1994 MAZDA MX-5 Workshop Manual

TECHNICAL DATA D. LUBRICATION SYSTEM - Engine ltem BP DOHC - -. Lubrication system Force-fed type E. COOLING SYSTEM Trochoid gear 344-41 I3.5--4.5,s-31 9&l96 {I .&2.0, 15--28) 295-392 {3.0-4.0,43-56) 0.02-0.1 8 {0.000&0.0070) 0.20 {0.0079) 0.09-0.18 (0.0036-0.0070) 0.20 {0.0079) 0.03-0.1 2 {0.0012-0.0047) 0.14 (0.0055) TY pe Relief pressure kPa {kgf/cm2, psi) Oil pressure kPa {kgf/cm2, psi) Inner rotor tooth tip to outer rotor clearance mm {in) Outer rotor to body clearance mm {in) Side clearance mm {in) Water seal type I Unified mechanical seal Thermostat 1,000 rpm 3,000 rpm Standard Maximum Standard Maximum Standard Maximum Oil filter Engine ltem - - Cooling system . . Impeller diameter mm {in) Number of impeller blades Type Relief pressure differential kPa {kgf/cm2, psi) BP DOHC Water-cooled, forced circulation - 75 i2.95) 6 Full-flow, paper element 74-1 17 {0.&1.2, 12-1 7) TY pe . ., . . . - Radiator I Water pump Wax, two-stage v. . . Full-open temperature "c {OF) Full-open lift mm {in) Engine oil TVD~ O~enina tem~erature "C con I Sub: 83.5-86.5 U83-187). Main: 86.5-89.5 (1 88-1 931 100 (21 2) Sub: 1.5 (0.06) min., Main: 8.0 (0.31) min. -. . - . . Cooling circuit checking pressure kPa {kgflcmz, psi) I 103 {I .05, 14.9) I Centrifugal, V-ribbed belt driven TY pe I Coolant fan I 4.0 (4.2, 3.5) 3.6 {3.8,3.2) 3.75 (4.0, 3.3) API Service SG, SH (ECII) ILSAC Capacity Corrugated fin viscosity Above -25°C (-1 3°F) SAE 1 OW-30 number Below 0°C {3Z°F) SAE 5W-30 Total (dry engine) L {US qt, Imp qt) Oil replacement L {US qt, Imp qt) Oil and oil filter replacement L {US qt, Imp qtl Cap valve o~enina pressure kPa {krrf/cm2, psi} 1 73.6--102 {0.75--1.05, 10.7-14.91 Capacity W-V I 120-1 2 Current A 1 below 7.7 Engine oil Type Number of blades Outer diameter mm {in) Coolant Capacity L {US qt, Imp qt) I 6.0 {6.3,5.3) Electric 5 320 (1 2.61 Gartner Banana

TD TECHNICAL DATA Idle speed rpm 1 800-900 (850 2 50) [MT]', 750-850 (800 f 50) [ATJ' lanition timina BTDC I 9"-11' (10' f 1")' u' F. FUEL AND EMISSION CONTROL SYSTEMS - Engine ltem Item 1 Throat diameter mm {in) 1 55 (2.2) 1 Antifreeze solution BP DOHC Specification 1 Throttle body Fuel pump TY pe I Impeller (in-tank) Coolant protection Above -1 6°C (3°F) Above -26°C (-15°F) Above -40°C {-40°n Tv~e -. Output pressure kPa (kgf/cm2, psi) I 294-437 {3.0--6.5,43--92) Fuel filter Specific gravity at 20°C {WF) 1.054 1.066 1.078 Volume percentage % Horizontal draft Water 65 55 45 -. . - Regulating pressure kPa {kgf/cm2, psi) I 280-289 I2.85--2.95, 40.141.9) Fuel iniector Coolant 35 45 55 TY pe IAC valve Solenoid resistance n 1 10.7-1 2.3 (at 20°C (68°F)) Low-pressure side TYP~ Type of drive Resistance n Purge solenoid valve Solenoid resistance n 1 23-27 (at 20°C (68°F)) I Nylon element Pressure regulator TY pe High-ohmic Voltage 13.8 (at 20°C (68"FI) Engine coolant temperature