Mazda MX-5 1995 Workshop Manual

 WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury and property damage
increase. The recommended servicing procedures for the ve-
hicle in this workshop manual were developed with Mazda-
trained technicians in mind. This manual may be useful to non-
Mazda trained technicians, but a technician with our service-re-
lated training and experience will be at less risk when performing
servicing operations. However, all users of this manual are ex-
pected to know general safety procedures.
This manual contains “Warnings” and “Cautions” applicable to
risks not normally encountered in a general technician's experi-
ence. They should be followed to reduce the risk of injury and the
risk that improper service or repair may damage the vehicle or
render it unsafe. ltis also important to understand that the “Warn-
ings” and “Cautions” are not exhaustive. It is impossible to warn
of all the hazardous consequences that might resuit from failure
to follow the procedures.
The procedures recommended and described in this manual are
effective methods of performing service and repair. Some re-
quire tools specifically designed for a specific purpose. Nonre-
commended procedures and tools should include consideration
for safety of the technician and continued safe operation of the
vehicle.
Parts should be replaced with genuine Mazda replacement
parts, not parts of lesser quality. Use of a nonrecommended re-
placement part should include consideration for safety of the
technician and continued safe operation of the vehicle.
O Mazda
O MX-5
Workshop
Manual
Supplement
FOREWORD
For proper repair and maintenance, a
thorough familiarization with this manual is
O 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 modifica-
tions 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.
All rights reserved. No part of this book
may be reproduced or used in any form or by
O any means, electronic or mechanical—in-
cluding photocopying and recording and the
use of any kind of information storage and re-
trieval system—without permission in writ-
ing.
WARRANTY
The manufacturer's warranty on Mazda
vehicles and engines can be voided if im-
proper service or repairs are performed by
persons other than those at an Authorized
Mazda Dealer.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles begin-
ning with the Vehicle Identification Numbers
(VIN), and related materials shown on the fol-
lowing page.
CONTENTS
Title Section
General Information
Front and Rear Axles
Steering System
Braking System
Body
Body Electrical System
Technical Data
Special Tools
There are explanations given only for the sections marked
with shadow ( HE).
© 1995 Mazda Motor Corporation
PRINTED IN JAPAN, SEP. ’95 ©
1509—10-951
VEHICLE IDENTIFICATION NUMBERS (VIN)
= == = wr we ow
JMZ NA18C20# 300001 —
RELATED MATERIALS
MX-5 Training Manual ........0..000.000000000000000 3165-10-89I
MX-5 Workshop Manual .......................0 1221-10-89!
MX-5 Workshop Manual Supplement............. 1246-10-90G
MX-5 Workshop Manual Supplement............. 1372-10-93!
MX-5 Workshop Manual Supplement............. 1451-10-94L
323,626 / MX-6, XEDOS 6, XEDOS 9
IMMOBILIZER SYSTEM SERVICE MANUAL ....... 1503—10—95A
MX-5 Wiring Diagram (Europe) .................. 5333-10-94L
MX-5 Wiring Diagram (UK) ...................... 5334-10-94L
MX-5 Wiring Diagram (Europe) .................. 5360-10-951
MX-5 Wiring Diagram (UK) .......e...reeoneeoron. 5361-10-95
GENERAL INFORMATION
ABBREVIATIONS ............eeoeeeconenoo Gl- 2
SCHEDULED MAINTENANCE ............ Gl- 2
SCHEDULED MAINTENANCE TABLE .... GI- 2
Gi
el ABBREVIATIONS, SCHEDULED MAINTENANCE
ABBREVIATIONS
ACC .............. Accessory MT L.L..L11110 100 Manual transmission
ATF... Automatic transmission fluid RH ............... Right hand
Go ARE ignition | SST uuu Special service tool
E 2110 101000 LU far OW 121120220000 e Switch
LSD .............. Limited slip differential
SCHEDULED MAINTENANCE
SCHEDULED MAINTENANCE TABLE
Chart symbols:
|: Inspect
Visual examination and/or functional measurement of a system’s operation or performance
A: Adjust
R: Replace
T: Tighten
Remarks: O
e To ensure efficient operation of the engine and all systems related to emission control, the ignition and
fuel systems must be serviced regularly. lt is strongly recommended that all servicing related to these
systems be done by an authorized Mazda Dealer.
e After 90,000 km (54,000 miles) or 72 months, continue to follow the described maintenance at the rec-
ommended intervals.
o Refer below for a description of items marked” in the maintenance chart.
*1: Also adjust and inspect the power steering and air conditioner drive belts, if equipped.
*2: Replacement of the timing belt is required at every 90,000 km (54,000 miles). Failure to replace
the timing belt may result in damage to the engine.
*3 : If the vehicle is operated under any of the following conditions, change the engine oil and oil ter
every 10,000 km {6,000 miles} or shorter.
a) Driving in dusty conditions
b) Extended periods of idling or low speed operation
c) Driving for long periods in cold temperatures or driving regularly at short distances ( less than
8 km {5 miles}) only
"4: If the vehicle is operated in very dusty or sandy areas, inspect and replace, if necessary the air
cleaner element more often than the recommended intervals.
*5 : This is a full function check of electrical systems such as lights, wiper and washer systems (includ-
ing wiper blades), and power windows.
"6: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if
the vehicle is operated in extremely humid climates, change the brake fluid annually.
Gl-2
A a Tee Tee TE Aa
SCHEDULED MAINTENANCE
el
Maintenance
Number of months or kilometers (miles), whichever comes first
interval Months
12
24
36
48
60
72
Kilometers
1,000
15,000
30,000
45,000
60,000
75,000
90,000
Maintenance item Miles
600
9,000
18,000
27,000
36,000
45,000
54,000
Drive belts*!
A
Engine timing belt*?
