Mazda 1990 MX-5 Instruction manual

CONTENTS
Title Section
General Information GI
Pre-Delivery Inspection and
Scheduled Maintenance Services A
Engine B
Lubrication System D
Cooling System E
Fuel and Emission Control Systems F
Engine Electrical System G
Clutch H
Manual Transmission J
Propeller Shaft L
Front and Rear Axles M
Steering System N
Braking System P
Wheels and Tires Q
Suspension R
Body S
Body Electrical System T
Heater and Air Conditioner
Systems U
Technical Data TD
Special Tools ST
1990
Mazda
MX-5
Workshop
Manual
FORWARD
This workshop manual is intended for use by
service technicians of Authorised Mazda
Dealers to help them service Mazda vehicles. It
can also be useful to owners and operators of
Mazda vehicles in diagnosing some problems
and performing limited repair and maintenance
on Mazda vehicles.
For proper repair and maintenance a
thorough familiarisation 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
drawing 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
Authorised 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 notice.
Parts Index PI
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles beginning with the
Vehicle Identification Numbers (VIN) shown on the
following page.
©1989 Mazda Motor Corporation
PRINTED IN JAPAN, MAR. ’89
1193-10-89C

VEHICLE IDENTIFICATION NUMBERS (VIN)
JM1 NA351 * LO 100001--
JM1 NA352 * LO 100001-

,--
f
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GENERAL INFORMATION
IMPORTANT INFORMATION ..................... GI- 2
BASIC ASSUMPTIONS .............•.............. GI- 2
SAFETY RISK ........................................ GI- 2
POSSIBLE LOSS OF WARRANTy ............. GI- 2
WARNING ON LUBRICANTS AND
GREASES •••••••••.•••••••••••...................... GI- 2
HOW TO USE THIS MANUAL .................... GI- 3
PREPARATION .•••.•.....••.••.•••.•••.•••.•••.•••.. GI- 3
REPAIR PROCEDURE ............................. GI- 3
SyMBOLS.•.••••.••••..•••.•..••..••..•...•••••..•••.. GI- 4
NOTES, CAUTIONS, AND WARNINGS ....... GI- 4
FUNDAMENTAL PROCEDURES ................. GI- 4
PROTECTION OF VEHICLE ..................... GI- 4
A WORD ABOUT SAFETy •..•••..•••.•••.•••.••• GI- 5
PREPARATION OF TOOLS AND
MEASURING EQUiPMENT•••.•••••••..••.••..• GI- 5
SPECIAL TOOLS .................................... GI- 5
REMOVAL OF PARTS .•••..•.........•••.•..•..... GI- 5
DiSASSEMBLy ...................................... GI- 5
REASSEMBLy .••.•••.•••...••.•......••.•••.••...•.• GI- 6
ADJUSTMENTS ..................................... GI- 7
RUBBER PARTS
AND TUBING .••••••••••.••.. GI- 7
JACK AND SAFETY STAND POSITIONS .... GI- 8
VEHICLE LIFT (2-SUPPORT TYPE)
POSiTIONS ............................................ GI- 8
TOWiNG••••••••••.••••••••.••••••.••..•••••••••••.•••.• II GI- 9
IDENTIFICATION NUMBER LOCATIONS..... GI- 9
UNITS•••••••••••••••••••••••••• II •••••••••••••••• II ••••••• GI-10
ABBREViATIONS ..................................... GI-10
CAUTION .•••• II' ••••••••••••• II. II' ••••••••••••••••••••• 01-11
INSTALLATION OF MOBILE
TWO-WAY RADIO SYSTEM •••••.••••.••••..•.• 01-11
SERVICE PRECAUTIONS CONCERNING
AIR BAG SYSTEM •.•••..•..••.•••.•••••••.•.•••••
GI-12
BATTERy .............................................. GI-13
POWER CONNECTOR IN
ENGINE COMPARTMENT ...................... GI-13
AUDIO ANTI-THEFT SYSTEM ..••••••••..••••••• GI-13
ELECTRICAL TROUBLESHOOTING TOOLS GI-14
CAUTION WITH ELECTRICAL PARTS••.•••.• 01-15
05UGIX-001
GI

GI
IMPORTANT INFORMATION
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have certain special tools that are necessary for the safe and effi-
cient performance of service operations on Mazda vehicles and that you know how to use them properly.
It also assumes that you are familiar with automobile systems and basic service and repair procedures. You
should not attempt to use this manual unless these assumptions are correct and you understand the conse-
quences described below.
SAFETY RISK
This manual contains certain notes, warnings, and other precautionary information that you should carefully
read and follow to reduce the risk of personal injury to yourself or others and the risk of improper service
that may damage the vehicle or render it unsafe. If there is no such information in regard to any specific
service method, this does not mean there is no possibility that personal safety or vehicle safety will be
jeopardized by the use of incorrect methods or tools.
POSSIBLE LOSS OF 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 Dealer.
WARNING ON LUBRICANTS AND GREASES
Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated
during service (e.g., engine sump oils) are more irritating and more likely to cause serious effects, including
skin cancer, in the event of gross and prolonged skin contact.
Wash skin thoroughly after work involving oil.
Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not
use gasoline, paraffin, or other solvents to remove oil from the skin.
Lubricants and greases may be slightly irritating to the eyes.
Repeated or prolonged skin contact should be avoided by wearing protective clothing. Particular care should
be taken with used oils and greases containing lead. Do not allow work clothing to be contaminated with
oil. Dry clean or launder such clothing at regular intervals.
05UGIX-002
GI-2
-
-

