Mazda 2006 MX-5 Manuale di servizio

Title Section

GENERAL INFORMATION 00

ENGINE 01

SUSPENSION 02

DRIVELINE/AXLE 03

BRAKES 04

TRANSMISSION/TRANSAXLE 05

STEERING 06

HEATER, VENTILATION &

AIR CONDITIONING (HVAC)

RESTRAINTS 08

BODY & ACCESSORIES 09

CONTENTS

2006 Mazda MX-5 Service Highlights (3404–1U–05F)

2006

Mazda MX-5

Service

Highlights

FOREWORD

This manual explains each component or

system operation and function for the

Mazda MX-5.

For proper repair and maintenance, a

thorough familiarization with this manual is

important, and it should always be kept in a

handy place for quick and easy reference.

All the contents of this manual, including

drawings and specifications, are the latest

available at the time of printing.

As modifications affecting repair or

maintenance occur, relevant information

supplementary to this volume will be made

available at Mazda dealers. This manual

should be kept up-to-date.

Mazda Motor Corporation reserves the right

to alter the specifications and contents of

this manual without obligation or advance

notice.

be reproduced or used in any form or by

any means, electronic or mechanical—

including photocopying and recording and

the use of any kind of information storage

and retrieval system—without permission in

writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

APPLICATION:

This manual is applicable to vehicles

beginning with the Vehicle Identification

Numbers (VIN) shown on the following

page.

PRINTED IN U.S.A., JUNE 2005

Form No. 3404–1U–05F

Part No. 9999–95–072F–06

2006 Mazda MX-5 Service Highlights (3404–1U–05F)

Revised 8/2005 (Ref. No. R076/05)

VEHICLE IDENTIFICATION NUMBERS (VIN)

JM1 NC15F✻6# 100001—

JM1 NC25F✻6# 100001—

RELATED MATERIALS

Material Name MNAO Part No.Mazda Material No.

2006 Mazda MX-5 Workshop Manual 9999–95–042B–06 1846–1U–05F

Engine Workshop Manual LF L3 9999–95–LFL3–05 1866–1U–05H

Manual Transmission Workshop Manual M15M-D 9999–95–421H–06 1847–1U–05F

Manual Transmission Workshop Manual P66M-D 9999–95–423H–06 1848–1U–05F

2006 Mazda MX-5 Bodyshop Manual 9999–95–060F–06 3405–1U–05F

2006 Mazda MX-5 Wiring Diagram 9999–95–026G–06 5639–1U–05F

GENERAL INFORMATION

00–00–1

SECTION 00–00

Toc of S CT

GENERAL INFORMATION . . . . 00-00

Toc of S CT

00–00 GENERAL INFORMATION

AIM OF DEVELOPMENT . . . . . . . . . . . . . 00–00–1

Product Concept . . . . . . . . . . . . . . . . . . 00–00–1

External View . . . . . . . . . . . . . . . . . . . . 00–00–1

Vehicle Outline . . . . . . . . . . . . . . . . . . . 00–00–2

VEHICLE IDENTIFICATION NUMBER

(VIN) CODE . . . . . . . . . . . . . . . . . . . . . . 00–00–10

VEHICLE IDENTIFICATION NUMBERS

(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–10

UNITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–11

Conversion to SI Units

(Système International d'Unités) . . . . 00–00–11

Rounding Off . . . . . . . . . . . . . . . . . . . . 00–00–11

Upper and Lower Limits . . . . . . . . . . . . 00–00–11

SAE STANDARD . . . . . . . . . . . . . . . . . . . 00–00–12

End of Toc

AIM OF DEVELOPMENT E5U000000000N01

Product Concept

•A car in which “oneness between car and driver, and still the one” dynamics and “lots of fun” are carried

forward and further evolved for a new generation.

External View

E5U000ZN5001

GENERAL INFORMATION

00–00–2

Vehicle Outline

Exterior design

•Fun-to-drive with instinctively attractive styling

—A two-fold type soft top has been adopted for improved ease of opening/closing.

Interior design

•A comfortable interior and sporty design incorporating Mazda’s inherited DNA

—A simple, clean-cut dashboard with a spacious feel has been adopted.

—A center panel that integrates module audio and air conditioning controls has been adopted.

—An instrument cluster with an emphasized sportiness has been adopted.

—Illumination that is both easily visible and comfortable for the eye has been adopted.

Engine

•Engine block

—Variable valve timing that optimally adjusts valve timing in accordance with driving conditions has been

adopted.

—An aluminum-alloy cylinder head and cylinder block have been adopted.

—Lightweight pistons, low-tension piston rings, and shimless tappets have been adopted to minimize friction

losses, thereby contributing to improved fuel economy.

—An auto-tensioner that automatically adjusts the belt to compensate for stretching has been adopted to

minimize maintenance requirements.

•Intake, exhaust, control

—Weight reduction has been achieved due to a hard-plastic dynamic chamber.

