recommended MAZDA MX-5 1994 Workshop Manual

SCHEDULED MAINTENANCE (EXCEPT CANADA) Schedule 1 (Normal driving conditions) If the vehicle is mainly operated where none of the "unique driving conditions" apply. Schedule 2 (Unique driving conditions) Repeated short-distance driving. Driving in dusty conditions. Driving with extended use of brakes. Driving in areas where road salt or other corrosives are used. Driving on rough or muddy roads. Extended periods of idling or low-speed operation. r Driving for long periods in cold temperatures or extremely humid climates. SCHEDULE 1 (NORMAL DRIVING CONDITIONS) Chart symbols: I : Inspect, and repair, clean, or replace if necessary R : Replace L : Lubricate Remarks: After 48 months or 96,000 km {60,000 miles), continue to follow the described maintenance at the recommended intervals. *1 This maintenance is required for all states except California. However, we recommend that it also be performed on California vehicles. '2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability. Gartner Banana

Schedule 2 (Unique driving conditions) (AT) Maintenance interval Maintenance item ENGINE Engine oil I R I R I R I R I R I R I R I R I R I R I R I R Engine oil filter Drive belts Number of months or kilometers {miles}, whichever comes first eoilpancapacity: 4.0 L {4.2 US qt, 3.5 Imp qt} Engine oil (Puerto Rico) I I IGNITION SYSTEM Service data and inspection point Months Kilometers (x 1,m) Miles (x 1,000) D-5 Replace every 4,800 km (3,000 miles) or every 3 months I I I I I I I I - - Engine timing belt (California) Spark plugs Page - - Air cleaner element I I FUEL SYSTEM 4 8 5 I F-99 8-1 2 -. . . '21nspect at 96,000 km {60,000 miles}, and again at 144,000 km {90,000 miles) Replace every 168,000 km (1 05,000 miles) - - R*' - 1'1 l Oilfiltercapacity: 0.15 L (0.16 US qt, 0.13 Imp qt} l Cracks or damage l Tension I R 1 Ie2 1 Engine timing belt ~ --- - - l Plug gap: 1 .&I -1 mm (0.040-4.043 in) l Recommended dark ~luas: 8 16 10 D-6 B-6 Replace every 96,000 km (60,000 miles) Idle speed Fuel filter Fuel lines and hoses NGK , BKRGE-11 BKR5E-I 1 12 24 15 IRI I*2 lt2 l Idle speed MT: 800-900 rpm (Neutral) 1 F-76 AT: 75M0 rpm (P range) 16 32 20 I!*'2 1 20 40 25 24 48 30 - Fittings, connections and com~onents for leaks 36 72 45 F-113 F-1 07 Fuel hoses (California) Hose and tube for emission 28 56 35 Cooling system Engine coolant 32 64 40 COOLING SYSTEM Replace every 168,000 km {I 05,000 miles} 1 1*2 48 96 60 40 80 50 I R 44 88 55 l Fittings, connections and components for leaks Fittings and connections F-1 07 - I R l Hoses for cracks or wear l Coolant level - E4 E-5 Gartner Banana

SCHEDULED MAINTENANCE (CANADA) SCHEDULE Chart symbols: I : Inspect, and repair, clean, or replace if necessary (Inspect, and replace if necessa ry... Air cleaner element only) R : Replace L : Lubricate Remarks: After 60 months or 96,000 km (60,000 miles}, continue to follow the described maintenance at the recommended intervals. '1 Replacement of the timing belt is required every 96,000 km, (60,000 miles}. Failure to replace this belt may result in damage to the engine. *2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability. Gartner Banana

Schedule interval Maintenance ENGINE Number of months or kilometers {miles), whichever comes first I -. Months 5 10 15 20 25 30 35 40 45 50 55 60 Kilometers 8 16 24 32 40 48 56 64 72 80 88 96 - Service data and inspection point 1~1.000~ Page Spark plugs FUEL SYSTEM -- Plug gap: 1 .GI .l mm {0.04M.043 in) l Recommended spark plugs: D-5 D-6 B-6 F-99 8-1 2 IGNITION SYSTEM R I I Engine oil Engine oil filter Drive belts Air cleaner element Engine timing belt 'l R I R I F-76 F-1 1 3 F-107 F-I30 - Idle speed Fuel filter Fuel lines and hoses PCV valve'2 Emission hoses and tubes R I COOLING SYSTEM I Cooling system Engine coolant R I R I I E4 E-5 E4 I R I R I R I R I*z I l Hoses for cracks or wear l Leaks - Level and strength I R RR I R R R I I R I OilPancapacity: 4.0 L (4.2 US qt, 3.5 Imp qt) 0 Oil filter capacity: 0.15L(0.16USqt,0.13Impqt) 'Cracksordamage 0 Tension - - R I I I I I R I l ldle speed MT: 800-900 rpm (Neutral) AT 750-850 rpm (P range) - l Fittings, connections and components for leaks Operation Fittings and connections I I R I I I I I I I I I R I Gartner Banana

