MAZDA MX-5 1994 Workshop Manual

WINDSHIELD WIPER AND WASHER s Disassembly / Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassemblv. 1. Brush plate holder 2. Motor gear shaft S-43 Gartner Banana

WINDSHIELD WINDSHIELD PREPARATION SST removal and Tool set, installation of window COMPONENTS Removal 1 Installation 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to lnstallation Note. 1. Wiper arm and blade 8. Weatherstrip Adjustment ................ page S-42 9. A-pillar trim 2. Cowl grille Removal Note ............. page S-60 3. Windshield molding 10. Windshield Installation Note ........... page S-28 Removal Note ............. page S-45 4. Rearview mirror and cover Installation Note ........... page S-45 5. Striker 11. Dam .--' 6. Sunvisor 12. Upper protector 7. Front header trim 13. Spacer Removal Note ............. page S-60 Gartner Banana

WINDSHIELD Removal Note Windshield If the glass will not be reused 1. Use a tool like that shown in the figure and insert the blade into the sealant. 2. Pull through the sealant around the edge of the glass. 3. Remove the glass. If the glass will be reused 1. Apply protective tape along the edge of the body to pro- tect it from damage. 2. Using an awl, make a hole through the sealant from the inside of the vehicle. 3. Pass piano wire through the hole. 4. Wind each end of the wire around a bar. 5. Working with another person, saw through the sealant around the edge of the glass. Use a long sawing action to spread the work over the whole length of wire to pre- vent it from breaking. 6. Remove the glass. Installation Note Windshield 1. Cut away the old sealant with a razor knife so that 1 to 2 mm (0.04 to 0.08 in) of sealant remains around the cir- cumference of the frame. If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2 mm (0.08 in} layer. 2. Carefully clean an area 5 cm (1.97 in) wide around the circumference of the glass and bonding area of the body. 3. Apply primer with a brush to the bonding area of the glass and the body. Keep the area free of dirt and grease, and do not touch the surface. Allow it to dry for approximately 30 minutes. 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

WINDSHIELD s 10. Use a scraper to smooth away any sealant that oozes out. Add more sealant to any points of poor contact. 11. Install a new windshield molding. (Refer to page S-28.) 12. Check for water leaks. 13. If a leak is found, wipe the water off well and remove the moldina and windshield. Reinstall the windshield with new m&ding. (Refer to page S-28.) Gartner Banana

REAR WINDOW GLASS REAR WINDOW GLASS (DETACHABLE HARDTOP) Tool set, window ===O EQ PREPARATION SST removal and installation of windshield 49 0305 870A n COMPONENTS Removal 1 lnstallation 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to lnstallation Note. For 1. Rear window molding 3. Dam Installation Note ........... page S-29 4. Upper protector 2. Rear window glass 5. Side protector Removal Note ............. page S-49 6. Lower protector Installation Note ........... page S-49 Gartner Banana

REAR WINDOW GLASS I PROTECTIVE TAPE I I PIANO WIRE GYSS DETACHABLE HARDTOP O...PLACES PIANO WIRE WILL NOT CUT 1 Removal Note Rear window glass 1. Apply protective tape along the edge of the detachable hardtop to protect it from damage. 2. Remove the glass mounting nuts. 3. Using an awl, make a hole through the sealant from the inside of the vehicle. 4. Pass piano wire through the hole. 5. Wind each end of the wire around a bar. 6. Saw through the sealant around the edge of the glass. Use a long sawing action to spread the work over the whole length of wire to prevent it from breaking. 7. Use a razor knife to cut where the piano wire will not cut. 8. Remove the glass. Installation Note Rear window glass 1. Cut away the old sealant with a razor knife so that 1 to 2 mm (0.04 to 0.08 in) of sealant remains around the cir- cumference of the frame. If all the sealant has come off in any one place, apply some primer after decreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2 mm I0.08 in) layer. 2. Carefully clean an area 5 cm (1.97 in) wide around the circumference of the glass and bonding area of the top. 3. Apply primer with a brush to the bonding area of the glass and top. Keep the area free of dirt and grease, and do not touch the surface. Allow the primer to dry for approximately 30 minutes. 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

REAR WINDOW GLASS 12. Check for water leaks. 13. If a leak is found, wipe the water off well and remove the molding and rear window glass. Reinstall the glass with new molding. (Refer to page S-29.) 25UOSX-022 Gartner Banana

REAR WINDOW REAR WINDOW (CONVERTIBLE TOP) COMPONENTS Removal / Installation 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to Installation Note. 1. Rear package trim 2. Set plate 3. Beltline cover 4. Beltline protector 5. Rain rail 6. Zipper stop 7. Rear window e Removal Note . . . . . . . . . . . . . page S-53 Installation Note . . . . . . . . . . . page S-54 Gartner Banana