1987 MAZDA 626 transaxle

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 ELECTRICAL COMPONENTS OF 4-WHEEL STEERING
4WS-0 Normal operation or failure of con-trol unit or harness
Start engine.
Disconnect R-01 (7-pin) connector. Check that 4WS warning light flashes or illuminates.
NG
Repair harness. (Fuse box to Control unit or Control unit to Body ground).
YES No electrical problem.
NO
Reconnect connector.
Check voltage between terminals and body ground.
Terminal Voltage
G(B) OV
H(B) OV
K(G) Approx. 12V
L(G) Approx. 12V
N(B) OV
OK Replace control unit.
4WS-1 Failure of speed sensors or wiring
harness
Check speed sensor at transaxle. (Referring to page 10—103)
OK
NG Replace speed sensor.
Check for continuity between terminal of transaxle speed sensor and R (O) terminal of the control unit connector.
NG^ Repair wiring harness (Control unit to Transaxle
speed sensor).
Cont'd 76G10X-028
10—98

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

OUTLINE 13
Front Coil Springs
Transa-
xle
Sun-
roof
Identification color
Model Market Engine Transa-
xle
Sun-
roof AAS ABS Green Light
green Pink Brown Purple Gray Orange
Sedan ECE F8 M4 — — — O
M5 — — — 0
4HAT — — — O
FE M5 — — — O
0 — — O
— o — o
o o — o
4HAT -— — o
— o — O
— — — o
o — — o
FE (DOHC) M5 — — — o
— o — 0
— o o o
— — o o
0 — — o
o o — o
0 0 o o
o — 0 o
FE (Fuel M5 — — — o
Injection) — 0 — O
EC-AT O — — o
o o — o
RF-N M5 — — — 0
RF-CX — — — o
Left Hand F8 M5 — — — o
Drive „ o — o
4HAT — — — o
RF-N M5 — — — o
Middle East FE M5 — — — o
-o — o
4HAT — — — o
— o — 0
Right Hand F6 3AT — — — 0
Drive M5 — — — o
FE M5 — — — 0
— o _ o
4HAT — — — o
— 0 — o
FE (DOHC) M5 — — — o
— o o 0
RF-N M5 — — — o
F8 M5 — — — 0
4HAT — — — o
76G13X003
O Available M4, M5.... ...Manual transaxle
— Not available EC-AT ....Electronically controlled automatic transaxle 4HAT ....Hydrallic controlled automatic transaxle
4WS ... 4-Wheel steering
AAS ....Auto adjusting suspention ABS ....Anti-lock brake system
3AT ... Automatic transaxle
13—5

13 OUTLINE
Rear Coil Springs
Transa-xle
Sun-
roof
Identification color
Model Market Engine Transa-xle
Sun-
roof AAS ABS Orange White Yellow Brown Blue Green Red Pink
Sedan ECE F8 M4 — — — R L
M5 — — — R L
4HAT — — R L
FE M5 — — — R L
— — R L
— o — R L
O 0 — R L
4HAT — „ — R L
— 0 — R L
— — — R L
o — — R L
FE (DOHC) M5 — — — R L
— o — R L
— o 0 R L
— — o R L
0 — — R L
0 o — R L
o 0 0 R L
o — o R L
FE (Fuel M5 — — — R L
Injection) — o — R L
EC-AT o — — R L
o o — R L
RF-N M5 — — — R R L L
RF-CX _ — — R L
Left Hand F8 M5 — — — R L
Drive — o — R L
4HAT — — — R L
RF-N M5 — — — R L
Middle East FE M5 — — — R L
— o — n L
4HAT — — — R L
— o — L
Right Hand F6 3AT — — — L R
Drive M5 — — — L R
FE M5 — — — L
— o — L R
4HAT — — — L
— o — L R
FE (DOHC) M5 — — — L R — o o L R
RF-N M5 — — L R
F8 M5 — — — L R
4HAT — — — L R
76G13X-006
0 Available R Right side M4, M5 Manual transaxle 3AT Automatic transaxle — Not available L Left side EC-AT... Electronically controlled automatic transaxle 4HAT..., Hydrallic controlled automatic transaxle 4WS...... 4-wheef steering AAS Auto adjusting suspention ABS Anti-lock brake system
13-8

