service MAZDA MX-5 1994 Service Manual

ANTILOCK BRAKE SYSTEM (ABS) P HYDRAULIC UNIT Removal 1 lnstallation 1. Disconnect the negative battery cable. - 2. Remove in the order shown in the figure, referring to Removal Note. 3. The only serviceable parts of the hydraulic unit are the valve relay and the motor relay. If there is a failure of any other part, replace the hydraulic unit assembly. 4. Install in the reverse order of removal, referring to Installation Note. 5. Add brake fluid, bleed the air, and check for fluid leakage. 1. Connectors 3. Nut bolts 2. Brake pipes 4. Hydraulic unit Removal / lnstallation Note . . . . page P-55 Gartner Banana

Before beginning any service procedure. refer to section T of this manual for I air bag system service warnings and audio antitheft system alarm conditions . INDEX ....................................... R- 2 OUTLINE ..................................... R- 4 SPECIFICATIONS ........................... R- 4 TROUBLESHOOTING GUIDE .................. R- 5 WHEEL ALIGNMENT .......................... R- 6 PRE-INSPECTION .......................... R- 6 FRONT WHEEL ALIGNMENT ................. R- 6 .................. REAR WHEEL ALIGNMENT R- 9 FRONT SUSPENSION (DOUBLE-WISHBONE) ... R-11 PREPARATION ............................. R-11 SHOCK ABSORBER AND SPRING ............ R-11 LOWER ARM ............................... R-15 UPPER ARM ............................... R-17 STABILIZER ................................ R-19 CROSSMEMBER ........................... R-20 REAR SUSPENSION (DOUBLE-WISHBONE) .... R-21 PREPARATION ............................. R-21 SHOCK ABSORBER AND SPRING ............ R-22 LOWER ARM ............................... R-23 UPPER ARM ............................... R-24 STABILIZER ................................ R-25 CROSSMEMBER ........................... R-26 25UORX-001 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

s MOLDING AND GARNISH Removal Note Front beltline molding Remove the outside mirror to remove the front beltline molding. (Refer to page S-34.) i/ Rear finisher Remove the rear combination light to remove the rear finisher. (Refer to Section T.) PRIMER 45UOSX42C I MOLDING I MOLDING Beltline molding Remove the convertible top to remove the beltline mold- ing. (Refer to page S-67.) Installation Note Windshield molding 1. Remove the windshield. (Refer to page S-44.) 2. Install the windshield. (Refer to page S-44.) 3. Apply primer with a brush to the bonding area of the new upper molding. Keep the bonding area free of dirt and -- grease, and do not touch the surface. Allow the primer to dry for approximately 30 minutes. 4. Align the center mark in the molding with the glass mark (0) 5. Install the upper portions of the molding into the body (Q) . 6. Push the corner of the molding into the body ((3). 7. Push the side portions of the molding into the body, beginning from the bottom (@). 8. Check for water leaks. If a leak is found, wipe the water off well and repeat the installation. Hardening time of repair sealant Time required until car Temperature Surface hardening time ,, be put into service 5°C (41 OF) Aoorox. 1.5 hr 12 hr I 35°C {95"F} I Approx. 10 rnin 2 hr 1 Gartner Banana

MOLDING AND GARNISH s F PRIMER I 35UOSX-021 MOLDING & GLASS I Rear window molding (detachable hardtop) 1. Remove the rear window glass. (Refer to page S-52.) 2. Install the rear window glass. (Refer to page S-52.) 3. Apply primer with a brush to the bonding area of the new rear window molding. Keep the area free of dirt and grease, and do not touch the surface. Allow the primer to dry for approximately 30 minutes. JOINT MOLDING I 4. Install the rear window molding to the glass, as shown. Temperature 5°C (41 OF) 20°C (68OF1 5. If the molding is too long, cut the excess molding 10mm (0.39 in) inside the joint molding edge. Hardening time of repair sealant Surface hardening time Approx. 1.5 hr ADD~OX. 1 hr Time required until car can be put into service 12 hr 4 hr . . . . I 35°C {95"F} I Approx. 10 min 2 hr 6. Check for water leaks. If a leak is found, wipe the water off well and repeat the installation. 45uosx-029 Gartner Banana

