Mazda MX-5 1994 Workshop Manual

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D - ADJUSTMENTS 1994 ENGINE PERFORMANCE Mazda - On-Vehicle Adjustments

D - ADJUSTMENTS

1994 ENGINE PERFORMANCE Mazda - On-Vehicle Adjustments

ENGINE MECHANICAL

Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay.

VALVE CLEARANCE

NOTE: All piston engines are equipped with hydraulic valve lash adjusters. Valve clearance is not adjustable.

IGNITION TIMING

NOTE: Before adjusting ignition timing, warm engine to normal operating temperature.

Turn off all accessories. Place transmission in Neutral (M/T) or Park (A/T).

Ensure idle speed is correct. See IDLE SPEED under IDLE SPEED & MIXTURE. If timing is not within specification, loosen distributor or Crank Angle Sensor

(CAS) lock bolt. Rotate distributor or CAS until timing marks are aligned.

Tighten lock bolt.

Fig. 1: Locating Ignition Timing Marks

1994 Mazda MX-5 Miata

D - ADJUSTMENTS 1994 ENGINE PERFORMANCE Mazda - On-Vehicle Adjustments

Courtesy of MAZDA MOTORS CORP.

NOTE: On Miata, use Blue 1-pin connector near airflow meter as a source of battery power for positive lead of tachometer or timing light (battery is in trunk). DO

NOT ground this connector, or 20-amp WIPER fuse will blow.

1. Connect Diagnostic Tester (49 B019 9A0) to diagnostic connector and select SELF-TEST mode (position

1), or connect jumper wire between diagnostic connector terminals TEN and GND. See Fig. 2 .

2. Connect timing light. Set timing to specification. See IGNITION TIMING SPECIFICATIONS table.

See Fig. 1 . Disconnect diagnostic tester or jumper wire from diagnostic connector.

Fig. 2: Diagnostic Connector Terminal ID (Miata)

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1994 Mazda MX-5 Miata

D - ADJUSTMENTS 1994 ENGINE PERFORMANCE Mazda - On-Vehicle Adjustments

Courtesy of MAZDA MOTORS CORP.

IGNITION TIMING SPECIFICATIONS

Application

Miata

(2)

(1) Place automatic transmission in Park.

M/T

10 @ 850

(2) Connect jumper wire between terminals TEN and GRN of diagnostic connector.

(1)

A/T

10 @ 800

IDLE SPEED & MIXTURE

NOTE: Mixture adjustment is NOT a normal tune-up procedure. DO NOT adjust mixture unless mixture control unit is replaced or vehicle fails emissions test.

NOTE: Idle mixture is not adjustable. If idle mixture is incorrect, see TESTS W/CODES article in the ENGINE PERFORMANCE section.

IDLE SPEED

NOTE: Before adjusting idle speed, warm engine to normal operating temperature.

Turn off all accessories. Place transmission in Neutral (M/T) or Park (A/T).

Ensure ignition timing is adjusted. See IGNITION TIMING .

NOTE: On Miata, use Blue 1-pin connector near airflow meter as a source of battery power for positive lead of tachometer or timing light (battery is in trunk). DO

NOT ground this connector, or 20-amp WIPER fuse will blow.

1. Connect Diagnostic Tester (49 B019 9A0) to diagnostic connector and select SELF-TEST mode, or connect jumper wire between diagnostic connector terminals TEN and GND. See Fig. 2 . Connect tachometer to diagnostic connector terminal IG (-).

2. If idle speed is not within specification, rotate idle air adjusting screw on throttle body. See IDLE SPEED

SPECIFICATIONS table. Disconnect jumper wire.

IDLE SPEED SPECIFICATIONS

Application

Miata

(2)

(1) Place automatic transmission in Park.

M/T: RPM

850

(2) Connect jumper wire between terminals TEN and GRN of diagnostic connector.

(1)

A/T: RPM

800

THROTTLE POSITION (TP) SENSOR

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1994 Mazda MX-5 Miata

D - ADJUSTMENTS 1994 ENGINE PERFORMANCE Mazda - On-Vehicle Adjustments

INSPECTION (A/T)

1. Disconnect TP sensor connector. Connect ohmmeter between TP sensor connector terminals "E" and

IDL. See Fig. 3 . Insert feeler gauge of specified thickness between throttle lever and throttle stop screw.

See TP SENSOR CONTINUITY (A/T) table.

2. If continuity is not as specified, adjust TP sensor. See ADJUSTMENT procedure. If continuity is as specified, connect ohmmeter between TP sensor connector terminals Vt and "E". If resistance is less than

1000 ohms with throttle fully closed and about 5000 ohms with throttle wide open, TP sensor is adjusted.

If resistance is not as specified, adjust TP sensor. See ADJUSTMENT procedure.

NOTE: If ohmmeter reading indicates a rough transition anywhere in range between lowest and highest readings, TP sensor potentiometer is faulty. Replace TP sensor.

ADJUSTMENT

1. Disconnect TP sensor connector. Connect ohmmeter between TP sensor connector terminals "E" and

IDL. See Fig. 3 . Loosen TP sensor attaching screws.

2. Insert a .010" (.25 mm) feeler gauge between throttle lever and throttle stop screw. Rotate TP sensor clockwise about 30 degrees, then rotate counterclockwise until ohmmeter indicates continuity.

3. Remove feeler gauge. Insert a .016" (.40 mm) feeler gauge between throttle lever and throttle stop screw.

If ohmmeter indicates no continuity, go to next step. If ohmmeter indicates continuity, repeat adjustment procedure.

4. Tighten TP sensor attaching screws. Open throttle valve fully and verify resistance between terminals "E" and Vt is about 5000 ohms.

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1994 Mazda MX-5 Miata

D - ADJUSTMENTS 1994 ENGINE PERFORMANCE Mazda - On-Vehicle Adjustments

Fig. 3: TP Sensor Connector Terminal ID (A/T)

Courtesy of MAZDA MOTORS CORP.

TP SENSOR CONTINUITY

Test Condition

(1)

.004" (.10 mm)

.024" (.60 mm)

(1) Insert feeler gauge of specified thickness between throttle lever and throttle stop screw.

(2)

Continuity

Yes

(2) Check continuity with ohmmeter connected between TP sensor terminals "E" and IDL.

INSPECTION (M/T)

1. Disconnect TP sensor connector. Insert feeler gauge of specified thickness between throttle lever and throttle stop screw. See TP SENSOR CONTINUITY (M/T) table.

2. Connect ohmmeter between specified terminals of TP sensor connector. See Fig. 4 . If continuity is not as specified, adjust TP sensor. See ADJUSTMENT procedure.

ADJUSTMENT

1. Disconnect TP sensor connector. Connect ohmmeter between terminals IDL and TL/E of TP sensor

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1994 Mazda MX-5 Miata

D - ADJUSTMENTS 1994 ENGINE PERFORMANCE Mazda - On-Vehicle Adjustments connector. See Fig. 4 . Insert a .016" (.41 mm) feeler gauge between throttle lever and throttle stop screw.

2. Loosen TP sensor screws. Rotate TP sensor clockwise about 30 degrees, then rotate counterclockwise until ohmmeter indicates continuity.

3. Remove feeler gauge. Insert a .027" (.69 mm) feeler gauge between throttle lever and throttle stop screw.

If ohmmeter indicates no continuity, go to next step. If ohmmeter indicates continuity, repeat adjustment procedure.

4. Tighten TP sensor attaching screws. Open throttle valve fully a few times. Recheck TP sensor adjustment.

Fig. 4: TP Sensor Connector Terminal ID (M/T)

Courtesy of MAZDA MOTORS CORP.

TP SENSOR CONTINUITY

Condition

.016" (.41 mm)

(1)

.027" (.7 mm)

(1)

WOT

Continuity Between IDL

& TL/E

Yes

Continuity Between POW &

Insert feeler gauge of specified thickness between throttle lever and throttle stop screw.

TL/E

Yes

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1994 Mazda MX-5 Miata

D - ADJUSTMENTS 1994 ENGINE PERFORMANCE Mazda - On-Vehicle Adjustments

(1)

THROTTLE (IDLE) SWITCH

NOTE: Throttle switch is either a part of TP sensor, which is adjusted automatically when TP is adjusted, or a separate, nonadjustable switch on throttle body. See

THROTTLE POSITION (TP) SENSOR .

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AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

AIR BAG RESTRAINT SYSTEM

1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

DESCRIPTION & OPERATION

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all WARNINGS and SERVICE PRECAUTIONS.

The Supplemental Restraint System (SRS), when used in conjunction with seat belt, provides increased protection for driver and passenger in a collision. The air bag restraint system consists of AIR BAG warning light, driver's air bag module, passenger's air bag module, clockspring, diagnostic module, back-up battery

(located inside diagnostic module), 4 crash sensors and wiring harness. One crash sensor (S-sensor) is located above heater unit in passenger compartment. Three other crash sensors (D-sensor) are located left front, right front, and center front of vehicle. See Fig. 1 .

The air bag is designed to deploy when S-sensor (rear) and at least one D-sensor (front) close in a collision when ignition is on. The back-up battery supplies current for the ignitor if the vehicle battery or fuses fail during a collision.

The diagnostic module monitors the air bag system for failures. If diagnostic module detects a short between air bag module and ground or a malfunction with S-sensor or any D-sensor, diagnostic module will melt system fuse to prevent unintended air bag deployment. If a failure occurs, the diagnostic module turns on the AIR BAG warning light. If AIR BAG warning light is burned out, diagnostic module will sound a buzzer to alert driver of a system malfunction.

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 1: Identifying Air Bag System Components

Courtesy of MAZDA MOTORS CORP.

SERVICE PRECAUTIONS

Following precautions should be observed when working with air bag systems:



Disable SRS before servicing any SRS or steering column component. Failure to do this could result in accidental air bag deployment and possible personal injury. See DISABLING & ACTIVATING AIR

BAG SYSTEM .

After an accident, all SRS components, including harness and brackets, must be inspected. If any components are damaged or bent, they must be replaced, even if a deployment did not occur. Check steering column, knee bolster, instrument panel steering column reinforcement plate and lower brace for damage. DO NOT service any component or wiring. If components or wiring are damaged or defective, replacement is necessary. DO NOT use components from another vehicle. Only use new replacement parts.



After repairs, turn ignition on while ensuring any accidental air bag deployment will not cause injury.

Ensure SRS indicator light is working properly and no system faults are indicated. See TESTING -

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags



SYSTEM OPERATION CHECK .

Always wear safety glasses when servicing or handling an air bag.



Air bag module must be stored in its original special container until used for service. It must be stored in a clean, dry place, away from sources of extreme heat, sparks and high electrical energy.

When placing a live air bag module on a bench or other surface, always face air bag and trim cover up, away from surface. This will reduce motion of module if it is accidentally deployed.



After deployment, air bag surface may contain deposits of sodium hydroxide, which can irritate skin.

Always wear safety glasses, rubber gloves and long-sleeved shirt during clean-up, and wash hands using mild soap and water. Follow correct disposal procedures. See DISPOSAL PROCEDURES .

NEVER allow any electrical source near inflator on back of air bag module.



If the ignition is on, DO NOT bump the SRS unit. This could cause the air bags to deploy.

When carrying a live air bag module, trim cover should be pointed away from your body to minimize injury in case of deployment.



DO NOT probe a wire through insulator; this will damage wire and eventually cause failure due to corrosion.

When performing electrical tests, always use specified digital multimeter and SRS test harnesses recommended by manufacturer. See SPECIAL TOOLS. DO NOT directly probe the component connector pins or wires.



When installing SRS wiring harnesses, ensure they will not be pinched or interfere with other vehicle components.

Inspect all ground connections. Ensure they are clean and tight.



DO not use any type of electrical equipment not specified by manufacturer. See SPECIAL TOOLS.

If SRS is not fully functional for any reason, vehicle should not be driven until system is repaired. DO

NOT remove any component or in any way disable system from operating normally. If SRS is not functional, park vehicle until repairs can be made.

DISABLING & ACTIVATING AIR BAG SYSTEM

WARNING: After disabling air bag system, wait at least 10 minutes before servicing.

Air bag system voltage is maintained for about 10 minutes after system is disabled. Failure to wait at least 10 minutes may cause accidental air bag deployment and possible personal injury.

PROCEDURES

Disabling System

Cancel radio anti-theft function. See CANCELING & ACTIVATING RADIO ANTI-THEFT under

DISABLING & ACTIVATING AIR BAG SYSTEM. Disconnect and shield negative battery cable. Wait at least 10 minutes for back-up power supply to be depleted. Remove cover panel below left side of instrument panel. Disconnect Orange and Blue clockspring connectors for driver air bag. See Fig. 2 . Remove glove compartment. Disconnect Orange and Blue passenger air bag module connectors. See Fig. 3 .

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Activating System

Ensure negative battery cable is disconnected. Connect Orange and Blue passenger air bag module connectors.

See Fig. 3 . Install glove compartment. Connect driver air bag Orange and Blue clockspring connectors. See

Fig. 2 . Install lower cover panel. Connect negative battery cable. See TESTING - SYSTEM OPERATION

CHECK . Activate radio anti-theft function. See CANCELING & ACTIVATING RADIO ANTI-THEFT under DISABLING & ACTIVATING AIR BAG SYSTEM.

Fig. 2: Locating Driver Air Bag Clockspring Connectors

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 3: Locating Passenger Air Bag Clockspring Connectors

Courtesy of MAZDA MOTORS CORP.

CANCELING & ACTIVATING RADIO ANTI-THEFT

Canceling

1. Obtain radio anti-theft code from vehicle owner. Turn ignition on. Push REW and FF until radio displays bars. Use channel preset buttons 1-4 to enter current code number.

2. Use preset button 1 to enter first digit of code, preset button 2 to enter second digit of code, etc. After entering all 4 digits of code, press and hold REW and FF for approximately 2 seconds until a beep is heard.

3. Radio will display CODE for approximately 5 seconds, then disappear to indicate radio is operative with anti-theft function by-passed. If radio displays ERR, repeat procedure.

NOTE: If 3 consecutive errors are made during activation of radio anti-theft, radio will become completely inoperable. If this happens, contact Panasonic.

Activating

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

1. Turn ignition on. Press REW and FF until radio displays bars. While radio is displaying bars, use channel preset buttons 1-4 to enter code number.

3. Radio will display COD with a backwards 9. This display will flash for 5 seconds, then disappear to indicate radio is operational with anti-theft activated. If radio displays ERR, repeat procedure.

POST-COLLISION INSPECTION

If air bags deployed, replace air bag modules and clockspring. Whether air bags deployed or not, inspect the following components and replace them if damaged: diagnostic module, impact sensors, instrument panel, steering column, and steering wheel. DO NOT attempt to repair any component or wiring harness. After replacing components as necessary, perform TESTING - SYSTEM OPERATION CHECK .

ADJUSTMENTS

CLOCKSPRING CENTERING

Set front wheels in straight-ahead position. Turn clockspring clockwise until it stops (DO NOT force). Return clockspring 2 3/4 turns counterclockwise until mark on clockspring aligns with steering column cover mark.

DISPOSAL PROCEDURES

DEPLOYED AIR BAG

Wrap deployed air bag module in a plastic bag and dispose of as you would any other part. Wear gloves and safety glasses when handling air bag module.

SCRAPPED VEHICLE

NOTE: When scrapping vehicles with an undeployed air bag(s), air bag(s) must be deployed inside vehicle.

Driver Air Bag

1. Before deploying air bag, inspect operating condition of Deployment Tool (49 H066 002). See

INSPECTING DEPLOYMENT TOOL under DISPOSAL PROCEDURES. Ensure vehicle is outside and away from other vehicles and people. Open doors. Open convertible top (if equipped). Disconnect negative battery cable.

2. Ensure air bag module is firmly mounted to steering wheel. Remove cover panel below left side of instrument panel. Disconnect Orange and Blue clockspring connectors for driver air bag. See Fig. 2 .

3. Connect deployment tool connector "A" to driver air bag clockspring connector. See Fig. 4 . Connect Red deployment tool clip to battery positive terminal. Connect Black deployment tool clip to battery negative

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags terminal. Verify deployment tool Red light is on.

4. Ensure all persons are at least 20 feet from vehicle. Press deployment tool activation switch to deploy air bag. Because of heat generated from air bag deployment, wait at least 15 minutes before handling deployed air bag module.

Passenger Air Bag

1. Before deploying air bag, inspect operating condition of Deployment Tool (49 H066 002). See

2. Remove glove compartment. Disconnect Orange and Blue passenger air bag module connectors. See Fig.

3 . Connect deployment tool connector "A" to Orange and Blue passenger air bag connector. See Fig. 4 .

Connect Red deployment tool clip to battery positive terminal. Connect Black deployment tool clip to battery negative terminal. Verify deployment tool Red light is on.

3. Ensure all persons are at least 20 feet from vehicle. Press deployment tool activation switch to deploy air bag. Because of heat generated from air bag deployment, wait at least 15 minutes before handling deployed air bag module.

INSPECTING DEPLOYMENT TOOL

NOTE: Deployment tool should always be inspected for proper operation before deploying air bag.

1. Connect Red deployment tool clip to battery positive terminal. Connect Black deployment tool clip to battery negative terminal. Observe deployment tool lights. Green light should be on with Red light off.

2. Connect deployment tool connector "A" to connector "B". See Fig. 4 . Green light should be off with Red light on. Press deployment tool activation switch. Green light should be on with Red light off.

3. If deployment tool lights function as described, it is safe to use deployment tool to activate air bag. If deployment tool lights do not function as described, DO NOT use deployment tool. Replace deployment tool with another unit and repeat procedure.

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 4: Identifying Air Bag Deployment Tool Connectors

Courtesy of MAZDA MOTORS CORP.

REMOVAL & INSTALLATION

WARNING: Follow air bag service precautions to prevent accidental air bag deployment and personal injury. See SERVICE PRECAUTIONS .

NOTE: After replacing components, check system to ensure proper operation. See

TESTING - SYSTEM OPERATION CHECK .

DRIVER AIR BAG MODULE

Removal

Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove 4 driver air bag module nuts. See

Fig. 5 . Disconnect driver air bag module connector. Disconnect support rope. See Fig. 5 . Remove driver air bag module.

Installation

1. With driver air bag module removed from vehicle, connect Orange and Blue clockspring connectors

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags located below left side of instrument panel. Connect negative battery cable. Turn ignition on. Observe

AIR BAG light. If code 32 is set, go to next step. If any code other than 32 is set, see DIAGNOSIS .

2. Turn ignition off. Disconnect negative battery cable. Disconnect Orange and Blue clockspring connectors located below left side of instrument panel. To install, reverse removal procedure.

3. Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light to ensure system is functioning properly. See TESTING - SYSTEM OPERATION

CHECK .

Fig. 5: Removing Driver Air Bag Module

Courtesy of MAZDA MOTORS CORP.

PASSENGER AIR BAG MODULE

Removal

Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove 4 passenger air bag module nuts.

Disconnect support rope. See Fig. 6 . Remove passenger air bag module.

Installation

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

1. With passenger air bag module removed from vehicle, connect Orange and Blue passenger air bag module connectors. Connect negative battery cable. Turn ignition on. Observe AIR BAG light. If code 33 is set, go to next step. If any code other than 33 is set, see DIAGNOSIS .

2. Turn ignition off. Disconnect negative battery cable. Disconnect Orange and Blue passenger air bag module connectors. To install, reverse removal procedure.

3. Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light to ensure system is functioning properly. See TESTING - SYSTEM OPERATION

CHECK .

Fig. 6: Removing Passenger Air Bag Module

Courtesy of MAZDA MOTORS CORP.

CLOCKSPRING

NOTE: Clockspring is part of combination switch. When replacing clockspring, replace clockspring and combination switch as an assembly.

Removal

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

1. Set front wheels in straight-ahead position. Before proceeding, follow air bag service precautions. See

SERVICE PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG

SYSTEM .

2. Remove driver air bag module. See DRIVER AIR BAG MODULE . Remove steering wheel nut. Using a puller, remove steering wheel. Remove steering column covers. Remove clockspring screws. Remove clockspring and combination switch as an assembly.

Installation

1. To install, reverse removal procedure. Before installing steering wheel, center clockspring. See

CLOCKSPRING CENTERING under ADJUSTMENTS. Tighten steering wheel nut to specification.

See TORQUE SPECIFICATIONS TABLE at the end of this article.

2. After installation, activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

Check AIR BAG warning light to ensure system is functioning properly. See TESTING - SYSTEM

OPERATION CHECK .

CRASH SENSORS

WARNING: Crash sensor orientation and mounting is important for proper operation.

All sensors must be positioned so arrow points forward. If sheet metal damage exists near sensor mounting point, inspect body structure at sensor mounting point for deformation. If structure is damaged, restore it to original shape.

Removal (Front D-Sensors)

1. Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

2. To remove center sensor, go to step 4). To remove left or right sensor, raise and support front of vehicle.

Remove wheel and tire assembly. Remove wheel well assembly to access sensor.

3. Remove 2 sensor covers. Unbolt sensor from vehicle. Disconnect sensor harness connector located in front of door jamb area. Remove sensor and harness from vehicle. See Fig. 7 .

4. To remove center sensor, remove top cover located forward of radiator to access sensor. Remove sensor cover. Unbolt sensor from vehicle. Disconnect sensor harness connector located on top of left wheel well in engine compartment. Remove sensor and harness from vehicle.

Removal (Rear S-Sensor)

Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS . Disable the air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Rear S-sensor is located above heater unit in passenger compartment. See Fig. 1 . Remove driver and passenger air bag modules. See DRIVER AIR BAG

MODULE and PASSENGER AIR BAG MODULE. Remove dashboard assembly to access sensor. Unbolt sensor from vehicle. Disconnect electrical connectors. Remove sensor from vehicle.

Installation (D-Sensor & S-Sensor)

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

To install, reverse removal procedure. Position sensor with arrow toward front of vehicle. Install air bag modules (if necessary). Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

Check AIR BAG warning light to ensure system is functioning properly. See TESTING - SYSTEM

OPERATION CHECK .

Fig. 7: Removing Front (D-Sensor)

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC MODULE

Removal & Installation

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

1. Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

2. Diagnostic module is located under left side of instrument panel. See Fig. 1 . Disconnect diagnostic module connectors. Remove 2 diagnostic module mounting nuts. Remove diagnostic module.

3. To install, reverse removal procedure. After diagnostic module is installed, activate air bag system. See

DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light to ensure system is functioning properly. See TESTING - SYSTEM OPERATION CHECK .

TESTING - SYSTEM OPERATION CHECK

Turn ignition on. AIR BAG warning light in instrument cluster should glow for 4-8 seconds and then turn off. If

AIR BAG warning light does not function as described, a failure has occurred in Supplemental Restraint

System (SRS). Repair malfunctioning SRS. See SERVICE PRECAUTIONS . See DIAGNOSIS .

WIRE REPAIR

DO NOT repair air bag system wiring. If a problem is found with air bag system wiring, replace faulty wiring.

DIAGNOSIS

WARNING: Follow air bag service precautions to prevent accidental air bag deployment and personal injury. See SERVICE PRECAUTIONS .

SELF-DIAGNOSTIC SYSTEM

NOTE: If AIR BAG warning light does not come on and buzzer sounds when ignition is turned on, check and repair warning light circuit first.

Diagnostic module will only display one code at a time. Diagnostic module will always display highest code first. As an example, diagnostic module displays Code 23. After repairing Code 23, if any other codes are stored, diagnostic module will display next code. Next code displayed will be Code 22 or less. After repairing system, perform TESTING - SYSTEM OPERATION CHECK . If AIR BAG warning light is still flashing during TESTING - SYSTEM OPERATION CHECK , record code displayed. Repair system as necessary.

Retrieving & Clearing Codes

If codes are stored, AIR BAG warning light will flash or remain on when ignition is turned on. Codes are automatically cleared when fault is corrected.

AIR BAG Warning Light Flashes

AIR BAG warning light indicates fault codes by flashing. Count the number of flashes between pauses to determine code. See AIR BAG CODES table. Codes are prioritized. If 2 or more faults are present, diagnostic module will display highest code number first. After identifying code, go to appropriate code test.

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

AIR BAG Warning Light Remains On

AIR BAG warning light on all the time when ignition is turned on indicates a Code 0 (zero). See AIR BAG

CODES table.

AIR BAG Warning Light Does Not Come On

Check for blown fuses, burned-out bulb, disconnected diagnostic module or open circuit between warning light and diagnostic module.

AIR BAG CODES

Code

(1)

Possible Cause

Poor Connection At Diagnostic Module

(2)

Open Circuit Or Poor Connection Of Power Source

Damaged D-Sensor (D-Sensor On)

Poor Installation Of S-Sensor

Damaged S-Sensor (S-Sensor On)

Open Circuit In S-Sensor Feed Circuit

S-Sensor Diagnostic Circuit Open

High Resistance Or Open Circuit In Driver Air Bag

Module Circuit

High Resistance Or Open Circuit In Passenger Air

Bag Module Circuit

Low Resistance In Driver Air Bag Module Circuit

Low Resistance In Passenger Air Bag Module

Circuit

Open Circuit Between Diagnostic Module And D-

Sensor

Poor Installation Of Right D-Sensor

Poor Installation Of Center D-Sensor

Poor Installation Of Left D-Sensor

System Down (Fuse Open)

Damaged Back-Up Battery

Damaged Diagnostic Module

Poor Connection Of All D-Sensors

(1) AIR BAG warning light remains on all the time indicating a Code 0 (zero).

(2) AIR BAG warning light will flash quickly and continuously, indicating Code 99.

CODE 0

Warning Light Remains On

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1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Ensure diagnostic module connectors are properly connected. Verify that shorting bar is in fully retracted position. Repair as necessary. If diagnostic module connectors and shorting bar are okay, go to next step.

2. Disconnect diagnostic module connector (with shorting bar). Remove shorting bar from diagnostic module connector. Observe AIR BAG warning light. If AIR BAG warning light is on, repair wiring harness between instrument cluster and diagnostic module connector. Perform TESTING - SYSTEM

OPERATION CHECK . If AIR BAG warning light is off, replace diagnostic module. Perform

TESTING - SYSTEM OPERATION CHECK .

CODE 12

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check INJ fuse (30 amp) located in engine compartment fuse panel. If fuse is okay, go to next step. If fuse is open, go to step

3).

2. Disconnect diagnostic module connectors. Connect negative battery cable. Using a DVOM, measure voltage on diagnostic module connector terminal 1L. If battery voltage is present, replace diagnostic module. Perform TESTING - SYSTEM OPERATION CHECK . If battery voltage is not present, repair wiring harness between air bag fuse and diagnostic module connector. Perform TESTING -

SYSTEM OPERATION CHECK .

3. Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminal 1L and ground. If continuity is not present, go to next step. If continuity is present, replace INJ fuse and repair wiring harness between INJ fuse and diagnostic module connector.

Perform TESTING - SYSTEM OPERATION CHECK .

4. Using a DVOM, check for continuity between diagnostic module connector terminal 1H and ground. If continuity is present, go to next step. If continuity is not present, replace diagnostic module. Perform

TESTING - SYSTEM OPERATION CHECK .

5. Disconnect S-sensor connector. Using a DVOM, check for continuity between diagnostic module connector terminal 1H and ground. If continuity is present, replace S-sensor. Perform TESTING -

SYSTEM OPERATION CHECK . If continuity is not present, replace wiring harness. Perform

TESTING - SYSTEM OPERATION CHECK .

CODE 13

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect negative battery cable. Turn ignition on. Observe AIR BAG warning light. If AIR BAG warning light displays

Code 13, go to step 4). If AIR BAG warning light displays a code other than 13, go to next step.

2. Disconnect negative battery cable. Remove driver air bag module. See DRIVER AIR BAG MODULE under REMOVAL & INSTALLATION. Connect driver air bag module Orange and Blue clockspring connectors. Connect negative battery cable. Turn ignition on. Observe AIR BAG warning light. If AIR

BAG warning light displays Code 13, replace clockspring assembly. Perform TESTING - SYSTEM

OPERATION CHECK . If AIR BAG warning light displays a code other than 13, go to next step.

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

3. Turn ignition off. Disconnect negative battery cable. Connect passenger air bag module Orange and Blue clockspring connectors. Connect negative battery cable. Turn ignition on. Observe AIR BAG warning light. If AIR BAG warning light displays Code 13, replace passenger air bag module. Perform TESTING

- SYSTEM OPERATION CHECK . If AIR BAG warning light displays a code other than 13, replace driver air bag module. Perform TESTING - SYSTEM OPERATION CHECK .

4. Turn ignition off. Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminal 2F and ground. If continuity is not present, got to next step. If continuity is present, replace wiring harness. Perform TESTING - SYSTEM OPERATION

CHECK .

5. Using a DVOM, check for continuity between diagnostic module connector terminal 2G and ground. If continuity is not present, go step XX). If continuity is present, go to next step.

6. Using a DVOM, check for continuity between diagnostic module connector terminal 2D and ground. If continuity is present, go to next step. If continuity is not present, go to step 8).

7. Disconnect S-sensor connector. Using a DVOM, check for continuity between S-sensor connector (sensor side) terminal "C" and ground. If continuity is present, replace S-sensor. Perform TESTING - SYSTEM

OPERATION CHECK . If continuity is not present, replace wiring harness. Perform TESTING -

SYSTEM OPERATION CHECK .

8. Using a DVOM, check resistance between diagnostic module connector terminals 1C, 1A, 2L and ground one at a time. If resistance on all terminals was 1.18 k-ohms, replace diagnostic module. Perform

TESTING - SYSTEM OPERATION CHECK . If resistance was not 1.18 k-ohms, on one or more terminals, test suspect D-sensor. See SENSOR IDENTIFICATION table. Go to next step.

SENSOR IDENTIFICATION

Diagnostic Module

Connector Terminal

D-Sensor

Center

Right

Left

9. Using a DVOM, check resistance between suspect D-sensor connector (sensor side) terminal "A" and ground. See Fig. 8 . If resistance is 1.18 k-ohms, replace wiring harness. Perform TESTING - SYSTEM

OPERATION CHECK . If resistance is not 1.18 k-ohms, replace suspect D-sensor. Perform TESTING

- SYSTEM OPERATION CHECK .

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 8: Identifying D-Sensor Terminal "A"

Courtesy of MAZDA MOTORS CORP.

CODE 21

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminal 1E and ground. If continuity is present, replace diagnostic module. Perform

TESTING - SYSTEM OPERATION CHECK . If continuity is not present, go to next step.

2. Disconnect Orange and Blue S-sensor connector. Using a DVOM, check for continuity between S-sensor connector (sensor side) terminal "A" and ground. See Fig. 9 . If continuity is present, replace wiring harness. Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace Ssensor. Perform TESTING - SYSTEM OPERATION CHECK .

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 9: Identifying S-Sensor Connector Terminals

Courtesy of MAZDA MOTORS CORP.

CODE 22

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminals 1H and 2D. If continuity is present, go to next step. If continuity is not present, replace diagnostic module. Perform TESTING - SYSTEM OPERATION CHECK .

2. Disconnect Orange and Blue S-sensor connector. Using a DVOM, check for continuity between S-sensor connector (sensor side) terminals "B" and "D". See Fig. 9 . If continuity is present, replace S-sensor.

Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace wiring harness. Perform TESTING - SYSTEM OPERATION CHECK .

CODE 23

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminals 1H and 2C. If continuity is present, replace diagnostic module. Perform TESTING -

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

SYSTEM OPERATION CHECK . If continuity is not present, go to next step.

2. Disconnect Orange and Blue S-sensor connector. Using a DVOM, check for continuity between S-sensor connector (sensor side) terminals "B" and "E". See Fig. 9 . If continuity is present, replace wiring harness.

Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace S-sensor.

Perform TESTING - SYSTEM OPERATION CHECK .

CODE 24

NOTE: For connector terminal identification, see WIRING DIAGRAM .

Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminals 2B and 2D. If continuity is present, replace diagnostic module. Perform TESTING - SYSTEM OPERATION

CHECK . If continuity is not present, replace wiring harness. Perform TESTING - SYSTEM OPERATION

CHECK .

CODE 32

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect a jumper wire between driver air bag module clockspring connector (harness side) terminals "B" and "C". See Fig.

10 . Connect negative battery cable. Turn ignition on. Observe AIR BAG warning light. If AIR BAG warning light displays Code 32, go to step 4). If AIR BAG warning light displays a code other than 32, go to next step.

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 10: Clockspring Connector Terminal ID (Harness Side)

Courtesy of MAZDA MOTORS CORP.

