ABS MAZDA MX-5 1994 Manual PDF

s WINDSHIELD WIPER AND WASHER WITH ABS 1. Washer tank cover 4. Washer tank hose 2. Front bumper and bracket 5. Washer tank Removal / Installation . . . . . . . page 5-24 6. Washer motor 3. Tank bracket Inspection . . . . . . . . . . . . . . . . . page S-38 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

u AIR CONDITIONER SERVICE WARNINGS Storing Refrigerant The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering u metal fragments and liquid refrigerant that can seri- ously injure you. Store the refrigerant at tempera- tures below 40°C (1 04°F). Handling Refrigerant Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostabite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, im- mediately wash them with clean water and consult a doctor. SERVICE CAUTIONS Compressor oil (ND-OILS) Do not spill compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off im- mediately. b PAG compressor oil (ND-OILS) has a higher mois- ture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. There- fore, install caps immediately after using the com- pressor oil or removing refrigerant system parts to prevent moisture absorption. 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

PLASTIC BODY PARTS HANDLING PRECAUTIONS 1. The repair procedure for plastic body parts must conform with the type of material. 2. Plastic body parts are identified by the codes in the following chart. 3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, weld- ing, painting, etc.), consideration must given to the property of the plastic. Code Material Name Heat Resistance * Temperature OC (OF) ABS PP P ETP Acrylonitrile Butadiene Styrene Copolymer Styrene Acrylonitrile Copolymer 80 (176) 80 (176) PVC Polypropylene Thermoplastic Elastomer Polyvinylchloride PUR 70 (158) 70 (158) 65 (149) Polyurethane EVA Foam Polyurethane Ethylene Vinyl Acetate Copolymer Polyethylene 80 (176) 40 (104) POM PMMA Polyamide Polycarbonate 100 (212) 130 (266) FRP Polyacetal Polymethyl Methacrylic Acrylate Fibrous Glass Reinforced Plastics 125 (257) 75 (167) PBT Polybutylene Telephthalate SMC Sheet Molding Compound * Temperatures higher than those listed may result in material deformation during repair Gartner Banana

t 9310 -4 U REAR I)fFFERENl'IAbS 2') i 0 RCAR 9IFFEHENTIALS (NORMAL DIFF . ( NORMAL DIFF , ) -- ----l- -- - PACER IOLT JCAWRIER ILLUST, N0,l) ILLUST. t40,2) 'LATE ,DAFF'LE-DSFF CA iINO Gartner Banana

3230 SfEERlNG CObUflN L SHAFTS 1210 1 SlEERlNO COLUMN Q SllAfTS :OVER 8 JOI lit-UPPER BASE, iW/O BOWER STEERIIIO) BOLT, StIAFt WAFT ,EN&V, ABSORBER JOINT ,STECRlNO Gartner Banana

