ROD GRAINGER
INTRODUCTION & ACKNOWLEDGEMENTS
Introduction & acknowledgements 0:8
CHAPTER 1: WORKING PROCEDURES & TECHNICAL SPECIFICATIONS
5. Buying new parts 1:7
4. leaning components 1:7
7. Dealing with breakdowns 1:8
3. Jacking and supporting the car 1:6
8. Technical specifications 1:10
Air conditioning system 1:26
Chassis 1:10
Clutch 1:17
Cooling system 1:14
Differential 1:22
Dimensions and weights 1:10
Electrical system (body) 1:25
Electrical system (engine) 1:16
Engine - detail 1:10
Engine - general 1:10
Front axle 1:21
Fuel and emission control systems 1:15
General 1:10
Lubrication system (engine) 1:13
Propshaft 1:21
Rear axle 1:22
Suspension 1:24
Transmission 1:10
Transmission (automatic) 1:18
Transmission (manual) 1:17
Wheels and tires 1:23
6. Tools & equipment 1:8
1. Using this manual 1:1
Conventions 1:1
Hey! Watch out! 1:2
Symbols & cross-references 1:1
2. Working procedures 1:2
Electrical connections & wire color coding 1:5
Gaskets & seals 1:3
General 1:2
Hose connections 1:3
Plastic fasteners 1:5
Screws, bolts & nuts 1:4
Torque tightening by feel 1:4
Work area/storage facilities 1:2
CHAPTER 2: TUNE-UP & MAINTENANCE
5. Air cleaner element - replacement 2:7
11. Battery - checking charge level, specific
gravity & electrolyte level 2:10
20. Brake & clutch fluid - checking level & changing 2:17
10. Differential oil - checking level & changing 2:9
4. Drivebelts (external) - inspection, replacement & adjustment 2:6
14. Engine coolant - topping-up & changing 2:12
3. Engine oil & oil filter - changing 2:5
19. Exhaust system - checking 2:16
17. General body maintenance 2:14
7. Idle speed - checking & adjustment 2:8
12. Ignition timing - checking & adjusting 2:11
1. Introduction 2:1
15. Lights, horn, wipers & washers - checking 2:13
2B. Maintenance schedule: Canada (& USA abnormal
operating conditions) 2:3
2C. Maintenance schedule: Europe & other markets 2:4
2A. Maintenance schedule: USA 2:2
13. Manifold fasteners - checking tightness 2:11
6. Spark plugs - checking, cleaning & adjusting 2:7
18. Steering & suspension checks 2:15
16. Tire pressures and checks 2:14
8. Transmission oil (manual trans) - checking level & changing 2:8
9. Transmission oil (auto trans) - checking level & changing 2:9
CHAPTER 3: ENGINE & CLUTCH
13. Camshaft drivebelt - replacement (engine in car) 3:49
14. Camshafts & followers - removal & installation (engine in car) 3:50
19. Clutch & release bearing - removal & installation (engine in car) 3:53
27. Clutch hydraulic lines/hoses - replacement 3:57
26. Clutch hydraulic system - air bleeding 3:57
22. Clutch master cylinder - removal & installation 3:55
23. Clutch master cylinder - teardown & rebuild 3:55
28. Clutch pedal height & lash - checking & adjustment 3:58
29. Clutch pedal removal & installation 3:58
24. Clutch release (slave) cylinder - removal & installation 3:56
25. Clutch release (slave) cylinder - teardown & rebuild 3:56
16. Crankshaft front oil seal - replacement (engine in car) 3:52
17. Crankshaft rear oil seal - replacement (engine in car) 3:53
15. Cylinder head - removal & installation (engine in car) 3:51
11. Engine & transmission - installation as a unit 3:41
12. Engine - installation (without transmission) 3:48
21. Engine mountings - replacement (engine in car) 3:54
3. Engine removal methods and preparation 3:1
4. Engine - removal (without transmission) 3:1
5. Engine - removal (with transmission) 3:8
6. Engine teardown - general advice 3:9
7. Engine teardown 3:9
8. Engine components - checking & repair 3:23
9. Engine rebuild 3:29
1. Major work possible with engine in car 3:1
2. Major work requiring engine removal 3:1
18. Starter ring gear - replacement (engine in car) 3:53
10. Transmission - fitting to engine (out of car) 3:41
20. Water pump - removal & installation (engine in car) 3:54
CHAPTER 4: TRANSMISSION & DRIVELINE
25. 4AT control unit, auto trans - testing 4:31
17. Differential nose (pinion) oil seal - replacement 4:27
16. Differential side (output shaft) oil seals - replacement 4:27
