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Mazda MX-5 Miata 1.8 Enthusiast's Workshop Manual
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Table of Contents

A(c) Rod Grainger & Veloce Publishing Chapter 1: General advice & using this manual 1. Using this manual 1:1 Conventions 1:1 Symbols & cross-references 1:1 Hey! Watch out! 1:2 2. Working procedures 1:2 General 1:2 Work area & storage facilities 1:2 Hose connections 1:2 Gaskets & seals 1:3 Screws, bolts & nuts 1:4 Torque tightening by feel 1:4 Electrical connections & wire color coding 1:4 Wrestling with two-piece plastic panel fasteners 1:5 3. Jacking & supporting the car 1:5 4. Cleaning components 1:6 5. Buying new parts 1:7 6. Tools & equipment 1:7 7. Dealing with breakdowns 1:8 8. Technical specifications 1:9 General 1:9 Dimensions 1:9 Transmission 1:9 Chassis 1:9 Engine - detail 1:9 Lubrication system (engine) 1:12 Cooling system 1:12 Fuel & emission control systems 1:13 Electrical system (engine) 1:13 Clutch 1:14 Transmission (gearbox), manual 1:14 Transmission, automatic 1:15 Driveshaft (propshaft) 1:15 Front axle 1:16 Rear axle 1:16 Differential 1:16 Steering 1:16 Braking system 1:16 Wheels & tires 1:17 Suspension 1:17 Wheel alignment 1:18 Electrical system (body) 1:18 Chapter 2: Tune-up & maintenance 1. Introduction 2:1 2A. Maintenance schedule: USA 2:2 2B. Maintenance schedule: USA (abnormal operating conditions) 2:3 2C. Maintenance schedule: Canada 2:4 -------------------------------------------------------------------------------- 2D. Maintenance schedule: UK & rest of world 2:6 3. Engine oil & oil filter - changing 2:7 4. Drivebelts (external) - inspection, replacement & adjustment 2:8 5. Air cleaner (filter) element - replacement 2:9 6. Sparkplugs - checking, cleaning & adjusting 2:9 7. Idle speed - checking & adjustment 2:10 8. Transmission (manual) oil - checking level & changing 2:10 9. Transmission (auto) fluid - checking level & changing 2:11 10. Differential oil - checking level & changing 2:11 11. Battery - checking charge, specific gravity & electrolyte level 2:12 12. Ignition timing - checking & adjusting 2:13 13. Driveaxles (halfshafts), rear - checking 2:13 14. Engine coolant - topping-up & changing 2:14 15. Lights, horn, wipers & washers - checking 2:15 16. Tires - checking pressures & condition 2:15 17. Body - general maintenance 2:16 18. Steering & suspension- checking 2:17 19. Exhaust system - checking 2:18 20. Brake & clutch fluid - checking level & replacing 2:18 Chapter 3: Engine & clutch 1. Major work possible with engine in car 3:1 2. Major work requiring engine removal 3:1 3. Engine removal methods & preparation 3:1 4. Engine - removal (with transmission) 3:1 5. Engine - removal (without transmission) 3:12 6. Engine dismantling - general advice 3:12 7. Engine dismantling 3:13 Intake manifold & wiring removal 3:13 Fuel rail removal 3:14 Starter motor removal 3:14 Engine mounting removal 3:14 Oil filter & oil cooler removal 3:14 Alternator removal 3:14 Exhaust manifold removal 3:15 Clutch removal 3:16 Sparkplug wires & coils removal 3:16 Thermostat removal 3:16 Cambox cover removal 3:17 Camshaft drivebelt removal 3:17 Camshaft drivebelt tensioner wheel & tensioner spring removal 3:18 Camshaft pulleys removal 3:18 Cylinder head front sealing plate removal 3:19 Thermostat housing removal 3:19 Water pump removal 3:19 Crankshaft inner pulley removal 3:19 Camshaft removal 3:20 Cam followers removal 3:20 Cylinder head removal 3:20 Valves removal 3:21 -------------------------------------------------------------------------------- Valve guides removal & installation 3:21 Oil pan removal 3:22 Oil pump, pickup pipe & oil pan baffle removal 3:22 Oil pump & oil pressure relief valve teardown 3:23 Flywheel (driveplate - auto trans) removal 3:23 Engine backplate removal 3:23 Crankshaft rear oil