2. Turn ignition off. Disconnect negative battery cable. Remove driver air bag module. See DRIVER AIR

BAG MODULE under REMOVAL & INSTALLATION. Remove jumper wire from driver air bag module clockspring connector (harness side). Connect driver air bag module Orange and Blue clockspring connectors. Connect a jumper wire between driver air bag module clockspring connector terminals "B" and "C". See Fig. 11 .

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 11: Identifying Clockspring Connector Terminals

Courtesy of MAZDA MOTORS CORP.

3. Connect negative battery cable. Turn ignition on. Observe AIR BAG warning light. If AIR BAG warning light displays Code 32, replace clockspring assembly. Perform TESTING - SYSTEM OPERATION

CHECK . If AIR BAG warning light displays a code other than 32, replace driver air bag module.

Perform TESTING - SYSTEM OPERATION CHECK .

4. Turn ignition off. Disconnect negative battery cable. Disconnect diagnostic module connectors. Using a

DVOM, check for continuity between diagnostic module connector terminals 2D and 2F. If continuity is present, replace diagnostic module. Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace wiring harness. Perform TESTING - SYSTEM OPERATION

CHECK .

CODE 33

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect a one ohm resistor (rated power one watt) between driver air bag module clockspring connector (harness side) terminals "B" and "C". See Fig. 10 . Connect a jumper wire between passenger air bag module connector

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

(harness side) terminals "B" and "C". See Fig. 12 .

2. Connect negative battery cable. Turn ignition on. Observe AIR BAG warning light. If AIR BAG warning light displays Code 33, go to next step. If AIR BAG warning light displays a code other than 33, replace passenger air bag module. Perform TESTING - SYSTEM OPERATION CHECK .

Fig. 12: Passenger Air Bag Module Connector Terminal ID (Harness Side)

Courtesy of MAZDA MOTORS CORP.

3. Turn ignition off. Disconnect negative battery cable. Disconnect diagnostic module connectors. Using a

DVOM, check for continuity between diagnostic module connector terminals 2D and 2G. If continuity is present, replace diagnostic module. Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace wiring harness. Perform TESTING - SYSTEM OPERATION

CHECK .

CODE 34

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect a one ohm resistor (rated power one watt) between passenger air bag module connector (harness side) terminals "B" and "C". See Fig. 12 .

2. Connect negative battery cable. Turn ignition on. Observe AIR BAG warning light. If AIR BAG warning light displays Code 34, go to next step. If AIR BAG warning light displays a code other than 34, go to step 4).

3. Turn ignition off. Disconnect negative battery cable. Disconnect diagnostic module connectors. Using a

DVOM, check for continuity between diagnostic module connector terminals 2D and 2F. If continuity is present, replace wiring harness. Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace diagnostic module. Perform TESTING - SYSTEM OPERATION CHECK .

4. Turn ignition off. Disconnect negative battery cable. Remove driver air bag module. See DRIVER AIR

BAG MODULE under REMOVAL & INSTALLATION. Inspect clockspring connector for broken pins.

If clockspring connector pins are okay, go to next step. If clockspring connector pins are broken, replace clockspring assembly. Perform TESTING - SYSTEM OPERATION CHECK .

5. Connect clockspring connector. Turn ignition on. Observe AIR BAG warning light. If AIR BAG warning light displays Code 34, replace clockspring assembly. Perform TESTING - SYSTEM OPERATION

CHECK . If AIR BAG warning light does not display Code 34, replace driver air bag module. Perform

TESTING - SYSTEM OPERATION CHECK .

CODE 35

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Inspect clockspring connector for broken pins. If clockspring connector pins are okay, go to next step. If clockspring connector pins are broken, replace clockspring assembly. Perform TESTING - SYSTEM OPERATION

CHECK .

2. Connect a one ohm resistor (rated power one watt) between driver air bag module clockspring connector

(harness side) terminals "B" and "C". See Fig. 10 . Connect negative battery cable. Turn ignition on.

Observe AIR BAG warning light.

3. If AIR BAG warning light displays Code 35, go to next step. If AIR BAG warning light displays a code other than 35, replace passenger air bag module. Perform TESTING - SYSTEM OPERATION

CHECK .

4. Turn ignition off. Disconnect negative battery cable. Disconnect diagnostic module connectors. Using a

DVOM, check for continuity between diagnostic module connector terminals 2D and 2G. If continuity is present, replace wiring harness. Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace diagnostic module. Perform TESTING - SYSTEM OPERATION CHECK .

CODE 41

NOTE: For connector terminal identification, see WIRING DIAGRAM .

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check resistance between diagnostic module connector terminals 1C, 1A, 2L and ground one at a time. If resistance on all terminals was 1.18 k-ohms, replace diagnostic module. Perform TESTING - SYSTEM OPERATION CHECK . If resistance was not 1.18 k-ohms, on one or more terminals, test suspect D-sensor. See SENSOR IDENTIFICATION table. Go to next step.

SENSOR IDENTIFICATION

Diagnostic Module

Connector Terminal

D-Sensor

Center

Right

Left

2. Using a DVOM, check resistance between suspect D-sensor connector (sensor side) terminal "A" and ground. See Fig. 8 . If resistance is 1.18 k-ohms, replace wiring harness. Perform TESTING - SYSTEM

OPERATION CHECK . If resistance is not 1.18 k-ohms, replace suspect D-sensor. Perform TESTING

- SYSTEM OPERATION CHECK .

CODE 44

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminal 2J and ground. If continuity is present, replace diagnostic module. Perform TESTING

- SYSTEM OPERATION CHECK . If continuity is not present, go to next step.

2. Disconnect right D-sensor connector. Using a DVOM, check for continuity between right D-sensor connector (sensor side) terminal "B" and ground. See Fig. 13 . If continuity is present, replace wiring harness. Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace right D-sensor. Perform TESTING - SYSTEM OPERATION CHECK .

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 13: Identifying D-Sensor Terminal "B"

Courtesy of MAZDA MOTORS CORP.

CODE 45

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminal 2H and ground. If continuity is present, replace diagnostic module. Perform

TESTING - SYSTEM OPERATION CHECK . If continuity is not present, go to next step.

2. Disconnect center D-sensor connector. Using a DVOM, check for continuity between center D-sensor connector (sensor side) terminal "B" and ground. See Fig. 13 . If continuity is present, replace wiring harness. Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace center D-sensor. Perform TESTING - SYSTEM OPERATION CHECK .

CODE 46

NOTE: For connector terminal identification, see WIRING DIAGRAM .

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminal 2E and ground. If continuity is present, replace diagnostic module. Perform

TESTING - SYSTEM OPERATION CHECK . If continuity is not present, go to next step.

2. Disconnect left D-sensor connector. Using a DVOM, check for continuity between left D-sensor connector (sensor side) terminal "B" and ground. See Fig. 13 . If continuity is present, replace wiring harness. Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace left D-sensor. Perform TESTING - SYSTEM OPERATION CHECK .

CODE 51

Code 51 will set because of one of the following conditions:



Blown diagnostic module internal fuse (fault conditions no longer present).



Diagnostic module has not been replaced after Code 13 was set and repaired.

 Intermittent short in air bag deployment circuit.

If Code 13 was set and repaired, replace diagnostic module. Perform TESTING - SYSTEM OPERATION

CHECK . If an intermittent short is suspected, inspect wiring harnesses and connectors for damage. If no damage is found in wiring harnesses and connectors, wiggle wiring harness to see if Code 13 sets. If Code 13 sets, see CODE 13 under DIAGNOSIS to repair system.

CODE 52

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Disconnect diagnostic module connectors. Using a DVOM, check for continuity between diagnostic module connector terminal 1H and ground. If continuity is present, go to next step. If continuity is not present, replace diagnostic module. Perform TESTING - SYSTEM OPERATION CHECK .

2. Disconnect Orange and Blue S-sensor connector. Using a DVOM, check for continuity between S-sensor connector (sensor side) terminal "B" and ground. See Fig. 9 . If continuity is present, replace S-sensor.

Perform TESTING - SYSTEM OPERATION CHECK . If continuity is not present, replace wiring harness. Perform TESTING - SYSTEM OPERATION CHECK .

CODE 53

Code 53 sets when diagnostic module is damaged. To correct this condition, replace diagnostic module.

Perform TESTING - SYSTEM OPERATION CHECK .

CODE 99

Code 99 sets when poor connections are present between all D-sensors and S-sensor. To correct this condition, ensure all D-sensor and S-sensor connectors are properly connected. Perform TESTING - SYSTEM

OPERATION CHECK .

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Steering Wheel Nut

Ft. Lbs. (N.m)

29-36 (39-49)

(1) Torque specifications are not available for air bag modules, clockspring, crash sensors, and diagnostic module.

POST-COLLISION AIR BAG SAFETY INSPECTION

POST-COLLISION AIR BAG SAFETY INSPECTION

Action

Replace After Deployment

Inspect & If Damaged, Replace Component (Even

If Air Bag Did Not Deploy)

Comments

Components



Air Bag Module(s)



Clockspring



Air Bag Diagnosis Control Unit

Impact Sensors & Sensors Mountings



Steering Column

Steering Wheel



Wiring Harness



DO NOT attempt wiring harness repairs.

Replace entire wiring harness.

 Impact sensors must always be installed with arrow on sensor facing front of vehicle.

WIRING DIAGRAM

Microsoft

1994 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Air Bags

Fig. 14: Air Bag System Wiring Diagram

Courtesy of MAZDA MOTORS CORP.

Microsoft

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

ANTI-LOCK BRAKE SYSTEM

1994 BRAKES Mazda - Anti-Lock

DESCRIPTION

The Anti-Lock Brake System (ABS) control unit senses reductions in front and rear wheel speed and modulates hydraulic pressure to the brakes to prevent wheel lock-up. The ABS consists of a hydraulic unit, 4 wheel speed sensors and sensor rotors, valve relay, motor relay, pump motor and ABS control unit. An ABS warning light is located on the instrument panel.

NOTE: For more information on brake system, see BRAKE SYSTEM article in the

BRAKES section.

OPERATION

Under normal driving conditions, Anti-Lock Brake System (ABS) functions like a standard brake system. When vehicle speed reaches 3.8 MPH, ABS will diagnose pump motor by briefly operating motor. Pump motor operation may be heard inside vehicle.

ABS control unit controls ABS by detecting speed sensor signals and activating solenoid valve in hydraulic unit. Control unit also controls pump motor and self-diagnostic function. If a problem is detected in ABS, ABS will function like a conventional brake system. ABS warning light will also come on.

With detection of wheel lock-up, short pedal pulsations, occurring in rapid succession, will be felt in brake pedal and steering wheel. Vehicle body may also vibrate slightly. These conditions are normal. Pedal pulsation will continue until there is no longer a need for anti-lock function or until vehicle is stopped.

CAUTION: See ANTI-LOCK BRAKE SAFETY PRECAUTIONS article in the GENERAL

INFORMATION section.

COMPONENT LOCATIONS

COMPONENT LOCATIONS

Application

ABS Control Unit

Diagnosis Connector

Front Sensor Rotor

Hydraulic Unit

Motor & Valve Relays

Pump Motor

Rear Sensor Rotor

Wheel Speed Sensor

Location

Passenger-Side Footwell

Left Side Of Engine Compartment

On Front Wheel Hub

Right Rear Of Engine Compartment

On Hydraulic Unit

On Rear Drive Shaft

On Wheel Hub

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

BLEEDING BRAKE SYSTEM

CAUTION: DO NOT allow reservoir to run dry during brake bleeding procedure. If brake fluid is spilled, clean surface immediately, as brake fluid will damage painted surfaces. Use only DOT 3 brake fluid and DO NOT mix with any other types.

1. Raise and support vehicle. Ensure brake fluid reservoir is at least half full during bleeding procedure.

When bleeding brake system, start with longest brakeline first. Remove bleeder cap. Connect one end of transparent vinyl tube to bleeder screw. Submerge other end of tube in a container half filled with clean brake fluid.

2. Have an assistant depress brake pedal several times and hold in depressed position. Loosen bleeder screw, and drain fluid into container. Tighten bleeder screw.

NOTE: Ensure brake pedal remains depressed until bleeder screw is tightened.

3. Refill brake fluid reservoir if necessary. Repeat step 2) until air is no longer discharged. Tighten bleeder screw to 52-78 INCH lbs. (6-9 N.m). Ensure fluid leakage is not present. Add fluid to reservoir. Repeat procedure for remaining wheels.

DIAGNOSIS

ABS can only be diagnosed using ABS Tester (0000-42-0010) and Adapter Harness (49-H066-003). ABS tester cannot diagnose ABS control unit. If a malfunction is detected in ABS and all other components in brake system are okay, replace ABS control unit.

If ABS tester is unavailable, test each component of ABS. See test procedures under TESTING. If all ABS components test okay, replace ABS control unit with a known good unit and retest system.

PRE-DIAGNOSIS INSPECTION

Visually inspect ABS components for possible cause of anti-lock problem. Visual inspection may help identify cause of simple malfunction.

DIAGNOSTIC PROCEDURE WITH ABS TESTER

ABS tester uses one display window and 2 switches for reading information from unit. Become thoroughly familiar with ABS tester displays and operation before proceeding. See Fig. 2 . To diagnose ABS system, proceed to CONNECTING ABS TESTER under DIAGNOSIS. If ABS tester does not operate, check fuses, ignition switch and ignition circuit.

CONNECTING ABS TESTER

CAUTION: DO NOT drive vehicle with ABS Tester (0000-42-0010) connected.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Turn ignition off. Connect Adapter Harness (49-H066-003) between hydraulic unit harness connector and battery positive terminal. See Fig. 1 . Roll back carpet from passenger-side footwell, and remove ABS control unit protector panel. Connect ABS Tester (0000-42-0010) harness to harness side of ABS control unit connector. Proceed to TESTING SEQUENCE charts under DIAGNOSING ABS. When diagnosing ABS, complete tests in the order given under TESTING SEQUENCE.

Fig. 1: Connecting ABS Tester & Adapter Harness

Courtesy of MAZDA MOTORS CORP.

DIAGNOSING ABS

ABS TESTER OPERATION

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 2: Operating ABS Tester

Courtesy of MAZDA MOTORS CORP.

TESTING SEQUENCE

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 3: Power Up/Alternator Test/ABS System Test (1 of 9)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 4: System Voltage Checks (2 of 9)

Courtesy of MAZDA MOTORS CORP.

Fig. 5: Static Tests/Brake Light Switch Test (3 of 9)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 6: Pump Test (4 of 9)

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Courtesy of MAZDA MOTORS CORP.

Fig. 7: Dynamic Tests/Wheel Sensor Test (5 of 9)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 8: Wheel Sensor Test (Cont.)/Solenoid Test (6 of 9)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 9: Solenoid Test (Cont.) (7 of 9)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 10: Solenoid Test (Cont.) (8 of 9)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 11: Solenoid Test (Cont.) (9 of 9)

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Courtesy of MAZDA MOTORS CORP.

TESTING

NOTE: Before testing ABS components, ensure battery and charging system are functioning properly. To prevent damage to ABS control unit connector, use very thin pins when probing connector.

ABS DIODE

Continuity Test

1. Check METER fuse and ABS warning light bulb. Check wiring harness between ABS warning light and

ABS control unit, and between ABS warning light and hydraulic unit. Repair or replace as necessary.

Disconnect hydraulic unit connector. Connect positive lead of DVOM to Blue/Yellow wire terminal and negative lead to Gray wire terminal of hydraulic unit connector. See Fig. 12 .

2. Ensure continuity is present between terminals. Reverse DVOM leads. Continuity should not be present with leads reversed. If ABS diode does not test as described, replace hydraulic unit.

Fig. 12: Hydraulic Unit Harness Connector Terminals ID

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Courtesy of MAZDA MOTORS CORP.

ABS GROUND

NOTE: To prevent damage to ABS control unit connector, use very thin pins when probing connector.

Continuity Test

Using a DVOM, check for continuity between ground and following ABS control unit connector terminals: 1D,

1S and AF. See Fig. 13 . If continuity is not present, repair wiring harness.

Fig. 13: Control Unit Harness Connector Terminals ID

Courtesy of MAZDA MOTORS CORP.

ABS WARNING LIGHT

Operational Test

1. Start engine, and observe ABS warning light. Light should illuminate for a few seconds. If light does not illuminate as described, remove instrument cluster. Connect 12 volts to terminal 2K (Black/Yellow wire) of instrument cluster. See Fig. 14 . Using a jumper wire, connect terminal 1K (Blue/Yellow wire) of instrument cluster to ground. ABS warning light should illuminate. If light does not illuminate, check bulb. If bulb is okay, check METER fuse and wiring harness. Repair or replace if necessary.

2. Install instrument cluster, and recheck warning light operation. If light still does not illuminate for a few seconds, check wiring harness between ABS warning light and ABS control unit, and between ABS warning light and hydraulic unit. Repair or replace if necessary.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 14: Instrument Cluster Connector Terminals

Courtesy of MAZDA MOTORS CORP.

STOPLIGHT SWITCH

Continuity Test

Disconnect stoplight switch harness connector. Using a DVOM, check continuity between stoplight switch connector terminals. Continuity should exist with pedal depressed. Continuity should not exist with pedal released. If continuity is not as specified, check STOP fuse and wiring harness. Check wiring harness between stoplight switch and ABS control unit. Repair or replace if necessary. If fuse and wiring harness are okay, replace switch.

FRONT & REAR VALVES

Resistance Test

1. Disconnect hydraulic unit 12-pin connector. Using a DVOM, measure resistance between following wires: Yellow/Green wire and Black wire; Brown wire and Black wire; Black/White wire and Black wire.

See Fig. 12 . Resistance should be1-1.2 ohms in each measurement.

2. If resistance is not as specified, replace hydraulic unit. If resistance is as specified, check wiring harness between ABS control unit and hydraulic unit. Repair or replace if necessary.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

HYDRAULIC UNIT

The only serviceable parts of hydraulic unit are the motor relay and valve relay. If other parts of unit malfunction, replace hydraulic unit.

MOTOR RELAY

Continuity Tests

1. Disconnect negative battery cable. Remove motor relay from hydraulic unit. Ensure continuity exists between terminals "B" and "C" of motor relay. See Fig. 15 . Connect 12 volts to terminal "C", and ground terminal "B". Ensure continuity exists between terminals "A" and "D".

2. Replace relay if continuity is not as specified. If continuity is as specified, check wiring harness between motor relay and ABS control unit fuse (60-amp). Repair or replace if necessary.

Fig. 15: Motor & Valve Relay Terminals

Courtesy of MAZDA MOTORS CORP.

PUMP MOTOR

Continuity Test

Disconnect 2-pin connector at hydraulic unit. Using a DVOM, check continuity between Red/Yellow wire terminal of 2-pin hydraulic unit connector and ground. If continuity is not present, replace hydraulic unit. If continuity is present, pump is okay. Check wiring between hydraulic unit and ABS control unit. Repair or replace if necessary.

VALVE RELAY

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Continuity & Voltage Tests

1. Disconnect negative battery cable. Remove valve relay from hydraulic unit. Using a DVOM, ensure continuity exists between valve relay terminals "C" and "E", and between terminals "B" and "D". See Fig.

15 .

2. Connect 12 volts to terminal "B", and ground terminal "D". Ensure continuity exists between terminals

"A" and "E". Replace relay if continuity is not as specified.

WHEEL SPEED SENSORS

Sensor Resistance Test

Disconnect speed sensor connector. Using a DVOM, measure resistance between speed sensor connector terminals. Resistance should be 1000-1200 ohms. If resistance is not as specified, replace speed sensor.

NOTE: To prevent damage to ABS control unit connector, use very thin pins when probing connector.

Harness Continuity & Voltage Tests

1. With ignition off and speed sensors connected, disconnect ABS control unit connector. Using a DVOM, check continuity between indicated ABS control unit terminals. See WHEEL SPEED SENSOR TESTS table. If continuity is not present, check wiring harness between wheel speed sensor and ABS control unit. Repair or replace if necessary.

2. If continuity exists, measure voltage between indicated ABS control unit terminals while rotating corresponding wheel one rotation per second by hand. See WHEEL SPEED SENSOR TESTS table. If voltage is not 50-60 millivolts, replace wheel speed sensor. If voltage is 50-60 millivolts, replace ABS control unit.

WHEEL SPEED SENSOR TESTS

Application

Left Front

Left Rear

Right Front

Right Rear

(1) See Fig. 13 to identify ABS control unit terminals.

(1)

Test Between ABS Control Unit Connector

Terminals

1K & 1G

1O & 1Q

1U & 1F

1L & 1P

WHEEL SPEED SENSOR ROTORS

Inspection

Perform a comprehensive visual inspection of sensor rotor. If any teeth are damaged or missing, or any other damage is noted, replace sensor rotor.

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

REMOVAL & INSTALLATION

ABS CONTROL UNIT

Removal & Installation

Disconnect negative battery cable. Roll back carpet from passenger-side footwell. Remove ABS control unit protector panel (if equipped). Disconnect ABS control unit electrical connector. Remove ABS control unit mounting nuts. Remove ABS control unit. To install, reverse removal procedure. Tighten ABS control unit mounting bolts/nuts to 61-87 INCH lbs. (6.9-9.8 N.m).

HYDRAULIC UNIT

Removal & Installation

Disconnect negative battery cable. Disconnect hydraulic unit electrical connector. Using Flare Nut Wrench (49-

0259-770B), disconnect brakelines from hydraulic unit. Remove hydraulic unit mounting bolts and nuts.

Remove hydraulic unit. To install, reverse removal procedure. Tighten mounting bolts and nuts to specification.

See TORQUE SPECIFICATIONS. Bleed air from system. See BLEEDING BRAKE SYSTEM.

FRONT WHEEL SPEED SENSOR ROTOR

Removal

Raise and support vehicle. Remove front wheel assemblies. Remove brake caliper, and wire aside. Remove rotor. Remove grease cap and wheel bearing lock nut. Remove wheel hub. Using Puller (49-0839-425C) and

Attachment (49-F027-007), remove sensor rotor from hub.

Installation

To install, reverse removal procedure. Install NEW sensor rotor on hub using Installer (49-V001-795). Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

REAR WHEEL SPEED SENSOR ROTOR

Removal

Raise and support vehicle. Remove rear wheel assemblies. Remove wheel bearing lock nut. Mark drive axle-toflange position for reassembly reference. Remove drive axle. Using chisel and hammer, remove sensor rotor from drive axle.

Installation

To install, reverse removal procedure. Install NEW sensor rotor on drive axle using Installer (49-H026-101A).

Align drive axle-to-flange marks. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

WHEEL SPEED SENSOR

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Removal & Installation

Raise and support vehicle. Remove wheel assemblies. Disconnect wheel speed sensor electrical connectors.

Remove filler pipe protector from left side and spare tire from right side. Remove mud guard. Remove speed sensor mounting bolt. Remove wheel speed sensor from vehicle. To install, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS.

VALVE & MOTOR RELAYS

Removal & Installation

Disconnect negative battery cable. Remove relay cover from hydraulic unit. Remove valve and motor relays.

See Fig. 16 . To install, reverse removal procedure.

Fig. 16: Locating Valve Relay & Motor Relay

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

BRAKE PEDAL FREE PLAY

Depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. Pedal free play should be .16-.28" (4-7 mm). Adjust free play by loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).

BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH

1. Released pedal height is measured from carpet surface, on vertical portion of firewall, to pedal pad center.

Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Rotate switch away from pedal. Loosen push rod lock nut. Rotate push rod until correct pedal height is obtained. See BRAKE

PEDAL HEIGHT SPECIFICATIONS table.

2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY under ADJUSTMENTS. Tighten push rod lock nut. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).

3. Rotate stoplight switch until it contacts pedal, and then rotate an additional 1/2 turn. Tighten stoplight switch lock nut to 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.

4. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.

Start engine. Depress brake pedal with a pressure of 132 lbs. (60 kg).

5. Measure applied pedal height. See BRAKE PEDAL HEIGHT SPECIFICATIONS table. If distance is not as specified, check for air in system, faulty rear brake adjustment, or worn shoes or pads.

BRAKE PEDAL HEIGHT SPECIFICATIONS

Application

Pedal Released

Pedal Applied

(1)

(1) Minimum height.

In. (mm)

6.8-7.1 (171-181)

3.7 (95)

PARKING/EMERGENCY BRAKE

1. Depress brake pedal several times. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 5-9 notches, parking brake is properly adjusted. If stroke is not 5-9 notches, raise and support rear of vehicle.

Release parking brake lever.

2. Rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Microsoft

Application

Brake Caliper Mounting Bolts

Brakeline Nuts

Drive Shaft-To-Flange Nuts

Hydraulic Unit Brakeline Union Bolts

Hydraulic Unit Mounting Nuts

Push Rod Lock Nut

Speed Sensor Mounting Bolt

Stoplight Switch Lock Nut

Wheel Bearing Lock Nut

Front

Rear

Wheel Lug Nuts

ABS Control Unit Mounting Bolts/Nuts

WIRING DIAGRAM

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Ft. Lbs. (N.m)

36-51 (49-69)

10-16 (14-22)

40-47 (54-64)

15-21 (20-29)

14-19 (19-26)

18-25 (24-34)

12-16 (16-22)

10-13 (14-18)

123-159 (167-216)

159-217 (216-294)

65-87 (88-118)

INCH Lbs. (N.m)

61-87 (6.9-9.8).

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Microsoft

1994 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1994 BRAKES Mazda - Anti-Lock

Fig. 17: Anti-Lock Brake System (ABS) Wiring Diagram

Microsoft

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission

TRANSMISSION SERVICING - A/T

1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission

IDENTIFICATION

NOTE: On models with anti-theft radio system, obtain code number from customer to deactivate radio anti-theft system BEFORE disconnecting negative battery cable. To deactivate radio anti-theft system, turn ignition switch to ACC position. Press FF and REW buttons simultaneously until "cod e" is displayed.

Press FF and REW buttons again until 4 bars are displayed. Use preset button

No. 1 to enter first number. Use preset buttons No. 2, 3 and 4 to set other numbers. Press FF and REW buttons for about 2 seconds until a beep is heard.

After 5 seconds, flashing "cod e" will go away and radio will operate.

AUTOMATIC TRANSMISSION APPLICATIONS

Model

Miata

Transmission

N4A-HL

LUBRICATION

SERVICE INTERVALS

Transmission Fluid

Check fluid level every 7500 miles or 6 months.

CHECKING FLUID LEVEL

Transmission

Park vehicle on level ground. Apply parking brake. Warm engine to normal operating temperature. Briefly place selector lever in all gears and return it to "P" position. Clean dipstick and insert it in tube. Remove dipstick. Level should be between "L" and "F" marks. Check fluid for discoloration and unusual smell. If necessary, add fluid. DO NOT overfill.

RECOMMENDED FLUID

Transmission

Use Dexron-II or M-III ATF.

FLUID CAPACITIES

TRANSMISSION REFILL CAPACITIES

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission

Application

Miata

Refill Qts. (L)

4.2 (4.0)

Dry Fill Qts. (L)

7.1 Qts. (6.7L)

DRAINING & REFILLING

Disconnect negative battery cable. Loosen oil pan bolts to drain fluid. Remove oil pan, and discard old gasket.

Clean oil pan, and install it using NEW gasket. Tighten oil pan bolts to specification. See TORQUE

SPECIFICATIONS . Connect negative battery cable. Add fluid, and check level. DO NOT overfill.

ADJUSTMENTS

BRAKE BAND (2ND GEAR)

1. Disconnect negative battery cable. Loosen oil pan, and drain fluid. Remove bracket, oil pan and gasket.

Disconnect vacuum hose at vacuum diaphragm (modulator), and remove vacuum diaphragm.

2. Disconnect solenoid valve connector, and remove harness from bracket (if equipped). Remove valve body bolts and valve body assembly. Loosen lock nut on 2nd gear brake band while holding piston stem stationary. See Fig. 1 .

Microsoft

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission

Fig. 1: Adjusting 2nd Gear Brake Band

Courtesy of MAZDA MOTORS CORP.

3. Tighten piston stem to 106-130 INCH lbs. (12-15 N.m). Loosen piston stem 3 turns. Tighten lock nut to

11-29 ft. lbs. (15-39 N.m) while holding stem stationary. Install valve body assembly. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

4. Connect solenoid valve connector, and install harness. Clean oil pan, and install it using NEW pan gasket.

Tighten pan bolts to specification. See TORQUE SPECIFICATIONS .

5. Install vacuum diaphragm, and connect vacuum hose. Connect negative battery cable. Add fluid, and check level. DO NOT overfill.

OVERDRIVE BRAKE BAND

1. Remove overdrive band servo cover and gasket. See Fig. 2 . Loosen overdrive adjustment screw lock nut

Microsoft

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission while holding piston stem stationary. Tighten piston stem to 61-87 INCH lbs. (7-10 N.m).

2. Back off piston stem 2 turns. While holding stem in this position, tighten lock nut to 11-30 ft. lbs. (15-40

N.m). Install overdrive bandservo cover with NEW gasket. Tighten cover bolts to 44-62 INCH lbs. (5-7

N.m).

Fig. 2: Adjusting Overdrive Band

Courtesy of MAZDA MOTORS CORP.

KICKDOWN & 4-3 SWITCH

1. Kickdown and 4-3 switch is located on upper part of accelerator pedal. To adjust kickdown section of switch, use steps 2) and 3). To adjust 4-3 section of switch, use steps 4) and 5).

2. Connect voltmeter between terminal "C" and ground. See Fig. 3 . Turn ignition on. Depress accelerator pedal fully. Voltmeter should read less than 1.5 volts until pedal is at least 7/8 depressed. Battery voltage should be present at or after 7/8 pedal travel.

Microsoft

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission

Fig. 3: Testing Kickdown & 4-3 Switch

Courtesy of MAZDA MOTORS CORP.

3. If voltage is not correct, disconnect switch and check continuity between terminals "C" and "D" when tip of switch is depressed .24-.26" (6.0-6.5 mm). If continuity is not present, replace switch. If continuity is present, adjust switch until battery voltage is present at 7/8 of pedal travel.

4. Connect voltmeter between terminal "A" and ground. See Fig. 3 . Turn ignition on. Depress accelerator pedal to limit. Voltmeter should read less than 1.5 volts until pedal is at least 3/4 depressed. Battery voltage should be present at or after 3/4 of pedal travel.

5. If voltage is not correct, disconnect switch and check continuity between terminals "A" and "B" when tip of switch is depressed .14-.18" (3.5-4.5 mm). If continuity is not present, replace switch. If continuity is present, adjust switch until battery voltage is present at 3/4 of pedal travel.

GEARSHIFT LINKAGE

1. Disconnect negative battery cable. Remove upper panel, selector sleeve and indicator panel. Remove boot plate. Place gearshift lever in "P" position. Loosen lock nut on side of gearshift lever. See Fig. 4 . Move

Microsoft

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission adjustment lever forward to set transmission in "P" position.

2. Adjust the lever so clearance between the guide plate and the guide pin with the lever in position "P" is as specified. Refer to specifications in the GEARSHIFT LEVER ADJUSTMENT SPECIFICATIONS table. See Fig. 5 . Tighten rear lock nut to 14-21 ft. lbs. (19-28 N.m).

3. Place gearshift lever in "N" and "D" positions to ensure clearances are correct. See GEARSHIFT

LEVER ADJUSTMENT SPECIFICATIONS table. See Fig. 5 . Adjust lever if necessary. Install boot plate, center console, indicator panel, selector sleeve, selector knob and upper panel. Connect negative battery cable.

GEARSHIFT LEVER ADJUSTMENT SPECIFICATIONS

Application

Gearshift In Position "P"

Clearance "A"

Clearance "B"

Gearshift In Position "N" Or "D"

Clearance "C"

Clearance "D"

(1) Clearance between guide plate and guide pin. See Fig. 5 .

(1)

In. (mm)

.035-.039 (.89-.99)

.020-.024 (.51-.61)

.024-.028 (.61-.71)

.059-.063 (1.50-1.60)

Fig. 4: Identifying Gearshift Lever Components

Microsoft

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission

Courtesy of MAZDA MOTORS CORP.

Fig. 5: Checking Gearshift Lever Adjustment Clearances

Courtesy of MAZDA MOTORS CORP.

VACUUM DIAPHRAGM ROD

1. If vacuum diaphragm (modulator) is replaced, vacuum diaphragm rod length (depth) must be checked for new rod length. Proper length rod should be installed after measurement.

2. Unscrew vacuum diaphragm from case. Remove diaphragm, diaphragm rod and rubber "O" ring.

Measure dimension "N" using Adjusting Gauge (49-G032-355). Use VACUUM DIAPHRAGM ROD

SELECTION table to select proper length rod. Also, see Fig. 6 .

