radiator MAZDA MX-5 1994 Owner's Manual

ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION L" SST r I I 16EOF2-012 BASIC INSPECTION Engine Oil 1. Remove the dipstick and check the engine oil level and condition. 2. Add or change oil as necessary. 49 B019 9AO System Selector Coolant (engine cold) For inspection of ignition timing and idle speed Warning Removing the radiator cap or the coolant drain plug while the engine is running, or when the en- gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause seri- ous injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when remov- ing the cap. Wrap a thick cloth around it and slow- ly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press down on the cap-still using a cloth-turn it, and remove it. 1. Verify that the coolant level is near the radiator filler neck. 2. Verify that the coolant level on the coolant dipstick is be- tween the F and L marks. 3. Add coolant if necessary. Battery Removing the label on the top of the battery or removing the vent caps will void the battery's warranty. 1. Clean any corrosion on the clamps or battery posts. 2. Verify that the battery top is clean. If necessary, clean with baking soda and water. 3. Verify that cables are in good condition and not frayed or corroded. Repair or replace if necessary. 4. Verify that cable clamps are tight. Note Because this is a maintenance free battery, it is not necessary to check the fluid level. Gartner Banana

OIL COOLER K OIL COOLER REMOVAL / INSPECTION / INSTALLATION 1. Remove in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to lnstallation Note. 45UOKX-57 1. Connector bolts 4. Oil pipe Inspect for clogging ins~ect for damaae or cracks -- - - 2. Packing installation Note ................ below 3. Transmission 5. Oil hose Removal ................. page K- 45 Inspect for damage or cracks Installation ............... page K-148 6. Radiator I UP SIDE DOWN SlDE lnstallation Note Oil pipe 1. Align the marks, and slide the oil cooler hose onto the oil cooler pipe until it contacts the ridge. 2. Install the hose clamp onto the hose at the center of the mark and at the angle shown. If reusing the hose, posi- tion the new hose clamp in the mark left by the previous hose clamp. 3. Verify that the hose clamp does not interfere with any other parts. 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

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

TECHNICAL DATA D. LUBRICATION SYSTEM - Engine ltem BP DOHC - -. Lubrication system Force-fed type E. COOLING SYSTEM Trochoid gear 344-41 I3.5--4.5,s-31 9&l96 {I .&2.0, 15--28) 295-392 {3.0-4.0,43-56) 0.02-0.1 8 {0.000&0.0070) 0.20 {0.0079) 0.09-0.18 (0.0036-0.0070) 0.20 {0.0079) 0.03-0.1 2 {0.0012-0.0047) 0.14 (0.0055) TY pe Relief pressure kPa {kgf/cm2, psi) Oil pressure kPa {kgf/cm2, psi) Inner rotor tooth tip to outer rotor clearance mm {in) Outer rotor to body clearance mm {in) Side clearance mm {in) Water seal type I Unified mechanical seal Thermostat 1,000 rpm 3,000 rpm Standard Maximum Standard Maximum Standard Maximum Oil filter Engine ltem - - Cooling system . . Impeller diameter mm {in) Number of impeller blades Type Relief pressure differential kPa {kgf/cm2, psi) BP DOHC Water-cooled, forced circulation - 75 i2.95) 6 Full-flow, paper element 74-1 17 {0.&1.2, 12-1 7) TY pe . ., . . . - Radiator I Water pump Wax, two-stage v. . . Full-open temperature "c {OF) Full-open lift mm {in) Engine oil TVD~ O~enina tem~erature "C con I Sub: 83.5-86.5 U83-187). Main: 86.5-89.5 (1 88-1 931 100 (21 2) Sub: 1.5 (0.06) min., Main: 8.0 (0.31) min. -. . - . . Cooling circuit checking pressure kPa {kgflcmz, psi) I 103 {I .05, 14.9) I Centrifugal, V-ribbed belt driven TY pe I Coolant fan I 4.0 (4.2, 3.5) 3.6 {3.8,3.2) 3.75 (4.0, 3.3) API Service SG, SH (ECII) ILSAC Capacity Corrugated fin viscosity Above -25°C (-1 3°F) SAE 1 OW-30 number Below 0°C {3Z°F) SAE 5W-30 Total (dry engine) L {US qt, Imp qt) Oil replacement L {US qt, Imp qt) Oil and oil filter replacement L {US qt, Imp qtl Cap valve o~enina pressure kPa {krrf/cm2, psi} 1 73.6--102 {0.75--1.05, 10.7-14.91 Capacity W-V I 120-1 2 Current A 1 below 7.7 Engine oil Type Number of blades Outer diameter mm {in) Coolant Capacity L {US qt, Imp qt) I 6.0 {6.3,5.3) Electric 5 320 (1 2.61 Gartner Banana

