1994 MAZDA MX-5 air condition

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . BRAKING SYSTEM INDEX ....................................... P- 2 OUTLINE ..................................... P- 4 SPEClFlCATlONS ........................... P- 4 BRAKE SYSTEM ............................. P- 5 PREPARATION ............................. P- 5 TROUBLESHOOTING GUIDE ................ P- 6 AIR BLEEDING ............................. P- 7 BRAKE HYDRAULIC LINE ................... P- 7 BRAKE FLUID .............................. P- 8 ............................. BRAKE PEDAL P- 9 MASTER CYLINDER (STANDARD) ............ P-11 MASTER CYLINDER (ABS) .................. P-14 POWER BRAKE UNIT ....................... P-20 PROPORTIONING BYPASS VALVE ........... P-23 FRONT BRAKE (DISC) ...................... P-25 CALIPER ................................... P-28 REAR BRAKE (DISC) ........................ P-29 CALIPER ................................... P-32 PARKING BRAKE SYSTEM .................... P-34 TROUBLESHOOTING GUIDE ................ P-34 PARKING BRAKE LEVER .................... P-34 PARKING BRAKE CABLE .................... P-36 ANTILOCK BRAKE SYSTEM (ABS) ............ P-37 DESCRIPTION .............................. P-37 PREPARATION ............................. P-37 TROUBLESHOOTING GUIDE ................ P-38 CIRCUIT DIAGRAM ......................... P-52 HYDRAULIC UNIT ........................... P-53 ........................ ABS CONTROL UNIT P-55 RELAYS .................................... P-56 ABS WHEEL SPEED SENSOR (FRONT) ....... P-58 ABS SENSOR ROTOR (FRONT) .............. P-59 ABS WHEEL SPEED SENSOR (REAR) ........ P-60 ABS SENSOR ROTOR (REAR) ............... P-61 25UOPX-001 Gartner Banana

P BRAKE SYSTEM k FIRST PEDAL VACUUM GAUG DEPRESSION FORCE GAUGE POWER BRAKE UNIT Quick Inspection, On-vehicle Power brake unit function check (Simple method) ii Step 1 1. With the engine stopped, depress the pedal a few times. 2. With the pedal depressed, start the engine. 3. If immediately after the engine starts the pedal moves down slightly, the unit is operating. Step 2 1. Start the engine and let it run 1 or 2 minutes. 2. Stop the engine. 3. Depress the pedal with the usual force. 4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating. 5. If a problem is found, inspect for damage or improper connection of the check valve or vacuum hose. Repair if necessary, and inspect it once again. Step 3 1. Start the engine. 2. Depress the pedal with the usual force. 3. Stop the engine with the pedal depressed. 4. Hold the pedal down for about 30 seconds. 5. If the pedal height does not change, the unit is operating. ,, 6. If there is a problem, check for damage or improper con- nection of the check valve or vacuum hose. Repair if necessary, and check once again. If the nature of the problem is still not clear after following the 3 steps above, follow the more detailed check described in "Method using tester," below. (Method using tester) Connect the SST, vacuum gauge, and pedal depression force gauge as shown in the figure. After bleeding the air from the SST, conduct the test as described in the 3 steps below. Inspection using gauges Connect the SST gauges, a vacuum gauge (A), and a pedal depression gauge (B) as shown. Bleed the air from the SST gauges before performing the following tests. a) Checking for vacuum loss Unloaded condition 1. Start the engine. 2. Stop the engine when the vacuum gauge indicates 66.7 kPa (500 mmHg, 19.7 inHg). 3. Observe the vacuum gauge for 15 seconds. If the gauge indicates 63.4-66.6 kPa (475-500 mmHg, ,, 18.7-19.7 inHg), the unit is operating. Gartner Banana

BRAKE SYSTEM P (20 kgf, 44 Ibf) (20 kgf, 44 Ibf) Loaded condition 1. Start the engine. 2. Depress the brake pedal with a force of 196 N (20 kgf, 44 Ibf). 3. With the brake pedal depressed, stop the engine when the vacuum gauge indicates 66.7 kPa I500 mmHg, 19.7 inHg). 4. Observe the vacuum gauge for 15 seconds. If the gauge indicates 63.4-66.6 kPa (475--500 mmHg, 18.7-19.7 inHg), the unit is operating. b) Checking for hydraulic pressure 1. If with the engine stopped (vacuum 0 kPa (0 mmHg, 0 inHg}) the fluid pressure is within specification, the unit is operating. 1 Pedal force Fluid pressure 2. Start the engine. Depress the brake pedal when the vac- uum reaches 66.7 kPa (500 mmHg, 19.7 inHg). If the fluid pressure is within specification, the unit is operat- ing. 1 96 N {20 kgf, 44 Ibf) I Pedal force I Fluid pressure I 1,079-1,177 kPa {I 1-1 2 kgf/cm2, 156-1 71 psi) lnspection of Check Valve 196 N {20 kgf, 44 Ibf) Note There is an arrow on the hose to indicate direction of hose installation. 5,199--5,494 kPa {53-56 kgf/cm2, 754--796 psi} lnspection 1. Disconnect both ends of the vacuum hose. 2. Apply suction and pressure to the hose from the engine side. Verify that air flows only toward the engine. If air passes in both directions or not at all, replace the vac- uum hose (along with the check valve). Gartner Banana

