check oil MAZDA MX-5 1994 Manual PDF

TRANSMISSION K 33. Apply ATF to the piston stem. 34. Adjust the 2nd brake band. (1) Loosen the locknut and tighten the piston stem. Tightening torque: 12.3--14.2 N-m (125--145 kgf-cm, lOg--l25 in-lbf) (2) Loosen the stem the number of turns shown below. Stem: 2 112 turns (3) Hold the stem and tighten the locknut. Tightening torque: 15-39 N.m (1.5-4.0 kgf-m, 11-28 ft-lbf) Caution Applying compressed air to the servo piston for longer than 3 seconds at a time will damage the seal. 35. Check the servo piston operation by applying com- pressed air through the oil passages of the 2nd band servo. @: Engage @: Release Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. 36. Apply ATF to the piston stem. Adjust the fourth gear brake band. (1) Loosen the locknut and tighten the piston stem. Tightening torque: 12-15 N-m (1.2-1.5 kgf-m, 8.7-11 ft-lbf) 11.8-14.7 N-m (1 20-150 kgf.cm, 105-1 30 in-lbf) (2) Loosen the stem the number of turns shown below. Stem: 2 turns Gartner Banana

K TRANSMISSION 0 (3) Hold the stem and tighten the locknut. Tightening torque: 15--39 N-m (1.5-4.0 kgf-m, 11-28 ftelbf) Caution Applying compressed air to the servo piston for longer than 3 seconds at a time will damage the seal. I 1 37. Check the servo piston operation by applying com- 45UOM431 pressed air through the oil passage of the fourth gear band servo. Air pressure: 392 kPa (4.0 kg/cm2, 57 psi) max. MANUAL PLATE 38. Set a new gasket on the fourth gear band servo. Install the fourth gear band servo cover. Tightening torque: 5.0-6.8 N-m (50-70 kgfscm, 44--60 indbf) 39. Apply ATF to a new O-ring and install it onto the solenoid valve connector. 40. Install the solenoid valve connector in the transmission case. 41. Set the valve body assembly in piston, and align the manual plate and manual valve. 42. Install the bolts. Tightening torque: 10.8-14.7 N.m (110--150 kgf-cm, 95.5--130 in-lbf) Gartner Banana

L PROPELLER SHAFT 2. Remove the propeller shaft from the extension housing, and immediately install the SST to prevent oil leakage. Inspection Propeller shaft Caution Cleaning sealed bearings with cleaning fluids or a steam cleaner can wash the grease out of the bearing. 1. Clean the propeller shaft (except for the universal joint) with a steam cleaner or solvent. 2. Measure the propeller shaft runout with a dial indicator. Replace the propeller shaft if runout is excessive. Maximum runout: 0.4mm (0.016 in} 3. Move the universal joints in the directions shown, and check for universal joint looseness. If there is looseness, replace the propeller shaft. ii 4. Check operation of the universal joint. If the universal joint has excessive resistance, replace the propeller shaft. Installation Note Propeller shaft 1. Align the marks, and install the propeller shaft. Tightening torque: 50-58 N.m (5.0-6.0 kgf.m, 37-43 ft4bf) 2. Verify that there is no abnormal noise or vibration when driving the vehicle. If noise or vibration comes from the propeller shaft, replace the propeller shaft. Gartner Banana

MANUAL STEERING N Rear cover 1. Apply grease to the outer race of the upper bearing and install it in the gear housing. 2. Install a new oil seal to the rear cover. 3. Apply sealant to the threads of the rear cover and install it into the gear housing. 4. Rotate the pinion to the left and right a few times to seat the bearing. 5. Tighten the rear cover so that the starting torque of the pinion is 200-350 g (7.1-12.3 oz} as checked by using the SST and a pull gauge. 6. Tighten the locknut. Do not allow the rear cover to turn. Tightening torque: 50--68 N-m (5.0-7.0 kgf.m, 37-50 ft.lbf} Adjusting cover 1. Carefully move the rack so that the pinion is set to the center (neutral position) of the rack gear as shown. 2. Install the roller assembly, needle roller, holder, dish springs, friction block, and the spring as shown. 3. Torque the adjusting cover to 9.8 N.m (1 kgf-m, 85 in.lbf), then loosen it 25O45". Use the SST to secure the adjusting cover and the locknut. Tightening torque: 40-58 N.m (4.CL6.0 kgf-m, 29--43 ft-lbf} 4. Measure the starting torque of the pinion by using the SST. Center position + 90" Pull gauge reading: 1,000-1,400 g (35-50 oz} Any other position Pull gauge reading: less than 1,700 g (60 or) 5. If not within specification, repeat steps 2 and 3. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N TROUBLESHOOTING GUIDE (CONT'D) Possible Cause I Problem Abnormal noise from steering system Loose oil pump Loose steering gear Loose oil pump bracket Drive belt loosettight Air in system Malfunctioning steering gear Malfunctioning oil pump Obstruction near steering column or pressure hose Loose steering linkage Worn steering joints Action Tighten Tighten Tighten Adjust Bleed air Replace Replace Repair or replace Tighten or replace Replace PageISection section B N-25 N- 9 N- 9 25UONX41 AIR BLEEDING 1. Check the fluid level. (Refer to page N-22.) 2. Turn the steering wheel fully to the left and right several times with the engine not running. 3. Recheck the fluid level. If it has dropped, add fluid. 4. Repeat steps 2 and 3 until the fluid level stabilizes. 5. Start the engine and let it idle. 6. Turn the steering wheel fully to the left and right several times. 7. Verify that the fluid is not foamy and that the fluid level has not dropped. 8. Add fluid if necessary, and repeat steps 6 and 7. Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Caution Never hold the steering wheel to the extreme left or right for more than five seconds with the engine running. This could damage the power steering d pump- 8. Turn the steering wheel fully to the left and right and measure the fluid pressure generated by the gear hous- ing. If the pressure is not within specification, replace the gear housing assembly. Gear housing fluid pressure: 7,601--8,335 kPa (77.545.0 kgflcm2, 1,103-1,208 psi) 9. Remove the gauge set. Install and tighten the pressure hose to the specified torque. Tightening torque: 3247 N.m (3.24.8 kgf.m, 24--34 ft.lbf} 10. Bleed the air from the system. (Refer to page N-21.) STEERING WHEEL AND COLUMN Obtain the code number and deactivate the audio anti- theft system before disconnecting the battery. (Refer to section T.) On-vehicle Inspection -1 Steering wheel effort 1. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position. 2. Start the engine and warm the power steering fluid to 50--60°C (1 22-1 40°F). 3. With the engine running at idle, attach a pull scale to the outermost point of the steering wheel spoke. Then, starting with the wheels in the straight-ahead posi- tion, measure the effort required to turn the steering wheel to the left and to the right. Steering wheel effort: 2635 N (2.63.6 kgf, 5.3-7.9 Ibf) (during one turn of the steering wheel) 2 4. If not within specification, check the following: fluid level, air in system, fluid leakage at hose or connections, func- tion of oil pump and steering gear, and tire pressure. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N POWER STEERING OIL PUMP Removal / Installation 1. Remove in the order shown in the figure, referring to Removal Note. u 2. Install in the reverse order of removal. 3. After installation: (1) Check connections for fluid leakage. (Refer to page N-22.) (2) Bleed air from the system. (Refer to page N-21.) 1. Drive belt 3. Press~~re pipe ................... ............... w Inspection page N-37 Removal Note page N-34 Adjustment .................. page N-38 4. Return hose Replacement ................ page N-38 5. Power steering oil pump 2. Power steering pressure switch connector Gartner Banana