seal housing removal 3:23 Connecting rod (big end) caps, con rods & pistons removal 3:24 Main bearing caps & crankshaft removal 3:24 Piston oil jets removal 3:25 Pistons removal from connecting rods 3:25 Piston rings removal 3:25 Engine teardown conclusion 3:26 8. Engine components - checking & repair 3:26 Checking & repair general 3:26 Cylinder head & valves removing carbon 3:26 Cylinder head checking & repair 3:26 Valves, guides & valve seats checking, repair & valve lapping 3:26 Valve springs checking & repair 3:27 Camshafts & camshaft bearings checking & repair 3:28 Cam followers checking & repair 3:28 Cylinder block checking & repair: core plug renewal 3:29 Pistons: removing carbon 3:29 Pistons, piston rings & piston pins checking & repair 3:29 Connecting rods checking & repair 3:30 Crankshaft & crankshaft bearings checking & repair 3:30 Cam drivebelt, tensioner, idler & pulleys checking & repair 3:31 Oil pump checking & repair 3:31 Oil jets checking & repair 3:31 Flywheel, pilot bearing & starter ring gear checking & repair 3:31 Driveplate (auto-trans) & starter ring gear checking & repair 3:32 Clutch cover, disc, release bearing & fork checking & repair 3:32 9. Engine rebuild 3:32 Engine rebuild general 3:32 Piston rings installation 3:32 Pistons & connecting rods rebuild & installation 3:33 Oil jets rebuild & installation 3:33 Crankshaft & bearing shells installation 3:33 Connecting rods & caps fitting to crankshaft 3:34 Crankshaft rear cover: oil seal installation 3:34 Crankshaft rear cover installation 3:34 Oil pump rebuild & fitting new oil seal 3:35 Oil pump installation 3:35 Oil pan baffle, oil pump pickup pipe & oil pan installation 3:35 Engine backplate installation 3:36 Flywheel (driveplate - auto trans) installation 3:36 Water pump installation 3:36 Valves, springs & valve stem oil seals installation 3:36 Cylinder head installation 3:37 Thermostat housing installation 3:37 -------------------------------------------------------------------------------- Cylinder head seal plate installation 3:38 Cam followers installation 3:38 Camshafts installation 3:38 Camshaft oil seals installation 3:38 Camshaft pulleys installation 3:38 Cam drivebelt idler & tensioner wheels & spring installation 3:39 Crankshaft inner (cam drivebelt) pulley installation 3:39 Camshaft drivebelt installation & valve timing 3:39 Cam drivebelt covers, w/pump & crankshaft pulley installation 3:40 Cambox cover installation 3:41 Thermostat & thermostat housing cover installation 3:41 Engine mounting bracket (right-hand) installation 3:41 Oil pressure gauge sender unit installation 3:41 Alternator installation 3:42 Oil cooler & oil filter installation 3:42 Starter motor installation 3:42 Heater outlet cover installation 3:43 Ignition coils & sparkplug wires installation 3:43 Clutch cover & disc installation 3:43 Engine mounting bracket (left-hand) installation 3:43 Power steering pump bracket installation 3:43 Coolant inlet casting installation 3:44 Dipstick tube installation 3:44 Engine lifting eyes installation 3:44 Camshaft position sensor installation 3:44 Manifolds installation special note 3:44 10. Transmission (gearbox) - installation (engine out of car) 3:45 11. Engine & transmission - installation as a unit 3:45 12. Engine - installation (without transmission) 3:55 13. Camshaft drivebelt (timing belt) - replacement (engine in car) 3:56 14. Camshafts & followers - removal & installation (engine in car) 3:57 15. Cylinder head - removal & installation (engine in car) 3:57 Cylinder head checking 3:58 16. Crankshaft front oil seal - replacement (engine in car) 3:58 17. Crankshaft rear oil seal - replacement (engine in car) 3:59 18. Camshaft oil seal - replacement (engine in car) 3:59 19. Starter ring gear - replacement (engine in car) 3:60 20. Engine mountings - replacement (engine in car) 3:60 