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Table Of Contents - Mazda MX-5 1990 Workshop Manual

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Workshop manual supplement (120 pages)

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Workshop manual (15 pages)

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Workshop manual (1273 pages)

Table Of Contents

Table of Contents

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Table of Contents

General Information3

Table Of Contents3

Important Information4

Basic Assumptions4

Warning On Lubricants And Greases4

Possible Loss Of Warranty4

Repair Procedure5

How To Use This Manual5

Notes, Cautions, And Warnings6

Fundamental Procedures6

Protection Of Vehicle6

A Word About Safety7

Preparation Of Tools And Measuring Equipment7

Removal Of Parts7

Inspection Of Parts8

Arrangement Of Parts8

Rubber Parts And Tubing9

Jack And Safety Stand Positions10

Vehicle Lift (2-Support Type) Positions10

Identification Number Locations11

Abbreviations12

Installation Of Mobile Two-Way Radio System13

Air Bag System14

Service Precautions Concerning Air Bag System14

Before Replacing Any Components14

Handling Of Air Bag Module14

Crash Sensor Installation15

Adjustment Of Clock Spring Connector15

Power Connector In Engine Compartment15

Audio Anti-Theft System15

Electrical Troubleshooting Tools16

Caution With Electrical Parts17

Battery Cable17

Disconnecting Connectors17

Locking Connectors17

Replacement Of Terminals18

Sensors, Switches, And Relays18

Wiring Color Codes19

Fuse Replacement19

Pre-Delivery Inspection And Scheduled Maintenance Services20

Pre-Delivery Inspection Table21

Under Hood-Engine Off21

Scheduled Maintenance Services22

Specifications30

Troubleshooting Guide30

Engine Tune-Up Procedure32

Ignition Timing, Idle Speed35

On-Vehicle Maintenance38

Tensioner, Tensioner Spring40

Cylinder Head Cover42

Timing Belt Guide Plate, Inner42

Steps After Installation42

Cylinder Head Gasket43

Water Bypass Pipe45

Cylinder Head Bolt45

Accelerator Cable46

Camshaft Pulley48

Crank Angle Sensor50

Front Oil Seal51

Pulley Lock Bolt51

Timing Belt Pulley52

Rear Oil Seal53

A/C Compressor56

Engine And Transmission Assembly58

Engine Stand Mounting60

Auxiliary Parts64

Crankshaft Pulley66

Cylinder Head67

Cylinder Block (External Parts)70

Oil Pan Baffle71

Cylinder Block (Internal Parts)72

Connecting Rod Cap73

Connecting Rod73

Main Bearing Cap74

Inspection I Repair75

Valve Mechanism76

Valve And Valve Guide76

Replacement Of Valve Guide77

Cylinder Block81

Cylinder Bore82

Piston Diameter83

Piston, Piston Ring, And Piston Pin83

Piston And Piston Pin84

Main Journal Diameter Undersize85

Crankpin Journal Diameter Undersize85

Main Bearing And Connecting Rod Bearing85

Tensioner, Idler86

Tensioner Spring86

Timing Belt Pulley, Camshaft Pulley86

Torque Specifications88

Cylinder Block (Internal Parts88

Oil Clearance Inspection90

Piston And Connecting Rod Assembly92

Cylinder Block (External Parts93

Clutch Disc And Clutch Cover97

Valve And Valve Spring98

Thermostat Housing99

Timing Belt Cover103

Engine Hanger105

Oil Level Gauge Pipe106

Water Outlet Pipe106

Oil Pressure Gauge Sender Unit106

Right Engine Mount107

Alternator Bracket107

Intake Manifold Assembly107

Ignition Coil And High-Tension Lead108

Engine Stand Dismounting109

Left Engine Mount109

Pis Oil Pump Bracket110

Water Inlet Pipe And Bypass Pipe110

Aic Compressor Bracket110

Transmission111

Installation111

Power Plant Frame113

Engine Mount Nut113

Transmission Harness113

Clutch Release Cylinder113

Radiator And Cooling Fan Assembly116

Air Cleaner Assembly116

Lubrication System118

Recommended Sae Viscosity120

Oil Pressure121

Crossmember Installation Bolt And Nut124

Cooling System131

Cooling System Index132

Outline Specifications133

