General Information: Other Mazda MX-5 NC

Range of Topics

1. This article contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: Removal/Installation Disassembly/Assembly Replacement Inspection Adjustment
2. Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.

Repair Procedure

1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are (Scheme 24) In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is (Scheme 24)with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part.

Scheme 24

Symbols

1. There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service.

SYMBOLS REFERENCE Symbol Meaning Kind Symbol Meaning Kind Apply oil New appropriate engine oil or gear oil Apply sealant Appropriate sealant Apply brake fluid New appropriate brake fluid Apply petroleum jelly Appropriate petroleum jelly Apply automatic transaxle/transmission fluid New appropriate automatic transaxle/transmission fluid Replace part O-ring, gasket, etc. Apply grease Appropriate grease Use SST or equivalent Appropriate tools

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Advisory Messages

1. You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this article.

Warning

1. A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution

1. A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note

1. A Note provides added information that will help you to complete a particular procedure.

Upper and Lower Limits

1. The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.

Scheme 31

UNITS

UNITS

Conversion to SI Units (Systems International d'Unites)

1. All numerical values in this article are based on SI units. Numbers shown in conventional units are converted from these values.

Rounding Off

1. Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

1. When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm 2 in the following specifications: 210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi} 270-310 kPa {2.7-3.2 kgf/cm 2 , 39-45 psi}
2. The actual converted values for 2.7 kgf/cm 2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39.

Protection of the Vehicle

1. Always be sure to cover fenders, seats and floor areas before starting work.

Scheme 32

Preparation of Tools and Measuring Equipment

1. Be sure that all necessary tools and measuring equipment are available before starting any work.

Scheme 33

Special Service Tools

1. Use special service tools or equivalent when they are required.

Scheme 34

Disconnection of the Negative Battery Cable

1. Before beginning any work, turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 min to allow the backup power supply of the SAS control module to deplete its stored power. Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is necessary to verify those memories before disconnecting the cable.

Using UV light (black light)

1. Remove any oil on the engine or transaxle/transmission. NOTE: Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or ATF (or transaxle/transmission oil).
2. Pour the fluorescent dye into the engine oil or ATF (or transaxle/transmission oil).
3. Allow the engine to run for 30 min.
4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
5. If no dye leakage is found, allow the engine to run for another 30 min. or drive the vehicle then reinspect.
6. Find where the oil is leaking from, then make necessary repairs. NOTE: To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the fluorescent dye instruction manual.

Scheme 35

1. Gather some of the leaking oil using an absorbent white tissue.
2. Take samples of engine oil and ATF (or transaxle/transmission oil), both from the dipstick, and place them next to the leaked oil already gathered on the tissue.
3. Compare the appearance and smell, and identify the type of oil that is leaking.
4. Remove any oil on the engine or transaxle/transmission.
5. Allow the engine to run for 30 min.
6. Check the area where the oil is leaking, then make necessary repairs.

Arrangement of Parts

1. All disassembled parts should be carefully arranged for reassembly.
2. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

Scheme 36

Cleaning of Parts

1. All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.

Scheme 37

Scheme 38

1. Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
2. If removed, these parts should be replaced with new ones: Oil seals Gaskets O-rings Lock washers Cotter pins Nylon nuts
3. Depending on location: Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. Oil should be applied to the moving components of parts. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.

Scheme 39

Rubber Parts and Tubing

1. Prevent gasoline or oil from getting on rubber parts or tubing.

Scheme 40

Hose Clamps

1. When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.

Scheme 41

Dynamometer

1. When inspecting and servicing the power train on the dynamometer or speed meter tester, pay attention to the following: Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Make sure the vehicle is in a facility with an exhaust gas ventilation system. Since the rear bumper might deform from the heat, cool the rear with a fan. (Surface of the bumper must be below 70°C {158°F} degrees .) Keep the area around the vehicle uncluttered so that heat does not build up. Watch the water temperature gauge and don't overheat the engine. Avoid added load to the engine and maintain normal driving conditions as much as possible. NOTE: When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the ABS/DSC CM determines that there is a malfunction in the ABS/DSC and illuminates the following lights: Vehicles with ABS ABS warning light Brake system warning light Vehicles with DSC ABS warning light Brake system warning light DSC indicator light If the above lights are illuminated, dismount the vehicle from the chassis dynamometer and turn the ignition switch to the LOCK position. Then, turn the ignition switch back to the ON position, run the vehicle at 10 km/h or more and verify that the warning lights go out. In this case, a DTC will be stored in the memory. Clear the DTC from the memory by following the memory clearing procedure [ABS]/[DSC] in the on-board diagnostic system. (See «ON-BOARD DIAGNOSIS [ABS]»(ref-244446-S22194336232006092400000) .), (See «ON-BOARD DIAGNOSIS [DYNAMIC STABILITY CONTROL]»(ref-244447-S25208804762006092400000) .)

SST

1. Some global SST or equivalent are used as SSTs necessary for engine repair. Note that these SSTs are marked with global SST numbers.
2. Note that a global SST number is written together with a corresponding Mazda SST number (Scheme 39)below.

Example ( ENGINE -- SERVICE TOOLS )

Scheme 42

Example (except ENGINE -- SERVICE TOOLS )

Scheme 43

Battery Cable

1. Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-244448-S25513985422006092400000) .)

Scheme 44

Locking Connector

1. When locking connectors, listen for a click indicating they are securely locked.

Scheme 45

Scheme 46

Scheme 47

1. When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.
2. Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side. CAUTION: To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into terminal.

Sensors, Switches, and Relays

1. Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.

