1994 MAZDA MX-5 Oil

IGNITION SYSTEM TROUBLESHOOTING Misfire I 1 Check 1 NO NO 1. Turn ignition switch ON 2. Connect data link connector terminals (TEN) and (GND) with a jumper wire 3. Check if MIL illuminates I Check if resistance of secondary windings is OK Replace ignition coil (Refer to page G-19) (Refer to page G-19) I Refer to section F Check 2 Check if resistance of Replace high-tension lead (Refer to page G-20) (Refer to page G-20) I I Check 3 Check if spark plug is OK ( I Check 4 1 YES I Check PCME terminals (Refer to section F) a 1 G, 1 H (Igniter) 0 2E, 2G (Crankshaft position sensor) Repair or replace (Refer to section F) ( 2F, 20 ass airflow sensor) YES Replace ignition coil (igniter malfunction) 1 Check 1 Check 3 Check 2 PLUG WEAR AND CARBON BUILDUP BURNS DAMAGE AND DETERIORATION DAMAGE Gartner Banana

IGNITION SYSTEM G GND TEN I I I IGNITION TIMING 1. Check the condition of the engine (spark plugs, leaks in hoses, etc.). 2. Verify that all accessories are OFF. 3. Warm up the engine to the normal operating tempera- ture. Note When using an externally powered timing light and/or tachometer connect it to the power connector (Blue: l-pin). Warning Do not ground the power connector. terminal (Blue: l-pin); some fuses will be burned. 4. Connect a timing light and tachometer to the data link connector terminal (IG-). 5. Connect the SST and set TEST SW to "SELF TEST" or connect data link connector terminals TEN and GND with a jumper wire. 6. Check the idle speed, and set it to specification if neces- sary (Refer to section F.) ' Idle speed (rpm):800-900 (MT) 75-50 (AT) 7. Verify that the timing mark (white) on the crankshaft pulley is aligned with the indicator pin. Ignition timing: 9"-11" BTDC (at idle) 8. If the marks are not aligned, remove the ignition coil bracket and push the ignition coil aside for easy access and then loosen the crankshaft position sensor lock bolts, and turn the crankshaft position sensor to make the adjustment. 9. Tighten the crankshaft position sensor lock bolts to the specified torque. Tightening torque: 19-25 N-m (1 3-2.6 kgf~m, l4--19 ft.lbf) 10. After adjusting the ignition timing, disconnect the jumper wire or SST from the data link connector. 11. Increase the engine speed and verify that the ignition timing advances. Gartner Banana

IGNITION SYSTEM IGNITION COIL lnspection Secondary coil winding 1. Remove the high-tension leads. u 2. Measure resistance of the secondary coil winding of each coil with an ohmmeter. Secondary coil winding resistance (at 20°C (68°F)): 8.7-1 2.9 kR 3. If not within specification, replace the ignition coil. 45UOGX-030 I I Insulation resistance of case 1. Remove the high-tension leads and disconnect the con- nectors. 2. Use a 500V megger tester to measure the insulation resistance between the primary terminal and the coil case. Resistance : Above 10 MR 3. If not within specification, replace the ignition coil. L I 45UOGX-031 Replacement 1. Disconnect the high-tension leads and ignition coil con- nector. 2. Remove the installation bolts and the ignition coil. 3. Install in the reverse order of removal. L Tightening torque: 19-25 N.m (1.9--2.6 kgf-m, 14--18 ft-lbf) 45UOGX-032 IGNITER Inspection 1. Check the poor connection of ignition coil, high-tension leads and PCME. 2. Check the ignition coil, and high-tension leads. 3. Mesure the voltage of the PCME terminal as follows. (Refer to section F.) 1 G igniter (Nos.1, 4) 1 H igniter (Nos.2, 3) 2E, 2G crankshaft position sensor (SGT) 2F, 20 mass airflow sensor 4. If all are normal, but misfire still occurs, replace the igni- tion coil. Gartner Banana

STARTING SYSTEM Inspection Armature 1. Ground of armature coil Check for no continuity between the commutator and the .J core with an ohmmeter. Check the entire circumference of the commutator. Replace the armature if there is conti- nuity. 2, Insulation of armature coil Check for no continuity between the commutator and the shaft with an ohmmeter. Check the entire circumference of the commutator. Replace the armature if there is conti- nuity. 3. Runout of commutator (1) Place the armature on V blocks, and measure the runout with a dial gauge. (2) Repair with a lathe if the runout is small or replace,the armature if necessary. -1' Runout: 0.03mm (0.001 in) 4. Outer diameter of commutator Replace the armature if the outer diameter of the com- mutator is at the grind limit or less. 5. Roughness of commutator surface If the commutator surface is dirty, wipe it with a cloth; if it is rough, repair it with a lathe or fine sandpaper. Grind limit: 30.8mm (1.21 in) 6. Segment groove depth If the depth of the molding between segments is at the depth limit or less, undercut the grooves to the standard depth. Standard depth: 0.5--0.8mm (0.02-4.03 in) Depth limit: 0.2mm (0.008 in) Gartner Banana

