engine MAZDA MX-5 1994 Workshop Manual

ENGINE SPEED SENSING POWER STEERING N 60.5mm (2.38 in) Control valve 1. Install a new O-ring and a new seal ring onto the pinion shaft. 2. Pass the pinion shaft back and forth through the SST until the O-ring and the seal rings are set. 3. Fit new seal rings onto the control valve by using the SST. 4. Remove the SST from pinion shaft and align the pin posi- tion of the control valve with the thread of the pinion shaft assembly. lnstall the control valve assembly. 5. Install the new snap ring to the pinion shaft assembly. Pinion shaft assembly 1. Apply sufficient grease to the teeth of the pinion shaft. 2. Apply ATF to the seal ring and the friction surface of the control valve. 3. Attach the SST to the gear housing and install the pinion shaft. Plug assembly 1. Apply ATF to the upper bearing and the new oil seal. 2. Set the oil seal into the plug. 3. Press in the oil seal by using the SST. 4. Put the upper bearing into the plug. 5. Press in the upper bearing by using the SST. 6. Install a new O-ring to the plug assembly. Gartner Banana

N ENGINE SPEED SENSING POWER STEERING 7. Attach the SST to the pinion and install the plug assem- bly. Adjusting cover 1. Tighten the mounting bracket in a vise. 2. Set the rack to the center position. 3. Tighten the adjusting cover to 4.9 N.m (50 kgf.cm, 43 in4bf) with the SST three times, then return it 25". 4. Apply sealant to the threads of the locknut. 5. Attach the locknut. 6. Measure the pinion torque by using the SST and a pull scale. Standard Center of rack + 90": 1 .O-1 .I N-m {I 0-1 2 kgf-cm, 8.7-1 0.4 in-lbf) ii Scale reading: 1 .&I .2 kg (2.2-2.64 Ib) 7. If not within specification, repeat steps 3 through 6. 8. Install the locknut. Tightening torque: 59-74 N.m (6.0-7.5 kgf.m, 44--54 ftdbf) Hermetic sealing inspection 1. Connect the SST to the power cylinder section of the gear housing. 2. Apply 53.3 kPa (400 mmHg, 15.7 inHg) vacuum with a vacuum pump and verify that it is held for at least 30 seconds. 3. If the vacuum is not held, replace the oil seal. Tie rod 1. Secure the rack gear in a vise, and tighten the tie rods with the wrench. Tightening torque: 79-98 N.m (8.0-10.0 kgf-m, 58-72 ft-lbf) 2. Align the washer with the rack groove, and crimp the washer. 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

N ENGINE SPEED SENSING POWER STEERING Removal Note Pressure pipe Mark the pressure pipe for reference during installation before loosening. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N Disassembly / Inspection / Assembly 1. The following precedure is for replacement of the O-rings only. Replace the pump assembly if other repairs are necessary. 2. Disassemble in the order shown in the figure, referring to Disassembly Note. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. N.m {kgfm, ftW] 1. Suction pipe 12. Cam ring ................... 2. O-ring Inspection page N-36 .............. 3. Pressure switch assembly Assembly Note page N-37 4, O-ring 13. Blade ................... 5. Connector Inspection page N-36 .............. 6. O-ring Assembly Note page N-37 7. Control valve 14. Rotor ................... Inspection ................... page N-36 Inspection page N-36 .............. 8. Spring Assembly Note page N-36 ................... Inspection page N-36 15. Side plate .................... 9. Bracket Inspection page N-36 10. Pump body rear 16. O-ring ................... w Inspection page N-36 17. O-ring 11. O-ring 18. Pin 19. Pump body front ................... Inspection page N-36 Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Disassembly Note Oil pump Use the SSTwhen securing the oil pump in a vise, so that force is not applied to the pulley or shaft. Inspection Pump body front, rear lnspect the front and rear of the pump body for cracks and damage, and the friction surface of the rotor for wear. Replace the pump assembly if a problem is found. Cam ring, rotor, blade, side plate 1. lnspect the blade friction surface of the cam ring for wear. 2. lnspect the pump body of the rotor and side plate friction surface for wear. 3. lnspect the cam ring friction surface of the blade for -, wear. 4. lnspect clearance between the rotor and blade. Control valve, spring 1. lnspect the control valve for cracks, damage and block- age, and the friction surface for wear. 2. lnspect the spring for damage. Assembly Note Rotor Install the rotor with the indentification mark facing upward. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N Cam ring Install the cam ring with the identification mark facing downward. Blade Install the blades into the rotor with the rounded edges facing outward. DRIVE BELT Inspection 1. Check the drive belt for wear, cracks, and fraying. Replace as necessary. 2. Verify that the drive belts are correctly mounted on the pulleys. 3. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply moderate pressure (98 N (10 kgf, 22 Ibf)) midway between the specified pulleys. Deflection mm {in) A belt that has been on a running engine for less than five minutes. 4. If the deflection is not within specification, adjust it. Limit 11.5 (0.45) New' 8-9 {0.32-0.35) Drive belt tension check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys. Used 9-10 {0.36-0.39) Tension N hf, Ibf) A belt that has been on a running engine for less than five minutes. .- - 2. If the tension is not within specification, adjust it. 25~0~x432 Limit 245 {25,55) New' 491-588 (50-60, 11 &I 32) Used 422490 {43--50, %--I 10) Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Adjustment Loosen PIS oil pump bolt @ and nuts @ and 0. Adjust the belt deflection by turning adjusting bolt @I. 4 Tightening torque @: 37-53 N.m (3.7-5.5 kgf.m, 27-39 ft-lbf) @: 37-53 N-m (3.7-4.5 kgf.m, 27-39 ft4bf) 0: 19-25 N-m (1 .S2.6 kgf.m, 14-1 8 ftlbf) I 15UONX-043 Replacement 1. Loosen bolt @, nuts @ and 0, and adjusting bolt @. 2. Remove and replace the drive belt. 3. Adjust the deflection (tension). (Refer to page N-37.) Gartner Banana