Scheme 48

Direction of View for Connector

1. The viewing direction of connectors is indicated with a symbol.
2. The figures showing the viewing direction are the same as those used in Wiring Diagrams.
3. The viewing directions are shown in the following three ways

Part-Side Connector

The viewing direction of part-side connectors is from the terminal side.

*: Part names are shown only when there are multiple connector drawings.

Scheme 49

Other

When it is necessary to show the terminal side of vehicle harness-side connectors, such as the following connectors, the viewing direction is from the terminal side.

1. Main fuse block and the main fuse block relays
2. Data link connector
3. Check connector
4. Relay box

Scheme 50

Jumper Wire

1. A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch.

Scheme 51

Voltmeter

1. The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage will be measured and the negative (-) probe (black lead wire) to a body ground.

Scheme 52

Ohmmeter

1. The ohmmeter is used to measure the resistance between two points in a circuit and to inspect for continuity and short circuits.

Scheme 53

Precautions Before Welding

A vehicle has various electrical parts. To protect the parts from excessive current generated when welding, be sure to perform the following procedure.

Scheme 54

1. Turn the ignition switch to the LOCK position.
2. Disconnect the battery cables.
3. Securely connect the welding machine ground near the welding area.
4. Cover the peripheral parts of the welding area to protect them from weld spatter.

JACKING POSITIONS

1. Use safety stands to support the vehicle after it has been lifted.

Front

Note. To prevent obstruction between the jack body and front bumper when the jack body is inserted, use a low-floor type jack (frame height is 170 mm or less). Near the center of the front crossmember.

Scheme 55

Rear

1. At the center of the rear differential.

Scheme 56

Front and Rear

1. Both sides of the vehicle, on side sills

Scheme 57

1. Both sides of the vehicle, on side sills

Scheme 58

TOWING

1. Proper lifting and towing are necessary to prevent damage to the vehicle. State and local laws must be followed.
2. A towed vehicle usually should have its rear wheels off the ground. If excessive damage or other conditions prevent this, use wheel dollies.

Scheme 59

Scheme 60

Scheme 61

Tiedown Hooks

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

1. Remove the tiedown eyelet from trunk.
2. Wrap a screwdriver or similar tool with a soft cloth to prevent damage to the painted bumper and open the cap located on the front bumper. CAUTION: The cap cannot be completely removed. Do not use excessive force as it may damage the cap or scratch the painted bumper surface.
3. Securely install the tiedown eyelet using the lug wrench.
4. Hook the tying rope to the tiedown eyelet. CAUTION: If the tiedown eyelet is not securely tightened, it may loosen or disengage from the bumper when tying down the vehicle. Make sure that the tiedown eyelet is securely tightened to the bumper.

Scheme 68

Scheme 69

SAE STANDARDS

1. In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this article. The «SAE STANDARDS TABLE»(ref-244444-S41900143942006092400000) lists the names and abbreviations that have been used in Mazda articles up to now and their SAE equivalents.

SAE STANDARDS TABLE

Exterior

INSPECT and ADJUST , if necessary, the following items to specification

1. Glass, exterior bright metal and paint for damage
2. Convertible top and detachable hardtop (if equipped) for damage
3. Wheel lug nuts
4. All weatherstrips for damage or detachment
5. Operation of hood release and lock
6. Operation of trunk lid and fuel-filler lid
7. Door operation and alignment
8. Headlight aiming

TRUNK ROOM

1. Check spare tire and air pressure
2. Inspect operation of trunk lid internal release

INSTALL the following items

1. Wheel caps (if equipped)
2. Mast antenna (if equipped)

Under Hood-Engine Off

INSPECT and ADJUST , if necessary, the following items to specification

1. Fuel, engine coolant, and hydraulic lines, fittings, connections, and components for leaks
2. Engine oil level
3. Power steering fluid level
4. Brake and clutch master cylinder fluid level
5. Windshield washer reservoir fluid level
6. Automatic transmission fluid level
7. Radiator coolant level and specific gravity
8. Tightness of battery terminals

Interior

INSPECT the operations of the following items

1. Seat controls (slide and recline)
2. Seat belts and warning system
3. Air bag system using warning light
4. Cruise control system (if equipped)
5. Ignition switch and steering lock
6. Starter interlock
7. Power door lock
8. Door locks, including childproof door locks
9. All lights including warning, and indicator lights
10. Horn, wipers, and washers
11. Wiper blades performance
12. Audio system
13. Power windows (if equipped)
14. Heater, defroster, and air conditioner at various mode selections (if equipped)

INSPECT the following items

1. Presence of spare fuse
2. Upholstery and interior finish

INSPECT and ADJUST , if necessary, the following items

1. Pedal height and free play of brake and clutch pedal
2. Parking brake

Under hood-engine running at operating temperature

INSPECT the following items

1. Automatic transmission fluid level

On Hoist

INSPECT the following items

1. Underside fuel, coolant and hydraulic lines, fittings, connections, and components for leaks
2. Tires for cuts or bruises
3. Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage
4. Manual transmission oil level
5. Differential oil level

Schedule 1 (Normal Driving Conditions) U.S.A.

1. The vehicle is mainly operated where none of the "unique driving conditions" apply.

MAINTENANCE REFERENCE (SCHEDULE 1)

Schedule 2 CANADA, Puerto Rico, and (Unique Driving Conditions) USA

1. Repeated short-distance driving.
2. Driving in dusty conditions.
3. Driving with extended use of brakes.
4. Driving in areas where salt or other corrosive materials are used.
5. Driving on rough or muddy roads.
6. Extended periods of idling or low-speed operation.
7. Driving for long periods in cold temperatures or extremely humid climates.

MAINTENANCE REFERENCE (SCHEDULE 2)