VACUUM DIAPHRAGM ROD SELECTION

Dimension "N" - In. (mm)

1.0099 (25.650) Or Less

1.0099-1.0197 (25.650-25.900)

1.0197-1.0394 (25.900-26.400)

1.0394-1.0492 (26.400-26.650)

1.0492-1.0689 (26.650-27.150)

1.0689 (27.150) Or More

Rod Length - In. (mm)

1.14 (29.0)

1.16 (29.5)

1.17 (29.7)

1.18 (30.0)

1.20 (30.5)

1.22 (31.0)

Microsoft

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission

Fig. 6: Checking Vacuum Diaphragm Rod Length

Courtesy of MAZDA MOTORS CORP.

NEUTRAL SAFETY SWITCH

1. Place gearshift lever in "N" position. Ensure gearshift linkage is adjusted correctly. See GEARSHIFT

LINKAGE under ADJUSTMENTS. Loosen neutral safety switch mounting bolts at transmission.

Remove screw from alignment pin hole at bottom of switch (if equipped).

2. Insert a 5/64" (2.0 mm) alignment pin (or drill bit) through alignment holes.

Microsoft

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - A/T 1990-94 TRANSMISSION SERVICING Mazda Automatic Transmission

3. On all models, tighten mounting bolts to specification. See TORQUE SPECIFICATIONS . Remove alignment pin. Install alignment pin hole screw (if equipped), and check switch operation. Vehicle should start only with gearshift in "P" or "N" position.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Neutral Safety Switch Mounting Bolt

Oil Pan Bolt

Valve Body Bolt

INCH Lbs. (N.m)

43-61 (5.0-7.0)

52-69 (6.0-8.0)

43-61 (5.0-7.0)

Microsoft

1994 DRIVE AXLES Axle Shaft - MX-5 Miata

1994 DRIVE AXLES

Axle Shaft - MX-5 Miata

DESCRIPTION

CV JOINT IDENTIFICATION

Application

Miata

Joint Type

DOJ

TROUBLE SHOOTING

NOTE: See the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL

INFORMATION section.

REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION

RWD AXLE SHAFT

Removal

1. Raise vehicle and support with safety stands. Remove wheel and tire assembly. Loosen drive axle shaft lock nut until flush with end of drive axle shaft. Mark differential and drive axle shaft flanges for installation reference. See Fig. 1 . Remove drive axle shaft flange nuts.

2. Remove upper control arm bolt, and pull knuckle/hub assembly outward. Remove inner CV joint from differential flange. Remove drive axle shaft from knuckle/hub assembly. If drive axle shaft is stuck in knuckle/hub assembly, use plastic or soft-faced hammer to tap drive axle shaft from knuckle/hub assembly. Remove drive axle shaft lock nut.

1994 Mazda MX-5 Miata

1994 DRIVE AXLES Axle Shaft - MX-5 Miata

Fig. 1: Removing Rear Drive Axle & Knuckle/Hub Assembly

Courtesy of MAZDA MOTORS CORP.

NOTE: DO NOT disassemble outer CV joint. Replace outer drive axle shaft and CV joint

Microsoft

1994 Mazda MX-5 Miata

1994 DRIVE AXLES Axle Shaft - MX-5 Miata as an assembly. Service outer boot only after inner CV joint has been removed.

Disassembly (DOJ Type)

1. Place drive axle shaft assembly in soft-jawed vise. Keep drive axle shaft assembly clean during disassembly and reassembly. Remove CV joint boot bands and slide boot away from CV joint housing.

Index mark CV joint housing, inner race and drive axle shaft for reassembly reference. Using screwdriver, remove large circlip ring from inner race groove in CV joint housing. See Fig. 2 .

2. Remove CV joint housing from ball, inner race and cage assembly. Remove snap ring retaining ball, inner race and cage assembly to drive axle shaft. Remove ball, inner race and cage assembly from drive axle shaft. Insert screwdriver between inner race and cage, and remove balls. Index mark inner race and cage for reassembly reference. Turn cage about 30 degrees to inner race and separate cage from inner race.

3. Wrap drive axle shaft end with tape. Remove inner CV joint boot. Remove outer CV joint boot bands and remove boot by sliding it off inner CV joint end. Clean and inspect all parts. Ensure drive axle shaft is not bent, twisted or damaged. Check splines for wear. Inspect bearing inner race, cage and balls for abnormal wear and replace as an assembly if necessary.

Fig. 2: Exploded View Of Axle Shaft Assemblies (DOJ)

Courtesy of MAZDA MOTORS CORP.

NOTE: Inner and outer CV joint boots differ in design and/or diameter. Ensure correct boot is installed at proper end when reassembling drive axle shaft. See Fig. 3 .

See REAR AXLE SHAFT BOOT IDENTIFICATION .

Reassembly (DOJ Type)

1. Pack outer CV joint assembly with grease. Wrap tape around drive axle shaft end and slide outer boot onto drive axle shaft (if removed). Slide inner CV joint boot onto drive axle shaft.

2. Install inner race into cage and turn cage approximately 30 degrees to inner race aligning marks made during disassembly. Insert balls through cage and seat them in grooves of inner race. Pack ball, inner race and cage assembly with grease. Align marks on inner race and drive axle shaft. Install ball, inner race and cage assembly on drive axle shaft with large side of cage facing drive axle shaft end. Install snap ring.

3. Apply grease to CV joint housing. Align marks on inner race, drive axle shaft and CV joint housing.

Position housing onto ball, inner race and cage assembly and install large circlip ring. Using NEW boot bands, position bands so when folded down, the direction is opposite drive axle shaft direction of rotation.

Fold boot band back by pulling on end of band with pliers. Lock end of band by bending locking clip.

Microsoft

1994 Mazda MX-5 Miata

1994 DRIVE AXLES Axle Shaft - MX-5 Miata

Installation

To install, reverse removal procedure. Align marks on differential and drive axle shaft flanges. Check rear wheel alignment. See the WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the

WHEEL ALIGNMENT section. Tighten all bolts and nuts to specification. See TORQUE

SPECIFICATIONS . Stake drive axle shaft lock nut.

NOTE: For rear axle shaft lengths, see REAR AXLE SHAFT LENGTHS .

Fig. 3: Measuring Axle Shaft & Identifying Boots

Courtesy of MAZDA MOTORS CORP.

REAR AXLE SHAFT BOOT IDENTIFICATION

Application Wheel Side Diameter - In. (mm)

Differential Side Diameter - In.

(mm)

Microsoft

1994 Mazda MX-5 Miata

1994 DRIVE AXLES Axle Shaft - MX-5 Miata

Miata

REAR AXLE SHAFT LENGTHS

Application

Miata

3.58 (90.8) 3.44 (87.4)

In. (mm)

24.56-25.94 (623.7-658.8)

REAR HUB ASSEMBLY

Removal & Disassembly

1. Raise vehicle and support with safety stands. Remove wheel and tire assembly. Remove brake caliper and support aside. See Fig. 1 . Remove rotor from hub.

2. Mount dial indicator on hub and measure wheel bearing play by pulling and pushing on hub. Wheel bearing play should be a maximum of .002" (.05 mm). Check and adjust drive axle shaft lock nut torque or replace wheel bearing if measurement exceeds specification.

3. Remove drive axle shaft lock nut. Remove ABS speed sensor and bracket from knuckle/hub assembly.

Remove upper and lower control arm bolts retaining knuckle/hub assembly. Remove knuckle/hub assembly from vehicle. If drive axle shaft is stuck in hub, use plastic or soft-faced hammer to tap drive axle shaft from hub assembly.

4. Pry inner seal from knuckle/hub assembly. See Fig. 4 . Using Puller (49-F026-103), Handle (49-G033-

102) and Attachment (49-G030-727), remove hub from knuckle. Remove snap ring retaining bearing.

Using Puller (49-F026-103), Handle (49-G030-797) and Attachment (49-F027-005), press bearing from knuckle.

5. Move inner bearing race away from hub using chisel and hammer. Using Puller (49-0636-145), Handle

(49-G033-102) and Attachment (49-G030-727), press inner bearing race from hub. DO NOT reuse wheel bearing.

6. Inspect all components for cracks, wear and damage. Replace components as necessary. DO NOT reuse dust cover (if removed). If replacing dust cover, mark location on knuckle and original dust cover for

NEW dust cover installation reference.

NOTE: Never press or chisel brake dust cover from knuckle/hub unless replacing cover. DO NOT reuse wheel bearing if it is removed from knuckle/hub.

Reassembly & Installation

1. Press NEW dust cover onto knuckle using Installer (49-G033-107) and Attachment (49-F027-009); align reference marks made from original dust cover. Press NEW wheel bearing into knuckle using Handle (49-

G030-797) and Attachments (49-F027-009 and 49-F027-007). Install snap ring.

2. Apply grease to inner bearing race. Press hub into knuckle and install inner seal. Lubricate inner seal lip.

Reverse removal procedure to install knuckle/hub assembly.

3. Check rear wheel alignment. See the WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section. Tighten all bolts and nuts to specification. See TORQUE

SPECIFICATIONS . Stake drive axle shaft lock nut.

Microsoft

1994 Mazda MX-5 Miata

1994 DRIVE AXLES Axle Shaft - MX-5 Miata

Fig. 4: Exploded View Of Rear Knuckle/Hub Assembly

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Microsoft

1994 Mazda MX-5 Miata

1994 DRIVE AXLES Axle Shaft - MX-5 Miata

TORQUE SPECIFICATIONS

Application

ABS Speed Sensor Bolt

Brake Caliper Mounting Bolts

Differential-To-Drive Axle Flange Nuts (4)

Drive Axle Shaft Lock Nut

Lower Control Arm Bolt/Nut

Upper Control Arm Bolt/Nut

Wheel Lug Nuts

Ft. Lbs. (N.m)

12-17 (16-23)

36-51 (49-69)

40-47 (54-64)

159-217 (216-294)

46-55 (62-75)

34-49 (46-66)

65-87 (88-118)

Microsoft

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

ALTERNATOR & REGULATOR - MITSUBISHI

1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

DESCRIPTION

Generator is a conventional 3-phase, self-rectifying type with 6 diodes (3 positive and 3 negative) that rectify current. Internal regulator is solid-state type.

ADJUSTMENTS

BELT DEFLECTION

Measure belt deflection in center of longest pulley-to-pulley span. See BELT DEFLECTION

SPECIFICATIONS. If belt deflection is not as specified, adjust as necessary.

BELT DEFLECTION SPECIFICATIONS

Application

New Belt

Used Belt

(1) With 22 lbs. (10 kg) applied to belt.

(1)

Deflection - In. (mm)

0.31-0.35 (8.0-9.0)

0.35-0.39 (9.0-10.0)

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL

INFORMATION section.

TROUBLE SHOOTING PRECAUTIONS

Observe the following precautions when trouble shooting or testing charging system:



Obtain code number and deactivate audio anti-theft system before disconnecting battery.



DO NOT reverse battery cable connections. Rectifier will be damaged.

DO NOT use high voltage type testers.



Battery voltage is always present at terminal "B".

DO NOT ground terminal "L" while engine is running.



DO NOT start engine with connector disconnected from terminals "L" and "S".

DO NOT apply battery voltage to terminal "L".

ON-VEHICLE TESTING

NOTE: Check generator wiring harness connections and drive belt tension. Battery

1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi must be fully charged before testing. Wait at least 30 seconds after starting engine before measuring system voltage.

CAUTION: Ensure generator terminal "B" does not contact ground.

GENERATOR OUTPUT

1. Connect an ammeter (100-amp minimum) in-line between generator terminal "B" connector and terminal

"B" of wiring harness connector. See Fig. 1 . Turn headlights and all accessories on. Depress brake pedal.

Operate engine at 2500-3000 RPM.

2. If amperage is not as specified, see GENERATOR MAXIMUM RATED OUTPUT table, repair or replace generator as necessary. If amperage is as specified, turn off headlights and all accessories. Release brake pedal. Operate engine at 2500-3000 RPM. If amperage is not about 5 amps or more, repair or replace generator as necessary.

3. If amperage is about 5 amps or more, measure voltage between ground and terminals "S" and "L" while operating engine at 2500-3000 RPM. If 14.1-14.7 volts is not present, repair or replace generator as necessary. If 14.1-14.7 volts is present, generator output is okay.

GENERATOR MAXIMUM RATED OUTPUT

Application

A/T

M/T

Amps

Microsoft

1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 1: Identifying Generator Terminals (Miata)

Courtesy of MAZDA MOTORS CORP.

BENCH TESTING

RECTIFIER/DIODE ASSEMBLY

1. Using an ohmmeter, check continuity of each diode in both directions (polarity). See Fig. 2 -4. If diode shows high resistance in one direction and low resistance in other direction, diode is okay.

2. If diode shows low resistance in both directions, diode is shorted. If diode shows high resistance in both

Microsoft

1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi directions, diode is open. If any diode is defective, replace rectifier assembly.

ROTOR & SLIP RINGS

Measure resistance between rotor slip ring contacts. See Fig. 5 -9. If resistance is not within specification, replace rotor. See ROTOR RESISTANCE SPECIFICATIONS . Check continuity between individual slip rings and rotor core/shaft. If continuity is present, replace rotor.

ROTOR RESISTANCE SPECIFICATIONS

Application

Miata

Ohms

3.5-4.5

STATOR

Check continuity between stator coil leads and stator core.

See Fig. 5 -9. If continuity is present, replace stator. Check continuity between leads of stator coil. If continuity is not present, replace stator.

BRUSHES

Replace brushes if worn to limit line. See Fig. 5 -9. Replace brush springs if corroded. For brush replacement procedure, see OVERHAUL.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 2: Testing Rectifier Diodes (Miata)

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 3: Rectifier Diode Schematic

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 4: Rectifier Diode Table

Courtesy of MAZDA MOTORS CORP.

Fig. 5: Testing Generator Stator, Rotor & Brushes (1 Of 5)

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 6: Testing Generator Stator, Rotor & Brushes (2 Of 5)

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 7: Testing Generator Stator, Rotor & Brushes (3 Of 5)

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 8: Testing Generator Stator, Rotor & Brushes (4 Of 5)

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 9: Testing Generator Stator, Rotor & Brushes (5 Of 5)

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

DISASSEMBLY

1. Place a 200-watt soldering iron against rear bearing for 3-4 minutes to heat rear cover to 122-140°F (50-

60°C). Carefully separate front case and rotor from rear cover and stator. See Fig. 10 -15 and 17.

2. Position rotor in vise. Remove pulley. Disassemble pulley, rotor and front case. Remove front bearing from front case. Using a bearing puller, remove rear bearing.

3. Remove "B" terminal nut and bushing from rear cover. Remove screws from brush holder and rectifier.

Separate rear cover and stator. When unsoldering rectifier and stator leads, disconnect as quickly as possible (5 seconds maximum) to avoid damage to rectifier. To remove brushes from holder, unsolder pigtail from terminal.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 10: Overhauling Generator (1 Of 6)

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 11: Overhauling Generator (2 Of 6)

Courtesy of MAZDA MOTORS CORP.

Fig. 12: Overhauling Generator (3 Of 6)

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Courtesy of MAZDA MOTORS CORP.

Fig. 13: Overhauling Generator (4 Of 6)

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 14: Overhauling Generator (5 Of 6)

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 15: Overhauling Generator (6 Of 6)

Courtesy of MAZDA MOTORS CORP.

REASSEMBLY

Brush Installation

1. Install brush and spring into holder. Allow brush to extend out of holder until wear limit line extends .08-

.16" (2-4 mm) beyond end of brush holder. See Fig. 16 . Solder pigtail onto brush holder.

2. Insert spring and brush into brush holder. Using a spring scale, pull brush into holder until end of brush protrudes .08" (2.0 mm) from holder. See Fig. 10 -15. Note reading on spring scale. Replace spring if tension is not 5.6-15.5 ozs. (160-440 g).

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 16: Measuring Installed Depth Of Brush

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 17: Exploded View Of Generator (Miata)

Courtesy of MAZDA MOTORS CORP.

WIRING DIAGRAM

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

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1994 Mazda MX-5 Miata

ALTERNATOR & REGULATOR - MITSUBISHI 1994 ELECTRICAL Mazda Alternator & Regulator - Mitsubishi

Fig. 18: Charging System Wiring Diagram (Miata)

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CLUTCH 1994 Clutch

CLUTCH

1994 Clutch

DESCRIPTION

Miata uses a hydraulically operated clutch.

HYDRAULIC SYSTEM BLEEDING

1. Remove bleeder screw cap, located at clutch release cylinder. Install vinyl hose onto bleeder screw.

Submerge other end of hose in container of brake fluid.

2. Fill reservoir with DOT 3 brake fluid. Have assistant press and release clutch pedal several times, then hold pedal down. With pedal pressed, loosen bleeder screw to let air and fluid escape.

3. Repeat step 2) until no more air bubbles emerge from hose. Tighten bleeder screw. Fill reservoir. Operate clutch while inspecting for leaks. Check clutch and brake operation.

ADJUSTMENTS

CLUTCH PEDAL FREE PLAY

Measure clutch pedal free play. See Fig. 1 . See CLUTCH PEDAL FREE PLAY . If free play is not within specification, inspect hydraulic and mechanical system components. If adjustment is required, loosen lock nut and rotate master cylinder push rod to obtain specified free play. Tighten lock nut.

CLUTCH PEDAL FREE PLAY

(1)

Application

Miata

In. (mm)

0.2-0.5 (5-13)

(1) See Fig. 1 .

CLUTCH PEDAL HEIGHT

Measure clutch pedal height from bulkhead to front side of pedal pad. See Fig. 1 . See CLUTCH PEDAL

HEIGHT .

CLUTCH PEDAL HEIGHT

(1)

Application In. (mm)

Miata 6.89-7.28 (175-185)

(1) Measure to carpet on bulkhead. See Fig. 1 .

CLUTCH DISENGAGEMENT HEIGHT

1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch

Measure clutch disengagement height, where clutch disengages, from pedal pad to bulkhead. See Fig. 1 . See

CLUTCH DISENGAGEMENT HEIGHT (MINIMUM) .

CLUTCH DISENGAGEMENT HEIGHT (MINIMUM)

(1)

Application In. (mm)

Miata 2.68 (68)

(1) Measure to carpet on bulkhead. See Fig. 1 .

Fig. 1: Adjusting Clutch Pedal

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch

REMOVAL & INSTALLATION

CLUTCH ASSEMBLY

Removal

1. Disconnect negative battery cable. Remove gearshift knob, console, and shift lever. See Fig. 2 . Raise and support vehicle. Remove engine undercover. Disconnect exhaust pipe from manifold. Mark drive shaft flanges for installation reference. Remove drive shaft.

Fig. 2: Exploded View Of Drive Line

Courtesy of MAZDA MOTORS CORP.

2. Remove clutch release cylinder. Remove starter. Disconnect speedometer cable from transmission. Note locations, and disconnect wiring harness from Power Plant Frame (PPF).

3. Remove PPF bracket from rear transmission extension housing. Remove PPF-to-differential side bolts.

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1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch

Pry out spacer. Remove PPF/differential mounting spacer. See Fig. 3 .

4. Thread M14 X 1.5 bolt into sleeve. See Fig. 4 . Twist bolt side to side while pulling it downward. Thread

M6 X 1 bolt into hole in housing block to hold sleeve. Remove long bolt. Remove short bolt.

NOTE: Do not remove spacers attached to top of Power Plant Frame (PPF). If they are removed, replace PPF.

5. Remove PPF side bolts. Remove PPF. Remove clutch housing bolts. Remove transmission. Remove clutch cover bolts evenly in crisscross pattern. Remove clutch cover and disc. See Fig. 5 .

Fig. 3: Installing & Removing Power Plant Frame

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch

Fig. 4: Removing Reamer Bolt Sleeve

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch

Fig. 5: Exploded View Of Clutch Assembly (Typical)

Courtesy of MAZDA MOTORS CORP.

Inspection

1. Inspect disc for loose rivets, worn springs, excessive wear, or oil contamination. Inspect flywheel and clutch cover for burns, scoring, or grooves.

2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond specification. See CLUTCH RUNOUT (MAXIMUM) . If flywheel ring gear is replaced, ensure chamfer on flywheel teeth faces engine.

3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT

(MAXIMUM) . Inspect disc hub and input shaft splines for excessive wear. Hub must slide smoothly on input shaft splines.

4. Inspect pilot bearing. Apply inward pressure while rotating pilot bearing. If bearing sticks or has excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect release bearing for smooth operation, and inspect it for wear, damage, or looseness. Replace bearing as

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1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch necessary.

CLUTCH RUNOUT (MAXIMUM)

Application

Disc

Flywheel

In. (mm)

0.028 (0.7)

0.008 (0.20)

Installation

1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a crisscross pattern to specification. See TORQUE SPECIFICATIONS .

2. Place a wooden block on jack, and position jack under front of oil pan. Raise front of engine to ease transmission installation. Install transmission. Tighten clutch housing bolts to specification. Place jack

(from front of engine) under transmission.

3. Raise transmission until it is level with engine. Position Power Plant Frame (PPF) in place. Install

PPF/differential mounting spacer, and tighten bolts to 27-38 ft. lbs. (37-52 N.m). Install and tighten PPF side mounting bolts.

NOTE: Front PPF-to-differential side mounting bolt is the reamer bolt, used to align frame.

4. Install sleeve into PPF housing block. Install spacer and bolts. Install reamer bolt into front hole, and tighten bolt. See Fig. 3 .

5. Install transmission-to-PPF bracket. Install remaining PPF bolts, and tighten to specification. See

TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

RELEASE BEARING & FORK

Removal & Installation

1. Remove transmission. See CLUTCH ASSEMBLY under REMOVAL & INSTALLATION. Remove release bearing and fork. Turn release bearing in both directions. Replace bearing if rough or noisy.

2. Inspect release fork for wear and damage. Replace if necessary. Apply molybdenum disulfide grease to release bearing contact and sliding surfaces. To complete installation, reverse removal procedure.

CLUTCH MASTER CYLINDER

Removal & Installation

Disconnect hydraulic line and master cylinder mounting nuts. Disengage push rod from clutch pedal. Remove master cylinder. To install, reverse removal procedure and bleed hydraulic system.

CLUTCH RELEASE CYLINDER

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1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch

Removal & Installation

Raise and support vehicle. Disconnect and plug hydraulic line. Remove release cylinder. To install, reverse removal procedure. Bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING .

OVERHAUL

CLUTCH MASTER CYLINDER

NOTE: For exploded view of clutch master cylinder, see Fig. 6 .

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1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch

Fig. 6: Exploded View Of Clutch Master Cylinder

Courtesy of MAZDA MOTORS CORP.

CLUTCH RELEASE CYLINDER

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NOTE:

1994 Mazda MX-5 Miata

CLUTCH 1994 Clutch

For exploded view of clutch release cylinder, see Fig. 7 .

Fig. 7: Exploded View Of Clutch Release Cylinder

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Clutch Cover Bolts

(1)

Clutch Housing-To-Engine Block Bolts

Drive Shaft Bolts

Flywheel-To-Crankshaft Bolts

PPF-To-Differential Mounting Spacer Bolt (Short)

PPF-To-Differential Side Mounting Bolts (Long)

PPF-To-PPF Bracket Bolt

PPF-To-Transmission Side Mounting Bolts (Long)

Transmission-To-PPF Bracket Bolts

Starter Mounting Bolts

(1) Tighten in a crisscross pattern.

Ft. Lbs. (N.m)

13-20 (18-27)

47-66 (64-90)

20-22 (27-30)

71-76 (96-103)

27-38 (37-52)

77-91 (104-123)

27-40 (37-54)

77-91 (104-123)

27-40 (37-54)

27-38 (37-52)

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ENGINE COOLING FAN 1994 ENGINE COOLING Mazda - Engine Cooling Fans

ENGINE COOLING FAN

1994 ENGINE COOLING Mazda - Engine Cooling Fans

COMPONENT TESTING

Cooling Fan Motor

1. Ensure battery is fully charged. Disconnect cooling fan motor connector. Connect ammeter between battery and cooling fan motor connector. See Fig. 1

2. Ensure cooling fan motor operates smoothly at specified current. See COOLING FAN MOTOR

CURRENT SPECIFICATIONS table. If cooling fan motor draws more or less than specified amperage, check wiring. If wiring is okay, replace cooling fan motor.

Fig. 1: Testing Cooling Fan Motor

Courtesy of MAZDA MOTORS CORP.

1994 Mazda MX-5 Miata

ENGINE COOLING FAN 1994 ENGINE COOLING Mazda - Engine Cooling Fans

COOLING FAN MOTOR CURRENT SPECIFICATIONS

Model

Miata

Amps

7.7

Cooling Fan Relay

1. Locate cooling fan relay. See Fig. 2 . Disconnect cooling fan relay wiring harness connector. Check continuity between cooling fan relay terminals "A" and "C". See Fig. 3 . Continuity should not exist.

Check continuity between terminals "B" and "D". Continuity should exist.

2. With battery voltage applied between terminals "B" and "D" of cooling fan relay, check continuity between terminals "A" and "C". Continuity should exist. If continuity is not as specified, replace cooling fan relay.

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1994 Mazda MX-5 Miata

ENGINE COOLING FAN 1994 ENGINE COOLING Mazda - Engine Cooling Fans

Fig. 2: Locating Cooling Fan Relay

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

ENGINE COOLING FAN 1994 ENGINE COOLING Mazda - Engine Cooling Fans

Fig. 3: Testing Cooling Fan Relay

Courtesy of MAZDA MOTORS CORP.

WIRING DIAGRAMS

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1994 Mazda MX-5 Miata

ENGINE COOLING FAN 1994 ENGINE COOLING Mazda - Engine Cooling Fans

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1994 Mazda MX-5 Miata

ENGINE COOLING FAN 1994 ENGINE COOLING Mazda - Engine Cooling Fans

Fig. 4: Electric Cooling Fan Wiring Diagram

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DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

DIFFERENTIAL

1994 DRIVE AXLES Mazda - Differential

AXLE RATIO & IDENTIFICATION

See AXLE RATIO SPECIFICATIONS . To determine axle ratio, divide number of ring gear teeth by number of pinion teeth.

AXLE RATIO SPECIFICATIONS

Application

Miata

Number Of Teeth Pinion/Ring Gear

N/A

Ratio

4.10:1

DESCRIPTION

A Limited Slip Differential (LSD) is optional on Miata. Rear axle uses CV joints to connect differential to axle hubs.

LUBRICATION

CAPACITY

DIFFERENTIAL CAPACITY SPECIFICATIONS

(1)

Application

Miata

(1) Fill to lower edge of filler plug hole.

Qts. (L)

1.06 (1.00)

FLUID TYPE

DIFFERENTIAL LUBRICATION SPECIFICATIONS

(1)

Application

Warmer Than 0°F (-18°C)

Cooler Than 0°F (-18°C)

(1) Fill to lower edge of filler plug hole.

Specification

GL-5/SAE 90W

GL-5/SAE 80W

TROUBLE SHOOTING

NOTE: See the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL

INFORMATION section.

REMOVAL & INSTALLATION

1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

DIFFERENTIAL ASSEMBLY

Removal

1. Raise and support vehicle. Remove wheel and tire assembly. Drain differential. Remove differential mounting pipe. Remove exhaust pipe. Mark drive shaft flange for reassembly reference and remove drive shaft from differential carrier. See Fig. 1 . Disconnect speedometer cable from transmission. Noting locations, disconnect wiring harness from Power Plant Frame (PPF).

Fig. 1: Exploded View Of Differential Components

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

2. Support transmission using a jack. Remove PPF bracket from rear transmission extension housing (M/T only). Remove PPF-to-differential side bolts. Pry out spacer. Remove PPF/differential mounting spacer.

See Fig. 2 . Install bolt (M14 X 1.5) into sleeve. See Fig. 3 .

3. Twist bolt from side to side while pulling it downward. Install a metric bolt (M6 X 1) into hole in housing block to hold sleeve and remove long bolt (M14 X 1.5). Remove short bolt (M6 X 1).

4. Remove PPF-to-transmission side bolts and remove PPF. Mark and disconnect CV joint drive axles from differential assembly, and support aside. Support differential assembly and remove differential-to-chassis mounting nuts. Remove differential from vehicle. Remove drive axle output shafts from carrier. Remove differential carrier-to-housing bolts. Remove differential carrier.

Fig. 2: View Of Power Plant Frame (PPF) Components

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

Fig. 3: Removing Reamer Bolt Sleeve

Courtesy of MAZDA MOTORS CORP.

Installation

1. To install, reverse removal procedure. Apply sealant to carrier mating flange. Align marks made during removal and install drive axles. Install differential. Raise transmission until engine and transmission are level.

2. Position Power Plant Frame (PPF) in place. Install PPF/differential mounting spacer. Tighten bolts to 27-

38 ft. lbs. (37-52 N.m). Install and tighten PPF-to-transmission side mounting bolts.

3. Ensure sleeve is installed into PPF housing block. Install spacer and bolts. Ensure reamer bolt is installed into front hole and tighten bolt. See Fig. 2 .

NOTE: Front PPF-to-differential side mounting bolt is reamer bolt which aligns

PPF. See Fig. 2 .

4. Install transmission-to-PPF bracket (M/T only). Install remaining PPF bolts. Refill differential with

Microsoft

1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential lubricant. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

OVERHAUL

DIFFERENTIAL

NOTE: Mark positions of all components before disassembly.

NOTE: Overhaul of Limited Slip Differential unit (if equipped) is not recommended.

Replace if defective. Overhaul procedures listed below are for Standard type only.

Disassembly

1. Mount carrier in Differential Carrier Hanger (49-M005-561). Mark side bearing caps for reassembly reference. Remove adjuster lock plates (if equipped). See Fig. 4 .

2. Loosen side bearing cap bolts and slightly back off adjusters. Remove side bearing caps. Remove differential assembly from carrier. Mark side bearing races for reassembly reference. Remove adjusters and side bearing races from differential.

3. Remove drive pinion lock nut and washer. Remove companion flange using Puller (49-0839-425C).

Remove oil seal, spacer, front bearing and collapsible spacer from carrier. Remove drive pinion, spacer and rear bearing assembly from carrier. Remove bearing races using a drift and hammer in slots provided on inner lip (as necessary).

4. Remove ring gear retaining bolts. Separate ring gear from differential case. Mark side bearings for reassembly reference. Using Puller (49-0839-425C), remove side bearings from differential case. Remove knock pin. Remove pinion shaft, pinion gears, thrust washers, and side gears. See Fig. 4 .

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1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

Fig. 4: Exploded View Of Standard Differential & Carrier Assembly

Courtesy of MAZDA MOTORS CORP.

Reassembly & Adjustment

1. Install side gears, thrust washers, pinion gears and pinion shaft. Position dial indicator against pinion gear. See Fig. 5 . Secure one side gear.

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1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

Fig. 5: Measuring Side Gear & Pinion Gear Backlash

Courtesy of MAZDA MOTORS CORP.

2. Check side gear and pinion gear backlash. If backlash exceeds .004" (.10 mm), replace thrust washers.

See THRUST WASHER SPECIFICATIONS . Install and stake knock pin. Noting marks made during disassembly, press side bearings onto differential assembly using Bearing Installer (49-G030-338 or 49-

UB71-525) and Body (49-F401-331). Apply locking compound to rear face of ring gear. Install ring gear and tighten ring gear retaining bolts to 51-61 ft. lbs. (69-83 N.m).

THRUST WASHER SPECIFICATIONS

Identifying Mark

Thickness - In. (mm)

.0787 (2.000)

.0807 (2.050)

.0827 (2.100)

.0846 (2.150)

.0866 (2.200)

3. Using Bearing Installer Set (49-F027-0A1) and press, install drive pinion bearing races in differential carrier.

4. Put original spacer, rear bearing and Collar (49-H027-001) on Dummy Drive Pinion (49-8531-565). See

Fig. 6 . Secure collar with "O" ring. Install assembly into differential carrier.

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1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

5. Install front bearing and collar (49-8531-567) on dummy drive pinion. Install companion flange, washer and original drive pinion lock nut. Tighten drive pinion lock nut so dummy drive pinion assembly can be turned by hand.

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1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

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1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

Fig. 6: Checking Drive Pinion Installation & Position

Courtesy of MAZDA MOTORS CORP.

6. Install dial indicator on Pinion Height Gauge (49-0727-570). Place pinion height gauge on a flat surface and zero dial indicator. Position gauge block (49-0305-555) on top of dummy drive pinion assembly.

