air condition MAZDA MX-5 1994 Workshop Manual

u AIR CONDITIONER PIN (2) Remove the discharge valve installation bolts and discharge valve body. 3. Removal of discharge valve Remove the bolts, discharge valve plate and discharge valve. 4. Removal of front and rear housings (1) Remove the through bolts and front housing. (2) Remove the rear housing. (3) Remove the pin and gaskets. Gartner Banana

AIR CONDITIONER u BUSHING 5. Removal of shaft seal Remove the shaft seal from the shaft. Do not disas- semble the compressor body. 6. Removal of shaft seal plate Remove the shaft seal plate by using a suitably sized bushing. 7. Installation of shaft seal plate Install the shaft seal plate by using a suitably sized bush- ing. 8. Installation of shaft seal (1) Lubricate the shaft seal with the compressor oil. (2) Install the shaft seal on the shaft. 9. Installation of front and rear housings (1) Install the new gaskets and pin on the compressor body. Gartner Banana

u AIR CONDITIONER (2) Install the front and rear housings and tighten the through bolts loosely. 10. Installation of discharge valve Install the discharge valve and discharge valve plate and tighten the bolts. Tightening torque: 4.6 N.m (47 kgtcm, 41 in-lbf) 11. lnstallation of discharge valve body (1) Install the discharge valve body and tighten the bolts loosely. (2) Tighten the discharge valve installation through bolts loosely. 12. Tightening of bolts (1) Tighten the through bolts. Tightening torque: 25 N-m (2.6 kgtm, 19 ftslbf) Gartner Banana

AIR CONDITIONER u O-RING (2) Tighten the discharge valve body installation through bolts. Tightening torque: 10.8 N-m (110 kgf-cm, 95.5 in-lbf) (3) Tighten the discharge valve body installation bolts. Tightening torque: 10.8 N-m (110 kgf-cm, 95.5 in-lbf) 1 3. Pour compressor oil (ND-OILS) Pour compressor oil into the A/C compressor. Compressor oil amount: Same amount as drained, plus 20 ml(20 cc, 0.6 fl or) 14. Installation of service valve (1) Apply the compressor oil to the new O-rings. (2) Install the service valves to the compressor and tight- en the installation bolts. Tightening torque: 12.3 N-m (125 kgf-cm, 109 in-lbf) Gartner Banana

u AIR CONDITIONER I NC COMPRESSOR 45UOUX-119 Adjustment Drive belt (With PIS) 1. Loosen PIS oil pump bolts @ and @ and nut 0. ...-' 2. Adjust the belt tension and deflection to specification by turning adjusting bolt 0. 3. Tighten bolts @ and @J and nut 0. (Without PIS) 1. Loosen the locknut. 2. Adjust the belt tension and deflection to specification by Tightening torque: @I: 3246 N.m (3.2-4.7 kgf-m, 24-33 ftelbf) @I: 37-53 Nem (3.7-5.5 kgf-m, 27-39 ft-lbf) 0: 19-25 N.m (1 3-2.6 kgf-m, 14--18 ft-lbf) turning the adjusting bolt. 3. Tighten the locknut. 1 Tension t Deflection when applying moderate pressure 98 N {lo 1 kgf, 22 Ibf) Tightening torque: 38-51 N-m (3.8-5.3 kgf-m, 28-38 ft-lbf) Specification NC COMPRESSOR 45UOUX-121 New 490-588 N (50.0-60.0 kgf, 11 0-1 32 Ibf) 8.0-9.0 mm {0.31-0.35 in) Specification Used 422490 N (43.0-50.0 kgf, 9!5-110 Ibf) 9.0-1 0.0 mm I0.35--0.39 in) New Used Tension Deflection when applying moderate pressure 98 N (10 kgf, 22 Ibf) 490-588 N {50.0-60.0 kgf, 110-132 IbfJ 8.0-9.0 mm i0.31-0.35 in) 422490 N (43.0-50.0 kgf, 95-1 1 0 Ibf) 9.0-1 0.0 mm I0.35-0.39 in) Gartner Banana

TECHNICAL DATA MEASUREMENTS ......................... TD- 2 ................................... ENGINE TD- 2 .................... LUBRICATION SYSTEM TD- 5 ........................ COOLING SYSTEM TD- 5 FUEL AND EMISSION CONTROL SYSTEMS . TD- 6 ENGINE ELECTRICAL SYSTEM ............. TD- 7 .................................. CLUTCH TD- 7 .................. MANUAL TRANSMISSION TD- 8 AUTOMATIC TRANSMISSION ............... TD- 9 ....................... PROPELLER SHAFT TD-11 FRONT AND REAR AXLES ................. TD-12 STEERING SYSTEM ....................... TD-12 BRAKING SYSTEM ........................ TD-13 WHEELS AND TIRES ...................... TD-13 ............................. SUSPENSION TD-14 BODY ELECTRICAL SYSTEM ............... TD-15 HEATER AND AIR CONDITIONING SYSTEM . TD-15 STANDARD BOLT AND NUT TIGHTENING ................................. TORQUE TD-15 45UTDX-001 Gartner Banana

