Mazda Trucks 1994-1998 Repair Guide

Power Steering Pump

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REMOVAL & INSTALLATION



Navajo and B Series Pick-up

See Figures 1 and 2



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Fig. Fig. 1: Exploded view of the power steering pump used on the 3.0L engine



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Fig. Fig. 2: Exploded view of the power steering pump used on the 4.0L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove some power steering fluid from the reservoir by disconnecting the fluid return line hose at the reservoir. Drain the fluid into a container and discard it.
  4.  
  5. Remove the pressure hose from the pump. If equipped, disconnect the power steering pump pressure switch.
  6.  
  7. On the 2.3L, 2.5L and 3.0L engines, loosen the idler pulley assembly pivot and adjusting bolts to slacken the belt tension.
  8.  
  9. On the 4.0L engine, slacken belt tension by lifting the tensioner pulley in a clockwise direction. Remove the drive belt from under the tensioner pulley and slowly lower the pulley to its stop.
  10.  
  11. Remove the drive belt from the pulley. If necessary, remove the oil dipstick tube.
  12.  
  13. If equipped, remove the power steering pump bracket support brace.
  14.  
  15. Install power steering pump pulley removal tool T69L-10300-B or equivalent. Hold the pump and rotate the tool counterclockwise to remove the pulley. Do not apply in and out pressure to the pump shaft, as internal pump damage will occur.
  16.  
  17. Remove the power steering retaining bolts. Remove the power steering pump from the vehicle.
  18.  

To install:
  1. Position the pump on the bracket. Install and tighten the retaining bolts.
  2.  
  3. Install the pulley removal tool and install the power steering pump pulley to the power steering pump.
  4.  

Fore and aft location of the pulley on the power steering pump shaft is critical. Incorrect belt alignment may cause belt squeal or chirp. Be sure that the pull off groove on the pulley is facing front and flush with the end of the shaft ± 0.010 in. (0.25mm).

  1. Continue the installation in the reverse order of the removal procedure. Adjust the belt tension to specification.
  2.  
  3. On the 2.3L, 2.5L and 3.0L engines torque the idler pivot pulley bolts 30-40 ft. lbs. for the 2.3L/2.5L engines and 35-47 ft. lbs. for the 3.0L engine
  4.  
  5. On the 4.0L while lifting the tensioner pulley in a clockwise direction, slide the belt under the tensioner pulley and lower the pulley to the belt.
  6.  

MPV
2.6L ENGINE

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Place a drain pan under the pump.
  4.  
  5. Loosen the idler pulley locknut and the pump adjusting bolt and remove the pump drive belt.
  6.  
  7. Remove the pump pulley nut.
  8.  
  9. Remove the pulley.
  10.  
  11. Unplug the pressure switch coupler.
  12.  
  13. Matchmark the high pressure line coupling and disconnect the line.
  14.  
  15. Remove the return hose.
  16.  
  17. Remove the pump-to-bracket bolts and lift out the pump.
  18.  

To install:
  1. Place the pump in position and install and tighten the mounting bolts. Connect the return and pressure lines. Install the drive pulley. Install and adjust the drive belt. Fill and bleed the system. Tighten the high pressure coupling to 23-35 ft. lbs. (31-48 Nm), aligning the high pressure coupling matchmarks. Tighten the pump mounting bolts to 23-34 ft. lbs. (31-48 Nm). Tighten the pulley nut to 29-43 ft. lbs. (39-58 Nm). Tighten the idler pulley locknut to 27-38 ft. lbs. (37-52 Nm). Connect the negative battery cable.
  2.  



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Fig. Fig. 3: Power steering pump mounting-2.6L engine

3.0L ENGINE

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the idler pulley locknut.
  4.  
  5. Loosen the pump adjusting bolt.
  6.  
  7. Remove the drive belt.
  8.  
  9. Remove the pump pulley nut.
  10.  
  11. Using a puller, remove the pulley.
  12.  
  13. Disconnect the pressure switch wiring connector.
  14.  
  15. Place a drain pan under the pump.
  16.  
  17. Matchmark the pressure line connection and disconnect it.
  18.  
  19. Remove the pressure line bracket bolt.
  20.  
  21. Disconnect the return line.
  22.  
  23. Remove the pump-to-bracket bolts and lift out the pump.
  24.  

