engine MAZDA MX-5 1994 Workshop Manual

P ANTILOCK BRAKE SYSTEM (ABS) Troubleshooting procedure 2. ALTEnuAtOR TEST START mtmE (ALTWJATOR TESTED BY RWNa ENQlNE) 3. A88 SYSTEM TEST TURN IGNITION K€Y ON (00 NOT ROES EWWE) - - 1. LOCATE ABS CONTROL UNIT. 2. DISCONNECT CONTROL UNlT HARNESS CONNECTOR FROM CONTROL UNIT. 3. CONNECT ABS TESTER HARNESS TO CONTROL UNlT HARNESS CON- NECTOR. 4. TURN IGNITION KEY TO ON POSITION. TESTER WlLL RAPIDLY DISPLAY SEVERAL MESSAGES DURING AN INITIAL SEGMENT CHECK I THEN 1 I MAZDA ABS 2 TEST 1 4 I YES ENG RUN? NO 1 I MAZDA ALT TEST I CHK ALTERNATOR NO FAULT DETECTED t I TURN OFF ENGINE I TESTER WlLL RAPIDLY DISPLAY SEVERAL MESSAGES DURING AN INITIAL SEGMENT CHECK. I THEN t 1 YES ENG RUN? NO t 1 MAZDA ABS 2 TEST I Gartner Banana

Q OUTLINE, TROUBLESHOOTING GUIDE OUTLINE Wheels SPECIFICATIONS Tires -2 TROUBLESHOOTING GUIDE Temporary spare 14x4T - - TY Pe Item Size Offset mm {in) Pitch circle diameter mm {in) Material Size Air pressure kPa {kgf/cm2, psi} Standard 14x5 112-JJ 45 11.77) 1 00 (3.94) Aluminum Alloy 185160R14 82H 177 {I .8, 26) Page Excessive or irregu- tar tire wear Premature tire wear Tire squeal body vibration I Unbalanced wheel@) 1 Adjust I Q-5 Steel T1 l5/7ODl4 41 2 {4.2,60) Action Problem 1 Tre deterioration 1 Replace I - I Deformed wheel(s) or tire(s) I Repair or replace I - Possible Cause Refer to page Q-4 for details. Road noise or I Insufficient tire pressure [ Adjust Incorrect tire pressure ( Adjust Incorrect tire pressure 1 Adjust Q-3 Q-3 0-3 Shake [Steering wheel "Ibrates Excessive tire and wheel runout Loose lug nuts Unbalanced wheel(s) Insufficient tire pressure Unevenly worn tires Malfunction of shock absorber Loose shock absorber mounting bolts Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Shimmy (Steering wheel vibrates lefiIright) Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Irregular tire wear Excessive tire and wheel runout Loose lug nuts Unbalanced wheel(s) - Q4 Q-5 Q-3 - section R section R section R section R Cracked or worn engine mount Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint I Damaged or worn front wheel bearing ( Replace ( section M Replace Replace Tighten Adjust or replace I Improperly adjusted front wheel alignment 1 Adjust I section R Uneven (one-sided) I Unequal tire pressures 1 Adjust 1 Q-3 - - Q-4 Q-5 Replace Replace Tighten Replace section B section N section N section N braking Steering wheel I Incorrect tire pressure 1 Adjust doesn't return properly or pulls to either left or right . General driving Instability Excessive steering (2-3 wheel play Irregular tire wear (lefthight) Unequal tire pressures Different types or brands of tires mixed (leftlright) Loose lug nuts Unequal tire pressures Damaged or unbalanced wheel(s) Loose lug nuts Loose lug nuts I 15UOQX-00 Replace Adjust Replace Tighten Adjust Replace or adjust Tighten Tighten - Q-3 - Q-4 Q-3 Q-5 Q-4 Q-4 Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS Front Suspension - Transmission item (Stabilizer Specifications MT I AT - I Susoension tvoe I . , . , I . , Shock absorber Cylindrical double acting, low-pressure-gas charged I Double-wishbone TY pe Torsion bar Coil spring I - Diameter mm linl I 20.0 10.79) Identification mark color 19.0 (0.75) White Wire diameter mm (in) Coil inner diameter mm {in) I Blue Free length mm {in) Coil number 11 .O (0.43) 83 i3.27) 11 .O (0.43) 83 (3.27) 292.5 (1 1 32) 6.32 3 +. 3 (0.12 + 0.12) 0°18' + 18' Total toe-in I - I 35UORX-001 Rear Suspension 302.0 (1 1.89) 6.32 mm {in) degree Total toe-in (per side) 1 degree Front wheel alignment (Unladedt1) 0°09' +. 09' Caster anglee3 4"26' +. 45' Kingpin angle 11 "20' Maximum steering angle Transmission Specifications MT I AT Item Differential - Suspension type Inner Outer "TORSEN" LSD 1 Standard Double-wishbone Coil springs 370 23' a 2" 32" 32' -t 2" Camber anglee2 Torsion bar 12.0 (0.47) 1 11.0 (0.43) 1 11 .O (0.43) Cylindrical double acting, low-pressure-gas charged - Stabilizer Identification mark color Wire diameter mm {in) 0°24' + 45' Type Diameter mm {in) I Coil number I 7.68 I 7.96 I Shock absorber Yellow 10.1 {0.40} Coil inner diameter mm {in) Free length mm {in) Green 10.2 {0.40) 35UORX-002 *I Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. '2 Difference between left and right must not exceed I O. '3 Difference between left and right must not exceed 1'30'. "TORSEN" is a registered trademark of ZEXEL-GLEASON USA.INC 83 I3.27) 348.5 j13.72) Rear wheel alignment (Unladed*') 83 (3.27) 356.5 (1 4.04) Total toe-in Total toe-in (per side) mm (in) degree degree 3 -c 3 (0.12 + 0.121 0°18' + 18' 0°09' + 09' Camber angle*2 -0°43' 2 30' Gartner Banana

TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Problem General instabllity Body "rolls" "Heavy" steering wheel operation Steering wheel pulls to one side Excessive steering wheel play Body leans Abnormal noise from suspension system Shake (Steering wheel tibrates upldown) Shimmy (Steering wheel vibrates leftlright) Possible cause Weak coil spring Malfunction of shock absorber Worn or damaged stabilizer and/or suspension arm bushings Worn or damaged upper or lower arm ball joint Improperly adjusted wheel alignment Weak stabilizer Worn or damaged stabilizer and/or suspension arm bushings Insufficiently lubricated or stuck upper arm lower arm ball joint lmproperly adjusted wheel alignment Weak coil spring Worn or damaged stabilizer and/or suspension arm bushings Deformed upper or lower arm or knuckle Loose upper or lower arm bushing Worn or damaged upper or lower arm bushing Worn or damaged upper or lower arm ball joint Weak coil spring Weak stabilizer andlor suspension arm bushings Loose mounting component Poorly lubricated or worn upper or lower arm ball joint Malfunction of shock absorber Worn or damaged stabilizer and/or suspension arm bushings Excessive tire or wheel runout Loose lug nuts Unbalanced wheel@) Cracked or worn engine mounting rubber Cracked or worn steering gear mounting rubber Loose steering gear mounting bolts Stuck or damaged steering ball joint Excessive tire or wheel runout Loose lug nuts Unbalanced wheel(s) Insufficient tire pressure Unevenly worn tires Malfunction of shock absorber Loose shock absorber mounting bolts Stuck or damaged upper or lower arm ball joint Cracked or worn suspension bushings Damaged or worn front wheel bearing lmproperly adjusted front wheel alignment Action Replace Replace Replace Replace Adjust Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace Replace Replace Tighten Replace Replace Replace Replace Tighten Adjust or replace Replace Replace Tighten Replace Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Replace Adjust Page R-13 R-12,22 R-16, 18, 19, 23,24,25 section M R-15,17 R- 6 R-19,25 R-16, 18,19, 23, 24,25 section M R-15,17 R- 6 R-13 R-16, 18,19, 23, 24,25 R-15,17 section M R-16,18 R-16,18 R-15,17 R-13 R-16, 18, 19, 23,24,25 section M 7 R-15,17 R-l2,22 R-16, 18,19, 23,24,25 section M - section Q section Q section B section N section N section N - section Q section Q section Q section Q R-l2,22 R-12,22 R-15, 17 R-16,18,19 section M R- 6 15UORX-00 Gartner Banana