BRAKE SYSTEM TROUBLESHOOTING GUIDE Problem Poor braking Brakes pull to one side Brakes do not release Pedal goes too far (Too much pedal stroke) Abnormal noise or vibra- tion durlng braking Possible cause Leakage of brake fluid Air in lines Worn pad Brake fluid, grease, oil, or water on pad Hardening of pad surface or poor contact Malfunction of disc brake piston Malfunction of master cylinder Malfunction of power brake unit Malfunction of check valve (vacuum hose) Damaged vacuum hose Deterioration of flexible hose Malfunction of proportioning bypass valve (PBV) Worn pad Brake fluid, grease, oil, or water on pad Hardening of pad surface or poor contact Abnormal wear, distortion, or eccentricity of disc Malfunction of automatic adjuster in rear brake Looseness or deformation of dust cover mounting bolt Malfunction of disc brake piston Worn or improperly adjusted wheel bearing preload lmproper adjustment of wheel alignment Unequal tire air pressure No brake pedal play lmproper adjustment of push rod clearance Clogged master cylinder return port Pad not returning properly lmproper return of malfunction of brake caliper piston Excessive runout of disc plate lmproper adjustment of wheel bearing preload Air in system because of insufficient brake fluid lmproper adjustment of pedal play Worn pad Air in lines Worn pad Deterioration of pads Brakes do not release Foreign material or scratches on disc plate contact surface Looseness of caliper mounting bolt(s) Damage or deviation of disc contact surface Poor contact of pads Insufficient grease on sliding parts Action Repair Air bleed Replace Clean or replace Grind or replace Replace Repair or replace Repair or replace Repair or replace Replace Replace Replace Replace Clean or replace Grind or replace Repair or replace Repair Tighten or replace Repair or replace Replace or adjust Adjust Adjust Adjust Adjust Clean Repair Replace Replace Adjust or replace Add fluid and bleed air Adjust Replace Bleed air Replace Grind or replace Repair Clean Tighten Replace Repair or replace Apply grease Page - P- 7 P-25,29 P-25,29 P-25,29 P-28,32 P-11, 14 P-22 P-22 P-22 P- 7 P-23,24 P-25,29 P-25,29 P-25,29 section M - section M P-28,32 section M section R section Q P- 9 P-l2,15 - - P-28,32 section M section M P- 7 P- 9 P-25,29 P- 7 P-25,29 P-25,29 - - P-26,30 section M P-25,29 - 15UOPX-00 Gartner Banana

BRAKE SYSTEM P Inspection Check the following and repair or replace parts as neces- sary. Disc pad 1. Oil or grease on facing. 2. Abnormal wear or cracks. 3. Deterioration or damage by heat. 4. Remaining lining thickness. Thickness Standard: 8.0mm (0.31 in) Minimum: 1 .Omm (0.04 in) Disc plate Tighten the disc plate to the wheel hub by using two wheel nuts. When measuring runout, measure at the outer edge of the disc plate surface. 1. Runout. Runout: O.lmm (0.004 in) max. 2. Wear and damage. Thickness Standard: 20.0mm (0.79 in) Minimum: 18.0mm (0.71 in) Gartner Banana

BRAKE SYSTEM P Inspection Check the following and repair or replace parts as neces- sary. Disc pad 1. Oil or grease on facing. 2. Abnormal wear or cracks. 3. Deterioration or damage by heat. 4. Remaining lining thickness. Specified thickness : 8.0mm (0.31 in) Minimum : l.Omm (0.04 in) Disc plate Tighten the disc plate to the wheel hub by using two wheel nuts. When measuring runout, measure at the outer edge of the disc plate surface. 1. Runout. Runout: O.lmm (0.004 in) max. 2. Wear or damage. Thickness Standard: 9.0mm (0.35 in) Minimum: 8.0mm (0.31 in) Gartner Banana