1994 MAZDA MX-5 ECU

N ENGINE SPEED SENSING POWER STEERING 7. Attach the SST to the pinion and install the plug assem- bly. Adjusting cover 1. Tighten the mounting bracket in a vise. 2. Set the rack to the center position. 3. Tighten the adjusting cover to 4.9 N.m (50 kgf.cm, 43 in4bf) with the SST three times, then return it 25". 4. Apply sealant to the threads of the locknut. 5. Attach the locknut. 6. Measure the pinion torque by using the SST and a pull scale. Standard Center of rack + 90": 1 .O-1 .I N-m {I 0-1 2 kgf-cm, 8.7-1 0.4 in-lbf) ii Scale reading: 1 .&I .2 kg (2.2-2.64 Ib) 7. If not within specification, repeat steps 3 through 6. 8. Install the locknut. Tightening torque: 59-74 N.m (6.0-7.5 kgf.m, 44--54 ftdbf) Hermetic sealing inspection 1. Connect the SST to the power cylinder section of the gear housing. 2. Apply 53.3 kPa (400 mmHg, 15.7 inHg) vacuum with a vacuum pump and verify that it is held for at least 30 seconds. 3. If the vacuum is not held, replace the oil seal. Tie rod 1. Secure the rack gear in a vise, and tighten the tie rods with the wrench. Tightening torque: 79-98 N.m (8.0-10.0 kgf-m, 58-72 ft-lbf) 2. Align the washer with the rack groove, and crimp the washer. Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Disassembly Note Oil pump Use the SSTwhen securing the oil pump in a vise, so that force is not applied to the pulley or shaft. Inspection Pump body front, rear lnspect the front and rear of the pump body for cracks and damage, and the friction surface of the rotor for wear. Replace the pump assembly if a problem is found. Cam ring, rotor, blade, side plate 1. lnspect the blade friction surface of the cam ring for wear. 2. lnspect the pump body of the rotor and side plate friction surface for wear. 3. lnspect the cam ring friction surface of the blade for -, wear. 4. lnspect clearance between the rotor and blade. Control valve, spring 1. lnspect the control valve for cracks, damage and block- age, and the friction surface for wear. 2. lnspect the spring for damage. Assembly Note Rotor Install the rotor with the indentification mark facing upward. Gartner Banana

BRAKE SYSTEM Disassembly / Assembly / lnspection 1. After removing the brake fluid, disassemble in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of removal, referring to Assembly Note. Caution The brake master cylinder Is made of aluminum, and can be easily damaged by tightening in a vise. When securing the master cylinder in a vise, tighten only the master cylinder flange. 1. Fluid level sensor connector 7. Snap ring Inspection ................... page P-17 8. Snap ring and spacer (ABS) 2. Screw 9. Primarv ist ton assemblv 3. Reservoir assembly inspect for abnormal wear, rust, and damage Inspect for damage and deformation 10. Secondary piston assembly 4. Bushings Inspect for abnormal wear, rust, and damage 5. Stop screw and O-ring 11. Master cylinder body e Assembly Note .............. page P-19 Inspect for abnormal wear, rust, and damage 6. Stop pin and O-ring (ABS) Replace unit as an assembly if damaged Assembly Note .............. page P-19 Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P ABS CONTROL UNIT 35-PIN CONNECTOR OHMMETER 15UOPX-OI Check rotor Check the rotor for missing or damaged teeth and replace as necessary. Check alternator Refer to section G. Check wheel-speed sensor Caution To prevent damage to the terminals, create a probe by wrapping a thin wire around the tester lead before inserting. 1. Using an ohmmeter, check for continuity at the control unit connector terminals. 0----0: Indicates continuity Right front Left rear Right rear 2. If the continuity is not as specified, check the wiring har- ness (Wheel-speed sensor - Control unit). 3. If the continuity is OK, check voltage between 1K and 1 G, 10 and 1 Q, 1 U and 1 F, and 1 L and 1 P while rotating the wheel one rotation per second by hand. 4. If voltage is not approximately 50 mV--60 mV, the wheel-speed sensor is faulty. 5. If voltage is approximately 50 mV-60 mV, the control unit is faulty. 1L Check hydraulics Verify that all brake fluid connections are tight and that no fluid is leaking. IP 1Q Left front 0--0 Check hydraulic unit wiring 1. Verify that the hydraulic unit connectors are properly secured. 2. Verify that the valve relay and motor relay are properly secured. IG 1K 0-4 1U 10 S-0 IF 0-4 Gartner Banana