Replace every 90,000 km (54,000 miles)
Engine oil*3
R
R
R
R
R
Oil filter™3
R
R
R
R
R
Cooling system
(including coolant level adjustment)
Engine coolant
Replace every 2 years
Idle speed
A
Air cleaner element“
R
Fuel filter
Fuel lines and hoses
Initial ignition timing
A
|
R
|
|
Spark plugs
A
A
Spark plugs (only for sweden)
Adjust every 50,000 km (30,000 miles)
EGR system
o
|
|
|
EGR system (only for sweden)
Inspect every 80,000 km {48,000 miles}
Evaporative system
ШИ
|
ШИ
Evaporative system (only for sweden)
Inspect every 80,000 km {48,000 miles}
Dash pot
| A
| A
Dash pot (only for sweden)
Adjust every 80,000 km {48,000 miles}
Battery condition
All electrical system™>
Headlight alignment
Brake and clutch pedal
Clutch fluid
Brake lines, hoses and connections
Brake fluid*®
Parking brake
Power brake unit and hoses
Disc brakes
Power steering fluid
Power steering system and hoses
Steering and front suspension
Manual transmission oil
Rear axle oil
Drive shaft dust boots
Bolts and nuts on chassis and body
4|—-I>|>|—-|-|- -|- >ID|- |- |- >| -
T
|
A
|
|
|
R
A
|
|
|
|
|
A
A
|
T
Body condition
(for rust, corrosion and perforation)
Inspect annually
Exhaust system and heat shields
Tires (including spare tire) with inflation
pressure adjustment
Hinges and catches
Underside of vehicle
Seat belts
Road test
—|-|-|>
—|-|-|>
F1
Before beginning any service procedure, refer to section T of the
MX-5 Workshop Manual (1451-10-94L) for air bag system service
warnings.
FUEL AND EMISSION
CONTROL SYSTEMS
(B6)
FEATURES
OUTLINE ...........e.eeeeensooocaoonec. F1- 2
SYSTEM WIRING DIAGRAM ............ F1- 2
CONTROL SYSTEM ..........eeec.eonanoo F1- 3
OUTLINE .eÑeneeoeenacoonoesoserooncen: F1- 3
SERVICE
SUPPLEMENTAL SERVICE
INFORMATION 12.00 cu sacc sense nc u cn Fi- 3
CONTROL SYSTEM ..................... F1—- 3
ENGINE CONTROL MODULE (ECM)
REMOVAL / INSTALLATION ............ F1- 3
ENGINE CONTROL MODULE (ECM)
INSPECTION os0s.000000. 0000000001000 F1- 4
ON-BOARD DIAGNOSTIC SYSTEM ....... F1- 5
DIAGNOSTIC TROUBLE CODE NUMBER
INSPECTION ...ne.e.eesncrvonranconca. Р1- 5
OUTLINE
F1
OUTLINE
e No changes have been made to vehicles that are not equipped with the immobilizer system.
e The ECM has been modified according to the addition of the immobilizer system.
SYSTEM WIRING DIAGRAM
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F1—2
CONTROL SYSTEM, SUPPLEMENTAL SERVICE INFORMATION F1
@ conTROL sysTEM
OUTLINE
e Immediately after the engine is started, the immobilizer judges if the ignition key is valid or not. When the
key is valid, the ECM continues to run the engine. When the key is invalid, the immobilizer unit actuates
the ECM to carry out the fuel cut-off and the ignition cut-off operations, and as a result, the engine stops
in a few seconds. (Refer to IMMOBILIZER SYSTEM SERVICE MANUAL.)
SUPPLEMENTAL SERVICE INFORMATION
The following changes and / or additions have been made since publication of the Mazda MX-5 Workshop
Manual Supplement (1451-10-94L) and IMMOBILIZER SYSTEM SERVICE MANUAL (1503-10-95A).
Engine control module (ECM)
e Removal / Installation procedure modified
e Inspection procedure modified
On-board diagnostic system
o Inspection procedure modified
CONTROL SYSTEM
ENGINE CONTROL MODULE (ECM) REMOVAL /
INSTALLATION
Note
e The ECM equipped on a vehicle with the immobilizer
system operates normally only when the correct 1D
number and cord word are inputinit. (Refer to IMMOBI-
LIZER SYSTEM SERVICE MANUAL.)
e The ECM with the ID number and cord word stored is
only applicable to the vehicle that the ECM has original-
ly been equipped.
. Disconnect the negative battery cable.
. Lift up the floormat in front of the passenger’s seat.
. Remove the protector cover.
“N —
Note
e || Пе set bolt is used, refer to set bolt removal note and
set bolt installation note.
. Disconnect the ECM connector.
. Remove the ECM.
. Install in the reverse order of removal.
O) сл +
Tightening torque:
18—26 N-m (1.8—2.7 kgf-m , 14—19 ft-Ibf )
7. Input the ID number and cord word, referring to “iIMMOBI-
LIZER SYSTEM SERVICE MANUAL”.
F1-3
F1 CONTROL SYSTEM
Set bolt removal note
©
e Using a chisel and a hammer, cut a groove on the head
e of the set bolt so that a screwdriver can be inserted.
® Loosen the set bolt by using an impact screwdriver or pli
AS || ers
/ ii
/
SET BOLT SET BOLT
=
CHISEL CHISEL
Set bolt installation note
e Install new set bolt and tighten it until the neck of the bolt
SET BOLT :
IS cut.
Tightening torque:
ip 18.6—25.5 N-m {1.90—2.60 kgf-m, 13.8—18.8 ft.Ibf }
— ©
CUT
ENGINE CONTROL MODULE (ECM) INSPECTION
Terminal voltage (Reference) O
e Terminal voltage list has been modified. (Inspection procedure and SSTs are not modified.)
