wheel MAZDA MX-5 1994 Workshop Manual

SRS AIR BAG SYSTEM T COMPONENT DESCRIPTION Component Air bag module Function Air bag system warning light Deploys air bag when current flows to integrated igniter Light illuminates or flashes if malfunction occurs in air bag system I EE with S-sensor, completes Circuit Clock spring I Ensures uninterrupted electrical connec- tion to air bag module while allowing turning of steering wheel Activated(closed) when crash impact de- Crash sensor Diagnostic module to infktor Activated(closed) when crash impact de- S-sensor 1 Monitors com~onents and harnesses in tected Acting with D-sensor, completes circuit to inflator Remark Located in instrument cluster Location: Driver side . . . . . . . . in steering wheel hub Passenger side . . . above the glove compartment Part of combination switch Located in front part of vehicle(left, right, and center) Located behind heater unit in passenger compartment Contains back-up battery air bag system Indicates system malfunction by flashing or illuminating air bag system warning light If warning light is bunt, sounds warning buzzer Detects short circuit between air bag module and ground or crash sensor rnal- function and melts system fuse to pre- vent unintended air bag deployment Gartner Banana

T SRS AIR BAG SYSTEM GENERALPROCEDURES Before Servicing 1. Deactivate the audio antitheft system, if installed. (Refer to page T-120.) 2. Disconnect the negative battery cable. 3. Remove the lower panel. 4. Disconnect the orange and blue clock spring connec- tors. 5. Remove the glove compartment. 6. Disconnect the orange and blue passenger-side air bag module connectors. I , 46UOTXd21 TROUBLESHOOTING Troubleshootinn Procedure The air bag diagnostic module has a self-diagnosis function that flashes or illuminates the AIR BAG sys- tem warning light to indicate trouble in the air bag system. The trouble can be determined by the warning light illumination or flashing pattern. If the light does not illuminate but the system still has trouble, a warn- ing buzzer will sound 5 cycles of 5 times each. . . Flowchart I START Troubleshoot warning light circuit Does AIR BAG system warning light illuminate for 4-8 secs and I I Yes t Refer to service code table and troubleshoot system Press horn switch while turning steering wheel. Does horn sound? I I I Yes Reconnect connectors Are air bag module and horn switch connectors properly con- nected to clock spring connec- tor? Yes I I I I Troubleshooting horn circuit - Gartner Banana

SRS AIR BAG SYSTEM T AIR BAG MODULE DISPOSAL PROCEDURE Before scrapping a vehicle with an undeployed air bag module, deploy the air bag. Never dispose of a live air bag module. If the deployment tool SST is not available, consult the nearest Mazda representa- i/ tive for assistance. 46UOTX-908 Air Bag Deployment 1. Move the vehicle to an open space, away from strong winds, and open all of the vehicle's doors. 2. Deactivate the audio antitheft system, if installed. (Refer to page T-120.) 3. Disconnect the negative battery cable. 4. Follow the appropriate procedure for the driver-side or passenger-side air bag module. Driver-side air bag module (1 ) Make sure the air bag module is firmly mounted to the steering wheel. (2) Remove the lower panel. (3) Disconnect the orange and blue clock spring con- nectors. (4) Inspect the SST. (Refer to page T-217.) (5) Connect the SST to the clock spring connector as shown in the figure. Passenger-side air bag module (1) Remove the glove compartment. (2) Disconnect the orange and blue passenger-side air bag module connector. 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

