1994 MAZDA MX-5 length

M DRIVE SHAFT 5. Align the marks, then install a new clip. Boot bands 1. Set the boots onto the rings. 2. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth-wrapped screwdriver. 3. Verify that the boots are not dented or twisted. 4. Measure the drive shaft length. Standard length: 623.7--658.8mm (24.556-25-936 in) 5. If not within specification, return to step 1. J Standard length (On-vehicle): 640.6mm (25,220 in) 6. Fold the new band back by pulling on the end of it with pliers. The band should be folded in the direction oppo- site the forward revolving direction of the drive shaft. 7. Lock the end of the band by bending the locking clips. Gartner Banana

MANUAL STEERING N Disassembly Note Steering lock mounting bolts and bracket Use a chisel to make a groove in the heads of the steer- ing lock mounting bolts. Remove the bolts with a screw- driver. Remove the steering lock assembly. Inspection Check the following, and replace the column assembly if necessary. Steering shaft 1. Column bearing damage. 2. Steering shaft length. Length: 603.7--605.7mm (23.77-23.84 in) Assembly Note Steering lock mounting bolts and bracket Install the steering lock assembly on the jacket. Install the new steering lock mounting bolts. Tighten the bolts until the heads break off. Gartner Banana

BRAKE SYSTEM CLEARANCE (0) CLEARANCE (C) CLEARANCE (B) 4. Remove the SST from the power brake unit without dis- turbing the adjusting nut. Set the SST onto the master cylinder as shown in the figure. -J Caution When pushing only use enough pressure to bot- tom the rod in the piston. If too much pressure is applied a false reading will occur. 5. Push lightly on the end of the SST gauge rod to be sure it is bottomed in the master cylinder piston, but do not push so hard that the piston mores. Note Any clearance between the SST body and the adjusting nut (clearance B) or between the body and the master cylinder (clear- ance C). Adjust the push rod as necessary as outlined in "Adjustment" below. I Measurement 1 Push rod I I Clearance at (B) I Too short I Adjustment The threads of the push rod are specially designed so that the bolt becomes harder to turn past a certain point. This is to prevent the bolt from coming loose. Turn the bolt only within this range when adjusting. Clearance at (C) No clearance at (B) or (C) '.A Clearance at B 1. Push lightly on the end of the SST gauge rod, and mea- sure the clearance between the adjusting nut and the SST body. Too long OK 2. Using the SST, turn the nut to lengthen the power booster push rod an amount equal to the clearance mea- sured at B. Clearance at C 1. Measure and record height Dl of the gauge rod. Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS Front Suspension - Transmission item (Stabilizer Specifications MT I AT - I Susoension tvoe I . , . , I . , Shock absorber Cylindrical double acting, low-pressure-gas charged I Double-wishbone TY pe Torsion bar Coil spring I - Diameter mm linl I 20.0 10.79) Identification mark color 19.0 (0.75) White Wire diameter mm (in) Coil inner diameter mm {in) I Blue Free length mm {in) Coil number 11 .O (0.43) 83 i3.27) 11 .O (0.43) 83 (3.27) 292.5 (1 1 32) 6.32 3 +. 3 (0.12 + 0.12) 0°18' + 18' Total toe-in I - I 35UORX-001 Rear Suspension 302.0 (1 1.89) 6.32 mm {in) degree Total toe-in (per side) 1 degree Front wheel alignment (Unladedt1) 0°09' +. 09' Caster anglee3 4"26' +. 45' Kingpin angle 11 "20' Maximum steering angle Transmission Specifications MT I AT Item Differential - Suspension type Inner Outer "TORSEN" LSD 1 Standard Double-wishbone Coil springs 370 23' a 2" 32" 32' -t 2" Camber anglee2 Torsion bar 12.0 (0.47) 1 11.0 (0.43) 1 11 .O (0.43) Cylindrical double acting, low-pressure-gas charged - Stabilizer Identification mark color Wire diameter mm {in) 0°24' + 45' Type Diameter mm {in) I Coil number I 7.68 I 7.96 I Shock absorber Yellow 10.1 {0.40} Coil inner diameter mm {in) Free length mm {in) Green 10.2 {0.40) 35UORX-002 *I Fuel tank full; radiator coolant and engine oil at specified levels; spare tire, jack, and tools in designated positions. '2 Difference between left and right must not exceed I O. '3 Difference between left and right must not exceed 1'30'. "TORSEN" is a registered trademark of ZEXEL-GLEASON USA.INC 83 I3.27) 348.5 j13.72) Rear wheel alignment (Unladed*') 83 (3.27) 356.5 (1 4.04) Total toe-in Total toe-in (per side) mm (in) degree degree 3 -c 3 (0.12 + 0.121 0°18' + 18' 0°09' + 09' Camber angle*2 -0°43' 2 30' Gartner Banana

