1994 MAZDA MX-5 Workshop Manual

ELECTRICAL PARTS GI BATTERY CABLE Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. CONNECTORS Data Link Connector Insert the probe into the service hole when connecting a jumper wire to the data link connector. Caution Inserting a jumper wire probe into the data link connector terminal may damage the terminal. Power Connector The special power connector in the engine compartment (Blue: 1 -pin) supplies battery positive voltage for exter- nally powered test equipment. Caution Do not ground the power connector terminal; the 20A wiper fuse will be burned. Disconnecting Connectors When disconnecting two connectors, grasp the connec- tors, not the wires. Connectors can be disconnected by pressing or pulling the lock lever as shown. Gartner Banana

GI ELECTRICAL PARTS Locking Connectors When locking connectors, listen for a click that will indi- cate they are securely locked. 4' Inspection 1. When a tester is used to check for continuity or to mea- sure voltage, insert the tester probe from the wiring har- ness side. I I 46UGIX-039 GI-I 6 2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side. Caution To prevent damage to the terminal, wrap a thin ..J wire around the lead before inserting it into the terminal. TERMINALS lnspection Pull lightly on individual wires to check that they are secured in the terminal. Replacement Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. Insert a thin piece of metal from the terminal side of the connector, and then, with the terminal locking tab pressed down, pull the terminal out from the connector. b' Gartner Banana

ELECTRICAL PARTS GI SENSORS, SWITCHES, AND RELAYS Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects. kD YELLOW WIRING HARNESS Wiring color codes Two-color wires are indicated by a two-color code sym- bol. The first letter indicates the base color of the wire and the second the color of the stripe. IGI Green 11 R 1 Red I B BR COLOR FUSE Replacement 1. When replacing a fuse, be sure to replace it with one of the specified capacity. If a fuse again fails after it has been replaced, the circuit probably has a short and the wiring should be checked. 2. Be sure the negative battery terminal is disconnected before replacing a main fuse (80A). CODE CODE Black Brown GY L LB LG 3. When replacing a pullout fuse, use the fuse puller sup- plied in the fuse box cover. COLOR 0 P Gray Blue Light Blue Light Green Orange Pink V W Y - Violet White Yellow - Gartner Banana

G I INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEMIAUDIO ANTITHEFT SYSTEM INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEM If a mobile two-way radio system is installed improperly or if a high-powered type is used, the CIS and other systems may be affected. L-.) When the vehicle is to be equipped with a mobile two-way radio, observe the following precautions: 1. lnstall the antenna at the farthest point from control units. 2. Install the antenna feeder as far as possible from the control unit harnesses (at least 30 cm (11.8 in)). 3. Ensure that the antenna and feeder are properly adjusted. 4. Do not install a hiah-h owe red mobile two-wav radio svstem. FEEDER W!RE CONTROL UNIT HARNESS AT LEAST 30 cm (11.8 in) 46UGIX-043 AUDIO ANTITHEFT SYSTEM An audio with an antitheft function is optionally available. Before removing the negative battery terminal or discon- necting the audio power source, obtain the code number and deactivate the audio antitheft system. (Refer to section T.) Gartner Banana

TOWING TIEDOWN HOOKS - FRONT /-- TIEDOWN HOOKS - REAR - TOWING Proper towing equipment is necessary to prevent dam- age to the vehicle. Laws and regulations applicable to vehicles in tow must always be observed. As a general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies. With either automatic or manual transmission. 1. Set the ignition switch in the ACC position; 2. Place the selector lever or shift lever in N (Neutral); 3. Release the parking brake. With manual transmission If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels. If any of these components are damaged, use wheel dollies. With automatic transmission If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies. If all four wheels are on the ground, the vehicle may be towed only forward. Don't exceed 56 kmlh {35 mph} and a distance of 56 km (35 miles); you could damage the transmission. If speed must exceed 56 kmlh (35 mph} or a towing dis- tance of 56 km (35 miles}, use one of these methods: Place the rear wheels on a dolly; Tow with the rear wheels off the ground; Disconnect the propeller shaft. If the transmission or rear axle is inoperative, two with the rear wheels off the ground. Caution Don't tow with sling-type equipment. This could damage your vehicle. Use wheel-lift or flatbed equipment. Caution Don't use the hook loops under the front for tow- ing. They are designed ONLY for tying down the vehicle when it's being transported. Using them for towing will damage the bumper. GI-I 9 Gartner Banana

PRE-DELIVERY INSPECTION AND SCHEDULED MAINTENANCE PRE-DELIVERY INSPECTION . . . . . . . . . . . . . . . . . . A- 2 PRE-DELIVERY INSPECTION TABLE . . . . . . . . . . A- 2 SCHEDULED MAINTENANCE (EXCEPT CANADA) . . . . . . . . . . . . . . . . . . . . . . . . . . A- 3 SCHEDULE 1 (NORMAL DRIVING CONDITIONS) . . . . . . . . . . A- 3 SCHEDULE 2 (UNIQUE DRIVING CONDITIONS) . . . . . . . . . . . A- 8 SCHEDULED MAINTENANCE (CANADA) . . . . . . . . A-1 3 SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 3 45UOAX-001 Gartner Banana

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

SCHEDULED MAINTENANCE (EXCEPT CANADA) Schedule 1 (Normal driving conditions) If the vehicle is mainly operated where none of the "unique driving conditions" apply. Schedule 2 (Unique driving conditions) Repeated short-distance driving. Driving in dusty conditions. Driving with extended use of brakes. Driving in areas where road salt or other corrosives are used. Driving on rough or muddy roads. Extended periods of idling or low-speed operation. r Driving for long periods in cold temperatures or extremely humid climates. SCHEDULE 1 (NORMAL DRIVING CONDITIONS) Chart symbols: I : Inspect, and repair, clean, or replace if necessary R : Replace L : Lubricate Remarks: After 48 months or 96,000 km {60,000 miles), continue to follow the described maintenance at the recommended intervals. *1 This maintenance is required for all states except California. However, we recommend that it also be performed on California vehicles. '2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability. Gartner Banana