steering wheel adjustment MAZDA 626 1987 Workshop Manual

ISC SYSTEM 4C
COMPONENT DESCRIPTION
Component Function Remark
A/C switch Detects air conditioner operation; sends
signal to engine control unit Switch ON when air conditioner
operating
Air valve When cold, supplies bypass air into dy-namic chamber • Engine speed increased to shorten warm-up period • Thermo wax type
• Installed in BAC valve
Clutch switch Detects in-gear condition; sends signal to engine control unit Switch ON when clutch pedal released
E/L control unit Detects that E/L is being applied; sends
signal to engine control unit
Engine control unit Detects signals from input sensors and switches; controls solenoid valve (Idle speed control)
Idle switch Detects when throttle valve fully closed;
sends signal to engine control unit
Installed on throttle body
Ne signal pick-up Detects crank angle at 180° intervals; sends signal to engine control unit Installed in distributor
Neutral switch Detects in-gear condition; sends signal to engine control unit
Switch ON when in gear
P/S pressure switch Detects P/S operation; sends signal to engine control unit Switch ON when steering wheel turned right or left
Solenoid valve (Idle speed control) Controls bypass air amount • Controlled by duty signal from engine control unit • Installed in BAC valve
• Operates idle-up
Test connector For initial idle speed adjustment • Gerrn, 1-pin
• Idle speed feedback control cancelled when connector grounded
Water thermo sensor Detects coolant temperature; sends
signal to engine control unit
76G04C-078
4C—45

TROUBLESHOOTING GUIDE 9
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Faulty operation of
driveshaft
Broken ball joint
Broken tri-pod joint
Worn or seized joint
Replace
Replace
Replace
9—31
9—35
9—31, 35
Abnormal noise from driveshaft Insufficient grease in joint or spline Excessive backlash on spline Worn joint
Add or replace
Replace
Replace
9—33, 36 9—31, 35 9-31, 35
Steering wheel pulls. (Steering wheel pulls toward either right or left side)
Bent steering linkage
Fatigued coil spring
Lower arm bushing worn or damaged Bent knuckle Bent lower arm or loose mounting Incorrect toe-in adjustment Improper tire air pressure Unevenly worn tires (left and right tires) Brake dragging
Refer to Section 10 Refer to Section 13 Refer to Section 13 Replace Refer to Section 13 Refer to Section 13 Refer to Section 12 Refer to Section 12 Refer to Section 11
9-11
Unstable handling Bent steering linkage
Joint in steering system worn or damaged
Incorrect steering pinion preload adjustment Fatigued coil spring
Faulty shock absorber(s) Lower arm bushing worn or damaged Incorrect toe-in adjustment (front or rear) Improper tire air pressure Wheel(s) bent or unbalanced
Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 13 Refer to Section 13 Refer to Section 13 Refer to Section 13 Refer to Section 12 Refer to Section 12
—
Excessive steering wheel play Faulty front wheel bearing Incorrect steering pinion preload adjustment Rack and pinion worn Joint in steering system worn or damaged Lower arm bushing worn or damaged
Adjust Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 13
9-11
Tires excessively worn or worn un-evenly
Incorrect toe-in adjustment Improper tire air pressure Unbalanced wheel(s)
Refer to Section 13 Refer to Section 12 Refer to Section 12 —
Abnormal noise
from axle
Faulty wheel bearing Replace 9-11,18,23
86U09X-006
9—7

