1994 MAZDA MX-5 MIATA WORKSHOP MANUAL – PDF DOWNLOAD
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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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