trunk MAZDA MX-5 1994 User Guide

PANEL REPLACEMENT CROSSMEMBER (NO. 1) ............................................. 36 SHROUD PANEL ASSY ............................................... 38 WHEEL APRON PANEL ............................................... 40 WHEEL APRON PANEL ASSY .................................... 42 COWL SIDE PANEL ...................................................... 44 SIDE SILL PANEL ASSY .............................................. 46 FRONT PILLAR, OUTER COWL SlDE PANEL, HINGE PILLAR, INNER COWL SlDE PANEL AND SIDE SILL PANEL ............................................ 48 REAR FENDER PANEL ................................................ 52 REAR END PANEL ....................................................... 54 TRUNK FLOOR PAN, FLOOR SIDE PANEL .............. 56 Gartner Banana

PANEL REPLACEMENT V INSTALLATION a Apply body sealer before installing new parts as shown in the illustration. \- a After temporary installation of new parts, check the fit with associating parts (door, trunk lid, rear combination lights, rear bumper, rear finisher etc.). L To plug weld 2 points indicated by (A), first spot weld point (B) and turn down the flange of the rear deck panel to the original position. Gartner Banana

PANEL REPLACEMENT L INSTALLATION After temporary installation of new parts, measure the dimensions to verify that they are as specified. Check the fit with associating parts (trunk lid, rear combination lights, rear bumper, etc.). Spot welds on rear combination light side must be smooth. Gartner Banana

PANEL REPLACEMENT - TRUNK FLOOR PAN, FLOOR SIDE PANEL REMOVAL to cut weld and I u Floor side panel (left) Trunk floor L / Floor side panel (right) Gartner Banana

PANEL REPLACEMENT L REMOVAL (left) splas\h protect'or (right) Work should be performed after the rear end panel and the rear fender panel (left) are removed. The trunk floor is replaced by cut-and-join operation indicated on page 60. The cut-and-join operation is performed after turning up the tank floor as indicated by arrows in the illustration. When drilling points (A) for spot welding, do not make open holes. - When the rear fender panel (left) is replaced at the same time, the panel can be removed without cutting away the spot welded points indicated by (A). Do not damage the rear side frame when rough-cutting. L Gartner Banana

PANEL REPLACEMENT TRUNK FLOOR PAN, FLOOR SIDE PANEL INSTALLATION Gartner Banana

PANEL REPLACEMENT L INSTALLATION Before installing new parts, measure the rear side frame dimensions to verify that they are as specified. After installing new parts, check the fit with associating parts. Turn down the tank floor to the original position after welding the cut-and-join location of the trunk floor and flattening it with a disc grinder. - Plug-weld the trunk floor, tank floor, and crossmember (No. 4). Weld a washer (PART NO. 99952 2240A) at the rear crossmember installing bolt (two points). Gartner Banana