7. Place pinion height gauge on top of gauge block. Position dial indicator to measure distance to a point where side bearing sits. Measure lowest point. See Fig. 6 . Measure both sides. Add both measurements together and divide by 2.

8. If result is not zero, replace pinion spacer. Spacers are available in a range of .1213-.1366" (3.080-3.470 mm) in .001" (.03 mm) increments. Remove dummy drive pinion. Press rear bearing on drive pinion.

9. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential carrier.

DO NOT install pinion oil seal yet. DO NOT exceed one-ton force; collapsible spacer will be damaged.

10. Install washer and drive pinion lock nut. Temporarily tighten drive pinion lock nut. Turn companion flange by hand to seat bearing. Using torque wrench, tighten drive pinion lock nut to specification. See

TORQUE SPECIFICATIONS . Check pinion bearing preload at drive pinion lock nut. See PINION

PRELOAD SPECIFICATIONS . If pinion bearing preload is not as specified, replace collapsible spacer and recheck preload.

PINION PRELOAD SPECIFICATIONS

Application

Miata

INCH Lbs. (N.m)

7.8-12.1 (0.9-1.3)

11. Remove drive pinion lock nut, washer and companion flange. Install pinion oil seal. Lubricate oil seal lip with differential oil. Install companion flange and washer. Install NEW drive pinion lock nut and tighten to specification. See TORQUE SPECIFICATIONS . Recheck pinion bearing preload. Lubricate end of companion flange with grease.

12. Position differential assembly into differential carrier. Install side bearing adjusters. Position side bearing caps. Align marks made during disassembly. Install side bearing cap bolts and hand-tighten bolts.

13. Tighten side bearing adjusters equally until adjusters contact bearing races. Mark ring gear in 4 locations,

90 degrees apart. Position dial indicator against ring gear to check ring gear backlash.

14. Check backlash at all 4 locations. Tighten side bearing adjusters equally until backlash is .0035-

.0043" (.09-.11 mm). Minimum backlash at any point is .002" (.05 mm). Difference between minimum and maximum backlash should not exceed .0028" (.07 mm).

15. To set differential bearing preload, tighten adjusters equally until distance between measuring points on carrier bearing caps is within specification. See Fig. 7 . See DIFFERENTIAL CARRIER

DIMENSIONS .

16. Ensure backlash did not change when preload was set. Tighten side bearing cap bolts to specification. See

TORQUE SPECIFICATIONS . Check ring gear tooth patterns. See the GEAR TOOTH CONTACT

PATTERNS article in the GENERAL INFORMATION section.

17. To complete reassembly, reverse disassembly procedure. Tighten all nuts and bolts to specification. See

TORQUE SPECIFICATIONS .

DIFFERENTIAL CARRIER DIMENSIONS

Application

(1)

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Sunday, July 05, 2009 1:27:02 PM Page 10

In. (mm)

1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

Miata

(1) See illustration for measuring point. See Fig. 7 .

7.300-7.303 (185.43-185.50)

Fig. 7: Measuring Carrier Case Spread

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Differential Carrier Bearings Cap Bolts

Differential Carrier Bearings Lock Plate Bolt

Differential Carrier-To-Housing Bolts

Differential-To-Chassis Mount Nuts

Inner Nut

Outer Nuts (2)

Drive Axle Inner CV Joint Flange Nuts

Drive Pinion Lock Nut

Drive Shaft Companion Flange Nuts

Exhaust Pipe Mount Nuts

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Sunday, July 05, 2009 1:27:02 PM

Ft. Lbs. (N.m)

27-38 (37-52)

13-19 (18-26)

17-20 (23-27)

Page 11

61-72 (83-98)

13-20 (18-27)

40-47 (54-64)

87-130 (118-176)

20-22 (27-30)

30-41 (40-55)

1994 Mazda MX-5 Miata

DIFFERENTIAL 1994 DRIVE AXLES Mazda - Differential

Filler Plug

Power Plant Frame Bracket

To-Power Plant Frame Bolt (M/T)

To-Transmission Bolts (M/T)

Power Plant Frame-To-Differential

Side Mounting Bolts (Long)

Spacer Bolt (Short)

Power Plant Frame-To-Transmission Side Mounting Bolts (Long)

Ring Gear Retaining Bolts

Wheel Lug Nuts

29-40 (39-54)

77-91 (104-123)

27-40 (37-54)

77-91 (104-123)

27-38 (37-52)

77-91 (104-123)

51-61 (69-83)

65-87 (88-118)

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BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

BRAKE SYSTEM

1994 BRAKES Mazda - Disc & Drum

DESCRIPTION & OPERATION

NOTE: For information on anti-lock brake systems, see ANTI-LOCK BRAKE SYSTEM article in the BRAKES section.

All models use hydraulic-operated brake system with a tandem master cylinder, proportioning valve and a power brake unit. All models are equipped with front disc brakes and either rear disc or drum brakes.

BLEEDING BRAKE SYSTEM

BRAKE LINE BLEEDING SEQUENCE

Application

Miata

Sequence

Longest Line First

ADJUSTMENTS

MASTER CYLINDER PUSH ROD

NOTE: Push rod has an adjustment screw to maintain correct distance between booster push rod and master cylinder piston. If push rod is adjusted too long, it prevents master cylinder piston from completely releasing hydraulic pressure, causing brakes to drag. If push rod is adjusted too short, it causes excessive pedal travel and an undesirable clunk in booster area.

1. Place Adjustment Gauge (49-F043-001) onto master cylinder. Turn screw on adjuster gauge until it contacts piston. Remove adjuster gauge. Apply 19.7 in. Hg to power brake unit.

2. Invert adjuster gauge and place it on power brake unit. Adjust push rod on power brake unit until there is no clearance between push rod and adjuster gauge screw.

PARKING/EMERGENCY BRAKE

1. On models with rear disc brakes, depress brake pedal several times. On models with rear drum brakes, start engine and depress brake pedal several times while vehicle is moving in reverse. Stop engine.

2. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 7-9 notches, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle. Release parking brake lever.

3. Rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

BRAKE PEDAL FREE PLAY

1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS table. Adjust play by loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).

BRAKE PEDAL FREE PLAY SPECIFICATIONS

Application

Miata

In. (mm)

.16-.28 (4-7)

BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH

1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.

PEDAL HEIGHT SPECIFICATIONS table.

2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY under ADJUSTMENTS. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).

3. Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight switch lock nut to 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.

4. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.

Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure.

5. Measure applied pedal height. See BRAKE PEDAL HEIGHT SPECIFICATIONS table. If distance is not as specified, check for air in system, rear brake adjustment or worn shoes or pads.

BRAKE PEDAL HEIGHT SPECIFICATIONS

Application

Pedal Released

Pedal Applied

(1)

(1) Minimum height.

In. (mm)

6.8-7.1 (171-181)

3.7 (95)

TESTING

PROPORTIONING VALVE

1. Connect 2 pressure gauges to proportioning valve. One to input port and other to output port. Bleed brake system. See BLEEDING BRAKE SYSTEM. Depress brake pedal until pressure gauge reads as specified and check output pressure. See PROPORTIONING VALVE PRESSURE SPECIFICATIONS table.

2. Depress brake pedal again, applying additional pressure. Recheck output pressure. See

PROPORTIONING VALVE PRESSURE SPECIFICATIONS table. If output pressure is not as specified, replace valve.

PROPORTIONING VALVE PRESSURE SPECIFICATIONS

Application

Miata

Inlet Pressure psi (kg/cm

)

427 (30)

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Sunday, July 05, 2009 1:28:03 PM Page 2

Outlet Pressure psi (kg/cm

)

399-455 (28-32)

1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

995 (70) 554-640 (39-45)

POWER BRAKE UNIT

1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal does not move as specified, go to next step.

2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is operating. If length of strokes is equal, test check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary, and go to next step.

3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal height remains at same height, power brake unit is operating. If pedal height recedes, test check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal & Installation

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt.

See Fig. 1 . Pivot caliper upward and support using rope. Remove pads, shims, guide plates or pad guides and "V" springs (if equipped). Replace pad if lining thickness is less than specified. See MINIMUM PAD

LINING SPECIFICATIONS (FRONT) table.

2. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads.

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Fig. 1: Exploded View Of Front Disc Brake Assembly

Courtesy of MAZDA MOTORS CORP.

MINIMUM PAD LINING SPECIFICATIONS

Application

Miata

FRONT DISC BRAKE CALIPER

Removal & Installation

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Sunday, July 05, 2009 1:28:03 PM Page 4

Thickness In. (mm)

.04 (1.0)

1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS under REMOVAL &

INSTALLATION. Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system.

FRONT BRAKE ROTOR

Removal & Installation

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. Wire caliper aside. Remove grease cap (if equipped). Remove rotor-to-hub screws

(if equipped). Remove rotor.

2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table. To install, reverse removal procedure.

REAR DISC BRAKE PADS

Removal & Installation

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove manual adjustment gear concealment plug from caliper. See Fig. 2 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.

2. Remove lower guide bolt from caliper. Rotate caliper upward and wire side. Remove "M" spring.

Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04" (1.0 mm). To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn.

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Fig. 2: Exploded View Of Rear Disc Brake Assembly

Courtesy of MAZDA MOTORS CORP.

REAR BRAKE CALIPER

Removal & Installation

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Disconnect brake hose from caliper.

2. Remove manual adjustment gear concealment plug from caliper. See Fig. 2 . Insert an appropriate size

Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.

3. Remove lower guide bolt from caliper. Rotate caliper upward. Pull caliper toward center of vehicle to slide it off of caliper mount. To install, reverse removal procedure. Bleed air from system.

REAR BRAKE ROTOR

Removal & Installation

1. Raise and support vehicle. Remove rear wheel assemblies. Remove rear brake caliper with brake hose

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum connected. Support caliper using wire. Remove rotor-to-hub screws (if equipped). Remove rotor.

2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table.

3. To install, reverse removal procedure. Check end play at grease cap. If end play exceeds .002" (.05 mm), check lock nut torque or replace wheel bearings.

REAR AXLE BEARING & OIL SEAL

NOTE: For information on models with sealed wheel bearings, see WHEEL BEARING in

SUSPENSION - REAR article in the SUSPENSION section.

MASTER CYLINDER

Removal & Installation

Disconnect fluid level sensor electrical connector. See Fig. 3 . Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid. Remove nuts attaching master cylinder to firewall or power brake unit. Remove master cylinder from vehicle. To install master cylinder, reverse removal procedure. Bleed air from system.

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Fig. 3: Removing Master Cylinder

Courtesy of MAZDA MOTORS CORP.

POWER BRAKE UNIT

Removal & Installation

Remove master cylinder from power brake unit. See MASTER CYLINDER under REMOVAL &

INSTALLATION. Disconnect vacuum line at power brake unit. See Fig. 4 . From inside vehicle, remove cotter pin and clevis pin. Separate push rod from brake pedal. Remove power brake unit-to-firewall nuts. Remove power brake unit. To install, reverse removal procedure. Bleed air from system.

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Fig. 4: Removing Power Brake Unit

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

NOTE: Use appropriate illustrations for exploded view of rear caliper assembly, master cylinder and power brake unit. See Fig. 5 through Fig. 7 .

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Fig. 5: Exploded View Of Rear Caliper Assembly

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Fig. 6: Exploded View Of Typical Master Cylinder

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Fig. 7: Exploded View Of Power Brake Unit

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

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1994 Mazda MX-5 Miata

BRAKE SYSTEM 1994 BRAKES Mazda - Disc & Drum

Application

Caliper Guide Bolt

Front

Rear

Caliper Mounting Bracket Bolt

Front

Rear

Wheel Lug Nut

Wheel Cylinder Mounting Bolt

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

Application

Front

(1)

Original Thickness

Discard Thickness

Rear

(1)

Original Thickness

Discard Thickness

(1) Maximum lateral runout is .004" (.10 mm).

Ft. Lbs. (N.m)

58-65 (78-88)

25-29 (34-39)

36-51 (49-69)

65-87 (88-118)

INCH Lbs. (N.m)

88-108 (10-12)

In. (mm)

.79 (20)

.71 (18)

.35 (9)

.31 (8)

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ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

ELECTRICAL COMPONENT LOCATOR

1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION

Component

ABS Components

Motor Relay

Location

Valve Relay

A/C Relay

Blower Motor Relay

Buzzer & Timer Unit

Circuit Opening Relay

Condenser Fan Relay

Cooling Fan Relay (View)

Cooling Fan Relay (Location)

Dashboard Illumination Light Relay

EFI Main Relay (View)

EFI Main Relay (Location)

Fuel Pump Relay

Headlight Relay

Headlight Retractor Relay

Horn Relay

Rear Defogger Relay

Rear Defogger Timer

Rear Lights Relays

On top of ABS pump, on right rear corner of engine compartment.

On center front of engine compartment, near radiator. See Fig. 1 .

On left rear of front inner fender panel bracket.

On bracket, behind left side of dash. See

Fig. 2 .

On bracket, behind left side of dash.

In engine compartment near charcoal canister. See Fig. 1 .

In engine compartment fuse/relay block.

See Fig. 2 .

In engine compartment fuse/relay block.

See Fig. 3 .

On left rear of front inner fender panel bracket.

In engine compartment fuse/relay block.

See Fig. 2 .

In engine compartment fuse/relay block.

See Fig. 3 .

Under left side of dash. See Fig. 1 .

On left rear corner of front inner fender panel bracket. See Fig. 2 .

On left rear of front inner fender panel bracket. See Fig. 2 .

On bracket, behind left side of dash. See

Fig. 2 .

In luggage compartment, near left taillight. See Fig. 2 .

On right side engine firewall. See Fig. 2 .

On left rear corner of front inner fender

1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Turn Signal/Hazard Flasher Unit panel bracket. See Fig. 2 .

On bracket, behind left side of dash. See

Fig. 2 .

CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION

Component

Fuse Block No. 1

Fuse Block No. 2

Location

Behind left side of dash. See Fig. 2 .

In right rear side of luggage compartment, behind trim panel. See Fig. 2 .

Fuse/Relay Block (Main)

Heater Blower Motor Circuit Breaker

On right rear corner of engine compartment, near firewall.

In passenger compartment fuse block.

CONTROL UNITS

CONTROL UNITS LOCATION

Component

ABS Control Unit

A/T Control Unit

Cruise Control ECM

Daytime Running Light (DRL) Control Unit

Driver SRS Module

Engine Control Unit (ECU)

Supplemental Safety Restraint (SRS) Driver

Module

Supplemental Safety Restraint (SRS)

Passenger Module

Location

Under passenger-side footwell, near ECU.

Behind left kick panel. See Fig. 1 & Fig. 4 .

Behind left side of dash, above fuse block. See Fig. 3 .

On bracket, behind left side of dash.

Center of steering wheel. See Fig. 5 .

Under passenger-side footwell. See Fig. 4 .

Behind left side of dash. See Fig. 5 .

Upper right side of dash. See Fig. 5 .

SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION

Component

ABS Wheel Sensors

Atmospheric Pressure Sensor

ATF Thermosensor

Brake Fluid Level Sensor

Coolant Temperature Sensor

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Sunday, July 05, 2009 1:25:25 PM Page 2

Location

On each front & rear wheel hub assembly.

Integral with ECU.

On left side of transmission. See

Fig. 6 .

In bottom of brake fluid reservoir.

On left rear of engine, on water outlet. See Fig. 1 .

1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Crank Shaft Position Sensor

Fuel Gauge Sending Unit

Intake Air Thermosensor

Key Interlock Solenoid

Mass Airflow Sensor

Oil Pressure Sensor

Oxygen Sensor (Heated)

SRS Crash/Impact Sensors (Air Bag)

Center

Front

Throttle Position (TP) Sensor

Vehicle Speed Sensor (VSS)

Washer Fluid Level Sensor

On right rear side of cylinder head. See Fig. 1 .

In fuel tank.

Integral of airflow meter.

On right side of steering column.

On top of air filter housing. See

Fig. 1 .

On left side of engine, near oil filter.

In engine compartment near DLC.

See Fig. 1 .

Behind center of dash. See Fig.

5 .

On center, left and right front of vehicle. See Fig. 5 .

On side of throttle body. See Fig.

1 .

On speedometer assembly. See

Fig. 6 .

On bottom of washer fluid reservoir.

MOTORS

MOTORS LOCATION

Component

A/C-Heater Blower Motor

Cruise Control Actuator

Fuel Pump

Shift Lock Actuator

Windshield Washer Motor

Windshield Wiper Motor

SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION

Component

Idle Speed Control (ISC) Valve

Lock-Up Solenoid

Purge Solenoid Valve

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Sunday, July 05, 2009 1:25:25 PM Page 3

Location

Under right side of dash.

Right side of engine, near air filter. See Fig. 3 .

In fuel tank.

Under center console, on base of gear selector. See

Fig. 4 .

On bottom of washer fluid reservoir.

On right side of firewall.

Location

On throttle body.

On bottom of transmission. See Fig. 6 .

On right strut tower. See Fig. 1 .

1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Shift Control Solenoid Valves

SWITCHES

SWITCHES LOCATION

Component

A/C Refrigerant Pressure Switch

A/C Thermoswitch

Back-Up Light Switch (M/T)

Clutch Switch

Cooling Fan Thermoswitch

Cruise Control Main Switch

Fuel Pump Switch

Inhibitor Switch

Multi-Function Switch

Neutral Switch (M/T)

Oil Pressure Switch

Parking Brake Switch

Power Steering Pressure Switch

"P" Range Switch

Seat Belt Buckle Switch

Starter Interlock Switch (M/T)

Stoplight Switch

On left side of transmission. See Fig. 6 .

Location

On A/C high pressure refrigerant line.

On front of evaporator case.

On left rear side of transmission.

On bracket, above clutch pedal. See Fig. 1 & Fig. 3 .

On thermostat housing.

On steering column (Left). See Fig. 3 .

Integral of airflow sensor.

On left side of transmission. See Fig. 6 .

On steering column (Right). See Fig. 3 .

On right rear side of transmission. See Fig. 1 & Fig. 3 .

On left side of transmission.

On base of parking brake lever.

On power steering pump assembly. See Fig. 1 .

Under center console, on base of gear selector. See Fig. 4 .

On driver-side seat belt buckle.

On bracket, above clutch pedal.

On bracket, above brake pedal. See Fig. 1 , Fig. 3 & Fig.

4 .

MISCELLANEOUS

MISCELLANEOUS LOCATION

Component

Actuator Cable

A/C-Heater Blower Motor Resistor

Data Link Connector (DLC)

Clock Spring

Location

Attached to cruise control actuator. See Fig. 3 .

On side of A/C-heater blower motor housing.

On left rear of engine compartment, near master cylinder. See

Fig. 1 .

Beneath steering wheel. See Fig. 5 .

COMPONENT LOCATION GRAPHICS

NOTE: Figures may show multiple component locations. Refer to appropriate table for proper figure references.

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1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Fig. 1: Component Locations (1 Of 6)

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1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Fig. 2: Component Locations (2 Of 6)

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1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Fig. 3: Component Locations (3 Of 6)

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1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Fig. 4: Component Locations (4 Of 6)

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1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Fig. 5: Component Locations (5 Of 6)

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1994 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1994 ELECTRICAL COMPONENT LOCATION Mazda Electrical Components

Fig. 6: Component Locations (6 Of 6)

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1994 ENGINES 1.8L 4-Cylinder

1994 ENGINES

1.8L 4-Cylinder

ENGINE IDENTIFICATION

NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL

PROCEDURES - GENERAL INFORMATION article in the GENERAL

INFORMATION section.

Engineering codes can identify basic engine type. See ENGINE IDENTIFICATION CODE table. Engines can be further identified by engine number.

On Miata, engine number is stamped on flange, at upper right rear of cylinder block deck as viewed from flywheel.

ENGINE IDENTIFICATION CODE

Application

Miata DOHC

Code

ADJUSTMENTS

VALVE CLEARANCE ADJUSTMENT

NOTE: Valve clearance is not adjustable. Some Hydraulic Lash Adjuster (HLA) noise may occur during engine start-up. Noise should disappear after engine reaches normal operating temperature. If noise persists, change engine oil. If oil change does not reduce noise, check with manufacturer for modified HLA.

REMOVAL & INSTALLATION

NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE

Disconnect fuel pump relay, located behind dash, left of steering column. Start engine and allow to idle until it stalls. Turn ignition off. Disconnect negative battery cable, and reconnect circuit opening relay. When disconnecting fuel hoses, cover connection with shop rag to catch fuel spray.

ENGINE

NOTE: On models with audio anti-theft system, radio will not operate if power to radio

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder is cut. Obtain code from customer to reactivate radio. To reactivate radio after reconnecting power supply, turn ignition switch to ACC position. press and hold FF and REW buttons until "cod e" is displayed. Again press and hold FF and REW buttons until bars (--- -) are displayed. Use preset button No. 1 to enter first number, No. 2 to enter second number, 3 for third number, etc. Press FF and REW buttons for about 2 seconds until a beep is heard. After 5 seconds, flashing "cod e" will go away and radio will operate.

Removal

1. Relieve fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative battery cable from trunk-mounted battery. Reference mark hood and remove. Raise vehicle, and remove engine undercover.

See Fig. 1 . Drain engine oil, transmission oil and cooling system.

2. Remove transmission. For automatic or manual transmission removal procedure, see appropriate

TRANSMISSION REMOVAL & INSTALLATION article in the TRANSMISSION/TRANSAXLE section.

3. Remove all cooling system hoses and A/T oil cooler lines at radiator (if equipped). Remove radiator and cooling fans as an assembly. Remove all drive belts. DO NOT disconnect power steering hoses or A/C compressor hoses. Remove power steering pump and A/C compressor from engine, and secure units away from engine.

4. Remove air cleaner assembly and throttle body intake duct assembly. See Fig. 2 . Remove throttle cable.

Note locations and disconnect all necessary electrical connectors, ground wires, vacuum hoses, fuel hoses, coolant hoses and control cables for engine removal. Plug all fuel hoses to prevent leakage.

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1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Fig. 1: Removing & Installing Drive Train Components

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Fig. 2: Removing Engine Components

Courtesy of MAZDA MOTORS CORP.

NOTE: Proper installation of PPF is critical for aligning drive shaft and eliminating harmonic vibrations.

Installation

1. To install, reverse removal procedure. After installing engine mount nuts, mount PPF to transmission, and tighten long bolts by hand. Ensure bolt sleeve and PPF/differential mounting spacer are installed to differential housing block.

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1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

2. Tighten PPF/differential mounting spacer bolts to 27-38 ft. lbs. (37-52 N.m). See Fig. 3 . Install PPF to differential. Hand-tighten long bolts. Ensure PPF-to-differential large shank reamer bolt and spacer are properly installed.

NOTE: Reamer bolt is the front long bolt attaching PPF to differential. This bolt aligns PPF with drive train.

3. When PPF is properly aligned between transmission and differential, tighten all long mounting bolts to specification. Install rear transmission-to-PPF bracket, and tighten to specification. See TORQUE

SPECIFICATIONS . To complete installation, reverse removal procedure. Before installing M/T shift lever, add gear oil to transmission through shifter hole. Fill all fluids to correct level.

Fig. 3: Locating PPF-To-Differential Reamer Bolt, Sleeve & Spacer

Courtesy of MAZDA MOTORS CORP.

INTAKE MANIFOLD

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1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Removal

1. Relieve fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and ducting. See Fig. 2 . Mark and disconnect coolant hoses, vacuum hoses and electrical connectors from intake manifolds.

2. Disconnect throttle cable. Remove fuel lines from fuel rail and pressure regulator. Remove throttle body intake duct housing and throttle body. Remove air valve.

3. Remove intake manifold support bracket from underneath manifold. Disconnect injector harness connectors, and remove injectors/fuel rail assembly. Remove intake manifold and gasket.

Installation

1. Ensure all gasket surfaces are clean and flat. Install new gasket and intake manifold to cylinder head.

Tighten manifold bolts/nuts evenly to specification, starting from center bolt and alternating outward. See

TORQUE SPECIFICATIONS . Install support bracket underneath intake manifold.

2. Install gasket and upper intake manifold (if equipped). Tighten bolts/nuts evenly to specification, alternating from top to bottom.

3. To complete installation, reverse removal procedure. Ensure throttle cable has .04-.12" (1-3 mm) free play. Ensure injectors twist freely and are not cocked in insulator "O" rings. Refill engine with coolant.

EXHAUST MANIFOLD

Removal & Installation

1. Disconnect oxygen sensor. Remove heat shields. Disconnect downpipe from exhaust manifold. Remove exhaust manifold.

2. To install, reverse removal procedure. Ensure all mating surfaces are clean and flat. Install new gasket to cylinder head. Tighten manifold bolts evenly to specification, starting from center bolt and alternating outward. See TORQUE SPECIFICATIONS .

CYLINDER HEAD

Removal

1. Drain engine coolant. Release fuel pressure. See FUEL PRESSURE RELEASE . Note locations and disconnect all necessary electrical connectors, ground wires, vacuum hoses, fuel hoses, coolant hoses and control cables for cylinder head removal. Plug all fuel hoses to avoid leakage.

2. Remove spark plug wires from spark plugs. Remove all drive belts. Remove water pump pulley. Remove timing belt. See TIMING BELT . Remove camshaft/rocker cover.

3. Remove front exhaust pipe. Remove intake manifold support bracket. Loosen all cylinder head bolts evenly, in 3 steps, in reverse of tightening sequence. See Fig. 4 . Remove bolts and cylinder head assembly.

Inspection

Carefully clean carbon and gasket material from all mating surfaces. Clean threads of cylinder head bolts. Use a

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1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder tap to clean threads in engine block. Check cylinder head for warpage. Resurface or replace head if it is not within specification. Check valve train components. Replace or resurface components if they are not within specification. See CYLINDER HEAD and VALVES & VALVE SPRINGS tables under ENGINE

SPECIFICATIONS.

Installation

Install cylinder head gasket, cylinder head assembly and bolts. Tighten cylinder head bolts in 2 steps and in sequence to specification. See Fig. 4 . See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Fig. 4: Cylinder Head Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

CRANKSHAFT FRONT SEAL

Removal

Disconnect negative battery cable. Remove drive belts and crankshaft pulley. Remove water pump pulley,

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1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder timing belt covers and timing belt. See TIMING BELT . Use Crankshaft Lock Tools (49-S120-710 and 49-

B011-102) to lock crankshaft sprocket into position. Remove crankshaft sprocket bolt. Remove crankshaft sprocket using steering wheel puller. Pry out seal.

Installation

1. Apply light oil coat to seal lip. Using a hammer and seal installer, tap seal into oil pump body until it is flush with edge of pump body. DO NOT bottom seal in pump body. Align keyway slots, and install crankshaft sprocket and Woodruff key with tapered side toward oil pump body. Install crankshaft sprocket bolt.

2. Using Crankshaft Lock Tools (49-S120-710 and 49-B011-102), lock crankshaft sprocket into position.

Tighten lock bolt to specification. See TORQUE SPECIFICATIONS .

3. Install timing belt. See TIMING BELT under REMOVAL & INSTALLATION. Install timing belt covers, pulleys and drive belts. Reconnect negative battery cable, and ensure timing is correct.

TIMING BELT

NOTE: For 1994 vehicles, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in

California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For removal and installation procedure, see TIMING BELT

REPLACEMENT - 1.8L - DOHC, BP ENG .

HYDRAULIC LASH ADJUSTER (HLA)

NOTE: If hydraulic lash adjusters are persistently noisy, check with manufacturer for availability of modified adjusters.

Removal

Disconnect negative battery cable. Remove camshaft. See CAMSHAFT . Mark location of each HLA for reassembly reference. Remove HLA from cylinder head.

Inspection

Place HLA in palm of hand. Attempt to compress HLA plunger with thumb. If plunger compresses, replace

HLA.

Installation

Insert HLA in original location. To complete installation, reverse removal procedure. Tighten camshaft caps evenly in sequence to specification. See Fig. 5 . See TORQUE SPECIFICATIONS .

CAMSHAFT

NOTE:

Microsoft

Intake camshaft has slot for crank angle sensor drive. Match mark camshafts

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder and sprockets for installation reference.

Removal

Remove cylinder head cover. Remove timing belt. See TIMING BELT . Remove distributor/crank angle sensor. Reference mark camshafts, caps and sprockets, and remove sprockets. Loosen camshaft cap bolts evenly in 2-3 steps, in sequence. See Fig. 5 . Remove camshafts.

Inspection

Check camshaft end play. Check camshaft journal diameters and bearing clearances. Check camshaft lobes for wear. See CAMSHAFT table under ENGINE SPECIFICATIONS. If any measurement is not within specification, replace camshaft and/or cylinder head.

Installation

To install, reverse removal procedure. On both camshafts, apply small amount of silicone sealant to contact area of cylinder head/camshaft seal cover cap. Tighten camshaft caps evenly in sequence to specification. See Fig.

5 . See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Fig. 5: Camshaft Cap Bolt Removal & Installation Sequence

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Courtesy of MAZDA MOTORS CORP.

CRANKSHAFT REAR OIL SEAL

Removal & Installation

1. Disconnect negative battery cable. Remove transmission/transaxle and flywheel. For automatic or manual transmission removal procedure, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in the TRANSMISSION/TRANSAXLE section. Pry out rear oil seal.

2. To install, apply light coat of oil to seal lip and push seal over crankshaft. Tap seal into rear cover until it is flush with edge of rear cover. DO NOT bottom seal in cover.

3. Completely remove used sealant from flywheel bolts. Apply lock-type sealant to bolts, and install flywheel to crankshaft. Tighten bolts to 71-76 ft. lbs. (96-103 N.m) in a star-pattern sequence. Install clutch assembly (if equipped), and tighten cover bolts to 13-20 ft. lbs. (18-26 N.m) in a star-pattern sequence. Install transmission. For automatic or manual transmission removal procedure, see appropriate

TRANSMISSION REMOVAL & INSTALLATION article in the TRANSMISSION/TRANSAXLE section (See above).

WATER PUMP

Removal & Installation

1. Drain engine coolant. Disconnect battery cable. Position No. 1 cylinder at TDC of compression stroke.

2. Remove air cleaner intake duct between throttle body and air cleaner/filter assembly. Remove upper radiator hose and by-pass hoses from thermostat housing.

3. Remove drive belts and water pump pulley. Remove power steering pump with hoses attached, and secure pump away from engine (if necessary). Remove timing belt, tensioner and idler. See TIMING

BELT .

4. Unbolt water inlet pipe from water pump. Water pump inlet pipe has lower radiator hose and by-pass pipe attached to it. Remove bolts from water pump. To install, reverse removal procedure. Tighten bolt to specification. See TORQUE SPECIFICATIONS .

NOTE: For further information on cooling systems, see COOLING SYSTEM

SPECIFICATIONS & DRIVE BELT ROUTING article and/or ENGINE COOLING

FAN article.

OIL PAN

NOTE: Engine must be supported in order to remove oil pan.

Removal & Installation

1. Disconnect negative battery cable. Remove dipstick, tube and "O" ring. Raise vehicle on hoist. Remove engine undercover. Drain engine oil. Disconnect steering column shaft at steering rack coupling. Remove engine mount nuts. See Fig. 6 . Lift and support engine using jack.

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

2. Support crossmember using transmission jack, and remove crossmember bolts. Slowly and carefully lower crossmember until clearance between oil pan and steering rack is about 4 inches. Remove oil pan bolts from engine block and transmission.

3. DO NOT damage sealant contact surfaces. Remove oil pan by prying between oil pan and transmission support. Remove oil pan baffle by prying it from engine. See Fig. 6 . DO NOT deform oil pan baffle.

Replace oil pan baffle if deformed. Clean sealant from oil pan, bolts, engine block and both sides of oil pan baffle.

4. To install, apply oil resistant sealant to engine block and oil pan. Install oil pan baffle and oil pan. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE

SPECIFICATIONS . Fill engine with oil to specification. See ENGINE LUBRICATION SYSTEM under ENGINE OILING.

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Fig. 6: Removing Crossmember & Oil Pan

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

CYLINDER HEAD

Cylinder Head

Clean carbon and gasket material from all mating surfaces. Using a tap, clean cylinder head threads. Check cylinder head for warpage, and resurface or replace if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Springs

Ensure valve spring free length, out-of-square and pressure are within specification. See VALVES & VALVE

SPRINGS table under ENGINE SPECIFICATIONS. Replace valve spring if necessary.

NOTE: Intake and exhaust valve stem seals are different. Exhaust seals can be identified by ridges molded into top of seal. Intake seals do not have identifying ridges. Incorrect installation of valve stem seals will cause premature failure.