TD TECHNICAL DATA A. MEASUREMENTS I Item I Measurements I B. ENGINE Overall length mm {in) Overall width mm (in) Overall height mm {in) Wheelbase mm {in) 3,948 (1 55.4) 1,676 i65.9) 1,224 I48.2) 2,266 I89.2) 1,410 (55.5) 1,428 (56.2) Tread - ltem Tvoe u Front mm (in) Rear mm {in) BP DOHC Gasoline. 4-cvcle . In-line, 4-cylinders Pentroof DOHC, belt-driven 16 valves 83.0 x 85.0 {3.27 x 3.35) 1,840 (1,840, 11 2) 9.0 1,255 {I 2.8, 1823-300 883 (9.0, 1281-300 196 {2.0, 28) s. Cylinder arrangement and number Combustion chamber Valve system Bore x Stroke mm {in] Total piston displacement ml {cc, cu in) Compression ratio Valve timing Compression pressure kPa (kgflcm2. psil-r~m I Valve and valve auide I Standard Minimum Maximum difference between each cvlinder - - IN openz (BTDCO) Close (ABDCO) Open (BBDCO) EX close (ATDC") Valve clearance mm {in) Cylinder head 5 48 56 14 IN 133.8-1 34.0 i5.268-5.275) 0.1 0 {0.004) max. 0.10 {0.004) max. 0.02G0.066 {0.0010-0,0025) 0.18 {0.0071) Height mm (in) Distortion mm {in) Grinding mm {in) - 0: Maintenance-free Cylinder head-to-HLA clearance mm (in} Valve head diameter mm Iin) Valve head margin thickness mm {in} Valve face angle I Valve seat 1 u Standard Maximum Valve length mm {in) EX IN EX IN EX IN EX Standard Minimum Standard Minimum IN EX IN EX 5.99--6.03 iO.2359--0.2374) 0.005--0.060 (0.0002-0.0023) 0.01 b0.065 (0.0004-0,0025) 0.20 {0.008} 18.3-1 8.9 {0.7214.744) 18.3-1 8.9 (0.721-0.744) Guide inner diameter mm (in) 0: Maintenance-free 32.9-33.1 {I .296--1.303) 27.85-28.15 {I .097-1 .I 08) 0.9 {0.035) 1 .O (0.039) 45" 45" 101.89 {4.0114} 100.39 {3.9524) 101.99 (4.0153) 100.49 (3,9563) 5.970-5.985 {0.2351-0.2356) 5.96G5.980 l0.2349-0.2354) Valve stem diameter mm {in) Valve stem-to-guide clearance mm (in) Guide projection (Height "A) mm {in) Seat angle IN EX Maximum IN EX IN 45" EX 45" Gartner Banana

TECHNICAL DATA Engine ------ BP DOHC I Clutch disc I Sinale drv date I u - w- ., Runout limit rnrn {in) 0.7 (0.026) Wear limit rnm linl 0.3 10.01 2) from rivet head . a, 1 outer diameter mm {in) I 215 (8.46) 1 J. MANUAL TRANSMISSION 150 (5.91) 3.5 (0.14) 3.8 (0.15) Inner diameter mm {in) Type _____L- Transmission ___2_ M15M-D Clutch cover Facing thickness mm {in) Diaphragm spring Flywheel side Pressure plate side Set load N {ksrf. Ibn 1 4,310 /440. 968) Gear ratio Runout rnm {in) Mainshaft Clearance between main- shaft and gear (or bush) mm {in} t-- Reverse Oil capacity L {US qt, Imp qt) 1 Maximum 3rd 4th 5th 3.758 2.0 (2.1, 1.8) 0.03 10.001 2) Clearance between shift fork and clutch sleeve Shift fork and rod rod gate and control lever 1.330 1 .OOO 0.814 Reverse idle gear Clearance between reverse idle gear bushing and shaft mrn {in) Synchronizer ring Wear limit Wear limit Clearance between syn- chronizer ring and side of gear when fitted mm {in} Wear limit 0.1 5 {0.006) Wear limit Wear limit I 1 mm {in) ( 75 i2.953) Standard 1.5 (0.059) 22.5 (0.886) 22.5 i0.886) 17.0 (0.669) Detent ball spring (I sV2nd) Detent ball spring (3~94th) Detent ball spring (5thlReverse) Lubricant Free length mm (in) Free length mrn {in) Free length mm {in) Above 10°C {50°F} All seasons API Service GL-4 or GL-5 SAE 80W-90 API Service GL-4 or GL-5 SAE 75W-90 Gartner Banana