ALPHABETICAL INDEX *** ENGLISH w** PULLE+',MAGNET CLUTCH----- PULLEY,TIMING BELT------- PULLEY, WATER PUMP-------- PUHP SET ,WATER----------- PUMP,FUEL---- -------- ---- PUMP,FUEL-SUB------------ pUMP,oIL----------------- RACE ,BRG .HUB CLUTCH------ 1 -G9 RACE.BRG.PUMP COVER------ 1-E9 RACE, INNER--------------- 1-F6 1-H9 RACE,OUTER--..------------ 1-H9 RACE ,OUTER-ONE WAY CLUTCH 1.-F9 RACE SHELL BEARING------- 1-D9 RACE ,SIDE-ONE WAY CLUTCH- 1 -F9 RACK ,STEERING GEAR-- ----- 1- J12 1-L12 RADIATOR----- ------ ------ 1-E5 RAILCL) ,RAIN-REAR-------- 2- J5 RAILCR) ,RAIN-REAR-------- 2 -H5 RAIL ,RAIN-SOFT TOP REAR-- 2-612 RECTIFIER---------------- 1-C7 REGULATOR(L1 ,WINDOW------ 2-21 U REGULATORCRI ,WINDOW------ 2-C10 2-N9 REGULATOR,VOLTAGE-------- 1 -C7 REINF. (L) ,BELT LINE-C.PIL 2-65 REINF. (L) ,FLOOR---------- 2-D6 REINF.(L) ,SIDE SILL------ 2-15 REINF. (L) STRIKER-------- 2-15 REINF.(Ll ,TIE DOWN HOOK-- 2-D5 REINF. (L ,WHEEL APRON---- 2-D5 WEINF.(R),RELT LINE-C.PIL 2-65 REINF.(R),SIDE SILL------ 2-65 REINF.(R) .STRIKER-------- 2-H5 RE~NF.(R);TIE DOWN HaOK-- 2-D5 REINF. (R) .WHEEL APRON---- 2-C5 REINF. ,FUEL TANK--------- 1-114 REfNFORCEMENT(R1--------- 2-C5 RElNFORCEMENT, BUMPER - - - - - 2-E3 2-H3 RELAY,FUEL PUMP---------- 2-Cl? RELAV,MAIN---------- ----- 2-C13 RELAY ,MOTOR-HYD. UNI' -- 1-M15 RELAY,N.O.---------- --. 2-1)1~ 2-61! RELAY ,RETRACTOR-COWL rANE 2-61? RETAINERnAn(R),WTHSTP---- 2-F12 RETAINER'B'CL1rWTHSTP---- 2-612 RETAINERIB'(R) , WTHSTP---- 2-F12 RETAINER'C'(L),WTHSTP---- 2-612 RETAItlER'Cn(R),WTHSTP---- 2-Fl2 RING--------------------- 1-J9 RING SET,PISTGN---------- 1-L3 RING(L)MOUNTING---------- 2-K3 RINO(R)MOLlNTING---------- 2-K3 RING,IOI----------------- 1 - D6 1-DB 1-EB 1-08 1-H3 1 -H4 1-K4 1 -K9 1 - L7 1 -M7 1 -N4 1-N7 2-C13 2-013 2-N12 RING,RETALNING-BALL BE4RI 1-G6 RING,RETAINING-DISC PLATE 1-Ell RING,RETAINING-SHIFT ROD- 1-J6 RING,sEAL---------------- 1-J9 1 -M7 RING,sNA~---------------- 1-C9 1 -D9 : i ! 1 11 ROD .PUSH-FRT CALIPER----- 1-611 RELAY~TRANSFER- ---------- 2-Jll ROD,REIEASE-------------- 1-C1G RELAY ,VALYE-HYU . UNIT---- 1-~151 ROD,RE1RACTABLE---------- 2-L3 RESISTOR ,BLOWER dWIT----- 2-~ll' ROD,SELkCTOR-REAR-------- 1-616 RESISTOR, INTERLOCK------- 2-G13 ROD,SHIF'T(lST&ZND)------- 1 - J6 RESISTOR ,PANEL LIGHT--- - - 2-C7 ROD,SHIFT(3RDB4THl------- 1- J6 REST ,FOOT----------- ----- 1-C151 ROD,SHIFT-OVER TOP B REVE 1-K6 1-M1(, ROLLER--- ----- --------..