STARTING SYSTEM Yoke assembly 1. Wiring damage of field coil (1) Check for continuity between the connector and the brushes with an ohmmeter. (2) Replace the yoke assembly if there is no continuity. 2. Ground of field coil (1) Check for no continuity between the connector and the yoke with an ohmmeter. (2) Repair or replace the yoke assembly if there is conti- . nuity. 3. Installation of field coil Replace the yoke assembly if the field coil is loose. Magnetic Switch 1. Wiring damage (S terminal - M terminal) Check for continuity between S terminal and M terminal with an ohmmeter. Replace the magnetic switch if there is no continuity. 2. Wiring damage (S terminal - body) Check for continuity between S terminal and the body with an ohmmeter. Replace the magnetic switch if there is no continuity. Brush and Brush Holder Insulation of brush holder Check for no continuity between each insulated brush and the plate with an ohmmeter. Replace the brush holder if there is continuity. Gartner Banana

OUTLINE, TROUBLESHOOTING GUIDE H OUTLINE SPECIFICATIONS I Clutch control L' Clutch cover Clutch disc Clutch pedal - Enginerrransmission BP DOHC item - M15M-D 1 Master cvlinder inne I Hydraulic Inner diameter mm {in) I 150 (5.91) I Pressure plate side I n n rn cr Tvpe . . Set load N {kgf, Ibf) Outer diameter mm {in) Pedal ratio 6.13 Full stroke mm {in) I 120 (4.72) Diaphraam spring .-.- 4,310 (440,968) 21 5 18.46) . - Height mm {in) * diameter mm {in) TROUBLESHOOTING GUIDE . - I 75--185 i6.89--7.283 15.87 (0.625) . - Release cylinder inner diameter mm {in) Clutch fluid I Problem I Possible Cause 19.05 i0.750) FMVSS116 DOT-3 Clutch disc facing surface hardened or oil on surface Pressure plate damaged u Diaphragm spring damaged or weak lnsufficient clutch pedal play I Slipping I Clutch disc facing worn excessively I Flywheel damaged Faulty disengagement I Clutch disc damaged or excessive runout Clutch disc spines rusted or worn Oil on clutch disc facing Diaphragm spring weak Excessive clutch pedal play Insufficient clutch fluid Leakage of clutch fluid I 1 Clutch disc facing hardened or damaged Clutch vibrates when accelerating I I Clutch disc facing rivets loose Oil on clutch disc facing Torsion dampers weak Clutch pedal stlcks Abnormal noise Pressure plate damaged or excessive runout Flywheel surface hardened or damaged Loose or worn engine mount Pedal shaft not pro~erlv lubricated Clutch release collar damaged Poor lubrication of release collar sleeve Torsion dampers weak Excessive crankshaft end play I I Pilot bearing worn or damaged I I Worn ~ivot points of release fork Action Replace Repair or replace Repair or replace Replace Adjust ~ebair or replace Replace Remove rust or replace Repair or replace Replace Adjust Add fluid Locate and repair or replace Repair or replace Replace Repair or replace Replace Replace Repair or replace Tighten or replace Lubricate or replace Replace Lubricate or replace Replace Repair Replace Repair or replace Page H-14 H-14 H-14 H-14 H-14 H-14 section B H- 6 H-14 H-14 H-14 section B H-14 H-14 45UOHX-OC Gartner Banana

H CLUTCH UNIT Removal Note Clutch cover and disc 1 . Install the SST. 2. Hold the flywheel by using the SST or equivalent. e 3. Loosen each bolt one turn at a time in a crisscross pat- tern until spring tension is released. Then remove the clutch cover and disc. Flywheel 1. Hold the flywheel by using the SST or equivalent. 2. Remove the flywheel. 3. Inspect for oil leakage from the crankshaft rear oil seal. If there is any such leakage or if the oil seal is damaged, refer to section B and replace the crankshaft oil seal. Pilot bearing Note The pilot bearing does not need to be removed unless you are replacing it. Remove the pilot bearing by using the SST. L' Installation Note Flywheel 1. Wipe the bolts clean, and apply sealant to the bolt threads. 2. Install the flywheel, and secure it by using the SST or equivalent. 3. Tighten the bolts in the pattern shown. Tightening torque: 97-1 02 N.m (9.8-1 0.5 kgf.m, 71-75.9 ft-lbf) Pilot bearing Install a new pilot bearing flush with the flywheel by using a suitable pipe. Gartner Banana

CLUTCH UNIT, CLUTCH RELEASE COLLAR, CLUTCH COVER, CLUTCH DlSC H Clutch disc 1. Clean the clutch disc splines and main drive gear splines, and apply Mori White TA No.2 or equivalent or- ganic molybdenum grease. 2. Hold the clutch disc in position by using the SST. Clutch cover 1. Hold the flywheel by using the SST or equivalent. 2. Align the dowel holes with the flywheel dowels. 3. Tighten the bolts evenly and gradually in the pattern shown. Tightening torque: 18-26 N.m (1.8-2.7 kgf.m, 14--19 ft.lbf} CLUTCH RELEASE COLLAR INSPECTION Caution Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing. Turn the collar while applying force in the axial direction. If the collar sticks or has excessive resistance, replace it. CLUTCH COVER INSPECTION 1. lnspect the contact surface for scoring, cracks, and burning. Repair or replace as necessary. 2. Remove minor scoring or burning with emery paper. Repair if scoring or burning is major. Replace if cracked. 3. lnspect the tips of the diaphragm spring for wear and cracks. 4. If there is wear or cracks, replace the clutch cover. I I 45UOHX-027 CLUTCH DlSC INSPECTION 1. lnspect the lining surface for burning and oil contamina- tion. Repair with sandpaper if the trouble is minor. Re- place the clutch disc if it is badly burned or oil soaked. 2. lnspect for loose facing rivets or torsion dampers. Replace the clutch disc if any are loose. Gartner Banana