2Y | 2W| 2U | 28 | 2Q | 20 | 2M] 2K | 21 | 2G | 2Е | 2С | 2А | | 10 | 18 1 1Q | 107 1MP KI 11 11С | 1Е | 1С | 1А
22 | 2X | 2V | 2T | 2R | 2P | 2N | 2L | 2J | 2H | 2F | 2D 1 28 1 1V | 1T | 1R | 1P| IN] IL) 1J 11H ГАР 110 | 18
Possible 0
Termi-
nal Signal Connected to Test condition Voltage (V) malfunction
Communica- Check signal by using oscilloscope. ° ЕСМ!
10 tion Immobilizer unit Refer to “IMMOBILIZER SYSTEM — * Immobilizer unit
(Immobilizer) SERVICE MANUAL" y
e Approx.
oF SOT Camshaft posi- Ignition switch ON О e 5 v | * Camshaft posi-
tion sensor tion sensor
Idle Approx. 2 V
“1 if the immobilizer unit functions normally, replace the ECM.
F1-4
ON-BOARD DIAGNOSTIC SYSTEM F1
O ON-BOARD DIAGNOSTIC SYSTEM
O DIAGNOSTIC TROUBLE CODE NUMBER INSPECTION
Note
e The following diagnostic trouble code numbers have been added according to the adoption of the im-
mobilizer system. Other code numbers remain unchanged.
Code No. Indicator pattern Diagnosed circuit
71 | | . | | Immobilizer unit—ECM communication error
prey pay pr e a
72 || | UL L ID number unregistered
al as ный ad
73 Code words do not match
hyp
ID numbers do not match
—
Code ward / ID number writing and reading error
| | || Code word unregistered
76
Diagnostic trouble : ЕД вл
code No.71 Immobilizer unit—ECM communication error
Symptom Command transmission exceeded limit
® Detect in immobilizer unit—ECM communication line
Possible cause ® Immobilizer unit malfunction
* ECM malfunction
| STEP INSPECTION ACTION
| O 1 Erase diagnostic trouble code from Yes | Go to next step
memory. Is same code No. present after | No | Carry out troubleshooting of other diagnostic trouble code
rechecking?
No. if displayed
2 Check continuity of wiring harness be- Yes Repair or replace as necessary
tween immobilizer unit and ECM, and
visually check connectors. Is there open
or short circuit in communication line be- No | Go to next step
tween ECM terminal and immobilizer
unit terminal A?
3 Erase diagnostic trouble code from Yes | Carry out troubleshooting of other diagnostic trouble code
memory and start engine. Does engine No. if displayed
continue running normally? No | If code No.71 displayed again, inspect immobilizer unit Go
to next step
rz IMMOBILIZER SYSTEM SERVICE MANUAL
4 Erase diagnostic trouble code from Yes | Carry out troubleshooting of other diagnostic trouble code
memory and start engine. Does engine No. if displayed
continue running normally? No | If code No.71 displayed again, replace immobilizer unit with
previous one and replace ECM
rr IMMOBILIZER SYSTEM SERVICE MANUAL
F1-5
F1
ON-BOARD DIAGNOSTIC SYSTEM
Diagnostic trouble nreaister
code No.72 ID number unregistered
Symptom ID number is not stored in ECM
Possible cause | ECM replacement procedure not correct
сте:
АСТЮМ
1
Reinput ID number
IMMOBILIZER SYSTEM SERVICE MANUAL
O
tion) entered?
Diagnostic role Code words do not match
Symptom Code words stored in immobilizer unit and ECM do not match
Possible cause | 2 Transformation of 0008 wore sored mene ni
STEP INSPECTION ACTION
1 Erase diagnostic trouble code from Yes | Go to next step
memory. Is same code No. present after | No | Carry out troubleshooting of other diagnostic trouble code
rechecking? No. if displayed
2 Is diagnostic trouble code No.75 also Yes Carry out troubleshooting of diagnostic trouble code No.75
shown? No | Gotonext step
3 Using new key, carry out key duplication Yes Replace ECM
wIMMOBILIZER SYSTEM SERVICE r= IMMOBILIZER SYSTEM SERVICE MANUAL
|5 Code word (required for key duplica- No | Replace immobilizer unit
= IMMOBILIZER SYSTEM SERVICE MANUAL
Do not use ECM on other vehicle for testing. Diagnostic trouble code No.73 will be displayed again.
Diagnostic trouble
code No.74
ID numbers do not match
Symptom
ID numbers stores in immobilizer unit and ECM do not match (Symptom occurs only after immobiliz-
er unit is replaced and key 1D number is registered)
Possible cause
* Unregistered key is used
* Transformation of ID number stored in ECM
STEP INSPECTION ACTION
1 Erase diagnostic trouble code from Yes | Go to next step
memory. Is same code No. present after No Carry out troubleshooting of other diagnostic trouble code
rechecking? No. if displayed
2 Start engine using another registered Yes Previous key defective of unregistered
key. Does engine start normally? No | Replace immobilizer unit and ECM at same time using set
parts
wwIMMOBILIZER SYSTEM SERVICE MANUAL
F1-6
ON-BOARD DIAGNOSTIC SYSTEM F1
Diagnostic trouble i
code No.75 Code word / ID number writing and reading error
Symptom ECM internal EEPROM damaged
Possible cause ECM internal EEPROM damaged
STEP INSPECTION ACTION
1 Erase diagnostic trouble code from Yes Replace ECM
memory. Is same code No. present after = IMMOBILIZER SYSTEM SERVICE MANUAL
rechecking? No | Carry out troubleshooting of other diagnostic trouble code
No. if displayed
Dlagnastie lrouble Code word unregistered
Symptom Code word is not stored in ECM
Possible cause ECM replacement procedure not correct
STEP ACTION
1 Reinput ID number
IMMOBILIZER SYSTEM SERVICE MANUAL
F1-7
F2
Before beginning any service procedure, refer to section T of the
MX--5 Workshop Manual (1451—10—94L) for air bag system service
warnings.
