1994 MAZDA MX-5 battery replacement

FUEL SYSTEM F FUEL PUMP RELAY Inspection Apply battery positive voltage and a ground to the termi- nals below and check the fuel pump relay operation as described. If not as specified, replace the fuel pump relay. B+: Battery positive voltage Replacement 1. Remove the undercover. B+ A 2. Remove the fuel pump relay. 3. Install in the reverse order of removal. Grounded B Correct result C - E: Continuity Gartner Banana

CONTROL SYSTEM LOCK 4. If not as specified, replace the main relay. MAIN RELAY lnspection 1. Verify that the main relay clicks when turning the ignition switch OFF -+ ON. 2. Apply battery positive voltage to terminal A and ground terminal B of the main relay. 3. Use an ohmmeter to check continuity of the terminals as shown. CLUTCH SWITCH Inspection 1. Disconnect the clutch switch connector. 2. Connect an ohmmeter to the switch. 3. Check continuity of the switch. Battery positive voltage applied - Continuity - Terminals CD L 4. If not as specified, replace the clutch switch. Battery positive voltage not applied No continuity Pedal Depressed Released Replacement 1. Disconnect the clutch switch connector. 2. Loosen the locknut. 3. Remove the clutch switch. 4. Install in the reverse order of removal. 5. Adjust the pedal height. (Refer to Section H.) Continuity Yes No 4. If not as specified, replace the neutral switch. NEUTRAL SWITCH lnspection 1. Disconnect the neutral switch connector. 2. Connect an ohmmeter to the switch. 3. Check continuity of the switch. Transmission Neutral Other ranges Continuity , Yes No Gartner Banana

G INDEX INDEX 1. Battery lnspection . . . . . . . . . . . . . . . . . page G- 8 Recharging . . . . . . . . . . . . . . . . page G- 9 Replacement . . . . . . . . . . . . . . page G-10 2. Alternator Removal / lnstallation . . . . . . . page G-10 Disassembly / Assembly . . . . page G-11 lnspection . . . . . . . . . . . . . . . . . page G-12 3. Drive belt lnspection . . . . . . . . . . . . . . . . . page G-13 Adjustment . . . . . . . . . . . . . . . . page G-14 4. Spark plug Removal / Installation . . . . . . . page G-18 Spark test . . . . . . . . . . . . . . . . . page G-18 lnspection . . . . . . . . . . . . . . . . . page G-18 5. Ignition coil lnspection . . . . . . . . . . . . . . . . . page G-19 Replacement . . . . . . . . . . . . . . page G-19 6. Igniter (in ignition coil) lnspection . . . . . . . . . . . . . . . . . page G-19 7. High-tension lead Removal / lnstallation . . . . . . . page G-20 lnspection . . . . . . . . . . . . . . . . . page G-20 8. Starter Removal / lnstallation . . . . . . . page G-22 Performance lnspection . . . . . page G-23 Disassembly / Assembly . . . . page G24 -' lnspection . . . . . . . . . . . . . . . . . page G26 9. Starter interlock switch (MT) lnspection . . . . . . . . . . . . . . . . . page G-28 Gartner Banana

CHARGING SYSTEM B TE S TERMINAL 1. Remove the battery cover. 2. Disconnect the battery cable from the battery. 3. Remove the battery from the vehicle. 4. Place the battery in a pan of the water to prevent it from ,-, over heating, but keep water away from the top of bat- tery. 5. Charge the battery. Replacement Note When replacing the battery, replace it with the same style Mazda genuine battery (with vent manifold). ALTERNATOR Caution Obtain the code number and deactivate the audio anti-theft system before disconnecting the bat- tery. (Refer to section T.) Caution Reversing the battery connections or using high- voltage testers will damage the rectifier. Caution Do not start the engine while the connector is dis- connected from L and S terminals. It can damage the alternator. Note .--,' Positive voltage is always present at alternator B ter- minal. Removal l Installation 1. Disconnect the negative battery cable. 2. Disconnect the steering pressure sensor connector. 3. Disconnect the water thermoswitch connector. 4. Disconnect the IAC valve connector. 5. Remove the intake air pipe. 6. Disconnect the wire and connector from the alternator. 7. Remove the alternator bolts and nut. 8. Remove the alternator. 9. Install in the reverse order of removal. Tightening torque Bolt 0: 38-51 N.m (3.8-5.3 kgf-m, 27-38 ftelbf) Bolt @ : 19-25 N.m j1.9-2.6 kgfem, 14--18 ft-lbf) Nut @I: 9.9--14 N.m (100-150 kgf-cm, 87-1 30 in-lbf) Gartner Banana