P BRAKE SYSTEM k FIRST PEDAL VACUUM GAUG DEPRESSION FORCE GAUGE POWER BRAKE UNIT Quick Inspection, On-vehicle Power brake unit function check (Simple method) ii Step 1 1. With the engine stopped, depress the pedal a few times. 2. With the pedal depressed, start the engine. 3. If immediately after the engine starts the pedal moves down slightly, the unit is operating. Step 2 1. Start the engine and let it run 1 or 2 minutes. 2. Stop the engine. 3. Depress the pedal with the usual force. 4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating. 5. If a problem is found, inspect for damage or improper connection of the check valve or vacuum hose. Repair if necessary, and inspect it once again. Step 3 1. Start the engine. 2. Depress the pedal with the usual force. 3. Stop the engine with the pedal depressed. 4. Hold the pedal down for about 30 seconds. 5. If the pedal height does not change, the unit is operating. ,, 6. If there is a problem, check for damage or improper con- nection of the check valve or vacuum hose. Repair if necessary, and check once again. If the nature of the problem is still not clear after following the 3 steps above, follow the more detailed check described in "Method using tester," below. (Method using tester) Connect the SST, vacuum gauge, and pedal depression force gauge as shown in the figure. After bleeding the air from the SST, conduct the test as described in the 3 steps below. Inspection using gauges Connect the SST gauges, a vacuum gauge (A), and a pedal depression gauge (B) as shown. Bleed the air from the SST gauges before performing the following tests. a) Checking for vacuum loss Unloaded condition 1. Start the engine. 2. Stop the engine when the vacuum gauge indicates 66.7 kPa (500 mmHg, 19.7 inHg). 3. Observe the vacuum gauge for 15 seconds. If the gauge indicates 63.4-66.6 kPa (475-500 mmHg, ,, 18.7-19.7 inHg), the unit is operating. Gartner Banana

BRAKE SYSTEM P (20 kgf, 44 Ibf) (20 kgf, 44 Ibf) Loaded condition 1. Start the engine. 2. Depress the brake pedal with a force of 196 N (20 kgf, 44 Ibf). 3. With the brake pedal depressed, stop the engine when the vacuum gauge indicates 66.7 kPa I500 mmHg, 19.7 inHg). 4. Observe the vacuum gauge for 15 seconds. If the gauge indicates 63.4-66.6 kPa (475--500 mmHg, 18.7-19.7 inHg), the unit is operating. b) Checking for hydraulic pressure 1. If with the engine stopped (vacuum 0 kPa (0 mmHg, 0 inHg}) the fluid pressure is within specification, the unit is operating. 1 Pedal force Fluid pressure 2. Start the engine. Depress the brake pedal when the vac- uum reaches 66.7 kPa (500 mmHg, 19.7 inHg). If the fluid pressure is within specification, the unit is operat- ing. 1 96 N {20 kgf, 44 Ibf) I Pedal force I Fluid pressure I 1,079-1,177 kPa {I 1-1 2 kgf/cm2, 156-1 71 psi) lnspection of Check Valve 196 N {20 kgf, 44 Ibf) Note There is an arrow on the hose to indicate direction of hose installation. 5,199--5,494 kPa {53-56 kgf/cm2, 754--796 psi} lnspection 1. Disconnect both ends of the vacuum hose. 2. Apply suction and pressure to the hose from the engine side. Verify that air flows only toward the engine. If air passes in both directions or not at all, replace the vac- uum hose (along with the check valve). Gartner Banana