1994 MAZDA MX-5 ABS

FUEL EVAPORATIVE SYSTEM FUEL EVAPORATIVE SYSTEM DESCRIPTION The fuel evaporative system consists of the fuel vapor valve, the two-way check valve, the charcoal can- ister, the purge solenoid valve, the powertrain control module (engine), and the input devices. The amount of evaporative fumes introduced into the engine and burned is controlled by the solenoid valve in relation to the engine's operating conditions. To maintain the best engine performance, the solenoid valve is controlled by the powertrab control module (engine). THROTTLE 1-1 POSITION SENSOR I1 I I (IDLE SWITCH) 7 BAROMETIC ABSOLUTE PRESSURE SENSOR PARWNEUTRAL SWITCH (AT) MASS AIRFLOW SENSOR CRANKSHAFT POSITION SENSOR (SGT-SIGNAL) n - DUTY - LOW HIGH (ENGINE) CHARCOAL PURGE SOLENOID VALVE CANISTER HEATED OXYGEN SENSOR ENGINE COOLANT POWERTRAIN TEMPERATURE SENSOR CONTROL MODULE CHECK VALVE # 11 FUEL VAPOR VALVE Operation The purge solenoid valve is controlled by duty signals from the powertrain control module (engine) to per- form purging of the charcoal canister. Purging is done when these conditions are met: i/ 1. After warm-up. 2. Driving in gear. 3. Accelerator pedal depressed (idle switch OFF). 4. Heated oxygen sensor functioning normally. Gartner Banana

TRANSMISSION 1. Snap ring 2. Washer 3. Retaining ring b 4. C-washer 5. Mainshaft rear bearing Disassembly Note . below Inspection ... page J-25 6. Retaining ring 7. C-washer 8. Thrust lock washer 9. Steel ball 10. Locknut (Countershaft) Disassembly Note ................ below 11. Countershaft rear bearing Disassembly Note ........... page J-18 Inspection ... page J-25 12. Counter 5th gear Inspection ... page J-23 13. Spacer 14. 5th gear 15. 5th synchronizer ring Inspection ... page J-24 16. Locknut (Mainshaft) Disassembly Note ........... page J-18 17. Clutch hub assembly (5thIReverse) Inspection ... page J-23 18. Reverse synchronizer ring Inspection ... page J-24 19. Reverse gear Inspection ... page J-23 20. Bearing Inspection ... page J-25 21. Bearing race 22. Washer 23. Counter reverse gear Inspection ... page J-23 24. Main drive gear bearing Disassembly Note ........... page J-18 Inspection ... page J-25 26. Countershaft front bearing Disassembly Note ........... page J-18 Inspection ... page J-25 27. Bearing housing assembly Disassembly Note ........... page J-18 Disassembly page J-20 28. Mainshaft gear assembly 29. Main drive gear Inspection ... page J-23 30. 4th synchronizer ring Inspection ... page J-24 31. Bearing Inspection ... page J-25 32. Washer 33. Countershaft Inspection ... page J-23 34. Spacer 35. Synchronizer key springs 36. Clutch hub sleeve 37. Synchronizer key . . Inspection ... page J-23 25. Snap ring 38. Clutch hub 45UOJX-012 Disassembly note Mainshaft rear bearing Remove the mainshaft rear bearing by using the SST. Locknut (Countershaft) 1. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 2. Use a suitable tool to uncrimp the tabs of the locknut. 3. Connect the SST to the mainshaft and secure it in a vise. 4. Remove the locknut. Gartner Banana

J TRANSMISSION Countershaft rear bearing Remove the countershaft rear bearing by using the SST. i/ Locknut (Mainshaft) 1. Shift the clutch hub sleeves into 1 st and Reverse gears to lock the rotation of the mainshaft. 2. Use a suitable tool to uncrimp the tabs of the locknut. 3. Secure the bearing housing in a vise. 4. Remove the locknut by using the SST. Main drive gear bearing Remove the main drive gear bearing with a suitable pipe. u Outer diameter of pipe: 70.0mm (2.76 in) Countershaft front bearing Remove the countershaft front bearing by using the SST. Bearing housing assembly Remove the bearing housing by lightly tapping the coun- tershaft with a copper hammer. Gartner Banana

