1994 MAZDA MX-5 MIATA WORKSHOP MANUAL – PDF DOWNLOAD
For proper repair and maintenance, a thorough familiarization with this manual is important, and it should always be kept in a handy place for quick and easy reference.
All the contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers.
This manual should be kept up-to-date. Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or advance notic e .
All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanicalincluding photocopying and recording and the use of any kind of information storage and retrieval system-without permission in writing.
WARRANTY The manufacturer’s warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Mazda Deale r .
Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page.
TABLE OF CONTENTS:
1994 MAZDA MX-5 MIATA WORKSHOP MANUAL – PDF DOWNLOAD
Workshop Manual................................................................... 1
General Information........................................................... 3
Safety Information........................................................ 4
How To Use This Manual.................................................... 6
Identification Number Locations........................................... 8
Units..................................................................... 8
Abbreviations............................................................. 9
SAE Standards............................................................. 10
Fundamental Procedures.................................................... 13
Electrical Trouble Shooting Tools......................................... 16
Electrical Parts.......................................................... 17
Mobile Two-Way Radio System............................................... 20
Audio AntiTheft System.................................................... 21
Towing.................................................................... 21
PDI & Scheduled Maintenance................................................... 22
Pre-Deliver Inspection.................................................... 23
Scheduled Maintenance (Except Canada)..................................... 24
Scheduled Maintenance (Canada)............................................ 34
Engine........................................................................ 38
Index..................................................................... 39
Outline................................................................... 40
Troubleshooting Guide..................................................... 40
Engine Tune-Up............................................................ 42
Compression............................................................... 47
On-Vehicle Maintenance.................................................... 48
Removal................................................................... 65
Engine Standing Mounting.................................................. 69
Disassembly............................................................... 72
Inspection / Repair....................................................... 84
Assembly.................................................................. 96
Engine Stand Dismounting.................................................. 118
Installation.............................................................. 120
Lubrication System............................................................ 124
Index..................................................................... 125
Outline................................................................... 126
Troubleshooting Guide..................................................... 126
Oil Pressure.............................................................. 127
Engine Oil................................................................ 128
Oil Filter................................................................ 129
Oil Cooler................................................................ 130
Oil Pan................................................................... 131
Oil Pump.................................................................. 134
Cooling System................................................................ 137
Index..................................................................... 138
Outline................................................................... 139
Trouble Shooting Guide.................................................... 139
Engine Coolant............................................................ 140
Radiator Cap.............................................................. 143
Radiator.................................................................. 144
Thermostat................................................................ 145
Water Pump................................................................ 146
Coolant Fan Motor......................................................... 148
Coolant Fan Relay......................................................... 149
Fuel & Emission Control Systems............................................... 150
Index..................................................................... 151
Outline................................................................... 154
Troubleshooting Guide..................................................... 160
Engine Tune-up............................................................ 224
On-Board Diagnosis System................................................. 227
Intake Air System......................................................... 247
Idle Speed Control System................................................. 253
Fuel System............................................................... 256
Pressure Regulator Control System......................................... 271
Exhaust Gas Recirculation................................................. 273
Exhaust System............................................................ 277
Emission Control System................................................... 278
Positive Crankcase Ventilation............................................ 279
Fuel Evaporation System................................................... 280
Catalytic Converter System................................................ 283
A/C Cut-Off Control System................................................ 284
Dechoke Control System.................................................... 286
Coolant Fan Control....................................................... 287
Control System............................................................ 290
Engine Electrical System...................................................... 308
Index..................................................................... 309
Outline................................................................... 310
Troubleshooting Guide..................................................... 311
Charging System........................................................... 313
Ignition System........................................................... 322
Starting System........................................................... 328
Clutch........................................................................ 336
Index..................................................................... 337
Outline................................................................... 338
Troubleshooting Guide..................................................... 338
Clutch Fluid.............................................................. 339
Clutch Pedal.............................................................. 340
Clutch Master Cylinder.................................................... 342
Clutch Release Cylinder................................................... 347
Clutch Unit............................................................... 349
Clutch Release Collar..................................................... 352
Clutch Cover.............................................................. 352
Clutch Disc............................................................... 353
Pilot Bearing............................................................. 353
Flywheel.................................................................. 353
Manual Transmission........................................................... 355
Index..................................................................... 356
Outline................................................................... 357
Troubleshooting Guide..................................................... 361
Transmission Oil.......................................................... 362
Transmission.............................................................. 363