FUEL AND EMISSION
CONTROL SYSTEMS
(BP)
FEATURES
OUTLINE .......2..0000 0000 case casa sn mam0 F2- 2
SYSTEM WIRING DIAGRAM ............ F2- 3
СОМТВО!. 5У5ЗТЕМ ..................... F2- 4
OUTLINE ...e..eeeeecconmsocncanrercernaea F2- 4
SERVICE
SUPPLEMENTAL SERVICE
INFORMATION ..........eeeeecconancono F2- 4
CONTROL SYSTEM ..................... F2- 5
ENGINE CONTROL MODULE (ECM)
REMOVAL / INSTALLATION ............ F2- 5
ENGINE CONTROL MODULE (ECM)
INSPECTIÓN ..Ñenenoarnooronnonaanona F2- 6
ON-BOARD DIAGNOSTIC SYSTEM ....... F2-11
DIAGNOSTIC TROUBLE CODE NUMBER
INSPECTION ..eÑe.eeconnenoncareoone. F2—11
F2 OUTLINE
OUTLINE O
e
The following points have been changed compared with the previous model.
e Immobilizer system added.
e STA (start) signal eliminated.
e Following points modified according to the ECM modairication.
e ECM pin location modified.
e Diagnostic trouble codes indicated in four digits.
e Oxygen monitor function and switch monitor function eliminated. *
* By using the New Generation Star (NGS) tester, “PID/DATA MONITOR AND RECORD” function
and “SIMULATION TEST” function become available instead of oxygen monitor function and switch
monitor function.
Until the NGS tester is introduced, inspect the oxygen sensor and the switch system input signals by
checking the ECM terminal voltages.
F2-2
F2
OUTLINE
SYSTEM WIRING DIAGRAM
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F2-3
F2 CONTROL SYSTEM, SUPPLEMENTAL SERVICE INFORMATION
CONTROL SYSTEM ©
OUTLINE
e Immediately after the engine is started, the immobilizer judges if the ignition key is valid or not. When +
key is valid the ECM continues to run the engine. When the key is invaiid, the immobilizer unit actuates
the ECM to carry out the fuel cut-off and the ignition cut-oti operations, and as à result, ne engine stops
ina few saconds. (Refer to IMMOBILIZER SYSTEM SERVICE MANUAL.)
SUPPLEMENTAL SERVICE INFORMATION
The following changes and / or additions have been made since publication of the Mazda MX-5 Workshop
Manual Supplement (1451-10-94L) and IMMOBILIZER SYSTEM SERVICE MANUAL (1503-10-95A).
Engine control module (ECM)
e Removal / Installation procedure modified
e Inspection procedure modified
On-board diagnostic system
e Inspection procedure modified O
F2-4
CONTROL SYSTEM F2
WN —
O SS
CHISEL
SET BOLT
7
CHISEL
SET BOLT
SET BOLT
CUT
CONTROL SYSTEM
ENGINE CONTROL MODULE (ECM) REMOVAL /
INSTALLATION
Note
e The ECM equipped on a vehicle with the immobilizer
system operates normally only when the correct ID
number and cord word are input in it. (Refer to IMMOBI-
LIZER SYSTEM SERVICE MANUAL.)
e The ECM with the ID number and cord word stored is
only applicable to the vehicle that the ECM has original-
ly been equipped.
. Disconnect the negative battery cable.
. Lift up the floormat in front of the passenger's seat.
. Remove the protector cover.
Note
e |fthe set bolt is used, refer to set bolt removal note and
set bolt installation note.
. Disconnect the ECM connector.
. Remove the ECM.
. Install in the reverse order of removal.
Tightening torque:
18—26 N-m {1.8&—2.7 kgf-m , 14—19 ft-Ibf }
. Input the ID number and cord word, referring to “IMMOBI-
LIZER SYSTEM SERVICE MANUAL”.
Set bolt removal note
Using a chisel and a hammer, cut a groove on the head
of the set bolt so that a screwdriver can be inserted.
Loosen the set bolt by using an impact screwdriver or pli-
ers.
Set bolt installation note
Install new set bolt and tighten it until the neck of the bolt
IS cut.
Tightening torque:
18.6—25.5 N-m (1.90—2.60 kgf-m , 13.8—18.8 ft-Ibf )
F2-5
F2 CONTROL SYSTEM
ENGINE CONTROL MODULE (ECM) INSPECTION O
Caution Oo
e The ECM terminal voltages vary with change in
measuring conditions and vehicle conditions, A!-
ways carry vul a tulal mispeclivi ví (he input 3ys-
tems, output systems, and ECM to determine the
cause of trouble. Otherwise, a wrong diagnosis will
be made.
. Disconnect the negative battery cable.
. Remove the ECM.
. Disconnect the ECM connector.
. Connect the SST (Harness Adapter) to the ECM connec-
tor.
. Connect the SSTs (Engine Signal Monitor and Harness
adapter, power) to the SST (Harness Adapter). Use con-
nector A of the harness adapter for ECM terminals 1A
through 1V and 3A through 3P. Use connector B for EC
terminals 4A through 4Z.
6. Place the SST (Sheet) on the SST (Engine Signal Moni-
tor).
7. Measure the voltage at each ECM terminal by switching
O1 > WN =
the selector switch and the monitor switch.
8. If any incorrect voltage is detected, check related sys-
INDICATOR LIGHTS LDL tems, wiring harnesses and connectors referring to the
possible malfunction in the terminal voltage list.