SECT ION NAME INDEX (my) - LO a NO * - ... - a 2-C03 2-E03 2-H03 2-403 2-KO3 2-1.03 2-CO4 2-E04 2-H04 2-104 2- JOG ?-KO4 2-M04 ?-NO4 9-CO4 ?-LO5 2-8 0% ?-KO5 ?-NO!, 7-CO6 ?*C47 i?-107 ?*f-d7 ?-GO I ?- 109 ,!-LO I Z-catj il- t. 0 a 2 .. f' fl g4 ?-GO9 ;,. JO9 ?-MQY ? il'j ? CII --- - - SEC .#I ---..- 0900 5000 5910 8030 5100 5103 $105 5110 5120 5170 5180 5230 5260 5310 5520 5539 5340 5370 5580 53 YO 5500 5570 55.10 5!>40 5560 55 "0 5588 5 IOU 5790 '; 19'. 5flOti !,bSB !J n c* u LlbIJ . ---..- - - --- SECfION NAME -----.- ------------------ ..--- KEY SETS FRONT BUNPER REAR EUHPER WINDOW HOULDING L COWL GRILLES HEAD LANPS HEAD LAHP RE T RACY ORS FRONT CONBINITION Lanes REAR COHBINATIOH LAHPS L ALENSE LAHPS BRNAMM3S REAR FIWISWER BONNET TRUNK LIB FWDNT PANELS FEIiDER P WHEEL APRON PANELS 3PCU L COWL PANELS SiUE PANELS {'!.OUR PANELS, FLCOR AYTACWHEHTS (HDCC GOVEAS 1 FLOOR AVYACHHEHTS DASHEOARD EOU IPMENI 5 nf VCR NttUD SPEEDOM TCW CADI.[; nt 1 ER CONPONE ws DASHBOAKU 6 WI LATLb PAKl S COHSOLC. VLUTILATOSI St.AI'S %CAI IC'ITS AIR OhC FblOlil li00k'$ F WLlh 'l !WOH Wt't:NAN I TUUHI 1)ouu IHlnS 1 WELAICL, PAW 1s - SEC * N( -----a 6110 6115 6 120 6130 6160 6190 6300 6330 6600 6610 661 1 6638 6635 6640 6600 6662 670U &7C 1 6707 6703 6784 6 ?i!U 6720 1 6730 6 760 ba20 6140 ~uen tB1U bVQU SECTION NAHE HEATER UNIT COMPONENTS HEATER CONTROLS COMPONENTS HEATER BL OWER COHPONENT S AIR CONDITIONER COMPRESSOR COHFONENTS (AIR CON DIT JlrNEiO COOLING UI\'TS (AIR COHDITIOHEW) WINDOW GLASSES SUNROOF SWITCHES C RFtAVS (ENGINE) DASHBOARD SWlTCHES COHBINATIOM SWITCH RELAYS L UNIT (BODY) DOOR SWITCH & HDRWS AUTO CRUISE CONTROL SYSTEH AUDIO SYSTEMS (RADIO & TAPE W. CK 1 AUDIO SYSTFffS (ANTENNA 6 SPEAK El?) NIP t He HARNESSES(FRON1 L REAR ) WlW iNG HARNESS CL.AHPS UtHaSH1EL.D W4SHER ANT1 LJCI BRAKE SYSTEH) WIHDSHIELU WASHER (AH71 LOCK BRAKE SYSTEM) UINUSHIELD WIPERS FRONT hEAD$Y TWIN & PIMY TRl n s FLOOR HATS L PAW QUARTER WINDOW L VRIHS LA I L Olr HI).. AUHAOd* I1 3 Gartner Banana

SECTION NAME KEY SETS FRONT BUHPER REAR SUNPER WINDOW rlOULBIHG L COWL GRILLES HEAD LAMPS IIEAD LAHP RE 1 RACTORS FRONT COHBINATION LAWS REAR CUHBlNATIOH LAHPS L ICE HOE LAWS ORNhHENTS REAR F f Hf Ci+CR BONNET TRUNK 110 f RWT PANEL S FLHOEW & WHfkL APWOt4 P4NkL!$ LUSH & COWL PANELS SIDE PANELS FLOOR PANELS F LOOR ATTACHHENTS (HOLE COVERS ) HkTER HOOD SCf 600NC TCH CAB1.k RC 1 ER COMPONENTS SECTION nAnE ---------_L---_-----__________L_______I__________________L_______I__________________L_______I________-__________L_______I__________________L_______I__________________L_______I________ HEAI'ER Wit COMPONENTS HEATER CONTROLS COHPONENf S HEATER BLOWER COWPONENTS AIR CONBlTXOMR COHPRESSOR COHPONENTS (AIR CDh DITIONER) COOLING UNIT (AIR CO#DlTZONERI WINDOW GLASSES SUNRtOF SWiTCMES L RELAvC (ENGINE) DASMIOAWD SWITCHES CO~bfNAI~OH SWlfCiI RELAYS L UNIT i8OBV) DOOR SWITCH L HORNS AUTO CRUISE CONTROL C't SIGH AUDIO SYSTEHS (ANTENNA C WEAK ER MIWBSH2El.D YASHCK (U/U ANTI LUCI MAKC SYSICI) 7250 QUARTER WINCOW L TRIHS Gartner Banana

5260 TRUNK LID LID ,TRUWK Hll4f3EtR),TRUIIK LID HXWECL), TRUNK LID SPRIHG( R ) BALANCE SPRf tW L ) ,BALANCE PLULi,DRhfN RUBBER, CUSHLOH CUSHIOH, LIB HINGE LOCK ,LID I Gartner Banana