HOW TO USE THIS MANUAL
GI
HOW TO USE THIS MANUAL
PREPARATION
PREPARATION points out the needed Special Service Tool (SST) for the service operation that it pre-
ceeds. Gather
all necessary SST before beginning work.
Example:
N TIE-ROD END BOOT AND STEERING GEAR BOOT SST NUMBER
TIE-ROD END BOOT AND STEERING GEAR BOOT
PREPARATION
49 011B B50C
Puller. ball joint
REPAIR PROCEDURE
49 H028 301
Installer. boot
9MUONX·030
SST NAME SST ILLUSTRATION
05UGIX-003
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the
parts fit together, and describes visual parts inspections.
If a damaged or worn part is found, repair or
replace
it as necessary.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration.
3. Pages related to service procedures are shown under the illustration. Refer to this information when ser-
vicing the related part.
Example:
EXPENDABLE
PARTS
APPLICATION
POINT
OF OIL'Ir_~~~
ETC.
TIGHTENING
TORQUE
SPECIFICATION
*2
(See page GI-4)
L-~~~~~~~ ______________________ ~====~
TIGHTENING
TORQUE UNIT
16. Bearing inner race
Removal ....................................
~e M-22
1W~~~~~tf~W:@@:\~rnfiW~·[:9.Iii~nJQ@m1l1----+- VISUAL
Installation ................................. page M-24 INSPECTION
RELATED
PAGE FOR
SERVICE
17. Spacer INFORMATION
18. Drive pinion
Removal .................................... page
M-21
Inspect splines and teeth for wear or damage
Adjustment
of helght................ page M-22
Ad flqe M-
~----
* 1: The numbers (CD ex.) refer to parts identification and where necessary servicing procedure.
*2: Units are in N·m (m-kg, ft-Ib) unless otherwise specified. 05UGIX-004
GI-3

GI HOW TO USE THIS MANUAL, FUNDAMENTAL PROCEDURES
SYMBOLS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such
materials during service.
Symbol Meaning Kind
.~
• Apply
oil
New engine oil or gear oil as appropriate
~
• Apply brake fluid Only brake fluid
• Apply automatic transmission fluid Only
ATF
i Apply grease Appropriate grease
' .. 1 Apply sealant Appropriate sealant
fj
Apply petroleum jelly Appropriate petroleum jelly
05UGIX-005
Note
• When special oil or grease is needed, this is shown in the illustration.
NOTES, CAUTIONS, AND WARNINGS
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each
one
is there for a specific purpose. NOTES give you added information that will help you to complete a
particular procedure. CAUTIONS are given to prevent you from making an error that could damage the
vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause per-
sonal injury. The following list contains some general WARNINGS you should follow when you work on
a vehicle.
05UGIX-006
GI-4
FUNDAMENTAL PROCEDURES
PROTECTION OF VEHICLE
9MUGIX-036
Always be sure to cover fenders, seats. and floor areas be·
fore starting work.
---

FUNDAMENTAL PROCEDURES
GI
9MUGIX-038
I U"'1 #.,1".1
47UOGX-005
A WORD ABOUT SAFETY
The following precautions must be followed when jacking up
the vehicle.
1. Block the wheels.
2. Use only the specified jacking positions.
3. Support the vehicle with safety stands.
Start the engine only after making certain the engine compart-
ment is clear of tools and people.
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT
Be sure that all necessary tools and measuring equipment are
available before starting any work.
SPECIAL TOOLS
Use special tools when they are required.
REMOVAL OF PARTS
While correcting a problem, try also to determine its cause.
Begin work only after first learning which parts and subassem-
blies must be removed and disassembled for replacement or
repair.
OISASSEMBLY
If the disassembly procedure is complex, requiring many parts
to be disassembled,
all parts should be disassembled in a way
that will not affect their performance or external appearance
and identified
so that reassembly can be performed easily and
effiCiently.
GI-5

GI
GI-6
FUNDAMENTAL PROCEDURES
9MUGIX-042
1. Inspection of parts
When removed, each part should be carefully inspected for
malfunctioning, deformation, damage, and other problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for re-
assembly.
Be sure to separate or otherwise identify the parts to be
replaced from those that will be reused.
3. Cleaning parts for reuse
All parts to be reused should be carefully and thoroughly
cleaned in the appropriate method.
REASSEMBLY
Standard values, such as torques and certain adjustments,
must be strictly observed
in the reassembly of all parts.
Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE
in Section TO for tightening torques not mentioned in the main
text.
If removed, these parts should be replaced with new ones:
1. Oil seals 2. Gaskets
3. O-rings 4. Lock washers
5. Cotter pins 6. Nylon nuts
Depending on location:
1. Sealant should be applied to gaskets.
2. Oil should be applied to the moving components of parts.
3. Specified oil or grease should be applied at the prescribed
locations (such as oil seals) before reassembly.

FUNDAMENTAL PROCEDURES GI
ADJUSTMENTS
Use suitable gauges and/or testers when making adjustments.
67UOGX-002
RUBBER PARTS AND TUBING
Prevent gasoline or oil from getting on rubber parts or tubing.
,
9MUGIX-005
GI-7

GI JACK AND SAFETY STAND POSITIONS, VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS
JACK AND SAFETY STAND POSITIONS
FRONT
Jack position: Safety stand positions:
At center of crossmember Side sills
REAR
Jack position: Safety stand positions:
At center of differential Side sills
VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS
FRONT
Frame
Side sills
GI-8
REAR
Frame
Side sills
9MUGIX-007
9MUGIX-009
05UGIX-010 .