Coolant Quality134

Coolant Leakage134

Coolant Level (Engine Cold)134

Radiator Cap134

Coolant Protection135

Antifreeze Solution Mixture Percentage135

Radiator Cap Valve136

Negative Pressure Valve136

Removal / Inspection / Installation137

Removal Inspection Installation138

Removal / Installation139

Pis Oil Pump140

Electric Cooling Fan System141

System Circuit141

System Inspection141

Water Thermoswitch143

Fuel And Emission Control Systems145

System Diagram149

Vacuum Hose Routing Diagram150

Component Descriptions154

Engine Control Operation Chart156

Output Devices And Engine Conditions158

Relationship Chart159

Using This Section160

Diagnostic Index160

Fuel Pressure Release And Servicing Fuel System163

Pinching Hose163

Cranks Normally But Will Not Start (No Combustion)164

Symptom Troubleshooting164

Cranks Normally But Will Not Start (Partial Combustion)166

Cranks Normally But Hard To Start170

Cranks Normally But Hard To Start - When Engine Is Cold172

Cranks Normally But Hard To Start - After Warm·up173

Rough Idle - Always174

Low Idle Speed/Rough Idle - Before Warm-Up176

Low Idle Speed/Rough Idle - After Warm-Up178

High Idle Speed180

Low Idle Speed182

Rough Idle Just After Starting183

Idle Moves Up And Down184

Engine Stalls At Idle186

Engine Stalls At Idle - Before Warm-Up188

Engine Stalls At Idle - After Warm-Up189

Engine Stalls During Start-Up190

Engine Stalls On Deceleration192

Engine Stalls Suddenly (Intermittent)195

Hesitates/Stumbles On Acceleration196

Surges While Cruising198

Lack Of Power200

Poor Acceleration204

Runs Rough On Deceleration/Backfire208

Exhaust Sulfer Smell213

High Oil Consumption213

Poor Fuel Economy214

Mil Always On216

A/C Does Not Work217

Engine Tune-Up218

Basic Inspection218

Air Cleaner Element219

Ignition Timing219

Self-Diagnosis Function221

Malfunction Code Number222

Principle Of Code Cycle223

Code Cycle Break223

Second Digit Of Malfunction Code (Ones Position)223

First Digit Of Malfunction Code (Tens Position)223

Code Numbers224

Circuit Diagram225

Code No.01 Igf-Signal225

Code No.02 Ne-Signal226

Code No.03 G-Signal226

Code No.os Airflow Meter228

Code No.09 Water Thermosensor229

Code No.10 Intake Air Theamosensor (In Airflow Meter)229

Code No.15 Oxygen Sensor230

Code No.17 Feedback System230

Code No.26 Solenoid Valve (Purge Control)231

Code No.34 Isc Valve231

After-Repair Procedure232

Switch Monitor Function233

Inspection Procedure233

Neutral And Clutch Switches234

Idle Terminal234

Pow Terminal234

Stoplight Switch234

Headlight Switch235

Blower Switch235

Water Thermoswitch Circuit (Not Included In Switch Inspection)235

Intake Air System236

Inspection Of Air Leakage237

System Operation237

Throttle Body238

Intake Manifold239

Accelerator Pedal And Cable240

Idle Speed Control (Ise) System241

Fuel System Description244

Circuit Opening Relay244

Pressure Regulator244

Priming Fuel System245

Fuel Pressure Hold Inspection246

Fuel Line Pressure Inspection247

Fuel Filter Bolts249

Brake Pipe Joint249

Rear Crossmember Assembly249

Fuel Hoses And Fuel Filler Hoses250

Fuel Filter Replacement250

High-Pressure Side250

Fuel Pump Operation251

Hold Pressure251

Fuel Pump Maximum Pressure252

Switching Operation254

Relay Circuit254

Fuel Line Pressure255

Injector Resistance256

Fuel Leakage Test257

Exhaust System Components259

Outline Of Emission Control System260

Structural View260

Positive Crankcase Ventilation261

Evaporative Emission Control System262

Charcoal Canister262

Solenoid Valve (Purge Control)263

Two-Way Check Valve263

Deceleration Control System265

Catalytic Converter System266

A/C Cut-Off Control System267

After Engine Has Been Started267

Acceleration267

Dechoke Control System268

Engine Control Unit268

Water Thermosensor268

Control System269

Throttle Sensor269