WINDSHIELD Removal Note Windshield If the glass will not be reused 1. Use a tool like that shown in the figure and insert the blade into the sealant. 2. Pull through the sealant around the edge of the glass. 3. Remove the glass. If the glass will be reused 1. Apply protective tape along the edge of the body to pro- tect it from damage. 2. Using an awl, make a hole through the sealant from the inside of the vehicle. 3. Pass piano wire through the hole. 4. Wind each end of the wire around a bar. 5. Working with another person, saw through the sealant around the edge of the glass. Use a long sawing action to spread the work over the whole length of wire to pre- vent it from breaking. 6. Remove the glass. Installation Note Windshield 1. Cut away the old sealant with a razor knife so that 1 to 2 mm (0.04 to 0.08 in) of sealant remains around the cir- cumference of the frame. If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2 mm (0.08 in} layer. 2. Carefully clean an area 5 cm (1.97 in) wide around the circumference of the glass and bonding area of the body. 3. Apply primer with a brush to the bonding area of the glass and the body. Keep the area free of dirt and grease, and do not touch the surface. Allow it to dry for approximately 30 minutes. Gartner Banana

REAR WINDOW GLASS I PROTECTIVE TAPE I I PIANO WIRE GYSS DETACHABLE HARDTOP O...PLACES PIANO WIRE WILL NOT CUT 1 Removal Note Rear window glass 1. Apply protective tape along the edge of the detachable hardtop to protect it from damage. 2. Remove the glass mounting nuts. 3. Using an awl, make a hole through the sealant from the inside of the vehicle. 4. Pass piano wire through the hole. 5. Wind each end of the wire around a bar. 6. Saw through the sealant around the edge of the glass. Use a long sawing action to spread the work over the whole length of wire to prevent it from breaking. 7. Use a razor knife to cut where the piano wire will not cut. 8. Remove the glass. Installation Note Rear window glass 1. Cut away the old sealant with a razor knife so that 1 to 2 mm (0.04 to 0.08 in) of sealant remains around the cir- cumference of the frame. If all the sealant has come off in any one place, apply some primer after decreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2 mm I0.08 in) layer. 2. Carefully clean an area 5 cm (1.97 in) wide around the circumference of the glass and bonding area of the top. 3. Apply primer with a brush to the bonding area of the glass and top. Keep the area free of dirt and grease, and do not touch the surface. Allow the primer to dry for approximately 30 minutes. Gartner Banana

TD TECHNICAL DATA A. MEASUREMENTS I Item I Measurements I B. ENGINE Overall length mm {in) Overall width mm (in) Overall height mm {in) Wheelbase mm {in) 3,948 (1 55.4) 1,676 i65.9) 1,224 I48.2) 2,266 I89.2) 1,410 (55.5) 1,428 (56.2) Tread - ltem Tvoe u Front mm (in) Rear mm {in) BP DOHC Gasoline. 4-cvcle . In-line, 4-cylinders Pentroof DOHC, belt-driven 16 valves 83.0 x 85.0 {3.27 x 3.35) 1,840 (1,840, 11 2) 9.0 1,255 {I 2.8, 1823-300 883 (9.0, 1281-300 196 {2.0, 28) s. Cylinder arrangement and number Combustion chamber Valve system Bore x Stroke mm {in] Total piston displacement ml {cc, cu in) Compression ratio Valve timing Compression pressure kPa (kgflcm2. psil-r~m I Valve and valve auide I Standard Minimum Maximum difference between each cvlinder - - IN openz (BTDCO) Close (ABDCO) Open (BBDCO) EX close (ATDC") Valve clearance mm {in) Cylinder head 5 48 56 14 IN 133.8-1 34.0 i5.268-5.275) 0.1 0 {0.004) max. 0.10 {0.004) max. 0.02G0.066 {0.0010-0,0025) 0.18 {0.0071) Height mm (in) Distortion mm {in) Grinding mm {in) - 0: Maintenance-free Cylinder head-to-HLA clearance mm (in} Valve head diameter mm Iin) Valve head margin thickness mm {in} Valve face angle I Valve seat 1 u Standard Maximum Valve length mm {in) EX IN EX IN EX IN EX Standard Minimum Standard Minimum IN EX IN EX 5.99--6.03 iO.2359--0.2374) 0.005--0.060 (0.0002-0.0023) 0.01 b0.065 (0.0004-0,0025) 0.20 {0.008} 18.3-1 8.9 {0.7214.744) 18.3-1 8.9 (0.721-0.744) Guide inner diameter mm (in) 0: Maintenance-free 32.9-33.1 {I .296--1.303) 27.85-28.15 {I .097-1 .I 08) 0.9 {0.035) 1 .O (0.039) 45" 45" 101.89 {4.0114} 100.39 {3.9524) 101.99 (4.0153) 100.49 (3,9563) 5.970-5.985 {0.2351-0.2356) 5.96G5.980 l0.2349-0.2354) Valve stem diameter mm {in) Valve stem-to-guide clearance mm (in) Guide projection (Height "A) mm {in) Seat angle IN EX Maximum IN EX IN 45" EX 45" Gartner Banana