15. Differential unit and carrier - removal & installation 4:26
18. Differential unit carrier mountings - replacement 4:28
19. Differential unit - teardown and rebuild 4:28
13. Driveshaft - removal, checking, repair & installation 4:25
14. Driveshaft - teardown & rebuild 4:26
20. Electronic devices, auto trans - general 4:28
22. Kickdown & 4-3 switch, auto trans - testing & replacement 4:29
21. O/drive electrical system, auto trans - testing
& component replacement 4:28
12. PPF (Power Plant Frame) - removal & installation 4:25
10. Propshaft - removal, checking, repair & installation 4:25
24. Shiftlock actuator & P-range switches, auto trans
- testing & replacement 4:30
23. Starter inhibitor, auto trans - testing, adjustment & replacement 4:30
1. Transmission (gearbox) - preparation for removal 4:1
3. Transmission (gearbox), automatic - removal 4:4
6. Transmission (gearbox), manual, components
- checking & repair 4:13
9. Transmission (gearbox), automatic - installation 4:24
8. Transmission (gearbox), manual - installation 4:24
7. Transmission (gearbox), manual - rebuild 4:14
2. Transmission (gearbox), manual - removal 4:1
4. Transmission (gearbox), manual - teardown and rebuild general 4:5
5. Transmission (gearbox), manual - teardown 4:6
11. Transmission (gearbox) rear oil seal - replacement 425
CHAPTER 5: ENGINE MANAGEMENT, FUEL, IGNITION & EXHAUST SYSTEMS
8. Accelerator cable & pedal
- adjustment & cable replacement 5:17
30. Airflow meter - removal, testing & installation 5:39
6. Air intake system checks 5:15
11. Airvalve - removal, inspection & installation 5:20
36. Clutch switch - checking, removal & installation 5:42
29. Crank angle sensor - removal, inspection & installation 5:38
24. Deceleration control system - checks & adjustment 533
25. Dechoke control system - description 5:33
28. ECU - location & testing 5:36
23. EEC System - component inspection & replacement 5:31
21. Emission control system - introduction 5:31
5. Engine compression check 5:15
2. Engine Management System - component summary 5:1
3. Engine Management System - overview 5:2
4. Engine Management System - troubleshooting 5:3
Part 1 - Initial ch
With open-topped styling and performance evocative of the classic sportscars of the 60s, the Mazda MX-5/Eunos had to be a huge international success and that's exactly what it's become. Now a familiar sight on the streets and boulevards of the world, the MX-5 is owned by real enthusiasts, the kind of people who will want to have hands-on involvement with the maintenance and repair of their prized possession. For those enthusiasts, here is what we believe is the best, easiest to use, workshop manual in the world ...
Rod set out to create a new kind of owner's workshop manual - friendly, easy to understand, easy to use and, yet, more detailed than any other manual currently available: two years later Rod's MX-5 manual was the result. Rod, and fellow enthusiasts Pete and Judith, stripped down an MX-5 in an ordinary domestic garage using ordinary tools and, in the process, took over 1500 step-by-step photographs. The result of all this work is a superbly detailed text which passes on to the reader every detail of important jobs, including how problems can be overcome without resorting to special tools. This manual even tells the reader the size of nuts and bolts so they can start work with the right tools and all clearances and torque values are given in the text as the reader needs them. At paragraph level, a unique symbol system provides cross-references or tells the reader that there are helpful associated photos, drawings and tables. The dreaded words "reassembly is a reversal of the dismantling procedure" are banned and every task, from changing a bulb to rebuilding the gearbox, is described in full. Besides detailed coverage of maintenance and repairs, this manual includes advice on rustproofing, cosmetic tuning and mechanical tuning. Rod's manual was prepared with the assistance of Mazda.
The manual applies to all 1.6 litre models built between 1989 & 1995.