21. Clutch & release bearing - removal & installation (engine in car) 3:60 22. Clutch master cylinder - removal & installation 3:60 23. Clutch master cylinder - overhaul 3:61 24. Clutch release (slave) cylinder - removal & installation 3:62 25. Clutch release (slave) cylinder - overhaul 3:62 Dismantling & checking 3:62 Rebuild 3:63 26. Clutch hydraulic system - bleeding 3:63 27. Clutch hydraulic lines/hoses - replacement 3:63 28. Clutch pedal height & free play - checking & adjustment 3:64 29. Clutch pedal removal & installation 3:65 -------------------------------------------------------------------------------- Chapter 4: Transmission & driveline 1. Transmission (gearbox) - preparation for removal 4:1 2. Transmission (gearbox), manual - removal 4:1 3. Transmission (gearbox), automatic - removal 4:4 4. Transmission (gearbox), manual - dismantling & rebuild general 4:5 5. Transmission (gearbox), manual - teardown 4:6 6. Transmission (gearbox), manual - components checking & repair 4:13 Mainshaft gear pinions 4:13 Mainshaft 4:14 Input shaft & countershaft 4:14 Clutch/selector hubs & forks 4:14 Synchro rings 4:14 Bearings 4:14 Springs 4:14 Casings 4:15 7. Transmission (gearbox), manual - rebuild 4:15 8. Transmission (gearbox), manual - installation 4:24 9. Transmission (gearbox), automatic - installation 4:24 10. Driveshaft (propshaft) - removal, checking, repair & installation 4:25 11. Transmission (gearbox) rear oil seal - replacement 4:26 12. PPF (Power Plant Frame) - removal & installation 4:26 13. Driveaxles - removal, checking, repair & installation 4:26 14. Driveaxle - dismantling, rebuild & new boots 4:27 15. Differential unit & carrier - removal & installation 4:27 16. Differential side (driveaxle) oil seals - replacement 4:28 17. Differential nose (pinion) oil seal - replacement 4:28 18. Differential unit carrier mountings - replacement 4:28 19. Differential unit - teardown & rebuild 4:28 20 Transmission (gearbox), automatic - troubleshooting 4:28 Chapter 5: Engine management, fuel, ignition & exhaust systems 1. Introduction 5:1 2. PCM system - component summary 5:1 Air cleaner (ACL) 5:1 Air valve (BAC valve) 5:2 Camshaft position sensor (CMP) 5:2 Catalytic converter 5:2 Charcoal canister 5:2 Clutch switch 5:2 Coolant temperature sensor 5:2 Crankshaft position sensor (CKP) 5:2 Data link connector (DLC) 5:2 Exhaust gas recirculation (EGR) system 5:2 Fuel pump relay (FPR) 5:2 Fuel filter 5:2 Fuel pump 5:2 Fuel vapor valve 5:2 Heated oxygen sensor 5:2 Idle air control (IAC) valve 5:2 Ignition coil 5:2 -------------------------------------------------------------------------------- Ignition control module 5:2 Ignition switch 5:2 Injector 5:2 Intake air temperature (IAT) sensor 5:2 Main relay 5:2 Malfunction indicator lamp 5:2 Mass airflow sensor (MAF) 5:2 Neutral switch 5:2 On board diagnostic (OBD) system 5:2 Positive crankcase ventilation (PCV) valve 5:3 Power steering pressure (PSP) switch 5:3 Powertrain control module (PCM) 5:3 Pressure regulator 5:3 Pressure regulator control (PRC) solenoid valve 5:3 Purge solenoid valve 5:3 Resonance chamber 5:3 Stoplight switch 5:3 Throttle body 5:3 Throttle sensor 5:3 Two port check valve (three port, automatic trans) 5:3 3. PCM system - overview 5:3 Fuel system 5:4 Air intake system 5:4 Emission control system 5:4 4. Powertrain control system - troubleshooting tips 5:5 Fault codes 5:5 5. Engine compression check 5:6 6. Air intake system checks 5:6 7. Throttle body - removal, inspection & installation 5:6 8. Accelerator cable & pedal - adjustment & cable replacement 5:7 9. Intake manifold - removal, checking & installation 5:9 10. Air intake control (IAC) valve - checking 5:11 11. Air (BAC) valve - removal, checking & installation 5:11 12 Fuel system - description 5:11 13. Fuel system - safety, depressurizing & repressurizing 5:11 Releasing fuel system pressure 5:11 Disconnecting fuel lines 5:11 Priming fuel system 5:12 14. Fuel system - checking 5:12 Fuel pump relay checking 5:12 Fuel pump checking 5:12 Fuel pressure checking 5:12 Fuel pressure hold checking 5:12 Fuel maximum pressure checking 5:13 Fuel line pressure checking 5:13 Pressure regulator control (PRC) valve checking 5:13 Injector operation checking 5:13 Fault not located? 