Mazda 2006 MX-5 Service manual

Title Section
GENERAL INFORMATION 00
ENGINE 01
SUSPENSION 02
DRIVELINE/AXLE 03
BRAKES 04
TRANSMISSION/TRANSAXLE 05
STEERING 06
HEATER, VENTILATION &
AIR CONDITIONING (HVAC)
07
RESTRAINTS 08
BODY & ACCESSORIES 09
CONTENTS
2006 Mazda MX-5 Service Highlights (3404–1U–05F)
2006
Mazda MX-5
Service
Highlights
FOREWORD
This manual explains each component or
system operation and function for the
Mazda MX-5.
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
notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by
any means, electronic or mechanical—
including photocopying and recording and
the use of any kind of information storage
and retrieval system—without permission in
writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN) shown on the following
page.
©2005 Mazda Motor Corporation
PRINTED IN U.S.A., JUNE 2005
Form No. 3404–1U–05F
Part No. 9999–95–072F–06

2006 Mazda MX-5 Service Highlights (3404–1U–05F)
Revised 8/2005 (Ref. No. R076/05)
VEHICLE IDENTIFICATION NUMBERS (VIN)
JM1 NC15F✻6# 100001—
JM1 NC25F✻6# 100001—
RELATED MATERIALS
Material Name MNAO Part No.Mazda Material No.
2006 Mazda MX-5 Workshop Manual 9999–95–042B–06 1846–1U–05F
Engine Workshop Manual LF L3 9999–95–LFL3–05 1866–1U–05H
Manual Transmission Workshop Manual M15M-D 9999–95–421H–06 1847–1U–05F
Manual Transmission Workshop Manual P66M-D 9999–95–423H–06 1848–1U–05F
2006 Mazda MX-5 Bodyshop Manual 9999–95–060F–06 3405–1U–05F
2006 Mazda MX-5 Wiring Diagram 9999–95–026G–06 5639–1U–05F

00
GENERAL INFORMATION
00–00–1
SECTION 00–00
Toc of S CT
GENERAL INFORMATION . . . . 00-00
Toc of S CT
00–00 GENERAL INFORMATION
AIM OF DEVELOPMENT . . . . . . . . . . . . . 00–00–1
Product Concept . . . . . . . . . . . . . . . . . . 00–00–1
External View . . . . . . . . . . . . . . . . . . . . 00–00–1
Vehicle Outline . . . . . . . . . . . . . . . . . . . 00–00–2
VEHICLE IDENTIFICATION NUMBER
(VIN) CODE . . . . . . . . . . . . . . . . . . . . . . 00–00–10
VEHICLE IDENTIFICATION NUMBERS
(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–10
UNITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–11
Conversion to SI Units
(Système International d'Unités) . . . . 00–00–11
Rounding Off . . . . . . . . . . . . . . . . . . . . 00–00–11
Upper and Lower Limits . . . . . . . . . . . . 00–00–11
SAE STANDARD . . . . . . . . . . . . . . . . . . . 00–00–12
End of Toc
AIM OF DEVELOPMENT E5U000000000N01
Product Concept
•A car in which “oneness between car and driver, and still the one” dynamics and “lots of fun” are carried
forward and further evolved for a new generation.
External View
E5U000ZN5001

GENERAL INFORMATION
00–00–2
Vehicle Outline
Exterior design
•Fun-to-drive with instinctively attractive styling
—A two-fold type soft top has been adopted for improved ease of opening/closing.
Interior design
•A comfortable interior and sporty design incorporating Mazda’s inherited DNA
—A simple, clean-cut dashboard with a spacious feel has been adopted.
—A center panel that integrates module audio and air conditioning controls has been adopted.
—An instrument cluster with an emphasized sportiness has been adopted.
—Illumination that is both easily visible and comfortable for the eye has been adopted.
Engine
•Engine block
—Variable valve timing that optimally adjusts valve timing in accordance with driving conditions has been
adopted.
—An aluminum-alloy cylinder head and cylinder block have been adopted.
—Lightweight pistons, low-tension piston rings, and shimless tappets have been adopted to minimize friction
losses, thereby contributing to improved fuel economy.
—An auto-tensioner that automatically adjusts the belt to compensate for stretching has been adopted to
minimize maintenance requirements.
•Intake, exhaust, control
—Weight reduction has been achieved due to a hard-plastic dynamic chamber.
—High torque is obtained from the lower-middle to the high engine speed ranges due to the adoption of the
variable intake air system.
—Maximum torque is achieved at all engine speeds due to the adoption of a variable valve timing system that
controls intake valve timing in accordance with driving conditions to attain highly efficient air charging.
—An exhaust gas recirculation (EGR) system has been adopted for all models resulting in cleaner exhaust
emissions and reduced fuel consumption.
E5U000ZN5002