sensor 7 20°C {68"F) I 2.21 -2.69 Resistance kn I 80°C (1 76OF} I 0.287-0.349 High-pressure side Diaphragm i/ Crankshaft position sensor Air valve Openin~l temperature OC {OF) I Below 45 (1 131 Paper element Twe 1 Fuel tank I Hall effect . . . . . . . Capacity L {US gal, Imp gal) I 48 {12.7, 10.5) Air cleaner housing Element type Free play mm (in) I 1-3 {0.039--0.118) I Fuel Oil permeated Specification Accelerator cable Unleaded regular (RON 87 or higher) J +....with system selector (49 B019 9AO) test switch at SELF TEST Gartner Banana

TECHNICAL DATA TI) G. ENGINE ELECTRICAL SYSTEM )ark current*' - Engine tem Voltage V 3attery Type and capacity (5-hour rate) Starter -. . BP DOHC MT mA 1 20.0 AT Tvm Ignition system 12, Negative ground S46A24L(S) (32 Ah) Maintenance-free A.C. ST- Output V-A Regulator type Regulated voltage V 12-65 Brush length mm {in) Drive belt deflection mm {in) 17.5 (0.69) 12.0 (0.471 - -- r-- I I hPe Spark plug 1 2-70 Standard Minimum New Used Brush length mm {in) BKR6E-11 (Standard ... MT) NIPPONDENSO : K16PR-U11 K20PR-U11 (Standard ... MT, AT) TYW OU~DU~ V-kW Standard 1 17.0 I0.67) Minimum 1 11.5 10.451 1 Type Spark advance control Ignition timing*2 BTDC ("CA)/rpm Transistorized (built-in voltage regulator) 14.3-1 4.9 21.5 (0.85) 8 I0.31) 5.5-7.0 {0.22--0.27) 6.0-7.5 {0.24--0.29) . . I . . Electronic spark advance (ESA) Powertrain control module (engine) controls spark advance Ignition coil H. CLUTCH Direct lot850 TY ~e Primary coil winding a Secondary coil winding ks2 . .- - Engine Item BP DOHC 1 Coaxial reduction 10/800 Molded (with igniter) - 8.7-1 2.9 NGK : BKR5E-11 *I Dark current is the.constant flow of current while the ignition switch is OFF. (i.e. powertrain control module (engine), audio, etc.) '2 With System Selector (49 B019 9AO) test switch at SELF TEST. , Plug gap mm (in) Firing order 124.95 1 .O-1.1 {0.040--0.043) 1-342 Clutch control Runout limit mm {in) 1 0.2 (0.008) I 12-1.4 Hydraulic Clutch pedal TYP Suspended A .- 6.13 120 (4.72) 175--185 {6.89--7.28) 0.G3.1 (0.02-0.12) 68 I2.68) Pedal ratio Full stroke mm {in) Height (with carpet) mm (in} Free play mm {in} Distance to carpet when clutch fully disengaged rnm [in Minimum Gartner Banana

TECHNICAL DATA Engine ------ BP DOHC I Clutch disc I Sinale drv date I u - w- ., Runout limit rnrn {in) 0.7 (0.026) Wear limit rnm linl 0.3 10.01 2) from rivet head . a, 1 outer diameter mm {in) I 215 (8.46) 1 J. MANUAL TRANSMISSION 150 (5.91) 3.5 (0.14) 3.8 (0.15) Inner diameter mm {in) Type _____L- Transmission ___2_ M15M-D Clutch cover Facing thickness mm {in) Diaphragm spring Flywheel side Pressure plate side Set load N {ksrf. Ibn 1 4,310 /440. 