TECHNICAL DATA --- M. FRONT AND REAR AXLES Specifications TY pe Bearing Angular ball bearing 0.05 10.002) Front axle Rear axle - Wheel bearing play mm {in) I Maximum Bearina Anaular ball bearina . .. Wheel bearina plav mm {in) I Maximum " " 0.05 {0.002) 'TORSEN" LSD I Standard TY pe Reduction aear Hvpoid sear Reduction ratio Differential aear 4.100 Worm near ("1ORSEN"LSD) I Straiaht-bevel gear - - Ring gear size mm {in) 1 Grade 182.88 17.201 API service GL-5 Oil 1 Viscosity Above -18°C {O°F): SAE 90 Below -18°C {O°F): SAE 80W Differential Capacity L {US at. Imp at) Locknut tightening torque: 128-284 N.m {I 3-29 kgf.m, 94.1-209.7 ft.lbf) Drive pinion preload (without oil seal) TORSEN" is a Backlash mm {in) . , egistered trademark of ZEXEL-GLEASON US, Side gear and pinion gear Final gear , INC Length (Pilot section to pilot section) mm (in N. STEERING SYSTEM Steering wheel Outer diameter mm {in} 1 370 11 4.6) Type item Free play mm {in) I 630 {O-1.18) Wheel effort N (kaf, Ibfl 14.9--29.4{0.5--3.0, 1.1-4.6) 123.545.3 12.A4.6,5.3--8.0) turns I 3.36 1 2.8 I 1 Manual steering Steering Shaft Shaft type I Collapsible, non-tilt Power steering Joint type I 2-cross joint Power steering system Gear ratio 1 m (infinite) Rack stroke rnm {in) I 121 .O 14.76) Power assist type Engine speed sensing Power steering fluid Fluid capacity L {US qt, Imp qt} Fluid pressure kPa {kgf/cm2, psi) Gear type - - ATF DexrongII oi M-111 0.8 {0.85,0.70) 7,603--8,339 (77.5850, 1 ,I 02-1,209) Rack-and-pinion Gartner Banana

TECHNICAL DATA TD P. BRAKING SYSTEM 3rake pedal Waster cylinder 'ront brake :Disc) Rear brake [Disc) Parking brake Power brake unit Rear wheel hydraulic control system -. . . . . Free play mm {in) I 4--7 {0.16--0.28) Item Heiaht (with car~et) mm {in) Reserve travel (without carpet, clearance when pedal is depressed at 589 N (60 kgf, Specifications 171-1 81 {6.73-7.13) . ,~ I Bore mm {in} I 22.22 (0.87) 132 Ibi)) mm {in) 1 Tv~e Tandem . . Fluid type Type Disc plate runout mm {in) [ 0.1 {0.004) max. Wheel cvlinder bore mm {in) I 51.1 i2.011 . . FMVSS116, DOT-3 Disc ~hickness of pad mm {in) Thickness of disc plate mm {in) I I . . Wheel cylinder bore mm {in) I 31.75 (1.25) Standard Limit .%mhd Limit Lever notches 1 7 n 8.0 I0.31) 1 .O (0.041 20.0 {0.79) 18.0 {0.71} . . Disc 8.0 {0.31) 1 .O i0.04) 9.0 10.35) . , TY pe Thickness of pad mm {in) Thickness of disc plate Tvoe I Sinale diawhraam Standard Limit &mdard mm {in) (Pulled at 196 N (20 kgf, 44 Ibf)) ,r- I " . - Diameter mm {in) I 21 4 (8.0) Limit 1-3 Push rod-to-piston clearance mm (in) When vacuum applied to the unit is approx. 66.7 kPa (500 mmHg, 19.7 inHg} 0.1-0.4 (0.004--0.016) Fluid pressure per treading force kPa {kgf/cm2, psi)/N {kgf, Ibf) Tv~e Q. WHEELS AND TIRES 1,079-1,177 {ll-12, 15&171)/196 (20,441 at 0 kPa 10 mmHg, 0 inHg) min. 5,199~5,494 {53-56, 754--796)/196 {20, 44) at 66.7 kPa (500 mmHg, 19.7 inHg} min. PBV Bend portion (Rear brake pressure) kPa {kgf/cm2, psi) 2,943 {30,427) Wheel Temporary spare 14x4T TY Pe ltem 1 Size Standard 14x5 112-JJ Offset mm {in) Pitch circle diameter mm {in) Material Tire Wheel and tire I 45 {I .77) 100 (3.94) Aluminum allov Steel Size Air pressure kPa {kgf/cm2, psi) 185/60R14 82H 179 11.8, 26) Runout limit mm {in) 1 TI 1 5/70D1 4 41 5 (4.2, 60) Horizontal Vertical 2.0 {0.079) 1.5 10.059) 10 (0.35) Maximum unbalance (at rim edge) 9 {oz) Gartner Banana

