mirror MAZDA MX-5 1994 Workshop Manual

PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE The following items may be done at any time prior to delivery to your customer. INSPECT and ADJUST, if necessary, the following items to specification: 0 Glass, exterior bright metal and paint for damage 0 Convertible top and detachable hardtop (if equipped) for damage 0 Wheel lug nuts and locks 89-117 N.m (9-1 2 kgf.m, 66-86 ft4bf) 0 All weatherstrips for damage or detachment Operation of hood release and lock Operation of fuel lid 0 Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps (if equipped) 0 Outside mirror(s) 0 Mast antenna (if equipped) UNDER HOOD-ENGINE OFF INSPECT and ADJUST, if necessary, the following items to specification : Fuel, coolant, and hydraulic lines, fittings, connections, and components for leaks Engine oil level 0 Power steering fluid level (if equipped) Brake and clutch master cylinder fluid level 0 Windshield washer reservoir fluid level 0 Radiator coolant level and specific gravity 0 Tightness of battery terminals pKiq INSTALL the following parts: CHECK operation of the following items: 0 Seat controls (sliding and reclining) 0 Door locks 0 Seat belts and warning system 0 Air bag system using indicator light (Refer to section T) Ignition switch and steering lock 0 Starter interlock switch (clutch pedal) All lights, including warning, and indicator lights 0 Audible warning system 0 Horn, wipers, and washers Audio system 0 Cigarette lighter Power windows (if equipped) 0 Power outside mirrors (if equipped) 0 Heater, defroster, and air conditioner at all mode selections (if equipped) CHECK the following items: Presence of spare fuses 0 Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: 0 Pedal height and free play of brake and clutch pedals I Pedal height mm {in} I Ft: $iy I Clutch pedal {6.89--7.28) (with carpet) Parking brake 7-9 notchesil96 N (20 kgf, 44 Ibf) 0.63.1 (0.024. 12) Brake pedal RUNNING AT OPERATING TEMPERATURE CHECK the following items: 0 Automatic transmission oil level 171-181 (6.73--7.13) (with carpet) I ON HOIST I 4--7 {0.16-0.28} CHECK the following items: 0 Underside fuel, coolant, and hydraulic lines, fittings, con- nections, and components for leaks 4 Tires for cuts or bruises 0 Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage Manual transmission oil level Differential oil level I ROAD TEST I CHECK the following items: Brake operation Clutch operation 0 Steering control 0 Operation of meters and gauges Squeaks, rattles and unusual noises 0 Overall engine performance Seat belt emergency locking retractors 0 Cruise control system (if equipped) I AFTER ROAD TEST I CHECK for necessary owner information materials, tools and spare tire in vehicle The following items must be done just before the delivery to your customer. 0 Load test battery and charge if necessary -1 Install fuses for accessories Adjust tire pressure to specification Load test fesuk 0 Remove seat and floor mat protective covers (Refer to Door Label) 0 Vacuum and clean interior of vehicle Clean outside of vehicle Inspect installation of option parts with invoice 45UOAX-002 Gartner Banana

BRAKE SYSTEM P MIRROR AIR BLEEDING The brakes should be bleed whenever a brake line is dis- connected. If a hydraulic line is disconnected at the mas- ter cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the next closest slave cylinder until all four cylinders have been bled. If the disconnection point is anywhere except the master cylinder, start at the point closest to the disconnection, and move to the next farthest slave cylinder until all four cylinders have been bled. 1. On level ground jack up the vehicle and support it evenly on safety stands. 2. Remove the bleeder cap and attach a vinyl tube to the bleeder screw. 3. Place the other end of the vinyl tube in a clear container. 4. One person should depress the brake pedal a few times, and then hold it in the depressed position. 5. A second person should loosen the bleeder screw, drain out the fluid, and close the screw by using the SST. 6. Repeat steps 4 and 5 until only clean fluid is seen. The reservoir should be kept about 3/4 full during bleeding to prevent air from reentering the lines. 7. Modify the brake pipe tightening torque to allow for a torque wrench-SST combination. (Refer to section GI) "Torque Formulas". 8. Tighten the brake pipe by using SST. 9. Check for correct brake operation. 10. Verify that there is no fluid leakage. Clean away any spilled fluid with rags. 11. After bleeding the air, add brake fluid to the reservoir up to the specified level. BRAKE HYDRAULIC LINE On-vehicle Inspection Check the following and replace parts as necessary. 1. Cracks, damage, and corrosion of the brake hose 2. Damage to the brake hose threads 3. Scars, cracks, and swelling of the flexible hose 4. All lines for fluid leakage 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

