engine oil MAZDA MX-5 1994 Manual Online

MANUAL STEERING TROUBLESHOOTING GUIDE Problem Steering heavy Posslble Cause 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 Malfunction of steering shaft joint lmproperly adjusted wheel alignment Malfunctioning steering gear Replace Replace gear Replace Replace Adjust Replace ~ction- Lubricate or replace section R N-12 N-12 N- 9 section R N-12 ~i&d~ection N-13 General instability while driving Steering wheel pulls to one side Shake (Steering wheel vibrates upidown) Worn or damaged stabilizer and/or suspension arm bushings Dragging brake Loose lower arm lmproperly adjusted wheel alignment lncorrect tire pressure Damaged or unbalanced wheel Worn or damaged steering joints lmproper steering pinion preload Weak front coil spring Worn or damaged stabilizer andlor suspension arm bushings Malfunctioning shock absorber lmproperly adjusted wheel alignment Excessive tire and/or wheel runout Loose lug nuts Unbalanced wheel(s) Incorrect tire pressure Incorrect tire pressure Unevenly worn tires Weak front spring Replace Repair Tighten Adjust Adjust Adjust or replace Replace Replace gear Replace Replace Replace Adjust Replace Tighten Adjust or replace section R section P section R section R section Q section Q N- 9 N-12 section R section R section R section R section Q section Q section Q Adjust Adjust Replace Replace section Q section Q section Q section R I Cracked or worn transmission mount I Cracked or worn engine mount 1 ~e~lace I section B lncorrect tire pressure Unevenly worn tires Malfunction of shock absorber Shimmy (Steering wheel vibrates circumferentially) Excessive steering wheel play 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(s) Adjust Replace Replace Replace Replace Tighten Replace Replace Tighten Adjust or replace section Q section Q section R section J N-12 N-12 N-13 section Q section Q section Q I Loose shock absorber mounting bolts 1 Tighten I section R 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 suspension arm bushings Loose steering gear mounting bolts I lmproperly adjusted front wheel alignment Poor steering wheel return Replace Replace Replace Adjust Replace Replace Replace Tighten Replace Adjust Replace Adjust Worn linkage &-tie-rod ball joint lncorrect tire pressure Stuck or damaged steering joints section R section R section M section R N-12 N- 9 section R N-12 N-12 section Q N- 9 section R Abnormal noise from steering system 25UONX-00! Improper steering pinion preload Ball joint not operating smoothly Steering shaft contacting something Loose steering gear Malfunctioning steering gear Obstruction near steering column Loose steering linkage Worn steering joints Replace gear Replace Repair Tighten Replace Repair or replace Tighten or replace Replace N-12 N-13 N- 9 N-12 N-12 N- 9 N-12 N- 9 Gartner Banana