-- 1-614 RETC,INER--- --------- ----- I-KP I I?OOF,DETACHABLC TOP------ 2-HI2 RETAICERI L ,FRONT BUMPER- 2-E3 I 2-112 RETAINER(L),WTHSTP-D.TOP- 2-K12. ROTOR-------------------- 1-D7 RETAINERIRI ,FRONT BUMPER- 2-E3 I ROTOR,SENSOR-FRT A.B .S. -- 1-Ell RETAINER(R) ,WTHSTP-D .TOP- 2-J12, 1-FS3 RETAINER ,FRT . BUMPER- ----- 2-F3 RUCBER(C) ,CUSHION-BONNET- 2-KG RETAIHER,LOCK CYL .------- 2-N9 ! RUBBER( tWR) ,MOUNT-TANK--- 1-J14 RETA!NER,R. BLI'MPER-------- ?-ti3 i RUBBER(UP) ,MOUNT-TANK---- 1-114 RETAINER,SER\lO----------- 1-EB RUBBER,BL'ADE-FRONT-.------ 2-Hl5 1-147 1 GURBEK,CUSHION--------- -- 2-M4 RETAINLR ,SPRING- - -- - ---- - 1 -NR ' KUBBEK,CUSHION-BONNET FRT 2-K4 RETAINER'A' (L) ,WTHSTP-- - - 2-~12' RUBBER,CUSHION-BONNET RR- 2-K4 .. .-.-- . . . . . . ---A CAT . AUfiA04- 03 RUBBER, SEAL-SEAL PLATE--- 1-~3 RUBBERISTAB -FRT--------- KUBBER,STOP-------------- 1-K13 1-L14 RUBBER,STOPPER----------- 1 -C15 1-Ll4 2-C10 RUBBER,SUB FRAME MTG----- 1-K11 1-N11 RUBBERIURETHNE----------- 2-17 i-~i3 SCREW,BRACKET-WIPER MOTOR 2-J15 SCREW,CHANGE LEVER KNOB-- 1-616 SCREW,DOOR SWITCH-------- 2-113 SCREW,EARTH SET-MOTOR BRK 2-J15 SCREW,GROMHET------------ 2- J3 SCREW,HEAD LAMP BEZEL---- 2 -M3 SCREY,HOO#-REAR DECK----- 2-F12 SCREWJD.ADJUST-TH. BODY- 1-K4 SCREU,#NUCKLE------------ 2-K8 2 - L 8 SCREW,HOTOR-ELECTRIC FAN- 1-D5 SCREW,OIL PUMP COVER----- 1 -N4 SCREU,RR HEATER UNIT----- 2-El1 SCREV,SIDE GARHNISH------ 2-J3 SCREW,TAPPING------------- 2-D8 7-K7 - .- . SCREW,TAPPING-DOOR LUCK-- 2-H9 SCREW,TAPPING-MUD GUARD-- 2-C6 SCREW,TIE DOWN HOOK------ 2-Dh SCREW,TOP LOCK----------- 2-Fl2 SCREW,WEDGE-LIFT GATE---- 2-Dl0 SCREW,WINDOW REGULATOR--- 2-N9 SEAL L BOOT SET,CAL.-FKT- 1-613 SEAL & BOOT SETICALS-RR-- 1-F11 SEAL KIT----------------- 1 -El4 SEAL KIT,ST. GEAR-------- 1-~12 SEAL KIT,VANE PUMP------- 1-Cl3 SEAL,OOtRING------------- 1 -c8 1-19 1 -N8 SEAL, hUMPER--- -. ------- - -- 2-65 SEAL,COOLIHG UNIT-------- 2-Hll SEAL,CUT RING------------ SEAL,DUST---------------- 1-K7 1-11: SEAL,DUST-BALL JOINT----- 1-H13 1-K1Z SEAL, SEAL, SEAL, SEAL , SEAL , SEAL SEAL, SEAL, SEAL, SEAL, SEAT C i-015 SENSORISTEERING PRESSURE- 1-C13 SENSOR,TEflP.-ENG.COO1.ANT- 2-C13 SENSOR,THROTTLE-CARB.---- 1-K4 1-J9 SHAFT,CYL -COMPRESSOR---- 2-K11 SHAFT,DIFF. PINION------- SHAFTIDRIVE-------------- 1-111 1 -Dl 1 SHAFT,DRIVE NO.l--------- 2-H15 SHAFTIDRIVE NO.2--------- 2-H15 SHAFT,ENGY.ABSORBER------ 1-112 SHAFT,INPUT-------------- 1 -K7 SHAFT,INTERMED.