Caution O
e Disconnecting the connectors of the ECM and the
SST (Harness Adapter) while the battery is con-
nected can damage the ECM and the SST (Engine
Signal Monitor). Disconnect the nagative battery
TERMINAL A cable and the SST (harness adapter, power) before
TERMINAL B disconnecting the connectors.
e Applying voltage to terminals A and B of the SST
(Engine Signal Monitor) can damage the SST (En-
gine Signal Monitor). ®
Note
e The indicator lights of the SST (Engine Signal Monitor),
provided for confirmation of the voltmeter range, is also
used for detection of the pulse such as the fuel injector
control signal, which is difficult to detect by using the
voltmeter.
e Terminals A and B of the SST (Engine Signal Monitor)
are for connection of an external instrument. By con-
necting an external instrument such as a circuit tester
or an oscilloscope, various inspections in addition to
the measurement of the ECM terminal voltages are
made possible.
e |f the tires are rotated by using a chassis roller with the
ignition switch at ON, the ABS control module may
memorize the action as a malfunction and the ABS
warning light may illuminate. If the ignition switch `@
turned to LOCK and then to ON again, the ABS warning
light will not illuminate, because the action will be con- a
sidered a past malfunction.
F2-6
F2
CONTROL SYSTEM
O Terminal voltage (Reference)
B+: Battery positive voltage
O *1: In data link connector
4Y [4AW4U14S [4Q| 40l4Mi4K [41 [4G|dE [4C | 4A] | 3O/3MI 3K| 31 [3G] 3E 13C |3A 1U{1S/1QH1O/1M 1H{1G|1E[1C|1A
42 [4X |4V 147 [4R[4P [AN 14L 14) 14H | 4FI 4D14B 1139 3N! 3LI 3J [3H] 3F13D|38 IVT IR 1P]IN 1J{1H{1F[1D] 18
Termi- Signal Connected to Test condition Voitage (V) Possible
nal malfunction
Cooling fan operat-
ing/Terminal TEN
TA | control Cooling fan relay | ón vaive open * Cooling fan relay
Cooling fan stop B+
Condenser fan op-
N , erating/Terminal Below 1.0
18 Condenser fan | Condenser fan Ignition switch | TEN ground and ‘У | ® Condenser fan
Condenser fan stop B+
1C — — — — —
Carry out inspection according to
diagnostic trouble code
1D Serial commu- pata link con Diagnostic trouble code output is a — * On-board diag-
nication MEN or KLN "1 part of serial communication nostic system
Judgement by terminal voltage is not
possible
| | Ignition switch No diagnostic B+
Diagnostic Data link con- ON (Terminal trouble code output * ECM terminal 1E
1E trouble code nector (Terminal 4 “FE
output FEN) TEN Diagnostic trouble Below — "FEN harness
grounded) code output 1.0—B+
1F — — — — —
Ignition switch ON B+
1G A/C control A/C relay Idle A/C operating Below 2.0 | * A/C relay
A/C stop B+
Headlight switch OFF Below 1.0
1H | Headlight Headlight switch gn” sw * Headlight switch
Headlight switch ON B+
. - | rT
11 | Diagnostic test recor (Tam a | lgnition switch | Open terminal TEN] B+ | * ECM terminal 1
mode TEN '1) ON Short terminal "TEN | Below 1.0 | — TEN hamess
Rear window de- Below 1.0
1 Rear window Rear window de- | Ignition switch | froster switch OFF — | * Rear window de-
defroster froster relay ON Rear window de- froster relay
: B+
froster switch ON |
A © ÓN and fan Approx. 2.0| ® A/C switch
1K A/C A/C switch Idle SWItC e Refrigerant pres-
A/C switch OFF B+ sure switch
F2-7
F2
CONTROL SYSTEM
B+: Battery positive voltage
*1: In data link connector
©
Termi- : Possible
nal Signal Connected to Test condition Voltage (V) malfunction
| Other than neutrai
pops: ari сны D+
1, | Load/Noload | Neutral/clutch Ignition switch | pedal released * Neutral switch
distinction switch ON Neutral position or * Clutch switch
cluteh pedal de- Below 1.0
pressed
Approx. 7.0
Vehicle speed Ignition switch ON or * Vehicle speed
M Vehicle speed sensor Below 1.5 sensor
Driving Approx. 3.0
1N — — — — —
10 — — — — —
Fan switch OFF or В+
iti ON at 1st
1P Blower Fan switch qn switch - * Fan switch
Fan switch ON at Below 1.0
2nd or higher
Brake pedal released Below 1.0
1Q Brake Brake switch Р * Brake switch
Brake pedal depressed B+
1R — — — — —
Communica- Check signal by using oscilloscope. ° ЕСМ
15 tion Immobilizer unit Refer to “IMMOBILIZER SYSTEM — * Immobilizer
(Immobilizer) SERVICE MANUAL"
17 — — — — —
Ignition switch ON B +
Fuel pump
1U control Fuel pump relay Cranking Below 1.0 * Fuel pump relay
Idle
Fuel pump Ignition switch ON B+
1V control | Fuel pump rela Crankin ® Fuel pump rela
(Equipped with pump relay 9 Below 1.0 pump relay
immobilizer) idle
3A — — — — —
ag | Mass air flow Mass air flow Ignition switch ON Below 1.0 | * Mass air flow
sensor (VGP) sensor Idle 1.0—2.0 sensor
Ignition switch ON Approx. 0
id! Engine cold 0.1—0.9
3C Heated oxy- Heated oxygen e Below 10 | * Heated oxygen
gen sensor sensor sensor
Acceleration After warms up 0.5—1.0
Deceleration 0—0.5
3D — — — — —
3E — — — — —
F2-8
CONTROL SYSTEM
F2
B+: Battery positive voltage
*1. In data link connector
Termi- . ces Possible
nal Signal Connected to Test condition Voltage (V) malfunction
Closed throttle ® Throttle position
3F Throttle posi- Throttle position Ignition switch position 0.1—1.1 sensor
