belt MAZDA MX-5 1994 Service Manual

INDEX POWER STEERING STEERING WHEEL PLAY: [ 0-30mm (0-1.18 in) ] / DRIVE BELT DEFLECTION I=' I LIMIT: 11.5mm (0.45 in) at 98 N (1 0 kgf, 22 Ibf) 'I =!IS 1. Boot Replacement ................ page N- 6 2. Steering wheel. and column .... On-vehicle inspection pages N- 8,24 Removal / ................... page N- 9 Disassembly / Inspection 1 Assembly .................. page N-10 3. Steering gear and linkage Removal I Installation ......... page N-25 Air bleeding ................. page N-21 Disassembly I Inspection / Assembly .................. page N-26 4. Power steering oil pump ......... Removal / Installation page N-33 ................. Air bleeding page N-21 .......... Power steering fluid page N-22 5. Drive belt ................... Inspection page N-37 .................. Adjustment page N-38 ................ Replacement page N-38 Gartner Banana

ENGINE SPEED SENSING POWER STEERING N For installation of oil seal 49 NO32 301 Protector body, oil seal For installation of oil seal Guide, oil seal 0 49 NO32 305 Protector, backup ring and oil seal For installtion of steering rack assembly For installation of holder 49 NO32 304 Protector, oil seal 49 DO32 31 3 Seal ring former For formation of seal ring of pinion shaft 49 DO32 315 Former and guide, seal ring For formation of seal ring of control valve 49 DO32 31 0 Protector, pinion shaft For installation of plug assembly For pressurize upper bearing 49 DO32 305 Remover, oil seal and bearing 49 GO32 31 7 Hose For inspection of cylinder sealing For inspection of cylinder sealing For disassembly of oil pump For measurement of pinion torque Preload attachment Holder 49 9200 020 V-ribbed belt tension gauge For measurement of drive belt tention Gartner Banana

N ENGINE SPEED SENSING POWER STEERING TROUBLESHOOTING GUIDE Steering feels heavy - - Poor lubrication, foreign material, or abnormal wear of steering ball joint Stuck or damaged lower arm ball joints lmproper steering pinion preload Damaged steering gear Malfunctioning steering shaft joint Problem I lmproperly adjusted wheel alignment Possible Cause 1 Malfunctioning steering gear lncorrect tire pressure Loose or damaged oil pump drive belt Low fluid level or air in fluid I Leakage of fluid I Insufficient oil pump pressure Steering wheel pulls lncorrect tire pressure to one side Unevenly worn tires ( Weak front spring General instability while driving Worn or damaged stabilizer and/or upper or lower arm bushing Dragging brake Loose lower arm lmproperly adjusted wheel alignment lncorrect tire pressure Damaged or unbalanced wheel Worn or damaged steering joint(s) lmproper steering pinion preload Weak front coil spring Worn or damaged stabilizer and/or upper or lower arm bushing Malfunctioning shock absorber Cracked or worn engine mount Cracked or worn transmission mount Shake (Steering wheel vibrates up/ down) Shimmy (Steering wheel vibrates left1 right) lmproperly adjusted wheel alignment Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Excessive steering wheel play Poor steering wheel return Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel@) lncorrect tire pressure Unevenly worn tires Malfunctioning shock absorber Loose shock absorber mounting bolts Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Damaged or worn front wheel bearing lmproperly adjusted front wheel alignment Worn steering gear Worn or damaged steering joints Worn or damaged lower arm bushing Loose steering gear mounting bolts Worn linkage or tie-rod ball joint lncorrect tire pressure Stuck or damaged steering joints lmproperly adjusted front wheel alignment lmproper steering pinion preload Ball joint not operating smoothly Steering shaft contacting something Action Lubricate or replace Replace Adjust Replace Replace Adjust Replace Adjust Adjust or replace Add fluid or bleed air Repair or replace Replace Adjust Replace Replace Replace Repair Tighten or replace Adjust Adjust Adjust or replace Replace Adjust Replace Replace Replace Adjust Replace Tighten Adjust or replace Replace Replace Replace Tighten Replace Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Replace Adjust Replace Replace Replace Tighten Replace Adjust Replace Adjust Adjust Replace Repair Pagelsection N-25 section R N-32 N-25 N- 9 section R N-25 section Q N-37 N-21,22 - N-34 section Q section Q section R section R section P section R section R section Q section Q N- 9 N-32 section R section R section R section R section Q section Q section Q section B section J N-26 N-25 N-25 section Q section Q section Q section Q section Q section R section R section R section R section M section R N-25 N- 9 section R N-25 N-25 section Q N- 9 section R N-32 N-25 N- 9 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