Oxygen Sensor269

Engine Control Unit Inspection271

Terminal Location274

Check Point For Each Terminal275

Crank Angle Sensor Removal278

Airflow Meter279

Water Thermosensor Removal280

Water Thermosensor Inspection280

Throttle Sensor Inspection280

Throttle Sensor Adjustment281

Throttle Sensor Replacement281

Inspection Of Terminal Voltage282

Inspection Of Sensitivity282

7, Main Relay (Fuel Injector Relay) Inspection283

8, Clutch Switch283

Power Steering Pressure Switch284

Neutral Switch Inspection284

Engine Electrical System285

Cylinder Arrangement287

Will Not Crank288

Cranks Slowly288

Discharged Battery289

Voltage Check292

Terminal And Cable293

Self-Diagnosis System296

Brush Spring299

Drive Belt Inspection299

Drive Belt Deflection299

Ignition System301

Ignition Coil305

Primary Coil Winding305

Secondary Coil Winding305

Installation Of Case305

High-Tension Lead306

Starting System Circuit Diagram307

Starting System Troubleshooting307

Performance Inspection309

Pull-Out Test309

Pinion Gap Check309

Ground Of Armature Coil311

Insulation Of Armature Coil311

Runout Of Commutator311

Yoke Assembly312

Magnetic Switch312

Wiring Damage Of Field Coil312

Ground Of Field Coil312

Starter Interlock Switch313

Clutch Fluid316

Clutch Pedal318

Clutch Pedal Height318

Clutch Pedal Free Play318

Clutch Master Cylinder320

Air Bleeding321

Piston And Secondary Cup Assembly324

Release Bearing328

Clutch Cover And Disc329

Pilot Bearing329

Clutch Cover330

Manual Transmission333

Transmission Oil340

Propeller Shaft343

Housing Components345

Extension Housing346

Transmission Case346

Oil Seal (Rear)346

Shift Fork And Shift Rod Parts347

Mainshaft And Countershaft Parts348

Mainshaft Rear Bearing349

Locknut (Countershaft)349

Countershaft Rear Bearing350

Locknut (Mainshaft)350

Main Drive Gear Bearing350

Countershaft Front Bearing350

Mainshaft Parts351

Clutch Hub Assembly (3Rd/4Th)352

Clutch Hub Assembly (1 St/2Nd)352

Bearing Housing Parts352

Reverse Idler Gear Shaft353

Mainshaft Front Bearing353

Countershaft Center Bearing353

Extension Housing Parts354

Each Gear And Main Drive Gear355

Countershaft355

Synchronizer356

Reverse Idler Gear And Shaft356

Intermediate Housing357

Select-Lock Spindle, Spring, And Spring Cap360

Adjustment Shim362

Adjustment Washer362

Thrust Lock Washer368

Spring And Ball371

Shift Fork And Rod371

Interlock Pin371

Shift Fork And Rod, Interlock Pin372

Spring, Spacer, Clip372

Release Fork376

Power Plant Frame (Ppf)378

Front And Rear Axles384

Differential, Standard387

Differential, Viscous Limited Slip387

Wheel Hub, Steering Knuckle388

Wheel Bearing Play389

Brake Caliper Assembly389

Disc Brake Type393

Rear Wheel Hub Assembly395

Double Offset Joint399

Cage, Inner Ring, And Balls402

Differential405

Differential Oil407

Oil Seal (Output Shaft)407

Operation Inspection409

Viscous Limited Slip Differential409

Differential, Standard; Differential, Viscous Limited Slip410

Output Shafts417

Differential Case417

Differential Gear Assembly417

Adjuting Nuts417

Drive Pinion418

Bearing Outer Races (Front, And Rear Bearing)418

Bearing Inner Race (Rear Bearing)418

Bearing Inner Races (Side Bearing)418

Differential Mounting Rubber419

Adjustment Of Pinion Height419

Adjustment Of Drive Pinion Preload421

Adjustment Of Backlash423

Thrust Washer Thickness423

Adjustment Of Drive Pinion And Ring Gear Backlash423

Inspection And Adjustment Of Teeth Contact424

Bearing Caps425

Steering System426

Boot Replacement431

Steering Wheel And Column433

Steering Wheel Play433

Looseness Or Play Of Steering Wheel433

Steering Wheel Effort433

Steering Wheel435

Steering Lock Mounting Bolts And Bracket436

Steering Gear And Linkage437

Engine Speed Sensing Power Steering438

Power Steering Fluid441

Fluid Leakage441

Fluid Pressure442