GENERAL INFORMATION
00–00–3
00–00
Suspension and steering
•Front suspension
—A newly developed in-wheel-type double-wishbone suspension has been adopted to take full advantage of
the low bonnet line enabled by the optimized engine layout.
—The front upper arm and the front lower arm have been lengthened and attached to the highly rigid front
crossmember to allow for linear alignment changes during jounce and rebound of the front wheels. Due to
this, roadholding and handling performance have been improved.
FRONT SHOCK
ABSORBER AND
COIL SPRING
FRONT UPPER
ARM FRONT SUSPENSION
TOWER BAR
TRANSVERSE
MEMBER
FRONT LOWER ARM
FRONT STABILIZER
FRONT
CROSSMEMBER
FRONT STABILIZER
CONTROL LINK
E5U213ZS5001

GENERAL INFORMATION
00–00–4
•Rear suspension
—A multi-link suspension composed of five links has been adopted.
—The links have been lengthened and optimally positioned. Due to this, they constantly provide ideal
geometry to respond to external forces applied during driving, improving handling stability and riding
comfort, and reducing road noise.
REAR SHOCK ABSORBER
AND COIL SPRING
REAR SHOCK
ABSORBER
REAR
CROSSMEMBER
REAR LATERAL
LINK (UPPER)
REAR
STABILIZER
REAR STABILIZER
CONTROL LINK
TOE CONTROL
LINK
REAR LATERAL
LINK (LOWER)
REAR TRAILING
LINK (UPPER)
REAR TRAILING
LINK (LOWER)
E5U214ZS5001

GENERAL INFORMATION
00–00–5
00–00
•Power steering
—With the adoption of an integrated mount for the steering gear, handling stability has been improved.
—With the adoption, for all vehicles, of a steering column with a tilt mechanism, operability has been
improved.
—With the adoption of a steering shaft with an energy absorbing mechanism, safety has been improved.
STEERING GEAR
POWER
STEERING
OIL PUMP
FLUID RESERVOIR
STEERING COLUMN AND SHAFT
STEERING WHEEL
E5U614ZS5001

GENERAL INFORMATION
00–00–6
Brakes
•The ABS HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted,
resulting in size and weight reduction.
•A semi-conductor element type front ABS wheel-speed sensor has been adopted, improving reliability and
reducing size and weight.
•A magnetic encoder type front ABS sensor rotor that is integrated with the wheel hub component has been
adopted, improving reliability and reducing size and weight.
•Electronic brakeforce distribution (EBD) control has been adopted, resulting in improved safety and handling
stability.
BRAKE
BRAKE SYSTEM
WARNING LIGHT
ABS WARNING
LIGHT
ABS HU/CM
REAR ABS WHEEL-
SPEED SENSOR
FRONT ABS WHEEL-
SPEED SENSOR
PCM
E5U413ZS5001

GENERAL INFORMATION
00–00–7
00–00
Transmission
•Manual transmission [M15M-D]
—A linked, triple-cone synchronizer mechanism has been adopted for 1st and 2nd gears.
—A linked, double-cone synchronizer mechanism has been adopted for 3rd gears.
—A linked, carbon-cone synchronizer mechanism has been adopted for 4th gears.
—A cam-type reverse lockout mechanism has been adopted.
2ND 4TH REV
1ST 3RD 5TH
INPUT SHAFT
MAIN DRIVE GEAR(4TH GEAR)
REVERSE GEAR
OUTPUT SHAFT
2ND GEAR
1ST GEAR
SHIFT PATTERN
COUNTERSHAFT
3RD GEAR
5TH GEAR
E5U511AS5001

GENERAL INFORMATION
00–00–8
•Manual transmission [P66M-D]
—A linked, triple-cone synchronizer mechanism has been adopted for 1st, 2nd, 3rd and 4th gears.
—A guide plate type reverse lockout mechanism has been adopted.
•Automatic transmission [SJ6A-EL]
—Newly developed SJ6A-EL type 6-speed AT has been adopted.
—With the adoption of the line pressure solenoid, TCC control solenoid, solenoid for C3 clutch, solenoid for
B2 brake, and the linear type solenoid, dynamic shift quality has been realized.
1ST
2ND
3RD
4TH
5TH
6TH
REV
SHIFT PATTERN
MAIN DRIVE GEAR
SHAFT
MAINSHAFT
1ST GEAR
2ND GEAR 3RD GEAR
4TH GEAR
5TH GEAR
6TH GEAR
REVERSE IDLER GEAR
E5U511BS5007