WHEEL ALIGNMENT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Specifications (Unladed*l) PRE-INSPECTION 1. Check the tire inflations, and adjust to the recommended d pressure if necessary. 2. lnspect the front wheel bearing play and correct if neces- sary. 3. lnspect the wheel and tire runouts. 4. Inspect the ball joints and steering linkage for excessive looseness. 5. The vehicle must be on level ground and carry no lug- gage or passengers. 6. Measure the height from the center of the wheel to the fender brim. The difference between left and right mea- surement must not exceed 10mm (0.39 in), and the rear measurement must be larger then the front measure- ment by 10-30mm (0.4--1.1 in). Caution The proper caster and camber angle vary depend- ing on the vehicle height. Refer to the following and to page R-9 for the specifications. Inspection and adjustment of wheel alignment must be done with the vehicle unladed*'. . . I Y -- t~otal toe-in l~er side) I 1 dearee 0'09' + 09' I Total toe-in 3 2 3 I0.12 2 0.12) 0'1 8' 2 18' mm (in) dearee Maximum steering angle U - Inner Outer 11 '20' -0°20' 2 45' 0'03' ? 45' 0'24' 2 45' 0°44' -+ 45' 1'02' -+ 45' 5'1 6' ? 45' 5O02' -+ 45' 4O49' 2 45' 4'35' -+ 45' 4'21 ' -+ 45' I Kingpin angle 37"23' -+ 2" 32O32' 2 2" '1 Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. OSUORX-009 ** Difference between left and right must not exceed lo. '3 Difference between left and right must not exeed 1'30'. 328-337 {I 2.9-1 3.3) 338-347 {I 3.3-1 3.7) 340-357 I13.7-14.1) 358-367 {I 4.1-14.4) 36&377 {I 4.4--14.8) 328-337 {I 2.9--13.3) 338-347 {I 3.3-1 3.7) 348-357 113.7-14.1) 358-367 {I 4.1-14.4) 368-377 {I 4.4--14.8) Camber angleg2 Caster angle*3 Height from center Of wheel to fender brim mm {in) Height from center Of wheel to fender brim mm (in) 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

FRONT SUSPENSION (DOUBLE-WISHBONE) CROSSMEMBER Removal I Inspection 1 lnstallation Note 4 Use a container or rags to collect the power steering fluid when disconnecting the power steering pipes. 1. Jack up the vehicle. 2. Remove the wheels and the undercover. 3. Support the engine with a hoist. 4. Lower the crossmember and other suspension parts as an assembly, and then separate the parts. 5. Remove in the order shown in the figure. 6. lnspect all parts and repair or replace as necessary. 7. Loosely tighten the stabilizer bracket, upper arm, and lower arm bolts. Tighten all other nuts and bolts to the specified torques. 8. Lower the vehicle. 9. With the vehicle unloaded, tighten the stabilizer bracket, upper arm, and lower arm bolts to the specified torques. 10. Adjust the front wheel alignment. (Refer to page R-6.) 11. Bleed the air from the brake system. (Refer to section P.) 12. Bleed the air from the Power Steering System. (Refer to section N.) Q - re-no ~L1.3--11.W, Okl-m} 94-1;2 (9.Cll.5,69--83) 1 &26 {1.&2.7,14--19) 1 S21 (1 3-- 1. Brake pipe Removal / lnstallation . . . . . . . . . Section P 2. Pinion shaft bolt Removal / lnstallation . . . . . . . . Section N 3. Power steering pipe Removal 1 lnstallation . . . . . . . . Section N 4. Shock absorber bolt 5. Stabilizer bracket bolt 6. Upper arm bolt 7. Performance rod 8. Adjusting cam bolt 9. Steering gear bracket bolt 10. Front crossmember assembly lnspect for damage Gartner Banana