Power Steering Oil Pump446

Pressure Pipe447

Braking System448

Brake Hydraulic Line453

Pedal Height454

Pedal-To-Floor Clearance455

Master Cylinder457

Push Rod Clearance458

Power Brake Unit460

Quick Inspection, On-Vehicle Power Brake Unit Function Check460

Unloaded Condition460

Loaded Condition461

Checking For Hydraulic Pressure461

Inspection Of Check Valve461

Proportioning Bypass Valve463

Front Brake (Disc)465

Wheels And Tires477

Special Notes About Wheels And Tires479

Notes Regarding Tire Replacement479

Tire Rotation480

Wheel Balance Adjustment481

Wheel Alignment487

Pre-Inspection487

Front Wheel Alignment487

Rear Wheel Alignment490

Front Suspension (Double-Wishbone)492

Shock Absorber And Spring493

Lower Arm Ball Joint497

Ball Joint Dust Boot497

Ball Joint Rotation Torque497

Upper Arm Ball Joint499

Rear Suspension (Double-Wishbone)502

Door Components514

Door Lock Striker515

Window Regulator, Glass, And Guide516

Regulator Handle517

Vertical Adjustment Of Door Glass518

Inboard/Outboard Adjustment Of Door Glass519

Fore And Aft Adjustment Of Side Edge Of Door Glass520

After Completion Of Adjustment521

Door Lock And Opener522

Balance Spring524

Trunk Lid Lock And Opener525

Power Window System526

Power Window Main Switch529

Fuel Filler Lid Opener530

Front Bumper531

Molding And Garnish534

Front Beltline Molding535

Rear Finisher535

Beltline Molding535

Windshield Molding535

Rear Window Molding (Detachable Hard Top)536

Hardening Time Of Repair Seal536

Windshield Wiper And Washer538

Wiper Does Not Operate In Lo Or Hi Position539

Wiper Automatic Park Function Does Not Work539

Intermittent Function Does Not Operate540

Washer Does Not Operate (Wiper Operates Ok) (For Usa)540

Washer Does Not Operate (Wiper Operates Ok) (For Canada)541

Washer Motor541

Front Wiper And Washer Switch541

Installation Note546

Rear Window Glass (Detachable Hard Top)549

Rear Window Glass550

Rear Window (Convertible Top)553

Dashboard And Console557

Center Lower Panel Assembly558

Center Panel Assembly558

Airflow Mode Wire558

Rec-Fresh Wire559

Temperature Blend Wire559

Front Header Trim561

A-Pillar Trim561

Quarter Trim561

Speaker Grille562

Emergency Locking Retractor (Elr)565

Buckle Switch565

Convertible Top568

Repair Of Top Fab-Ric575

Repair Of Hole In Top Fabric575

Repair Of Tear In Top Fabric576

Detachable Hard Top577

Convertible Top, Detachable Hard Top578

Weatherstrip (Convertible Top/Detachable Hard Top)579

Underbody Dimensions580

Body Electrical System583

Fuses And Relays585

Cruise Control System587

Audio System588

Electrical Symbols593

Switches And Relays593

Other Electrical Symbols593

Main Fuse Block594

Cartridge-Type596

Headlight Retractor Relay598

Turn And Hazard Warning Flasher Unit598

Timer And Buzzer Unit599

Key Remainder Alarm Test599

Seat Belt Alarm Test599

Seat Belt Warning Lamp Timer599

Voltage Test600

Continuity Test600

4-Terminal Normally Open Relay (No Relay)601

Headlight Relay And Cooling Fan Relay601

Horn Relay And Tns Relay601

Combination Switch (U.s. Spec.)602

Steering Lock603

Combination Switch603

Clock Spring Connector Adjustment604

Lights, Dimmer, And Passing Switch605

Turn Signal Switch605

Windshield Wiper And Washer Switch605

Cruise Control Switch605

Canada Spec.606

Headlight Retractor Switch607

Hazard Warning Switch607

Instrument Cluster (Meter)608

Speedometer Does Not Operate Or Indication Is Incorrect610

Tachometer Does Not Operate611

Water Temperature Gauge Does Not Operate.612

Fuel Gauge Does Not Operate613

Oil Pressure Gauge Does Not-Operate614

Water Temperature Gauge616

Printed Circuit618

Speed Sensor618

Fuel Gauge Sender Unit (In Fuel Tank)618

Oil Pressure Sensor619

Speedometer Cable619

Warning Lamp And Sender Unit620

Brake Warning Lamp622

Brake Warning Lamp Remains Illuminated622

