1994 MAZDA MX-5 transmission oil

HOW TO USE THIS MANUAL Example: SHOWS EXPENDABLE PARTS SHOWS APPLICATION POINT OF OIL, ETC SHOWS RELATED PAGE FOR. SERVICE SELECTIVE 1. 8011 2. Lock plate 3. Bearing cup t. Adjusting screw 5. Bearing outer race 5. Locknul 16. Bearing inner race 18. drive pinion 1. Washer Removal ..................... .. .... page M-2' SHOWS TIGHTENING TORQUE SPECIFICATIONS *2 SHOWS TIGHTENING TORQUE UNIT -SHOWS VISUAL INSPECTION INFORMATION *1: The numbers (0, etc.) refer to part identification and servicing procedures. *2: Units are in N.m {kgf.m, ftlbf} unless otherwise specified. $ L SYMBOLS There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such materials during service. Symbol I Meaning ~pp~y oil Apply brake fluid I Apply automatic transmission fluid Apply grease Apply sealant Kind 0 New engine oil or gear oil as appropriate Apply petroleum jelly Appropriate grease Appropriate sealant Appropriate petroleum jelly 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

Schedule 1 (Normal driving conditions) (MT) (Cont'd) Maintenance 1 Number of months or kilometers {miles), whichever comes first I I 1 Months 1 6 18 124 130 136 142148 Service data and inspection point 36,000 1 48,000 1 60,000 1 72,000 1 84,000 1 96,000 Maintenance item I CHASSIS AND BODY Brake lines, hoses, and connections Disc plate thickness Front: 18.0mm (0.71 in)--Minimum I I 1 near: 8.0mm {o31 inFMnimum P-6 I Disc brakes I Pad thickness: I I I I I ~10mrn~0.04inMlinimum I Proper attachment and connections Steering operation and linkage I I I I I I I 0-3'0mm (0-1.1 8 in) Operation and looseness Fluid leakaae or oozina I I Front suspension ball joints I I Free play: I I I I I I I - - Manual transmission oil I I I I I , I Damage, looseness and I grease leakage Oil capacity: 2.0 L (2.1 US at. 1.8 Imp qtJ Ill I I I I I Cracking and damage I , I Oil capacity: I I I Differential oil I Drive shaft dust boots I Bolts and nuts on chassis and body I I I n I 1 .OO L {I .06 US qt, 0.88 Imp qt} Ill Exhaust system heat shield I I I I 1 Retiahten all loose bolts and nuts L All locks and hinges lLlLl - AIR CONDITIONER SYSTEM I L Refrigerant pressure Low pressure: 0.1 5-0.25 MPa {I -52.5 kgf/cm2, 21-36 psi) High pressure: 1.37-1 -57 MPa {I 4.0-1 6.0 kgf/cm2, 1 XI-228 psi] - L Corn~ressor I lnswct the o~eration annuallv Refrigerant L Inspect the refrigerant amount annually L I L " Insulator clearance between body and exhaust system Lubricate all locks and hinges F-128 - Gartner Banana

2 (Unique driving conditions) (MT) (Cont'd) Number of months or kilometers miles), whichever comes first 24 28 32 36 40 44 48 48 56 64 72 80 88 96 Service data and inspection point Page Maintenance interval Maintenance item .# CHASSIS AND BODY Proper attachment and connections Brake lines, hoses, and connections IIII Disc brakes I Steering operation and linkage Disc plate thickness Front: 18.0mm (0.71 inkMinimum Rear: 8.0mm I0.31 in)--Minimum Pad thickness: 1 .Omm 10.04 inbMinimum Free play: O-30mm {0-1.18 in) Operation and looseness Fluid leakage or oozing Front suspension ball joints 1111 Damage, looseness and arease leakaae I I I I Drive shaft dust boots Cracking and damage Manual transmission oil Oil capacity: 2.0 L (2.1 US at, 1.8 I~D at1 Differential oil Oil capacity: 1 .OO L(1.06 US qt, 0.88 Imp qt} Retighten all loose bolts and nuts I I I Bolts and nuts on chassis and body Exhaust system heat shield Insulator clearance between bodv and exhaust svstem I I I I All locks and hinges ILlLlLlL Lubricate all locks and hinges - I AIR CONDITIONER SYSTEM ~p - ~-~p- Refrigerant Inspect the refrigerant amount annually Refrigerant pressure Low pressure: 0.1 5-0.25 MPa {I S-2.5 kgf/cm2, 21 -36 psi} High pressure: 1.37-1 57 MPa (1 4.0-1 6.0 kgf/cm2, 194-228 psi) Comoressor I lnsoect the ooeration annuallv I I - Gartner Banana

