Mazda RX7 Steering System - Power and Pinion: pump belt, steering gear and etc.

Mazda RX7 1993-1995 FD3S

Steering system is a power-assisted rack and pinion. The system consists of a rack and pinion steering gear and power-assist pump/reservoir. The steering gear and pump/reservoir are connected by flexible lines.

TESTING

HYDRAULIC SYSTEM PRESSURE TEST

Pump Fluid Pressure Test
1. Disconnect pressure line from steering gear and steering pump. Connect pressure gauge/valve between steering pump and steering gear. See Fig. 1 . Bleed air from system.
2. Completely open valve. Start engine and operate at idle. Turn steering wheel from lock to lock to increase fluid temperature to 122-140°F (50-60°C). To measure pump fluid pressure, close gauge valve completely.
3. Increase engine speed to 1000-1500 RPM. Measure oil pump fluid pressure. Ensure pump pressure is within specification. If pressure is not within specification, replace pump.

CAUTION: DO NOT leave gauge valve closed for more than 15 seconds, or pump may be damaged.

Fig. 1: Connecting Pressure Gauge/Valve (Typical)
Fig.1

Gear Fluid Pressure Test
1. Ensure steering pump pressure is within specification. To measure steering gear fluid pressure, open gauge valve completely. Increase engine speed to 1000-1500 RPM.
2. Turn steering wheel from lock to lock. Measure steering gear fluid pressure. Ensure gear pressure is within specification.If pressure is not within specification, replace gear.

HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS
Specifications are measured at 1000-1500 RPM, with fluid temperature at 122-140°F (50-60°C).

Mazda RX7 1993-1995: 1110-1209 (78-85) psi (kg/cm2)

LUBRICATION

FLUID CAPACITY

POWER STEERING FLUID CAPACITY

Mazda RX7 1993-1995: 1.01 (.96) Qts. (L)

FLUID TYPE

Dexron-II or Mazda M-III fluid is recommended for all models.

FLUID LEVEL CHECK

Check fluid level on oil pump dipstick (if equipped) or reservoir. Fluid should be between marks on level gauge dipstick (if equipped) or reservoir. If fluid level is low, fill as necessary. Recheck fluid level. DO NOT overfill.

HYDRAULIC SYSTEM BLEEDING

1. Raise and support front of vehicle. With ignition off, turn steering wheel from lock to lock several times. Check fluid level. Add fluid as necessary. Repeat procedure until fluid level no longer decreases.
2. Start engine and operate at idle. Turn steering wheel from lock to lock 5 times. Check fluid level. Add fluid as necessary. Continue procedure until fluid is clear of air bubbles and does not decrease in level.

ADJUSTMENTS

PINION PRELOAD

Pinion preload should be checked when steering gear assembly has been disassembled or overhauled. Check preload after steering gear assembly has been reassembled, but tie rods have not yet been installed.

Fig. 2: Tightening Adjusting Cover (Miata Shown; Others Are Similar)
Fig.2

Fig. 3: Checking Pinion Preload (Miata Shown; Others Are Similar)
Fig.3

1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten adjusting cover 87 INCH lbs. (9.8 N.m), then loosen adjusting cover 20-25 degrees. See Fig. 2 .
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3 . Measure pinion preload using spring scale. Pinion preload should be 3.3 lbs. (1.5 kg) maximum.
3. If preload is not as specified, repeat steps 1) and 2). If preload is as specified, apply thread sealant to adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 37-50 ft. lbs.
(50-68 N.m).

POWER STEERING PUMP BELT

BELT ADJUSTMENT SPECIFICATIONS
Belt deflection is measured at midpoint between idler pulley and pump, with 22 lbs. (10 kg.) of pressure applied.

New Belt: .14-.16 (3.5-4.0) In. (mm)
Used Belt: .18-.20 (4.5-5.0) In. (mm)

STEERING GEAR REMOVAL AND INSTALLATION

Use a suitable container or rags to collect fluid when disconnecting pressure and return lines.

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies. Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles.
2. Remove stabilizer bar-to-frame bolts and brackets. Disconnect pressure and return line connections from steering gear. Mark steering column intermediate shaft-to-steering column gear pinion for installation reference.
3. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Remove steering gear mounting bolts. Support crossmember with jack and remove crossmember nuts and bolts. Slowly lower jack and remove steering gear and linkage from vehicle.
4. To install, reverse removal procedure. Tighten bolts and nuts to specification. Tighten steering gear mounting bolts in sequence: left rear, right rear, left front, right front. Fill and bleed power steering system. Check and adjust front wheel alignment.

POWER STEERING PUMP REMOVAL AND INSTALLATION

Use a suitable container or rags to collect fluid when disconnecting pressure and return lines.

1. Remove drive belt. Remove pulley lock nut and remove pulley from pump. Disconnect power steering pressure switch electrical connector (if equipped).
2. Place reference marks on steering pump and pressure line fitting for reassembly. Disconnect pressure and return line connections from steering pump. Remove pump-to-bracket bolts and nuts. Remove pump from vehicle.
3. To install, reverse removal procedure. Tighten bolts and nuts to specification. Adjust belt tension. Bleed air from system. Inspect system for leaks.

OVERHAUL

STEERING GEAR

Disassembly and Reassembly
1. Remove steering gear assembly. As an aid to disassembly and reassembly, use illustrations. See Fig. 4 . For reassembly reference, keep components in order of disassembly. Replace worn or damaged components as necessary.
2. After steering rack reassembly, but before installing tie rods, check pinion preload.

Fig. 4: Exploded View Of Rack and Pinion Steering Gear
Fig.4

POWER STEERING PUMP

Fig. 5: Exploded View Of Power Steering Pump
Fig.5

TORQUE SPECIFICATIONS

Intermediate Shaft-To-Pinion Shaft Bolt: 13-19 (18-26) Ft. Lbs. (N.m)
Pinion Shaft Lock Nut: 14-22 (19-30) Ft. Lbs. (N.m)
Power Steering Pump Mounting Bolts/Nuts: 12-17 (16-23) Ft. Lbs. (N.m)
Power Steering Pump Pulley Lock Nut: 29-43 (39-58) Ft. Lbs. (N.m)
Pressure Line Fitting-To-Power Steering Pump: 17-26 (23-36) Ft. Lbs. (N.m)
Pressure Line Fitting-To-Steering Gear: 12-17 (16-23) Ft. Lbs. (N.m)
Steering Gear Mounting Bolts/Nuts: 27-38 (37-52) Ft. Lbs. (N.m)
Steering Rack-To-Tie Rod: 58-72 (79-98) Ft. Lbs. (N.m)
Tie Rod Castle Nuts: 22-32 (30-44) Ft. Lbs. (N.m)
Tie Rod End-To-Tie Rod Lock Nut: 25-37 (34-50) Ft. Lbs. (N.m)
Wheel Lug Nuts: 65-87 (88-118) Ft. Lbs. (N.m)

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Mazda RX-7 1993-1995 FD3S

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