WHEELS AND TIRES SHOULDER WEAR CENTER WEAR (c) (4 FEATHERED EDGE TOE-IN OR TOE- UNEVEN WEAR OUT WEAR Troubleshooting guide Abnormal tire wear patterns, such as those shown in the illustration can occur. Refer to the chart for the possible causes and actions. d' Possible cause I Action I I Underinflation (both sides worn) I Measure and adjust pressure Overinflation Measure and adjust pressure Lack of rotation Rotate tires I Incorrect camber (one side worn) Hard cornering Lack of rotation Incorrect toe-in I Adjust toe-in I Repair or replace suspension parts Reduce speed Rotate tires 1. Cracks, damage, and foreign matter (such as metal pieces, nails, and stones) in the tire and cracks, deformation, and damage to the wheel. 2. Loose wheel lug nut(s). 3. Air leaking from valve stem. Incorrect camber or caster Malfunctioning suspension Unbalanced wheel Out-of-round brake drum or disc Other mechanical conditions Lack of rotation REMOVAL / INSTALLATION When reinstalling a wheel, retighten the lug nuts to the specified torque after about 1,000 km (620 miles} driv- ing. Repair or replace suspension parts Repair or replace Balance or replace Correct or replace Correct or replace Rotate tires Caution Applying oil to the lug nuts, bolts, or wheels will cause the lug nuts to become loosened. Tighten the lug nuts to the specified torque in a criss- cross fashion. Verify that the wheel-to-hub contact surfaces are clean. Tightening torque: 88-11 8 N.m (9-1 2 kgf.m, 65--87 ft-lbf) Gartner Banana

Before beginning any service procedure. refer to section T of this manual for I air bag system service warnings and audio antitheft system alarm conditions . INDEX ....................................... R- 2 OUTLINE ..................................... R- 4 SPECIFICATIONS ........................... R- 4 TROUBLESHOOTING GUIDE .................. R- 5 WHEEL ALIGNMENT .......................... R- 6 PRE-INSPECTION .......................... R- 6 FRONT WHEEL ALIGNMENT ................. R- 6 .................. REAR WHEEL ALIGNMENT R- 9 FRONT SUSPENSION (DOUBLE-WISHBONE) ... R-11 PREPARATION ............................. R-11 SHOCK ABSORBER AND SPRING ............ R-11 LOWER ARM ............................... R-15 UPPER ARM ............................... R-17 STABILIZER ................................ R-19 CROSSMEMBER ........................... R-20 REAR SUSPENSION (DOUBLE-WISHBONE) .... R-21 PREPARATION ............................. R-21 SHOCK ABSORBER AND SPRING ............ R-22 LOWER ARM ............................... R-23 UPPER ARM ............................... R-24 STABILIZER ................................ R-25 CROSSMEMBER ........................... R-26 25UORX-001 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

T LIGHTING SYSTEM Troubleshooting Symptom: Stoplights do not illuminate (All). 45UOTX-105 '' HIGH-MOUNT STOPLIGHT 05UOTX-12: Step 1 1. Check STOP 15A fuse in the fuse box. 2. If the fuse is burned, replace it. Check and repair the wire harness, if necessary. 3. If the fuse is OK, go to Step 2. ~easure the voltage at the following terminal wires of the stoplight switch connector. B+: Battery positive voltage Inspection 1 ~erm w I voltage 1 condition Action I B+ I Check B terminal I Repair wiring harness Other I (STOP 15A fuse - Storrliaht switch) I Brake pedal B+ I Go to Step 3 depressed Other 1 Check stoplight switch w -- 1. 6heck the stoplight bulbs. 2. If a bulb is burned, replace it. 3. If the bulbs are OK, go to Step 4. Step 4 Measure the voltage at the following terminal wires of the right and left rear combination light connectors. B+: Batterv ~ositive voltacle -. - '"spection I Terminal I Voltage 1 condition Action Brake pedal depressed B+ Other B+ Other Check F terminal Repair wiring harness (Stoplight switch - Rear combina- tion light) Repair wiring harness (Rear combination light - GND) Check for poor connection of con- nectors Gartner Banana

LIGHTING SYSTEM T u I Symptom: Stoplights does not illuminate (One only). 45UOTX-108 STOPLIGHT 'I HIGH-MOUNT STOPLIGHT Removal / Installation - -- 1. stoplight, High-mount stoplight 2. Remove and install as shown in the figure. Step 1 1. Check the stoplight bulb of the faulty side. 2. If a bulb is burned, replace it. 3. If the bulb is OK, go to Step 2. Step 2 Measure the voltage at the following terminal wires of the faulty rear combination ligjht connector. B+: Battery ~ositive voltaae -. - I Inspection I TernM I Voltage I condition Action - STOPLIGHT (LH AND RH) HIGH-MOUNT STOPLIGHT Brake pedal depressed F B+ Other B+ Other Check F terminal Repair wiring harness (Stoplight switch - Rear mrnbina- tion light) Repair wiring harness (Rear combination light - GND) Check for poor connection of con- nectors Gartner Banana