Power Steering - High Steering Effort/MIL/DTC C1099
Bulletin No: 06-001/10 Last Issued: 04/09/2010Subject:
HEAVY STEERING EFFORT WITH POWER STEERING MALFUNCTION INDICATOR LAMP ON AND DTC Cl 099
BULLETIN NOTE
APPLICABLE MODEL(S)NINS
2007-2009 Mazda3 vehicles (NOT including Mazdaspeed3) with VINS below (produced between April 1, 2007
and November 4, 2008)
^ 2OO7JM1BK******742201 -774382
^ All 2008
^ 2009 JM1BK****** 187372 - 251982
2007-2009 Mazda5 vehicles with VINS JM1 CR****** 155672 - 349055 (produced between produced between
April 1, 2007 and November 4, 2008)
DESCRIPTION
Some customers may feel that the steering effort is hard or heavy with power steering malfunction indicator lamp illumination and DTC Cl 099 [ELECTRO HYDRAULIC POWER ASSIST STEERING (EHPAS)] stored in memory. This problem is caused by contamination of the system from such things as corrosion getting inside the power steering line, sticking in the power steering pump, and lowering the revolution speed. The system then goes into a fail safe function.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE OUTLINE
1. Verify customer concern.
2. Clean the steering gear box by flushing all fluid lines with 10 quarts of fluid.
3. Remove the electric power steering oil pump assembly (A) and (B).
4. Replace the power steering oil pump unit (shaded part of A) on the pump assembly with oil pump kit.
5. Install the repaired power steering oil pump assembly and new
6. Fill the pump reservoir with ATF MIII and remove air from the line.
REQUIRED PARTS
Although there are no special tools required for the flushing procedure, some locally sourced parts and fabrication are necessary. These parts are commonly found at large home improvement centers or hardware stores.
FLUSHING PARTS PREPARATION (required one time)
1. Drill a hole for the appropriate sized fluid fitting through the side ofthe bucket within a 1/2" of the bottom, then clean the shavings out of the bucket.
NOTE: If using the CARLON ENVIROFLEX" 1/2" fluid fitting drill a 3/4" diameter hole.
CAUTION: EAreme care must be taken to avoid contamination of the ATF and the bucket since just a fraction of contamination (about 40-50 micron) might damage the pump. Take proper care when storing or using the ATF and the bucket by placing a lid or cover on them.
FLUSHING PROCEDURE
1. Raise the car on a hoist and remove the right front wheel.
2. Remove the undercover and right side splash shield.
3. Set the waste bucket or container (A) nearthe power steering pump.
4. Remove the return hose (B) from the return pipe (C) and connect a drain hose (D) to the return pipe with a hose clamp, then plug or clamp the return hose.
5. Lower the vehicle (It is not necessary to set the tires on the floor).
6. Remove the reservoir and hose (E) from the pump and connect the suction hose (F) from the bucket (G) to the top of the pump unit.
NOTE: Secure the suction hose with hose clamps to avoid it from disconnecting.
7. Fill the bucket with 10 quarts of new fluid and place above the power steering pump.
Power steering fluid specification: ATF M-lll or equivalent
NOTE: The power steering fluid is going to be gravity fed, so place the bucket above the pump. Suggest placing it on a transmission jack.
8. Start the engine and turn the steering wheel back and forth to move the fluid through the gear box and the
pipe assemblies. Stop the engine as soon as all 10 quarts of fluid has been used up, which can be seen
through the clear vinyl suction hose.
NOTE: The pump will draw 10 quarts of fluid in about 2 minutes. W~thin 2 minutes, turn the steering lock to
lock at least 6 times, or until the fluid is gone from the bucket. A continuous flow of 10 quarts of fluid
is required for best results.
CAUTION: DO NOT turn the steering wheel if the fluid is gone from the bucket - no fluid is shown in the
suction hose. Otherwise, the steering gear and linkage could be damaged.
9. Recycle the waste oil according to local regulations.
PUMP AND PIPE REPLACEMENT PROCEDURE
1. Remove the electric power steering oil pump assembly and . Refer to MS3 online instructions or
the Workshop Manual section 06-14.
NOTE: The Workshop Manual procedure may have you remove the front bumper and washer tank, but it is NOT necessary.
Outline of this procedure: Replace the pump unit (A) of the electric power steering oil pump assembly and I(B), reusing the original reservoir (C) and return hose with clamp (D).
NOTE: If a new return hose comes with the pipe assembly, use the new return hose.
NOTE:
^ It is not necessary to perform Programmable Module Installation (PMI)" when using the Oil Pump Service Kit because the control module is not being replaced.