TECHNICAL DATA R. SUSPENSION Front sus~ension I i/ Differential - . - ~- Coil springs MT I AT Shock absorbers "TORSEN" LSD TY ~a Cylindrical double-acting, low-pressure gas charged Standard Stabilizer Double-wishbone Torsion bar Wire diameter mm {in) Coil inner diameter mm {in} Rear suspension Tv~e I Double-wishbone TY pe Diameter mm {in) 20.0 (0.79) I Identification color 11 .O {0.43} 83.0 f3.27) . . Free length mm {in) Coil number 19.0 {0.75} . . 292.5 (1 1.52) 1 302.0 {I 1.89) 6.32 I - . I1 . ,I . , I Shock absorbers Cylindrical double-acting, low-pressure gas charged White I I Identification color I Yellow I Green I Blue Torsion bar 12.0 (0.471 1 11 .O 10.43) .a Stabilizer TYPe Diameter mm {in) Coil springs Wheel alignment I Front wheel alignment (Unladen'') I I - Caster angle*3 King pin angle I tun'aoen 'I 1 Camber angle'2 -0°43' 2 30' I I - Wire diameter mm {in) Coil inner diameter mm {in) Free length mm {in} Coil number Maximum steering angle 4O26' -c 45' 11 "20' Rear wheel alignment ,, l-l_A_-*i, *1 Fuel tank full; radiator coolant and engine oil at specified level, and spare tire, jack, and tools in designated position. *2 Difference between left and right must not exceed lo. *3 Difference between left and right must not exceed 1'30'. 10.1 (0.40) Inner Outer 10.2 I0.40) mm (in) Camber ana~e*~ J 3 + 3 10.12 r 0.12) 0°18' 2 18' -. - 3 r 3 {0.12 2 0.12) 0'24' 2 45' 37O23' 2 2" 32O32' 2 2" Total toe-in 83.0 i3.27) U' mm {in} degree 348.5 113.72) Total toe-in 356.5 {I 4.04) dearee 7.68 0'18' & 18' 7.96 Gartner Banana

SPECIAL TOOLS ILLUSTRATION TOOL NUMBER B DESCRIPTION PRIORITY ILLUSTRATION PRIORITY 49 F026 103 Puller, wheel hub Attachment $72 49 GO33 102 Handle Attachment $68 & $77 Installer, dust cover Attachment A 49 vo01 795 Installer, oil seal STEERING SYI 'EM PRIORITY ILLUSTRATION TOOL NUMBER & DESCRIPTION PRIORITY ILLUSTRATION DESCRIPTION Gauge set, power steering Installer, dust boot 49 H002 671 Adapter Protector, pinion shaft 498032302A Adapter Holder, power steering pump Gartner Banana