1990 Mazda MX-5 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
1990 Mazda MX-5 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 1273
Downloadable : Yes
File Type : PDF
Size: 70.6 MB
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DESCRIPTION:
1990 Mazda MX-5 Workshop Manual – PDF DOWNLOAD
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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.
TABLE OF CONTENTS:
1990 Mazda MX-5 Workshop Manual – PDF DOWNLOAD
Service Manual 1
General Information 3
Important Information 4
How To Use This Manual 5
Fundamental Procedures 7
Jack & Safety Stand Positions 10
Vehicle Lift Positions 10
Towing 11
Identification Number Locations 11
Abbreviations 12
Caution 13
PDI & Scheduled Maintenance 20
Scheduled Maintenance Services 22
Pre-Delivery Inspection 21
Engine 28
Index 29
Outline Specifications 30
Troubleshooting Guide 30
Engine Tune-up Procedure 32
Preparation 32
Engine Oil 32
Engine Coolant 32
Drive Belt 33
HLA 34
Ignition Timing, Idle Speed 35
Compression 37
On-vehicle Maintenance 38
Preparation 38
Timing Belt 39
Cylinder Head Gasket 43
HLA 47
Front Oil Seal 51
Rear Oil Seal 53
Removal 55
Engine Stand Mounting 60
Disassembly 63
Preparation 63
Auxilliary Parts 64
Timing Belt 65
Cylinder Head 67
Cylinder Block External Parts 70
Cylinder Block Internal Parts 72
Inspection / Repair 75
Preparation 75
Cylinder Head 75
Valve Mechanism 76
Camshaft 79
HLA 81
Cylinder Block 81
Oil Jet 83
Piston, Piston Ring & Piston Pin 83
Connecting Rod 84
Crankshaft 85
Bearing 86
Timing Belt 86
Tensioner, Idler 86
Tensioner Spring 86
Pulley 87
Assembly 87
Preparation 87
Cylinder Block Internal Parts 88
Cylinder Block External Parts 93
Cylinder Head 97
Timing Belt 101
Auxiliary Parts 105
Engine Stand Dismounting 109
Installation 111
Lubricaton System 118
Index 119
Outline Specifications 120
Troubleshooting Guide 120
Oil Pressure 121
Engine Oil 122
Oil Filter 122
Oil Pan 123
Oil Pump 126
Cooling System 131
Index 132
Outline Specifications 133
Troubleshooting Guide 133
Engine Coolant 134
Radiator Cap 136
Radiator 137
Thermostat 138
Water Pump 139
Electric Cooling Fan System 141
Fan Motor 142
Water Thermoswitch 143
Fan relay 144
Fuel & Emission Control Systems 145
Index 146
Outline 149
System Diagram 149
Vacuum Hose Routing Diagram 150
Wiring Diagram 151
Specifications 153
Component Descriptions 154
Troubleshooting Guide 156
Engine Control Operation Chart 156
Relationship Chart 159
Using This Section 160
Diagnostic Index 162
Precaution 163
Symptom Troubleshooting 164
Engine Tune-Up 218
Self-Diagnosis Function 221
Malfunction Code Number 224
Switch Monitor Function 233
Intake Air System 236
Idle Speed Control 241
Fuel System 244
Description 244
Precaution 245
System Operation 246
Fuel Tank 248
Fuel Filter 250
Fuel Pump 251
Circuit Opening Relay 254
Pressure Regulator 255
Injector 256
Exhaust System 259
Outline Of Emission Control System 260
Positive Crankcase Ventilation (PCV) System 261
Evaporative Emission Control System 262
Deceleration Control System 265
Catalytic Convertor System 266
A/C Cut-Off System 267
Dechoke Control System 268
Control System 269
Preparation 269
Structural View 270
Engine Control Unit 271
Crank Angle Sensor 278
Airflow Meter 279
Water Thermosensor 280
Throttle Sensor 280
Oxygen Sensor 282
Main Relay 283
Clutch Switch 283
Neutral Switch 284
Power Steering Pressure Switch 284
Engine Electrical System 285
Index 286
Outline Specifications 287
Troubleshooting Guide 288
Charging System 290
Preparation 290
Circuit Diagram 290
Troubleshooting 291
Battery 292
Alternator 296
Self-Diagnosis System 296
Drive Belt 299
Ignition System 301
Preparation 301
Circuit Diagram 301
Troubleshooting 302
Ignition Timing 303
Spark Plug 304
Ignition Coil 305
Igniter 306
High-Tension lead 306
Starting System 307
Circuit Diagram 307
Troubleshooting 307
Starter 308
Starter Interlock Switch 313