5:13 15. Fuel tank - removal, checking & installation 5:13 Draining the fuel tank 5:14 -------------------------------------------------------------------------------- Inspection & repair 5:16 16. Fuel pump/fuel gauge sender - removal & installation 5:18 17. Fuel pump relay - removal & installation 5:20 18. Fuel pressure regulator - removal & installation 5:20 19. Fuel injectors & rail - removal, leak testing & installation 5:20 20. Fuel filter - removal & installation 5:21 21. Emissions control system - introduction 5:22 22. PCV valve - checking & replacement 5:22 23. EVAP/EGR systems - component checking & replacement 5:22 Fuel vapor valve 5:23 Two-way check valve (three-way check valve, auto trans) 5:23 EVAP system hoses 5:24 Charcoal canister 5:24 Purge solenoid valve 5:24 EGR valve 5:24 EGR solenoid valves 5:24 EGR boost sensor 5:25 EGR valve position sensor 5:25 24. Dechoke control system - description 5:25 25. Ignition system - introduction 5:25 26. Ignition timing - checking & adjusting 5:25 27a. Ignition system checks 5:26 Self-diagnosis (OBD system) checks 5:26 Sparkplugs 5:26 Sparkplug leads 5:27 Ignition coils 5:27 27b. Ignition coils - removal & installation 5:27 28. PCM (powertrain control module) 5:28 29a. Camshaft position sensor - removal, checking & installation 5:29 29b. Crankshaft position sensor - adjustment, removal & installation 5:29 30. Mass airflow (MAF) sensor - removal, checking & installation 5:30 31. Engine coolant temp. sensor - removal, checking & installation 5:30 32. TPS unit - checking, adjustment, removal & installation 5:31 33. Heated oxygen sensor - checking, removal & replacement 5:31 34. Power steering pressure switch - checking, removal & installation 5:32 35. Main (fuel injection) relay - checking & replacement 5:32 36. Clutch switch - checking, removal & installation 5:33 37. Neutral switch - checking, removal & installation 5:33 38. Exhaust system - checking, removal & replacement 5:34 39. Exhaust manifold removal & installation 5:36 Chapter 6: Cooling, heating & air conditioning systems 1. Introduction 6:1 2. Engine coolant - topping-up & changing 6:1 Mixing engine coolant 6:2 Topping up the cooling system 6:2 Changing the coolant 6:2 3. Cooling system - checking 6:2 4. Cooling system - hose replacement 6:3 Top hose 6:3 -------------------------------------------------------------------------------- Bottom hose 6:3 Coolant inlet casting & hose connections 6:4 Heater hose connections 6:4 Intake manifold hose connections 6:4 After fitting new hoses 6:4 5. Radiator - removal & installation 6:4 6. Thermostat - removal, testing & installation 6:5 7. Water pump - removal & installation 6:6 8. Radiator fan/s - testing, removal & installation 6:6 Checking coolant temperature sensor 6:7 Fan motor testing 6:7 Fan motor removal & installation 6:7 Fan relay testing 6:7 9. Heating & ventilation system - how it works 6:8 10. Blower unit - checking 6:8 Checking the circuit breaker or fuse 6:8 Checking the blower motor voltage 6:8 Checking the blower resistor 6:8 11. Blower unit - resistor removal & installation 6:8 12. Blower motor - removal & installation 6:9 13. Blower unit - removal & installation 6:9 14. Heater unit - removal, inspection & installation 6:9 15. Heater/air con control assy - removal, inspection & installation 6:11 Checking the blower & air conditioning switch 6:11 16. Air conditioning system - checking 6:12 Precautions 6:12 Visual check of