Preparation........................................................... 363
Removal............................................................... 364
Disassembly........................................................... 367
Inspection............................................................ 377
Assembly.............................................................. 380
Installation.......................................................... 399
Automatic Transmission........................................................ 402
Index..................................................................... 403
Outline................................................................... 404
Troubleshooting Guide..................................................... 409
On-Board Diagnosis System................................................. 412
Mechanical System Test.................................................... 423
Road Test................................................................. 430
Automatic Transmission Fluid.............................................. 436
Electrical System Components.............................................. 439
Transmission.............................................................. 447
Removal............................................................... 447
Disassembly........................................................... 451
Torque Convertor...................................................... 462
Oil Pump.............................................................. 463
Fourth Gear Unit...................................................... 468
Direct Clutch......................................................... 471
Fourth Gear Band Servo................................................ 477
Drum Support, Accumulator & Fourth Gear Case.......................... 480
2nd Band Servo........................................................ 484
Front Clutch.......................................................... 487
Rear Clutch........................................................... 492
Front Planetary Gear Unit............................................. 497
Rear Planetary Gear Unit.............................................. 499
Low & Reverse brake................................................... 503
Parking Mechanism..................................................... 508
Oil Seal.............................................................. 512
Control Valve Body.................................................... 513
Vacuum Diaphragm...................................................... 531
Assembly.............................................................. 533
Installation.......................................................... 548
Oil Cooler................................................................ 552
Drive Plate............................................................... 553
Shift Mechanism........................................................... 555
Hydraulic Circuit......................................................... 569
Propeller Shaft............................................................... 582
Outline................................................................... 583
Troubleshooting Guide..................................................... 583
Propeller Shaft........................................................... 584
Front & Rear Axles............................................................ 586
Index..................................................................... 587
Outline................................................................... 588
Troubleshooting Guide..................................................... 589
Front Axle................................................................ 590
Rear Axle................................................................. 595
Drive Shaft............................................................... 602
Differential.............................................................. 608
Steering System............................................................... 628
Index..................................................................... 629
Outline................................................................... 631
Manual Steering........................................................... 631
Power Steering............................................................ 645
Braking System................................................................ 666
Index..................................................................... 667
Outline................................................................... 669
Brake System.............................................................. 670
Parking Brake System...................................................... 699
ABS....................................................................... 702
Wheels & Tires................................................................ 728
Outline................................................................... 729
Troubleshooting Guide..................................................... 729
Wheels & Tires............................................................ 730
Suspension.................................................................... 733
Index..................................................................... 734
Outline................................................................... 736
Troubleshooting Guide..................................................... 737
Wheel Alignment........................................................... 738
Front Suspension.......................................................... 743
Rear Suspension........................................................... 753
Body.......................................................................... 759
Index..................................................................... 760
Hood...................................................................... 763
Door...................................................................... 765
Window Regulator, Glass & Guide........................................... 767
Door Lock & Opener........................................................ 773
Trunk Lid................................................................. 774
Trunk Lid Lock & Opener................................................... 776
Power Window System....................................................... 777
Fuel-Filler Lid Opener.................................................... 781
Front Bumper.............................................................. 782
Rear Bumper............................................................... 783
Molding & Garnish......................................................... 785
Outside Mirror............................................................ 788
Windshield Wiper & Washer................................................. 793
Windshield................................................................ 802
Rear Window Glass (Hardtop)............................................... 806
Rear Window (Softtop)..................................................... 810
Dashboard & Console....................................................... 814
Trim...................................................................... 817
Floor Covering............................................................ 820
Seat Belt................................................................. 821
Seat...................................................................... 823
Convertible Top........................................................... 825
Hardtop................................................................... 839
Brace Bar................................................................. 842
Underbody Dimensions...................................................... 843
Body Electrical System........................................................ 846
Index..................................................................... 847
Outline................................................................... 853
Fuse...................................................................... 855
Relay..................................................................... 858
Switch.................................................................... 862
Instrument Cluster........................................................ 867
Warning Light & Sender Unit............................................... 879
Lighting System........................................................... 885
Horn...................................................................... 929