WINDSHIELD CENTER I SPACER mrn (in) 46UOSX-05( I REPAIR SEALANT mrn {i~ GLASS SEC. A-A % rnrn {in) 45UOSX-052 I V NOTCH GLASS MARK a 4. Securely bond a new dam along the circumference of the glass 7 mm i0.28 in) from the edge. Allow it to dry completely. - 5. Install the spacers onto the body as shown. If a spacer is damaged, replace it. 6. 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 (BOO1 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 I0.43 in} high. Keep the bead of sealant smooth and even, reshaping it where necessary with a spatula. 7. If a protector is damaged, securely bond a new protector onto the body as shown. Allow it to dry completely. 8. Install the glass, aligning the glass mark with the V notch in the spacer. Push it in lightly toward the vehicle to corn- press the sealant. 9. To prevent the glass from being pushed out by air pres- sure if a door is closed, open all of the windows until the repair sealant has hardened. Hardening time of repair sealant I Temperature I Surface hardening time ( Time required until car can be PU~ into service I I I 5°C (41 OF) I Approx. 1.5 hr I 12 hr 20°C (68°F) 35°C (95°F) Approx. 1 hr Approx. 10 min 4 hr 2 hr Gartner Banana

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

DASHBOARD AND CONSOLE DASHBOARD AND CONSOLE COMPONENTS Removal l Installation 1. Disconnect the negative battery cable. Warning Handling the air bag module improperly can accidently deploy the air bag, which may seri- ously injure you. Read SERVICE WARNINGS, section T, before handling the air bag module. 2. Remove in the order shown in the figure, referring to Removal Note. To remove the dashboard, remove the control wires of the heater unit and blower unit. 3. Install in the reverse order of removal. 1. Ashtray 2. Change lever knob 3. Rear console assembly a. Back plate b. Shift lever boot 7. Speedometer cable 8. Instrument cluster 9. Center louver Removal Note ............. page S-57 10. Center an el assemblv c. Power window switch Removal Note ............. page S-58 d. Cover (Without power window) 1 1. Glove box assembly e. Console lock assembly 12. Passenger-side airbag module (if equipped) 4. Center lower panel assembly Removal 1 Installation ......... section T Removal Note ............. page S-57 13. Hood release knob -1 5. Steering shaft 14. Center hole cover 6. Meter hood assembly 15. Side cover Removal Note ............. page $57 16. Dashboard Gartner Banana