refrigerant charge 6:13 Checking thermoswitch operation 6:13 Checking system fittings & refrigerant lines 6:13 Checking the condenser cooling fan 6:13 Checking the air conditioning relay 6:13 Magnetic clutch checks 6:13 Chapter 7: Electrical system 1. Introduction 7:1 2. Electrical system - procedures, precautions & jump starting 7:1 Isolating & reconnecting battery 7:1 Electrical test equipment 7:1 Wiring connectors 7:2 Wiring & color coding 7:2 Fuses & relays 7:3 Power point 7:3 Booster (Jump) starting 7:3 3. Fuses & relays - location, removal & replacement 7:4 4. Charging system - general 7:6 5. Battery - removal, checking, charging & installation 7:6 Removal & cleaning 7:7 Battery voltage check 7:7 Battery charging 7:7 Battery installation 7:8 -------------------------------------------------------------------------------- Installing a new battery 7:8 6. Charging system - troubleshooting 7:8 7. Alternator - checking 7:8 Checking the terminal voltages 7:8 Checking alternator operation 7:8 Checking the dark current 7:8 8. Alternator - removal, overhaul & installation 7:8 9. Starter system - description & troubleshooting 7:10 Initial checks 7:10 Interlock switch - checking (manual trans) 7:11 Range switch checking & adjustment (auto trans) 7:11 10. Starter motor - removal, overhaul & installation 7:12 Testing 7:12 11a. Ignition switch - t/shooting, removal & installation 7:14 11b. Key (ignition) reminder switch - troubleshooting 7:14 12. Combination switch - t/shooting, removal & installation 7:14 13. H/light retract & haz. warn. switch - removal, t/shooting & install. 7:15 14. Instrument panel - removal, t/shooting & installation 7:16 Removal 7:16 Bulb replacement 7:17 Speedometer 7:17 Tachometer (rev counter) 7:18 Engine temperature sender unit & gauge 7:18 Fuel gauge sender & fuel gauge 7:18 Oil pressure gauge 7:18 General checks 7:18 Installation 7:18 15. Warning lamps, switches & sensors - location & t/shooting 7:19 Brake warning circuit 7:19 Hazard warning indicator light circuit (not fitted on all models) 7:19 "Hold" circuit (auto transmission models) 7:19 Seatbelt warning circuit (where fitted) 7:19 Windshield washer fluid level sensor circuit (where fitted) 7:20 16. Lighting system - initial troubleshooting 7:20 17. Headlight circuit - troubleshooting 7:20 18. Headlight raise/retract system - troubleshooting 7:21 19. Headlight dim-dip system (if fitted) - troubleshooting 7:22 20. Headlight passing light (flasher) system - troubleshooting 7:22 21. Headlight beam - adjustment 7:22 22. Headlamp deck height - adjustment 7:23 23. Headlight retractor motor - t/shooting, removal & installation 7:23 24. Headlight unit - removal, installation & bulb replacement 7:25 25. Parking light (sidelight) circuit -troubleshooting 7:26 Parking front & rear, side marker & license plate lights. 7:26 26. Daytime running lights (DRL) circuit - troubleshooting 7:26 27. Stop (brake) light circuit - troubleshooting 7:28 28. Turn signal & hazard warning circuit - troubleshooting 7:28 29. Backup (reversing) light circuit -troubleshooting 7:30 30. Tail light unit - bulb & lens replacement 7:32 31. Front combination light unit - bulb replacement 7:32 32. Side marker lights (where fitted) - bulb replacement 7:33 -------------------------------------------------------------------------------- 33. Turn signal side repeater lights (where fitted) - bulb replacement 7:33 34. License plate light - bulb replacement 7:33 35. Foglight, rear (where fitted) - bulb replacement 7:33 36. Driving/foglights, front (where fitted) - bulb replacement 7:33 37. Interior lights - troubleshooting & bulb replacement 7:34 38. Trunk (boot) light - troubleshooting & bulb replacement 7:35 39. Panel light control switch (where fitted) - testing 7:35 40. Horn circuit - troubleshooting & horn replacement 7:35 41. Rear window defogger (where