Clutch 314
Index 315
Outline Specifications 316
Troubleshooting Guide 316
Clutch Fluid 317
Clutch Pedal 318
Clutch Master Cylinder 320
Clutch Release Cylinder 325
Clutch Unit 327
Release Bearing 330
Clutch Cover 330
Clutch Disc 331
Pilot Bearing 331
Flywheel 331
Manual Transmission 333
Index 334
Outline 335
Troubleshooting Guide 339
Transmission Oil 340
Transmission 341
Preparation 341
Removal 342
Disassembly 345
Inspection 355
Assembly 358
Installation 377
Propeller Shaft 380
Outline Specifications 381
Troubleshooting Guide 381
Propeller Shaft 382
Front & Rear Axles 384
Index 385
Outline Specifications 386
Troubleshooting Guide 386
Front Axle 388
Rear Axle 392
Drive Shaft 399
Differential 405
Steering System 426
Index 427
Outline Specifications 429
Manual Steering 429
Preparation 429
Troubleshooting Guide 430
Boot 431
Steering Wheel & Column 433
Steering Gear & Linkage 437
Power Steering 438
Preparation 438
Troubleshooting Guide 438
Air Bleeding 440
Power Steering Fluid 441
Steering Wheel & Column 443
Steering Gear & Linkage 444
Power Steering Oil Pump 446
Drive Belt 447
Braking System 448
Index 449
Outline Specifications 450
Brake System 451
Preparation 451
Troubleshooting Guide 452
Air Bleeding 453
Brake Hydraulic Line 453
Brake Fluid 454
Brake Pedal 454
Master Cylinder 457
Power Brake Unit 460
Proportioning Bypass Valve 463
Front Brake (Disc) 465
Caliper 468
Rear Brake (Disc) 469
Caliper 472
Parking Brake System 474
Troubleshooting Guide 474
Parking Brake Lever 474
Parking Brake Cable 476
Wheels & Tires 477
Outline Specifications 478
Troubleshooting Guide 478
Wheels and Tires 479
Suspension 482
Index 483
Outline Specifications 485
Troubleshooting Guide 486
Wheel Alignment 487
Front Suspension 492
Preparation 492
Shock Absorber & Spring 493
Lower Arm 496
Upper Arm 498
Stabilizer 500
Crossmember 501
Rear Suspension 502
Preparation 502
Shock Absorber & Spring 503
Lower Arm 504
Upper Arm 505
Stabilizer 506
Crossmember 507
Body 508
Index 509
Hood 512
Door 514
Window Regulator, Glass & Guide 516
Door Lock & Opener 522
Trunk Lid 523
Trunk Lid Lock & Opener 525
Power Window System 526
Fuel Filler Lid Opener 530
Front Bumper 531
Rear Bumper 532
Molding & Garnish 534
Door Mirror 537
Horn 537
Windshield Wiper & Washer 538
Windshield 545
Rear Window Glass 549
Rear Window 553
Dashboard & Console 557
Trim 560
Floormat 563
Seat Belt 564
Seat 566
Convertible Top 568
Hard Top 577
Underbody Dimensions 580
Body Electrical System 583
Index 584
Switches 584
Fuses & Relays 585
Lights 586
Cruise Control System 587
Audio System 588
Air Bag System 589
Troubleshooting 590
Outline 591
How To Use This Section 591
Electrical Trouble Shooting Tools 591
General Precautions 592
Electrical Symbols 593
Fuse 594
Structural View 594
Description 595
Specifications 595
Replacement 596
Relay 597
Structural View 597
Description 598
Headlight Rectractor Relay 598
Turn & Hazard Warning Flasher Unit 598
DRL Unit 600
4-Terminal Normally Open Relay 601
Switch 602
Structural View 602
Description 603
Steering Lock 603
Combination Switch 603
Headlight Retractor Switch 607
Hazard Warning Switch Assembly 607
Instrument Cluster 608
Structural View 608
Description 609
Circuit Diagram 609
Troubleshooting 610
Removal / Installation 615
Disassembly / Assembly 615
Speedometer 616
Tachometer 616
Water Temperature Gauge 616
Fuel Gauge 617
Oil Pressure Gauge 617
Printed Circuit 618
Speed Sensor 618
Water Thermosensor 618
Fuel Gauge sender Unit 619
Oil Pressure Sensor 619
Speedometer Cable 619
Warning Lamp & Sender Unit 620
Structural View 620
Circuit Diagram 621
Troubleshooting 622
Brake Fluid Level Sensor 625
Parking Brake Switch 625
Seat Belt Buckle Switch 625
Lighting System 626
Structural View 626
Headlights 627
Stoplights 640
Turn & Hazard Warning Lights 644
Back-Up Lights 653
Tail Lights, Side Marker Lights, Parking Lights & License Plate Lights 656