BODY ELECTRICAL SYSTEM ................................... INDEX T- 2 ........................... SWITCHES T- 2 FUSES AND RELAYS .................. T- 3 .............................. LIGHTS T- 4 CRUISE CONTROL SYSTEM ........... T- 5 ...................... AUDIO SYSTEM T- 6 SRS AIR BAG SYSTEM ................ T- 7 ............................... OUTLINE T- 8 TROUBLESHOOTING GUIDE ........... T- 8 ELECTRICAL SYMBOLS ............... T- 9 ................................... FUSE T- 10 STRUCTURAL VIEW ................... T- 10 ...................... SPECIFICATIONS T- 11 ........................ DESCRIPTION T- 12 ....................... REPLACEMENT T- 12 ....................... RELAY .. ....... T- 13 STRUCTURAL VIEW ................... T- 13 ........................ DESCRIPTION T- 13 RETRACTABLE HEADLIGHT RELAY .... T- 14 ....................... FLASHER UNIT T- 14 ........................... TNS RELAY T- 15 .......................... HORN RELAY T- 15 COOLANT FAN RELAY ................. T- 15 REAR WINDOW DEFROSTER RELAY ... T- 16 HEADLIGHT RELAY ................... T- 16 ................................ SWITCH T- 17 ................... STRUCTURAL VIEW T- 17 ........................ DESCRIPTION T- 17 .................... IGNITION SWITCH T- 18 COMBINATION SWITCH ............... T- 19 RETRACTOR SWITCH AND HAZARD WARNING ............................. SWITCH T- 21 ................. INSTRUMENT CLUSTER T- 22 ................... STRUCTURAL VIEW T- 22 ........................ DESCRIPTION T- 22 .................... CIRCUIT DIAGRAM T- 23 ................. TROUBLESHOOTING T- 24 ............ REMOVAL / INSTALLATION T- 29 ........... DISASSEMBLY 1 ASSEMBLY T- 29 ...................... SPEEDOMETER T- 30 ........................ TACHOMETER T- 30 WATER TEMPERATURE GAUGE ....... T- 30 ......................... FUEL GAUGE T- 31 OIL PRESSURE GAUGE ............... T- 31 .................... PRINTED CIRCUIT T- 32 VEHICLE SPEED SENSOR ............. T- 32 WATER TEMPERATURE SENDER UNlT . T- 32 FUEL GAUGE SENDER UNlT ...................... (IN FUEL TANK) T- 32 OIL PRESSURE SENSOR .............. T- 33 ............... SPEEDOMETER CABLE T- 33 WARNING LIGHT AND SENDER UNIT ..... T- 34 ................... STRUCTURAL VIEW T- 34 CIRCUIT DIAGRAM .................... T- 35 ................. TROUBLESHOOTING T- 36 BRAKE FLUID LEVEL SENSOR ......... T- 39 PARKING BRAKE SWITCH ............. T- 39 ..................... BUCKLE SWITCH T- 39 ...................... LIGHTING SYSTEM T- 40 ................... STRUCTURAL VIEW T- 40 ......................... HEADLIGHTS T- 41 ......................... STOPLIGHTS T- 53 TURN AND HAZARD WARNING LIGHTS . T- 57 ..................... BACK-UP LIGHTS T- 66 TAILLIGHTS. SIDE MARKER LIGHTS. PARKING LIGHTS AND LICENSE PLATE LIGHTS . T- 69 DAYTIME RUNNING LIGHTS (DRL) .................... (CANADA SPEC.) T- 72 ........... REAR COMBINATION LIGHT T- 76 .................... INTERIOR LIGHTS T- 78 ................ ILLUMINATION LIGHTS T- 82 .................................. HORN T- 84 ................... STRUCTURAL VIEW T- 84 .................... CIRCUIT DIAGRAM T- 85 ................. TROUBLESHOOTING T- 86 ............ REMOVAL 1 INSTALLATION T- 87 ............ REAR WINDOW DEFROSTER T- 89 ................... STRUCTURAL VIEW T- 89 ........................ DESCRIPTION T- 89 ................. TROUBLESHOOTING T- 90 ................ REPAIRING FILAMENT T- 93 ............. CRUISE CONTROL SYSTEM T- 94 ................... STRUCTURAL VIEW T- 94 .................... CIRCUIT DIAGRAM T- 95 ................. TROUBLESHOOTING T- 96 ....... SELF-DIAGNOSTIC INSPECTION T-100 ............... CRUISE CONTROL UNIT T-103 .................... ACTUATOR CABLE T-104 ..................... CLUTCH SWITCH T-105 .......... STOP LIGHTIBRAKE SWITCH T-105 ...... CRUISE CONTROL MAIN SWITCH T-106 ........... CRUISE CONTROL SWITCH T-106 ............. VEHICLE SPEED SENSOR T-106 ........................... ACTUATOR T-107 a .................................. AUDIO T-108 ................... STRUCTURAL VIEW T-108 ................... SYSTEM DIAGRAM T-109 ............................ FEATURES T-110 FUNCTION AND OPERATING ......................... PROCEDURE 1-111 ............. OPERATION DESCRIPTION T-113 .................. ANTITHEFT SYSTEM T-120 ................. TROUBLESHOOTING T-122 ............ REMOVAL I INSTALLATION T-145 .................... POWER ANTENNA T-149 ......................... INSPECTION T-153 CONNECTOR TERMINAL .................... SPECIFICATIONS T-154 SRS AIR BAG SYSTEM .................. T-156 PREPARATION ........................ T-156 ................... STRUCTURAL VIEW T-156 .......... COMPONENT DESCRIPTION T-157 SYSTEM DIAGRAM ................... T-158 ................. SERVICE WARNINGS T-159 GENERAL PROCEDURES ............. T-160 TROUBLESHOOTING ................. T-160 DRIVER-SIDE AIR BAG MODULE ....... T-206 PASSENGER-SIDE AIR BAG MODULE . . T-207 DIAGNOSTIC MODULE ................ T-208 CLOCK SPRING ....................... T-209 CRASH SENSOR (D-SENSOR) ......... T-210 CRASH SENSOR (S-SENSOR) ......... T-213 AIR BAG MODULE DISPOSAL . .. PROCEDURE ........................ T-215 INSPECTION OF SST (DEPLOYMENT TOOL) ............... T-217 Gartner Banana

INDEX T PARWNEUTRAL SWITCH SERVICE, SECTION K 1. Cruise control unit ...... Removal / Installation page T-103 ................ Inspection page T-103 2. Cruise actuator ................ Inspection page T-107 Removal / Installation ...... page T-107 3. Actuator cable ...... Removal / Installation page T-104 ............... Adjustment page T-104 4. Clutch switch ...... Removal / Installation page T-105 ............... Adjustment page T-105 5. Stoplight switch ...... Removal / Installation page T-105 ............... Adjustment page T-105 6. Cruise control main switch ................ Inspection page T-106 7. Cruise control switch ................ Inspection page T-106 Gartner Banana