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

TROUBLESHOOTING GUIDE 1 0
TROUBLESHOOTING GUIDE
MANUAL STEERING
Problem Probable Cause Remedy Page
Steering "heavy" Poor lubrication, foreign material, or abnormal wear of Refer to Section 13
(vehicle jacked up, steering bail-joints
both wheels off Stuck or damaged ball-joints Replace 10--18 ground) Improperly adjusted steering pinion preload Adjust 10--56
Damaged steering gear Replace 10--28 Worn or damaged steering bushing Replace 10--53 Stuck lower-arm ball-joint Refer to Section 13
Malfunction of steering-shaft joint Replace 10--21
Steering wheel Incorrect tire pressure Refer to Section 12
pulls to one side Unevenly worn tires Refer to Section 12
Weakened front spring Refer to Section 13 Worn or damaged stabilizer and/or lower arm bushing Refer to Section 13
Dragging brake Refer to Section 11
Loose lower arm Refer to Section 13
Improperly adjusted wheel alignment Refer to Section 13
General instability Incorrect tire pressure Refer to Section 12
while driving Damaged or unbalanced wheel Refer to Section 13
Worn or damaged steering joints Replace 10--21 Improperly adjusted steering pinion preload Adjust 10--56
Weakened front spring Refer to Section 13
Worn or damaged stabilizer and/or lower arm bushing Refer to Section 13
Malfunctioning shock absorber Refer to Section 13 Improperly adjusted wheel alignment Refer to Secton 13
Steering wheel Incorrect tire pressure Refer to Section 12
vibrates Unevenly worn tires Refer to Section 12
Worn wheel bearing, or incorrect adjustment Refer to Section 13
Worn or damaged steering joints Replace 10--21
Improperly adjusted steering pinion preload Adjust 10--56
Loose gear housing mounting bolts Tighten 10--30
Worn steering gear bearing Replace
Worn or damaged stabilizer and/or lower arm bushing Refer to Section 13
Improperly adjusted wheel alignment Refer to Section 13
Worn lower-arm ball-joint Refer to Section 13
Damaged unbalanced wheel Refer to Section 13
Malfunctionina or loose shock absorber Refer to Section 13
Excessive steering Improperly adjusted steering gear backlash Adjust 10--56
wheel play Worn rack and pinion gear Replace 10--51
Worn or damaged steering joints Replace 10--21
Worn or damaaed lower-arm bushinq Refer to Section 13
Poor steering Incorrect tire pressure Refer to Section 12
wheel return Stuck or damaged steering joints Replace 10 -21
Improperly adjusted front wheel alignment Refer to Section 13
Improperly adjusted steering pinion preload Adjust 10--56
Abnormal noise Loose steering linkage Tighten 10--28
from steering Worn steering joints Replace 10--21
system ImDroDerlv adiusted steerina aear backlash Adiust 10--56
86U10X-007
10—7

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

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

INSPECTION AND ADJUSTMENT 1 0
Thermometer [50—60°C (122—140°C)]
Gauge
(Turn steering wheel
completely
left/right)
Valve fully open
76G10X-032
Gear housing 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 More than 2,943 kPa
(More than 30 kg/cm2, more than 427 psi)
If the fluid pressure is low, repair or replace the gear
box.
6. Remove the gauge set, then tighten the high-
pressure hose to the specified torque.
Tightening torque:
31—36 Nm (3.2—3.7 m-kg, 23—27 ft-lb)
7. Bleed the air from the system. (Refer to page
10-15.)
10—17

4-WHEEL STEERING GEAR AND LINKAGE 1 0
Front joint Rear joint
Rear bracket
Front bracket
76G10X-033
86U10X-313
ADJUSTMENT OF STEERING ANGLE
TRANSFER SHAFT
If the steering angle transfter shaft is disconnected
from the front or rear steering gear or after adjusting
the wheel alignement, or if the rear steering angle is
not correct, adjust the rear turning angle as described
below.
Warning
Improper installation of the 4WS steering
transfer shaft may affect control of the vehi-
cle and result in the risk of an accident or per-
sonal injury.
1. Raise the vehicle on a lift or safety stands.
2. Remove cover B and joint bolt A.
3. Slide the shaft out of the joint.
4. Remove the plug from the rear steering gear. Sight
through the hole and turn the steering angle input
shaft to align the notch in the input shaft with the
center of hole.
5. Remove the set bolt attached to the rear steering
gear, and install it in the steering gear to set the
input shaft.
Tightening torque:
4.9—7.8 N-m (50—80 cm-kg, 43—69 in-lb)
86U10X-314
Note
After the input shaft is set, manually turn the rear
joint and chack that the shaft does not move.
86U10X-315
10—35

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