30
TECHNICAL DATA
MEASUREMENT 30— 2
ENGINE (SOHC) 30— 2
ENGINE (DOHC) 30— 8
ENGINE (DIESEL) 30—11
LUBRICATION SYSTEM (GASOLINE) 30—14
LUBRICATION SYSTEM (DIESEL) 30—15
COOLING SYSTEM (GASOLINE) 30—16
COOLING SYSTEM (DIESEL) 30—17
FUEL AND EMISSION CONTROL SYSTEM
(CARBURETOR) 30—18
FUEL AND EMISSION CONTROL SYSTEM
(FUEL INJECTION FE) 30—20
FUEL AND EMISSION CONTROL SYSTEM
(FE DOHC) 30—21
FUEL AND EMISSION CONTROL SYSTEM
(DIESEL) 30—22
ENGINE ELECTRICAL SYSTEM 30—23
CLUTCH 30—25
MANUAL TRANSAXLE 30—26
AUTOMATIC TRANSAXLE
(ELECTRONICALLY CONTROLLED AND
4-SPEED) 30—27
AUTOMATIC TRANSAXLE (3-SPEED) 30—33
FRONT AND REAR AXLES 30—36
STEERING SYSTEM 30—36
BRAKING SYSTEM 30—37
WHEEL AND TIRE 30—38
SUSPENSION 30—38
BODY ELECTRICAL SYSTEM 30—39
STANDARD BOLT AND NUT
TIGHTENING TORQUE 30—40
76G30X-001

30 TECHNICAL DATA
7A. MANUAL TRANSAXLE
Engine model FE DOHC Ffl FE FE
B
valve F8 Item —— Leaded UriBsded Ffl 12 valve Carb. Fl F8 RF-N RF-CX

Transmission
Shift
lever
position Floor shift
Gear ratio
First 3.307
Second 1.833
Third 1.310
Fourth 1.030
Fifth 0.837
1,233
0.970
0.795
0.914

1.161
0.861

0.755 0.680
Reverse 3.166
Oil capacity liters US qt, Imp
qt)
3.35 (3.6, 3.0)
Fluid type
ATF: DEXRON-II
Above 0°F: API GL-4
or
GL-5
SAE80W—90
or
SAE90

Clearance

Clearance
of
lever and reverse idle
gear
mm (in)

Standard 0.1—0.32 (0.004-0.013) Clearance
of
lever and reverse idle
gear
mm (in)
Wear limit 0.5 (0.020)
Clearance
of
shift fork and clutch hub sleeve
mm (in)

Standard 0.2—0.4 (0.008-0.016) Clearance
of
shift fork and clutch hub sleeve
mm (in)
Wear limit 0.5 (0.020)
Clearance
of
synchronizer ring
and

gear
mm
(in)
Standard 1.5 (0.059) Clearance
of
synchronizer ring
and

gear
mm
(in) Wear limit 0.8 (0.021)
Gear thrust clearance
mm (in)
First Standard 0.05—0.28 (0.002-0.011)
Gear thrust clearance
mm (in)
First Limit 0.3 (0.020)
Gear thrust clearance
mm (in)
Second Standard 0.18—0.46 (0.007-0.018)
Gear thrust clearance
mm (in)
Second Limit 0.5 (0.02) Gear thrust clearance
mm (in) Third Standard 0.05-0.20 (0.002-0.008)
Gear thrust clearance
mm (in) Third Limit 0.25 (0.010)
Gear thrust clearance
mm (in)
Fourth Standard 0.17—0.37 (0.0064—0.014)
Gear thrust clearance
mm (in)
Fourth Limit 0.4 (0.016)
Bearing preload
of
primary shaft gear
Primary shaft
0.1-0.25 N-m (1.0-2.5 cm-kg, 0.86-2.18 in-lb) Secondary shaft 0.2-0.4 N-m (2.0—4.0 cm-kg, 1.7-3.4 in-lb)
Bearing preload adjust shim mm (in) 0.25 (0.010), 0.30 (0.012), 0.35 (0.014), 0.40 (0.016), 0.45 (0.018), 0.50 (0.020), 0.55 (0.022), 0.60 (0.024), 0.65 (0.026), 0.70 (0.028), 0.75 (0.030), 0.80 (0.031)