TECHNICAL DATA 1 Charge I 1.4 Belt 1.4 r. BODY ELECTRICAL SYSTEM 1 Air bag I 2 1 Retractor 1.4 Item Wattage (Bulb trade number) Hold Anti lock Wamlng and indicator lights 1.4 1.4 Washer Rear window defroster Beam Turn (LH and RH) Illumination Malfanction indicator Brake 1.4 1.4 I Exterior lights 3.4 3.4 3.4 x 4 1.4 1.4 Headlights Front turn signawparking lights Front side marker lights License plate lights Rear turn signal lights Rear side marker lights Stop/taillights Back-UP linhts High-mount stoplight I 18.4 (921) ACS 1 1.4 Hazard switch 1.4 60140 2718 (1 157 NA) 3.8 (1 94) 7.5 27 (1 1 56) 3.8 (1 94) 2718 {I 157) 27 (1 1561 Interior llahts - I lllumination lights I Cruise control main switch I 1.4 I 5 Ash tray U. HEATER AND AIR CONDITIONING SYSTEM I Item I Specit lcations I 3.4 Heater control switch ane el I 1.4 STANDARD BOLT AND NUT TIGHTENING TORQUE Refrigerant amount S (04 Compressor oil amount rnl {cc, fl oz) Refrigerant normal pressure MPa (kgflcm2, psi) 600 {2 1.21 130-1 70 {I 30-1 70,3.9-5.1) Low pressure: 0.154.25 (1 .5-2.5,21-361 Hiah Pressure: 1 37-1.57 (1 4--16, 199--228) Gartner Banana

UNDERCOATING, PVC PAINTING AND RUST PREVENTIVE WAX TREATMENT - Repair of PVC (polyvinyl chloride) paint surface (repair of deep scratch) Repair base coat (including putty) Repair PVC paint v Mask 1 Apply PVC Remove masking Refer to next page + - Done in same way as ordinary body repair. Thoroughly clean away dirt from the Shave until smooth surface. For places where the paint film is scratched, use a knife or similar tool to carefully shave the surface until it is smooth. Use sandpaper (#120-#130) to roughen to assure good adhesion. Mask wide area Use masking over a wide area, be- cause the mist will scatter widely. Depending upon the size of the pattern, adjust the distance of the spray gun from the surface and/or the air pressure; apply one or two coatings. Pattern estimation conditions 111 Large I Small I Smooth finish I U For partial area painting, spray smoothly, taking care that no un- even surfaces are formed. Spray dismce Coating Air pressure After repair Before repair 10-20 cm (3.9-7.9 in) 1-2 294-392kPa (%^4?6/CZ) After finishing with the tools (spray gun, etc.), wash them im- mediately with water. (Even paint thinner will not be effective if hardening is complete.) Remove masking immediate- ly after coating is finished. (If removed after drying, edges might also peel off.) Wipe away overspray with a damp cloth before it dries. (If after drying, paint thinner will not be effective.) Damp cloth 20-40 cm (7.9-15.7 in) 2-3 392-588 kPa 4-6 kg/crd j (0.6-0.9 psi 20-30 cm (7.9-1 1.8 in) 1-2 (?%it:::') 0.6-0.7 psi d Gartner Banana

UNDERCOATING, PVC PAINTING AND RUST PREVENTIVE WAX TREATMENT Air dry a minimum of 4-6 hours [20°C (68OF)l. L Heat dry a minimum of 30-40 minutes [60°C (140°F)]. Color coat i Apply coating after PVC paint film is thoroughly dry. Sanding is not necessary if all oil and grease were completely removed. Conditions such as air pressure, paint viscosity, etc. can be same as for ordinary body coating. -1 Done in same way as for ordinary body coating. Nozzle type A Nozzle type B RUST PREVENTIVE WAX TREATMENT WAX APPLICATION PROCEDURE Preparation of equipment 1. Prepare equipment suitable for the wax chosen. 2. Use the correct nozzle, spray pattern, and in- jection pressure based on instructions provided for the wax. 3. If necessary, clean the nozzle with thinner before beginning work. Preparation of vehicle (or parts) 1. Scrape mud, etc. off the wax application area. 2. Dry any water collected at the wax application area. 3. The temperature of the vehicle body should be kept at more than 10°C (50°F) during the opera- tion. 4. Close all windows of the vehicle. Caution When repairing a damaged part, complete painting first, then apply the wax. The reasons are: a) The wax is sometimes dissolved by heat [more than 120°C (248OF)I during the drying process, resulting in deteriorated anticor- rosion effects. b)lf the wax applied before painting is smeared over the paint application surface, poor painting will result because the wax repels the paint. Gartner Banana

ALUMINUM BODY PARTS Although repair of aluminum components is done by the same procedures as repair of steel com- ponents, certain points should be noted, as described below. 1. Because aluminum has a greater characteristic of expansion/elongation than steel, a lesser strik- ing force should be used for hammering so that the aluminum component does not become excessively distorted. 2. When heat is used as a method of repair of an aluminum component, the temperature should be kept as low as possible, and the heated area restricted as much as possible. This is to prevent a loss of rigidity due to overheating. 3. When removing old paint from aluminum, a fine-grain sandpaper (#I20 - #180) should be used, because aluminum is a relatively soft material. 4. A special aluminum primer must be used before attempting application of putty or paint, be- cause such materials do not adhere well to aluminum. 5. Determine the type of putty to be used (sheet-metal putty or polyethylene putty) according to the condition of the damage. 6. If bare aluminum is exposed as a result of grinding, sanding, etc., apply special primer for aluminum. 7. Such steps as primer surfacer drying, primer surfacer sanding, top-coat application and drying are done in the same way as for steel painting. - Gartner Banana