fitted) - troubleshooting & repair 7:36 42. Cruise control system - self-diagnosis function 7:37 43. Cruise control system - troubleshooting 7:38 44. Airbag system - working procedures, disarming & re-arming 7:40 Description 7:40 Working procedures 7:40 Disarming/re-arming airbag system 7:41 45. Airbag system - troubleshooting 7:41 46. Airbag module (driver's) - removal & installation 7:41 47. Airbag module (passenger's) - removal & installation 7:42 48. Windshield wiper & washer system - troubleshooting 7:43 49. Wiper motor - t/shooting, removal, o/haul & installation 7:43 50. Wiper mechanism - removal, installation & adjustment 7:46 51. Windshield washer pump motor - testing & replacement 7:47 52. Headlight washer system (if fitted) - troubleshooting 7:47 53. Cigarette lighter - removal & installation 7:48 54. Audio unit 7:49 Removal & installation 7:49 Security 7:49 Audio system troubleshooting 7:49 Nothing works 7:49 System works on one stereo channel only 7:49 System won't play cassette tapes 7:49 Radio inoperative (cassette tape player OK) 7:49 CD player inoperative - disc will not load 7:50 CD skips during play 7:50 55. Antenna (manual) - removal & installation 7:50 56. Antenna (power) - removal & installation 7:50 57. Alarms & immobilisers - general 7:51 58. Wiring diagrams - general 7:51 Chapter 8: Suspension & steering 1. Introduction 8:1 2. Wheel alignment - general 8:1 3. Wheel alignment - checking & adjustment 8:3 Toe-in (front wheels) - adjustment 8:3 Caster angle (front wheels) - adjustment 8:3 Camber angle (front wheels) - adjustment 8:4 Toe-in (rear wheels) adjustment 8:4 Camber angle (rear wheels) adjustment 8:4 4. Shock absorber & spring (front) - removal, o/haul & installation 8:5 Checking 8:6 -------------------------------------------------------------------------------- 5. Wishbone, lower front - removal, o/haul & installation 8:7 6. Wishbone, upper front - removal, o/haul & installation 8:9 7. Stabilizer bar (front) - removal, checking & installation 8:11 8. Crossmember (front) - removal & installation 8:11 9. Steering (manual) - description 8:12 10. Steering (manual) - checking 8:13 11. Steering wheel & column - removal, checking & installation 8:13 12. Tie rod ball joint & rack dust boot - removal & installation 8:16 13. Steering (manual) rack - removal, o/haul & installation 8:17 14. Steering (power) - description 8:18 15. Steering (power) - fluid level check & air bleeding 8:18 16. Steering (power) - checking for leaks 8:18 17. Steering (power) - pressure check 8:19 18. Steering (power) - checking 8:19 19. Steering (power) rack - removal, o/haul & installation 8:19 20. Steering (power) pump - removal & installation 8:21 21. Steering (power) pump - dismantling, o/haul & reassembly 8:21 22. Shock absorber & spring (rear) - removal, o/haul & installation 8:22 23. Wishbone, lower rear - removal, o/haul & installation 8:23 24. Wishbone, upper rear - removal, o/haul & installation 8:24 25. Stabilizer bar (rear) - removal, checking & installation 8:24 26. Crossmember (rear) - removal, checking & installation 8:25 Chapter 9: Brakes, wheels & tires 1. Brake system - Introduction & on-vehicle checks 9:1 2. Brake hydraulic system - topping-up fluid & bleeding 9:1 3. Brake system hydraulic fluid - replacement 9:2 4. Brake lines & hoses - checking & replacement 9:2 Rigid line replacement 9:2 Flexible hose replacement 9:3 5. Brake pedal - removal, installation & adjustment 9:3 6. Brake master cylinder & servo - removal, installation & adjustment 9:4 Master cylinder removal 9:4 Vacuum servo (power brake) unit removal 9:4 Vacuum servo (power brake) unit installation 9:4 Master cylinder installation 9:5 Special notes: ABS equipped cars 9:5 7. Brake master cylinder - overhaul 9:6 8. Brake servo - checking (in-situ) 9:7 9. Brake proportioning bypass valve - checking (in-situ) 