MAZDA MX-5 1994 Workshop Manual

GENERAL SERVICE INFORMATION SERVICE PRECAUTIONS ............................................ 2 JACKING AND SAFETY STAND POSITIONS ............ 8 VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS ....... 8 TOW CABLE ATTACHMENT POSITIONS .................. 9 IDENTIFICATION NUMBER LOCATIONS ................... 9 VEHICLE DIMENSIONS ................................................ 10 WHEEL ALIGNMENT .................................................... 10 Gartner Banana

GENERAL SERVICE INFORMATION V SERVICE PRECAUTIONS V Arrangement of workshop Vehicle protection Arrangement of workshop is important for safe 1. Use seat covers and floor covers. and efficient work. 2. Use heat-resistant protective covers to protect glass areas and seats from heat or sparks during welding. 3. Protect items such as moldings, garnishes, ornaments, with tape when welding. Use of pulling equipment When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents. Gartner Banana

GENERAL SERVICE INFORMATION './ SERVICE PRECAUTIONS Safety precautions Safety Protective head covering and safety shoes The fuel tank must be removed if welding is to should always be worn. Depending upon the be done near it or if an open flame is to be nature of the work, gloves, safety glasses, ear brought near it. protectors, face shield, etc., should also be The connection piping must be plugged to used. -, prevent fuel leakage. Mask C_i Before removing a wire harness or an electri- cal component, disconnect the negative bat- tery cable. Gartner Banana

GENERAL SERVICE INFORMATION w EFFICIENT REPLACEMENT OF BODY PANELS V REMOVAL Body measurements Selection of cut-and-join locations Before removal or rough cutting, first measure For parts where complete replacement is not the body at and around the damaged area ac- feasible, careful cutting and joining operations cording to the dimensions figure, and if there should be followed. If the location to be cut is is deformation, use frame repair equipment to a flat area where there is no reinforcement, the make a rough correction. cutting location selected should be where the welding distortion will be a minimum. Prevention of body deformation Use a clamp or a jack for removal and rein- force at and around the rough-cutting location to prevent deformation of the body. Removal of associated parts Protect moldings, garnishes, and ornaments, with tape when removing associated parts. Rough-cutting of damaged panel Check that are no parts (such as pipes, hoses, wire harnesses, etc.) nearby or on the opposite side which could be damaged by heat. For cut-and-join areas, allow for an overlap of 30-50mm (1.18-1.97 in) and then roughly cut the damaged panel. Gartner Banana

u GENERAL SERVICE INFORMATION INSTALLATION PREPARATIONS Application of weld-through primer 1 For treatment against cor- rosion, remove paint, grease, and other material from tl ,portion of the new part and body to be welded, and apply weld- Determination of welding method If the total thickness at the area to be welded is 3mm (0.12 in) or more, use a drill to make holes of about 07 for plug welding, then use a CO2 gas shielded-arc welder to make the plug welds. Note Do not attempt to spot weld sections over 3mm (0.12 in) thick, as the weld strength would be too low. or less Making holes for plug-welding Rough cutting of new parts For places that cannot be spot welded, make For cut-and-join areas, allow for an overlap of a hole of 05-06 (at the new part of the body 30-50mm (1.18-1.97 in) and then roughly cut side) using a punch or drill. the new part, using a hand saw or air saw as necessary. 30-50mm (1.18-1.97 in) (1.18-1.97 in) overlap Gartner Banana

GENERAL SERVICE INFORMATION d INSTALLATION Checking pre-weld measurements and matching Align to the standard reference dimensions, based upon the body dimensions illustration, so that new parts are installed at the correct position. Welding notes Welding should be performed in accordance with the following reference standards. Note a) Plug welding should be performed by the CO2 gas shielded-arc welding method. b) Panel connections by brazing should be only at the indicated locations. Original welding Repair welding Pitch: 50mm Pitch: within 35mm (1.97 in) Original number of Spot welding welds x 1.3 or more Original spot welding Repair welding If 3rnm (0.12 in) or more Original number of welds or more Plug welding Spot welding notes OXXX Original spot weld @Before spot welding, make a trial weld; If satisfactory, proceed with the actual weld- ing. the tip contact surface and facing surfaces ~~[l/jLJL!= @Before spot welding, check once again that - Em -- to be welded are completely clean. @Because the weld strength is affected by the / shape of the spot welder tip, the tip should always be properly maintained, and, in ad- Hammer and chisel Test piece method method dition, in order to minimize problems caused by overheating, a certain amount of cooling time should be allowed after each 5 or 6 weld points. @Spot welds should, as a general rule, be & U made at points other than the originally Center diameter: lr welded points. w 3mm (0.12 in) n 2 Yi'%%Lr: 415 of tip Gartner Banana

GENERAL SERVICE INFORMATION L ANTI-CORROSION TREATMENT When replacing body panels, always apply body sealer, anti-rust treatment. or undercoating ac- cording to the requirements of the market. Application of surface agent and body sealer After first applying the coating of surfacing agent, apply body sealer where necessary. Note For locations where application of body sealer is difficult after installation, apply .t-before the installation. Application of rust inhibitor Undercoating Apply rust inhibitor to the back of welded areas, Use antirust treatment for underbody welding using an installation hole or a gap near that spots and wheel housings. section. Gartner Banana

GENERAL SERVICE INFORMATION JACK AND SAFETY STAND POSITIONS FRONT Jack position: Center of crossmember REAR Jack position: Center of differential Safety stand positions: Side sills I Safety stand positions: Side sills VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS FRONT Frame Side sills REAR Frame Side sills Gartner Banana

u GENERAL SERVICE INFORMATION TIEDOWN HOOK - FRONT /'-- TIEDOWN HOOK - REAR -?-A TOWING Proper towing equipments are necessary to prevent damage to the vehicle during any towing operation. Laws and regulations applicable to vehicles in tow must always be observed. Release the parking brake, place the shift lever in neutral, and set the ignition switch in the ACC posi- tion. As a rule, towed vehicles should be pulled with the driving wheels off the ground. WITH MANUAL TRANSMISSION If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels. If any of these components are damaged, use a towing dolly. CAUTION The power assist for the brakes and steering are inoperable while the engine is off. Do not use the tiedown hooks under the front or rear of the vehicle for towing. These hooks are designed ONLY for transport tiedown. If the tiedown hooks are used for towing, the front or rear skirt and bumper will be damaged. IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER (VIN) ENGINE MODEL AND NUMBER L i Gartner Banana

GENERAL SERVICE INFORMATION VEHICLE DIMENSIONS d Measurement I I Overall height mm (in) I Overall length mm (in) Overall width mm (in) 3,948 (155.4) 1,676 (65.9) WHEEL ALIGNMENT Front wheel alignment (Unloaded*) 2,266 (89.2) 1,410 (55.5) 1,428 (56.2) Wheelbase mm (in) Rear wheel alignment (Unloaded*) Tread Total toe-in Front mrn (in) Rear mm (in) mm (in) degree Camber angle I 0'24' f 30' 3 + 3 (0.12 f 0.12) 0°18' + 18' Maximum steering angle Inner Outer I 37'23' f 2O 32O32' f 2O Caster angle * Fuel tank full; radiator coolant and engine oil at specified levels; and spare tire, jack, and tools in designated positions. 4O4Y f 45' 1 1°20' 3 * 3 (0.12 f 0.12) 0'18' + 18' King pin angle Camber angle Total toe-in -0'43' f 30' mm (in) degree Gartner Banana