968) Gear ratio Runout rnm {in) Mainshaft Clearance between main- shaft and gear (or bush) mm {in} t-- Reverse Oil capacity L {US qt, Imp qt) 1 Maximum 3rd 4th 5th 3.758 2.0 (2.1, 1.8) 0.03 10.001 2) Clearance between shift fork and clutch sleeve Shift fork and rod rod gate and control lever 1.330 1 .OOO 0.814 Reverse idle gear Clearance between reverse idle gear bushing and shaft mrn {in) Synchronizer ring Wear limit Wear limit Clearance between syn- chronizer ring and side of gear when fitted mm {in} Wear limit 0.1 5 {0.006) Wear limit Wear limit I 1 mm {in) ( 75 i2.953) Standard 1.5 (0.059) 22.5 (0.886) 22.5 i0.886) 17.0 (0.669) Detent ball spring (I sV2nd) Detent ball spring (3~94th) Detent ball spring (5thlReverse) Lubricant Free length mm (in) Free length mrn {in) Free length mm {in) Above 10°C {50°F} All seasons API Service GL-4 or GL-5 SAE 80W-90 API Service GL-4 or GL-5 SAE 75W-90 Gartner Banana

TECHNICAL DATA K. AUTOMATIC TRANSMISSION tem Transmission ;ear ratio NC4A-EL 4utomatic trans- nission fluid :ATF) 3il pump Drum support Direct clutch Forth gear plan- etary gear unit Front clutch Rear clutch Front planetary gear unit Rear planetary gear unit Low and reverse brake Oil distributor First Second Third Fourth Reverse TY pe Capacity L {US qt, Imp qt) Body clearance Standard mm {in) -Maximum Tip clearance Standard mm {in) Maximum Side clearance Standard mm {in) Maximum Seal ring and groove clear- Standard ance mm {in) Maximum Side plate clearance mm {in) Side plate size mm{in) End play mm {in) Bearing race size mm {in) Standard Pinion clearance mm {in) Maximum Total end play mm {in) Bearing race size mm (in) Retaining plate clearance mm {in) Retaining plate size mm {in) End play mm (in) Bearing race size mm {in) Retaining plate clearance mm {in) Retaining plate size mm {in) Total end play mm {in) Bearing race site mm {in) Standard Pinion clearance rnm {in) Maximum Standard Pinion clearance mm {in) Maximum Retaining plate clearance mm {in) Retaining plate size mm {in) Seal ring to groove Standard clearance mm {in) Maximum Valve spring specification 2.458 1.458 1 .OOO 0.720 2.1 82 ~exron~ll or M-Ill 7.3 {7.7, 6.4) 0.02-0.04 {0.000&0.0015) 0.08 (0.0031) 0.14--0.21 IO.0056--0.0082) 0.25 {0.0098) 0.05-0.20 {0.0020--0.0078) 0.25 {0.0098) 0.04-0.1 6 {0.0016--0.0062) - - 0.40 {0.0157) 0.2 {0.008) 0.4{0.016),0.6{0.024},0.8{0.031),1.0{0.039),1.2{0.047) 0.5-0.8 {0.020--0.031) 0.8 {0.031), 1 .O {0.039}, 1.2 (0.0471, 1.4 {0.055), 1.6 {0.063), 1.8 {0.071), 2.0 {0.079), 2.2 {0.087) 0.2-0.7 {0.008-0.028) 0.8 {0.031} 0.254.50 {0.0099-0.0196) 1.2 {0.047}, 1.4 (0.0551, 1.6 {0.063), 1.8 {0.071), 2.0 {0.079), 2.2 {0.087) 0.9-1.1 {0.036-4.043) 5.8 {0.228),6.0 (0.2361, 6.2 (0.2443, 6.4 (0.2521, 6.6 {0.260), 6.8 {0.268),7.0 {0.276) 0.5-4.8 {0.020-0.031) 0.8 {0.031), 1.0 {0.039), 1.2 {0.047), 1.4 {0.055}, 1.6 (0.063), 1.8 {0.071}, 2.0 (0.079), 2.2 (0.087) 0.