Day Time Running Lights 660
Rear Combination Light Lens 665
Interior Lamps 667
Illumination Lamps 671
Horn 673
Structural View 673
Circuit Diagram 674
Troubleshooting 675
Removal / Installation 677
Cruise Control System 679
Structural View 679
Circuit Diagram 680
Troubleshooting 681
Inspection Of Cruise Control System 684
Actuator 686
Cruise Control Unit 687
Actuator Cable 688
Clutch Switch 688
Brake Switch 689
Cruise Control Main Switch 689
Cruise Control Switch 689
Speed Sensor 690
Audio 690
Structural View 690
System Diagram 691
Features 691
Function & Operating Procedure 692
Troubleshooting 697
Removal / Installation 708
Inspection 710
Connector Terminal Specifications 710
Panasonic Service Network 711
Air Bag System 712
Structural View 712
Component Description 713
System Diagram 714
Service Precaution 715
Circuit Diagram 718
Troubleshooting Guide 720
Removal / Installation 732
Inspection 739
Air Bag Module Disposal Procedure 742
HVAC 744
Index 745
Troubleshooting Guide 747
Heater 761
Air Conditioner 769
Structural View 769
Refrigerant System 770
Cooling Unit 775
Condenser & Receiver / Drier 778
Refrigerant Lines 780
Condenser Fan 781
A/C Relay 782
Refrigerant Pressure Switch 782
Compressor 783
Technical Data 787
Measurements 788
Engine 788
Lubricating System 791
Cooling System 791
Fuel & Emission Control Sytems 792
Engine Electrical System 793
Clutch 794
Manual Transmission 794
Propeller Shaft 795
Front & Rear Axles 795
Steering System 795
Braking System 796
Wheels & Tires 796
Suspension 797
Body Electrical System 797
Heater & Air Conditioning System 798
Torque Settings 798
Special Tools 799
General Information 800
Engine 801
Clutch & Manual Transmission 802
Differential 803
Front & Rear Axles 804
Steering System 804
Braking System 805
Front & Rear Suspensions 805
Checkers & Other Equipment 806
Parts Index 807
Wiring Diagrams 811
Wiring Color Code 811
General Information 812
Joint Connector & Ground Circuit 829
Electrical Wiring Schematic 833
Starting & Charging System 835
Engine Control System & Ignition 837
Fuel Control System 845
Cooling Fan System 847
Instrument Clusters 849
Windshield Wiper & Washer 851
Headlights 855
Front Fog Lights 855
Headlight Retractor Motor 855
Daytime Running Light 859
Other Driving Lights 861
Illumination Lights 863
Turn Signal & Hazard Lights 865
Stop Lights 865
Reversing Lights 865
Horn 865
High Mount Stop Light 865
HVAC 869
Automatic Transmission System 871
Cigar Lighter 876
Interior Lamps 876
Audio System 878
Power Window 882
ABS System 884
Cruise Control System 886
Air Bag Control System 889
CPU: Sound Warning System 891
Common Connector List 893
Parts Index 895
Parts Catalog 897
Engine 897
Pictorial Index 898
Section Index 906
Short Engine & Gasket Sets (1000) 910
Cylinder Head & Cover (1010) 911
Cylinder Block (1030) 914
Oil Pan & Timing Cover (1040) 916
Piston, Crankshaft & Flywheel (1100) 918
Valve System (1200) 921
Inlet Manifold (1300) 924
Exhaust Manifold (1310) 925
Fuel System (1320) 926
Fuel Distributor (1325) 928
Air Cleaner (1330) 929
Throttle Body (1364) 931
Emission Control System: Inlet Side (1370) 932
Cap & Hose Clip: Inlet & Exhaust Side (1399) 933
Oil Pump & Filter (1400) 934
Cooling System (1500) 936
Bracket, Pulley & Belt (1580) 940
Clutch Disc & Cover: Manual (1600) 943
Transmission Case: Manual (1700) 944
Transmission Gears: Manual (1710) 945
Change Control System: Manual (1720) 950
Engine Electrical System (1800) 953
Alternator (1830) 956
Starter (1840) 958
Battery (1850) 960
Torque Convertor, Oil Pump & Pipings: Automatic (1910) 961
Transmission Case & Main Control System: Automatic (1920) 964
Control Valve: Automatic (1925) 971
Clutches & Planetary Gears: Automatic (1930) 975
Governor, Low & Reverse Piston: Automatic (1940) 983
Manual Linkage System: Automatic (1950) 986
Gasket & Seal Kit: Automatic (1960) 988
Rear Propeller Shaft (2505) 1003
