lock MAZDA MX-5 1994 Workshop Manual

P ANTILOCK BRAKE SYSTEM (ABS) -.A 1. Sensor rotor 3. Drive shaft ................... ................. Installation Note below Installation section M 2. Boot and boot band ................... Installation section M lnstallation note ABS sensor rotor Set a new sensor rotor on the drive shaft and press it on with the SST. Gartner Banana

WHEEL ALIGNMENT LEFT WHEEL INCREASE CAM BOLT RIGHT WHEEL 0) '. jr INCREASE Adjustment Maximum steering angle 1. Remove the steering gear boot clamp. 2. Loosen the tie rod locknut. 3. Turn the tie rod to provide the correct maximum steering angle. 4. After adjustment, tighten the locknut to the specified torque. Tightening torque: 3539 N-m (3.W.0 kgf-m, 26-28 ftdbf) 5. Adjust the toe-in. (Refer to page R-8.) 6. Verify that the boot is not twisted, and install the boot clamp. Caster Caster is adjusted by turning the front and/or rear adjust- ing cam bolts at the lower arm. Caution Adjust the caster before adjusting the camber. 1. Loosen the front and/or rear cam nuts. 2. Turn the front and/or rear adjusting cam bolts to provide the correct caster angle. Left wheel Right wheel Caster I Front cam I Rear cam I Front cam I Rear cam Counter- 1 Clockwise I Clockwise 1 I Increase I ( clockwise Note Turning the front cam one graduation on the scale changes the caster angle about 22' and the camber about 25'. Turning the rear cam one graduation changes the caster angle about 22' and the camber about 2'. Decrease 3. Adjust the camber and the toe-in. Clockwise Clockwise Counter- clockwise Counter- clockwise Gartner Banana

WHEEL ALIGNMENT LEFT WHEEL POSITIVE RIGHT WHEEL POSITIVE Camber Camber is adjusted by turning the front and rear adjust- ing cam bolts at the lower arm. 2 Caution Adjust the camber after adjusting the caster. 1. Loosen the front and rear cam nuts. 2. Turn the front and rear adjusting cam bolts the same amount in the opposite direction to provide the correct camber angle. Left wheel Note Turning the front cam one graduation changes the camber about 25' and the caster about 22'. Turning the rear cam one graduation changes the camber about 2' and the caster about 22'. Right wheel Positive Negative Note If the cam cannot be turned far enough to make the adjustment, begin again at adjustment of the caster using the other cam. i 3. Tighten the nuts. I Caster I Front cam 1 Rear cam I Front cam I Rear cam Tightening torque: 94--112 N.m (9.5-11.5 kgf.m, 69-43 ftlbf) clockwise Counter- Clockwise 4. Adjust the toe-in. Toe-in 1. Remove the steering gear boot clamp. 2. Loosen the left and right tie rod locknuts, and turn the tie rods by the same amount. 3. Loosen the left and right tie rod locknuts and turn the tie rods equally. Both tie rods are right threaded, so turning the right tie rod toward the front of the vehicle and the left toward the rear increases toe-in. Clockwise Counter- clockwise Note Turning both tie rods one complete turn changes toe-in by about 7 mm (0.28 in}. 4. Tighten the tie rod locknuts to the specified torque. Clockwise Counter- clockwise Tightening torque: 35-39 N.m (3.5--4.0 kgf.m, 26--28 ft4bf) Counter- clOCkWise Clockwise 5. Verify that the boot is not twisted, and install the boot - clamp. Gartner Banana

