steering MAZDA MX-5 1994 Repair Manual

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 Removal / Installation 1. When disconnecting the flexible hose and brake line, remove the clip after loosening the flare nut by using the SST. > 2. When connecting the flexible hose, do not over tighten or twist it. 3. Verify that the hose does not contact other parts when the vehicle bounces or when the steering wheel is turned all the way to the left or right. 4. Modify the brake pipe tightening torque to allow for a torque wrench-SST combination. (Refer to section GI) "Torque Formulas". 5. Tighten the flare nut by using the SST. Tightening torque: 13-22 N.m (1 3-2.2 kgf-m, %&-I 6 ft-lbf} 6. Bleed the air from the brake system. BRAKE FLUID Inspection Check the fluid level in the reservoir. It should be between MAX and MIN. If the fluid level is extremely low, check the brake system for leaks. J Fluid specification: FMVSS 11 6: DOT-3 Replacement 1. Follow the procedure outlined in Air Bleeding. (Refer to page P-7.) 2. Continuity air bleeding and replacing the brake fluid until only clean fluid is seen. 3. Fill the reservoir to MAX. Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P ANTILOCK BRAKE SYSTEM (ABS) DESCRIPTION - 1. There is the following distinctive characteristics in the ABS vehicles compared with the non-ABS vehicles. Note that it does not indicate malfunction. When the brakes are applied rapidly or on a slippery road surface, the ABS will activate; the brake pedal will pulsate slightly and the vehicle and the steering wheel will vibrate slightly. When the vehicle speed reaches approximately 6 kmh (3.8 mph}, the pump motor sound is heard momentarily. This sound is due to ABS self-diagnosis. 2. By retaining or reducing the hydraulic fluid pressure in the hydraulic unit, the ABS tester is used to locate the cause of a problem within the antilock brake system. Because there is no way to check the ABS control unit itself, replace the control unit assembly only after first confirming that the other electrical parts operate normally. PREPARATION SST Wrench, flare nut 49 H026 101 A Installer, sensor rotor 49 F027 007 Attachment 072 For removal and installation of brake pipe For installation of sensor rotor (rear) For removal of sensor rotor (front) 49 0839 425C Puller set, bearing Installer, oil seal Harness, adapter For removal of sensor rotor (front) For installation of sensor rotor (front) For connection of ABS tester Gartner Banana

Q OUTLINE, TROUBLESHOOTING GUIDE OUTLINE Wheels SPECIFICATIONS Tires -2 TROUBLESHOOTING GUIDE Temporary spare 14x4T - - TY Pe Item Size Offset mm {in) Pitch circle diameter mm {in) Material Size Air pressure kPa {kgf/cm2, psi} Standard 14x5 112-JJ 45 11.77) 1 00 (3.94) Aluminum Alloy 185160R14 82H 177 {I .8, 26) Page Excessive or irregu- tar tire wear Premature tire wear Tire squeal body vibration I Unbalanced wheel@) 1 Adjust I Q-5 Steel T1 l5/7ODl4 41 2 {4.2,60) Action Problem 1 Tre deterioration 1 Replace I - I Deformed wheel(s) or tire(s) I Repair or replace I - Possible Cause Refer to page Q-4 for details. Road noise or I Insufficient tire pressure [ Adjust Incorrect tire pressure ( Adjust Incorrect tire pressure 1 Adjust Q-3 Q-3 0-3 Shake [Steering wheel "Ibrates Excessive tire and wheel runout Loose lug nuts Unbalanced wheel(s) Insufficient tire pressure Unevenly worn tires Malfunction of shock absorber Loose shock absorber mounting bolts Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Shimmy (Steering wheel vibrates lefiIright) Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Irregular tire wear Excessive tire and wheel runout Loose lug nuts Unbalanced wheel(s) - Q4 Q-5 Q-3 - section R section R section R section R Cracked or worn engine mount Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint I Damaged or worn front wheel bearing ( Replace ( section M Replace Replace Tighten Adjust or replace I Improperly adjusted front wheel alignment 1 Adjust I section R Uneven (one-sided) I Unequal tire pressures 1 Adjust 1 Q-3 - - Q-4 Q-5 Replace Replace Tighten Replace section B section N section N section N braking Steering wheel I Incorrect tire pressure 1 Adjust doesn't return properly or pulls to either left or right . General driving Instability Excessive steering (2-3 wheel play Irregular tire wear (lefthight) Unequal tire pressures Different types or brands of tires mixed (leftlright) Loose lug nuts Unequal tire pressures Damaged or unbalanced wheel(s) Loose lug nuts Loose lug nuts I 15UOQX-00 Replace Adjust Replace Tighten Adjust Replace or adjust Tighten Tighten - Q-3 - Q-4 Q-3 Q-5 Q-4 Q-4 Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS Front Suspension - Transmission item (Stabilizer Specifications MT I AT - I Susoension tvoe I . , . , I . , Shock absorber Cylindrical double acting, low-pressure-gas charged I Double-wishbone TY pe Torsion bar Coil spring I - Diameter mm linl I 20.0 10.79) Identification mark color 19.0 (0.75) White Wire diameter mm (in) Coil inner diameter mm {in) I Blue Free length mm {in) Coil number 11 .O (0.43) 83 i3.27) 11 .O (0.43) 83 (3.27) 292.5 (1 1 32) 6.32 3 +. 3 (0.12 + 0.12) 0°18' + 18' Total toe-in I - I 35UORX-001 Rear Suspension 302.0 (1 1.89) 6.32 mm {in) degree Total toe-in (per side) 1 degree Front wheel alignment (Unladedt1) 0°09' +. 09' Caster anglee3 4"26' +. 45' Kingpin angle 11 "20' Maximum steering angle Transmission Specifications MT I AT Item Differential - Suspension type Inner Outer "TORSEN" LSD 1 Standard Double-wishbone Coil springs 370 23' a 2" 32" 32' -t 2" Camber anglee2 Torsion bar 12.0 (0.47) 1 11.0 (0.43) 1 11 .O (0.43) Cylindrical double acting, low-pressure-gas charged - Stabilizer Identification mark color Wire diameter mm {in) 0°24' + 45' Type Diameter mm {in) I Coil number I 7.68 I 7.96 I Shock absorber Yellow 10.1 {0.40} Coil inner diameter mm {in) Free length mm {in) Green 10.2 {0.40) 35UORX-002 *I Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. '2 Difference between left and right must not exceed I O. '3 Difference between left and right must not exceed 1'30'. "TORSEN" is a registered trademark of ZEXEL-GLEASON USA.INC 83 I3.27) 348.5 j13.72) Rear wheel alignment (Unladed*') 83 (3.27) 356.5 (1 4.04) Total toe-in Total toe-in (per side) mm (in) degree degree 3 -c 3 (0.12 + 0.121 0°18' + 18' 0°09' + 09' Camber angle*2 -0°43' 2 30' Gartner Banana

TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Problem General instabllity Body "rolls" "Heavy" steering wheel operation Steering wheel pulls to one side Excessive steering wheel play Body leans Abnormal noise from suspension system Shake (Steering wheel tibrates upldown) Shimmy (Steering wheel vibrates leftlright) Possible cause Weak coil spring Malfunction of shock absorber Worn or damaged stabilizer and/or suspension arm bushings Worn or damaged upper or lower arm ball joint Improperly adjusted wheel alignment Weak stabilizer Worn or damaged stabilizer and/or suspension arm bushings Insufficiently lubricated or stuck upper arm lower arm ball joint lmproperly adjusted wheel alignment Weak coil spring Worn or damaged stabilizer and/or suspension arm bushings Deformed upper or lower arm or knuckle Loose upper or lower arm bushing Worn or damaged upper or lower arm bushing Worn or damaged upper or lower arm ball joint Weak coil spring Weak stabilizer andlor suspension arm bushings Loose mounting component Poorly lubricated or worn upper or lower arm ball joint Malfunction of shock absorber Worn or damaged stabilizer and/or suspension arm bushings Excessive tire or wheel runout Loose lug nuts Unbalanced wheel@) Cracked or worn engine mounting rubber Cracked or worn steering gear mounting rubber Loose steering gear mounting bolts Stuck or damaged steering ball joint Excessive tire or wheel runout Loose lug nuts Unbalanced wheel(s) Insufficient tire pressure Unevenly worn tires Malfunction of shock absorber Loose shock absorber mounting bolts Stuck or damaged upper or lower arm ball joint Cracked or worn suspension bushings Damaged or worn front wheel bearing lmproperly adjusted front wheel alignment Action Replace Replace Replace Replace Adjust Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace Replace Replace Tighten Replace Replace Replace Replace Tighten Adjust or replace Replace Replace Tighten Replace Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Replace Adjust Page R-13 R-12,22 R-16, 18, 19, 23,24,25 section M R-15,17 R- 6 R-19,25 R-16, 18,19, 23, 24,25 section M R-15,17 R- 6 R-13 R-16, 18,19, 23, 24,25 R-15,17 section M R-16,18 R-16,18 R-15,17 R-13 R-16, 18, 19, 23,24,25 section M 7 R-15,17 R-l2,22 R-16, 18,19, 23,24,25 section M - section Q section Q section B section N section N section N - section Q section Q section Q section Q R-l2,22 R-12,22 R-15, 17 R-16,18,19 section M R- 6 15UORX-00 Gartner Banana

