trunk MAZDA MX-5 1994 Workshop Manual

G I ELECTRICAL TROUBLESHOOTING TOOLSIELECTRICAL PARTS I VOLTMETER I BLACK LINE GROUND ELECTRICAL TROUBLESHOOTING TOOLS TEST LIGHT 4) The test light, as shown in the figure, uses a 12V bulb. The two lead wires should be connected to probes.The test light is used for simple voltage checks and for check- ing for short circuits. Caution Using a bulb over 3.4W when checking the control unit may damage the control unit. JUMPER WIRE A jumper wire is used to create a temporary circuit. Con- nect the jumper wire between the terminals of a circuit to bypass a switch. Caution Do not connect a jumper wire from the power source line to a body ground; this may cause burning or other damage to harnesses or elec- tronic components. VOLTMETER The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15V or more is used by con- necting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (-) probe (black lead wire) to a body ground. d OHMMETER The ohmmeter is used to measure the resistance between two points in a circuit, and to check for continu- ity and short circuits. I I 45UGIX-006 GI-I 4 Caution Do not connect the ohmmeter to any circuit to which voltage is applied; this will damage the ohmmeter. ELECTRICAL PARTS BAlTERY The battery installed in the right rear of the trunk is unique. When a replacement battery is installed, install it with a genuine Mazda battery replacement kit or equivalent. (Refer to section G.) J Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . BODY INDEX ............................. S- 2 HOOD ............................. S- 5 COMPONENTS ................... S- 5 DOOR ............................. S- 7 COMPONENTS ................... S- 7 WINDOW REGULATOR. GLASS. AND GUIDE ....................... S- 9 COMPONENTS ................... S- 9 ......... DOOR LOCK AND OPENER S-15 ................... COMPONENTS S-15 TRUNK LID ........................ S-16 COMPONENTS ................... S-16 .... TRUNK LID LOCK AND OPENER S-18 COMPONENTS ................... S-18 ......... POWER WINDOW SYSTEM S-19 .............. STRUCTURAL VIEW S-19 TROUBLESHOOTING ............. S-20 ........ b POWER WINDOW SWITCH S-22 ... POWER WINDOW REGULATOR S-22 ......... FUEL-FILLER LID OPENER S-23 COMPONENTS ................... S-23 FRONT BUMPER ................... S-24 COMPONENTS ................... S-24 REAR BUMPER .................... S-25 COMPONENTS ................... S-25 ........... MOLDING AND GARNISH S-27 COMPONENTS ................... S-27 OUTSIDE MIRROR ................. S-30 STRUCTURAL VIEW .............. S-30 ............. TROUBLESHOOTING S-31 POWER OUTSIDE MIRROR ....... S-33 POWER OUTSIDE MIRROR SWITCH ........................ S-33 COMPONENTS ................... S-34 WINDSHIELD WIPER AND WASHER . S-35 TROUBLESHOOTING ............. S-35 WIPER MOTOR .................. S-38 ................ WASHER MOTOR S-38 FRONT WIPER AND WASHER ........................ SWITCH S-38 ................... COMPONENTS S39 WINDSHIELD ...................... S-44 PREPARATION ................... S-44 ................... COMPONENTS S-44 REAR WINDOW GLASS ......... (DETACHABLE HARDTOP) S-48 PREPARATION ................... S48 ................... COMPONENTS S48 REAR WINDOW .............. (CONVERTIBLE TOP) S-52 ................... COMPONENTS S-52 ....... DASHBOARD AND CONSOLE S-56 ................... COMPONENTS S56 TRIM .............................. S-59 COMPONENTS ................... S-59 ................. FLOOR COVERING S-62 ................... COMPONENTS -21 SEAT BELT ........................ S-63 COMPONENTS ................... S-63 ...................... SEAT BELT S-64 ................ BUCKLE SWITCH S-64 SEAT .............................. S-65 ................... COMPONENTS S-65 ................ CONVERTIBLE TOP S-67 PREPARATION ................... S-67 ................... COMPONENTS S-67 ........... DETACHABLE HARDTOP S-81 COMPONENTS ................... S-81 BRACE BAR ....................... S-84 ................... COMPONENTS S-84 ......... UNDERBODY DIMENSIONS S-85 PROJECTED DIMENSIONS ........ S-85 ..... STRAIGHT-LINE DIMENSIONS S-87 45uoSx-001 Gartner Banana

INDEX s 1. Trunk lid Removal 1 Installation ....... page S-16 Adjustment ................ page S-17 2. Trunk lid lock and opener Removal / Installation ....... page S-18 Adjustment ................ page S-18 3. Fuel-filler lid opener ....... Removal 1 Installation page S-23 .. 4. Rear bumper w Removal 1 Installation ....... page S-25 Disassembly 1 Assembly .... page S-26 5. Molding and garnish Removal / Installation ....... page S-27 6. Rear window glass (Detachable hardtop) Removal / Installation ....... page S-48 7. Rear window (Convertible top) Removal / Installation ....... page S-52 8. Convertible top Removal / Installation ....... page S-67 Disassembly 1 Assembly .... page S-69 Repair .................... page S-79 Adjustment ................ page S-82 9. Detachable hardtop .... Disassembly 1 Assembly page S-81 Adjustment ................ page S-82 Gartner Banana

TRUNK LID TRUNK LID COMPONENTS Removal / Installation 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal. 7.9-10.7 Nrn (80-110 kgfwn, 70--95 indbf} 1. Wire harness 4. Balance spring 2. Trunk lid Removal Note ............. page S-17 Adjustment ................ page S-17 Adjustment ................ page S-17 3. Rod holder 5. Rear package trim 6. Set plate 7. Hinge Gartner Banana