P ANTILOCK BRAKE SYSTEM (ABS) Disassembly 1 Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. 2.2-2.6 Nm [22-27 kgfcm, 2&29 [2--3,14--22) 6.9-9.8 Nm (70-1 00 kgfcm, 81-47 Inlbf) 1 15--25 11 S-2.5,11-18) 19-25 [1.92.6,14--19) t4.m [kgfm, Wlbf) 25uopx-o: 1. Nut, washer . 2. ABS bracket 3. Connector bolt 4. Gasket 5. Pipe joint 6. Bolt 7. Clip Installation Note 8. Cover 9. Motor relay ................... Inspection page P-56 10. Valve relay ................... Inspection page P-57 11. Casing 12. Mount 13. Stud ................. below 14. Nut, washer 15. Ground wire 16. Hydraulic unit Assembly note A SECTION A-A Clip Secure only the larger part of the wiring harness in the clips. The 2-pin connector part of the harness should re- main outside the clips. Gartner Banana

FRONT SUSPENSION (DOUBLE-WISHBONE) R Disassembly I Inspection I Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. 4. Tighten all nuts and bolts to the specified torques, referring to the figure. (FRONT ONLY) & 3 1. Sheet (front only) 2. Cap 3. Mounting plate 4. Bound stopper lnspect for damage 5. Coil spring .......... Disassembly Note page R-13 ............ Assembly Note page R-14 6. Shock absorber lnspect for oil leakage and abnormal noise Disassembly note Coil spring Warning Removing the coil spring nut is dangerous. The shock absorber and spring could fly off under tre- mendous pressure and cause serious injury or death. Secure the shock absorber in the SST before removing the coil spring nut. 1. Loosen the piston rod upper nut several turns, but do not remove the nut. 2. Assemble the SST. 3. Compress the coil spring with the SST, and remove the upper nut. 4. Remove the coil spring. Gartner Banana

I3 FRONT SUSPENSION (DOUBLE-WISHBONE) I t'- SHOCK ABSORBER 05UORX-02 Inspection Shock absorber Check the following and replace if necessary. 1. lnspect for damage and oil leakage. 2. lnspect the rubber bushing for deterioration and wear. 3. Compress and extend the shock piston at least three (3) times. Verify that the operational force does not change and that there is no unusual noise. 4. (1) Compress the shock absorber piston and release it. (2) Verify that the piston extends fully at a normal speed. Assembly note Coil spring and bound stopper 1. Set the shock absorber in a vise. 2. Install the bound stopper on the shock absorber as shown. 3. lnstall the compressed coil spring (compressed with SST). 4. Install the mounting plate. 5. Tighten the mounting plate nut, but do not torque it yet. 6. Remove the SST. 7. Secure the mounting plate in a vise. 8. Tighten the piston rod upper nut. Tightening torque: 30-36 N.m (3.0-3.7 kgf.m, 22-26 ftdbf) Disposal of shock absorber Caution The gas in the shock absorber is color less, order less, and non-toxic. Wear safety glasses as drilling chips may be expelled by the pressurized gas. 1. Lay the shock absorber flat. 2. Drill a hole in the shock absorber body. Drill size: 2-3mm (0.08-0.11 in). 3. Allow the gas to escape from the shock absorber. 4. Discard the shock absorber. Gartner Banana

TRUNK LID s 5 2 1.5 (0.2 i 0.06) A TRUNK -&- SEC. B-B mm (in) 05UOSX421 Removal Note Balance spring Warning Removing the balance spring without securing the trunk lid can be dangerous. The trunk lid may fall and injure you. Open the trunk lid fully and se- cure it before removing the balance spring. 1. Lift the balance spring with a protected screwdriver. 2. Remove the balance spring. Adjustment Trunk lid Loosen the trunk lid mounting nuts and adjust as shown. Balance spring Slide the balance spring to the desired position as described below with a protected screwdriver. Hinge b Left side Standard 0 Right side 0 Left side Increase Right side Left side Decrease Right side 0: Indicated position Gartner Banana