—105 ft-lb)
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ENGINE SPEED SENSING POWER STEERING 1 0
3. Tap in a new roll pin.
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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.
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Tie-rod end
Align with the mark made before disassembly, and
then tighten the nut.
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Oil pipe
Secure the mounting bracket in a vise so that the oil
pipe connections face upward.
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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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OIL PUMP 1 0
OIL PUMP
REMOVAL AND INSTALLATION
1. Jack up the front of the vehicle, and support it with safety stands.
2. Remove in the order shown in the figure, referring to the removal note for specially marked parts.
3. Install in the reverse order of removal.
4. Tighten all nuts and bolts to the specified torque, referring to the figure.
Note
a) The power steering fluid will leak out when the return hose or the pressure hose is dis-
connected. Prepare a suitable container for it to drain into.
b) After installation, inspect the deflection of the oil pump belt and bleed the air from the
system, then check for fluid leakage. 2WS (Gasoline engine)
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4. Bracket
5. Oil pump
6. Oil pump pulley
1. Belt
2. Nut
3. Pipes
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1 0 OIL PUMP
4WS
16—23 N-m (1,6-2.3 m-kg, 12-17 ft-lb)
39—59 N m (4.0—6.0 m-kg, Z9—43 ft-lb)
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb^.
(1.6-2,3 m-kg, 12-17 lt-!b)
31—46 N-m (3.2—4.7 m-kg, 23—34 ft-lb)
88—98 N-m (9.0—10.0 m-kg, 65—72 ft-lb)
49—59 N-m (5.0—6.0 m-kg, 36—43 ft-lb)
1. Belt
2. Nut
3. Pipes
4. Bracket
5. Oil pump
6. Oil pump pulley
Removal Note
Oil pump (2WS Gasoline engine, 4WS)
1. Hold the oil pump pulley with the SST, and remove
the pulley nut.
2. Slide the pulley forward. Remove the hose, pipes,
and the pump.
3. Remove the pulley.
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