Valve Stem Oil Seals

Use Installer Set (49-L012-0A0) to install valve seals. See Fig. 7 . Adjust installer dimension "L" to seal depth of .720-.744" (18.3-18.9 mm). Using hand pressure ONLY, install seal until it contacts cylinder head. Lightly oil valve seal lip.

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Fig. 7: Installing Valve Guide Seals

Courtesy of MAZDA MOTORS CORP.

NOTE: Use only new exhaust valve guides to replace intake or exhaust valve guides.

Valve Guides

1. Check valve stem-to-valve guide oil clearance. Ensure valve guide inside diameter is within specification.

See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

2. Completely disassemble cylinder head. Gradually heat cylinder head in water to 194°F (94°C). Using

Valve Guide Remover (49-B002-005), drive valve guide out, working from combustion chamber side of cylinder head. Repeat procedure if required, keeping cylinder head hot so aluminum head will not warp.

3. If required, install new circlip on guide. Using proper components of Valve Guide Installer (49-L012-

0A0), adjust installer guide depth (dimension "L") to specification using depth micrometer or caliper. See

VALVE GUIDE INSTALLED HEIGHT table. See Fig. 8 .

4. Insert guide into pre-adjusted installer, and drive guide into cylinder head from camshaft side until guide circlip and/or installer contact cylinder head. Measure dimension "L" (guide installed height). See Fig. 8 or Fig. 9 . If installed height is not within specification, adjust or replace valve guide or cylinder head as necessary.

VALVE GUIDE INSTALLED HEIGHT

Application

Miata

Microsoft

Sunday, July 05, 2009 1:23:06 PM Page 15

In. (mm)

.720-.744 (18.30-18.90)

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Fig. 8: Adjusting Valve Guide Installer & Installing Guide

Courtesy of MAZDA MOTORS CORP.

Fig. 9: Measuring Installed Valve & Guide Height

Courtesy of MAZDA MOTORS CORP.

Valve Seat

1. Service valve guide before valve seat. Valve seat replacement information is not available from manufacturer. Inspect valve seat for roughness and damage. Check valve seat angle and seat width.

2. Measure seat contact width on valve, and ensure seat contact position is in center of valve face. Service

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder seat if angle and width are not within specification. See CYLINDER HEAD table under ENGINE

SPECIFICATIONS. Measure valve installed height after servicing valve seat. See Fig. 9 . See VALVE

INSTALLED HEIGHT table.

3. If valve installed height is within serviceable range, install adjusting shim on spring seat. If installed height exceeds serviceable range, replace cylinder head.

VALVE INSTALLED HEIGHT

Application

Normal

Serviceable

In. (mm)

1.772-1.791 (45.00-45.50)

1.733-1.772 (45.60-46.50)

Valves

Check valve face angle, head diameter, margin thickness and stem diameter. Service or replace valves if measurements are not within specifications. See VALVES & VALVE SPRINGS table under ENGINE

SPECIFICATIONS.

Valve Seat Correction Angles

Measure seat contact width on valve. See VALVE SEAT . Ensure valve/seat contact position is at center of valve face. If seat contact is too wide or too high, correct it using a 70-degree cutter.

VALVE TRAIN

Hydraulic Lash Adjusters

1. Remove camshaft cover. Check movement of each Hydraulic Lash Adjuster (HLA) by pushing downward using hand pressure only. If HLA compresses, replace HLA. To remove HLA, remove camshafts. See CAMSHAFT under REMOVAL & INSTALLATION. Mark location of HLA before removing it from bore. Lift HLA from cylinder head.

NOTE: If hydraulic lash adjusters are persistently noisy, check with manufacturer for availability of modified adjusters.

2. Inspect HLA friction surfaces for wear and damage. Replace HLA if required. Coat HLA with engine oil, and install it in original location. Ensure HLA moves smoothly in bore by using small magnet attached to

HLA.

CYLINDER BLOCK ASSEMBLY

NOTE: During disassembly, match mark components for reassembly reference.

Piston & Connecting Rod Assembly

1. Before removing rod cap from crankshaft, measure and record rod side play. See CONNECTING RODS table under ENGINE SPECIFICATIONS.

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

2. Remove rod cap from crankshaft. Install short pieces of rubber hose over rod bolts. Push piston and rod assembly out of block.

3. To install, ensure parts are matched to cylinder. Ensure piston, rod, rings and bearings are properly fitted and in related positions. See Fig. 10 . Install piston and rod assembly into block.

Fig. 10: Assembling Piston, Rod & Rings

Courtesy of MAZDA MOTORS CORP.

Piston Pin Replacement

Match mark piston-to-pin and rod-to-piston positions for proper reassembly. Remove piston pin retaining clip.

Drive piston pin out of piston and rod assembly. To install, insert one piston pin retaining clip into groove in piston. Ensure piston is positioned properly on connecting rod. See Fig. 10 . Tap piston pin into piston and through rod. Install second retaining clip. Piston should pivot freely.

Fitting Pistons

1. Ensure pistons are not scored or damaged. Measure piston diameter on piston skirt, at 90-degree angle from piston pin, .65" (16.5 mm) below lowest ring groove. See PISTONS, PINS & RINGS table under

ENGINE SPECIFICATIONS.

2. Check piston-to-cylinder wall clearance in 3 different vertical places of piston travel. If clearance is not within specification, re-bore cylinders to fit oversize pistons. Using NEW piston rings, measure piston ring side clearance around entire piston circumference. If clearance is not within specification, replace piston.

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

NOTE: Pistons and rings are available in .010" (.25 mm) and .020" (.50 mm) oversize.

Piston Rings

Insert NEW piston ring into cylinder, and measure ring end gap. Grind ring ends or replace piston ring if ring end gap is not within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

1. Check crankshaft connecting rod journals for wear, out-of-round, taper and undersize. Machine or replace crankshaft and/or bearings as necessary. See CRANKSHAFT, MAIN & CONNECTING ROD

BEARINGS table under ENGINE SPECIFICATIONS.

2. Before removing main cap, measure and record crankshaft end play by prying crankshaft forward then rearward. Using Plastigage method, measure and record main bearing oil clearance. Remove crankshaft.

Measure and record each main journal diameter in 2 places.

3. Main bearing caps are marked and must be installed in original position. Tighten bearing caps evenly to specification. See TORQUE SPECIFICATIONS .

Thrust Bearing

Install thrust bearing before installing crankshaft. Check crankshaft end play with crankshaft bearings and caps installed, but without connecting rods attached to crankshaft. DO NOT turn crankshaft until bearings are lubricated. Replace thrust bearing if end play is not within specification. See CRANKSHAFT, MAIN &

CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Oversize thrust bearings are available.

Cylinder Block

Check cylinder bore out-of-round, taper, ridge and piston-to-cylinder bore clearance. Check head gasket surface for warpage. If warpage is not within specification, machine or replace cylinder block as necessary. See

CYLINDER BLOCK table under ENGINE SPECIFICATIONS. Remove, clean and install oil jets for piston oil spraying.

ENGINE OILING

ENGINE LUBRICATION SYSTEM

NOTE: For cross-sectional view of engine oil circuit, See Fig. 11 .

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Fig. 11: Cross-Sectional View Of Engine Oil Circuit

Courtesy of MAZDA MOTORS CORP.

Crankcase Capacity

See ENGINE OIL CRANKCASE CAPACITY table.

Oil Pressure

With engine at operating temperature, oil pressure should be 28-43 psi (2.0-3.0 kg/cm

) at 1000 RPM, and 43-

57 psi(3.0-4.0 kg/cm

) at 3000 RPM.

Oil Pressure Relief Valve

Pressure relief valve opening pressure is 50-64 psi (3.5-4.5 kg/cm

2 body and is not adjustable.

). Pressure relief valve is located in oil pump

ENGINE OIL CRANKCASE CAPACITY

Application

Without Filter

With Filter

Qts. (L)

3.8 (3.8)

4.0 (3.8)

OIL PUMP

Removal & Installation

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

1. Disconnect negative battery cable. Remove dipstick, tube and "O" ring. Drain engine oil and coolant.

Remove drive belts, crankshaft and water pump pulleys. Remove alternator, A/C compressor and mounting bracket. Without disconnecting A/C hoses, secure A/C compressor away from engine. Remove timing belt and related components. See TIMING BELT under REMOVAL & INSTALLATION.

2. Hold crankshaft sprocket in place, and remove crankshaft sprocket bolt. Remove crankshaft sprocket using steering wheel puller. Leave crankshaft Woodruff key in place.

3. Remove oil pan and oil pump pick-up tube. See OIL PAN under REMOVAL & INSTALLATION.

Remove oil pump housing assembly. See Fig. 12 . Carefully clean all gaskets and sealant from mating surfaces without damaging sealing/mating surfaces. Remove all sealant from components and bolts.

Check oil pump clearances. Repair or replace pump if necessary. See OIL PUMP SPECIFICATIONS table.

4. To install, reverse removal procedure. Tighten all bolts to specifications. See TORQUE

SPECIFICATIONS .

OIL PUMP SPECIFICATIONS

Application

Inner Gear Tip-To-Outer Gear Clearance

Outer Gear-To-Pump Body Clearance

Gear End Play-To-Pump Body Clearance

Pressure Spring Length

Maximum Clearance In. (mm)

.0079 (.201)

.0055 (.140)

1.809 (45.94)

Microsoft

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Fig. 12: Exploded View Of Oil Pump

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Alternator Top Bolt

Camshaft Sprocket Bolt

Compressor Bracket-To-Engine Bolt

Connecting Rod Cap Nut

Crankshaft Pulley Attaching Bolts

Crankshaft/Timing Belt Sprocket Bolt

Crossmember-To-Frame Bolt

Cylinder Head Bolt

(2)

Step 1

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Sunday, July 05, 2009 1:23:06 PM

Ft. Lbs. (N.m)

27-38 (37-52)

36-45 (49-61)

28-38 (38-51)

35-37 (48-50)

9-13 (12-18)

116-123 (157-167)

47-66 (63-89)

Page 22

35-40 (47-54)

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Step 2 (Final)

Distributor Bolt

Drive Shaft Bolts

Engine Mount-To-Frame Nut

Exhaust Header Pipe-To-Exhaust Manifold Nut

Exhaust Manifold Nut

Flywheel Bolt

Fuel Rail Bolt

Intake Manifold Bolt/Nut

Intake Manifold Support Bracket

Main Bearing Cap Bolt

Step 1

Step 2 (Final)

Motor Mount Nut

Motor Mount-To-Engine Bolt

Oil Pan Support-To-Transaxle

Oil Pump-To-Block Bolt

PPF/Differential Spacer Mounting Bolt

(2)

PPF-To-Differential Long Mounting Bolt

(2)

PPF-To-Transmission Side Mounting Bolt

(2)

PPF/Transmission Rear Bracket Mounting Bolt

Spark Plug

Timing Belt Tensioner Bolt

Water Pump Bolt

Camshaft Cap Bolt

Camshaft/Rocker Cover Bolt

Crankshaft Pulley Bolts

Oil Jet

Oil Pan Bolt

Oil Strainer Bolt

Water Pump Pulley Bolt

(1) Tighten evenly to specification in alternating sequence.

(2) Tighten in sequence. See Fig. 4 .

(3) Tighten in sequence. See Fig. 5 .

ENGINE SPECIFICATIONS

Microsoft

56-60 (76-81)

14-19 (19-26)

20-22 (27-30)

42-57 (57-77)

23-34 (31-46)

(1)

28-34 (38-46)

71-76 (96-103)

14-19 (19-26)

(1)

14-19 (19-26)

(1)

22-27 (30-37)

(1)

40-43 (54-58)

42-58 (57-79)

27-40 (37-54)

28-38 (38-52)

14-19 (19-26)

27-38 (37-52)

77-91 (104-123)

27-40 (37-54)

11-17 (15-23)

27-38 (37-52)

14-19 (19-26)

INCH Lbs. (N.m)

(3)

100-125 (11.3-14.1)

43-78 (5-9)

109-152 (12-17)

104-156 (12-18)

69-95 (8-11)

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

GENERAL SPECIFICATIONS

Application

Displacement

Bore

Stroke

Compression Ratio

Fuel System

Horsepower @ RPM

Torque Ft. Lbs. @ RPM

Specification In. (mm)

112.2 Cu. In.

3.27" (83.0)

3.35" (85.0)

9.0:1

PFI

128 @ 6500

110 @ 5000

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application

Crankshaft

End Play

Standard

Maximum

Maximum Runout

Main Journals

Diameter

Out-Of-Round & Taper

Oil Clearance

Standard

Maximum Wear Limit

Crankpin Journal

Diameter

Out-Of-Round & Taper

Oil Clearance

Standard

Maximum Wear Limit

CONNECTING RODS

Application

Bore Diameter

Crankpin Bore

Pin Bushing Bore

Center-To-Center Length

Maximum Bend

Side Play

Standard

Wear Limit

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Sunday, July 05, 2009 1:23:06 PM Page 24

In. (mm)

.0031-.0111 (.079-.282)

.012 (.30)

.0016 (.040)

1.9660-1.9668 (49.938-49.956)

.002 (.05)

.0007-.0014 (.018-.036)

.0039 (.100)

1.7693-1.7699 (44.940-44.956)

.002 (.05)

.0008-.0027 (.017-.068)

.0039 (.100)

In. (mm)

1.8898-1.8904 (48.000-

48.016)

.7875-.7880 (20.003-20.014)

5.230-5.234 (132.85-132.95)

.003 (.08)

.0043-.0103 (.110-.262)

.012 (.30)

PISTONS, PINS & RINGS

Application

Pistons

Clearance

Standard

Maximum

Diameter

Standard

Pins

Diameter

Piston Fit

Rings

End Gap

No. 1

Standard

Wear Limit

No. 2

Standard

Wear Limit

Oil Ring

Standard

Wear Limit

Side Clearance

Standard

Wear Limit

CYLINDER BLOCK

Application

Cylinder Bore

Standard Diameter

Maximum Taper & Out-Of-Round

Deck Height

Standard

Minimum

Maximum Deck Warpage

CYLINDER HEAD

Application

Cylinder Head Height

Maximum Warpage

Microsoft

Sunday, July 05, 2009 1:23:06 PM

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

In. (mm)

.0013-.0023 (.032-.059)

.006 (.15)

3.2659-3.2667 (82.954-82.974)

.7869-.7871 (19.987-19.993)

-.0002-.0005 (-.005-.013)

.006-.012 (.15-.30)

.039 (1.0)

.006-.012 (.15-.30)

.039 (1.0)

.008-.028 (.20-.71)

.039 (1.0)

.0012-.0026 (.030-.065)

Wear Limit

In. (mm)

3.2677-3.2684

(83.000-83.019)

.0007 (.019)

8.720 (221.5)

8.712 (221.3)

.006 (.15)

Page 25

In. (mm)

5.268-5.276 (133.81-134.01)

.004 (.10)

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

Valve Seat Contact Angle

Valve Guides

Valve Guide I.D.

Valve Guide Installed Height

(1)

Valve Stem-To-Guide Oil Clearance

Intake

Exhaust

Maximum Wear Limit

Cylinder Head-To-HLA Clearance

45°

.2366-.2374 (6.009-6.029)

.720-.744 (18.28-18.89)

.0010-.0024 (.025-.060)

.0012-.0026 (.030-.065)

.008 (.20)

.0010-.0071 (.025-.180)

(1) Valve guide installed height is measured from top of installed guide to spring seat. See Fig. 6 .

VALVES & VALVE SPRINGS

Application

Valves

Face Angle

Contact Width

Installed Height

(1)

Normal

Serviceable

Minimum Margin

Intake

Exhaust

Minimum Refinish Length

Intake

Exhaust

Stem Diameter

Intake

Standard

Minimum

Exhaust

Standard

Minimum

Valve Springs

Free Length

Maximum Out-Of-Square

Compressed Length (Minimum)

1.8L DOHC

(1)

Specification In. (mm)

45°

.031-.055" (.79-1.40)

1.772-1.791" (45.00-45.50)

1.733-1.772" (45.60-46.50)

.035" (0.9)

.039" (1.0)

3.952" (100.39)

3.956" (100.49)

.2350-.2356" (5.970-5.985)

.2331" (5.920)

.2348-.2354" (5.965-5.980)

.2329" (5.952)

1.821" (46.26)

.064" (1.62)

1.555" (39.50)

(1) Valve height is measured from top of installed valve to spring seat. See VALVE INSTALLED

HEIGHTS table under OVERHAUL. See Fig. 7 .

Microsoft

CAMSHAFT

Application

End Play

Journal Diameter

Maximum Journal Out-Of-Round

Maximum Journal Runout

Journal Oil Clearance

Maximum Wear Limit

Lobe Height

Standard

Intake

Exhaust

Minimum

Intake

Exhaust

1994 Mazda MX-5 Miata

1994 ENGINES 1.8L 4-Cylinder

In. (mm)

.0032-.0120 (.081-.305)

1.0213-1.0222 (25.940-25.965)

.0015 (.038)

.0012 (.030)

.0014-.0032 (.035-.081)

.006 (.15)

1.7360 (44.094)

1.7560 (44.600)

1.7281 (43.894)

1.7480 (44.400)

Microsoft

Miata & Protege

1994-98 ENGINE COOLING

Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5 Miata &

Protege

APPLICATION

Information presented in this article applies to the following years and models. See YEAR & MODEL

APPLICATION .

YEAR & MODEL APPLICATION

Years

1997

1998

1997-98

1994-97

1995-98

Model

B2300

B4000

B2500, B3000 & B4000

Millenia

MPV

MX-5 Miata

Protege

ADJUSTMENTS

NOTE: If a new belt is used, adjust belt deflection at midpoint of new belt specification.

B4000 & MILLENIA (2.3L)

NOTE: "B" Series Pickup and Millenia 2.3L are equipped with serpentine belts that are automatically adjusted by tensioner. Millenia is equipped with 2 serpentine belts

(alternator and power steering pump). Replace belts if tensioner indicates belt is out of adjustment range. See Fig. 1 - Fig. 3 . DO NOT apply belt dressing to serpentine belt.

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 1: Checking Serpentine Belt Tension (B4000)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 2: Checking Alternator Serpentine Belt Tension (Millenia, 2.3L)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 3: Checking Power Steering Pump Serpentine Belt Tension (Millenia, 2.3L)

Courtesy of MAZDA MOTORS CORP.

MILLENIA

NOTE: If a new belt is used, adjust belt deflection at midpoint of new belt specification.

Alternator (2.5L)

Loosen idler pulley locknut and adjust belt deflection by turning adjusting bolt. See Fig. 4 and Fig. 19 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 4: Adjusting Alternator Belt (Millenia, 2.5L)

Courtesy of MAZDA MOTORS CORP.

Power Steering Pump (2.5L)

Loosen idler pulley locknut and adjust belt deflection by turning adjusting bolt. See Fig. 5 and Fig. 20 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 5: Adjusting Power Steering Pump Belt (Millenia, 2.5L)

Courtesy of MAZDA MOTORS CORP.

MPV

NOTE: If a new belt is used, adjust belt deflection at midpoint of new belt specification.

Alternator

Loosen alternator bolts and adjust belt deflection by levering generator outward and applying tension. See Fig.

6 and Fig. 21 . See ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE

SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 6: Adjusting Alternator Belt (MPV)

Courtesy of MAZDA MOTORS CORP.

A/C Compressor

Loosen locknut and adjust belt deflection by turning adjusting bolt. See Fig. 7 and Fig. 23 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 7: Adjusting A/C Compressor Belt (MPV)

Courtesy of MAZDA MOTORS CORP.

Power Steering Pump

Loosen locknut and adjust belt deflection by turning adjusting bolt. See Fig. 8 and Fig. 22 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 8: Adjusting Power Steering Pump Belt (MPV)

Courtesy of MAZDA MOTORS CORP.

MX-5 MIATA

NOTE: If a new belt is used, adjust belt deflection at midpoint of new belt specification.

Alternator

Loosen alternator bolts and adjust belt deflection by turning adjusting bolt. See Fig. 9 and Fig. 25 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 9: Adjusting Alternator Belt (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

A/C Compressor

Loosen locknut and adjust belt deflection by turning adjusting bolt. See Fig. 10 and Fig. 26 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 10: Adjusting A/C Compressor Belt (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Power Steering Pump

Loosen power steering pump nut and bolt, and adjust belt deflection by turning adjusting bolt. See Fig. 11 and

Fig. 25 . See ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE

SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 11: Adjusting Power Steering Pump Belt (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

PROTEGE

NOTE: If a new belt is used, adjust belt deflection at midpoint of new belt specification.

Alternator

Loosen bolts and adjust belt deflection by turning adjusting bolt. See Fig. 12 and Fig. 27 . See ADJUSTMENT

SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 12: Adjusting Alternator Belt (Protege)

Courtesy of MAZDA MOTORS CORP.

Power Steering Pump

Loosen nuts and bolts and adjust belt deflection by turning adjusting bolt. See Fig. 13 , Fig. 14 and Fig. 28 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 13: Adjusting Power Steering Pump Belt (Without A/C, Protege)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 14: Adjusting Power Steering Pump Belt (With A/C, Protege)

Courtesy of MAZDA MOTORS CORP.

DRIVE BELT ROUTING

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 15: Identifying Drive Belt Routing (B2300 & B2500)

Courtesy of FORD MOTOR CO.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 16: Identifying Drive Belt Routing (B3000)

Courtesy of FORD MOTOR CO.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 17: Identifying Drive Belt Routing (B4000)

Courtesy of FORD MOTOR CO.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 18: Identifying Drive Belt Routing (Millenia, 2.3L)

Courtesy of FORD MOTOR CO.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 19: Identifying Drive Belt Routing & Deflection Check Point (Millenia, 2.5L, 1 Of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 20: Identifying Drive Belt Routing & Deflection Check Point (Millenia, 2.5L, 2 Of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 21: Identifying Drive Belt Routing & Deflection Check Point (MPV, 1 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 22: Identifying Drive Belt Routing & Deflection Check Point (MPV, 2 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 23: Identifying Drive Belt Routing & Deflection Check Point (MPV, 3 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 24: Identifying Drive Belt Routing & Deflection Check Point (MX-5 Miata, 1 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 25: Identifying Drive Belt Routing & Deflection Check Point (MX-5 Miata, 2 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 26: Identifying Drive Belt Routing & Deflection Check Point (MX-5 Miata, 3 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 27: Identifying Drive Belt Routing & Deflection Check Point (Protege, 1 Of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 28: Identifying Drive Belt Routing & Deflection Check Point (Protege, 2 Of 2)

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENT SPECIFICATIONS

NOTE: Check belt deflection when engine is cold, or has bin off for 30 minutes.

DEFLECTION SPECIFICATIONS (MILLENIA, 2.5L)

Application

New Belt

(2)

Alternator

Power Steering Pump

Used Belt

Alternator

Power Steering Pump

Wear Limit

Alternator

Power Steering Pump

(1) Deflection with 22 lbs. (10 kg) pressure applied midway on belt run.

Microsoft

Sunday, July 05, 2009 1:23:44 PM Page 29

(1)

Specification - In. (mm)

0.22-0.25 (5.5-6.5)

0.24-0.27 (6-7)

0.25-0.29 (6.5-7.5)

0.27-0.31 (7-8)

0.31 (8)

0.35 (9)

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

(2) Used on for less than 5 minutes.

DEFLECTION SPECIFICATIONS (1996, MPV)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

(1) Deflection with 22 lbs. (10 kg) pressure applied midway on belt run.

(2) Used on for less than 5 minutes.

DEFLECTION SPECIFICATIONS (1997-98, MPV)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

(1) Deflection with 22 lbs. (10 kg) pressure applied midway on belt run.

(2) Used on for less than 5 minutes.

(1)

Specification - In. (mm)

0.36-0.39 (9-10)

0.16-0.17 (4-4.5)

0.28-0.29 (7-7.5)

0.39-0.47 (10-12)

0.17-0.21 (4.5-5.5)

0.30-0.32 (7.5-8.2)

0.71 (18)

0.33 (8.5)

0.53 (13.5)

Specification - In. (mm)

0.36-0.39 (9-10)

0.18-0.19 (4.5-5)

0.28-0.29 (7-7.5)

0.39-0.47 (10-12)

0.20-0.22 (5-5.6)

0.30-0.32 (7.5-8.2)

0.71 (18)

0.33 (8.5)

0.53 (13.5)

DEFLECTION SPECIFICATIONS (MX-5 MIATA)

Application

Microsoft

Sunday, July 05, 2009 1:23:44 PM Page 30

(1)

Specification - In. (mm)

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

(1) Deflection with 22 lbs. (10 kg) pressure applied midway on belt run.

(2) Used on for less than 5 minutes.

0.22-0.27 (5.5-7)

0.32-0.35 (8-9)

0.24-0.29 (6-7.5)

0.35-0.39 (9-10)

0.31 (8)

0.45 (11.5)

DEFLECTION SPECIFICATIONS (PROTEGE)

Application

New Belt

(2)

Alternator

Power Steering Pump

Used Belt

Alternator

Power Steering Pump

Wear Limit

Alternator

Power Steering Pump

(1) Deflection with 22 lbs. (10 kg) pressure applied midway on belt run.

(2) Used on for less than 5 minutes.

(1)

Specification - In. (mm)

0.22-0.27 (5.5-7)

0.32-0.35 (8-9)

0.24-0.29 (6-7.5)

0.35-0.39 (9-10)

0.31 (8)

0.45 (11.5)

TENSION SPECIFICATIONS (MILLENIA, 2.5L)

Application

New Belt

(2)

Alternator

Power Steering Pump

Used Belt

Alternator

Power Steering Pump

Wear Limit

Microsoft

Sunday, July 05, 2009 1:23:44 PM Page 31

(1)

Specification - Lbs. (kg)

160-190 (70-90)

130-150 (55-70)

110-150 (50-70)

88-120 (40-55)

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Alternator

Power Steering Pump

(1) Measure tension using Tension Gauge (49 9200 020), or equivalent.

(2) Used on for less than 5 minutes.

TENSION SPECIFICATIONS (1996, MPV)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

(1) Measure tension using Tension Gauge (49 9200 020), or equivalent.

(2) Used on for less than 5 minutes.

(1)

99 (45)

77 (35)

Specification - Lbs. (kg)

124-143 (56-65)

115-129 (52-59)

77-85 (35-39)

104-123 (47-56)

97-112 (44-51)

66-74 (30-34)

59 (27)

55 (25)

TENSION SPECIFICATIONS (1997-98, MPV)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

(1) Measure tension using Tension Gauge (49 9200 020), or equivalent.

(2) Used on for less than 5 minutes.

Microsoft

Sunday, July 05, 2009 1:23:44 PM Page 32

(1)

Specification - Lbs. (kg)

124-143 (56-65)

115-129 (52-59)

77-85 (35-39)

104-123 (47-56)

97-112 (44-51)

66-74 (30-34)

59 (27)

55 (25)

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

TENSION SPECIFICATIONS (MX-5 MIATA)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

(1) Measure tension using Tension Gauge (49 9200 020), or equivalent.

(2) Used on for less than 5 minutes.

TENSION SPECIFICATIONS (PROTEGE)

Application

New Belt

(2)

Alternator

Power Steering Pump

Used Belt

Alternator

Power Steering Pump

Wear Limit

Alternator

Power Steering Pump

(1) Measure tension using Tension Gauge (49 9200 020), or equivalent.

(2) Used on for less than 5 minutes.

(1)

Specification - Lbs. (kg)

110-167 (50-76)

110-132 (50-60)

110-158 (50-72)

95-110 (43-50)

77 (35)

55 (25)

Specification - Lbs. (kg)

110-160 (50-76)

110-130 (50-60)

110-150 (50-72)

95-110 (43-50)

77 (35)

55 (25)

TROUBLE SHOOTING

NOTE: Ensure drive belts are not worn, cracked or frayed and are correctly mounted on pulleys. See Fig. 29 .

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 29: Identifying Correct Belt Mounting

Courtesy of MAZDA MOTORS CORP.

B2500, B3000 & B4000

CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause drive belt to come off drive pulleys.

NOTE: Replace belts if tensioner indicates belt is out of adjustment range. DO NOT apply belt dressing to serpentine belt. Use illustration to help align serpentine belt and to check belt routing and tension. See Fig. 15 through Fig. 17 .

To check drive belt for proper operation, with engine running, check drive belt tracking (position of drive belt on one of the grooveless pulleys, idlers or drive belt tensioner). If edge of drive belt rides beyond edge of pulley, noise and premature wear may result. If a drive belt tracking condition exists, visually check drive belt tensioner for damage, especially mounting pad surface. If drive belt tensioner is not installed correctly with locating pins in locating holes, mounting surface pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal noises.

If above procedures do not correct drive belt noise, try replacing drive belt with a known good drive belt.

However, drive belt noise may return, with mileage, if one of above conditions still exists uncorrected.

Microsoft

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

With engine running, visually observe grooves in pulleys (not pulley flanges) for excessive wobble. Replace components as required. Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent component from mounting properly. Correct any interference conditions and recheck belt tracking. Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification.

Replace drive belt is excessive cracking or wear, severe glazing or frayed cords are present. Minor cracks in back of drive belt are considered acceptable.

SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS (1997 2300)

Model

B2300

Coolant Replacement

Interval

Specification

(1)

50,000 Miles Or 48

Months

Coolant Capacity

With A/C

Without A/C

Pressure Cap

Thermostat Open Temperature

Starts

Fully Open

Thermostat Open Lift

(1) Every 30,000 miles, and every 36 months thereafter.

7.2 Qts. (6.8L)

6.5 Qts. (6.2L)

12 psi

192°F (89°C)

212°F (100°C)

.13" (3.2 mm)

COOLING SYSTEM SPECIFICATIONS (1998 B2500, B3000 & B4000)

Model

B2500

Coolant Replacement

Interval

Coolant Capacity

With A/C

Without A/C

Pressure Cap

Thermostat Open Temperature

Starts

Fully Open

Thermostat Open Lift

Microsoft

Sunday, July 05, 2009 1:23:44 PM

Specification

(1)

50,000 Miles Or 48

Months

7.2 Qts. (6.8L)

6.5 Qts. (6.2L)

14.4-17.6 psi

Page 35

183-190°F (84-88°C)

212°F (100°C)

.13" (3.2 mm)

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

B3000

Coolant Replacement

Interval

Coolant Capacity

With A/C

Without A/C

Pressure Cap

Thermostat Open Temperature

Starts

Fully Open

Thermostat Open Lift

B4000

Coolant Replacement

Interval

Coolant Capacity

With A/C

Without A/C

Pressure Cap

1997

1998

Thermostat Open Temperature (1997)

Starts

Fully Open

Thermostat Open Lift (1997)

Thermostat Open Temperature (1998)

Starts

Fully Open

Thermostat Open Lift (1998)

(1) Every 30,000 miles, and every 36 months thereafter.

(1)

183-190°F (84-88°C)

(1)

50,000 Miles Or 48

Months

10.2 Qts. (9.6L)

9.5 Qts. (9.0L)

14.4-17.6 psi

212°F (100°C)

.13" (3.2 mm)

50,000 Miles Or 48

Months

8.6 Qts. (8.1L)

7.8 Qts. (7.4L)

12 psi

14.4-17.6 psi

192°F (89°C)

212°F (100°C)

.13" (3.2 mm)

183-190°F (84-88°C)

212°F (100°C)

.13" (3.2 mm)

COOLING SYSTEM SPECIFICATIONS (1994-97 MIATA)

Model

Miata

Coolant Replacement

1994-95

Interval

1996-97

Interval

Microsoft

Sunday, July 05, 2009 1:23:44 PM Page 36

Specification

24,000 Miles Or 30 Months

(1)

45,000 Miles Or 36

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Coolant Capacity

Pressure Cap

Thermostat Open Temperature

Starts

Main Valve

Sub Valve

Fully Open

Thermostat Open Lift

Main Valve

Sub Valve

(1) Every 30,000 miles, and every 24 months thereafter.

COOLING SYSTEM SPECIFICATIONS (1997-98 MILLENIA)

Model

Millenia

Coolant Replacement

Interval

Coolant Capacity

Pressure Cap

Thermostat Open Temperature

Starts

Fully Open

Thermostat Open Lift

(1) Every 30,000 miles, and every 24 months thereafter.