FUSE SPECIFICATIONS Main Fuse Block u I Fuse Amperes Protected circuit HEAD INJ MAIN BTN 30A 30A COOLING FAN (AD FAN) 1 ABS I 60A I Antilock brake svstem I Headlight relay, Headlight switch Alternator, Diagnostic module (for air bag system) 80A 40A ST SIG RETRACTOR Fuse Box No.1 Except circuits protected in main fuse block: INJ 30A, HEAD 30A, RETRACTOR 30A TNS relay, Headlight switch 30A 20A EGI main relay, Coolant fan relay A/C relay 10A 30A Park l Neutral switch, Circuit-opening relay Retractable headlight actuator Fuse ENGINE METER (POWER WIND) Amperes 15A WIPER TAIL ROOM I 10A I PCME, Key reminder switch, Audio unit I Protected circuit EGI main relay, Coolant fan relay 15A 30A STOP HAZARD CIGAR 15A I Cigarette lighter, Audio unit 1 Instrument cluster, Turn signal switch, Timer and buzzer unit, Cruise control main switch Power window switch 20A 15A Fuse Box No.2 Blower switch, Wiper switch Taillights, Side marker lights, License plate lights, Parking lights 15A 15A Fuse Amperes Protected circuit I Stoplight switch, Horn switch, Cruise control unit Flasher unit Fuse Color Code (DEFOG) (ANTENNA) I Fuse amperes I Color code Fuse type 25UOTX-013 20A 20A I I 10A Red 1 I Rear window defroster Power antenna Plate type 15A 20A Light blue Yellow 30A 30A 80A Light green Pink Black Cartridge type Gartner Banana

T FUSE DESCRIPTION Main Fuse Block The main fuse block is located on the right side of the engine compartment and contains nine fuses and two relays. -1 Fuse Box Fuse block No.1 is located above the dead pedal of the driver side. The fuse box cover shows the speci- fied fuse locations. A circuit breaker is included in the fuse box to protect the heater blower motor circuit. Fuse block No.2 is located to the side of the battery in the trunk compartment. 45UOTX-016 REPLACEMENT Caution Determine and correct the cause of a burnt fuse before replacing it. If the fuse is replaced before doing this, it may burn again. Plate type 1. Disconnect the negative battery cable. 2. Replace the failed fuse with the fuse puller. 3. Reconnect the negative battery cable. Cartridge-type 80A fuse (Black) 1. Disconnect the negative battery cable. 2. Remove the fuse block mounting nuts, and remove the service cover. 3. Remove the fuse installation bolts, and pull out the fuse. 4. Install the new fuse and the fuse installation bolts. 5. Install the main fuse block. 6. Reconnect the negative battery cable. Gartner Banana

T INSTRUMENT CLUSTER INSTRUMENT CLUSTER STRUCTURAL VIEW 1. Speedometer 2. Tachometer 3. Water temperature gauge 4. Fuel gauge 5. Oil pressure gauge 6. Warning and indicator lights 7. Trip meter 8. Odometer DESCRIPTION Speedometer Two scales are shown on the speedometer face. The main scale for U.S. specification vehicles is MPH (0-140 MPH); the main scale for Canada specification vehicles is kmlh (0-220 kmlh). The odometer indication is the same as the main scale. Tachometer The tachometer has a RED STRIPED ZONE (6,500-7,000 rpm) that indicates momentary allowable engine speed. The engine should not be operated in the RED ZONE (7,000-8,000 rpm). Fuel Gauge 2 The fuel gauge continues to indicate the amount of fuel remaining in the fuel tank after the ignition switch has been turned OFF. Gartner Banana