9:7 10. Brake pads (front) - wear check 9:7 11. Brake pads (front) - removal & installation 9:8 12. Brake disc (front) - checking, removal & installation 9:9 13. Brake caliper (front) - removal & installation 9:10 14. Brake caliper (front) - overhaul 9:10 15. Brake pads (rear) - wear check 9:11 16. Brake pads (rear) - removal & installation 9:12 17. Brake disc (rear) - checking, removal & installation 9:14 18. Brake caliper (rear) - removal & installation 9:14 19. Brake caliper (rear) - overhaul 9:15 -------------------------------------------------------------------------------- 20. Parking brake - checking & adjustment 9:16 21. Parking brake lever - removal, checking & installation 9:16 22. Parking brake cable - removal, checking & installation 9:17 Lever to compensator cable - replacement 9:17 Compensator to brake cables - replacement 9:17 23. ABS (anti-lock brake system) - checking 9:18 24. Tires - checking 9:18 Tread wear 9:18 Tire damage 9:18 Matching tires 9:19 Tire size & ratings 9:19 25. Wheel changing (with car's toolkit) 9:19 26. Tires - rotation 9:20 27. Tire pressures - checking & adjusting 9:20 28. Tire fitting & wheel balancing 9:20 29. Wheels - checking & maintenance 9:20 30. Wheel hubs & bearings - checking & overhaul 9:20 31. Wheel studs - removal & installation 9:23 Chapter 10: Interior 1. Introduction 10:1 2. Console, rear (between seats) - removal & installation 10:1 3. Dash center panel - removal & installation 10:2 4. Dash panel - removal, checking & installation 10:3 5. Interior trim - removal & installation 10:7 Front header rail trim & sun visors 10:7 A-pillar trim 10:7 Front side (footwell) trim 10:7 Scuff plate 10:8 Quarter trim 10:8 Door speaker & grille 10:9 Door trim 10:9 6. Door glass & lifter mechanism - removal & installation 10:11 7. Window lift system (power) - checking & overhaul 10:13 8. Window lift system (manual) - checking & overhaul 10:15 9. Door glass alignment - checking & adjustment 10:15 Height adjustment 10:15 Inward/outward adjustment 10:15 Fore/aft adjustment 10:16 Adjustment checks 10:16 10. Door latch & lock assembly - removal, overhaul & installation 10:16 Aftermarket central locking 10:17 11. Seats - removal, checking, overhaul & installation 10:17 12. Carpets - removal & installation 10:19 13. Trunk (boot) carpet & trim - removal & installation 10:20 14. Seatbelts - removal, checking & installation 10:21 15. Brace bar - removal & installation 10:21 Removal 10:21 Installation 10:21 -------------------------------------------------------------------------------- Chapter 11: Body 1. Introduction 11:1 2. Body - maintenance & cosmetic care 11:1 Why maintenance matters 11:1 Washing 11:1 Polishing 11:2 Vinyl trim cleaners & polishes 11:2 Tar spots 11:2 Color restorers 11:2 3. Paintwork - damage repair 11:2 4. Body - damage repair & painting 11:2 Assessing the damage 11:3 Pulling out a dent 11:3 Repairing holed or gashed areas 11:3 Filling 11:4 Sanding 11:4 Painting 11:4 Finishing 11:5 5. Hood (bonnet) - removal & installation 11:6 6. Trunk (boot) lid, fittings & rear panel - removal & installation 11:6 Trunk lid removal & installation 11:7 Trunk latch - removal, installation & adjustment 11:7 Rear finisher (license plate) panel & trunk lock barrel - removal 11:8 Trunk lid balance springs - removal, installation & adjustment 11:9 Trunk lid hinges - removal & installation 11:10 7. Fuel filler cable & lid - removal, installation & emergency opening 11:10 8A. Door mirror - removal & installation 11:11 8B. Door mirror (power) - checking 11:11 9. Door - removal, installation & adjustment 11:12 10. Bumper (rear) - removal & installation 11:13 11. Bumper (front) - removal & installation 11:15 12. Fender (wing), front - removal & installation 11:17 13. Windshield - removal & installation 11:18 14. Hard top - installation & adjustment 11:19 