Rear Drive Shaft (2550) 1004
Rear Axle (2600) 1005
Rear Brake Mechanisms (2610) 1006
Rear Differentials: Normal Diff (2710) 1008
Rear Differentials: Limited Slip Diff (2710A) 1012
Rear Suspension Mechanisms (2800) 1017
Rear Spring & Damper (2801) 1018
Rear Stabilizer (2810) 1019
Rear Lower Arms & Sub Frame (2830) 1020
Steering Wheel (3200) 1022
Steering Column & Shafts (3210) 1025
Steering Gear: w/o Power Steering (3220) 1026
Steering Gear: w/ Power Steering (3220A) 1029
Power Steering System (3240) 1032
Front Axle (3300) 1034
Front Brake Mechanisms (3310) 1035
Front Suspension Mechanisms (3400) 1037
Front Spring & Damper (3401) 1039
Crossmember & Stabilizer (3410) 1040
Tires & Jack (3700) 1042
Engine & T/mission Mountings (3900) 1046
Exhaust System (4000) 1047
Clutch Release & Master Cylinders: Manual Transmission (4140) 1049
Clutch Pipings: Manual Transmission (4145) 1050
Accelerator Control System (4160) 1051
Fuel Tank (4200) 1052
Clutch & Brake Pedals: Manual Transmission (4300) 1056
Brake Pedals: Automatic Transmission (4300A) 1060
Brake Master Cylinder & Power Brake (4340) 1062
Brake Pipings (4360) 1064
Parking Brake System (4400) 1066
Fuel Pipings (4500) 1068
Chassis 1070
Pictorial Index 1071
Section Index 1079
Change Control System: AT (4600) 1083
Key Sets (0900) 1099
Front Bumper (5000) 1101
Rear Bumper (5010) 1104
Window Mouldings & Cowl Grilles (5030) 1106
Head Lamps (5100) 1108
Head Lamp Retractors (5103) 1109
Front Combination Lamps (5105) 1113
Rear Combination Lamps (5110) 1115
License Lamps (5120) 1118
Rear Finisher (5180) 1119
Bonnet (5230) 1121
Trunk Lid (5260) 1123
Body Panels: Front (5310) 1126
Body Panels: Fender & Wheel Apron (5320) 1127
Body Panels: Dash & Cowl Panel (5330) 1130
Body Panels: Side (5340) 1131
Body Panels: Floor (5370) 1138
Floor Attachments: Hole Covers (5380) 1141
Floor Attachments (5390) 1142
Dashboard Equipments (5500) 1145
Meter Hood (5520) 1147
Speedometer Cable (5530) 1148
Meter Components (5540) 1149
Dashboard & Related Parts (5560) 1151
Console (5570) 1154
Ventilator (5580) 1158
Seats (5700) 1159
Seat Belts (5790) 1166
Front Doors (5800) 1167
Front Door Mechanisms (5830) 1171
Front Door Trims & Related Parts (5840) 1174
Heater (6100) 1177
Heater Unit Components (6110) 1178
Heater Controls Components (6115) 1179
Heater Blower Components (6120) 1180
Air Conditioner (6130) 1181
O Ring Set, Piping (6135) 1185
Compressor Components: Air Conditioner (6140) 1186
Cooling Unit: Air Conditioner (6150) 1188
Window Glasses (6300) 1190
Sunroof (6330) 1191
Switches & Relays: Engine (6600) 1200
Dashboard Switches (6610) 1204
Combination Switches (6611) 1205
Relays & Unit: Body (6630) 1206
Door Switches & Horns (6635) 1207
Auto Cruise Control System (6640) 1208
Audio Systems: Radio & Tape Deck (6680) 1209
Audio Systems: Antenna & Speaker (6682) 1211
Wiring Harnesses: Front & Rear (6700) 1212
Wiring Harnesses: Engine & T/mission (6701) 1214
Wiring Harnesses: Dashboard (6702) 1217
Wiring Harnesses: Door, Floor/Ceiling (6703) 1218
Wiring Harness Clamps (6704) 1219
Windshield Washer (6720) 1222
Windshield Wipers (6730) 1224
Wiper Motor Components: Front (6740) 1226
Front Header Trim & Pillar Trims (6820) 1227
Trims & Scuff Plates (6840) 1229
Floor Mats & Pads (6860) 1231
Service Tools (6870) 1233
Visors, Assist Handles & Mirrors (6900) 1234
Caution Plates & Labels (6930) 1236
Quarter Windows & Trims (7250) 1238
Body 1239
Pictorial Index 1240
Section Index 1248
Accessories (7900) 1252
Part Number Index 1254
Alphabetical Index 1262
Model Identification 1268
Body Paints and Interior Colors 1269
Complete Assembly Parts Numbers 1270
Vehicle Identification System 1271
Abbreviation List 1272
Index 1254
Part Number Index 1254
Alphabetic Index 1262
Model Identification 1268
Body Paints & Interior Colors 1269
Complete Assy Part Numbers 1270
Abbreviations 1272
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