WHEEL ALIGNMENT REAR WHEEL ALIGNMENT Specifications (Unladed*) I Item I Specifications I L *' Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. 05Uo~x-01~ *2 Difference between the leff and right must be exeed lo. 3 + 3 i0.12 * 0.12) 0'18' k18' 0'09' 2 09' -1 "08' +. 30' Total toe-in Total toe-in (per side) Camber angle'' LEFT WHEEL - mm {in) degree degree INCREASE I 1 346-355 (1 3.6-1 4.0) Height from center of wheel to fender brim'2 mm Iin) RIGHT WHEEL C INCREASE 356-3135 {14.0-14.4) 366-375 {I 4.4--14.8) 376-385 {I 4.8-1 5.2) 386--395 {I 5.2-1 5.6) LEFT WHEEL -C -0°54' r 30' -0'43' 2 30' -0°35' r 30' -0'30' +. 30' Toe-in Toe-in is adjusted by turning the front and/or rear adjust- ing cam bolts at the lower arm. Caution Adjust the toe-in before adjusting the camber. 1. Loosen the front and/or rear cam nuts. 2. Turn the front and/or rear adjusting cam bolts to provide the correct toe-in. I Counter- Counter- Decrease Clockwise Clockwise clockwise clockwise Toe-in Note Turning the front cam one graduation changes the toe-in about 2.8mm (0.11 in} and the camber about 15'. Turning the rear cam one graduation changes the toe-in about 2.8mm I0.11 in} and the camber about 6'. 3. 'Adjust the camber. Left wheel Camber Camber is adjusted by turning the front and rear cams at the lower arm. Right wheel Caution Adjust the camber after adjusting the toe-in. Front cam I Rear cam I Front cam I Rear cam 1. Loosen the front and rear cam nuts. 2. Turn the front and rear adjusting cam bolts the same amount in the opposite direction to provide the correct camber angle. Gartner Banana

WHEEL ALIGNMENT RIGHT WHEEL C I I I I Counter- I Counter- I Clockwise I Clockwise I clockwise I 4 Positive clockwise Left wheel Right wheel Note Turning the front cam one graduation changes the camber about 15' and the toe-in about 2.8mm (0.11 in}. Turning the rear cam one graduation changes the camber about 6' and the toe-in about 2.8mm I0.11 in). If the cam cannot be turned far enough to make the adjustment, begin again at adjustment of the toe in using the other cam. Negative 3. Tighten the nuts. Caster Tightening torque: 73-95 Nm (7.4--9.7 kgf.m, 54--70 ft4bf) Front cam I Rear cam I Front cam I Rear cam Counter- clockwise Counter- clockwise Clockwise 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 INDEX 1. Hood Removal I lnstallation . . . . . . . page S- 5 2. Door Removal I lnstallation . . . . . . . page S- 7 Adjustment . . . . . . . . . . . . . . . . page S- 8 3. Window regulator, glass, and guide Removal I lnstallation . . . . . . . page S- 9 Adjustment . . . . . . . . . . . . . . . . page S-10 4. Door lock and opener Removal I lnstallation . . . . . . . page S-15 5. Front bumper Removal I lnstallation . . . . . . . page S-24 6. Molding and garnish Removal I lnstallation . . . . . . . page S-27 7. Outside mirror Structural view . . . . . . . . . . . . . page S-30 Troubleshooting . . . . . . . . . . . . page S-31 lnspection . . . . . . . . . . . . . . . . . page S-33 Removal 1 lnstallation . . . . . . . page S-34 8. Windshield wiper and washer Troubleshooting . . . . . . . . . . . . page $35 Inspection . . . . . . . . . . . . . . . . . page S-38 Removal / lnstallation . . . . . . . page S-39 Disassembly 1 Assembly . . . . page S-43 Adjustment . . . . . . . . . . . . . . . . page S-42 -- 9. Windshield Removal / lnstallation . . . . . . . page S-44 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

HOOD s HOOD COMPONENTS Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 1. Headlight seal 5. Hinge 2. Side headlight seal 6. Hood stay 3. Washer pipe 7. Hood lock 4. Hood Adjustment .................. page S-6 Adjustment .................. page S-6 8. Release wire Gartner Banana

HOOD SEC. 6-6 mm (in) 05UOSX-159 Adjustment Hood Adjust the hood laterally and vertically by loosening the hood to-hinge mounting bolts and repositioning the hood. Hood lock Adjust the hood lock after the hood has been aligned. Loosen the hood lock mounting bolts and nut, and align the lock with the striker on the hood. Gartner Banana