1994 MAZDA MX-5 Workshop Manual

ABBREVIATIONS 4BDC .... 4BS ...... 4CC ...... 4T ........ 4TDC ..... 4TF ...... 4TS ...... 3AC ...... 3BDC .... 3TDC ..... :ID ....... 2U ....... IOHC .... IRL ...... ITM ...... IC-AT .... iGRA .... EGRV .... ELR ...... EPC ...... ESPS ..... ETS ...... EX ....... FMEM .... HFC ...... HLA ...... H U ....... IC ........ IG ........ IN ........ INT ....... LFC ...... LH ....... LSD ...... M ........ MAF RTN . MT ....... PCTS ..... PCV ...... PIP ....... PRC ...... PIS ....... PMI ...... PWR GND RH ....... RPM ...... RTS ...... SIG RTN . . SLS ...... ... SPOUT S R ....... SST ...... ST ....... SW ....... TDC ...... TNS ...... TRS ...... VPWR .... WSS ..... WTS...... After bottom dead center Antilock brake system Accessory Automatic transmission After top dead center Automatic transmission fluid Ambient temperature sensor Bypass air control Before bottom dead center Before top dead center Cylinder identification display Control unit Double overhead camshaft Daytime running light Diagnostic test mode Electronically controlled automatic transmission EGR air solenoid valve EGR vacuum solenoid valve Emergency locking retractor Electronic pressure control Engine speed sensing power steering Evaporator temperature sensor Exhaust Failure mode effects management High fan control Hydraulic lash adjuster Hydraulic unit Integrated circuit Ignition Intake Intermittent Low fan control Left hand Limited slip differential Motor Mass airflow return Manual transmission Passenger compartment temperature sensor Positive crankcase ventilation Profile ignition pickup Pressure regulator control Power steering Power window Power ground Right hand Revolutions per minute Reduce torque signal Signal return Slip lockup signal Spark output Sensor rotor Special service tool Start Switch Top dead center Tail number side (taillights, license plate lights and side marker lights) Torque reduced signal Vehicle power Wheel speed sensor Water temperature sensor Gartner Banana

SAE STANDARDS SAE STANDARDS In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have 4 been used in Mazda manuals up to now and their SAE equivalents. 46UGIX-047 Engine and Emission Systems Accelerator Pedal Air Cleaner Housing I Mixture Control Solenoid I F2 Carburetor ] Abbreviation AP ACH MCS VAF M AF Abbreviation - - - - - Volume Airflow Sensor I I Name Accelerator Pedal Air Cleaner AirlFuel (NF) Solenoid Valve Airflow Meter Airflow Sensor I Mass Airflow Sensor I I Alternator I I - - - -~ I Barometric Absolute Pressure I I Sensor I I Alternator Atmospheric Pressure Sensor I - 1 Carburetor CARB 1 Catalytic Converter OC ALT BAR0 Carburetor 1 Oxidation Catalvst I - - - - - I Direct Ignition I DL1 EG I 1 Electronic Gasoline lniection Svstem I CIS Three Way Catalyst Warm Up Three Way Catalyst Fuel Pump Relay Coolant Fan Control Crankshaft Position Sensor Data Link Connector Circuit Opening Relay Cooling Fan Control Crank Angle Sensor Diaanosis Connector Distributorless Ignition I Continuous Fuel lniection Svstem I 1 #1 #2 FPR C FC CPS DLC I Previous Standard SAE Standard Name I Remark - ( Electronic Spark Ignition EGR Gas Sensor EGR Position Sensor EGR Position Switch El Electronic Ignition 1 #3 EGR Function Control I - I EGR Modulator Solenoid I EGRC 4 ECU I Evaporative Emission Control Svstem I EVAP - - I -,--- I - I Exhaust Gas Recirculation System I EGR Engine Control Unit PCM PCME Engine Modification Ennine Speed EM RPM - - - - - Feedback System Flexible Fuel - I Intercooler Powertrain Control Module I #5 I EGR Function Sensor CLS FF Fuel Pump IC Regulator Intake Air Thermosensor CAC I Powertrain Control Module (Engine) I #4 FP VR IATS - I ISC Solenoid Valve I IACV Engine Modification I Engine Speed - Fuel Evaporative System I Exhaust Gas Recirculation 1 System name 1 Closed Loop System I Flexible Fuel Knock Sensor I I - ( Knock Sensor I KS I Malfunction Indicator Light I I - I Malfunction Indicator Liaht MIL Multiport Fuel Injection Oxidation Catalyst - 1 Multiport Fuel Injection #1: Directy connected to exhaust manifold #2: In some models, there is a "Fuel Pump Relay" that controls pump speed. That relay is now called the 'Fuel Pump Relay (Speed)". #3: Controlled by the PCME (PCM) 4 #4: EGR valve controller device name #5: Device that controls engine and powertrain MFI - 1 Oxidizina Converter OC Gartner Banana