-1 .O iO.032-0.039) 6.2 {O.244},6.4 {O.252}, 6.6 (0.2601, 6.8 (0.2681, 7.0 {0.276), 7.2 {0.283), 7.6 (0.299) 0.25-0.50 {0.0099--0.0196} 1.2 {0.047}, 1.4 {0.055), 1.6 {0.063), 1.8 {0.071), 2.0 {0.079}, 2.2 I0.087) 0.2-0.7 {0.008--0.027) 0.8 (0.031j 0.2-0.7 {0.00&0.027) 0.8 {0.031} 0.8-1.05 {0.031-0.041) 11.8 I0.4651, 12.0 {0.472}, 12.2 {0.480}, 12.4 {0.488}, 12.6 {0.496}, 12.8 (0.504) 0.04--0.16 (0.001 6--0.0062) 0.40 {0.0157) Control valve . . 11.7 (0.461) 7.4 (0,291 ) 10.0 (0.394) 7.5 (0.295) Pressure regulator 1-2 shift - 2-3 shift 3-4 shift Wire dia. mm fin) Outer dia. mm fin) . . 43.0 (1.693) 26.4 (1 .039) 50.0 (1.969) 40.2 (1.563) Free length mm (in of coils 13.0 9.6 13.7 15.0 -. 1.2 (0.047) 0.7 (0.026) 1 .O (0.039) 0.8 (0.031 ) Gartner Banana

TECHNICAL DATA Mode NOR- MAL 4 POWER - Transmission Item _5 Valve spring specification . , Throttle condition NC4A-EL Control valve Oil pump Drum support Band servo Wide open throttle Outer dia. mm {in) 9.2 (0.362) 6.7 {0.264) 9.0 (0.354) 7.4 (0.291) 8.5 (0.335) 5.5 (0.21 7) 5.0 (0.1971 9.4 (0.370) 11.2 i0.441) 8.9 (0.350) 9.3 (0.366) 6.5 (0.256) 5.5 {0.217) 16.0 (0.630) 27.7 {I .092) 28.25 (1.11 2) 8.0 (0.31 5) - 7.2 (0.283) Half throttle Direct, front, and rear clutches Low and reverse brake Parking rod Shift point (shift s~eed) Pressure modifier - - -- Closed throttle position Kickdown (Wide open throttle) Free length rnm {in) 19.8 (0.780) 17.5 (0.689) 17.5 (0.689) 14.5 (0.571) 21.3 (0.839) 39.5 {I .555) 15.5 {0.610} 19.5 (0.768) 62.0 (2.441) 82.5 (3.248) 43.4 {I .709) 26.8 11.055) 25.7 (1.012) 40.4 (1.591) 47.0 {I .850) 38.7 {I .52) 30.5 {I .20) 5.9-6.2 (0.2324.244) 32.0 {I .260) Throttle backup Wide open throttle Half throttle Small Large Closed throttle position No. of coils 5.3 7.4 5.2 5.0 7.3 24.4 12.0 5.0 21.3 29.7 22.0 14.0 16.5 9.8 14.0 5.4 14.5 - 14.0 N-R reducing Backup control 3-2 control Orifice check 1-2 reducing 1-2 accumulator N-W2-3 accumulator N-D accumulator Throttle relief (ball) Lockup control Fourth gear accumulator Fourth gear 2nd Kickdown (Wide open throttle) Wire dia. mm {in) 0.7 (0.028) 0.7 (0.028) 0.9 (0.035) 0.6 (0.024) 0.9 (0.035) 0.65 (0.026) 0.23 {0.009) 0.8 (0.031) 1.2 t0.047) 1.1 (0.043) 1.4 (0.055) 0.9 (0.035) 0.7 (0.028) 2.6 {0.102) 3.5 (0.1 38) 3.5 (0.1 38) 1.3 (0.051) - 0.7 (0.028) d Shift I D1-+D2 I D2+D3 D3 lockup ON D3+D4 b-+D2 - Vehicle speed kmlh (mph) 58-64 (36-39) 1 OQ108 (62-46) 9&106 (61-65) 152-1 62 (9%100) 3346 (21 -28) D2-*D3 '33434 D4 lockup ON D4-+b 0i-t~~ D2*D3 03 lockup ON D3-D4 58-76 (36-47) 82-1 1 0 (5 1-48} 74-1 00 (46--62) 28-34 (1 7-21 ) 44--55 {2&34) 90-1 08 (5666) 9&106 (61-65) 14-1 64 (87-1 01) Gartner Banana

TECHNICAL DATA :em - ange - D - S Transmission Mode NC4A-EL HOLD - POWER HOLD POWER HOLD -ine pressure Vehicle speed kmlh {mph) 27-33 {I 7-20) 3545 {22-27) 152-1 58 (94-97) 12-1 8 (8-1 1) 95-1 05 {59--65) 5-4 (36--39) 1 OO--108 {62--66) 98-1 05 (6 145) 44-55 {28--34) 9&108 {56--67) 94--106 {58--66) 11-17 (7-10) 92-1 00 (5742) 4248 (2629) 99--105 {61-65) 95-1 05 (59-45) 56-62 {35-38) 44-55 (27-34) 96-104 {60-64) 11-17 {7-10) 99-1 05 {61--65) 4248 {26-29) 3541 (21-25) 95--105 (59-65) 775-970 {7.9-9.9, 11 3-1 40) 1,972-2,167 l20.1-22.1,286--314) 285-362 {2.9-3.7,42-52) 795-91 2 (8.1-9.3, 11 61 32) 785-921 (8.G9.4, 114-1 33) 79S912 {8.1-9.3, 116--132) 29!5-392 {3.0-4.0,43-56) 883-1,078 I9.0-11 .O, 128-1 56) 2.1 00-2,500 Throttle condition All positions Wide open throttle Half throttle Closed throttle position Kickdown (Wide open throttle) All positions Wide open throttle Half throttle Closed throttle position Kickdown (Wide open throttle) All positions R range kPa {kgf/cm2, psi) D range kPa {kgf/cm2, psi) S range kPa {kgf/cm2, psi) L range kPa {kgf/cm2, psi) I Shift Dl432 D2-'D3 D443 D3+D1 DS lockup ON s142 s2+s3 S3 lockup ON S142 S2-'s3 S3 lockup ON S3+S1 s3-'s2 s241 s3+s2 S3 lockup ON Ld-2 L14-2 L3+L2 L241 L3-'L2 L2-4-1 L241 L3 lockup ON Idle Stall Idle Stall Idle Stall Idle Stall r~m L. PROPELLER SHAFT Adjusting rod length mm {in) 29.0 {I .14) 29.5 {I. 16) 29.75 (1.1 7) 30.0 {I .18) 30.5 (1.20) 31 .O (1.22) 0.5-0.6 0.75-0.85 'ngine stall speeo Item Max. permissible run-out mm {in) lacuum dia- thragm Time lag Specification 0.4 {0.016) Clearance between body and throttle valve mm {in) Below 25.65 {I ,0099) 25.65-25.15 {I .0099-1.0295) 25.90-26.40 {I ,0197-1.0394) 26.1 5-26.65 (1.0295-1.0492) 26.65--27.15 {I .0492-1.0669) 27.1 5 {1.0689} or over N - D sec. N-R sec. L-' Gartner Banana

TECHNICAL DATA --- M. FRONT AND REAR AXLES Specifications TY pe Bearing Angular ball bearing 0.05 10.002) Front axle Rear axle - Wheel bearing play mm {in) I Maximum Bearina Anaular ball bearina . .. Wheel bearina plav mm {in) I Maximum " " 0.05 {0.002) 'TORSEN" LSD I Standard TY pe Reduction aear Hvpoid sear Reduction ratio Differential aear 4.100 Worm near ("1ORSEN"LSD) I Straiaht-bevel gear - - Ring gear size mm {in) 1 Grade 182.88 17.201 API service GL-5 Oil 1 Viscosity Above -18°C {O°F): SAE 90 Below -18°C {O°F): SAE 80W Differential Capacity L {US at. Imp at) Locknut tightening torque: 128-284 N.m {I 3-29 kgf.m, 94.1-209.7 ft.lbf) Drive pinion preload (without oil seal) TORSEN" is a Backlash mm {in) . , egistered trademark of ZEXEL-GLEASON US, Side gear and pinion gear Final gear , INC Length (Pilot section to pilot section) mm (in N. STEERING SYSTEM Steering wheel Outer diameter mm {in} 1 370 11 4.6) Type item Free play mm {in) I 630 {O-1.18) Wheel effort N (kaf, Ibfl 14.9--29.4{0.5--3.0, 1.1-4.6) 123.545.3 12.A4.6,5.3--8.0) turns I 3.36 1 2.8 I 1 Manual steering Steering Shaft Shaft type I Collapsible, non-tilt Power steering Joint type I 2-cross joint Power steering system Gear ratio 1 m (infinite) Rack stroke rnm {in) I 121 .O 14.76) Power assist type Engine speed sensing Power steering fluid Fluid capacity L {US qt, Imp qt} Fluid pressure kPa {kgf/cm2, psi) Gear type - - ATF DexrongII oi M-111 0.8 {0.85,0.70) 7,603--8,339 (77.5850, 1 ,I 02-1,209) Rack-and-pinion Gartner Banana