1994 MAZDA MX-5 Workshop Manual

ENGINE SPEED SENSING POWER STEERING POWER STEERING FLUID Inspection Fluid level 1. Verify that the fluid level is between the H and L marks. 2. Add the specified power steering fluid if it is below the L mark. Remove the fluid if it is above the H mark. Fluid specification: ATF ~exron~11 or M-111 , I 25UONX-015 Fluid leakage 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 pump. Start the engine and let it idle. Turn the steering wheel fully left and fully right to apply fluid pressure. Inspect the points shown in the figure for fluid leakage. 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 STEERING GEAR AND LINKAGE Removal / Installation 1. Turn the wheels to the straight-ahead position. 2. Loosen the wheel lug nuts. 3. On level ground, jack up the front of the vehicle and support it on safety stands. 4. Remove the wheels. Note Turning the steering wheel while the steering gear is removed will make reinstallation difficult. Do not turn the steering wheel while the steering gear is removed. If the steering wheel is turned in that condi- tion, the clockspring connector may have to be adjusted. (Refer to section T.) 5. Remove in the order shown in the figure, referring to Removal Note. 6. With the wheels in the straight-ahead position, install in the reverse order of removal. 7. Tighten all necessary bolts and nuts to the specified torque. 8. After installation: (1) Check for fluid leakage. (Refer to page N-22.) (2) Bleed air from the system. (Refer to page N-21.) (3) Adjust the front wheel alignment. (Refer to section R.) 1. Cotter pin 5. Pressure pipe 2. Nut ~emovai Note ............... page N-26 3. Tie-rod endlsteering knuckle 6. Return hose Removal Note ............... page N- 7 7. Mounting bracket bolt 4. Bolt 8. Steering gear and linkage Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Removal Note Pressure pipe Before removing the pressure pipe, make marks for J proper reinstallation. I 05UONX-03! Disassembly / Inspection I Assembly 1. is assemble in ihe order shown in ihe figure, referring to Disassembly Note. 2. Inspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. 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