spare wheel 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

ANTILOCK BRAKE SYSTEM (ABS) ABS WHEEL SPEED SENSOR (REAR) Removal 1 Inspection I Installation 1. Remove the filler pipe protector (left side). 2. Remove the spare tire (right side). 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. 1. Connector 2. Mud guard 3. Bolts 4. Wheel speed sensor lnspection . . . . . . . . . . . . . . . . . . . . . . . below lnspection Wheel speed sensor 1. Measure resistance between terminals of the wheel speed sensor. Resistance: 1 .O-1.2 kR 2. If not as specified, replace the wheel speed sensor. Gartner Banana

Q OUTLINE, TROUBLESHOOTING GUIDE OUTLINE Wheels SPECIFICATIONS Tires -2 TROUBLESHOOTING GUIDE Temporary spare 14x4T - - TY Pe Item Size Offset mm {in) Pitch circle diameter mm {in) Material Size Air pressure kPa {kgf/cm2, psi} Standard 14x5 112-JJ 45 11.77) 1 00 (3.94) Aluminum Alloy 185160R14 82H 177 {I .8, 26) Page Excessive or irregu- tar tire wear Premature tire wear Tire squeal body vibration I Unbalanced wheel@) 1 Adjust I Q-5 Steel T1 l5/7ODl4 41 2 {4.2,60) Action Problem 1 Tre deterioration 1 Replace I - I Deformed wheel(s) or tire(s) I Repair or replace I - Possible Cause Refer to page Q-4 for details. Road noise or I Insufficient tire pressure [ Adjust Incorrect tire pressure ( Adjust Incorrect tire pressure 1 Adjust Q-3 Q-3 0-3 Shake [Steering wheel "Ibrates Excessive tire and wheel runout Loose lug nuts Unbalanced wheel(s) Insufficient tire pressure Unevenly worn tires Malfunction of shock absorber Loose shock absorber mounting bolts Stuck or damaged lower arm ball joint Cracked or worn suspension bushings Shimmy (Steering wheel vibrates lefiIright) Replace Tighten Adjust or replace Adjust Replace Replace Tighten Replace Replace Irregular tire wear Excessive tire and wheel runout Loose lug nuts Unbalanced wheel(s) - Q4 Q-5 Q-3 - section R section R section R section R Cracked or worn engine mount Cracked or worn steering gear mount Loose steering gear mounting bolts Stuck or damaged steering ball joint I Damaged or worn front wheel bearing ( Replace ( section M Replace Replace Tighten Adjust or replace I Improperly adjusted front wheel alignment 1 Adjust I section R Uneven (one-sided) I Unequal tire pressures 1 Adjust 1 Q-3 - - Q-4 Q-5 Replace Replace Tighten Replace section B section N section N section N braking Steering wheel I Incorrect tire pressure 1 Adjust doesn't return properly or pulls to either left or right . General driving Instability Excessive steering (2-3 wheel play Irregular tire wear (lefthight) Unequal tire pressures Different types or brands of tires mixed (leftlright) Loose lug nuts Unequal tire pressures Damaged or unbalanced wheel(s) Loose lug nuts Loose lug nuts I 15UOQX-00 Replace Adjust Replace Tighten Adjust Replace or adjust Tighten Tighten - Q-3 - Q-4 Q-3 Q-5 Q-4 Q-4 Gartner Banana

