oil level MAZDA 626 1987 Repair 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

1 0 TROUBLESHOOTING GUIDE
POWER STEERING
Problem Possible cause Remedy Page
Hard steering
Loose
or
damaged belt Low fluid level,
or air in
fluid Leakage
of
fluid
Malfunctioning electrical system* Insufficient oil pump pressure Improperly adjusted wheel alignment Malfunctioning steering gear Linkage ball joint not operating smoothly
Adjust
or
replace Add fluid
or
bleed
air
Repair
or
replace Repair
or
replace Repair
or
replace Refer
to
Section
13
Repair
or
replace Replace
10—12 10-11 10-13 10-87 10-16
10—28,
37
10-18

Poor return
Insufficient tire pressure
Improperly adjusted wheel alignment
Ball-joint not operating smoothly
Steering shaft contacting something
Refer
to
Section
12

Refer
to
Section
13

Replace
Repair
10-20 10-21

Excessive play
Loose gear box housing mounting bolts Worn linkage
or
tie-rod ball joint Worn lower ball joint Worn
or
damaged steering joint Worn rack and pinion gear
Tighten Replace
Refer
to
Section
13

Replace
Replace
10—30
10—18
10—21
10-58,
75
Steering wheel
vibrates

Insufficient tire pressure Damaged
or
unbalanced wheel Improperly adjusted wheel alignment Loose gear box housing mounting bolts Incorrect pinion preload adjustment Worn ball joints
Loose shock absorber mounting Malfunctioning shock absorber
Refer
to
Section
12

Refer
to
Section
13

Refer
to
Section
13

Tighten Adjust
Replace Refer
to
Section
13
Refer
to
Section
13

10-30 10-72,
81
10—18

Steering wheel
pulls

Unevenly worn tires
Incorrect tire pressure
Dragging brake
Improperly adjusted wheel alignment
Refer
to
Section
12

Refer
to
Section
12

Refer
to
Section
11

Refer
to
Section
13 —
Excessively light
steering at high
speed*

Malfunctioning electrical system Repair
or
replace 10-87
*... Only
for
electronically
-
controlled type

76G10X-002
10—8

ON-VEHICLE MAINTENANCE 1 0
"{krf
'"""^JlW^M 1
V
^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

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 4-WHEEL STEERING GEAR AND LINKAGE
86U10X-075
86U10X-076
86U10X-077
Front joint Rear joint
Rear bracket
Front bracket
Installation Note
Front steering gear
Tighten the universal joint to the pinion shaft.
Tightening torque:
18—26 N (1.8—2.7 m-kg, 13—20 ft-lb)
Install the subframe.
Tightening torque:
36—54 Nm (3.7—5.5 m-kg, 27—40 ft-lb)
Adjust the rear turning angle. (Refer to page 10—35.)
Rear steering gear
Adjust the rear steering angle after installation of the
rear steering gear. (Refer to page 10—35.)
Note
When the replacement of rear steering gear
or the oil pan gasket owing to the oil leakage,
add fluid to the specified level. (Refer to page
10—12)
Steering angle transfer shaft
Caution
Installation of the steering angle transfer shaft
must be done correctly.
Work carefully, referring to the adjustment of
steering angle transfer shaft (page 10—35).
If not installed correctly, the rear steering an-
gle may be incorrect, causing steering prob-
lems or damage to the rear steering gear
assembly.
86U10X-078
10—42

1 0 4-WHEEL STEERING GEAR AND LINKAGE
86U10X-085
Rear Steering Gear and Linkage
1. Check the following and replace the rear steering
gear assembly if necessary.
(a) Damaged or cracked case
(b) Faulty stepper motor or rear-to-front steering
ratio sensor
(c) Sticking bearings
(d) Oil leakage
Note
There is no fluid in a new replacement rear
steering gear assembly, add fluid to the spe-
cified level. (Refer to 10—12.)
2. Check and tighten bolts and nuts, if necessary.
3. Check the following and replace any faulty parts.
(a) Cracked, damaged, or deteriorated rear stee-
ring gear boots and bands
(b) Cracked or damaged oil pan
(c) Malfunctioning solenoid valve
86U10X-086
10-46

ELECTRICAL COMPONENTS OF 4-WHEEL STEERING 1 0
Warning light output pattern Malfunction Flow chart No.
ON
ncc
Stepper motor or wiring harness 4WS—6 Stepper motor or wiring harness 4WS—6
ON
r\cc
Oil leakage or oil
level switch
4WS—7 Oil leakage or oil
level switch
4WS—7
ON
OFF
Control unit 4WS—8 Control unit 4WS—8
ON
ncc
Control unit, alter-nator, or wiring harness
4WS—9
ON
ncc
Control unit, alter-nator, or wiring harness
4WS—9 Control unit, alter-nator, or wiring harness
4WS—9
86U10X-226
10—97

ELECTRICAL COMPONENTS OF 4-WHEEL STEERING 1 0
SPEED SENSOR (IN METER)
1. Jack up the front of the vehicle.
2. Connect a voltmeter between 2A (GR) terminal of
the control unit connector and a body ground.
3. Start the engine. Check that periodic voltage is de-
tected when turning'the front wheels slowly.
4. If periodic voltage is not detected, check the wir-
ing harness. Replace the speed sensor if
necessary.
86U10X-233
SPEED SENSOR (AT TRANSAXLE)
1. Jack up the front of the vehicle.
2. Connect a voltmeter between R (O) terminal of the
control unit connector and a body ground.
3. Start the engine. Check that periodic voltage is de-
tected when turning the front wheels slowly.
4. If periodic voltage is not detected, check the wir-
ing harness. Replace the speed sensor if
necessary.
86U10X-234
REAR-TO-FRONT STEERING RATIO SENSOR
Check the resistance between the terminals with an
ohmmeter.
Terminal [ Resistance
GB—GO l 3.5—6.5 kfi
GB—GW ' 3.2—5.9 kfi

If
the resistance is not within specification, replace the
rear steering gear assembly.
86U10X-235
OIL LEVEL SWITCH (IN P/S RESERVOIR)
Check for continuity of the switch with an ohmmeter.
Fluid level Continuity
More than L No
Less than L Yes

If
the continuity is not within specification, replace the
P/S reservoir.
86U10X-236
10—103

WARNING LIGHT AND SENDER 1 5
Washer Fluid Low Level Warning Light
76G15X-039
76G15X-040
Engine Oil Pressure Warning Light
76G15X-041
15—35