TROUBLESHOOTING GUIDE F 24 Overloaded ) Low intake air amount Throttle valve not oDen fully LACK OF POWER ESCRIPmH - TEP - 1 - 2 : Performance poor under load Reduced maximum speed :heck factors other than engine Clutch slipping as Section H Brake dragging Section P Low tire pressure as Section Q Unrecommended tire size Section Q ;heck if throttle valve wide open throttles when lepressing accelerator fully rROUBLESHOOTlNG HINTS] Factors other than engine malfunction O AirlFuel mixture too lean or too rich Clutch slipping Fuel line pressure low or high Brake dragging Insufficient fuel injection Low tire pressure @ Poor ignition Unrecommended tire size 8 Low engine compression >heck if "00 is displayed on Self-Diagnosis Check- !r with ignition switch ON page F-79 :heck switches for correct operation with Self- Diagnosis Checker Monitor Lamp and ignition switch ON as page F-95 SELECT SW A YSTEM SELECT 1 - Yes Yes Clogged intake air system - INSPECTION I - C 0 0 0 0 - c C - ( E -- I I i I I No - Yes No - Yes - No ACTION %to next step 20 to next step Sheck if accelerator cable is correctly installed page F-103 3 If OK, check throttle body @r page F-101 3 If not OK, install accelerator cable correctly page F-103 - 30 to next step Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) page F-81 "88" flashes Check PCME terminal 1 E voltage @r page F-145 Specification: Battery positive voltage (Ignition switch ON) o If OK, replace PCME page F-143 O If not OK, check wiring between PCME and Self-Diagno- sis Checker E+T page F-7 Go to next step -- Lamp not ONlOFF with specified switch Check for cause (Refer to specified check sequence) page F-96 Lamp always ON Check wiring between PCME terminal 1 D and Self-Diag- nosis Checker @r page F-7 Gartner Banana

TROUBLESHOOTING GUIDE TROUBLESHOOTING HINTS] D Factors other than engine malfunction Clutch slipping Brake dragging Low tire pressure Unrecommended tire size 25 O AirIFuel mixture too lean or too rich Fuel line pressure low or high Insufficient fuel injection @ Poor ignition 6 Low engine compression POOR ACCELERATION Overloaded D Low intake air amount Throttle valve not open fully Clogged intake air system )ESCRIPTION I Performance poor while accelerating INSPECTION :heck factors other than engine Clutch slipping Section H D Brake dragging Section P t Low tire pressure Section Q D Unrecommended tire size Section Q :heck if throttle valve wide open throttles when jepressing accelerator fully Check if "00" is displayed on Self-Diagnosis Check- er with ignition switch ON page F-79 Check switches for correct operation with Self- Diagnosis Checker Monitor Lamp and ignition switch ON page F-95 SELECT SW A SYSTEM SELECT 1 - Yes - No Yes - No - Yes - No Yes - No ACTION Go to next step Repair Go to next step Check if accelerator cable is correctly installed * page 0 If OK, check throttle body ce Page 0 If not OK, install accelerator cable correctly page Go to next step -- Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequenc US page "88" flashes Check PCME terminal 1 E voltage Us Page Specification: Battery positive voltage (Ignition switch ON) 0 If OK, replace PCME * Page 9 If not OK, check wiring between PCME and Self- sis Checker * Page Go to next step Lamp not ONlOFF with specified switch Check for cause (Refer to specified check sequenc * Paw Lamp always ON Check wiring between PCME terminal 1 D and Self nosis Checker * Page ! F-103 ! F-101 I F-103 :e) r F-81 ! F-145 I F-143 Diagno- ! F-7 :e) ! F-96 -Diag- ! F-7 Gartner Banana

TROUBLESHOOTING GUIDE F POOR FUEL ECONOMY I [TROUBLESHOOTING HINTS] Nhile fuel consumption is drastically increased during city driving, short-run operation, stop and go driving, extended winterwarm- ~p periods, etc., as opposed to "trip" mileage, an attempt should be made to determine these factors when confronted with "poor mileage" conditions. However, since the operator is not always at fault, the following is offered. 3 Operator depressing accelerator more than usual due to O Alcohol blended fuel used low engine power @ High vehicle load Poor ignition Low tire pressure Low intake air amount Unrecommended tire used Electric spark advance control malfunction Brake dragging Clutch slipping @ Fuel cut control malfunction Exhaust component restricted @ High idle speed AirIFuel mixture too rich High fuel line pressure INSPECTION Check factors other than engine Low tire pressure Section Q Unrecommended tire used @zT Section Q Clutch slipping Section H Brake dragging Section P Exhaust component restricted @zT page F-128 ACTION - Yes Go to next step Repair Check if air hoses are connected correctly @zT page F-99 Yes - No Go to next step Repair @zT page F-99 Check if air cleaner element is clean page F-76 Yes - No Go to next step Replace page 699 Check if "00" is displayed on Self-Diagnosis Check- er with ignition switch ON @zT page F-79 Yes Go to next step SELECT SW A SYSTEM SELECT 1 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) page F-81 "88" flashes Check PCME terminal 1 E voltage US page F-145 Specification: Battery positive voltage (Ignition switch ON) 6 If OK, replace PCME page F-143 6 If not OK, check wiring between PCME and Self-Diagno- sis Checker page F-7 Check switches for correct operation with Self- Diagnosis Checker Monitor Lamp and ignition switch ON page F-95 SELECT SW A Yes Go to next step ~~p Lamp not ONIOFF with specified switch Check for cause (Refer to specified check sequence) @zT page F-96 Lamp always ON Check wiring between PCME terminal 1 F and Self-Diag- nosis Checker us page F-7 Gartner Banana