SAE STANDARDS Engine and Emission Systems (cont'd) I Previous Standard I SAE Standard b I - Abbreviation ( Name I Oxvaen Sensor - .w- - I I ." I 02s I Oxygen Sensor I - PTC Reed Valve Relief 1 Solenoid Valve Secondary Air lnjection System - Seauential Fuel lniection SMFl L - Service Code(s) DTC - Spark Ignition Dl - Supercharger SC Abbreviation I Name Open Loop Positive Temperature Coefficient Hnatar Secondarv Air Pulse Valve Remark . .--.-. Pressure Sensor Secondary Air Bypass valve Pulsed Secondarv Air lniection H02S I Heated Oxvaen Sensor I With heater OL EFE Secondary Air lnjection Sequential Multipoint Fuel lnjection Diagnostic Trouble Code(s) Open Loop Early Fuel Evaporation MAP MVS Distributor lgnition Supercharger Manifold Absolute Pressure Sensor Manifold Vacuum Sensor I - - - - - - Checks vacuum only Pulsed iniection - Switching Solenoid Valve Test Mode(s) Three Way Catalyst Throttle Body Throttle Sensor Turbocharaer .. Maifold Differential Pressure Manifold Vacuum Zone Switch , - I - 1 VAC I MDP 1-1 Water Thermosensor L - I Vacuum Switch I ECTS I Engine Coolant Temperature Sensor I SASV DTM TWC TB TPS TC MVZS #6: Supplies air to three way catalyst #7: Diagnostic trouble codes depend on the test mode - Secondary Air Switching Valve Diagnostic Test Mode(s) Three Way Catalyst Throttle Body Throttle Position Sensor Turbocharaer Transmission (Transaxle) and Steering System L - - Previous Standard I I I I Abbreviation - - - SAE Standard Fully Open Inhibitor Switch - I Lock-up Position - - Name Clutch Position EC-AT Control Unit Fullv Closed Abbreviation CPP PCMT CTP TCC I Torque Converter Clutch - - - WOT PNS Output Signal(s) Overdrive I Name Clutch Pedal Position Powertrain Control Module (Transaxle) Powertrain Control Module (Transmission) Closed Throttle Position Wide Open Throttle ParWNeutral Switch Power Steering Pressure Switch Pulse Generator Vehicle Speed Sensor - 1 3rd Gear Remark FF FR PTCS 4GR 3GR I Third Gear Powertrain Control Signal(@ Fourth Gear SPS VSPG VSS Steering Pressure Sensor Vehicle Speed Pulse Generator Vehicle Speed Sensor Gartner Banana

GI SAE STANDARDS Body Electrical System and Heater and Air Conditioner Systems Previous Standard SAE Standard - - Abbreviation I Name I Abbreviation 1 Name Remark 1 VB - - - AIC Switch Air Conditioner 46UGIX-050 #8: System name. Other related names are unchanged. Battery Voltage Coolant Level Sensor Ground Self-Diagnosis System ACS A/C B+ COLS GND OBD Air Conditioning Sensor Air Conditioner d Battery Positive Voltage Coolant Level Sensor Ground On-Board Diagnosis System #8 Gartner Banana

FUNDAMENTAL PROCEDURES GI FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas before starting work. PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equip- ment are available before starting any work. SPECIAL TOOLS Use special tools when they are required. REMOVAL OF PARTS While correcting a problem, try also to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from enter- ing. DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disas- sembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently. Gartner Banana

FUNDAMENTAL PROCEDURES 1. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. 2. Arrangement of parts All disassembled parts should be carefully arranged for reassembly.Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. 3. Cleaning parts for reuse All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. Warning Using compressed air can cause dirt and other ,, particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using com- pressed air. REASSEMBLY Standard values, such as torques and certain adjust- ments, must be strictly observed in the reassembly of all parts. Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in section TD for tightening torques not men- tioned in the main text. If removed, these parts should be replaced with new ones: 1. Oil seals 4. Gaskets 2. O-rings 5. Lock washers 3. Cotter pins 6. Nylon nuts Depending on location: 1. Sealant should be applied to gaskets. 2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the pre- scribed locations (such as oil seals) before reassembly. Gartner Banana

FUNDAMENTAL PROCEDURES GI ADJUSTMENTS Use suitable gauges and testers when making adjust- ments. RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tubing. HOSE CLAMPS 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. VISE When using a vise, put protective plates in the jaws of the vise to prevent damage to parkGI-1 3 TORQUE FORMULAS When using a torque wrench-SST combination, the writ- ten torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the for- mula that applies to you. GI-I 3 L&A Unit centimeter centimeter centimeter inch inch Torque Unit N.m kgfm kgfcm ft.lbf in-lbf A = The length of the SST past the torque wrench drive. L = The length of the torque wrench. Formula N,m x [U(L+A)] kgf.m x [U(L+A)] kgfcrn x [U(L+A)] ft4bf x [U(L+A)] in.lbf x [U(L+A)] Gartner Banana

G I ELECTRICAL TROUBLESHOOTING TOOLSIELECTRICAL PARTS I VOLTMETER I BLACK LINE GROUND ELECTRICAL TROUBLESHOOTING TOOLS TEST LIGHT 4) The test light, as shown in the figure, uses a 12V bulb. The two lead wires should be connected to probes.The test light is used for simple voltage checks and for check- ing for short circuits. Caution Using a bulb over 3.4W when checking the control unit may damage the control unit. JUMPER WIRE A jumper wire is used to create a temporary circuit. Con- nect the jumper wire between the terminals of a circuit to bypass a switch. Caution Do not connect a jumper wire from the power source line to a body ground; this may cause burning or other damage to harnesses or elec- tronic components. VOLTMETER The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15V or more is used by con- necting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (-) probe (black lead wire) to a body ground. d OHMMETER The ohmmeter is used to measure the resistance between two points in a circuit, and to check for continu- ity and short circuits. I I 45UGIX-006 GI-I 4 Caution Do not connect the ohmmeter to any circuit to which voltage is applied; this will damage the ohmmeter. ELECTRICAL PARTS BAlTERY The battery installed in the right rear of the trunk is unique. When a replacement battery is installed, install it with a genuine Mazda battery replacement kit or equivalent. (Refer to section G.) J Gartner Banana