FRONT AXLE M FRONT AXLE PREPARATION SST 49 01 18 850C Puller, ball joint 49 VOOl 795 For installation of Installer, oil sensor rotor seal (AW 49 0839 425C Puller set, bearing For disconnection of lower arm ball joint For disconnection of tie-rod end and upper arm ball joint For removal of sensor rotor (AW 49 0727 575 Puller, ball joint For removal of sensor rotor (ABS) 49 F027 007 Attachment @72 Gartner Banana

FRONT AXLE WHEEL HUB, STEERING KNUCKLE Inspection / Removal / lnstallation 1. lnspect wheel bearing play, referring to Inspection. 2. Remove in the order shown in the figure, referring to Removal Note. 3. lnspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal, referring to Installation Note. 25UOMX-OC 1. Front wheel 9. Lower arm 2. Brake caliper assembly Removal Note .............. page M-7 3. Disc plate 4. Hub cap 5. Locknut Installation Note ............ page M-7 6. Front wheel hub assembly lnspect for cracks and damage Disassembly / Inspection / Assembly ................. page M-8 7. Wheel speed sensor (ABS) 8. Tie-rod end Removal Note .............. page M-7 Service ..................... section N .............. Removal Note page M-7 ..................... Service section R 10. Upper arm .............. Removal Note page M-7 ..................... Service section R 11. Dust cover and knuckle spindle lnspect dust cover for damage and distortion lnspect knuckle spindle for cracks and damage Disassembly / Inspection 1 ................. Assembly page M-8 lnspection Wheel bearing play 1. Remove the wheel, brake caliper assembly, and disc plate, referring to Removal note below. 2. Position a dial indicator against the wheel hub. Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play. If the bearing play exceeds specification, check and adjust the locknut torque or replace the wheel hub i assembly if necessary. Maximum wheel bearing play: 0.05mm i0.002 in) Gartner Banana

M FRONT AXLE Disassembly 1 Inspection 1 Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. DO NOT DISASSEMBLE @$ REPLACE N.m (kgfm, ftdbf} 1. Dust cover 4. Hub bolt 2. Knuckle spindle Disassembly Note ........... page M-8 3. Sensor rotor (ABS) Assembly Note ............. page M-9 Disassembly Note ........... page M-8 5. Front wheel hub assembly Assembly Note ............. page M-9 Inspection .................. page M-9 Disassembly note ' Sensor rotor (ABS) I Secure the front wheel hub in a vise and remove the sen- sor rotor by using the SST. Note The sensor rotor does not need to be removed unless you are replacing it. ..-.' Gartner Banana

FRONT AXLE M Hub bolts Note The hub bolts do not need to be removed unless you are replacing them. Remove the hub bolts with a press. Assembly note Hub bolts Install the new hub bolts with a press. Sensor rotor (ABS) Install a new sensor rotor by using the SST and a press. Inspection Front wheel hub assembly Inspect for damage. Gartner Banana

REAR AXLE M DISC BRAKE TYPE Inspection 1 Removal 1 Installation 1. lnspect wheel bearing play, referring to Inspection. 2. Remove in the order shown in the figure, referring to Removal Note. 3. lnspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal, referring to Installation Note. 5. After installation, adjust the rear wheel alignment. (section R.) @ REPLACE 21 6294 {2230,159-217) N.m {kgf m, Rlbf) 1. Rear wheel 2. Brake caliper assembly Removal Note . . . . . . . . . . . . . page M-12 3. Disc plate 4. Locknut Installation Note . . . . . . . . . . . page M-12 5. Wheel speed sensor (ABS) 6. Sensor bracket 7. Knuckle, wheel hub, and dust cover lnspect knuckle for cracks and damage lnspect wheel hub for cracks and damage lnspect dust cover for damage and distortion Disassembly / Inspection / Assembly . . . . . . . . . . . . . . . . page M-13 Gartner Banana