Rear Window Defroster..................................................... 934
Cruise Control System..................................................... 939
Audio..................................................................... 953
Air Bag System............................................................1001
HVAC..........................................................................1063
Index.....................................................................1064
Troubleshooting...........................................................1066
Heater....................................................................1077
Air Conditioner...........................................................1085
Technical Data................................................................1109
Special Tools.................................................................1124
Wiring Diagrams...................................................................1135
Wiring Color Code.............................................................1136
System Index..................................................................1137
General Information...........................................................1138
Ground Points.................................................................1153
Electrical Wiring Schematic...................................................1158
System Circuit Diagrams.......................................................1161
A/T Control System........................................................1204
ABS (Antilock Brake System)...............................................1226
Air Bag Control System....................................................1232
Audio System..............................................................1215
Back-Up Lights............................................................1198
Charging System...........................................................1162
Cigarette Lighter.........................................................1213
Cooling Fan System........................................................1176
Cruise Control System.....................................................1228
Daytime Running Light Control.............................................1193
Diagnosis Connector.......................................................1239
Engine Control System.....................................................1166
Front Fog Lights..........................................................1187
Front Parking Lights......................................................1196
Front Side Marker Lights..................................................1196
Fuel Control System.......................................................1174
Headlights................................................................1187
Heater & Air Conditioner..................................................1202
High-Mount Spotlight......................................................1198
Horn......................................................................1198
Ignition System...........................................................1166
Instrument Cluster........................................................1178
Interior Lamps............................................................1213
Licence Plate Lights......................................................1196
Panel Lamp Control System.................................................1211
Power Antenna.............................................................1221
Power Window..............................................................1223
Rear Side Marker Lights...................................................1196
Rear Window Defroster.....................................................1213
Retractable Headlight System..............................................1187
Shiftlock System..........................................................1208
Sound Warning System......................................................1237
Starting System...........................................................1162
Stop Lights...............................................................1198
Tail Lights...............................................................1196
Turn Signal & Hazard Warning Lights.......................................1200
Windshield Wiper & Washer.................................................1181
Common Connector List.........................................................1243
Parts Location................................................................1246
Parts Index...................................................................1248
Body Shop Manual..................................................................1250
General Service Information...................................................1251
Dimensions....................................................................1261
Construction..................................................................1273
Panel Replacenment............................................................1285
Sealing.......................................................................1311
Undercoating, PVC Painting & Rrust Preventive Wax Treatment...................1319
Parts Catalog.....................................................................1351
Engine / Chassis..............................................................1351
Pictorial Index...........................................................1352
Section Index.............................................................1360
Engine & Gasket Sets (1000)...............................................1363
Cylinder Head & Cover (1010)..............................................1365
Cylinder Block (1030).....................................................1368
Oil Pan & Timing Cover (1040).............................................1369
Piston, Crankshaft & Flywheel (1100)......................................1371
Valve System (1200).......................................................1374
Inlet Manifold (1300).....................................................1376
Exhaust Manifold (1310)...................................................1377
Fuel System (1320)........................................................1378
Fuel Distributor (1325)...................................................1380
Air Cleaner (1330)........................................................1381
Throttle Body (1364)......................................................1383
Emission Control (1370)...................................................1384
Oil Pump & Filter (1400)..................................................1386
Cooling System (1500).....................................................1388
Bracket, Pulley & Belt (1580).............................................1391
Clutch Disc & Cover: Manual (1600)........................................1393
Transmission Case: Manual (1700)..........................................1394
Transmission Gears: Manual (1710).........................................1395
Change Control System: Manual (1720)......................................1400
Engine Electrical System (1800)...........................................1403
Alternator (1830).........................................................1405
Starter: MT (1840)........................................................1407
Starter: AT (1840A).......................................................1409
Battery (1850)............................................................1411
Torque Converter, Oil Pump & Pipings (1910)...............................1412
Transmission Case & Main Control System: Automatic (1920).................1415
Control Valve: Automatic (1925)...........................................1420
Clutches & Planetary Gears: Automatic (1930)..............................1427
Governor, Low & Reverse Piston: Automatic (1940)..........................1434
Manual Linkage System: Automatic (1950)...................................1437
Gasket & Seal Kit: Automatic (1960).......................................1439
Rear Propeller Shaft (2505)...............................................1452
Rear Drive Shaft (2550)...................................................1453
Rear Axle (2600)..........................................................1454
Rear Brake Mechanisms (2610)..............................................1455
Rear Differentials: Normal Diff. (2710)...................................1457
Rear Differentials: Limited Slip Diff. (2710A)............................1461
Rear Suspension Mechanisms (2800).........................................1464
Rear Spring & Damper (2801)...............................................1465