TECHNICAL DATA R. SUSPENSION Front sus~ension I i/ Differential - . - ~- Coil springs MT I AT Shock absorbers "TORSEN" LSD TY ~a Cylindrical double-acting, low-pressure gas charged Standard Stabilizer Double-wishbone Torsion bar Wire diameter mm {in) Coil inner diameter mm {in} Rear suspension Tv~e I Double-wishbone TY pe Diameter mm {in) 20.0 (0.79) I Identification color 11 .O {0.43} 83.0 f3.27) . . Free length mm {in) Coil number 19.0 {0.75} . . 292.5 (1 1.52) 1 302.0 {I 1.89) 6.32 I - . I1 . ,I . , I Shock absorbers Cylindrical double-acting, low-pressure gas charged White I I Identification color I Yellow I Green I Blue Torsion bar 12.0 (0.471 1 11 .O 10.43) .a Stabilizer TYPe Diameter mm {in) Coil springs Wheel alignment I Front wheel alignment (Unladen'') I I - Caster angle*3 King pin angle I tun'aoen 'I 1 Camber angle'2 -0°43' 2 30' I I - Wire diameter mm {in) Coil inner diameter mm {in) Free length mm {in} Coil number Maximum steering angle 4O26' -c 45' 11 "20' Rear wheel alignment ,, l-l_A_-*i, *1 Fuel tank full; radiator coolant and engine oil at specified level, and spare tire, jack, and tools in designated position. *2 Difference between left and right must not exceed lo. *3 Difference between left and right must not exceed 1'30'. 10.1 (0.40) Inner Outer 10.2 I0.40) mm (in) Camber ana~e*~ J 3 + 3 10.12 r 0.12) 0°18' 2 18' -. - 3 r 3 {0.12 2 0.12) 0'24' 2 45' 37O23' 2 2" 32O32' 2 2" Total toe-in 83.0 i3.27) U' mm {in} degree 348.5 113.72) Total toe-in 356.5 {I 4.04) dearee 7.68 0'18' & 18' 7.96 Gartner Banana

SPECIAL TOOLS ST ENGINE TOOL NUMBER & DESCRIPTION 'OOL NUMBER & DESCRIPTION PRIORITY ILLUSTRATION PRIORITY ILLUSTRATION - 19 01 07 680A Engine stand 49 EOll IAO Brake set, ring gear Lock tool, crankshaft Hanger set, engine stand Arm, valve spring lifter Remover & installer, valve guide 49 801 2 0A2 Pivot Remover & installer, piston pin Adapter set, radiator cap tester Remover, valve seal Oil pressure gauge V-ribbed belt tension gauge 49 LO1 2 OAO Installer set, valve seal & valve guide 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

CONSTRUCTION No. 0 Part Name Bumper bracket Hood (Bonnet) 1 8 / Front frame, upper rear Crossmember No. 1 Shroud panel assy Radiator bracket No. @ Dash side junction I @ / Front frame, rear Part Name Crossmember No. 2 @ @I @ Light lid Dash panel assy Seat bracket No. 3 gusset Front frame, upper front Dash panel assy I @ / Stabilizer bracket @ @I Cowl panel, front Instrument bracket Apron reinforcement Front wheel apron assy I @ I Front wheel apron panel Q Tie-down hook reinforcement Front floor side pan Tunnel side junction Front frame @ @ Front fender panel Torque box Gartner Banana