To install:
  1. Place the pump in position and install the mounting bolts. Connect the return and pressure line. Install the drive pulley and belt. Adjust the drive belt to the proper tension. Fill and bleed the system. Connect the negative battery cable. Observe the following torques:

    mounting bolts to 34 ft. lbs. (46 Nm).
     
    pressure line connection to 35 ft. lbs. (47 Nm).
     
    pressure line bracket bolt: 17 ft. lbs. (23 Nm).
     
    pulley bolt: 43 ft. lbs. (58 Nm).
     
    adjusting bolt: 35 ft. lbs.
     
    idler pulley locknut: 38 ft. lbs. (52 Nm).
     

  2.  



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Fig. Fig. 4: Power steering pump mounting-3.0L engine

BLEEDING



Navajo and 1994-97 B Series Pick-up
  1. Disconnect the coil wire.
  2.  
  3. Crank the engine and continue adding fluid until the level stabilizes.
  4.  
  5. Continue to crank the engine and rotate the steering wheel about 30° to either side of center.
  6.  
  7. Check the fluid level and add as required.
  8.  
  9. Connect the coil wire and start the engine. Allow it to run for several minutes.
  10.  
  11. Rotate the steering wheel from stop to stop.
  12.  
  13. Shut of the engine and check the fluid level. Add fluid as necessary.
  14.  

1998 B Series Pick-up

See Figure 5



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Fig. Fig. 5: Bleeding the power steering system using a vacuum pump

  1. Remove the power steering fluid reservoir cap. Check the fluid level and top off, if necessary.
  2.  
  3. Tightly install the stopper of a vacuum pump into the filler neck of the reservoir.
  4.  
  5. Start the vehicle.
  6.  
  7. Apply the maximum amount of vacuum possible and maintain it for a minimum of 3 minutes with the engine running at idle.
  8.  
  9. Release the vacuum and remove the vacuum pump from the vehicle.
  10.  
  11. Check the fluid level in the reservoir and fill up to the correct level, if necessary.
  12.  
  13. Install the vacuum pump again. Apply and maintain maximum vacuum.
  14.  
  15. Rotate the steering wheel fully to the left and right every 30 seconds. Do this for approximately 5 minutes. Do NOT hold the steering wheel against the stops for more than 3-5 seconds at a time or damage to the power steering pump could occur.
  16.  
  17. Turn off the engine, release the vacuum and remove the vacuum pump.
  18.  
  19. Install the fluid reservoir cap.
  20.  
  21. Check the entire system for leaks. If the system shows signs of air, repeat this procedure.
  22.  

MPV
  1. Check the fluid level.
  2.  
  3. With the engine OFF, turn the steering wheel fully to the left and right several times. If the vehicle is elevated to do this, make certain the vehicle is level before rechecking the fluid level.
  4.  
  5. Recheck the fluid level, and add fluid (Dexron®II or M-III) if necessary.
  6.  
  7. Repeat the previous 2 steps until the fluid level stabilizes.
  8.  
  9. Start the engine and let it idle.
  10.  
  11. Turn the steering wheel fully to the left and right several times.
  12.  
  13. Verify that the fluid level has not dropped, and that the fluid is smooth, not foamy.
  14.  
  15. If necessary, repeat the previous 2 steps until the fluid level stabilizes.
  16.  

QUICK-CONNECT PRESSURE LINE



See Figure 6 and 7



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Fig. Fig. 6: Quick-disconnect coupling

If a leak occurs between the tubing and the tube nut, replace the hose assembly. If a leak occurs between the tube nut and the pump outlet replace the plastic washer.

  1. Check the fitting to determine whether the leak is between the tube and tube nut or between the tube nut and pump outlet.
  2.  
  3. If the leak is between the tube nut and pump outlet check to be sure the nut is tightened to 30-40 ft. lbs. Do not overtighten this nut.
  4.  
  5. If the leak continues or if the leak is between the tube and tube nut, remove the line.
  6.  
  7. Unscrew the tube nut and inspect the plastic seal washer. Replace the plastic seal washer when the line is removed.
  8.  
  9. To aid in the assembly of the new plastic seal washer, a tapered shaft may be required to stretch the washer so that it may be slipped over the tube nut threads.
  10.  
  11. If the rubber O-ring is damaged it cannot be serviced and the hose assembly will have to be replaced.
  12.  
  13. Connect the tube nut and torque to 30-40 ft. lbs.
  14.  


CAUTION
The quick connect fitting may disengage if not fully assembled, if the snapring is missing or if the tube nut or hose end is not machined properly. If the fitting disengages replace the hose assembly. The fitting is fully engaged when the hose will not pull out. To test for positive engagement the system should be properly filled, the engine started and the steering wheel turned from stop to stop.



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Fig. Fig. 7: Torque Specification

 
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