tion (TVO) sensor ON * ECM terminal 31
Wide open throttle 3.1—4.5 voltage
; Engine coolant +: | Engine coolant Approx. 2.5| © Engine coolant
3G oe oe! temperature grition switch temp. 20 °C {68 °F ) PP - temperature sen-
sensor After warm up Below 1.0 sor
3H — — — — —
Throttle position
Constant volt- sensor " * ECM terminal 48
3l age (Vref) EGR valve posi- Ignition switch ON Approx. 5.0 voltage
tion sensor
ti * EGR valve posi-
h
3 EGR valve EGR valve posi- Ignition switch ON Approx. 0.8 tion sensor
position tion sensor id pprox. v.51 6 ECM terminal 31
e voltage
3K Intake air tem- | Intake air tem- Ignition switch Intake air tempera- Approx. 2.5 * Mass air flow
perature perature sensor ON ture 20 °C {68 °F } РРГОХ. ©. sensor
Accelerator pedal Below 1.0
aL Closed throttle | Closed throttle Ignition switch | released | * Throttle position
position position switch ON Accelerator pedal B sensor
depressed +
3M — — — — —
3N — — — — —
Analogue sen- * ECM 30 terminal
30 sor ground Ground Constant Below 1.0 harness (Open)
Ignition switch ON B
Power steer- Power steering + * Power steering
ЗР ing pressure pressure switch Idle P/S not operating pressure switch
P/S operating Below 1.0
4A ECM ground Ground Constant Below 1.0 * ECM 4A hamess
(Open)
Main relay (FUEL а . OFF Below 1.0 | _ кис
4B Power supply INJ relay) Ignition switch ON В Main relay
Е * ECM 4C terminal
4C Fuel injector Ground Constant Below 1.0 harness continuity
9 (Open)
. * ECM 4D terminal
4D Output device Ground Constant Below 1.0 harness continuity
g (Open)
4E — — — — —
F2-9
F2
CONTROL SYSTEM
B+: Battery positive voltage
*1: In data link connector
Termi- Possible
hal Signal Connected to Test condition Voltage (V) malfunction
lanition switch ON | bor |
7 Sar APprox. v.U
Camshaft posi- | Idle Approx. 2.0| Camshaft posi-
tion sensor N . О ог tion sensor
Ignition switch ON
4G SGC 9 Approx. 5.0
Idle Approx. 1.5
4H — — — — —
®* ECM terminal 4I—
41 Back-up pow- Battery Constant B+ battery harness
pply and connector
ду | Pressure regu- | PRC solenoid ldle (Approx.149 sec after hot start) Below 3.0 | * РАС solenoid
lator control valve Other B+ valve
4K — — — — —
ti 0 or * ECM terminal 4L
Ignition switch ON |
aL Engine speed | Tachometer gnition sw Approx. 11 | —tachometer
Idle Approx. 6” | * ECM
4M — — — — —
Ignition switch ON Below 1.0
AN | IGT Ignition coi grifion swt X * Ignition coil
Idle Approx. 0.2
ao | EGR control EGR solenoid Ignition switch ON B+ * EGR solenoid
(Vent) valve (Vent) Idle valve (Vent)
ap | EGR control EGR solenoid Ignition switch ON B+ * EGR solenoid
(Vacuum) valve (Vacuum) | idle valve (Vacuum)
Ignition switch ON Below 4.8 |
4Q Idle air control Idle air control ® Idle air control
valve Idle № warm up (No Approx. 10 valve
Ignition switch ON Below 1.0
4R | IGT2 Ignition coil gnition swi - e ¡gnition coil
Idie Approx. 0.2
45 — — — — —
Purge solenoid | lgnition switch ON * Purge solenoid
4T | Purge control | Valve de B+ valve
4U Fuel injector No.1 | Ignition switch ON B+
aw | control Fuel injector No.3 Idle B+" uel injector
4X Fuel injector No.4
4Y — — — — —
47 — — — — —
* Engine Signal Monitor: Green and red lights flash
F2-10
ON-BOARD DIAGNOSTIC SYSTEM F2
SELECT SW A ON-BOARD DIAGNOSTIC SYSTEM
SYSTEM SELECT 1
TEST SW DIAGNOSTIC TROUBLE CODE NUMBER INSPECTION
UNS
a SELF TEST Using the SST
y 1. Connnect the SST (System Selector) to the data link con-
4
AL EN
y > +25 oy
nector.
49 H018 9A1
. Set system select to position 1.
. Set test switch to SELF-TEST.
. Connect the SST (Self-Diagnosis Checker) to the system
selector connector and to a ground.
. Set select switch to position A.
. Turn the ignition switch to ON and verify that “88” flashes
on the digital display and buzzer sounds for 3 seconds.
. If not, check the main relay, power supply circuit, and data
link connector wiring.
‘о 5H . If “88” flashes and the buzzer sounds continuously for
во more than 20 seconds, check for a short circuit between
ECM terminal 1E and the data link connector. Replace the
ECM if necessary and perform step 3 through 7 again.
5 o O° 9. Note any code numbers and check for the causes by re-
49 BO19 9A0
oo NY O O1 4 D N
обо ferring to the check sequences shown on page F2-12.
Repair as necessary.
BANE NN ¿AAN
Note
e À diagnostic trouble code is cosist of four numbers.
They are shown one by one in the right window on the
display by each flash. (*1” is always shown on the left
1ST 2ND 3RD 4TH
FLASH FLASH FLASH FLASH
e If there is no malfunction, “00” is displayed on the dis-
play.
e When there are multiple malfunctions, the codes are
displayed in numerical order.
DIAGNOSTIC
TROUBLE : 1950 10. After repairs, cancel the code numbers by performing the
NUMBER After Repair Procedure” (Refer to page F2-12).
Using a voltmeter
= 1. Connect the data link connector terminals TEN and GND
в
O | UL <> by using a jumper wire.
2. Connect a voltmeter — (negative) terminal to the data link
connector teminal FEN, and + (positive) terminal to the +
(positive) terminal of the battery.