Drive and differential

Final gear
TvDe

Reduction ratio
Side
bearina Dreload

Helical aear
4.1051 3.850 4.1051 3.850
4.150

1.4-2.0 N
m
(14—20 cm-kg, 12-17 in-lb)
Bearing preload adjust shim mm (in)
0.10 (0.004), 0.15 (0.006), 0.20 (0.008), 0.25 (0.010), 0.30 (0.012), 0.35 (0.014), 0.40 (0.016), 0.45 (0.018), 0.50 (0.020), 0.55 (0.022), 0.60 (0.024), 0.65 (0.026), 0.70 (0.028), 0.75 (0.030), 0.80 (0.031), 0.85 (0.033), 0.90 (0.035), 0.95 (0.037), 1.00 (0.039), 1.05 (0.041), 1.10 (0.043), 1.15 (0.045), 1.20 (0.047)
Backlash
of
side aear and
Dinion
aear mm (in) 0-0.1 (0-0.004)

30—26

TECHNICAL DATA 30
7B. AUTOMATIC TRANSAXLE (ELECTRONICALLY CONTROLLED AND 4-SPEED)
————Model
Item -————
G4A-EL
(EC-AT)
G4A-HL (4-Speed) ————Model
Item -————
G4A-EL
(EC-AT) FE engine F8 engine

Gear ratio
1st 2.800
Gear ratio
2nd 1.540
Gear ratio 3rd 1.000 Gear ratio
4th (OD) 0.700
Gear ratio
Reverse 2.333
Oil capacity liters (US qt, Imp
qt)
6.2 (6.6, 5.4)
Fluid type ATF Dexron
II or M III

Fluid level with the engine idling
in P
Between
F
and
L
marks
on
gauge

Stall speed

After brake-in D,
S, L rpm
2170-2270 2430-2530 2180—2280 After brake-in R
rpm
2130—2230 2390—2490 2140—2240

Time lag

N
D sec
0.5-1.0 0.4-1.2
N
R sec
0.5-1.0 0.4—1.5

Line pressure

D,
S, L

Idle kPa (kg/cm2,
psi)
353-432 (3.6-4.4, 51—63) 350-490 (3.6-5.0, 51-71)
D,
S, L

Stall kPa (kg/cm2,
psi)
873-1,040 (8.4-10.6, 127-151) 980-1230 (10.0-12.5, 142-178)
R
Idle kPa (kg/cm2,
psi)
598-942 (6.1-9.6, 87-137) 600-830 (6.1-8.5, 87—121)
R
Stall kPa (kg/cm2,
psi)
1,668-2,011 (17.0-20.5, 242-292) 1470-1960 (15.0-20.0, 213-284)

Throttle pressure

D
Idle kPa (kg/cm2,
psi)
39-88 (0.4-0.9, 6-13) 83-113 (0.85-1.15, 12-16)
D
Stall kPa (kg/cm2,
psi)
471—589 (4.8-6.0, 68-85) 540-610 (5.5-6.2, 78—88)

Governor pressure

D
30 km/h (19 mph)
kPa (kg/cm2,
psi) —
79-114
(0.81-1.16, 12-16)
82-117
(0.84-1.19, 12-17)
D 55 km/h (34 mph) kPa (kg/cm2, psi)
—
146-190 (1.49-1.94, 21-28) 157-201 (1.60-2.05, 23-29) D
85 km/h (53 mph) kPa (kg/cm2,
psi) —
276-339 (2.81-3.46, 40-49)
302-366 (3.08-3.73, 44-53)

30-27