K TROUBLESHOOTING TROUBLESHOOTING GENERAL NOTES A problem with the EC-AT may be caused by the engine, the EC-AT powertrain, the hydraulic control LJ system, or the electronic control system. When troubleshooting, therefore, begin from these points, which can be inspected quickly and easily. The recommended troubleshooting sequence is described below. WHEEL CHOCK 63 TEMPERATURE w-7u'C (1461WF) Step 1 : On-board Diagnosis System Inspection Check for diagnostic trouble code(s) memorized in the powertrain control module (Transmission) with the Self- Diagnosis Checker. (Refer to page K-11 .) Note You can also check the flashing sequence of the hold indicator light for diagnostic trouble code(s). (Refer to page K-1 1 .) Step 2: Mechanical System Test Check the engine stall speed, time lag, and line pres- sure. (Refer to page K-22.) Step 3: Road Test Check the shift point, shift schedule, and shift shock. (Refer to page K-29.) Gartner Banana

WHEEL ALIGNMENT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Specifications (Unladed*l) PRE-INSPECTION 1. Check the tire inflations, and adjust to the recommended d pressure if necessary. 2. lnspect the front wheel bearing play and correct if neces- sary. 3. lnspect the wheel and tire runouts. 4. Inspect the ball joints and steering linkage for excessive looseness. 5. The vehicle must be on level ground and carry no lug- gage or passengers. 6. Measure the height from the center of the wheel to the fender brim. The difference between left and right mea- surement must not exceed 10mm (0.39 in), and the rear measurement must be larger then the front measure- ment by 10-30mm (0.4--1.1 in). Caution The proper caster and camber angle vary depend- ing on the vehicle height. Refer to the following and to page R-9 for the specifications. Inspection and adjustment of wheel alignment must be done with the vehicle unladed*'. . . I Y -- t~otal toe-in l~er side) I 1 dearee 0'09' + 09' I Total toe-in 3 2 3 I0.12 2 0.12) 0'1 8' 2 18' mm (in) dearee Maximum steering angle U - Inner Outer 11 '20' -0°20' 2 45' 0'03' ? 45' 0'24' 2 45' 0°44' -+ 45' 1'02' -+ 45' 5'1 6' ? 45' 5O02' -+ 45' 4O49' 2 45' 4'35' -+ 45' 4'21 ' -+ 45' I Kingpin angle 37"23' -+ 2" 32O32' 2 2" '1 Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. OSUORX-009 ** Difference between left and right must not exceed lo. '3 Difference between left and right must not exeed 1'30'. 328-337 {I 2.9-1 3.3) 338-347 {I 3.3-1 3.7) 340-357 I13.7-14.1) 358-367 {I 4.1-14.4) 36&377 {I 4.4--14.8) 328-337 {I 2.9--13.3) 338-347 {I 3.3-1 3.7) 348-357 113.7-14.1) 358-367 {I 4.1-14.4) 368-377 {I 4.4--14.8) Camber angleg2 Caster angle*3 Height from center Of wheel to fender brim mm {in) Height from center Of wheel to fender brim mm (in) Gartner Banana

Mazda MX-5 Body Shop Manual - FOREWORD This Bodyshop manual was prepared as refer- ence material of the service personnel of authorized Mazda dealers to enable them to cor- L- rectly carry out the task of rendering services on Mazda vehicles. In order to ensure that the customers are satis- fied with Mazda products, proper servicing must be provided. For this purpose, the service person- nel must fully understand the contents of this manual and at the same time, are recommended to keep the manual in a place where reference can readily be made. CONTENTS i- The information, photographs, drawings and specifications entered in this manual were the best available at the time of printing this manual. All alterations to this manual occurring as the result of modifications will be notified by the is- suance of Service Information or supplementary volumes. It is, therefore, requested that the manual be dept up to date by carefully maintain- ing a follow-up of these materials. Title -W Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without any obligation or advance notice. Page All rights reserved. No part of this book may be reproduced or utilized in any form or by any means, mechanical, including photocopying, recording, or by any informational storage and retrieval system without permission in writing. Mazda Motor Corporation HIROSHIMA, JAPAN 01989 Mazda Motor Corporation PRINTED IN JAPAN October, '890 3167-10-89J Gartner Banana