WHEELS AND TIRES Q WHEELS AND TIRES SPECIAL NOTES ABOUT WHEELS AND TIRES ,, 1. Do not use wheels or tires other than those types specified. 2. Aluminum wheels are easily scratched. When washing them, use a soft cloth, never a wire brush. If the vehicle is steam cleaned, do not allow boiling water to contact the wheels. 3. If alkaline compounds (such as salt-water or road salts) get on aluminum wheels, wash them as soon as possible to prevent damage. Use only a neutral detergent. - - 9MUOQX-004 NOTES REGARDING TIRE REPLACEMENT Note the following points when tires are to be removed from or mounted onto the wheels. 1. Be careful not to damage the tire bead, the rim bead, or the edge of the rim. 2. Apply a soapy solution to the tire bead and the edge of the rim. 3. Use a wire brush, sandpaper, or cloth to clean and remove all rust and dirt from the rim edge and the rim bead. For aluminum wheels, use only a cloth for this purpose; never use a wire brush or sandpaper. 4. Remove pebbles, glass, nails, and other foreign items embedded in the tire tread. 5. Be sure the air valve is installed correctly. 6. After mounting a tire on a wheel, inflate it to 250-300 kPa I2.55--3.06 kgf/cm2, 35.55--42.66 psi). Verify that the bead is seated correctly on the rim and that there are no air leaks. Then reduce the pres- sure to the specified level. 7. If a tire iron is used to change a tire on an aluminum wheel, be sure to use a piece of rubber between the iron lever and the wheel to avoid damage to the wheel. Work should be done on a rubber mat, not on a hard or rough surface. INSPECTION / ADJUSTMENT Check the following and adjust or replace as necessary. 1. Air pressure. Check the air pressure of all tires when they are cold, including the spare tire, with an air pressure gauge. u Air pressure: Standard tires 177 kPa (1.8 kgf/cm2, 26 psi) Temporary spare tires 412 kPa (4.2 kgf/cm2, 60 psi) 2. Wheel runout. Set the probe of a dial indicator against the wheel, and turn the wheel one full revolution. WEAR INDICATOR Wheel runout: Horizontal 2.0mm (0.079 in) max. Vertical 1.5mm (0.059 in) max. WEAR lNDICAToR 3. Tire wear. Specifications Remaining tread Ordinary tires: 1.6mm (0.063 in) min. (Tire should be replaced if wear indicators are exposed.) Snow tires: 50% of tread (Tire should be replaced if wear indicators are exposed .) Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS Front Suspension - Transmission item (Stabilizer Specifications MT I AT - I Susoension tvoe I . , . , I . , Shock absorber Cylindrical double acting, low-pressure-gas charged I Double-wishbone TY pe Torsion bar Coil spring I - Diameter mm linl I 20.0 10.79) Identification mark color 19.0 (0.75) White Wire diameter mm (in) Coil inner diameter mm {in) I Blue Free length mm {in) Coil number 11 .O (0.43) 83 i3.27) 11 .O (0.43) 83 (3.27) 292.5 (1 1 32) 6.32 3 +. 3 (0.12 + 0.12) 0°18' + 18' Total toe-in I - I 35UORX-001 Rear Suspension 302.0 (1 1.89) 6.32 mm {in) degree Total toe-in (per side) 1 degree Front wheel alignment (Unladedt1) 0°09' +. 09' Caster anglee3 4"26' +. 45' Kingpin angle 11 "20' Maximum steering angle Transmission Specifications MT I AT Item Differential - Suspension type Inner Outer "TORSEN" LSD 1 Standard Double-wishbone Coil springs 370 23' a 2" 32" 32' -t 2" Camber anglee2 Torsion bar 12.0 (0.47) 1 11.0 (0.43) 1 11 .O (0.43) Cylindrical double acting, low-pressure-gas charged - Stabilizer Identification mark color Wire diameter mm {in) 0°24' + 45' Type Diameter mm {in) I Coil number I 7.68 I 7.96 I Shock absorber Yellow 10.1 {0.40} Coil inner diameter mm {in) Free length mm {in) Green 10.2 {0.40) 35UORX-002 *I Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. '2 Difference between left and right must not exceed I O. '3 Difference between left and right must not exceed 1'30'. "TORSEN" is a registered trademark of ZEXEL-GLEASON USA.INC 83 I3.27) 348.5 j13.72) Rear wheel alignment (Unladed*') 83 (3.27) 356.5 (1 4.04) Total toe-in Total toe-in (per side) mm (in) degree degree 3 -c 3 (0.12 + 0.121 0°18' + 18' 0°09' + 09' Camber angle*2 -0°43' 2 30' 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