Check Parking Brake Switch622

Brake Warning Lamp Does Not Come On When Parking Braking On623

Seat Belt Warning Lamp624

Brake Fluid Level Sensor625

Parking Brake Switch625

Seat Belt Buckle Switch625

Lighting System626

Headlights Do Not Operate. (U.s. Spec.)628

Headlights Do Not Operate. (Canada Spec.)630

Headlight Switch Inspection631

Headlight Does Not Operate (Right Or Left)632

Headlight Retractor Motors Do Not Operate (Both Sides)633

Headlight Retractor Motor Does Not Operate (One Side)635

Headlight Aiming637

Retractor Hinge637

Retractor Motor638

Retractor Switch638

Headlight Relay (U.s. Spec.)639

Stoplights Do Not Operate (All).641

Stoplights Does Not Operate (One Only).642

Turn And Hazard Warning Lights644

Turn And Hazard Warning Lights Do Not Operate (U.s. Spec.)645

Turn And Hazard Warning Lights Do Not Operate (Canada Spec.)647

Turn Signal(S) Flashes Rapidly649

Hazard Warning Function Does Not Operate650

Back-Up Lights653

Back-Up Light(S) Does Not Operate654

No Lights Illuminate657

Daytime Running Lights (Drl) Do Not Operate661

Daytime Running Lights (Drl) Function Does Not Cancel662

Interior Lamps667

Interior Lamp(S) Do Not Illuminate668

Interior Lamp(S) Remains Illuminated With Doors Closed670

Illumination Lamps671

Illumination Lamp Control Does Not Operate672

Horn Does Not Sound675

Vehicle Speed Cannot Be Set681

Inspection Of Brake Switch682

Inspection Of Clutch Switch682

Inspection Of Cruise Control Switch682

Inspection Of Stoplight Switch683

Inspection Of Actuator683

Inspection Of Speed Sensor683

Inspection Of Cruise Control System Using Self-Diagnostic Function684

Second Digit Of Condition/Operation Code (Ones Position)685

First Digit Of Condition/Operation Code (Tens Position)685

Condition/Operation Code Numbers686

Cruise Control Unit687

Actuator Cable688

Brake Switch689

Cruise Control Main Switch689

Function And Operating Procedure692

Speaker(S) Do Not Operate697

Poor Sound Quality Or Noise702

Poor Sound Quality704

Cassette Tape Will Not Load705

Cassette Tape Will Not Play706

Compact Disc Will Not Load707

Door Speakers710

Headrest Speakers710

Connector Terminal Specifications710

Before Component Replacement715

Prohibitation Of Component Disassembly And Wire Harness Repair715

Heater And Air Conditioner Systems744

Blower Motor Does Not Operate750

Magnetic Clutch Does Not Operate752

Additional (Condenser) Fan Does Not Operate754

Insufficient Cooling755

Intermittent Cooling755

Blower Motor765

Resistor Assembly765

Heater Control Switch Assembly766

Air Conditioner769

Refrigerant System770

Basic Procedure Of Refrigerant System Service770

Refrigerant Container Service Valve770

Installation Of Manifold Gauge Set771

Performance Test773

Checking Refrigerant Charge774

Checking Refrigerant Pressure774

Normal Pressure774

Cooling Unit775

Expansion Valve776

Thermoswitch777

Condenser And Receiver/Drier778

Receiver I Drier779

Refrigerant Lines780

Condenser Fan781

Refrigerant Pressure Switch782

Magnetic Clutch784

Technical Data787

Wiring Diagram811

Wiring Color Code811

Contents Of Wiring Diagrams813

Using Wiring Diagrams813

Ground Points814

Ground Indication814

On Circuit Diagrams And Ground Points814

System Circuit Diagram/Connector Diagram815

Routing Diagram817

Harness Symbols818

Logic Symbols821

Abbreviations Used In This Booklet821

Precautions When Servicing Electrical System822

Handling Connectors823

Using Electrical Test Equipment824

Measuring Voltage825

Measuring Continuity/Resistance826

Checking Switches826

Checking Diodes826

Checking Sensors, Solenoid Valves826

Finding Short Circuits827

Engine Control System841

Terminal Voltage843

Fuel Control System845

Cooling Fan System847

Instrument Clusters849

Power Window882

Parts Catalog897

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Troubleshooting