3. Turn the ignition switch to ON.
+ BATTERY 4. Observe the voltmeter needle and note the code number
POSITIVE (s).
GND TERMINAL
TEN B+: BATTERY POSITIVE VOLTAGE
FEN O
Note
=1345 e Code No. indication by the voltmeter needie is as
713 shown.
А S < © 5. Check for the cause by referring to the check segences.
! | Repair as necessary.
NOTE ONE'S DIGIT ONLY 6. After repairs, cancel the code numbers by performing the
|| = 1402 “After Repair Procedure” (Refer to page F2-12).
11 14 10 12
F2-11
F2
ON-BOARD DIAGNOSTIC SYSTEM
BATTERY
NEGATIVE NI
==
Diagnostic trouble code
e For troubleshooting procedure of each diagnostic trouble code other than additional diagnostic trouble
code, refer to the workshop manual for the previous model.
After Repair Procedure
1.
о! N
After repairs, disconnect the negative battery cable for at
least 20 seconds, and depress the brake pedal. Recon:
nect the negative battery cable.
. Warm up the engine to normal operating temperature.
Ona tra; his ndo: ingnantian anai in and verify that na
2 EEE Ly wre
service codes are displayed.
Code No.
Previous New Indicator pattern Diagnosed circuit
model model
03 1345 | || ||| | Camshaft position sensor (SGC signal)
04 — —
08 0100 | | | / Mass air flow sensor
09 0115 TL Engine coolant temperature sensor
10 0110 | | | | | Intake air temperature sensor
12 0120 | | || Throttle position sensor
14 1195 | Barometric pressure sensor
15 0134 TTT Heated oxygen sensor (inactivation)
16 1402 | I | | I EGR valve position sensor
17 1170 I | mm Heated oxygen sensor (inversion)
25 1250 | | | ||] | PRC solenoid valve
26 0443 monn Purge solenoid valve
28 1485 | ЛОМО Tm EGR solenoid valve (vacuum)
29 1486 | M ООП СОДИ EGR solenoid valve (vent)
34 0505 ГТО Idle air control valve
F2-12
ON-BOARD DIAGNOSTIC SYSTEM F2
Previous New indicator pattern Diagnosed circuit
model model
O Code No.
— 0500 | | | | | Vehicle speed sensor
— 1602” ni | Immobilizer unit—ECM communication error (Immobilizer)
— 1603’ ll | | ID number unregistered (Immobilizer)
— 1604" ГО | ||| Code word unregistered (Immobilizer)
— 1608 | ANNA ECM internal circuit malfunction
O — 1621” [Lm mm Code words do not match (Immobilizer)
— 1622” FAT NET ID numbers do not match (Immobilizer)
. Code word / ID number writing and reading error (Immobiliz-
* : Equipped with immobilizer
Diagnostic trouble | Vehicle speed sensor-malfunction
code No. P0500
Symptom No vehicle speed sensor signal input from vehicle speed sensor while driving
© Vihicle speed sensor malfunction
Possible cause * Open or short circuit in wiring from vehicle speed sensor to ECM terminal 1M
STEP INSPECTION ACTION
O 1 Does vehicle speed sensor connector or Yes Repair or replace connector
ECM connector have poor connection? No Go to next step
2 Is ECM terminal 1M voltage OK? Yes | Goto step 4
No Go to next step
3 Is there continuity between vehicle Yes Go to next step
speed sensor terminal and PCM termi- —
nal 1M? No Repair or replace wiring harness
4 Erase diagnostic trouble code from Yes Replace ECM
ey: I's same code No. present after No |” ntermittent poor connection of hamess or connector (Repair
rechecking: connector and/or harness)
F2-13
F2
ON-BOARD DIAGNOSTIC SYSTEM
Diagnostic trouble
code No. P1602
Immobilizer unit—ECM communication error
Symptom
Command transmission exceeded limit
Fossibie cause
||
Defect in immobilizer unit—ECM communication line
immobilizer unit malfunction
po Manuicuón
STEP INSPECTION ACTION
1 Erase diagnostic trouble code from Yes | Go to next step
oi Is same code No. present after | No | Carry out troubleshooting of other diagnostic trouble code
rechecKIng : No. if displayed
2 Check continuity of wiring harness be- Yes Repair or replace as necessary
tween immobilizer unit and ECM, and
vusually check connectors. Is there
open or short circuit in communication No | Goto next step
line between ECM terminal and immobi-
lizer unit terminal A?
3 Erase diagnostic trouble code from Yes Carry out troubleshooting of other diagnostic trouble code
memory and start engine. Does engine No. if displayed
continue running normally? No | if code No.1602 displayed again, inspect immobilizer unit
Go to next step
rw IMMOBILIZER SYSTEM SERVICE MANUAL
4 Erase diagnostic trouble code from Yes Carry out troubleshooting of other diagnostic trouble code
memory and start engine. Does engine No. if displayed
continue running normally? No | If code No.1602 displayed again, replace immobilizer unit
| with previous one and replace ECM
wr IMMOBILIZER SYSTEM SERVICE MANUAL
Diagnostic trouble
code No. P1603
ID number unregistered
Symptom
ID number is not stored in ECM
Possible cause
ECM replacement procedure not correct
STEP
ACTION
1 Reinput ID number
IMMOBILIZER SYSTEM SERVICE MANUAL
Diagnostic trouble
code No. P1604
Code word unregistered
Symptom
Code word is not stored in ECM
Possible cause
ECM replacement procedure not correct
STEP
ACTION
1 Reinput ID number
wIMMOBILIZER SYSTEM SERVICE MANUAL
Diagnostic trouble
code No. 1608
ECM malfunction
Symptom
ECM does not read diagnostic trouble codes from output devices
Possible cause
* ECM malfunction
STEP
INSPECTION
ACTION
Replace ECM
F2-14
ON-BOARD DIAGNOSTIC SYSTEM
F2
Diagnostic trouble
code No. P1621 Code words do not match
Symptom
Code words stored in immobilizer unit and ECM do not match
Possible cause
® Transformation of code word stored in immobilizer unit
© Transformation of code word stored in ECM
STEP INSPECTION ACTION
1 Erase diagnostic trouble code from Yes | Go to next step
rechocki Is same code No. present after | No [| Carry out troubleshooting of other diagnostic trouble code
