1994 MAZDA MX-5 Workshop Manual

Gartner Banana

VEHICLE IDENTIFICATION NUMBERS (VIN) JM1 NA353*R# 500001 - Gartner Banana

GENERAL INFORMATION SAFETY INFORMATION ...................... GI- 2 LUBRICANTS .............................. GI- 2 JACKING POSITIONS ...................... GI- 2 SAFETY STAND POSITIONS ................ GI- 2 VEHICLE LIFT POSITIONS .................. GI- 3 DYNAMOMETER ........................... GI- 3 COMPRESSED AIR ........................ GI- 3 HOW TO USE THIS MANUAL ................. GI- 4 ADVISORY MESSAGES .................... GI- 4 PREPARATION ............................ GI- 4 REPAIR PROCEDURE ...................... GI- 4 SYMBOLS ................................. GI- 5 IDENTIFICATION NUMBER LOCATIONS ....... GI- 6 UNITS ...................................... GI- 6 ABBREVIATIONS ............................ GI- 7 SAE STANDARDS ........................... GI- 8 FUNDAMENTAL PROCEDURES ............... GI-11 PROTECTION OF THE VEHICLE ............ GI-11 PREPARATION OF TOOLS AND MEASURING EQUIPMENT ............................. GI-11 SPECIAL TOOLS ........................... GI-11 REMOVALOF PARTS ...................... GI-11 DISASSEMBLY ............................ GI-11 REASSEMBLY ............................. GI-1 2 ADJUSTMENTS ............................ GI-13 RUBBER PARTS AND TUBING .............. GI-13 HOSE CLAMPS ............................ GC13 TORQUE FORMULAS ...................... GI-13 VISE ...................................... GI-13 ELECTRICAL TROUBLESHOOTING TOOLS ... GI-14 TEST LIGHT ............................... GI-14 JUMPER WIRE ............................ GC14 VOLTMETER .............................. GI-14 OHMMETER ............................... GI-14 ELECTRICAL PARTS ......................... GI-1 4 BATTERY ................................. GI-1 4 BATTERY CABLE .......................... GI-1 5 CONNECTORS ............................ GI-15 TERMINALS ............................... GI-16 SENSORS. SWITCHES. AND RELAYS ....... GI-17 WIRING HARNESS ......................... GI-17 FUSE ..................................... GI-17 INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEM ................................... GI-18 AUDIO ANTITHEFT SYSTEM ................. GI-18 TOWING .................................... GI-19 45UGIX-001 Gartner Banana

SAFETY INFORMATION SAFETY INFORMATION LUBRICANTS ) Avoid prolonged and repeated contact with petroleum-based oils. Used oil may irritate the skin, and can ...--/ cause skin cancer and other skin disorders. Wash thoroughly after working with oil. We recommend water soluble hand cleaners. Do not use kero- sene, gasoline, or any other solvent, to remove oil from your skin. If repeated or prolonged contact with oil is necessary, wear protective clothing. Soiled clothing, particu- larly those soiled with used oils and greases containing lead, should be cleaned at regular intervals. 46UGIX-002 JACKING POSITIONS Warning Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking positions and block the wheels. Use safety stands to support the vehicle after it has been lifted. Front At the center of the crossmember SAFETY STAND POSITIONS Front Both sides of the vehicle, on side sills Rear At the center of the differential Rear Both sides of the vehicle, on side sills Gartner Banana

SAFETY INFORMATION VEHICLE LIFT POSITIONS Front DYNAMOMETER Rear When test-running a vehicle on a dynamometer Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit. Cool the exhaust pipes with a fan. Keep the area around the vehicle uncluttered. Watch the water temperature gauge. COMPRESSED AIR When using compressed air to clean or remove parts / Wear protective eyewear. L- a Hold a rag over the opening to prevent parts from shooting out. Take precautions so that people around you are not struck by flying debris. Gartner Banana

GI HOW TO USE THIS MANUAL HOW TO USE THlS MANUAL ADVISORY MESSAGES You'll find several Warnings, Cautions, and Notes in this manual. Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note A Note provides added information that will help you to complete a particular procedure. PREPARATION This points out the needed SSTs for the service operation. It is best to gather all necessary SSTs before beginning work. Example: 46UGIX-013 REPAIR PROCEDURE MANUAL STEERING PREPARATION SST NUMBER USAGE SST 1 1 Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. If a damaged or worn part is found, repair or replace it as necessary. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the over- view illustration. Pages related to service procedures are shown under the illustration. Refer to this information when servicing the related part. 46UGIX-014 I id' I SST NAME SST ILLUSTRATION For removal of t~e rod end 49 01 18 850C Puller, ball pnt 49 01 18 850C For removal of t~e rod end Gartner Banana

HOW TO USE THIS MANUAL Example: SHOWS EXPENDABLE PARTS SHOWS APPLICATION POINT OF OIL, ETC SHOWS RELATED PAGE FOR. SERVICE SELECTIVE 1. 8011 2. Lock plate 3. Bearing cup t. Adjusting screw 5. Bearing outer race 5. Locknul 16. Bearing inner race 18. drive pinion 1. Washer Removal ..................... .. .... page M-2' SHOWS TIGHTENING TORQUE SPECIFICATIONS *2 SHOWS TIGHTENING TORQUE UNIT -SHOWS VISUAL INSPECTION INFORMATION *1: The numbers (0, etc.) refer to part identification and servicing procedures. *2: Units are in N.m {kgf.m, ftlbf} unless otherwise specified. $ L SYMBOLS There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such materials during service. Symbol I Meaning ~pp~y oil Apply brake fluid I Apply automatic transmission fluid Apply grease Apply sealant Kind 0 New engine oil or gear oil as appropriate Apply petroleum jelly Appropriate grease Appropriate sealant Appropriate petroleum jelly Gartner Banana

IDENTIFICATION NUMBER LOCATIONS/UNITS IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER (VIN) AUTOMATIC TRANSMISSION MODEL AND NUMBER ENGINE MODEL AND NUMBER UNITS Electrical current ............ A (ampere) Electric potential ............ V (volt) Electric power. .............. W (watt) Length ..................... mm (millimeter) in (inches) Negative pressure ........... kPa (kilo Pascal) mmHg (millimeter of mercury) inHg (inches of mercury) Positive pressure ............ kPa (kilo Pascal) kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) Resistance ................. SZ (ohm) Torque ..................... N-m (Newton meter) kgfm (kilogram force per meter) kgfzm (kilogram force per centimeter) ft-lbf (foot pounds) in-lbf (inch pounds) Volume .................... L (liter) US qt (U.S. quart) Imp qt (Imperial quart) Gartner Banana