torque MAZDA MX-5 1994 Workshop Manual

s REAR WINDOW GLASS mm {in) I 45UOSX-059 1 , REPAIR SEALANT mm (in) " GLASS UPPER PROTECTOR SEC. A- SIDE PROTECTOR I LOWER PROTECTOR I 45UOSX461 STUD REPAIR SEALANT / 4. Securely bond a new dam along the circumference of the glass 8 mm (0.31 in) from the edge. Allow it to dry completely. i/ 5. Prepare the nozzle of the sealant tube so that it has a flange that can run along the edge of the glass and a V from which the sealant can flow. Once the primer is dry, apply repair sealant (8001 77 739) around the entire cir- cumference to fill the gap between the dam and the edge of the glass with a ridge of sealant 11 mm (0.43 in) high. Keep the bead of sealant smooth and even, reshaping it where necessary with a spatula. 6. If a protector is damaged, securely bond a new protector onto the detachable hardtop as shown. Allow it to dry completely. 7. Align the studs of the glass with the detachable hardtop and mount the glass. 8. Push the glass lightly toward the front to compress the sealant. 9. Tighten the glass mounting nuts. Tightening torque: 2.4--3.3 N-m (24--34 kgf-cm, 20.9-29.5 in-lbf) 10. Use a scraper to smooth away any sealant that oozes out. Add more sealant to any points of poor contact. 11. Install the new rear window molding. (Refer to page S-29.) Hardening time of repair sealant I Temperature I Surface hardening time I Time required until car can be out into service I 8 20°C (68°F) I Approx. 1 hr I 4 hr I I 35°C {95"F) 1 Approx. I0 min I 2 hr I d I I 5°C I41 OF) I Approx. 1.5 hr 12 hr Gartner Banana

REAR WINDOW s OUTER RAIN RAIL 9 , BELTLINE COVER PROTECTOR 5. lnstall the zipper stops to the rear window and the top fabric. 6. Affix the rear window to the top fabric with the Velcro. 7. Mount the outer rain rail to the studs. 8. Mount the top fabric to the studs. 9. Mount the rear window to the studs. 10. Mount the inner rain rail to the studs. 11. Loosely install the set plates beginning at the left side. 12. Unzip the rear window, and lower the convertible top fully. 13. lnstall the rain rail with the fasteners. 14. lnstall the beltline protectors. 15. lnstall the beltline cover. 16. Raise the convertible top completely, and lock the top latch assemblies. 17. Zip the rear window into place. 18. Tighten the set plate mounting nuts. Tightening torque: 8.Q-11.7 N.m (90-1 20 kgfem, 79-1 04 ft-lbf) 19. Rivet the top fabric to the link assembly. 20. lnstall the rear package trim. 21. If there is any sagging of the top fabric, remove the pull tab and realign the zipper. Gartner Banana

s CONVERTIBLE TOP PUL BRACKET Removal Note Convertible top 1. Unlock the top latch assemblies. 2. Unzip the rear window, and lower the convertible top \- ' fully. Installation Note Convertible top 1. Insert the rain rail into the beltline molding lip, and mount it over the studs. 2. Align and install the link bracket over the studs with no clearance between the studs and the bracket. 3. Tighten the bolts to the specified torque. Tightening torque: lS--2S N.m (1.9--2.6 kgf.m, l5--18 ftlbf) Gartner Banana

DETACHABLE HARDTOP PROTECTOR ADJUSTING NUT DETACHABLE HARDTOl WINDSHIELD HEADER I @ 1 5 r 2 (0.2 f 0.08) @ 1 0 r 2 (0 * 0.08) mm (in) 45UOSX-11 f Adjustment Top latch assembly 1. Lift the protector away from the top latch assembly ad- justing nut. d 2. Turn the adjusting nut clockwise to decrease clearance A and height B; turn the nut counterclockwise to increase them. 3. Secure the adjusting nut with the protector. I I Side latch assembly 1. Lift the protector away from the side latch assembly ad- justing nut. 2. Turn the adjusting nut clockwise to tighten the striker and side latch assembly engagement; turn the nut counter- clockwise to loosen the engagement. - 3. Secure the adjusting nut with the protector. ADJUSTING NUT 45UOSX-117 Rear deck latch assembly 1. Remove the screw and open the latch cover. 2. Loosen the plate mounting bolts. 3. Install the detachable hardtop to the body. 4. Move the plate right, left, fore, or aft until it is tight. 5. Tighten the plate mounting bolts. Tightening torque: 18-26 N.m (1.8-2.7 kgfsm, 14--19 ft-lbf) 6. Close the latch cover and install the screw. Gartner Banana