----------- 1-112 SHAFT,INTERMEDIATE------- 1-69 SHAFT YAIN--------------- I I 1-E6 SHAFT,MANUAL------------- 1-K9 SHAFT, PARKING PAWL------- 1-K9 StIAFT,PINXON---- -------- 1-67 SHAFT,PROPELLER-FRT------ 1 -C11 SHAFTJPULLEY------------- 1-65 SHAFT,REV. IDLE GEAR----- 1 -ti6 SHEET(L),DECK LOCK------- 2-J12 SHEET(R1,DECK LOCK------- 2-112 SHEET,RUBBER------------- 1-C12 SHIELD,SPLASH------------ SHIMBADJUST-------------- 2-C6 1 -GS 1-K6 SHIM,ADJUST-COUNTER SHAFT 1-H6 SHIM,HINGE-DOOR---------- 2- J9 SILENCER,FLOOR----------- 2-C16 SILENCER,MAIN------------ 1-Dl4 SILL(C),SIDE-INNER------- 2-F5 SILL(FRT.L),SIDE-INNER--- 2-F5 SILL(FRT.R)lSIDE-INNER--- 2-F5 SILL(L),SIDE OUT.-------- 2-15 SILL(Ri,SIDE OUT.-------- 2-H5 SILL(RR.Ll,SIDE-INNER---- 2-F5 SILL(RR.RllSIDE-INNER---- 2-F5 SLEEVE.BEAR1NG-FRONT----- 1-E7 1-67 SLEEVE,BEARING-REAR------ 1-E7 1-67 SLEEVE,CLUTCH HUB-------- 1-L: SLEEVE,GEAR-------------- 1-F6 1-66 SLEEVE,REGULATOR PLUG---- 1-60 SLEEVE,SEAL-0.D.CARRIEK-- 1-F9 SLEEVE,SPEEDOMETER------- 1-D6 SLIDEnA',BUMPER---------- 2- E3 SLIDE'UP.',BUMPER-------- SOCKET------------------- 2-H3 2-67 SOCKET(L),RR SIDE TURN--- 2-F4 SOCKET(L),RK.COMB.------- 2-E4 SOCKETfR1,RR SIDE TURN--- 2-F4 SOCKET(K),RR.COMB.------- 2-E4 SOCKET,F. COMB. LAMP----- 2-C4 SOCKET,LICENSE LAMP------ 2-H4 SOCKET,METER SET--------- 2-67 SOCKET,SIDE TURN--------- 2-D4 2-E4 SOLENOID,LOCK UP CONTROL- 2-Dl3 SOUND CONTROLLER--------- SPACE-------------------- 2-M13 1-111 SPACER--------------------- 1-L11 1-C16 1-66 1-H6 1-14 1-J6 1- J11 1-K11 1-L14 1 -M6 1-Mll 1-M14 1 -N11 SPACER,AIR 1NT.PIPE------ 1-14 SPACERIDOWEL------------- 1-L9 SPACER,E.A,FOAM---------- 2-F3 SPACERIPLANT FRAME------- 1-C14 SPACERISTEERING GEAR----- 1-L12 SPACERISTRAP------------- 1-H:; 1-N6 SPACER,WINDOW------------ 2-Nll SPEAKER,LOUD-DOOR-------- 2-F14 SPEAKER,LOUD-FRONT------- 2-El0 ?-FIG -- SPEkKER,LOUD-REAR-------- 2-F14 SPEAKER,PILLBW-SEAT------ 2- J8 SPEEDOMETER-------------- 2-H7 SPINDLE,ADJUSTER--------- 1-Fll SPINDLEISELECT LOCK------ 1-K6 SPRING------------------- 1-El4 1-H8 1-18 1-LO 2-DB 2-K3 SPRING LIFT,LID---------- 1-Kl4 SPRING(L1,BALANCE-------- 2-N4 SPRfNG(L),LEVER---------- 1-F11 SPRXNG(W>,BALANCE-------- 2-MG SPRlNG(R),LEVEK---------- 1-F11 SPRING,ACCUM N-R--------- 1-10 SPRING,ACCUM 1-2--------- 1-JB SPRIN6,ASHTRAY----------- 2-D7 SPRING,BACK UP----------- 1 -K8 SPRINO,BALL PARK--------- 1-K9 - - ----- Gartner Banana

I ABBREVIATIONS The follov~~rig abbrev~ations are used throlrghout Mazda Microfiche parts catalog : in the illustration, tex, section numbel- index, alphabetical index. - Delmnbn Head Hamcu High. ARiuda Ccnpnator Hlph Axawe ConpnMlor Harmback blchbtcf Hel*~% Hydm Conrml Auc~mnr Tfl.118tbn t+=w Dutr )baler tibh - Hilh Ahds I #ad Inbry Cmeris llrgh.Tbn*ron Ahbrevlalur~ -- H I4ARN H.A.C. 1 ST PND ZD. ZSEAT 3D. JRD 3.SP 40. 