Rear Stabilizer (2810)....................................................1466
Rear Lower Arms & Sub Frame (2830)........................................1467
Steering Wheel (3200).....................................................1469
Steering Column & Shafts (3210)...........................................1470
Steering Gear: w/o Power Steering (3220)..................................1471
Steering Gear: w/ Power Steering (3220A)..................................1473
Power Steering System (3240)..............................................1476
Front Axle: w/o Anti Lock Brake System (3300).............................1478
Front Axle: Anti Lock Brake System (3300A)................................1479
Front Brake Mechanisms (3310).............................................1480
Front Suspension Mechanisms (3400)........................................1481
Front Spring & Damper (3401)..............................................1483
Crossmember & Stabilizer (3410)...........................................1484
Tires & Jack (3700).......................................................1485
Engine & T/mission Mountings (3900).......................................1488
Exhaust System (4000).....................................................1489
Clutch Release & Master Cylinders: Manual Transmission (4140).............1490
Clutch Pipings: Manual Transmission (4140)................................1491
Accelerator Control System (4160).........................................1492
Fuel Tank (4200)..........................................................1493
Fuel Lid Opener (4210)....................................................1496
Clutch & Brake Pedals: Manual Transmission (4300).........................1497
Brake Pedals: Automatic Transmission (4300A)..............................1500
Brake Master Cylinder & Power Brake: w/o Anti Lock Brake System (4340)....1502
Brake Master Cylinder & Power Brake: Antilock Brake System (4340A)........1504
Brake Pipings: w/o Anti Lock Brake System (4360)..........................1506
Brake Pipings: Anti Lock Brake System (4360A).............................1508
Antilock Brake System (4370)..............................................1510
Parking Brake System (4400)...............................................1512
Fuel Pipings (4500).......................................................1514
Change Control System: AT (4600)..........................................1516
Body..........................................................................1518
Pictorial Index...........................................................1519
Section Index.............................................................1527
Key Sets (0900)...........................................................1530
Front Bumper (5000).......................................................1532
Rear Bumper (5010)........................................................1535
Window Mouldings & Cowl Grilles (5030)....................................1537
Head Lamps (5100).........................................................1538
Head Lamp Retractors (5103)...............................................1539
Front Combination Lamps (5105)............................................1542
Rear Combination Lamps (5110).............................................1544
License Lamps (5120)......................................................1547
Ornaments (5170)..........................................................1548
Rear Finisher (5180)......................................................1549
Bonnet (5230).............................................................1550
Trunk Lid (5260)..........................................................1552
Front Panels (5310).......................................................1553
Fender & Wheel Apron Panels (5320)........................................1554
Dash & Cowl Panels (5330).................................................1556
Side Panels (5340)........................................................1557
Floor Panels (5370).......................................................1562
Floor Attachments: Hole Covers (5380).....................................1565
Floor Attachments (5390)..................................................1566
Dashboard Equipments (5500)...............................................1568
Meter Hood (5520).........................................................1570
Speedometer Cable (5530)..................................................1571
Meter Components (5540)...................................................1572
Dashboard & Related Parts (5560)..........................................1574
Console (5570)............................................................1577
Ventilator (5580).........................................................1580
Seats (5700)..............................................................1582
Seat Belts (5790).........................................................1594
Air Bag (5795)............................................................1596
Front Doors (5800)........................................................1599
Front Door Mechanisms (5830)..............................................1602
Front Door Trims & Related Parts (5840)...................................1606
Heater (6100).............................................................1610
Heater Unit Components (6110).............................................1611
Heater Controls Components (6115).........................................1612
Heater Blower Components (6120)...........................................1613
Air Conditioner (6130)....................................................1614
Compressor Components: Air Conditioner (6140).............................1618
Cooling Unit: Air Conditioner (6150)......................................1620
Window Glasses (6300).....................................................1621
Sunroof (6330)............................................................1622
Switches & Relays: Engine (6600)..........................................1633
Dashboard Switches (6610).................................................1636
Combination Switch (6611).................................................1637
Relays & Unit: Body (6630)................................................1638
Door Switch & Horns (6635)................................................1640
Auto Cruise Control System (6640).........................................1641
Audio Systems: Radio & Tape Deck (6680)...................................1642
Audio Systems: Antenna & Speaker (6682)...................................1647
Wiring Harnesses: Front & Rear (6700).....................................1650
Wiring Harnesses: Engine & T/mission (6701)...............................1652
Wiring Harnesses: Dashboard (6702)........................................1653
Wiring Harnesses: Door, Floor/Ceiling (6703)..............................1654
Wiring Harness Clamps (6704)..............................................1655
Windshield Washer: w/o Anti Lock Brake System (6720)......................1658
Windshield Washer: Antilock Brake System (6720A)..........................1660
Windshield Wipers (6730)..................................................1663
Wiper Motor Components: Front (6740)......................................1665
Front Header Trim & Pillar Trims (6820)...................................1666
Trims & Scuff Plates (6840)...............................................1667
Floor Mats & Pads (6860)..................................................1669
Service Tools (6870)......................................................1671
Visors, Assisst Handles & Mirrors (6900)..................................1672
Caution Plates & Labels (6930)............................................1674
Quarter Window & Trims (7250).............................................1676
Index.........................................................................1677
Pictorial Index...........................................................1678
Section Index.............................................................1686
Part Number Index.........................................................1689
Alphabetical Index........................................................1697
Model Identification......................................................1703
Body Paints & Interior Colors.............................................1704
Complete Assembly Parts Numbers...........................................1705
Vehicle Identification System.............................................1706
Abbreviation List.........................................................1707
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