B ON-VEHICLE MAINTENANCE REAR OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove the transmission. (MT Refer to section J. AT: Refer to section K.) 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to lnstallation Note. Nm (kgfm, ft-lbf) I 1. Clutch cover, clutch disc (MT) 4. Oil seal Removal / Installation ......... section H Removal Note .................. below 2. Flywheel (MT) Installation Note ........... page 6-27 ......... Removal / Installation section J 3. Drive plate (AT) ......... Removal / Installation section K Removal Note Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. 05UOBX-063 Gartner Banana

B REMOVAL REMOVAL Caution Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death -d and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line safety Procedures" on section F. PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E.) 3. Remove the transmission. 4. Remove in the order shown in the figure, referring to Removal Note. Step 1 1. Air cleaner housing assembly 2. Accelerator cable 3. Radiator hose 4. Oil cooler hose 5. Coolant reservoir hose 6. Fan connector 7. Radiator and fan assembly 8. PIS andlor A/C drive belt ................ Removal 9. Alternator drive belt .................. Removal page B- 6 10. PIS oil pump (If equipped) ............. Removal Note page 529 11. AIC compressor (If equipped) Removal Note ............. page 529 1 page B- 6 Gartner Banana

B INSTALLATION ALTERNATOR Drive belt 1. lnstall the alternator drive belt. (Refer to page B-5.) 2. lnstall the PIS and/or AIC drive belt. 3. Adjust the drive belt deflection, and tighten the alternator - and PIS mounting bolts and nuts. (Refer to page 8-7.) Radiator and coolant fan assembly 1. lnstall the radiator and coolant fan assembly. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft4bf) 2. lnstall the AIC pipe bracket to the radiator Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in4bf) 3. Connect the upper and lower radiator hoses. 4. Connect the coolant reservoir hose. 5. Connect the coolant fan motor connector. Steps After Installation 1. lhstall the transmission. (Refer to sections J, K.) 2. lnstall the under cover. 3. If the engine oil was drained, fill with the specified amount and type of engine oil. (Refer to section D.) 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E.) 5. If the transmission oil was drained, fill with the specified amount and type of transmission oil. (Refer to sections J, K.) 6. Connect the negative battery cable. 7. Start the engine and check the following. (1) Engine oil, transmission oil, and engine coolant leakage (2) Ignition timing, idle speed (Refer to page 59.) (3) Operation of emission control system 8. Perform a road test. 9. Recheck the engine oil and engine coolant levels. Gartner Banana

OIL PAN D RIGHT . . LEFT Removal Note Engine mount nut 1. Loosen the oil pan mounting bolts. 2. Remove the engine mounting nuts. 3. Lift the engine slightly with a hoist. Crossmember installation bolt and nut 1. Support the crossmember with a transmission jack. 2. Remove the crossmember installation bolts and nuts. 3. Separate the steering intermediate shaft from the pinion shaft. 4. Lower the crossmember until the clearance between the oil pan and the steering gear housing exceeds approx. 100mm (3.94 in). Oil pan 1. Remove the oil pan mounting bolts. Caution Pry tools can easily scratch the cylinder block and the oil pan contact surfaces. Prying off the oild pan can also easily bend the oil pan flange. Refer to the following instructions before remov- ing the oil pan. 2. Insert a screwdriver only at the points shown in the fig- ure. 3. Remove the oil pan. Oil baffle 1. Insert a screwdriver between the cylinder block and the oil baffle to separate them. 2. Remove the oil baffle. Installation Note Oil baffle 1. Remove all foreign material from the contact surfaces. 2. Apply a continuous bead of silicone sealant to the oil baffle along the inside of the bolt holes, and install within five minutes. Gartner Banana