4SPor 4SPD 41SS' 4TH 5D. I4RK SSP or 5.?PD IOTH-ANNIV. IAI . .9 A.A.S. or A.kSUSP a.s v BTHR 3UMP. BURG. 8Y.A.C.V. ICl C. or (C) CALIF. CIARU CAN. CARE- GAT C.h3 CL C.Q.R. CH CI'O :;:.dm CHI: CLP. CLNR CRTR CLU ..CM C.MEHRER CHTMR COMB. :OW. coum COMPS. CONDSR CONN. CONS. CQHT. COW 'XWR COW. CPE CPr. cw C.P.dN17 CRK CRlrjT CFsHlFT CTR CUSH. '-Y 1 PI D. or OR D. DBL CAB b. BLUE D. BRP DE MF REF0 UE S UEMlSl D any DIAI'H DIC'F. DlSCW MST DMPR DOHC Bbcd Soknod Vuhe Breather Bumpet L.H.D LH. 31M Lh'OUf L NOSE WGT. CPU P (PI PARK or PARKO PASS. P.B. P.C.V. Sypss AI~ Contml Vatve D.P. DRUWB DlTlRE or D.TIRE HB H.0 RE HCAK Center Caldornla Cold Area Canada Cbrbulenor Cslalysr Cowwn Diw Cunvenlwnal Englm (.Recpmcettnp Garol!ne Cnglno) Com!ant Qear Ram Coach Chaw0 Chamber Chcck Cwl1np Ck'awr Cbamne Lahlor Clutch ..Lbt~l~me!er (9) Cmssmo~nlrer Contalner Combrulmn Comwnwn Compresw Cornpon~rlor Candennr Conmor or C~nnscl:n(l cQ.5 r Control Conven~mnal LO L.S. VALVE WARTITION L.P.G. PHLPPNS PlLR PIV PKQ PHEUW. PNL. WSl PCISIT. POW. WINDOW P.P. PRESS PROTN PROTR. PWTGL P.S. P.SOUNO PSTN rc D.T. TOP DUMP. ox. D. b LW [El ECE HIDUT'I HEA. or HEAT. HI - Ill ALTl H.I C. HlGHT HL ~r H.L. or HILAYF H K9NO HNOA ..HP H.P R. L.S D. or LS. DlFF ..L T LTAILCUTE LVR Lwa Lrn. m-P ECON. E.C.P.G. SYS ADS. A.B.S. A.B.S.V. EQI IW .U hU. CY L. MINT. MIP MA. SUSP -(so HT. HK or WTOP Hwl I11 10. 10 or ; 3N. IL ILLUMI. IN. IND. lHHl0 INJ INN. HI; INSP. :Ia;T. INT. INT.COOCt'R INtEn INTMT or INTEAMn I R.S. or I.R. SUSP A.C. A.C.C. ELECT. EM. ENEOY or ENGY EHQ. EOUR EQUIP. Ex. US-. UC.1OTH-ANHN. Ex r. EXTRACT. 19 F.- ..F FED. FINIS F.I.P. FLEX I' 1 MIXER FIX. Flu ? F L.CECI( FOLD. Ft 4 FRI FfiHIFT RJ1.L CON. 101 a MRN GAS MSOH QEN O HATCH OLD M aLs aov ORN GHY [~RYIORN ACCEL ACTR A.C.V. AW. M. W ST MF MtR ML MLD. or MLW. .UM H.P. wx. MRH UI'. L WQ. MT NI M* YARR. Y.C. v.0 YO. WNCP YON TILT WR wz. Y.6.W P.T.O. fll ADJ.SUSY AIR P. AIR CON. ALfH ALUM. AMP. AMLOO ANNA/ ANT ARO A.8. AbSORRER ASH. AsW AT An nus AUST. AUTO. [W ML. Ml B.CnLOR MXOR BOY BELT. B LK P 'I Fmnl- ..Iwt ( IwI) Fdenl Flnblrrr Flwl lnjactmn Pump Fbrib& Fwl lr *ion Whet t'lrh Fir W Ful Lqt D.a Foldno Ffbnoa Fmnt Fkr C. Fu ., atr~m(W Convorlor Corvr Coup( Colnpblo Computer Csnlcl Ptwrrrltq UnR CmnC C-~ttet Column shm Center Curhon Cyltnder HEFR! JEY Rca 0.- REQU REG QAS fiECUL. RqL REM. CON R€l RRAM I E3wcT Hf IHF R or RR 14 S (S1 SAFL S AFRICA SAL'DI S1800Y SWOX 1.S C. NRY . KC Kt1 KW [Ll L c* (L) L. L L T Ll UAA SUSP LLLJMRY BLU M BLVA ma BRKT BHN BRT - - Omn Qray Onan Otwn Gartner Banana