TECHNICAL DATA TD BP DOHC 0.8-1.4 {0.0324.055) 45.0 (1.772) 46.5 11.831) Engine Item Seat contact width mm {in) Valve spring End gap (Measured in cylinder) mm {in) Seat sinking mm {in) Free length mm {in) Minimum length mm {in) Out-of-square mm {in) Camshaft bearing oil clearance mm {in} Ring groove width in piston mm {in) Standard Maximum Piston ring-to-ring groove clearance mm {in) IN EX IN EX IN EX Standard (No.1-No.5) Maximum 46.26 (1.821) 46.26 (1.821) 39.5 {I 56) with a set load of 224--253 N I22.8-25.8 kgf, 50.2-56.7 Ibf) 39.5 (1 56) with a set load of 224-253 N I22.8-25.8 kgf, 50.2-56.7 Ibf) 1.62 (0.0638) max. 1.62 (0.0638) max. Camshaft 0.035-0.081 {0.0014-0..0031) 0.1 5 (0.006) 0.03 {0.001 2) max. 0.07-0.1 9 {0.002~.0074) 0.20 {0.008) Camshaft runout mm {in) TOP Second Cam height mm {in) Camshaft end play mm (in) 0.15-0.30 {0.006-0.011) 0.15-0.30 {0.006--0.011) -- - I Standard Minimum Standard Minimum Standard (No.1-N0.5) IN EX Standard Maximum Oil (rail) Maximum I 1 .O {0.039) 44.094 {I .7360) 43.894 {I .7281) 44.600 11.7559) 44.400 {I .7480) 25.940-25.965 11.021 3-1.0222) Journal diameter mm Iin) Cylinder block 0.20-0.70 {0.00&0.027) TOD Second Oil 1.52-1 535 {0.0594--0.0604) 1.52-1.54 (0.0599--0.0606} 3.02-3.04 f0.11894.1196) Second Maximum 221.5 (8.720) 0.1 5 {0.006) max. 0.20 {0.008) max. 83.00&83.019 i3.2678-3.2684) 83.25683.263 {3.277&3.2780) 83.508-883.51 3 (3.2877-3.2879) 0.01 9 {0.0007} max. Height mm {in) Distortion mm (in) Grinding mm {in} 0.03-0.07 {0.00124.0027) 0.1 5 {0.006) Cylinder bore diameter mm {in] Standard size 0.25 {0.01) oversize 0.50 (0.02) oversize Piston , Cylinder bore taper and out-of-round mm {in) 82.95442.974 i3.2659--3.2666) 83.211-43.21 7 (3.2761-3.2762) 83.461-83.467 (3.2853--3.2860) 0.0324.059 {0.001 3--0.0023) 0.15 (0.006) Piston diameter Measured at 90" to Pin bore axis and 16.5mm i0.65 in) below oil ring groove mm {in) Standard size 0.25 {0.01) oversize 0.50 (0.02) oversize Piston ring Piston-to-cylinder clearance mm (in) Thickness mm {in) Standard Maximum TOP 1.47-1 -49 (0.0579--0.0586} Second 1.47-1.49 {0.0579--0.0586) Gartner Banana