^ Steps 2-4 are for replacement of the oil pump of the electric power steering oil pump assembly. Before performing the steps, inspect the EHPAS control module and motor visually, and replace the electric power steering oil pump assembly if a malfunction or damage is found.
CAUTION:
^ The internal parts of the EHPAS control module and motor could be damaged if they receive an impact. Be careful when handling the EHPAS control module and motor to prevent it from impacting anything. Replace the electric power steering oil pump assembly if it has received an impact.
^ If fluid or foreign matter enter the motor, it could damage the motor. Be careful to not allow fluid or foreign matter to enter the motor. Even if a small amount of fluid or foreign material has entered the motor, replace the electric power steering oil pump assembly.
^ Do not use a vise to secure parts as the EHPAS control module or the motor could be damaged.
2. Drain the power steering fluid. After draining the power steering fluid, wipe off any fluid remaining around the port area of the power steering oil pump using a clean rag.
3. Disassemble in the order indicated in the figure.
4. Assemble in the reverse order of disassembly.
POWER STEERING OIL PUMP DISASSEMBLY NOTE
a. Remove the power steering oil pump installation bolts (4).
CAUTION: DO NOT remove I loosen the motor to control unit bolts. Once they are loosened, they cannot be retorqued properly. If the bolts are loosened or removed, replace the motor and control unit.
NOTE: Remove the control module and securely set on clean rags or a mat so that the EHPAS control module and motor do not get scratched.
b. Remove the power steering oil pump from the EHPAS control module and motor.
CAUTION:
^ If the pump (A) and housing (B) become separated when removing the power steering oil pump, the housing could fall and damage the part. When removing, be careful to not allow the pump and housing to become separated.
^ Be especially careful that fluid does not get on the area shown in the figure as it could enter the EHPAS control module and motor, and then damage the motor by shorting it out when removing the power steering oil pump.
0-RING DISASSEMBLY NOTE
a. Remove the 0-ring.
CAUTION: When removing the 0-ring, do not use a screwdriver or similar tool as it could damage the 0-ring installation area of the motor. If the 0-ring installation area is inadvertently damaged, replace the electric power steering oil pump.
b. W~pe off any fluid from around the oil pump installation surface of the EHPAS control module and motor using a clean cloth.
0-RING ASSEMBLY NOTE
a. Verify that no foreign material is adhering to the 0-ring installation area and assemble the 0-ring.
CAUTION: If there is foreign matter adhering to the 0-ring installation area, carefully remove it so that the 0-ring installation area is not damaged. If the 0-ring installation area is inadvertently damaged, replace the electric power steering oil pump assembly.
BUSHING, POWER STEERING OIL PUMP ASSEMBLY NOTE
a. Before assembling the bushing, verify that there is no fluid or foreign matter adhering to the oil pump installation surface of the EHPAS control module and motor. Wipe off any fluid or foreign matter using a clean cloth.
b. Install the bushing (A) to the EHPAS control module and motor shaft (B) with the chamfer area (C) oriented to the power steering oil pump side
c. Insert the pump shaft of the power steering oil pump into the bushing and temporarily install the power steering oil pump.
NOTE: The new power steering oil pump is secured to the pump and housing with a temporary band. Temporarily install it with the band left on.
d. Rotate the pump left and right in the area shown (A) so that the pump shaft securely engages with the bushing on the motor shaft and the temporary band (B) does not contact the motor housing.
e. Remove the band and tighten the power steering oil pump installation bolts using a hexagonal bit socket with a bit area length of 90 mm (3.5 in.) or more (A).
Tightening torque: 7-10 Nm (72-101 kgfcm, 62-88 in-Ibf)
NOTE: Install the control module with it securely set on clean rags or a mat so that the EHPAS control module and motor do not get scratched.
5. Install the electric power steering oil pump assembly by tightening the bolts. Refer to MS3 online instructions or the Workshop Manual section 06-14.
6. Install the new connecting the return hoses (A) and installing the connecting bolts (B) with gas
kets (C).
7. Refill the reservoir with power steering fluid. Power steering fluid specification: ATF M-lll or equivalent
8. Bleed air from the system. Refer to MS3 online instructions or Workshop Manual section 06-14.
NOTE: It is not necessary to perform Programmable Module Installation (PM I)" when using the Oil Pump Service Kit because the control module is not being replaced.
9. Verify repair.
10. Install the undercover and the right side splash shield.
PART(S) INFORMATION
Required Parts:
WARRANTY INFORMATION
NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
^ This repair will be covered under Mazda's New Vehicle Limited Warranty term. Additional diagnostic time cannot be claimed for this repair.