T LIGHTING SYSTEM Stoplight Switch Adjustment 1. Adjust the brake pedal height. (Refer to section P.) 2. Disconnect the stoplight switch connector. 4 3. Loosen the stoplight switch locknut. 4. Turn the stoplight switch until it contacts the pedal arm. Turn an additional 112 turn. 5. Tighten the locknut. Locknut tightening torque: 14-18 N.m (1.4-1.8 kgf-m, 120-156 in-lbf) I I I Brake pedal depress I 0 0 1 I Inspection Stoplight switch 1. Disconnect the stoplight switch connector. 2. Check for continuity between terminals of the switch. lnspection condition 3. If not as specified, replace the stoplight switch. Terminal A I B I Brake pedal released I m : Continuity Gartner Banana

T SRS AIR BAG SYSTEM Installation Note Crash sensor (D-sensor) 1. If the crash sensor mounting area is damaged, repair the area to its original shape before reinstalling the sensor. i/ 2. Point the arrow on the crash sensor toward the front of the vehicle. Then install it and tighten the bolts to the specified torque. Inspection 1. Disconnect the D-sensor connectors (center, RH, and LH). Measure resistance of each sensor. 2. If not as specified, replace the crash sensor. (Refer to pages T-210,211.) Resistance Approx. 1.1 8 WZ Terminal A B Gartner Banana

T SRS AIR BAG SYSTEM Installation Note Crash sensor (S-sensor) 1. If the crash sensor mounting area is damaged, repair the area to its original shape before reinstalling the sensor. 4 2. Point the arrow on the crash sensor toward the front of the vehicle. Then install it and tighten the bolts to the specified torque. Inspection 1. Disconnect the S-sensor connector. 2. Check for continuity between terminals of the S-sensor. 0---0 : Continuity Terminals I Ground I 3. If not as specified, replace the S-sensor. (Refer to page T-213.) A I B 1 C D I E Gartner Banana

TROUBLESHOOTING Case 1: Insufficient refrigerant Measured pressure Low-pressure side: 0.05-4.09 MPa (0.5--1.0 kgf/cm2, 8-1 4 psi) u High-pressure side: 0.69-498 MPa (7.0-1 0.0 kgflcm2, 100-142 psi) Condition Outlet air from vents not cold. Bubbles seen in sight glass. Step 1 1. Check for oil stains on the pipes, hoses and other parts. (Refer to illustration below.) 2. If oil staining is found at the connection of pipes or hoses, replace the O-ring; then evacuate, charge, and test the svstem. 3. If oil staining k not found, go to Step 2. Step 2 1. Check for leakage from the following connections with a gas leak tester. lnlet and outlet of condenser. lnlet and outlet of receiver drier. lnlet and outlet of A.C compressor. Sight glass. lnkt and outlet of cooling unit. 2. If leakage is evident, go to Step 3. 3. If leakage cannot be found, evacuate, charge, and test the system. (System OK, but refrigerant leaked gradually over time.) Step 3 L-/ 1. Check tightening torque of the connection where leak was detected. 2. If the connection is loose, tighten the connection to the specified torque; then evacuate, charge, and test system. 3. If the connection is properly tightened, replace the O-ring; then evacuate, charge, and test the system. Gartner Banana

u AIR CONDITIONER COOLING UNIT Removal 1 Installation 1. Discharge the refrigerant system. 2. Remove the glove compartment. (Refer to section S.) il 3. Remove in the order shown in the figure. Immediately plug all open fittings to keep moisture out of the system. 4. Install in the reverse order of removal. Position the unit so that its connections match those of the heater unit and blower unit. Apply clean compressor oil to the O-rings before connecting the fittings; do not ap- ply compressor oil to the fitting nuts. Tightening torque Inlet pipe: 10-19 N-m (1.0-2.0 kgfsm, 8-14 ft-lbf} Outlet pipe: 20-29 N-m (2.0-3.0 kgf-m, 15--21 ft-lbf} 5. Charge the refrigerant system. (Refer to page U-25.) 7.910.7 N.m {EO-110 kgfmn, 69.5-95.4 In4bf} 45uoux-071 1. Cooling unit 2. Sealing plate Disassembly / Assembly . . . . . . page U-31 U-30 Gartner Banana

AIR CONDITIONER u CONDENSER AND RECEIVER DRIER Removal 1 Installation 1. Raise the front of the vehicle at least 300 mm (11.8 in) and support it on safety stands. 2. Discharge the refrigerant system. 3. Remove the splash shield and air guide. 4. Remove in the order shown in the figure. Immediately plug any open fittings to keep moisture out of the system. 5. Install in the reverse order of removal. Apply clean compressor oil to the O-rings before connecting the - fittings; do not apply compressor oil to the fitting nuts. Tightening torque Receiver drier inlet and outlet: 10-19 N-m (1.0-2.0 kgf-m, 8-14 ft-lbf) Condenser inlet: 15-24 N.m (1.5-2.5 kgfsm, 11-18 ft-lbf} 6. Install the air guide and splash shield. 7. Charge the refrigerant system. (Refer to page U-25.) 1. Condenser 2. Receiver drier On-vehicle Inspection . . . . . . . . . page U-34 On-vehicle Inspection . . . . . . . . . page U-34 U-33 Gartner Banana