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

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

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . BODY INDEX ............................. S- 2 HOOD ............................. S- 5 COMPONENTS ................... S- 5 DOOR ............................. S- 7 COMPONENTS ................... S- 7 WINDOW REGULATOR. GLASS. AND GUIDE ....................... S- 9 COMPONENTS ................... S- 9 ......... DOOR LOCK AND OPENER S-15 ................... COMPONENTS S-15 TRUNK LID ........................ S-16 COMPONENTS ................... S-16 .... TRUNK LID LOCK AND OPENER S-18 COMPONENTS ................... S-18 ......... POWER WINDOW SYSTEM S-19 .............. STRUCTURAL VIEW S-19 TROUBLESHOOTING ............. S-20 ........ b POWER WINDOW SWITCH S-22 ... POWER WINDOW REGULATOR S-22 ......... FUEL-FILLER LID OPENER S-23 COMPONENTS ................... S-23 FRONT BUMPER ................... S-24 COMPONENTS ................... S-24 REAR BUMPER .................... S-25 COMPONENTS ................... S-25 ........... MOLDING AND GARNISH S-27 COMPONENTS ................... S-27 OUTSIDE MIRROR ................. S-30 STRUCTURAL VIEW .............. S-30 ............. TROUBLESHOOTING S-31 POWER OUTSIDE MIRROR ....... S-33 POWER OUTSIDE MIRROR SWITCH ........................ S-33 COMPONENTS ................... S-34 WINDSHIELD WIPER AND WASHER . S-35 TROUBLESHOOTING ............. S-35 WIPER MOTOR .................. S-38 ................ WASHER MOTOR S-38 FRONT WIPER AND WASHER ........................ SWITCH S-38 ................... COMPONENTS S39 WINDSHIELD ...................... S-44 PREPARATION ................... S-44 ................... COMPONENTS S-44 REAR WINDOW GLASS ......... (DETACHABLE HARDTOP) S-48 PREPARATION ................... S48 ................... COMPONENTS S48 REAR WINDOW .............. (CONVERTIBLE TOP) S-52 ................... COMPONENTS S-52 ....... DASHBOARD AND CONSOLE S-56 ................... COMPONENTS S56 TRIM .............................. S-59 COMPONENTS ................... S-59 ................. FLOOR COVERING S-62 ................... COMPONENTS -21 SEAT BELT ........................ S-63 COMPONENTS ................... S-63 ...................... SEAT BELT S-64 ................ BUCKLE SWITCH S-64 SEAT .............................. S-65 ................... COMPONENTS S-65 ................ CONVERTIBLE TOP S-67 PREPARATION ................... S-67 ................... COMPONENTS S-67 ........... DETACHABLE HARDTOP S-81 COMPONENTS ................... S-81 BRACE BAR ....................... S-84 ................... COMPONENTS S-84 ......... UNDERBODY DIMENSIONS S-85 PROJECTED DIMENSIONS ........ S-85 ..... STRAIGHT-LINE DIMENSIONS S-87 45uoSx-001 Gartner Banana

s INDEX 1. Power window system ............. Structural view page S-19 ............ Troubleshooting page S-20 ................. Inspection page S-22 2. Fuel-filler lid opener ....... Removal / Installation page $23 3. Dashboard and console ....... Removal / Installation page S-56 ................. Adjustment page S-58 4. Trim ....... Removal / Installation page S-59 5. Floor covering ....... Removal / Installation page S-62 6. Seat belt ....... Removal / Installation page $63 ................. Inspection page S-64 7. Seat ....... Removal 1 Installation page S-65 Disassembly / Assembly .... page S-66 'd' ................. Inspection page S-65 8. Brace bar Removal / Installation ....... page S-84 Gartner Banana

WINDOW REGULATOR, GLASS, AND GUIDE S WINDOW REGULATOR, GLASS, AND GUIDE COMPONENTS Removal / Installation 1. Raise the door glass about 190 mm (7.5 in) from the fully open position. 2. Disconnect the negative battery cable. Note Remove the door screen carefully so that it may be reused. 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to lnstallation Note. 1. Regulator handle Removal Note . . Installation Note 2. lnner handle cover 3. Pull handle 4. Door trim Removal Note . . 5. lnner handle 6. Sealing pad 7. Door screen 8. Upper glass stopper 9. page S-10 ........... page S-10 ........... 10. 12. page S-61 ........... 13. Front beltline molding Removal Note ............. page S-28 Door glass Adjustment ................ page S-10 Window regulator Glass guide Door weatherstrip Division channel Quarter glass weatherstrip Quarter glass Speaker (if necessary) Dovetail (if necessary) Gartner Banana