15. Convertible top - removal, installation & adjustment 11:19 16. Convertible top rear window & rain rail - removal & installation 11:21 17. Convertible top fabric - removal & installation 11:22 18. Convertible top - fabric repairs 11:25 Chapter 12: Underbody & rustproofing 1. Introduction 12:1 2. Rustproofing - why it's a good idea 12:1 3. Rustproofing procedure 12:1 Chapter 13: Troubleshooting Introduction 13:1 Engine problems 13.1 Won't start/stops suddenly 13:1 Does not crank when starter operated 13:1 Cranks very slowly when starter operated 13:1 -------------------------------------------------------------------------------- Cranks normally, but does not start 13:2 Difficult to start when cold 13:2 Difficult to start when warm 13:2 Starts, but doesn't run normally 13:2 Idle (tickover) erratic or rough 13:2 Stalls 13:2 Hesitates or stumbles during acceleration 13:2 Power surges/losses when gas pedal held steady 13:2 Lacks power 13:3 Engine runs roughly during deceleration 13:3 Abnormal fuel consumption 13:3 Low oil pressure 13:3 Excessive oil consumption 13:3 Clutch problems 13:3 Clutch does not release when pedal depressed 13:3 Clutch slipping 13:3 Clutch judder 13:3 Unusual noise 13:3 Transmission (manual) problems 13:3 Gear engagement difficult or noisy 13:3 Transmission jumps out of gear 13:4 Unusual noises 13:4 Abnormal vibration 13:4 Transmission (automatic) problems 13:4 General 13:4 Final drive problems 13:4 Engine runs normally, & gears engage, but car does not move 13:4 Abnormal noise or vibration 13:4 Cooling system problems 13:4 Overheating indicated &/or steam from under hood (bonnet) 13:4 Coolant ejected from overflow pipe/oil in coolant 13:4 Temperature gauge needle does not reach 'normal' sector 13:4 Coolant loss 13:4 Steering & suspension problems 13:4 Car wanders off line 13:4 Excessive steering free play 13:4 Steering excessively stiff or heavy (manual steering) 13:4 Steering excessively stiff or heavy (power steering) 13:4 Wheel (front) wobble or vibration 13:4 Wheel (rear) wobble or vibration 13:5 Car rolls excessively or wallows in corners 13:5 Abnormal tire wear 13:5 Abnormal smells, noises or vibration 13:5 Fuel smells in or around car 13:5 Smell of burning 13:5 Sulfur (sulphur) smell from exhaust 13:5 Unusual noises 13:5 Pinging or knocking sound when engine under load 13:5 Light tapping or rattling noise from engine 13:5 Rumbling or knocking noises from engine 13:5 -------------------------------------------------------------------------------- Squealing or screeching from under hood (bonnet) 13:5 Whistling noises from under hood (bonnet) 13:5 Exhaust system noises 13:5 Droning or rumbling from wheel area 13:5 Clutch noises 13:5 Suspension noises 13:5 Brake system problems 13:5 Poor brake performance 13:5 Brakes pull to one side 13:6 Brakes dragging 13:6 Excessive pedal movement 13:6 Brake noise or vibration 13:6 Anti-lock braking system (ABS) malfunction 13:6 Parking brake ineffective 13:6 Electrical problems 13:6 Battery becomes discharged frequently 13:6 Headlights dim or inoperative 13:6 Turn signals inoperative on one side only 13:6 Turn signals inoperative on both sides of car 13:6 Burned out fuses or circuit breaker open 13:6 Index 14:1 A(c) Rod Grainger & Veloce Publishing

About the Author

Rod Grainger, the Publisher at Veloce, has been involved with automotive publishing for forty years, and has written a number of car-related books including several workshop manuals. Rod thought the design and concept of the Mazda MX-5 was inspirational and that it would attract owners interested in maintaining, repairing and improving their cars. Also that such owners would appreciate a different kind of technical manual, one aimed at enthusiasts and written in a friendly, jargon-free, even humourous manner.

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