TRUNK LID s 5 2 1.5 (0.2 i 0.06) A TRUNK -&- SEC. B-B mm (in) 05UOSX421 Removal Note Balance spring Warning Removing the balance spring without securing the trunk lid can be dangerous. The trunk lid may fall and injure you. Open the trunk lid fully and se- cure it before removing the balance spring. 1. Lift the balance spring with a protected screwdriver. 2. Remove the balance spring. Adjustment Trunk lid Loosen the trunk lid mounting nuts and adjust as shown. Balance spring Slide the balance spring to the desired position as described below with a protected screwdriver. Hinge b Left side Standard 0 Right side 0 Left side Increase Right side Left side Decrease Right side 0: Indicated position Gartner Banana

s TRUNK LID LOCK AND OPENER TRUNK LID LOCK AND OPENER COMPONENTS Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. Rear console 6. Rear combination light .................... Removal 1 Installation ....... page S-56 Removal Section T Opener lever 7. Rear finisher ............. Opener cable Removal Note page S-28 4. Trunk end trim 8. Key cylinder 5. Trunk lid lock assembly 9. Striker ..................... Adjustment below Adjustment Trunk lid lock assembly Verify that the trunk lid can be closed easily and that there is no looseness. If necessary, loosen the lock assembly mounting bolts and adjust the lock assembly. Gartner Banana

TRIM s TRlM COMPONENTS Removal 1 Installation 1. Remove as shown by prying out the trim clips, referring to Removal Note. 2. Install in the reverse order of removal. Note Remove the brace bar for removal of the quarter trim. (Refer to page S-84.) 1. Front header trim 5. Quarter trim ............. Removal Note ............. page S-60 Removal Note page S-60 2. A-pillar trim 6. Door trim ............. Removal Note ............. page S-60 Removal Note page S-61 3. Front side trim 7. Rear package trim Removal Note ............. page S-60 8. Trunk end trim 4. Scuff plate 9. Trunk side trim Removal Note ............. page S-60 Gartner Banana

T FUSE DESCRIPTION Main Fuse Block The main fuse block is located on the right side of the engine compartment and contains nine fuses and two relays. -1 Fuse Box Fuse block No.1 is located above the dead pedal of the driver side. The fuse box cover shows the speci- fied fuse locations. A circuit breaker is included in the fuse box to protect the heater blower motor circuit. Fuse block No.2 is located to the side of the battery in the trunk compartment. 45UOTX-016 REPLACEMENT Caution Determine and correct the cause of a burnt fuse before replacing it. If the fuse is replaced before doing this, it may burn again. Plate type 1. Disconnect the negative battery cable. 2. Replace the failed fuse with the fuse puller. 3. Reconnect the negative battery cable. Cartridge-type 80A fuse (Black) 1. Disconnect the negative battery cable. 2. Remove the fuse block mounting nuts, and remove the service cover. 3. Remove the fuse installation bolts, and pull out the fuse. 4. Install the new fuse and the fuse installation bolts. 5. Install the main fuse block. 6. Reconnect the negative battery cable. Gartner Banana

CONSTRUCTION No. @ I Rear deck panel @ @ - - 1 8 1 Quarter panel Part Name @ I Rear deck member Trunk lid Rear end panel I @ 1 Light housing No. Part Name @ Q @ I Tunnel gusset Seal plate Splash protector @ @ I @ I Rear fender panel Bulkhead panel Floor side panel Floor center pan 0 I Crossmember No. 4 @ @ I @ I Door body @ Q Rear fender gusset Rear fender rain rail Fuel filler lid Parking bracket Crossmember No. 3 8 1 Floor side plate @ @ I @ / Side sill, inner B @ @ I ~ut plate Rear fender, lower Trunk board bracket Tank floor pan assy Trunk floor assy 1 8 1 Side sill reinforcement Q @ 0 I Rear side frame Striker reinforcement Side sill, inner C I I I 1 8 ( Cowl side panel @ @ I Closing bracket I @ I Hinge pillar Floor side panel @ @ 8 1 Battery clamp bracket I @ I Side sill, inner Side sill, outer Bumper bracket Cap bracket @ I Corner junction 1 8 1 Front header, Q @ @ @ Side sill gusset Hinge pillar, outer Side panel, inner Wheel inner house @ @ @ Beltline reinforcement Front pillar, outer Front pillar, inner @ Front header, upper Gartner Banana

CONSTRUCTION @ I Trunk lid I @ I Splash protector No. @I I Rear deck member Part Name @ @ I @ I Light housing No. Rear end panel Rear deck panel @ I Floor center pan Part Name @ I @ / Rear fender panel @ @I @ I Crossmember No. 3 Seal plate Quarter panel Floor side panel I @ I Rear fender, lower @ Fuel filler lid @ @ 1 Floor side plate I I I I @ 1 Side sill B, inner Crossmember No. 4 Tank floor pan assy @ @ 1 Bumper bracket @ @ Trunk floor assy @ @ I Q / Front header, upper Door body Side sill, outer @ Floor side panel Rear side frame -1 .............. Both side rust-proof treated steel .............. One side rust-proof treated steel (Reverse side only) Side sill reinforcement Striker reinforcement Side sill C, inner @ @ 0 @ Side panel, inner Wheel inner house Beltline reinforcement Corner junction @ @ @ Side sill A, inner Hinge pillar, outer Cowl side panel Gartner Banana