188-193°F (86.5-89.5°C)

183-188°F (83.5-86.5°C)

(1)

Months

6.3 Qts. (6.0L)

10.7-14.9 psi

212°F (100°C)

.31" (8 mm)

.06" (1.5 mm)

Specification

45,000 Miles Or 36

Months

7.9 Qts. (7.5L)

13.5-17.7 psi

176-183°F (80-84°C)

203°F (95°C)

.33" (8.5 mm)

COOLING SYSTEM SPECIFICATIONS (1997-98 MPV)

Model

MPV

Coolant Replacement

Interval

Coolant Capacity

Pressure Cap

Thermostat Open Temperature (1997)

Starts

Fully Open

Thermostat Open Lift (1997)

Thermostat Open Temperature (1998)

Microsoft

Sunday, July 05, 2009 1:23:44 PM

Specification

(1)

45,000 Miles Or 36

Months

10.3 Qts. (9.7L)

10.7-14.9 psi

179-184°F (81.5-84.5°C)

205°F (96°C)

.35" (9.0 mm)

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Starts

Fully Open

Thermostat Open Lift (1998)

(1) Every 30,000 miles, and every 24 months thereafter.

COOLING SYSTEM SPECIFICATIONS (1995-98 PROTEGE)

Model

Protege

Coolant Replacement

1995

Interval

1996-98

Interval

Coolant Capacity

Pressure Cap

Thermostat Open Temperature (1995)

Starts

Main Valve

Sub Valve

Fully Open

Thermostat Open Lift (1995)

Main Valve

Sub Valve

Thermostat Open Temperature (1996-98)

Starts

Fully Open

Thermostat Open Lift (1996-98)

(1) Every 30,000 miles, and every 24 months thereafter.

176-183°F (80-84°C)

203°F (95°C)

.33" (8.5 mm)

Specification

24,000 Miles Or 30 Months

(1)

45,000 Miles Or 36

Months

6.3 Qts. (6.0L)

10.7-14.9 psi

188-193°F (86.5-89.5°C)

183-188°F (83.5-86.5°C)

212°F (100°C)

.31" (8 mm)

.06" (1.5 mm)

183-193°F (83.5-89.5°C)

212°F (100°C)

.33" (8.5 mm)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (MILLENIA, 2.5L)

Application

Alternator Locknut

Power Steering Pump Locknut

TORQUE SPECIFICATIONS (MPV)

Application

Alternator Adjusting Bolt

Microsoft

Sunday, July 05, 2009 1:23:44 PM

Ft. Lbs. (N.m)

24-33 (32-46)

Ft. Lbs. (N.m)

1994 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

"A"

"B"

A/C Compressor Locknut

Power Steering Pump Locknut

TORQUE SPECIFICATIONS (MX-3 MIATA)

Application

Alternator Adjusting Bolt

"A"

"B"

A/C Compressor Locknut

Power Steering Pump Bolt

"A"

"B"

"C"

TORQUE SPECIFICATIONS (PROTEGE)

Application

Alternator Adjusting Bolt

"A"

"B"

Power Steering Pump Bolt

"A"

"B"

"C"

14-18 (19-25)

28-38 (38-51)

Ft. Lbs. (N.m)

14-18 (19-25)

28-38 (38-51)

24-33 (32-46)

27-39 (37-53)

14-18 (19-25)

Ft. Lbs. (N.m)

28-38 (38-51)

14-18 (19-25)

32-44 (44-60)

28-38 (38-51)

Microsoft

SUSPENSION - FRONT 1994 SUSPENSION Mazda - Front

SUSPENSION - FRONT

1994 SUSPENSION Mazda - Front

DESCRIPTION

An independent front suspension with MacPherson-type struts is used on all models. Miata uses double wishbone design upper and lower control arms with struts mounted between lower control arm and upper fender panel. See Fig. 1 .

Lower control arm pivots at crossmember and is connected by ball joint to steering knuckle. All models are equipped with a stabilizer bar which attaches to each lower control arm and frame.

Fig. 1: Front Suspension Components

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

NOTE: See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the

WHEEL ALIGNMENT section.

WHEEL BEARING

Raise and support vehicle. Remove wheel assembly. Remove brake caliper and wire aside. Remove rotor.

Attach dial indicator to axle hub and measure bearing play. Check bearing axial play by rocking hub assembly by hand. Maximum axial play should be .002" (.05 mm). If play exceeds specification, check and adjust lock nut torque or replace hub and bearing assembly.

1994 Mazda MX-5 Miata

SUSPENSION - FRONT 1994 SUSPENSION Mazda - Front

INSPECTION

BALL JOINT CHECKING

Lower Ball Joint

Remove lower control arm. Rotate ball joint stud 3-4 times. Install Preload Attachment (49-0180-510B) to ball joint stud. Measure ball joint preload using spring scale. Preload should be 1.1-3.3 lbs. (0.5-1.5 kg).

Upper Ball Joint

Remove upper control arm. Rotate ball joint stud 3-4 times. Install Preload Attachment (49-0180-510B) to ball joint stud. Measure ball joint preload using spring scale. Preload should be 0.9-4.0 lbs. (0.4-1.8 kg).

REMOVAL & INSTALLATION

NOTE: Refer to Fig. 1 during removal and installation.

WHEEL BEARING

NOTE: Replace hub and bearing assembly as a unit.

Removal

Raise and support vehicle. Remove wheel assembly. Remove brake caliper and wire aside. Remove grease cap and axle lock nut. Remove brake rotor. Remove hub and bearing assembly. Remove wheel speed sensor rotor from hub.

Inspection

Wash all disassembled components before inspection. Check for damage, excessive wear and signs of bearing seizure. Inspect steering knuckle and hub for cracks, scoring and rust. Check for damaged dust cover and poor fit with steering knuckle. Replace components as necessary.

Installation

To install, reverse removal procedure. Adjust wheel bearing preload. See WHEEL BEARING under

ADJUSTMENTS.

LOWER CONTROL ARM & BALL JOINT

Removal

1. Raise and support vehicle. Remove wheel assembly. Remove engine splash shield (if equipped). Remove brake caliper and wire aside (as necessary). Remove compression rod or tension rod (if equipped).

Separate tie rod end from knuckle (as necessary). Remove stabilizer bar from lower control arm.

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1994 Mazda MX-5 Miata

SUSPENSION - FRONT 1994 SUSPENSION Mazda - Front

2. Remove strut lower mounting bolt and separate lower strut from lower control arm or knuckle. Remove lower control arm ball joint cotter pin and nut. Separate lower control arm ball joint stud from knuckle.

Remove lower control arm pivot bolts and remove lower control arm.

Inspection

Check lower control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check ball joint for excessive wear. Examine dust boot for damage. Replace components as necessary.

Bushing Replacement

Cut or press old bushing from control arm. Coat NEW bushing with paraffin-based oil. Press NEW bushing into control arm.

Installation

To install, reverse removal procedure. Tighten lower control arm-to-frame bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS table.

UPPER CONTROL ARM & BALL JOINT

Removal

Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor harness band. Remove strut lower mounting bolt and separate lower strut from lower control arm. Remove upper control arm ball joint cotter pin and nut. Separate upper control arm ball joint stud from knuckle using

Puller (49-0118-850C). Remove upper control arm pivot bolts and remove upper control arm.

Inspection

Check upper control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check ball joint for excessive wear. Examine dust boot for damage. Replace components as necessary.

Bushing Replacement

Cut or press old bushing from control arm. Coat NEW bushing with paraffin-based oil. Press NEW bushing into control arm.

Installation

To install, reverse removal procedure. Tighten upper control arm pivot bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS table.

STRUT ASSEMBLY

Removal

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1994 Mazda MX-5 Miata

SUSPENSION - FRONT 1994 SUSPENSION Mazda - Front

Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor harness band. Remove stabilizer link bolt. Remove upper control arm ball joint cotter pin and nut. Separate upper control arm ball joint stud from knuckle using Puller (49-0118-850C). Loosen lower control arm pivot bolts. Remove strut upper mount nuts and lower bolt. Move lower control arm just enough to remove strut assembly. Be careful not to damage brake line.

NOTE: Prior to removing strut-to-steering knuckle bolts, make an alignment mark for reassembly reference. Note position of mounting mark on top of strut assembly before removing strut.

Disassembly

Clamp upper strut mount in vise. Loosen piston lock nut 2 turns only. Compress coil spring using coil spring compressor. Remove piston lock nut. Slowly release compressor tension. Remove components. Remove coil spring. Remove strut from vise.

Inspection

Check strut tube for damage, oil leakage and abnormal noise. Check rubber components for deterioration or damage. Inspect coil spring for signs of fatigue or damage. Replace components as necessary.

Reassembly

Clamp strut in vise. Install coil spring and components in reverse order of disassembly. Ensure coil spring is well seated in upper and lower spring seats.

Installation

To install, reverse removal procedure.

STABILIZER BAR

Removal & Installation

1. Raise and support vehicle. Remove engine splash shield (if equipped). Remove mounting hardware and stabilizer bar. Note position of frame bushing seam.

2. Inspect all components for wear, bends or damage. Replace components as necessary.

3. To install, reverse removal procedure. Ensure frame bushing is aligned with White line on stabilizer bar.

Ensure seam faces front of vehicle. Fully tighten all bolts with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS table.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Brake Caliper Bracket Bolts

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Sunday, July 05, 2009 1:13:51 PM Page 4

Ft. Lbs. (N.m)

36-51 (49-69)

1994 Mazda MX-5 Miata

SUSPENSION - FRONT 1994 SUSPENSION Mazda - Front

Drive Axle Lock Nut

Lower Ball Joint-To-Knuckle Nut

Lower Ball Joint-To-Lower Control Arm Bolts/Nut

Lower Control Arm-To-Frame Front Adjusting Bolt Lock Nut

Rear Adjusting Bolt Lock Nut

Stabilizer Bar Bracket-To-Frame Bolts

Stabilizer Bar-To-Stabilizer Link Bolt

Stabilizer Link-To-LowerControl Arm Bolt

Strut Assembly Lock Nut

Strut Assembly-To-Lower Control Arm Bolt/Nut

Strut Upper Mount Nuts

Tie Rod-To-Knuckle Nut

Upper Ball Joint-To-Knuckle Nut

Upper Control Arm Pivot Bolt/Nut

Wheel Lug Nuts

Wheel Speed Sensor Bolt

123-159 (167-216)

42-57 (57-77)

54-69 (73-93)

69-83 (93-113)

61-76 (83-103)

13-19 (18-26)

27-40 (36-54)

21-27 (29-36)

54-69 (73-93)

21-27 (29-36)

21-32 (29-44)

30-45 (41-61)

87-101 (118-137)

65-87 (88-118)

12-17 (16-23)

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1994 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

1994 ELECTRICAL

Fuses & Circuit Breakers - MX-5 Miata

IDENTIFICATION

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN

PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

MAIN FUSE BLOCK

Main fuse block is located on passenger's side of engine compartment. See Fig. 1 .

Fig. 1: Locating Main Fuse Block

1994 Mazda MX-5 Miata

1994 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Fig. 2: Identifying Main Fuse Block Components

Courtesy of MAZDA MOTORS CORP.

Fig. 3: Main Fuse Block Legend

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

FUSE BLOCK

Fuse block is located under driver's side of instrument panel. See Fig. 4 .

Fig. 4: Locating Fuse Block

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

1994 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 5: Identifying Fuse Block Components

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

1994 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 6: Fuse Block Legend

Courtesy of MAZDA MOTORS CORP.

TRUNK FUSE PANEL

Trunk fuse panel is located on passenger's side of trunk. See Fig. 7 .

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1994 Mazda MX-5 Miata

1994 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 7: Locating Trunk Fuse Panel

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

1994 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 8: Identifying Trunk Fuse Panel Components & Legend

Courtesy of MAZDA MOTORS CORP.

Microsoft

HEATER SYSTEM 1994 Heater System

HEATER SYSTEM

1994 Heater System

DESCRIPTION & OPERATION

Heater case, mounted under center of instrument panel, contains airflow mode doors and air-mix (temperature blend) doors. See Fig. 1 . Blower case, mounted under right side of instrument panel, contains blower motor, blower resistor and fresh/recirculated air door. All doors are controlled manually from control panel by cable.

Blower resistors, located on bottom of blower case, determine blower speed.

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section.

CAUTION: When battery is disconnected, radio will go into anti-theft protection mode. Obtain radio anti-theft protection code from owner prior to servicing vehicle.

1994 Mazda MX-5 Miata

HEATER SYSTEM 1994 Heater System

Fig. 1: Exploded View Of Heater Unit

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

AIRFLOW MODE DOOR

Set airflow mode control lever at vent position. Disconnect control cable at airflow mode door lever. See Fig.

1 . Extend airflow mode door lever until it stops. Attach control cable to door lever. Secure cable using clip.

Ensure control lever slides freely between defrost and vent positions.

AIR-MIX (TEMPERATURE BLEND) DOOR

Set temperature control lever at maximum hot setting. Disconnect control cable at air-mix door lever. See Fig.

1 . Extend air-mix door lever until it stops. Attach control cable to door lever. Secure cable using clip. Ensure control lever slides freely between hot and cold settings.

FRESH/RECIRCULATED AIR DOOR

Set fresh/recirculated air control lever at fresh air setting. Disconnect control cable at fresh/recirculated air door lever. Retract recirculated/fresh air door lever until it stops. Attach control cable to door lever. Secure cable using clip. Ensure control lever slides freely between recirculated air and fresh air settings.

TESTING

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section.

BLOWER MOTOR CIRCUIT

1. Check 30-amp HEATER circuit breaker in passenger compartment fuse block. If Red button has not popped out, go to next step. If Red button has popped out, repair short circuit in wiring harness, then press Red button to reset circuit breaker.

2. Turn ignition on. Turn blower switch to 4th position (high). Using voltmeter, backprobe Blue wire terminal of blower motor connector on bottom of blower case. If battery voltage exists, go to next step. If battery voltage is not present, repair wiring harness between circuit breaker and blower motor.

3. Ensure ignition is on. Backprobe Blue wire terminal of blower resistor 1-pin connector. If battery voltage exists, go to next step. If battery voltage is not present, replace blower motor.

4. Backprobe Blue/White wire terminal of blower resistor 4-pin connector. If battery voltage exists, go to next step. If battery voltage is not present, replace blower resistor.

5. Backprobe Blue/Red wire terminal of blower resistor 4-pin connector. If battery voltage exists, go to next step. If battery voltage is not present, replace blower resistor.

6. Backprobe Blue/Green wire terminal of blower resistor 4-pin connector. If battery voltage exists, go to

Microsoft

1994 Mazda MX-5 Miata

HEATER SYSTEM 1994 Heater System next step. If battery voltage is not present, replace blower resistor.

7. Backprobe Blue/Yellow wire terminal of blower resistor 4-pin connector. If battery voltage exists, go to next step. If battery voltage is not present, replace blower resistor.

8. Turn blower switch to 4th position (high). Backprobe Black wire terminal of blower switch connector. If battery voltage is not present, go to next step. If battery voltage exists, repair Black wire between blower switch and body ground.

9. Turn ignition blower switch off. Backprobe Blue/White wire terminal of blower switch connector. If battery voltage exists, go to next step. If battery voltage is not present, repair Blue/White wire between blower resistor and blower switch.

10. Backprobe Blue/Red wire terminal of blower switch connector. If battery voltage exists, go to next step.

If battery voltage is not present, repair Blue/Red wire between blower resistor and blower switch.

11. Backprobe Blue/Green wire terminal of blower switch connector. If battery voltage exists, go to next step.

If battery voltage is not present, repair Blue/Green wire between blower resistor and blower switch.

12. Backprobe Blue/Yellow wire terminal of blower switch connector. If battery voltage exists, replace blower switch. If battery voltage is not present, repair Blue/Yellow wire between blower resistor and blower switch.

BLOWER MOTOR

Disconnect blower motor 2-pin connector from bottom of blower case. Apply battery voltage across blower motor terminals. Replace blower motor if it does not operate.

BLOWER RESISTOR

Disconnect blower resistor connectors from blower case. Check continuity, in turn, between Blue wire terminal of 1-pin connector and each terminal of 4-pin connector. Ensure continuity exists. Replace resistor if continuity does not exist.

BLOWER SWITCH

Disconnect blower switch connector. Place blower switch in indicated positions, and check continuity between specified blower switch terminals. See BLOWER SWITCH TEST table. See Fig. 2 . If continuity is not as specified, replace blower switch.

BLOWER SWITCH TEST

Switch Position

Off

Low

Medium-Low

Medium-High

High

(1) There should not be continuity between any terminals.

Continuity Between Terminals

(1)

"A" & "G"

"C", "G" & "H"

"E", "G" & "H"

"B", "G" & "H"

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1994 Mazda MX-5 Miata

HEATER SYSTEM 1994 Heater System

Fig. 2: Identifying Blower Switch Terminals

Courtesy of MAZDA MOTORS CORP.

REMOVAL & INSTALLATION

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section.

BLOWER UNIT

Removal & Installation

Remove glove box. Disconnect electrical connectors. Loosen seal plate between blower unit and evaporator unit

(if equipped). Remove blower unit bolts and blower unit. Disassemble blower unit to remove blower motor and blower resistor. To install, reverse removal procedure.

CONTROL PANEL

Removal & Installation

Remove rear center console. Remove vent outlets from center panel. Remove center panel. Remove control panel screws, and pull control panel from center panel. Disconnect heater control cables. To install, reverse removal procedure.

HEATER CORE

Removal & Installation

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1994 Mazda MX-5 Miata

HEATER SYSTEM 1994 Heater System

Drain coolant. Disconnect heater hoses at engine compartment firewall. Remove grommets from holes (if equipped). Remove instrument panel. See REMOVAL & INSTALLATION in A/C-HEATER SYSTEM -

MANUAL article in the AIR CONDITIONING & HEAT section. Remove heater unit. Disassemble heater unit to remove heater core. See Fig. 1 . To install, reverse removal procedure. Fill cooling system.

WIRING DIAGRAM

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1994 Mazda MX-5 Miata

HEATER SYSTEM 1994 Heater System

Microsoft

1994 Mazda MX-5 Miata

HEATER SYSTEM 1994 Heater System

Fig. 3: Heater System Wiring Diagram

Microsoft

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

A/C-HEATER SYSTEM - MANUAL

1994 Manual A/C-Heater Systems

A/C SYSTEM SPECIFICATIONS

MANUAL A/C SYSTEM SPECIFICATIONS

Application

Compressor Type

Specification

Nippondenso TV12 Rotary

Vane

Compressor Belt Deflection

(1)

New

Used

Compressor Oil Capacity

(2)

Refrigerant Capacity

System Operating Pressures

High Side

5/16-23/64" (8-9 mm)

23/64-25/64" (9-10 mm)

3.9-5.1 ozs.

21.2 ozs.

Low Side

200-227 psi (14.0-16.0 kg/cm

)

22-35 psi (1.5-2.5 kg/cm

)

(1) Measure with 22-lb. (10 kg) pressure applied halfway between crankshaft pulley and Power Steering

(P/S) pulley or idler pulley (without P/S).

(2) Use ND-Oil 9 refrigerant oil.

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section.

CAUTION: When battery is disconnected, radio will go into anti-theft protection mode. Obtain radio anti-theft protection code from owner prior to servicing vehicle.

DESCRIPTION

Blower assembly, mounted under right side of instrument panel, contains blower motor, blower resistor and fresh/recirculated air door. Evaporator unit, located left of blower case, contains evaporator, evaporator thermoswitch and expansion valve. Heater unit, located left of evaporator case, contains heater core, airflow mode door and air-mix (temperature blend) door.

ELECTRICAL COMPONENT LOCATIONS

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

Component

Relay

A/C

Condenser Fan

Blower Resistor

Evaporator Thermoswitch

Pressure Switch

Receiver-Drier And Evaporator

Location

Right Front Corner Of

Engine Compartment

Right Front Corner Of

Engine Compartment

Bottom Of Blower Case

On Evaporator Upper Case

In High-Pressure Line, Between

OPERATION

All air control doors are controlled manually by cable from control panel. Blower resistor determines blower speed. With blower switch in high position, blower motor is grounded directly through blower switch. With blower switch in all other positions, blower motor is grounded through blower resistor and blower switch.

A/C compressor clutch circuit is completed when A/C relay is energized and pressure switch is closed. A/C relay is energized when Engine Control Unit (ECU) grounds the solenoid circuit of the relay. The ECU energizes A/C relay if evaporator thermoswitch is closed and A/C and blower switches are on. The ECU also controls A/C relay operation according to engine load.

ADJUSTMENTS

NOTE: For door control cable adjustments, see ADJUSTMENTS in HEATER SYSTEM article in the AIR CONDITIONING & HEAT section.

TESTING

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section.

NOTE: For test procedures not covered in this article, see TESTING in HEATER

SYSTEM article in the AIR CONDITIONING & HEAT section.

A/C SYSTEM PERFORMANCE

1. Connect manifold gauge set. Operate engine at 1500 RPM. Operate A/C at maximum cooling. Open all doors and windows. Place thermometers at center vent outlet and blower inlet.

2. Allow A/C to stabilize. Ensure blower inlet temperature is 86-95°F (30-35°C), and high pressure is 200-

227 psi (14.0-16.0 kg/cm

). Calculate difference between blower inlet temperature and center vent outlet

Microsoft

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems temperature. Read temperatures at center vent outlet and blower inlet. Compare temperature difference to relative humidity. Ensure values are within specified range. See appropriate A/C SYSTEM

PERFORMANCE table.

A/C SYSTEM PERFORMANCE

Temperature °F (°C)

(1)

70-81 (21-27)

63-73 (17-23)

57-68 (14-20)

52-63 (11-17)

(1) Difference between blower inlet temperature and center vent outlet temperature.

Relative Humidity (%)

A/C COMPRESSOR CLUTCH CIRCUIT

1. Check 20-amp WIPER fuse in passenger compartment fuse block. Check 20-amp AD FAN (additional fan) fuse in engine compartment fuse block. If fuses are okay, go to next step. If either fuse is blown, check for shorted wiring harness before replacing fuse.

2. Operate engine at idle. Turn A/C and blower on. Using voltmeter, backprobe Black/Red wire terminal of compressor clutch connector. If battery voltage exists, replace compressor clutch. If battery voltage is not present, go to next step.

3. Ensure engine is running. Ensure A/C and blower are on. Using voltmeter, backprobe Blue/Yellow wire terminal of A/C relay connector. If battery voltage exists, go to next step. If battery voltage is not present, repair wiring harness between AD FAN fuse and A/C relay.

4. Backprobe Blue wire terminal of A/C relay connector. If battery voltage exists, test A/C relay. See A/C

RELAY. If relay is okay, repair wiring harness between A/C relay and compressor clutch. If battery voltage is not present, repair open Blue wire between WIPER fuse and A/C relay.

CONDENSER (ADDITIONAL) FAN CIRCUIT

1. Check AD FAN (additional fan) fuse in engine compartment fuse block and power window fuse (3-amp) in passenger compartment fuse block. If fuses are okay, go to next step. If either fuse is blown, check for shorted wiring harness before replacing fuse.

2. Turn ignition on. Using voltmeter, backprobe Black/Yellow wire terminal of condenser fan motor connector. If battery voltage exists, go to next step. If battery voltage is not present, test condenser fan relay. See CONDENSER FAN RELAY . If relay is okay, go to step 4).

3. Disconnect condenser fan connector. Check continuity between Black wire terminal of condenser fan motor connector and ground. If continuity exists, replace condenser fan motor. If continuity does not exist, repair wiring harness between condenser fan motor and ground.

4. Turn ignition off. Check continuity of Black/Yellow wire between condenser fan motor connector and condenser fan relay connector. If continuity exists, repair wiring harness between AD FAN fuse and 30amp power window fuse. if continuity is not present, repair open Black/Yellow wire between condenser fan motor and condenser fan relay.

A/C SWITCH

Microsoft

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

Disconnect A/C switch connector. Turn A/C switch on. Check continuity between indicated terminals. See A/C

SWITCH TEST table. See Fig. 1 . Replace A/C switch if continuity is not as specified.

A/C SWITCH TEST

Terminal

"D" & "A"

"F" & "A"

(1) Continuity exists in only one direction.

Continuity

(1)

Yes

(1)

Yes

Fig. 1: Identifying A/C Switch Terminals

Courtesy of MAZDA MOTORS CORP.

A/C RELAY

Remove relay. Check continuity between indicated relay terminals. See A/C RELAY TEST table. See Fig. 2 .

Replace relay if continuity is not as specified.

A/C RELAY TEST

Test Between Terminals

"A" & "B"

"C" & "D"

(1) With no voltage applied.

(2) With battery voltage applied to terminals "A" and "B".

Continuity

(1)

(2)

Yes

Microsoft

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

Fig. 2: Identifying A/C Relay Terminals

Courtesy of MAZDA MOTORS CORP.

CONDENSER FAN RELAY

Remove condenser fan relay. Check continuity between indicated relay terminals. See CONDENSER FAN

RELAY TEST table. See Fig. 3 . If continuity is not as specified, replace relay.

CONDENSER FAN RELAY TEST

Test Between Terminals

"A" & "B"

"C" & "E"

"C" & "F"

"C" & "E"

(1) With no voltage applied.

(2) With battery voltage applied to terminals "A" and "B".

Continuity

(1)

(2)

Yes

Microsoft

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

Fig. 3: Identifying Condenser Fan Relay Terminals

Courtesy of MAZDA MOTORS CORP.

CONDENSER FAN MOTOR

Disconnect condenser fan motor connector. Connect positive battery lead to condenser fan motor Black/Yellow wire terminal, and ground Black wire terminal. Replace condenser fan motor if it does not operate.

EVAPORATOR THERMOSWITCH

1. Remove glove box. Operate engine at idle. Turn A/C off. Turn blower switch to 4th position (high) for a few minutes to ensure evaporator temperature is greater than 32°F (0°C). Turn blower switch and engine off.

2. Disconnect evaporator thermoswitch connector. Check continuity between thermoswitch terminals. If continuity exists, go to next step. If there is no continuity, replace thermoswitch.

3. Submerge thermoswitch sensing bulb in ice cold water of less than 32°F (0°C). Ensure continuity does not exist between thermoswitch terminals. Replace thermoswitch if continuity is not as specified.

PRESSURE SWITCH

1. Turn ignition off. Connect manifold pressure gauge set to system. If high-side pressure is 30-370 psi (2.3-

26.0 kg/cm

), go to next step. If pressure is not as specified, check refrigerant level.

2. Disconnect pressure switch connector. Check continuity between switch terminals. If continuity exists, pressure switch is okay. If there is no continuity, replace pressure switch.

REMOVAL & INSTALLATION

Microsoft

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in the appropriate AIR BAG RESTRAINT

SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section.

NOTE: For removal and installation procedures not covered in this article, see HEATER

SYSTEM article in the AIR CONDITIONING & HEAT section.

COMPRESSOR

Removal & Installation

1. Before disconnecting negative battery cable, obtain radio anti-theft code from vehicle owner. Disconnect negative battery cable.

2. Raise and support front of vehicle with safety stands. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove splash shield and air guide.

3. Disconnect compressor clutch connector. Disconnect refrigerant lines from compressor, and plug open fittings. Remove compressor drive belt. Remove compressor bolts and compressor. To install, reverse removal procedure. Adjust drive belt deflection. Apply clean compressor oil to "O" ring before connecting fittings. DO NOT apply oil to fitting nuts. Evacuate and charge A/C system.

CONDENSER & RECEIVER-DRIER

Removal

Raise and support front of vehicle with safety stands. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove splash shield and air guide. Remove condenser. Remove receiver-drier.

Plug open fittings.

Installation

To install, reverse removal procedure. Apply clean compressor oil to "O" rings before connecting fittings. DO

NOT apply compressor oil to fitting nuts. If installing new compressor, add .9 ounce of new compressor oil. If installing new receiver-drier, add .3 ounce of new compressor oil. Evacuate and charge A/C system.

EVAPORATOR UNIT

Removal

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant pipes from evaporator tubes at engine compartment firewall, and plug open fittings. Remove passengerside instrument panel undercover. Remove glove box.

2. Disconnect electrical connectors. Loosen seal plates between evaporator unit, heater unit and blower unit.

Remove evaporator unit. Disassemble evaporator unit to remove evaporator core and thermo-switch. See

Fig. 4 .

Microsoft

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

Installation

To install, reverse removal procedure. Apply clean compressor oil to "O" rings before connecting fittings. DO

NOT apply compressor oil to fitting nuts. Evacuate and charge A/C system.

Fig. 4: Exploded View Of Evaporator Unit

Courtesy of MAZDA MOTORS CORP.

INSTRUMENT PANEL

Removal & Installation

Before disconnecting negative battery cable, obtain radio anti-theft code from vehicle owner. Disconnect

Microsoft

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems negative battery cable. Remove components in the order listed in illustration. See Fig. 5 . To install, reverse removal procedure.

Fig. 5: Exploded View Of Instrument Panel

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Compressor Bracket-To-Engine Bolt

Compressor-To-Compressor Bracket Bolt

Refrigerant Pipe Fittings

Condenser Inlet

Evaporator Outlet

Evaporator Unit Nut

Refrigerant Pipe Fittings

Compressor Inlet & Outlet

Evaporator Inlet

Receiver-Drier Inlet & Outlet

Steering Wheel Nut

WIRING DIAGRAM

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Sunday, July 05, 2009 1:18:03 PM

Ft. Lbs. (N.m)

28-38 (38-51)

11-15 (15-21)

11-18 (15-24)

15-21 (20-29)

INCH Lbs. (N.m)

71-97 (8-11)

89-132 (10-15)

89-168 (10-19)

79-121 (9-14)

1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

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1994 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1994 Manual A/C-Heater Systems

Fig. 6: Manual A/C-Heater System Wiring Diagram

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MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

MAINTENANCE INFORMATION

1990-95 MAINTENANCE Mazda Maintenance Information

MODEL IDENTIFICATION

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

Fig. 1: VIN Code ID Explanation

1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

MAINTENANCE SERVICE INFORMATION

SEVERE & NORMAL SERVICE DEFINITIONS

NOTE: Use the Severe Service schedule if the vehicle to be serviced is operated under

ANY (one or more) of these conditions:

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on following primary operating conditions:

Normal Service



Driven More Than 10 Miles Daily

No Operating Conditions From Severe Service Schedule

Severe Service (Unique Driving Conditions)



Repeated Short Distance Driving

Dusty Conditions



Extended Use Of Brakes

Salt Or Other Corrosive Materials On The Roads



Rough Or Muddy Roads

Extended Idling Or Low Speed Operation



Extended Operation In Extreme Temperatures

CAMSHAFT TIMING BELT

CAUTION: Failure to replace a faulty camshaft timing belt may result in serious engine damage.

The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called "Free Wheeling".

Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.

Belts or components should be inspected and replaced if any of the following conditions exist:



Cracks Or Tears In Belt Surface

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information



Missing, Damaged, Cracked Or Rounded Teeth



Oil Contamination

Damaged Or Faulty Tensioners



Incorrect Tension Adjustment

Replace camshaft timing belt at 60,000 mile intervals.

SERVICE POINT LOCATIONS

Fig. 2: Service Point Locations

Courtesy of MAZDA MOTOR OF AMERICA, INC.

INFORMATION LABEL LOCATIONS

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

Fig. 3: Information Label Locations

Courtesy of MAZDA MOTOR OF AMERICA, INC.

SERVICE LABOR TIMES

NOTE: Labor times are provided, where available, within appropriate SERVICE

INTERVAL table in SCHEDULED SERVICES article.

WHEEL & TIRE SPECIFICATIONS

WHEEL TIGHTENING

Tighten wheel lug nuts to 65-87 ft. lbs. (88-118 N.m).

BATTERY SPECIFICATIONS

CAUTION: When battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in the

GENERAL INFORMATION Section.

Vehicle is equipped with a special 9 9/16" x 4 3/4" x 7 3/8" 12-volt battery that is vented to outside of vehicle.

CAUTIONS & WARNINGS

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

NOTE: See the AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY

EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental

Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAG

RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section.

CAUTION: Disconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger's side of vehicle in case of accidental air bag inflation

AIR CONDITIONING SERVICING

CAUTION: Avoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-

134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.

WARNING: R-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See the appropriate A/C SYSTEM GENERAL SERVICING article in the AIR

CONDITIONING & HEAT section.

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions:



DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK

BRAKE SYSTEM article in the BRAKES Section.

DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

 acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.

Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

BATTERY WARNING

WARNING: When battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See appropriate COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section below.

REPLACING BLOWN FUSES

CAUTION: Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD WEAR INDICATOR

CAUTION: Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

CAUTION: Continued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.

CAUTION: Any modification to the exhaust system on turbo models, which reduces exhaust backpressure, will lead to lean fuel mixtures and excessive spark advance. This could cause serious engine damage.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNING: Many solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not.

Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

ENGINE OIL

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

CAUTION: Never use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNING: Relieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

Halogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

HEADLIGHT RETRACTOR

CAUTION: If headlight retractor freezes during cold weather operation, DO NOT attempt to force mechanism. Headlights should be kept raised at all times in cold weather. To raise them, use only headlight retractor switch. DO

NOT use headlight switch.

RADIATOR CAP

CAUTION: Always disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNING: Keep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

WARRANTY INFORMATION

CAUTION: Always refer to customer's copy of warranty information for specific model application and/or coverage limitations.

BASIC NEW CAR WARRANTY

Basic components are warranted against defects in materials and workmanship for 36 months or 50,000 miles, whichever occurs first. Tires are covered by a separate warranty offered by tire manufacturer.

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

ANTI-PERFORATION WARRANTY

Covers body sheet metal panels for 60 months, regardless of mileage, against perforation due to corrosion.

SAFETY RESTRAINT SYSTEM WARRANTY

Supplemental air bag system, seat belts and related components are warranted for 5 years or 60,000 miles, whichever comes first, against defects in materials and workmanship.

REPLACEMENT PARTS & ACCESSORIES

Manufacturer-supplied parts and accessories are warranted against defects in material or workmanship for 12 months without regard to mileage. If installed by a Mazda dealer, part or accessory will be repaired or replaced without charge during warranty period. If not installed by a dealer, part or accessory will be repaired or replaced without charge for parts, but labor cost will be responsibility of owner.

EMISSION DEFECT WARRANTY (EXCEPT CALIFORNIA)

Warrants that vehicle was designed, built and equipped to conform with applicable Federal emission regulations at time of sale and that vehicle is free of defects in materials and workmanship which may cause vehicle to fail to conform with applicable regulations for 5 years or 50,000 miles, whichever occurs first.

EMISSION PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)

Covers all repairs, adjustments and replacements if vehicle fails to conform to applicable emission standards and such failure results in vehicle owner bearing a penalty or other sanction under local, state or Federal law.

Warranty period is 5 years or 50,000 miles, whichever comes first. After 2 years or 24,000 miles, manufacturer will make necessary adjustments, repairs and replacements at no cost to owner only when noncompliance is caused by failure of components which have been installed in vehicle for sole or primary purpose of reducing vehicle emissions. See copy of warranty for specific components covered.

EMISSION DEFECT WARRANTY (CALIFORNIA)

For 3 years or 50,000 miles, whichever occurs first, any defective emission-related part on vehicle will be repaired or replaced by manufacturer at no cost to owner. Certain emission-related parts are covered for repair or replacement for 7 years or 70,000 miles, whichever occurs first. See copy of warranty for specific components covered.

EMISSION PERFORMANCE WARRANTY (CALIFORNIA)

For 3 years or 50,000 miles, manufacturer will make all necessary repairs and adjustments to ensure vehicle passes a required Smog Check inspection.

FUSES & CIRCUIT BREAKERS

FUSE PANEL LOCATION

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

Fuse box is located above driver's left knee, accessible through a removable cover. The main fuse block is located at the right rear of the engine compartment.

The Trunk Mounted Fuse Panel is located on the right side of the trunk, near the trunk hinge. (1992-95 Models)

MAIN FUSE BLOCK IDENTIFICATION

Fig. 4: Main Fuse Block Identification

Courtesy of MAZDA MOTOR OF AMERICA, INC.

WARNING: Always disconnect battery ground cable before servicing "high-current fuses. It is recommended that "high-current" fuses be replaced by a qualified technician.

Fuse & Circuit Breaker Identification



1 - 30 Amp (Pink) Headlights



2 - 30 Amp (Pink) Fuel Injection, Alternator



3 - 80 Amp (Black) Protection Of All Circuits

4 - 40 Amp (Green) Taillights, Shift Lock, Cruise Control, Horn, Stoplights, Hazard Warning Lights,

Interior Lights, Warning Buzzers, Radio/Cassette, Compact Disc Player, Clock



5 - Empty (1990) 60 Amp (Yellow) (1991-94) Anti-Lock Brake System 30 Amp (Green) (1995) -

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information



Anti-Lock Brake System

6 - 30 Amp (Pink) Cooling Fan



7 - 10 Amp (Red) (1994) Air Bag Not Used (1995) -

8 - 20 Amp (Yellow) A/C Additional Fan



9 - 10 Amp (Red) Fuel Injection

10 - 30 Amp (Pink) Headlight Retractor

TRUNK MOUNTED FUSE PANEL IDENTIFICATION

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

Fig. 5: Trunk Mounted Fuse Panel Identification (1992-95)

Courtesy of MAZDA MOTOR OF AMERICA, INC.

Fuse & Circuit Breaker Identification



1 - 10 Amp (Red) (1992-95) Rear Defroster

2 - 10 Amp (Red) (1992-95) Power Antenna

INTERIOR FUSE PANEL IDENTIFICATION

Fig. 6: Interior Fuse Panel Identificatio (1990-93)

Courtesy of MAZDA MOTOR OF AMERICA, INC.

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information

Fig. 7: Interior Fuse Panel Identification (1994-95)

Courtesy of MAZDA MOTOR OF AMERICA, INC.

NOTE: Fuses identified by numbers 11-27 reference the years 1990-93. Fused identified by alfa characters A-Q reference the years 1994-95.

Fuse & Circuit Breaker Identification



11 (A) - 15 Amp (Blue) Engine Cooling Fan



12 (B) - 10 Amp (Red) Gauges, Warning Lights, Turn Signal Lights, Cruise Control

13 (C) - 15 Amp (Blue) Air Bag Not Used (1995)



14 (D) - 30 Amp Heater

15 (E) - Empty



16 (F) - 30 Amp (Green) Power Windows

 17 (G) - 20 Amp (Yellow) Wipers, Washers

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1994 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1990-95 MAINTENANCE Mazda Maintenance Information



18 (H) - Empty



19 (I) - 15 Amp (Blue) Taillights

20 (J) - Empty



21 (K) - 15 Amp (Blue) Shift Lock, Cruise Control, Horn, Stoplights

22 (L) - 15 Amp (Blue) Hazard Warning Lights



23 (M) - Empty



24 (N) - 10 Amp (Red) Interior Lights, Warning Buzzers, Radio/Cassette, Compact Disc Player, Clock

25 (O) - 15 Amp (Blue) Radio/Cassette, Compact Disc Player, Clock, Cigarette Lighter



26 (P) - Empty

27 (Q) - Empty

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TRANSMISSION SERVICING - M/T 1994 Manual Transmission Servicing

TRANSMISSION SERVICING - M/T

1994 Manual Transmission Servicing

IDENTIFICATION

MANUAL TRANSMISSION APPLICATION

Model

Miata

Transmission

M15M-D

LUBRICATION

SERVICE INTERVALS

Fluid Inspection & Replacement

Check fluid level(s) at least once a year. Change transmission fluids every 60,000 miles for normal driving conditions and every 30,000 miles for severe driving conditions.

CHECKING FLUID LEVEL

Transmission Fluid

Remove fill plug from transmission. Fluid should be up to bottom of fill hole on side of case.

RECOMMENDED FLUID

TRANSMISSION FLUID SPECIFICATIONS/CAPACITY

Application

All-Season Usage

Temp. Greater Than 50°F (10°C)

Pints (liters)

(1) API GL-4 or GL-5.

Recommended Fluid

(1)

SAE 75W-90

(1)

SAE 80W-90

Capacity

4.2 (2.0)

ADJUSTMENTS

GEARSHIFT LINKAGE

No external linkage adjustment is required.

TORQUE SPECIFICATIONS

1994 Mazda MX-5 Miata

TRANSMISSION SERVICING - M/T 1994 Manual Transmission Servicing

TORQUE SPECIFICATIONS

Application

Drain Plug

Fill Plug

Ft. Lbs. (N.m)

29-43 (39-58)

18-29 (24-39)

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STEERING SYSTEM - POWER 1994 STEERING Mazda - Power Rack & Pinion

STEERING SYSTEM - POWER

1994 STEERING Mazda - Power Rack & Pinion

DESCRIPTION

Steering system is a power-assisted rack and pinion. The system consists of a rack and pinion steering gear and power-assist pump/reservoir. The steering gear and pump/reservoir are connected by flexible lines.

TESTING

HYDRAULIC SYSTEM PRESSURE TEST

Pump Fluid Pressure Test

1. Disconnect pressure line from steering gear and steering pump. Connect pressure gauge/valve between steering pump and steering gear. See Fig. 1 . Bleed air from system.

2. Completely open valve. Start engine and operate at idle. Turn steering wheel from lock to lock to increase fluid temperature to 122-140°F (50-60°C). To measure pump fluid pressure, close gauge valve completely.

3. Increase engine speed to 1000-1500 RPM. Measure oil pump fluid pressure. Ensure pump pressure is within specification. See HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS table. If pressure is not within specification, replace pump.

CAUTION: DO NOT leave gauge valve closed for more than 15 seconds, or pump may be damaged.

1994 Mazda MX-5 Miata

STEERING SYSTEM - POWER 1994 STEERING Mazda - Power Rack & Pinion

Fig. 1: Connecting Pressure Gauge/Valve

Courtesy of MAZDA MOTORS CORP.

Gear Fluid Pressure Test

1. Ensure steering pump pressure is within specification. To measure steering gear fluid pressure, open gauge valve completely. Increase engine speed to 1000-1500 RPM.

2. Turn steering wheel from lock to lock. Measure steering gear fluid pressure. Ensure gear pressure is within specification. See HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS table. If pressure is not within specification, replace gear.

HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS

(1)

Application

Miata psi (kg/cm

)

1102-1209 (77-85)

(1) Specifications are measured at 1000-1500 RPM, with fluid temperature at 122-140°F (50-60°C).

LUBRICATION

FLUID CAPACITY

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1994 Mazda MX-5 Miata

STEERING SYSTEM - POWER 1994 STEERING Mazda - Power Rack & Pinion

POWER STEERING FLUID CAPACITY

Application

Miata

Qts. (L)

.85 (.80)

FLUID TYPE

Dexron-II or Mazda M-III fluids are recommended for all models.

FLUID LEVEL CHECK

Check fluid level on oil pump dipstick (if equipped) or reservoir. Fluid should be between marks on level gauge dipstick (if equipped) or reservoir. If fluid level is low, fill as necessary. Recheck fluid level. DO NOT overfill.

HYDRAULIC SYSTEM BLEEDING

1. Raise and support front of vehicle. With ignition off, turn steering wheel from lock to lock several times.

Check fluid level. Add fluid as necessary. Repeat procedure until fluid level no longer decreases.

2. Start engine and operate at idle. Turn steering wheel from lock to lock 5 times. Check fluid level. Add fluid as necessary. Continue procedure until fluid is clear of air bubbles and does not decrease in level.

ADJUSTMENTS

NOTE: On-vehicle adjustment procedures are not available from manufacturer. For belt adjustment specifications, see POWER STEERING PUMP BELT .

POWER STEERING PUMP BELT

BELT ADJUSTMENT SPECIFICATIONS

Application

New Belt

Used Belt

(1)

Deflection In. (mm)

.31-.35 (7.8-8.9)

.35-.39 (8.9-10.0)

(1) Belt deflection is measured at midpoint between idler pulley and pump, with 22 lbs. (10 kg.) of pressure applied.

REMOVAL & INSTALLATION

STEERING GEAR

NOTE: Use a suitable container or rags to collect fluid when disconnecting pressure and return lines.

Removal & Installation

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1994 Mazda MX-5 Miata

STEERING SYSTEM - POWER 1994 STEERING Mazda - Power Rack & Pinion

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.

Remove cotter pins and castle nuts from tie rod ends.

2. Using Puller (49-0118-850C ), separate tie rod ends from steering knuckles. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Place reference marks on steering gear and pressure line fitting for reassembly.

3. Disconnect pressure and return line connections from steering gear. Remove steering gear-to-frame mounting bolts. Remove steering gear and linkage from vehicle.

4. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Fill and bleed system. Check and adjust front wheel alignment. See WHEEL ALIGNMENT

SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

POWER STEERING PUMP

NOTE: Use a suitable container or rags to collect fluid when disconnecting pressure and return lines.

Removal & Installation

1. Remove drive belt. Disconnect power steering pressure switch electrical connector (if equipped). Place reference marks on steering pump and pressure line fitting for reassembly. Disconnect pressure and return line connections from steering pump. Remove pump-to-bracket bolts and nuts. Remove pump from vehicle.

2. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE

SPECIFICATIONS table. Adjust belt tension. See POWER STEERING PUMP BELT under

ADJUSTMENTS. Bleed air from system. Inspect system for leaks.

OVERHAUL

STEERING GEAR

NOTE: See Fig. 2 for exploded views of rack and pinion steering gears.

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1994 Mazda MX-5 Miata

STEERING SYSTEM - POWER 1994 STEERING Mazda - Power Rack & Pinion

Fig. 2: Exploded View Of Rack & Pinion Steering Gear

Courtesy of MAZDA MOTORS CORP.

POWER STEERING PUMP

NOTE: See Fig. 3 for exploded views of power steering pumps.

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1994 Mazda MX-5 Miata

STEERING SYSTEM - POWER 1994 STEERING Mazda - Power Rack & Pinion

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1994 Mazda MX-5 Miata

STEERING SYSTEM - POWER 1994 STEERING Mazda - Power Rack & Pinion

Fig. 3: Exploded View Of Power Steering Pump

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Intermediate Shaft-To-Pinion Shaft Bolt

Pinion Housing Lock Nut

Pinion Shaft Lock Nut

Power Steering Pump Mounting Bolts/Nuts

Pressure Line Fitting-To-Power Steering Pump

Pressure Line Fitting-To-Steering Gear

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

Tie Rod Castle Nuts

Tie Rod End-To-Tie Rod Lock Nut

Ft. Lbs. (N.m)

13-19 (18-26)

33-40 (45-54)

22-29 (30-39)

27-40 (37-54)

23-35 (31-47)

34-43 (46-58)

58-72 (79-98)

21-32 (28-43)

25-29 (34-39)

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SUSPENSION - REAR 1994 SUSPENSION Mazda - Rear

SUSPENSION - REAR

1994 SUSPENSION Mazda - Rear

DESCRIPTION

Rear suspension consists of MacPherson-type struts, crossmember, upper and lower arms and stabilizer bar with control link. Upper and lower arms attach to crossmember and knuckle. A stabilizer bar with control link is mounted to lower arm and crossmember. Rear wheel alignment is adjusted by turning adjusting cams on lower arm.

ADJUSTMENTS

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

NOTE: See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the

WHEEL ALIGNMENT section.

WHEEL BEARING

Raise and support vehicle. Remove rear wheel assembly. Remove caliper assembly and wire aside. Remove brake rotor. Attach dial indicator to axle hub and measure bearing play. Check bearing axial play by rocking hub assembly by hand. Maximum bearing play is .002" (.05 mm). If play exceeds specification, check drive axle lock nut torque or replace wheel bearing.

REMOVAL & INSTALLATION

WHEEL BEARING

Removal

1. Raise and support vehicle. Remove rear wheel assembly. Remove drive axle lock nut. Remove brake caliper assembly and wire aside. Remove screws and rotor. Disconnect ABS speed sensor. Remove knuckle assembly from upper and lower arms.

2. Using Handle (49-G030-102), Installer (49-G030-727) and Puller (49-F026-103), remove hub from knuckle. Remove snap ring from knuckle. Using handle, installer and Puller (49-0636-145), remove wheel bearing inner race from hub. Remove wheel bearing outer race from knuckle using Handle (49-

G030-797), Puller (49-F026-103) and Adapter (49-F027-005).

Inspection

Check wheel hub and knuckle for cracks and damage. Check dust cover for deformation. Check bearing for excessive wear or seizure.

Installation

1994 Mazda MX-5 Miata

SUSPENSION - REAR 1994 SUSPENSION Mazda - Rear

Press NEW wheel bearing into knuckle using Handle (49-G030-797), Installer (49-F027-007) and Adapter (49-

F027-009). Press hub into knuckle using adapter. To install, reverse removal procedure. Tighten drive axle lock nut to specification. See TORQUE SPECIFICATIONS table. Stake drive axle lock nut. Check axial play. See

WHEEL BEARING under ADJUSTMENTS.

STRUT ASSEMBLY

Removal & Disassembly

1. Raise vehicle and remove fuel tank filler pipe protector. Remove rear wheel assembly. Remove stabilizer bar nut and bolt from lower control arm. Remove 2 upper strut mount-to-body nuts. Remove lower strut bolt. Loosen upper and lower arm bolts. Lower arms and remove strut assembly.

2. Clamp strut securely in soft-jawed vise. Compress coil spring. Remove lock nut and washer. Remove remaining components and note order for reassembly.

Inspection

Check strut for leaks or abnormal noise. Inspect components for wear or damage. Check for loose installation of bolts and nuts. Replace components as necessary.

Reassembly & Installation

To reassemble, reverse disassembly procedure. To install, reverse removal procedure. Ensure coil spring is seated in upper and lower seats. Tighten nuts and bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS table. Check rear wheel alignment.

See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

LOWER ARM

Removal

Raise and support vehicle. Remove rear wheel assembly. Remove stabilizer bar control link nut and bolt. See

Fig. 1 . Remove lower strut bolt. Remove lower arm-to-crossmember bolts. Remove lower arm-to-knuckle bolts. Remove lower arm. Inspect arm for damage, cracks and deformation. Check for damaged or worn bushings.

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1994 Mazda MX-5 Miata

SUSPENSION - REAR 1994 SUSPENSION Mazda - Rear

Fig. 1: Exploded View Of Rear Lower Arm Assembly

Courtesy of MAZDA MOTORS CORP.

Installation

To install, reverse removal procedure. Tighten all bolts with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS table. Adjust rear wheel alignment.

See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

UPPER ARM

Removal

Raise and support vehicle. Remove rear wheel assembly. Remove upper arm-to-crossmember bolts. Remove

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1994 Mazda MX-5 Miata

SUSPENSION - REAR 1994 SUSPENSION Mazda - Rear upper arm-to-knuckle bolts. Remove upper arm. Inspect arm for damage, cracks and deformation. Check for damaged or worn bushings.

Installation

To install, reverse removal procedure. Tighten all bolts with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS table. Adjust rear wheel alignment.

See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

STABILIZER BAR

Removal

Raise and support vehicle. Remove rear wheel assembly. Remove stabilizer bar-to-crossmember bolts, brackets and bushings. See Fig. 2 . Remove stabilizer bar control link-to-lower arm nut and bolt. Remove stabilizer bar and control link from vehicle. Separate stabilizer bar from control link. Inspect stabilizer bar and components for damage, cracks and deterioration.

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1994 Mazda MX-5 Miata

SUSPENSION - REAR 1994 SUSPENSION Mazda - Rear

Fig. 2: Exploded View Of Rear Stabilizer Bar & Control Link

Courtesy of MAZDA MOTORS CORP.

Installation

To install, reverse removal procedure. Ensure bushing is aligned with White line on stabilizer. Ensure seam faces front of vehicle. Tighten nuts and bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS table.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

ABS Speed Sensor Harness Bracket Bolts

Caliper Assembly-To-Knuckle Bolt

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Sunday, July 05, 2009 1:14:27 PM Page 5

Ft. Lbs. (N.m)

12-17 (16-23)

36-51 (49-69)

1994 Mazda MX-5 Miata

SUSPENSION - REAR 1994 SUSPENSION Mazda - Rear

Control Link-To-Lower Arm Nut

Lower Arm-To-Crossmember Nuts

Lower Arm-To-Knuckle Nut

Drive Axle Lock Nut

Stabilizer Bar Brackets Bolts

Stabilizer Bar-To-Control Link Bolt

Strut Piston Rod Lock Nut

Strut-To-Body Nuts

Strut-To-Lower Arm Bolt

Upper Arm-To-Crossmember Nuts

Upper Arm-To-Knuckle Bolt

Wheel Lug Nuts

27-40 (36-54)

54-70 (73-95)

46-55 (63-75)

159-217 (216-294)

15-21 (20-28)

27-40 (36-54)

22-27 (30-36)

54-69 (73-93)

34-49 (46-67)

65-87 (88-118)

Microsoft

C - SPECIFICATIONS 1994 ENGINE PERFORMANCE Mazda - Service & Adjustment Specifications

C - SPECIFICATIONS

1994 ENGINE PERFORMANCE Mazda - Service & Adjustment Specifications

INTRODUCTION

Use this article to quickly find specifications related to servicing and on-vehicle adjustments. This is a quickreference article to use when you are familiar with an adjustment procedure and only need a specification.

CAPACITIES

BATTERY SPECIFICATIONS

Application

Miata

Amp Hr. Rating

FLUID CAPACITIES

Application

Crankcase (Includes Filter)

Cooling System (Includes Heater)

Manual Transmission

(1)

Automatic Transmission (ATF M-III or Dexron-II)

Rear Differential

(2)

Quantity

4.0 Qts. (3.8L)

6.3 Qts. (6.0L)

2.1 Qts. (2.0L)

7.7 Qts. (7.3L)

1.06 Qts. (1.0L)

(1) Use SAE 75W-90 for all-season conditions, and SAE 80W-90 for temperatures greater than 50°F

(10°C).

(2) Use SAE 90 for temperatures greater than 0°F (-18°C), and SAE 80W for temperatures less than 0°F

(-18°C).

QUICK-SERVICE

SERVICE INTERVALS & SPECIFICATIONS

REPLACEMENT INTERVALS

Component

Air Filter

Camshaft Timing Belt

Coolant

Fuel Filter

Oil

Oil Filter

Spark Plugs

BELT ADJUSTMENT

Miles

30,000

60,000

30,000

60,000

7500

30,000

1994 Mazda MX-5 Miata

C - SPECIFICATIONS 1994 ENGINE PERFORMANCE Mazda - Service & Adjustment Specifications

Application

Alternator

A/C Compressor

Power Steering

(1)

Deflection: In. (mm)

5/16 - 23/64 (8-9)

(1) Measure belt deflection by applying moderate pressure, about 22 lbs. (10 kg), to belt, midway between pulleys.

ENGINE COMPRESSION

1. Warm engine to normal operating temperature. Remove all spark plugs. Disconnect ignition coil primary wire connector.

2. On all models, hold throttle plate fully open. Crank engine, and note compression pressure.

COMPRESSION RATIO

Application

Miata

Specification

9.0:1

COMPRESSION SPECIFICATIONS

Application

Miata

(1)

Minimum psi (kg/cm

) @ RPM Standard psi (kg/cm

) @ RPM

128 (9.0) @ 300 182 (12.8) @ 300

(1)

Difference between cylinders should not be more than 28 psi (2.0 kg/cm

VALVE CLEARANCE

NOTE: All piston engines are equipped with hydraulic valve lash adjusters. Valve clearance is not adjustable.

IGNITION SYSTEM

IGNITION COIL

IGNITION COIL RESISTANCE

Application

Miata

DISTRIBUTOR SENSORS

Primary

.78-.94

Secondary

8700-12,900

NOTE: See BASIC TESTING article in the ENGINE PERFORMANCE section for crank angle sensor testing.

HIGH TENSION WIRE RESISTANCE

Microsoft

1994 Mazda MX-5 Miata

C - SPECIFICATIONS 1994 ENGINE PERFORMANCE Mazda - Service & Adjustment Specifications

High tension wire resistance should not exceed 4900 ohms per foot.

SPARK PLUGS

SPARK PLUG TYPE

Application

Miata

SPARK PLUG SPECIFICATIONS

Application

Miata

(1) Gap is not adjustable.

(1)

Gap: In. (mm)

.040 (1.0)

FIRING ORDER & TIMING MARKS

NGK No.

BKR5E-11 or BKR6E-11

Torque: Ft. Lbs. (N.m)

13 (18)

Fig. 1: Firing Order (Miata)

IGNITION TIMING

IGNITION TIMING SPECIFICATIONS

Application

Miata

(2)

(1) Place automatic transmission in Park.

Man. Trans.

10 @ 850

(2) Connect jumper wire between terminals TEN and GRN of diagnostic connector.

(1)

Auto. Trans.

10 @ 800

DISTRIBUTOR SPECIFICATIONS

NOTE: On models with computer-controlled ignition, see appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section to diagnose ignition timing

Microsoft

1994 Mazda MX-5 Miata

C - SPECIFICATIONS 1994 ENGINE PERFORMANCE Mazda - Service & Adjustment Specifications problems.

FUEL SYSTEM

FUEL PUMP

NOTE: Fuel pump performance measures fuel pressure and volume availability, not regulated fuel pressure.

FUEL PUMP PERFORMANCE

Application

Miata

Pressure: psi (kg/cm

43-92 (3.0-6.5)

) Min. Vol. In 30 Sec.: Pts. (L)

REGULATED FUEL PRESSURE

At Idle W/ Vacuum: psi

(kg/cm

)

31-38 (2.2-2.7)

At Idle W/O Vacuum: psi

(kg/cm

)

38-46 (2.7-3.2)

Application

Miata

INJECTOR RESISTANCE

Application

Miata

Ohms

12-16

IDLE SPEED & MIXTURE

IDLE SPEED SPECIFICATIONS

Application

Miata

(2)

(1) Place automatic transmission in Park.

M/T RPM

850

(2) Connect jumper wire between terminals TEN and GRN of diagnostic connector.

(1)

A/T RPM

800

THROTTLE POSITION (TP) SENSOR

NOTE: For information on connector terminal identification and test conditions specified in the following tables, see ADJUSTMENTS article in the ENGINE

PERFORMANCE section.

TP SENSOR CONTINUITY

Test Condition

(1)

.004" (.1 mm)

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Sunday, July 05, 2009 1:19:49 PM Page 4

(2)

Continuity

Yes

1994 Mazda MX-5 Miata

C - SPECIFICATIONS 1994 ENGINE PERFORMANCE Mazda - Service & Adjustment Specifications

.024" (.6 mm)

(1) Insert feeler gauge of specified thickness between throttle lever and throttle stop screw.

(2) Check continuity with ohmmeter connected between TP sensor terminals "E" and IDL.

TP SENSOR CONTINUITY (M/T)

Condition

.016" (.4 mm)

(1)

.027" (.7 mm)

(1)

Wide Open Throttle

Continuity Between IDL &

TL/E

Yes

Continuity Between POW

(1) Insert feeler gauge of specified thickness between throttle lever and throttle stop screw.

& TL/E

Yes

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STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

STARTER - DIRECT DRIVE

1994 ELECTRICAL Mazda Starter - Direct Drive

DESCRIPTION

Nippondenso direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive housing. The overrunning clutch pinion drive is mounted directly on end of armature shaft drive.

NOTE: For information on Miata A/T, see STARTER - REDUCTION GEAR article in the

ELECTRICAL section.

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL

INFORMATION section.

ON-VEHICLE TESTING

NOTE: On Miata M/T, obtain code number and deactivate audio anti-theft system before disconnecting battery.

NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are clean and tight and engine grounds are good.

CIRCUIT TESTING

If starter does not operate, check voltage at starter "S" terminal with ignition switch in START position (and clutch depressed on M/T). See Fig. 1 . If voltage is greater than 8 volts, repair or replace starter as required. If voltage is less than 8 volts, check ignition switch, park/neutral switch (A/T), interlock switch (M/T) and wiring.

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

Fig. 1: Nippondenso Direct Drive Type Starter

Courtesy of MAZDA MOTORS CORP.

INTERLOCK SWITCH (M/T) (CLUTCH START SWITCH)

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive pedal is depressed. If continuity does not exist, adjust or replace interlock switch.

BENCH TESTING

NO-LOAD TEST

Connect fully-charged 12-volt battery, voltmeter and ammeter to starter. See Fig. 2 . Using remote starter wires or jumper, engage solenoid. Starter should spin smoothly. Compare readings with specifications. See NO-

LOAD TEST SPECIFICATIONS table. If voltage is less than specified, amperage is more than specified or shaft speed is less than specified, disassemble and inspect starter components.

NO-LOAD TEST SPECIFICATIONS

Application

Miata M/T

Voltage (Minimum)

Amperage (Maximum)

Shaft Speed (Minimum RPM)

Specification

11.5

6600

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

Fig. 2: Testing Direct Drive Starter Circuits

Courtesy of MAZDA MOTORS CORP.

SOLENOID TESTS

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

CAUTION: Perform solenoid tests with starter and solenoid assembled. DO NOT engage starter solenoid for more than 10 seconds during testing or damage to coil winding may result.

Solenoid Pull-In Test

Connect positive battery lead to solenoid "S" terminal and negative battery lead to starter body. See Fig. 2 .

Starter pinion drive gear should extend outward and stop. If starter pinion drive gear does not extend, replace solenoid.

Solenoid Hold-In Test

After performing solenoid pull-in test, with positive battery lead connected to solenoid "S" terminal and negative battery lead connected to starter body, disconnect field lead ("M" terminal wire) at solenoid. Starter pinion drive gear should remain extended. If starter pinion drive gear returns, replace solenoid.

Solenoid Return Test

Disconnect field lead ("M" terminal wire) at solenoid. Connect positive battery lead to solenoid "M" terminal and negative battery lead to starter body. See Fig. 2 . Using screwdriver, pry overrunning clutch pinion drive outward. Release screwdriver and ensure overrunning clutch pinion drive returns to original position.

Solenoid

1. Disconnect all wires from solenoid, including "M" terminal wire between solenoid and starter. Using ohmmeter, ensure continuity exists between "S" and "M" terminals, and between "S" terminal and solenoid body. See Fig. 1 and Fig. 2 . If continuity does not exist between specified terminals, replace solenoid.

2. Using ohmmeter, ensure continuity does not exist between "M" and "B" terminals. If continuity exists, replace solenoid.

PINION GAP ADJUSTMENT

1. Disconnect field lead ("M" terminal wire) at solenoid. See Fig. 2 . Connect positive battery lead to solenoid "S" terminal and negative battery lead to starter body. Starter pinion drive gear should extend outward and stop.

2. Quickly measure pinion gap between end of pinion drive and circlip retainer. See Fig. 3 . DO NOT operate starter solenoid for more than 10 seconds. Pinion gap should be .02-.08" (0.5-2.0 mm).

3. If pinion gap is not within specification, adjust by increasing or decreasing thickness of solenoid shims located between solenoid and drive housing.

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

Fig. 3: Checking & Adjusting Pinion Gap

Courtesy of MAZDA MOTORS CORP.

ARMATURE TEST

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.

2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If continuity exists, replace armature. Check continuity between commutator and shaft. If continuity exists, replace armature.

3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.

COMMUTATOR TEST

1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted, turn commutator in a lathe.

2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning. See COMMUTATOR SPECIFICATIONS table.

3. Commutator mica undercut depth should be .020-.030" (.50-.80 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut to standard depth.

COMMUTATOR SPECIFICATIONS

Application

Miata M/T

Maximum Runout In. (mm)

.001 (.03)

Minimum Diameter In.

(mm)

1.21 (30.8)

BRUSH TEST

1. Connect ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, replace brush holder assembly.

2. Check brush length. See BRUSH LENGTH SPECIFICATIONS table. If brush length is less than specified, replace brushes.

3. Using brush spring scale, measure spring tension. See BRUSH TENSION SPECIFICATIONS table. If tension is less than specified, replace brush holder assembly. Ensure brushes move freely in holders.

BRUSH LENGTH SPECIFICATIONS

Application Standard Length In. (mm)

Miata M/T .67 (17.0)

Minimum Length In. (mm)

.45 (11.5)

BRUSH TENSION SPECIFICATIONS

Application

Miata M/T

Standard Ft. Lbs. (N)

(1)

(1) Information is not available from manufacturer.

Minimum Ft. Lbs. (N)

(1)

FIELD WINDING TEST

1. Connect one ohmmeter lead to field coil lead ("M" terminal wire). Connect other lead of ohmmeter to

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive soldered portion of brush lead. If continuity does not exist, repair or replace field coil.

2. Check field coil for short to ground by connecting one ohmmeter lead to field coil lead ("M" terminal wire) and other ohmmeter lead to field coil housing. If continuity exists, repair or replace field coil.

OVERRUNNING CLUTCH PINION DRIVE

Hold overrunning clutch housing and turn pinion gear by hand. If pinion turns in both directions or does not turn at all, clutch is faulty. Replace clutch. DO NOT clean overrunning clutch with solvent, as it is packed with grease and sealed by manufacturer.

REMOVAL & INSTALLATION

NOTE: On Miata M/T, obtain code number and deactivate audio anti-theft system before disconnecting battery.