N ENGINE SPEED SENSING POWER STEERING ENGINE SPEED SENSING POWER STEERING PREPARATION SST For removal of tie-rod end For installation of tie-rod end boot 49 01 1 8 850C Puller, ball joint Installer, boot For inspection of power steering fluid pressure For inspection of power steering fluid pressure - --- - - Gauge (Part of 49 1232 670A) Gauge set, power steering For inspection of power steering fluid pressure For inspection of power steering fluid pressure 49 H002 671 Adapter, power steering gauge dP--= &--- Valve body (Part of 49 1232 670A) For removal and installation of upper bearing For pressurize oil seal For removal of backup ring and oil seal For inspection of power steering fluid pressure 49 DO32 306 Support block For removal of upper bearing For pressurize oil seal For removal of backup ring and oil seal 49 DO32 304 Installer, oil seal and bearing Handle / For installtion of oil seal and center bearing 49 DO32 301 Installer body, oil seal and bearing 49 NO32 303 Remover, backup ring and oil seal 49 DO32 31 6 Protractor For removal of oil seal and center bearing For installation of adjusting cover 49 DO32 307 Remover, oil seal and bearing For installtion of oil seal 49 DO32 303 Attachment For installation of center bearing Attachment 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 THERMOMETER GAUGE (50"--60°C (1 22-1 40°F)) / THERMOMETER GAUGE (50"--60°C {I 22-140°F)) / Fluid pressure 1. Assemble the SST as shown in the figure. Tightening torque: 40-49 N-m i4.0-5.0 kgf-m, 2%--36 ft.lbf) 2. Mark both hose connections to ensure that the hose is reinstalled in its original position. 3. Disconnect the pressure hose from the oil pump. Attach the SST. 4. Bleed the air from the system. (Refer to page N-21.) 5. Open the gauge valve fully. Start the engine and turn the steering wheel fully left and right to raise the fluid temper- ature to 50-60°C (122-140°F). Caution Do not let the valve stay closed for more than 5 seconds. The increase in fluid temperature will damage the oil pump. 6. Close the gauge valve completely. Increase the engine speed to 1,000-1,500 rpm and measure the fluid pres- sure generated by the oil pump. If the pressure is not within specification, replace the oil pump assembly. Oil pump fluid pressure: 7,601--8,335 kPa (77.5--85.0 kgf/cm2, 1 ,I 03-1,208 psi) 7. Open the gauge valve fully and increase the engine speed to 1,000-1,500 rpm. 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 1. Oil pipe lnspect for clogging and damage 2. Tie-rod end ................ u Disassembly Note below lnspect ball joint for damage and malfunction 3. Locknut (Tie-rod end) 4. Boot clamp 5. Boot wire 6. Boot lnspect for cracks and other damage 7. Housing cover 8. Locknut (Pinion shaft) 9. Tie rod ............ Disassembly Note page N-28 .............. Assembly Note page N-32 lnspect for bending lnspect ball joint for damage and malfunction 10. Washer 11. Locknut (Adjusting cover) 12. Adjusting cover .............. Assembly Note page N-32 13. Plate 14. Yoke spring lnspect for weakness and damage 15. Support yoke lnspect for damage and wear 16. Dust cover lnspect for cracks and other damage - 17. Retaining ring 18. Pinion shaft assembly ............ Disassembly Note page N-28 ................... Inspection page N-29 .............. Assembly Note page N-31 19. Plug assembly ............ Disassembly Note page N-28 .............. Assembly Note page N-31 20. Upper bearing lnspect for wear, damage and malfunction 21. Oil seal 22. O-ring 23. Plug 24. Snap ring 25. Control valve .............. Assembly Note page N-31 26. Seal ring 27. O-ring 28. Seal ring 29. Pinion shaft 30. Mounting bracket and mount 31. Stop ring 32. Steering rack assembly ............ Disassembly Note page N-28 .............. Assembly Note page N-30 33. Holder .............. Assembly Note page N-30 lnspect for wear and damage 34. O-ring 35. Y-packing 36. Seal ring 37. O-ring 38. Steering rack lnspect for cracks, damage and wear 39. Oil seal ............ Disassembly Note page N-28 .............. Assembly Note page N-30 40. Backup ring ............ Disassembly Note page N-28 .............. Assembly Note page N-30 lnspect for cracks and other damage 41. Lower bearing ............ Disassembly Note page N-29 lnspect for wear, damage and malfunction 42. Oil seal ............ Disassembly Note page N-29 .............. Assembly Note page N-29 43. Spacer ............ Disassembly Note page N-29 lnspect for cracks, damage and wear 44. Center bearing Disassembly Note ............ page N-29 .............. Assembly Note page N-29 lnspect for wear, damage and malfunction 45. Mounting bracket 46. Mount 47. Gear housing lnspect for cracks and other damage 25UONX-020 Disassembly Note Tie-rod end Mark the tie rod, locknut and tie-rod end for proper reas- sembly. Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Tie rod 1. Uncrimp the washer. 2. Carefully remove the tie rod. Pinion shaft assembly 1. Secure the mounting bracket in a vise. 2. Remove the retaining ring. 3. Tap the pinion shaft with a punch to remove it. Plug assembly 1. Remove the plug assembly from the pinion shaft. 2. Press out the upper bearhg and oil'seal by using the SST. 3. Remove the O-ring from the plug. Steering rack assembly 1. Remove the stop ring with a pin punch. 2. Temporarily tighten the tie rod to the tube side and pull it carefully to remove the rack. Backup ring and oil seal Tap the SST from the gear housing side to remove the backup ring and the oil seal. Gartner Banana

ENGINE SPEED SENSING POWER STEERING N v SEAL RING Lower bearing Note The lower bearing does not need to be removed unless you are replacing it. Tap the end of the gear housing column to remove the lower bearing. Oil seal, spacer and center bearing Press out the oil seal, the spacer and the center bearing by using the SST. Inspection Pinion shaft assembly 1. lnspect the teeth of the pinion shaft for wear and damage.Replace the pinion shaft assembly if neces- sary. 2. lnspect the control valve for damage, oil passage clog- ging, seal ring and friction surface wear and damage. Replace the pinion shaft assembly if necessary. Assembly Note Oil seal, center bearing 1. Apply grease to the center bearing and set it in the gear housing. 2. Press in the center bearing by using the SST. 3. Set the spacer in the gear housing. 4. Apply grease to a new oil seal and set it in the gear hous- ing. 5. Press in the oil seal by using the SST. Gartner Banana