—High torque is obtained from the lower-middle to the high engine speed ranges due to the adoption of the

variable intake air system.

—Maximum torque is achieved at all engine speeds due to the adoption of a variable valve timing system that

controls intake valve timing in accordance with driving conditions to attain highly efficient air charging.

—An exhaust gas recirculation (EGR) system has been adopted for all models resulting in cleaner exhaust

emissions and reduced fuel consumption.

E5U000ZN5002

GENERAL INFORMATION

00–00–3

00–00

Suspension and steering

•Front suspension

—A newly developed in-wheel-type double-wishbone suspension has been adopted to take full advantage of

the low bonnet line enabled by the optimized engine layout.

—The front upper arm and the front lower arm have been lengthened and attached to the highly rigid front

crossmember to allow for linear alignment changes during jounce and rebound of the front wheels. Due to

this, roadholding and handling performance have been improved.

FRONT SHOCK

ABSORBER AND

COIL SPRING

FRONT UPPER

ARM FRONT SUSPENSION

TOWER BAR

TRANSVERSE

MEMBER

FRONT LOWER ARM

FRONT STABILIZER

FRONT

CROSSMEMBER

FRONT STABILIZER

CONTROL LINK

E5U213ZS5001

GENERAL INFORMATION

00–00–4

•Rear suspension

—A multi-link suspension composed of five links has been adopted.

—The links have been lengthened and optimally positioned. Due to this, they constantly provide ideal

geometry to respond to external forces applied during driving, improving handling stability and riding

comfort, and reducing road noise.

REAR SHOCK ABSORBER

AND COIL SPRING

REAR SHOCK

ABSORBER

REAR

CROSSMEMBER

REAR LATERAL

LINK (UPPER)

REAR

STABILIZER

REAR STABILIZER

CONTROL LINK

TOE CONTROL

LINK

REAR LATERAL

LINK (LOWER)

REAR TRAILING

LINK (UPPER)

REAR TRAILING

LINK (LOWER)

E5U214ZS5001

GENERAL INFORMATION

00–00–5

00–00

•Power steering

—With the adoption of an integrated mount for the steering gear, handling stability has been improved.

—With the adoption, for all vehicles, of a steering column with a tilt mechanism, operability has been

improved.

—With the adoption of a steering shaft with an energy absorbing mechanism, safety has been improved.

STEERING GEAR

POWER

STEERING

OIL PUMP

FLUID RESERVOIR

STEERING COLUMN AND SHAFT

STEERING WHEEL

E5U614ZS5001

GENERAL INFORMATION

00–00–6

Brakes

•The ABS HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted,

resulting in size and weight reduction.

•A semi-conductor element type front ABS wheel-speed sensor has been adopted, improving reliability and

reducing size and weight.

•A magnetic encoder type front ABS sensor rotor that is integrated with the wheel hub component has been

adopted, improving reliability and reducing size and weight.

•Electronic brakeforce distribution (EBD) control has been adopted, resulting in improved safety and handling

stability.

BRAKE

BRAKE SYSTEM

WARNING LIGHT

ABS WARNING

LIGHT

ABS HU/CM

REAR ABS WHEEL-

SPEED SENSOR

FRONT ABS WHEEL-

SPEED SENSOR

PCM

E5U413ZS5001

GENERAL INFORMATION

00–00–7

00–00

Transmission

•Manual transmission [M15M-D]

—A linked, triple-cone synchronizer mechanism has been adopted for 1st and 2nd gears.

—A linked, double-cone synchronizer mechanism has been adopted for 3rd gears.

—A linked, carbon-cone synchronizer mechanism has been adopted for 4th gears.

—A cam-type reverse lockout mechanism has been adopted.

2ND 4TH REV

1ST 3RD 5TH

INPUT SHAFT

MAIN DRIVE GEAR(4TH GEAR)

REVERSE GEAR

OUTPUT SHAFT

2ND GEAR

1ST GEAR

SHIFT PATTERN

COUNTERSHAFT

3RD GEAR

5TH GEAR

E5U511AS5001

GENERAL INFORMATION

00–00–8

•Manual transmission [P66M-D]

—A linked, triple-cone synchronizer mechanism has been adopted for 1st, 2nd, 3rd and 4th gears.

—A guide plate type reverse lockout mechanism has been adopted.

•Automatic transmission [SJ6A-EL]

—Newly developed SJ6A-EL type 6-speed AT has been adopted.

—With the adoption of the line pressure solenoid, TCC control solenoid, solenoid for C3 clutch, solenoid for

B2 brake, and the linear type solenoid, dynamic shift quality has been realized.

1ST

2ND

3RD

4TH

5TH

6TH

REV

SHIFT PATTERN

MAIN DRIVE GEAR

SHAFT

MAINSHAFT

1ST GEAR

2ND GEAR 3RD GEAR

4TH GEAR

5TH GEAR

6TH GEAR

REVERSE IDLER GEAR

E5U511BS5007

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