REMOVAL & INSTALLATION

Disconnect negative battery cable. Raise vehicle on hoist. Remove engine undercover (if equipped). Disconnect wiring from starter. Remove starter mounting bolts and starter. To install, reverse removal procedure. Tighten starter mounting bolts to specification. See TORQUE SPECIFICATIONS.

OVERHAUL

NOTE: Overhaul procedures are not available from manufacturer. See illustration for exploded view of starter. See Fig. 4 .

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

Fig. 4: Exploded View Of Direct Drive Starter

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Starter Mounting Bolts

Starter-To-Bracket Bolt

Battery Cable Nut (Solenoid Terminal "B")

WIRING DIAGRAM

Ft. Lbs. (N.m)

27-38 (37-52)

12-16 (16-22)

INCH Lbs. (N.m)

87-104 (9.8-11.7)

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

Microsoft

1994 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1994 ELECTRICAL Mazda Starter - Direct Drive

Fig. 5: Starting System Wiring Diagram (Miata M/T)

Microsoft

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

STARTER - REDUCTION GEAR

1994 ELECTRICAL Mazda Starter - Reduction Gear

DESCRIPTION

The Nippondenso reduction gear starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive housing.

Gear reduction is performed by coaxial planetary gear set. See Fig. 1 .

NOTE: For information on Miata M/T, STARTER - DIRECT DRIVE article in the

ELECTRICAL section.

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

Fig. 1: Nippondenso Reduction Gear Type Starters

Courtesy of MAZDA MOTORS CORP.

TROUBLE SHOOTING

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL

INFORMATION section.

ON-VEHICLE TESTING

NOTE: On Miata A/T, obtain code number and deactivate audio anti-theft system before disconnecting battery.

NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are clean and tight and engine grounds are good.

CIRCUIT TEST

If starter does not operate, check voltage at starter "S" terminal with ignition switch in START position (and clutch depressed on M/T). See Fig. 1 . If voltage is greater than 8 volts and vehicle does not crank, repair or replace starter as required. If voltage is less than 8 volts, check ignition switch, park/neutral switch (A/T), interlock switch (M/T) and wiring.

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

Fig. 2: Testing Reduction Gear Starter Circuits

Courtesy of MAZDA MOTORS CORP.

INTERLOCK SWITCH (M/T) (CLUTCH START SWITCH)

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

Interlock switch is mounted on bracket near top front of clutch pedal. Disconnect interlock switch wiring connector. Using ohmmeter, ensure continuity exists between interlock switch connector terminals when clutch pedal is depressed and no continuity exists when clutch pedal is released. If continuity is not as described, adjust or replace interlock switch.

BENCH TESTING

NO-LOAD TEST

LOAD TEST SPECIFICATIONS table. If voltage is less than specified, amperage is more than specified or shaft speed is less than specified, disassemble and inspect starter components.

NO-LOAD TEST SPECIFICATIONS

Application

Voltage (Minimum)

Amperage (Maximum)

Shaft Speed (Minimum RPM)

Specification

11.0

3000

SOLENOID TESTS

CAUTION: Perform solenoid tests with starter and solenoid assembled. DO NOT engage starter solenoid for more than 10 seconds during testing or damage to coil winding may result.

Solenoid Pull-In Test

Connect positive battery lead to solenoid "S" terminal and negative battery lead to starter body. See Fig. 2 .

Starter pinion drive gear should extend outward and stop. If starter pinion drive gear does not extend, replace solenoid.

Solenoid Hold-In Test

Solenoid Return Test

Solenoid

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1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

2. Using ohmmeter, ensure continuity does not exist between "M" and "B" terminals. If continuity exists, replace solenoid.

PINION GAP ADJUSTMENT

2. Quickly measure pinion gap between end of pinion drive and circlip retainer. See Fig. 3 . DO NOT operate starter solenoid for more than 10 seconds. Pinion gap should be .02-.08" (0.5-2.0 mm).

3. If pinion gap is not within specification, adjust by increasing or decreasing thickness of solenoid shims located between solenoid and drive housing.

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

Fig. 3: Checking & Adjusting Pinion Gap

Courtesy of MAZDA MOTORS CORP.

ARMATURE TEST

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.

3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.

COMMUTATOR TEST

1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted, turn commutator in a lathe.

2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning. See COMMUTATOR SPECIFICATIONS table.

3. Commutator mica undercut depth should be .020 -.030" (.50 -.80 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut to standard depth.

COMMUTATOR SPECIFICATIONS

Application Maximum Runout In. (mm)

A/T .001 (.03)

Minimum Diameter In. (mm)

1.21 (30.8)

BRUSH TEST

1. Connect one ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, replace brush holder assembly.

2. Check brush length. See BRUSH LENGTH SPECIFICATIONS table. If brush length is less than specified, replace brushes.

3. Using brush spring scale, measure spring tension. See BRUSH TENSION SPECIFICATIONS table. If tension is less than specified, replace brush holder assembly. Ensure brushes move freely in holders.

BRUSH LENGTH SPECIFICATIONS

Application Standard In. (mm)

A/T .69 (17.5)

Minimum In. (mm)

.47 (12.0)

BRUSH TENSION SPECIFICATIONS

Application

A/T

Standard Ft. Lbs. (N)

(1)

(1) Information is not available from manufacturer.

Minimum Ft. Lbs. (N)

(1)

FIELD WINDING TEST

1. Connect one ohmmeter lead to field coil lead ("M" terminal wire). Connect other lead of ohmmeter to soldered portion of brush lead. If continuity does not exist, repair or replace field coil.

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

OVERRUNNING CLUTCH PINION DRIVE

REMOVAL & INSTALLATION

NOTE:

REMOVAL & INSTALLATION

OVERHAUL

NOTE:

On Miata A/T, obtain code number and deactivate audio anti-theft system before disconnecting battery.

Overhaul procedures are not available from manufacturer. See illustrations for exploded views of starters. See Fig. 4 or Fig. 5 .

Fig. 4: Exploded View Of Coaxial Planetary Gear Type Starter (A/T)

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

Application

Starter Mounting Bolts

Battery Cable Nut (Solenoid Terminal "B")

WIRING DIAGRAM

Ft. Lbs. (N.m)

27-38 (37-51)

INCH Lbs. (N.m)

78-113 (9-13)

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

Microsoft

1994 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1994 ELECTRICAL Mazda Starter - Reduction Gear

Fig. 5: Starting System Wiring Diagram (Miata A/T)

Microsoft

STEERING COLUMN 1994 STEERING Mazda - Steering Column

STEERING COLUMN

1994 STEERING Mazda - Steering Column

DESCRIPTION & OPERATION

Steering columns are designed to be collapsible upon impact. The steering column consists of solid steering shaft with a lower joint assembly. Some models are equipped with tilt steering. Turn signal, headlight, ignition and windshield washer/wiper switches are mounted on column. Switches can be serviced by removing steering wheel and column covers. Miata is equipped with air bag restraint system consisting of an air bag module and clockspring connector assembly located in the steering column.

AIR BAG DISABLING & ACTIVATING

WARNING: Wait about 10 minutes after disabling air bag system before servicing. Air bag system voltage is maintained for about 10 minutes after system is disabled. Failure to wait 10 minutes before servicing system may cause accidental air bag deployment and possible personal injury.

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

DISABLING SYSTEM

1. Obtain radio code from customer and deactivate audio anti-theft function. Turn ignition off. Disconnect and shield negative battery cable. Wait at least 10 minutes for back-up power supply to be depleted.

2. Disconnect Orange and Blue clockspring connectors located at base of steering column.

ACTIVATING SYSTEM

Reconnect clockspring connectors. Reconnect negative battery cable. Turn ignition on. Check AIR BAG warning indicator light to ensure system is operating properly.

REMOVAL & INSTALLATION

STEERING WHEEL & HORN PAD

CAUTION: DO NOT strike steering shaft with hammer, as it may collapse.

WARNING: Before servicing Miata, disconnect and shield negative battery cable. Use caution when working around steering column, as air bag could deploy.

1994 Mazda MX-5 Miata

STEERING COLUMN 1994 STEERING Mazda - Steering Column

Removal & Installation

1. Disconnect negative battery cable. Remove 4 air bag module nuts from underside of steering wheel.

Disconnect electrical connector and remove air bag module. See AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/EQUIPMENT section.

2. Remove steering wheel lock nut. Using a puller, remove steering wheel. To install, reverse removal procedure. Tighten steering wheel lock nut and air bag module nuts.

COMBINATION SWITCH

Removal

Remove steering wheel. See STEERING WHEEL & HORN PAD under REMOVAL & INSTALLATION.

Remove upper and lower column covers. Disconnect combination switch connectors. Remove screws, and remove combination switch with clockspring assembly.

Installation

1. Install combination switch and clockspring assembly. Before installing steering wheel, center clockspring. To center clockspring, set front wheels in straight-ahead position. Turn clockspring connector clockwise until it stops. DO NOT force clockspring.

2. Rotate connector 2 3/4 turns (counterclockwise). Rotate clock-spring connector further (as necessary) to align marks on connector and outer housing. See Fig. 1 .

3. Install steering wheel. Tighten steering wheel lock nut to specification. See TORQUE

SPECIFICATIONS table. Install air bag module. See AIR BAG RESTRAINT SYSTEM article in the

ACCESSORIES/EQUIPMENT section.

Microsoft

1994 Mazda MX-5 Miata

STEERING COLUMN 1994 STEERING Mazda - Steering Column

Fig. 1: Aligning Clockspring Connector Alignment Marks

Courtesy of MAZDA MOTORS CORP.

IGNITION SWITCH/STEERING LOCK ASSEMBLY

Removal & Installation

1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and

COMBINATION SWITCH . Disconnect ignition switch connectors. Remove key interlock cable from ignition switch/steering lock assembly (if equipped).

2. Using a hammer and chisel, make a groove in ignition switch/steering lock assembly shear screws.

Remove 2 shear screws with screwdriver. Remove ignition switch/steering lock assembly. To install, reverse removal procedure. Tighten NEW shear screws until heads break off.

STEERING COLUMN

Microsoft

1994 Mazda MX-5 Miata

STEERING COLUMN 1994 STEERING Mazda - Steering Column

CAUTION: Excessive pressure or impact to steering shaft assembly during service may cause column to collapse.

Removal & Installation

1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and

COMBINATION SWITCH under REMOVAL & INSTALLATION. See Fig. 2 . Remove ignition switch/steering lock assembly. See IGNITION SWITCH/STEERING LOCK ASSEMBLY under

REMOVAL & INSTALLATION.

2. Remove lower panel. Remove air duct (if equipped). Remove "U" joint dust boot (if equipped). Remove steering shaft assembly-to-intermediate shaft "U" joint bolt. Remove lower steering shaft assembly-tofirewall nuts. Separate steering shaft from intermediate shaft. Remove steering column upper bracket bolts. Remove steering column.

3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE

SPECIFICATIONS table.

Microsoft

1994 Mazda MX-5 Miata

STEERING COLUMN 1994 STEERING Mazda - Steering Column

Fig. 2: Exploded View Of Steering Column

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

STEERING COLUMN

Disassembly

Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and

COMBINATION SWITCH under REMOVAL & INSTALLATION. See Fig. 2 . Remove ignition switch/steering lock assembly. See IGNITION SWITCH/STEERING LOCK ASSEMBLY under

Microsoft

1994 Mazda MX-5 Miata

STEERING COLUMN 1994 STEERING Mazda - Steering Column

REMOVAL & INSTALLATION. Remove steering column. See STEERING COLUMN under REMOVAL &

INSTALLATION. Turn steering shaft to remove.

Inspection

Inspect all components for damage and wear. Check steering shaft for bends, damage or sheared plastic pins.

Check bearings for excessive play. Replace components as necessary. Measure length of steering shaft. See

STEERING SHAFT DIMENSIONS table. See Fig. 3 .

Reassembly

To reassemble, reverse disassembly procedure. Grease steering shaft, bushings and bearings. Use NEW shear screws.

STEERING SHAFT DIMENSIONS

(1)

Application

Miata

Length - In. (mm)

23.77-23.85 (603.7-605.7)

(1) For measuring points, see Fig. 3 .

Fig. 3: Measuring Steering Shaft Dimensions

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Column Upper Bracket Mounting Bolts

Steering Shaft Assembly-To-Firewall Nuts

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Sunday, July 05, 2009 1:16:23 PM Page 6

Ft. Lbs. (N.m)

12-18 (16-25)

13-20 (18-27)

Steering Shaft "U" Joint Bolts

Steering Wheel Lock Nut

Key Interlock Cable Bolt

1994 Mazda MX-5 Miata

STEERING COLUMN 1994 STEERING Mazda - Steering Column

13-19 (18-26)

30-36 (40-49)

INCH Lbs. (N.m)

35-53 (4-6)

Microsoft

ENGINE PERFORMANCE Self-Diagnostics

ENGINE PERFORMANCE

Self-Diagnostics

INTRODUCTION

If no faults were found while performing BASIC TESTING , proceed with self-diagnostics. If no fault codes or only pass codes are present after entering self-diagnostics, ee to TESTS W/O CODES article in the ENGINE

PERFORMANCE section for diagnosis by symptom (i.e. ROUGH IDLE, NO START, etc.).

SELF-DIAGNOSTIC SYSTEM

HARD FAILURES

Hard failures cause CHECK ENGINE light to illuminate and remain on until the malfunction is repaired. If light comes on and remains on (light may flash) during vehicle operation, cause of malfunction must be determined using diagnostic (code) charts. If a sensor fails, control unit will use a substitute value in its calculations to continue engine operation. In this condition, vehicle is functional, but loss of good driveability will most likely be encountered.

INTERMITTENT FAILURES

Intermittent failures may cause CHECK ENGINE light to flicker or illuminate and go out after the intermittent fault goes away. The corresponding trouble code, however, will be retained in control unit memory. If related fault does not reoccur within a certain time frame, related trouble code will be erased from control unit memory.

Intermittent failures may be caused by sensor, connector or wiring related problems. See INTERMITTENTS in

TESTS W/O CODES article in the ENGINE PERFORMANCE section.

RETRIEVING CODES

Trouble Code Access

1. Use Self Diagnostic Checker (49 H018 9A1) and System Selector (49 B019 9A0) to retrieve trouble codes. Connect one lead of self diagnostic checker to ground and the other to system selector. Connect system selector to diagnostic connector. If system selector is not available, connect a jumper wire between terminals TEN and GND. See Fig. 1 .

2. With ignition on and engine stopped, observe CHECK ENGINE light or Malfunction Indicator Light

(MIL). Note trouble codes. Check TROUBLE CODE IDENTIFICATION for possible cause. If light remains on continuously, MIL circuit is grounded or ECU is defective.

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 1: Locating Self-Diagnostic Connector (Miata)

Courtesy of MAZDA MOTORS CORP.

CLEARING CODES

Disconnect negative battery cable for at least 5 seconds. Reconnect battery cable. Ground test connector with jumper wire. Turn ignition on and verify no codes are displayed.

TROUBLE CODE IDENTIFICATION

NOTE: This article may refer to the on-board computer as either Electronic Control

Module (ECM) or Powertrain Control Module-Engine (PCME).

NOTE: See PIN VOLTAGE CHARTS article in the ENGINE PERFORMANCE section to identify ECU connector terminals.

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 2: Trouble Code Identification Table

Courtesy of MAZDA MOTORS CORP.

TROUBLE CODE IDENTIFICATION TABLE

TROUBLE CODE IDENTIFICATION

DTC

CODE 1

CODE 3

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Sunday, July 05, 2009 1:19:17 PM Page 3

Description

Ignition Signal

SGT Signal - Crank Angle

CODE 4

CODE 8

CODE 9

CODE 10

CODE 12

CODE 14

CODE 15

CODE 16

CODE 17

CODE 25

CODE 26

CODE 28

CODE 29

CODE 34

CODE 1: (IGNITION SIGNAL)

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

SGC Signal - Crank Angle

Airflow Meter

Coolant Thermosensor

Intake Air Thermosensor

Throttle Sensor

Atmospheric Pressure Sensor

Oxygen Sensor

EGR Function Sensor - CKT Diagram

Feedback System

PRC Solenoid Valve

Purge Control Solenoid Valve

EGR Vacuum Solenoid Valve

EGR Vent Solenoid Valve

Idle Speed Control

Fig. 3: Trouble Code No. 1 Diagnostic Chart (Ignition Signal)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 4: Trouble Code No. 1 Ignition System Circuit Diagram

Courtesy of MAZDA MOTORS CORP.

CODE 3: (SGT SIGNAL - CRANK ANGLE)

Fig. 5: Trouble Code No. 3 Diag. Chart (SGT Signal - Crank Angle)

Courtesy of MAZDA MOTORS CORP.

CODE 4: (SGC SIGNAL - CRANK ANGLE)

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 6: Trouble Code No. 4 Diag. Chart (SGC Signal - Crank Angle)

Courtesy of MAZDA MOTORS CORP.

CODE 8: (AIRFLOW METER)

AIRFLOW METER WIRE COLORS

Terminal

"E"

"B"

Wire Color

BLK/LT. GRN

RED

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 7: Trouble Code No. 8 Diagnostic Chart (Airflow Meter)

Courtesy of MAZDA MOTORS CORP.

CODE 9: (COOLANT THERMOSENSOR)

Fig. 8: Trouble Code No. 9 Diagnostic Chart (Coolant Thermosensor)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

CODE 10: (INTAKE AIR THERMOSENSOR)

AIRFLOW METER WIRE COLORS

Terminal

"C"

"D"

Wire Color

BLK/BLU

RED/BLK

Fig. 9: Trouble Code No. 10 Diag. Chart (Intake Air Thermosensor)

Courtesy of MAZDA MOTORS CORP.

CODE 12: (THROTTLE SENSOR)

THROTTLE POSITION SENSOR WIRE COLORS

Terminal

"A"

"C"

"D"

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Wire Color

BLK/BLU

RED/BLK

LT. GRN/WHT

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 10: Trouble Code No. 12 Diagnostic Chart (Throttle Sensor)

Courtesy of MAZDA MOTORS CORP.

CODE 14: (ATMOSPHERIC PRESSURE SENSOR)

Fig. 11: Trouble Code No. 14 Diag. Chart (Atmospheric Pressure Sensor)

Courtesy of MAZDA MOTORS CORP.

CODE 15: (OXYGEN SENSOR)

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 12: Trouble Code No. 15 Diagnostic Chart (Oxygen Sensor)

Courtesy of MAZDA MOTORS CORP.

CODE 16: (EGR FUNCTION SENSOR) CKT DIAGRAM

Fig. 13: Trouble Code No. 16 Diagnostic Chart (EGR Function Sensor)

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 14: Trouble Code No. 16 Circuit Diagram (Miata)

Courtesy of MAZDA MOTORS CORP.

CODE 17: (FEEDBACK SYSTEM)

Fig. 15: Trouble Code No. 17 Diagnostic Chart (Feedback System)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

CODE 25: (PRC SOLENOID VALVE)

PRC SOLENOID VALVE WIRE COLORS

Terminal

"A"

"B"

Wire Color

WHT/RED

YEL/GRN

Fig. 16: Trouble Code No. 25 Diagnostic Chart (PRC Solenoid Valve)

Courtesy of MAZDA MOTORS CORP.

CODE 26: (PURGE CONTROL SOLENOID VALVE)

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 17: Trouble Code No. 26 (Purge Control Solenoid Valve)

Courtesy of MAZDA MOTORS CORP.

CODE 28: (EGR VACUUM SOLENOID VALVE)

EGR VACUUM SOLENOID VALVE WIRE COLORS

Terminal

"A"

"B"

Wire Color

WHT/RED

YEL/RED

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 18: Trouble Code No. 28 (EGR Vacuum Solenoid Valve)

Courtesy of MAZDA MOTORS CORP.

CODE 29: (EGR VENT SOLENOID VALVE)

EGR VENT SOLENOID VALVE WIRE COLORS

Terminal

"A"

"B"

Wire Color

WHT/RED

YEL/BLK

Fig. 19: Trouble Code No. 29 (EGR Vent Solenoid Valve)

Courtesy of MAZDA MOTORS CORP.

CODE 34: (IDLE SPEED CONTROL)

Microsoft

1994 Mazda MX-5 Miata

ENGINE PERFORMANCE Self-Diagnostics

Fig. 20: Trouble Code No. 34 Diagnostic Chart (Idle Speed Control)

Courtesy of MAZDA MOTORS CORP.

SUMMARY

If no hard fault codes (or only pass codes) are present, driveability symptoms exist or intermittent codes exist, proceed to TESTS W/O CODES article in the ENGINE PERFORMANCE section for diagnosis by symptom

(i.e. ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.

Microsoft

MAZDA 1.8L 4-Cylinder - BP Engine

NOTE:

MAZDA

1.8L 4-Cylinder - BP Engine

Engine identification code is on machined pad at left rear end of engine, at transmission mating flange.

MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE

For 1994-96 vehicles, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

For 1997-98 vehicles, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

For 1999-00 vehicles, the replacement interval is 60,000 miles except for vehicles registered in California,

Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York,

Pennsylvania, Rhode Island, Vermont, Virginia and Washington D.C. For these states, inspect timing belt at

60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

For 2001-05 MX-5 Miata, the replacement interval is 60,000 miles.

REMOVAL & INSTALLATION

TIMING BELT

Removal (MX-5 Miata)

1. Disconnect negative battery cable. Drain cooling system. Remove front strut bar and strut brackets, if equipped.

2. Disconnect Intake Air Temperature (IAT) sensor harness connector. Remove air cleaner cover and necessary air hoses or pipes. Remove drive belt(s).

3. Remove Camshaft Position (CMP) sensor, if equipped. Remove Crankshaft Position (CKP) sensor.

4. Remove high tension leads and ignition coil(s). Remove spark plugs.

5. Remove upper radiator hose and by-pass hoses from thermostat housing. See Fig. 1 or Fig. 2 .

6. If equipped with an control valve and pipe, remove oil pipe and cover with a shop rag to prevent oil spill.

Remove Oil Control Valve (OCV) case.

7. Remove water pump pulley, crankshaft pulley and crankshaft position sensor plate. See Fig. 1 or Fig. 2 .

8. Remove crankshaft pulley from crankshaft pulley boss. Remove plate with crankshaft pulley. Ensure crankshaft pulley boss locating pin faces straight up. Holding crankshaft pulley boss stationary, remove crankshaft pulley boss bolt. Remove pulley boss.

9. Remove upper, middle, and lower timing belt covers. If timing belt is to be reused, mark timing belt with

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine arrow to indicate rotation direction.

10. Install pulley boss on crankshaft to temporarily tighten with pulley lock bolt. Ensure timing marks on camshaft sprockets and crankshaft sprockets are aligned. See Fig. 3 .

11. Loosen timing belt tensioner lock bolt. Move tensioner away from belt with spring fully expanded, and tighten lock bolt. Remove timing belt.

Fig. 1: Exploded View Of Timing Belt & Components (1994-00 MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 2: Exploded View Of Timing Belt & Components (2001-04 MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks

Courtesy of MAZDA MOTORS CORP.

Removal (Protege)

1. Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right splash shield from wheelwell.

2. Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at

TDC of compression stroke. Hold crankshaft stationary, and remove crankshaft pulley from crankshaft pulley boss. See Fig. 4 .

3. Remove spark plug wires from spark plugs. Remove valve cover. Remove dipstick pipe. Remove upper timing belt cover. If timing belt is to be reused, mark timing belt rotation direction.

4. Support engine from above, and remove engine mount bracket from timing belt end of engine. Remove middle and lower timing belt covers.

5. Holding crankshaft stationary, remove crankshaft pulley boss. Align timing marks on crankshaft and camshaft sprocket(s). See Fig. 3 . Loosen timing belt tensioner lock bolt. Temporarily secure tensioner

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine away from belt with spring fully expanded. Remove timing belt.

Fig. 4: Exploded View Of Timing Belt & Components (Protege)

Courtesy of MAZDA MOTORS CORP.

Inspection (All Models)

1. Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner and idler pulley bearing for looseness or roughness of rotation. Replace parts as necessary.

2. Inspect tensioner spring for stretching. Replace tensioner spring if free length is not greater than

2.33" (59.2 mm). Free length is measured between inside edges of hooked portions of spring.

Installation (All Models)

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

1. Position notch on crankshaft sprocket to 12 o'clock position (aligned with mark on oil pump). See Fig. 3 .

Align timing marks on camshaft sprocket(s). Timing mark on intake camshaft sprocket is an "I"; timing mark on exhaust camshaft is an "E".

2. Install timing belt tensioner spring with damper rubber closing face away from tensioner. See Fig. 5 .

Temporarily secure the timing belt tensioner with tensioner spring fully expanded.

3. Install timing belt around crankshaft sprocket, then working in a counterclockwise direction, route belt around idler pulley, camshaft sprocket(s), and tensioner pulley. Ensure there is no slack in belt between crankshaft sprocket, idler pulley, and camshaft sprockets.

4. Temporarily install the crankshaft pulley boss and bolt. Rotate crankshaft about 2 turns in direction of normal engine rotation. Align timing belt pulley boss mark with tensioner set mark for correct timing belt tension adjustment. See Fig. 6 .

5. Holding crankshaft stationary, remove the crankshaft pulley boss and bolt. Ensure the crankshaft and camshaft timing marks are still aligned. Loosen timing belt tensioner lock bolt to apply tension to timing belt. Without moving tensioner, tighten tensioner lock bolt to specification. See TORQUE

SPECIFICATIONS .

6. Install crankshaft pulley boss, and final tighten bolt to specification. Rotate crankshaft 1 5/6 times.

Camshaft timing marks should be aligned with marks on rear cover, and the crankshaft pulley boss locating pin should point straight up. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure.

7. Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 7 . Ensure timing belt deflection is .35-.45" (8.5-11.5 mm).

8. To install remaining components, reverse removal procedure. While installing valve cover gasket, apply light bead of silicone sealer to 6 corners where gasket meets ends of camshafts. Tighten all valve cover bolts in the correct sequence. See Fig. 8 .

CAUTION: When installing OCV case, do not damage "O" ring of OCV adopter on camshaft cap, or it may cause hydraulic leakage. When installing oil pipe, no load should be applied on any connection part, or it may cause oil leakage.

9. On MX-5 Miata, install OCV case using several steps to tighten bolts to specification in the sequence shown. See Fig. 9 . Install OCV filter so that it aligns with the projected part on flange end of oil pipe.

See Fig. 10 . Apply engine oil to new washer. Temporarily install upper and side oil pipe.

10. Using several steps, tighten top oil pipe bolts in the sequence shown. See Fig. 11 . Temporarily tighten lower side oil pipe bolt to 26-61 INCH lbs. (3-7 N.m). Tighten upper side oil pipe bolt to 9-13 ft. lbs. (12-

18 N.m). Using several steps, tighten side oil pipe bolts in the sequence shown. See Fig. 12 .

11. On all models, fill and bleed cooling system. Fill with 50/50 mix of water and coolant. To bleed system, fill system. Run engine at 2500 RPM for 5 minutes. Run engine at 3000 RPM for 5 minutes. Recheck coolant level and fill as necessary. On Protege, check ignition timing.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 5: Installing Timing Belt Tensioner Spring

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 6: Aligning Timing Belt At Tensioner Set Mark

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 7: Measuring Timing Belt Deflection

Courtesy of MAZDA MOTORS CORP.

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1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 8: Identifying Valve Cover Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 9: Identifying OCV Case Bolts Tightening Sequence (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 10: Installing OCV Filter (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 11: Identifying Top Oil Pipe Bolt Tightening Sequence (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Fig. 12: Identifying Side Oil Pipe Bolt Tightening Sequence (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Alternator Pivot Bolt

Alternator Top Bolt

Camshaft Sprocket Bolt

Crankshaft Pulley Boss Bolt

Crankshaft Pulley-To-Pulley Boss

Engine Mount Bracket Nuts (Protege)

Idler Pulley Bolt

Ignition Coil Mounting Bolt (1999-00)

Spark Plugs

Strut Bar Bolt

Strut Bar Bracket Nut

Timing Belt Tensioner Bolt

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Ft. Lbs. (N.m)

28-38 (38-51)

14-18 (19-25)

37-44 (50-60)

116-123 (157-167)

9-13 (12-18)

55-77 (75-104)

28-38 (38-51)

14-18 (19-24)

11-16 (15-22)

12-16 (16-22)

22-27 (30-37)

28-38 (38-51)

1994 Mazda MX-5 Miata

MAZDA 1.8L 4-Cylinder - BP Engine

Wheel Lug Nut (Protege) 66-94 (89-127)

INCH Lbs. (N.m)

70-95 (8-11) Ignition Coil Mounting Bolt (2001-04)

Oil Pipe Bolt (MX-5 Miata)

Side Oil Pipe

Top Oil Pipe

Radiator Drain Plug

Timing Belt Cover Bolt

Valve Cover Bolt

Except 2001-03 MX-5 Miata

2001-03 MX-5 Miata

70-95 (8-11)

7-10 (0.7-1.1)

71-97 (8-11)

43-78 (5-9)

71-97 (8-11)

() Tighten bolt No. 1 to 12-17 ft. lbs. (16-24 N.m). Tighten bolt No. 2 to 70-95 INCH lbs. (8-11 N.m).

Tighten bolt No. 3 to 25-35 ft. lbs. (34-47 N.m). See Fig. 12 .

Microsoft

M - VACUUM DIAGRAMS 1994 ENGINE PERFORMANCE Mazda Vacuum Diagrams

M - VACUUM DIAGRAMS

1994 ENGINE PERFORMANCE Mazda Vacuum Diagrams

INTRODUCTION

This article contains underhood views or schematics of vacuum hose routing. Use these vacuum diagrams during the visual inspection in BASIC TESTING article in the ENGINE PERFORMANCE section. This will assist in identifying improperly routed vacuum hoses which cause driveability and/or computer indicated malfunctions.

VACUUM DIAGRAMS

Fig. 1: Vacuum System Schematic (1.8L)

Courtesy of MAZDA MOTORS CORP.

1994 Mazda MX-5 Miata

M - VACUUM DIAGRAMS 1994 ENGINE PERFORMANCE Mazda Vacuum Diagrams

Fig. 2: Vacuum Hose Routing Diagram (1.8L)

Courtesy of MAZDA MOTORS CORP.

Microsoft

AIR CONDITIONING

1994 System Wiring Diagrams Mazda - Miata

1994 System Wiring Diagrams

Mazda - Miata

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 1: A/C Circuit

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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Fig. 2: Heater Circuit

ANTI-LOCK BRAKES

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 3: Anti-lock Brake Circuits

COMPUTER DATA LINES

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 4: Data Link Connector Circuit

COOLING FAN

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 5: Cooling Fan Circuit

CRUISE CONTROL

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 6: Cruise Control Circuit

DEFOGGERS

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 7: Defogger Circuit

ENGINE PERFORMANCE

1.8L

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 8: 1.8L, Engine Performance Circuits (1 of 2)

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 9: 1.8L, Engine Performance Circuits (2 of 2)

EXTERIOR LIGHTS

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 10: Exterior Light Circuit, W/ DRL

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 11: Exterior Light Circuit, W/O DRL

GROUND DISTRIBUTION

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 12: Ground Distribution Circuit (1 of 2)

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 13: Ground Distribution Circuit (2 of 2)

HEADLIGHTS

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 14: Headlight Circuit

HORN

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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Fig. 15: Horn Circuit

INSTRUMENT CLUSTER

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 16: Instrument Cluster Circuit

INTERIOR LIGHTS

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 17: Interior Light Circuit

POWER ANTENNA

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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Fig. 18: Power Antenna Circuit

POWER DISTRIBUTION

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 19: Power Distribution Circuit (1 of 3)

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 20: Power Distribution Circuit (2 of 3)

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 21: Power Distribution Circuit (3 of 3)

POWER MIRRORS

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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Fig. 22: Power Mirror Circuit

POWER WINDOWS

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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Fig. 23: Power Window Circuit

RADIO

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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Fig. 24: Base Radio

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 25: Premium Sound Radio Circuit

SHIFT INTERLOCKS

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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Fig. 26: Shift Interlock Circuit

STARTING/CHARGING

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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Fig. 27: Charging Circuit

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 28: Starting Circuit, A/T

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 29: Starting Circuit, M/T

SUPPLEMENTAL RESTRAINTS

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Fig. 30: Supplemental Restraint Circuit

TRANSMISSION

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 31: Transmission Circuit

WARNING SYSTEMS

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 32: Warning System Circuits

WIPER/WASHER

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

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1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 33: Wiper/Washer Circuit

1994 Mazda MX-5 Miata

1994 System Wiring Diagrams Mazda - Miata

Microsoft

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