WHEEL ALIGNMENT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Specifications (Unladed*l) PRE-INSPECTION 1. Check the tire inflations, and adjust to the recommended d pressure if necessary. 2. lnspect the front wheel bearing play and correct if neces- sary. 3. lnspect the wheel and tire runouts. 4. Inspect the ball joints and steering linkage for excessive looseness. 5. The vehicle must be on level ground and carry no lug- gage or passengers. 6. Measure the height from the center of the wheel to the fender brim. The difference between left and right mea- surement must not exceed 10mm (0.39 in), and the rear measurement must be larger then the front measure- ment by 10-30mm (0.4--1.1 in). Caution The proper caster and camber angle vary depend- ing on the vehicle height. Refer to the following and to page R-9 for the specifications. Inspection and adjustment of wheel alignment must be done with the vehicle unladed*'. . . I Y -- t~otal toe-in l~er side) I 1 dearee 0'09' + 09' I Total toe-in 3 2 3 I0.12 2 0.12) 0'1 8' 2 18' mm (in) dearee Maximum steering angle U - Inner Outer 11 '20' -0°20' 2 45' 0'03' ? 45' 0'24' 2 45' 0°44' -+ 45' 1'02' -+ 45' 5'1 6' ? 45' 5O02' -+ 45' 4O49' 2 45' 4'35' -+ 45' 4'21 ' -+ 45' I Kingpin angle 37"23' -+ 2" 32O32' 2 2" '1 Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. OSUORX-009 ** Difference between left and right must not exceed lo. '3 Difference between left and right must not exeed 1'30'. 328-337 {I 2.9-1 3.3) 338-347 {I 3.3-1 3.7) 340-357 I13.7-14.1) 358-367 {I 4.1-14.4) 36&377 {I 4.4--14.8) 328-337 {I 2.9--13.3) 338-347 {I 3.3-1 3.7) 348-357 113.7-14.1) 358-367 {I 4.1-14.4) 368-377 {I 4.4--14.8) Camber angleg2 Caster angle*3 Height from center Of wheel to fender brim mm {in) Height from center Of wheel to fender brim mm (in) Gartner Banana

WHEEL ALIGNMENT LEFT WHEEL INCREASE CAM BOLT RIGHT WHEEL 0) '. jr INCREASE Adjustment Maximum steering angle 1. Remove the steering gear boot clamp. 2. Loosen the tie rod locknut. 3. Turn the tie rod to provide the correct maximum steering angle. 4. After adjustment, tighten the locknut to the specified torque. Tightening torque: 3539 N-m (3.W.0 kgf-m, 26-28 ftdbf) 5. Adjust the toe-in. (Refer to page R-8.) 6. Verify that the boot is not twisted, and install the boot clamp. Caster Caster is adjusted by turning the front and/or rear adjust- ing cam bolts at the lower arm. Caution Adjust the caster before adjusting the camber. 1. Loosen the front and/or rear cam nuts. 2. Turn the front and/or rear adjusting cam bolts to provide the correct caster angle. Left wheel Right wheel Caster I Front cam I Rear cam I Front cam I Rear cam Counter- 1 Clockwise I Clockwise 1 I Increase I ( clockwise Note Turning the front cam one graduation on the scale changes the caster angle about 22' and the camber about 25'. Turning the rear cam one graduation changes the caster angle about 22' and the camber about 2'. Decrease 3. Adjust the camber and the toe-in. Clockwise Clockwise Counter- clockwise Counter- clockwise Gartner Banana

WHEEL ALIGNMENT LEFT WHEEL POSITIVE RIGHT WHEEL POSITIVE Camber Camber is adjusted by turning the front and rear adjust- ing cam bolts at the lower arm. 2 Caution Adjust the camber after adjusting the caster. 1. Loosen the front and rear cam nuts. 2. Turn the front and rear adjusting cam bolts the same amount in the opposite direction to provide the correct camber angle. Left wheel Note Turning the front cam one graduation changes the camber about 25' and the caster about 22'. Turning the rear cam one graduation changes the camber about 2' and the caster about 22'. Right wheel Positive Negative Note If the cam cannot be turned far enough to make the adjustment, begin again at adjustment of the caster using the other cam. i 3. Tighten the nuts. I Caster I Front cam 1 Rear cam I Front cam I Rear cam Tightening torque: 94--112 N.m (9.5-11.5 kgf.m, 69-43 ftlbf) clockwise Counter- Clockwise 4. Adjust the toe-in. Toe-in 1. Remove the steering gear boot clamp. 2. Loosen the left and right tie rod locknuts, and turn the tie rods by the same amount. 3. Loosen the left and right tie rod locknuts and turn the tie rods equally. Both tie rods are right threaded, so turning the right tie rod toward the front of the vehicle and the left toward the rear increases toe-in. Clockwise Counter- clockwise Note Turning both tie rods one complete turn changes toe-in by about 7 mm (0.28 in}. 4. Tighten the tie rod locknuts to the specified torque. Clockwise Counter- clockwise Tightening torque: 35-39 N.m (3.5--4.0 kgf.m, 26--28 ft4bf) Counter- clOCkWise Clockwise 5. Verify that the boot is not twisted, and install the boot - clamp. Gartner Banana