ELECTRICAL SYSTEM COMPONENTS K Replacement 1. Disconnect the negative battery cable. 2. Remove the front console. 3. Remove the indicator panel installation screws. 4. Disconnect the connector and remove the hold switch terminals. 5. Remove the selector lever knob assembly. 6. lnstall a new selector lever knob assembly. lnspection of continuity 1. Disconnect the negative battery cable. 2. Disconnect the hold switch connector. 3. Check continuity of the switch. Tightening torque: 2.0-2.9 N.m (20-30 kgfscm, 18-26 in-lbf) Position Normal Depressed 7. lnstall the hold switch terminals and connect the connec- tor. 8. lnstall the indicator panel installation screws. (Refer to page K-163.) 9. lnstall the front console. 10. Connect the negative battery cable. PARKINEUTRAL SWITCH lnspection lnspection of operation 1. Verify that the starter operates only with the ignition switch at the START position and the selector lever in P and N ranges. 2. Verify that the back-up lights illuminate when shifted to R range with the ignition switch in the ON position. 3. Verify that the positions of the selector lever and the se- lector indicator light of the instrument cluster are aligned. 4. Check the ParkINeutral switch if not as specified. 0--4: Continuity 45UOKX-525 4. If not as specified, replace the selector lever knob as- sembly. (Refer to below.) 5. If the switch is OK, check the wiring harness. (Hold switch - powertrain control module (transmission), Hold switch - Body ground.) 6. lnstall the front console. 7. Connect the negative battery cable. Terminal A 0 B 0 Gartner Banana

ELECTRICAL SYSTEM COMPONENTS K ATF THERMOSENSOR Inspection 1. Refer to "Replacement" below for removal of the ATF thermosensor. 2. Place the ATF thermosensor in ATF with a thermometer as shown, and heat the ATF gradually. 3. Measure resistance between the terminals of the ATF thermosensor. ATF temperature- {OF) 1 Resistance (kR) 20 (68) 2.5 4. If not correct, replace the ATF thermosensor. 5. Refer to "Replacement" for installation of the ATF ther- mosensor. Replacement 1. Disconnect the negative battery cable. 2. On level ground, jack up the vehicle and support it evenly on safety stands. 3. Disconnect the ATF thermosensor connector. 4. Remove the ATF thermosensor. 5. Install the new ATF thermosensor. Tightening torque: 7.9-1 0.7 N-m (80-11 0 kgf-cm, 70-95.4 in-lbf) 6. Connect the ATF thermosensor connector. 7. Connect the negative battery cable. VEHICLE SPEED PULSE GENERATOR Inspection 1. Disconnect the negative battery cable. 2. On level ground, jack up the vehicle and support it evenly on safety stands. 3. Disconnect the vehicle speed pulse generator connec- tor. 4. Measure resistance between the terminals of the vehicle speed pulse generator. Resistance: 24552 5. If not correct, replace the vehicle speed pulse generator. 6. Connect the vehicle speed pulse generator connector. 7. Connect the negative battery cable. Gartner Banana

K ELECTRICAL SYSTEM COMPONENTS Replacement 1. Disconnect the negative battery cable. 2. On level ground, jack up the vehicle and support it evenly on safety stands. 4 3. Disconnect the vehicle speed pulse generator connec- tor. 4. Remove the vehicle speed pulse generator. 5. Install the new vehicle speed pulse generator. Tightening torque: 7.9--10.7 N-m (80-110 kgfecm, 70-95.4 in-lbf) 6. Connect the vehicle speed pulse generator connector. 7. Connect the negative battery cable. 1-2 SHIFT, 2-3 SHIFT, 3-4 SHIFT, 3-2 CONTROL SOLENOID VALVE Inspection 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Disconnect the solenoid valve connector. d 3. Measure resistance between each terminal and ground. Resistance: l3-27a 4. If not correct, check the wiring harness for an open or short circuit. Replace the solenoid valve. Solenoid valve 1-2 shift 2-3 shift 3-4 shift 3-2 control LOCKUP CONTROL SOLENOID VALVE lnspection 1. Disconnect the solenoid valve connector. 2. Measure the resistance between the terminals. Terminal C D - A B Resistance: l3-2Sil 3. If not correct, replace the solenoid valve. Gartner Banana

ELECTRICAL SYSTEM COMPONENTS K Terminal 2D (Input) 2E (Output) 2F (Input) 2G (Output) 2H (Input) - !I (Output) !J (Input)' - !K (Output) - !L (Ground)' 'M (Output) 1-2 shift solenoid valve 1 2E (S range) 2-3 shift solenoid valve Connected to Voltmeter I I +terminal . ParWneutral switch (D range) 2D - - (L range) 3-4 shift solenoid lalve Jehicle speed pulse 2J lenerator .ockup control ;olenoid valve 2K lehicle speed pulse 2L lenerator - 1 - I I - , - Z - 1 d - _4 3 V - - ower) E P (Ground) - 2P Ground ov - Q (Battery sattery 2Q B+ lgnition switch ON ower) OV Ignition switch OFF R - - - - - s (Battery Battery 2s B+ lgnition switch ON ~wer) Ground OV lgnition switch OFF Throttle position sen- 2T 'I- (Input) sor Approx. Throttle valve closed throttle position to wide 0.44.1 V open throttle Checked with AC range 1-2 control solenoid 'alve I 2M 1 ( Blow l.5V I 1 B+ 3-2 or 4-2 downshift OV Other conditions - - - I I I I lattery 20 B+ Constant Replacement Disconnect the negative battery cable. Disconnect the powertrain control module (Transmis- sion) connector. Remove the bolt and nut shown in the figure, and re- move the powertrain control module (Transmission). Install the new powertrain control module (Transmis- sion). Tightening torque: 19-25 N-m (1 .S2.6 kgf-m, 14--18 ftslbf) Connect the powertrain control module (Transmission). Connect the negative battery cable. Gartner Banana