INDEX INDEX 1. Hood Removal I lnstallation . . . . . . . page S- 5 2. Door Removal I lnstallation . . . . . . . page S- 7 Adjustment . . . . . . . . . . . . . . . . page S- 8 3. Window regulator, glass, and guide Removal I lnstallation . . . . . . . page S- 9 Adjustment . . . . . . . . . . . . . . . . page S-10 4. Door lock and opener Removal I lnstallation . . . . . . . page S-15 5. Front bumper Removal I lnstallation . . . . . . . page S-24 6. Molding and garnish Removal I lnstallation . . . . . . . page S-27 7. Outside mirror Structural view . . . . . . . . . . . . . page S-30 Troubleshooting . . . . . . . . . . . . page S-31 lnspection . . . . . . . . . . . . . . . . . page S-33 Removal 1 lnstallation . . . . . . . page S-34 8. Windshield wiper and washer Troubleshooting . . . . . . . . . . . . page $35 Inspection . . . . . . . . . . . . . . . . . page S-38 Removal / lnstallation . . . . . . . page S-39 Disassembly 1 Assembly . . . . page S-43 Adjustment . . . . . . . . . . . . . . . . page S-42 -- 9. Windshield Removal / lnstallation . . . . . . . page S-44 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

OUTSIDE MIRROR OUTSIDE MIRROR STRUCTURAL VIEW t 35uosx-022 1. Power outside mirror switch 2. Power outside mirror Inspection . . . . . . . . . . . . . . . . . page S-33 Inspection . . . . . . . . . . . . . . . . . page S-33 Removal 1 Installation . . . . . . . page S-34 Removal 1 Installation . . . . . . . page S-34 S30 Gartner Banana

OUTSIDE MIRROR TROUBLESHOOTING Gartner Banana

OUTSIDE MIRROR Power outside mirrors do not operate 1 B+: Battery positive voltage 1 u Check CIGAR 15A fuse Replace fuse after checking and repairing wiring harness I Turn ignition switch to ON I ,,.,,,,,,,,,.,,,,.,. switch connector Repair harness (Fuse box - Power outside mirror switch) 1 OK I I I RIGHT i i~&) wire Disconnect power outside mirror switch connector Check for continuity between terminal wire (0) and ground Fbpair harness (Power outside mirror switch -Ground) 1 Check power outside mirror switch (Refer to page S-33) Reconnect power outside mirror switch connector Check for B+ at terminal wires of power outside mirror I I Switch position I Terminal I Voltage I UP I (BRl wire 1 B+ switch connector with mirror switch in positions indicated below NG c OK Right Left Check for B+ at terminal wires py of power outside mirror con- nector with mirror switch in positions indicated below Check power outside mirror (Refer to page S-33) - DOWN LEFT RIGHT UP DOWN LEFT RIGHT OK > ,- , - (LGIB) wire (LG/B) wire (B R/B) wire (BR) wire (LGIB) wire (LGIB) wire (BRIB) wire - Repair harness (Power outside mirror switch - Power outside mirror) B+ B+ B+ B+ B+ B+ B+ Gartner Banana

OUTSIDE MIRROR POWER OUTSIDE MIRROR lnspection 1. Remove the power outside mirror. (Refer to page S-34.) 2. Check for continuity between the mirror terminals. Movement 0 I n I 0 O---<): Continuity 3. If not as specified, replace the power outside mirror. POWER OUTSIDE MIRROR SWITCH lnspection 1. Remove the power outside mirror switch. (Refer to page S-34.) 2. Check for continuity between the switch terminals. Left Right 0---0: Continuity 3. If not as specified, replace the power outside mirror switch. Gartner Banana

OUTSIDE MIRROR COMPONENTS Removal / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal. I. Remote control mirror 5. Door trim 1 2. Regulator handle Removal / Installation . . . . . . . page S-59 Removal Note . . . . . . . . . . . . . page S-10 6. Inner handle Installation Note . . . . . . . . . . . page S-10 7. Sealing pad 3. Inner handle cover 8. Door screen 4. Pull handle 9. Power outside mirror 10. Power outside mirror switch Gartner Banana