dimensions MAZDA MX-5 1994 Workshop Manual

J TRANSMISSION TRANSMISSION CASE SNAP RING Countershaft front bearing Install the countershaft front bearing by using the SST, and secure it with a new snap ring. d Adjustment shim After measuring dimensions (A) and (B) shown in the fig- ure, use an adjustment shim(s), as specified below, of the thickness corresponding to the value of (A) minus (B), so that bearing end play will be within specification. Bearing end play: 04.lmm (0-0.004 in) Adjustment shim thickness: 0.lOmm (0.004 in), 0.15mm (0.006 in), 0.30mm (0.012 in) Clutch release fork 1. Apply Mori White TA No.2 or equivalent organic rnolyb- denum grease to the shaded areas of the clutch release collar and release fork. 2. Install the clutch release collar and clutch release fork. Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS Item TY ~e Specifications Suspended Pedal level ratio Maximum stroke mm (in) 4.1 : I 1 20 14.72) - -- TY ~e Bore mm (in) Pad dimensions (area x thickness) mm2 x mm {in2 x in) Tandem (with level sensor) 22.22 (0.875) -- - TY ~e Cylinder bore mm (in) Disc plate dimension (effective diame- ter x thickness) mm {in) Disc (ventilated) 51.1 (2.01) Pad dimensions (area x thickness) mm2 x mm (in2 x in) Cylinder bore mm {in) Disc plate dimensions (effective diameter x thickness) mm (in) Disc (solid) 31.75 (1.25) Size mm {in) Vacuum multiplier 21 4 (8) Proportioning bypass valve (PBV) FMVSS 11 6: DOT-3 Brake fluid Mechanical, two rear brakes Hand lever Parking brake TY Pe - Operation system 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 UNDERBODY DIMENSIONS BUMPER BRACKET MOUNTING NUT FRAME REFERENCE HOLE $1 6 (0.63) STABILIZER MOUNTING NUT FRONT FENDER PANEL MOUNTING NUT SUSPENSION MOUNTING BOLT FRONT MOUNTING BLOCK FRAME REFERENCE HOLE 12 x 18 (0.47 x 0.71) CROSSMEMBER MOUNTING NUT FRONT FENDER PANEL MOUNTING NUT CROSSMEMBER MOUNTING NUT FRAME REFERENCE HOLE @I2 (0.47) FRAME REFERENCE HOLE $20 (0.79) FRAME REFERENCE HOLE 12 x 18 (0.47 x 0.71) FRAME REFERENCE HOLE $12 (0.47) SUSPENSION MOUNTING BOLT SUSPENSION MOUNTING NUT REAR MOUNTING BLOCK SUSPENSION MOUNTING BOLT FRAME REFERENCE HOLE 16 x 22 (0.63 x 0.871 BUMPER BRACKET REFERENCE HOLE $7 (0.281 BUMPER MOUNTING HOLE 12 x 14 (0.47 x 0.55) mm {in) Gartner Banana

UNDERBODY DIMENSIONS s STRAIGHT-LINE DIMENSIONS Gartner Banana

GENERAL SERVICE INFORMATION SERVICE PRECAUTIONS ............................................ 2 JACKING AND SAFETY STAND POSITIONS ............ 8 VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS ....... 8 TOW CABLE ATTACHMENT POSITIONS .................. 9 IDENTIFICATION NUMBER LOCATIONS ................... 9 VEHICLE DIMENSIONS ................................................ 10 WHEEL ALIGNMENT .................................................... 10 Gartner Banana

GENERAL SERVICE INFORMATION w EFFICIENT REPLACEMENT OF BODY PANELS V REMOVAL Body measurements Selection of cut-and-join locations Before removal or rough cutting, first measure For parts where complete replacement is not the body at and around the damaged area ac- feasible, careful cutting and joining operations cording to the dimensions figure, and if there should be followed. If the location to be cut is is deformation, use frame repair equipment to a flat area where there is no reinforcement, the make a rough correction. cutting location selected should be where the welding distortion will be a minimum. Prevention of body deformation Use a clamp or a jack for removal and rein- force at and around the rough-cutting location to prevent deformation of the body. Removal of associated parts Protect moldings, garnishes, and ornaments, with tape when removing associated parts. Rough-cutting of damaged panel Check that are no parts (such as pipes, hoses, wire harnesses, etc.) nearby or on the opposite side which could be damaged by heat. For cut-and-join areas, allow for an overlap of 30-50mm (1.18-1.97 in) and then roughly cut the damaged panel. Gartner Banana

GENERAL SERVICE INFORMATION d INSTALLATION Checking pre-weld measurements and matching Align to the standard reference dimensions, based upon the body dimensions illustration, so that new parts are installed at the correct position. Welding notes Welding should be performed in accordance with the following reference standards. Note a) Plug welding should be performed by the CO2 gas shielded-arc welding method. b) Panel connections by brazing should be only at the indicated locations. Original welding Repair welding Pitch: 50mm Pitch: within 35mm (1.97 in) Original number of Spot welding welds x 1.3 or more Original spot welding Repair welding If 3rnm (0.12 in) or more Original number of welds or more Plug welding Spot welding notes OXXX Original spot weld @Before spot welding, make a trial weld; If satisfactory, proceed with the actual weld- ing. the tip contact surface and facing surfaces ~~[l/jLJL!= @Before spot welding, check once again that - Em -- to be welded are completely clean. @Because the weld strength is affected by the / shape of the spot welder tip, the tip should always be properly maintained, and, in ad- Hammer and chisel Test piece method method dition, in order to minimize problems caused by overheating, a certain amount of cooling time should be allowed after each 5 or 6 weld points. @Spot welds should, as a general rule, be & U made at points other than the originally Center diameter: lr welded points. w 3mm (0.12 in) n 2 Yi'%%Lr: 415 of tip 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

DIMENSIONS BODY DIMENSIONS ................................................. 12 EXPLANATION OF BODY DIMENSIONS ................... 12 PROJECTED DIMENSIONS ......................................... 13 UNDERBODY PROJECTED DIMENSIONS ............. 13 STRAIGHT-LINE DIMENSIONS .................................... 14 UNDERBODY STRAIGHT-LINE DIMENSIONS ....... 14 FRONT BODY STRAIGHT-LINE DIMENSIONS ...... 16 CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS .......................................................... 18 INTERIOR STRAIGHT-LINE DIMENSIONS (FRONT) ............................................................... 19 INTERIOR STRAIGHT-LINE DIMENSIONS (REAR) ................................................................... 20 REAR BODY STRAIGHT-LINE DIMENSIONS ......... 21 Gartner Banana