WHEEL ALIGNMENT REAR WHEEL ALIGNMENT Specifications (Unladed*) I Item I Specifications I L *' Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. 05Uo~x-01~ *2 Difference between the leff and right must be exeed lo. 3 + 3 i0.12 * 0.12) 0'18' k18' 0'09' 2 09' -1 "08' +. 30' Total toe-in Total toe-in (per side) Camber angle'' LEFT WHEEL - mm {in) degree degree INCREASE I 1 346-355 (1 3.6-1 4.0) Height from center of wheel to fender brim'2 mm Iin) RIGHT WHEEL C INCREASE 356-3135 {14.0-14.4) 366-375 {I 4.4--14.8) 376-385 {I 4.8-1 5.2) 386--395 {I 5.2-1 5.6) LEFT WHEEL -C -0°54' r 30' -0'43' 2 30' -0°35' r 30' -0'30' +. 30' Toe-in Toe-in is adjusted by turning the front and/or rear adjust- ing cam bolts at the lower arm. Caution Adjust the toe-in before adjusting the camber. 1. Loosen the front and/or rear cam nuts. 2. Turn the front and/or rear adjusting cam bolts to provide the correct toe-in. I Counter- Counter- Decrease Clockwise Clockwise clockwise clockwise Toe-in Note Turning the front cam one graduation changes the toe-in about 2.8mm (0.11 in} and the camber about 15'. Turning the rear cam one graduation changes the toe-in about 2.8mm I0.11 in} and the camber about 6'. 3. 'Adjust the camber. Left wheel Camber Camber is adjusted by turning the front and rear cams at the lower arm. Right wheel Caution Adjust the camber after adjusting the toe-in. Front cam I Rear cam I Front cam I Rear cam 1. Loosen the front and rear cam nuts. 2. Turn the front and rear adjusting cam bolts the same amount in the opposite direction to provide the correct camber angle. Gartner Banana

TECHNICAL DATA TD P. BRAKING SYSTEM 3rake pedal Waster cylinder 'ront brake :Disc) Rear brake [Disc) Parking brake Power brake unit Rear wheel hydraulic control system -. . . . . Free play mm {in) I 4--7 {0.16--0.28) Item Heiaht (with car~et) mm {in) Reserve travel (without carpet, clearance when pedal is depressed at 589 N (60 kgf, Specifications 171-1 81 {6.73-7.13) . ,~ I Bore mm {in} I 22.22 (0.87) 132 Ibi)) mm {in) 1 Tv~e Tandem . . Fluid type Type Disc plate runout mm {in) [ 0.1 {0.004) max. Wheel cvlinder bore mm {in) I 51.1 i2.011 . . FMVSS116, DOT-3 Disc ~hickness of pad mm {in) Thickness of disc plate mm {in) I I . . Wheel cylinder bore mm {in) I 31.75 (1.25) Standard Limit .%mhd Limit Lever notches 1 7 n 8.0 I0.31) 1 .O (0.041 20.0 {0.79) 18.0 {0.71} . . Disc 8.0 {0.31) 1 .O i0.04) 9.0 10.35) . , TY pe Thickness of pad mm {in) Thickness of disc plate Tvoe I Sinale diawhraam Standard Limit &mdard mm {in) (Pulled at 196 N (20 kgf, 44 Ibf)) ,r- I " . - Diameter mm {in) I 21 4 (8.0) Limit 1-3 Push rod-to-piston clearance mm (in) When vacuum applied to the unit is approx. 66.7 kPa (500 mmHg, 19.7 inHg} 0.1-0.4 (0.004--0.016) Fluid pressure per treading force kPa {kgf/cm2, psi)/N {kgf, Ibf) Tv~e Q. WHEELS AND TIRES 1,079-1,177 {ll-12, 15&171)/196 (20,441 at 0 kPa 10 mmHg, 0 inHg) min. 5,199~5,494 {53-56, 754--796)/196 {20, 44) at 66.7 kPa (500 mmHg, 19.7 inHg} min. PBV Bend portion (Rear brake pressure) kPa {kgf/cm2, psi) 2,943 {30,427) Wheel Temporary spare 14x4T TY Pe ltem 1 Size Standard 14x5 112-JJ Offset mm {in) Pitch circle diameter mm {in) Material Tire Wheel and tire I 45 {I .77) 100 (3.94) Aluminum allov Steel Size Air pressure kPa {kgf/cm2, psi) 185/60R14 82H 179 11.8, 26) Runout limit mm {in) 1 TI 1 5/70D1 4 41 5 (4.2, 60) Horizontal Vertical 2.0 {0.079) 1.5 10.059) 10 (0.35) Maximum unbalance (at rim edge) 9 {oz) 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

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