rechecking: No. if displayed
2 Is diagnostic trouble code No.1623 also Yes | Carry out troubleshooting of diagnostic trouble code No.
shown? 1623
No Go to next step
3 Using new key, carry out key duplication Yes | Replace ECM
IMMOBILIZER SYSTEM SERVICE ı= page F2-5
MANUAL : — ;
Is code word (required for key duplica- No | Replace immobilizer unit
tion) entered? = IMMOBILIZER SYSTEM SERVICE MANUAL
0 Do not use ECM on other vehicle for testing. Diagnostic trouble code No. 1621 will be displayed again.
Diagnostic trouble
code No. P1622 ID numbers do not match
Symptom
ID numbers stored in immobilizer unit and ECM do not match (Symptom occurs only after immobi-
lizer unit is replaced and key ID number is registered)
Possible cause * Unregistered key is used
® Transformation of ID number stored in ECM
O STEP INSPECTION ACTION
1 Erase diagnostic trouble code from Yes | Go to next step
memory. Is same code No. present after | No | Carry out troubleshooting of other diagnostic trouble code
rechecking? No. if displayed
2 Start engine using another registered Yes Previous key defective of unregistered
key. Does engine start normally? No | Replace immobilizer unit and ECM at same time using set
parts
page F2-5 and IMMOBILIZER SYSTEM SERVICE
MANUAL
Diagnostic trouble
code No. P1623
Code word / ID number wrinting and reading error
Symptom ECM internal EEPROM damaged
Possible cause ECM internal EEPROM damaged
STEP — INSPECTION ACTION
1 Erase diagnostic trouble code from Yes Replace ECM
memory. Is same code No. present after ss page F2-5
rechecking? No | Carry out troubleshooting of other diagnostic trouble code
No. if displayed
F2-15
Before beginning any service procedure, refer to section T of the
MX-5 Workshop Manual (1451-10-94L) for air bag system service
warnings.
FRONT AND REAR AXLES
FEATURES
QUTLINE ......eñeecocosveneconescoacano M- 2
OUTLINE OF CONSTRUCTION .......... M- 2
TORQUE SENSING LIMITED SLIP
DIFFERENTIAL (“TORSEN” TYPEB LSD) M- 2
OUTLINE ......2.22000 0000 a nc cu a same mass M- 2
CONSTRUCTION -....eeeeeeneanonacmoo M- 3
OPERATION -.......eeeocsaornedconmares M- 4
“TORSEN” is a registered trademark of ZEXEL
M OUTLINE, TORQUE SENSING LIMITED SLIP DIFFERENTIAL (“TORSEN” TYPE В LSD)
OUTLINE
OUTLINE OF CONSTRUCTION O
e A torque sensing limited slip differential (“TORSEN” type B LSD) is an optional equipment for LH drive
modeis to improve drivability and stability.
TORQUE SENSING LIMITED SLIP DIFFERENTIAL (“TORSEN” TYPE B LSD)
OUTLINE
e The “TORSEN"” type B LSD has been equipped on the LH drive models, instead of the previous “TOR-
SEN" type A LSD”, to improve drivability and stability,
e The standard differential assembly and the “TORSEN” type B LSD assembly are interchange-able.
e The “TORSEN” type B LSD has the following benefits compared with the “TORSEN” type A LSD.
1. For operation restriction mechanism, the “TORSEN" type A LSD uses the friction of the worm gear teeth,
while the “TORSEN” type B LSD employs the friction between the planet gear and the gear case, and
between the side gear and the thrust washer.
2. Inthe “TORSEN" type ALSD, the bias ratio differs depending on the rotation direction. In the “TORSEN"
type B LSD, however, the bias ratio is the same regardless of the rotation direction.
* The differential which has been called “TORSEN" LSD in the previous manual is called “TORSEN" type A
LSD in this manual.
** Bias ratio
The bias ratio is to indicate the effectiveness of the LSD function. In the standard type differential, which
applies the equal rotational torque to both RH and LH driving wheels, when either of the wheels is
splipped by snow or ice and is spinning, the same amount of rotational torque is applied to the other
wheel. In the LSD, rotational torque of the spinning when is increased and applied to the other wheel.
This torque ratio is called bias ratio. O
Rotational torque of slower wheel
Bias ratio = -
Rotational torque of faster wheel
TORQUE SENSING LIMITED SLIP DIFFERENTIAL (“TORSEN” TYPE B LSD) M
O CONSTRUCTION
THRUST WASHER
SIDE GEAR
THRUST WASHERS
SIDE GEAR ME y;
THRUST WASHERS
GEAR POCKETS
PLANET GEARS
<
ZZ,
DA
a
SIDE GEARS
e The TORSEN" type BLSD assembly consists of two side gears, eight planet gears, and five thrust wash-
ers. The side gears are located on both ends of the drive shaft. Four planet gears are engaged with each
side gear in parallel direction. These planet gears engage with each other by the helical gear at both ends
as shown. the planet gears are supported by the gear pockets in the gear case. The “TORSEN” type B
O LSD assembly cannot be disassembled.
M-3
M TORQUE SENSING LIMITED SLIP DIFFERENTIAL (“TORSEN” TYPE B LSD)
OPERATION
RADIAL FORCE
GEAR CASE
/ De
SLOW
FN
PLANET GEARS
SIDE GEARS
FAST
RING GEAR ROTATION
4 $ Rotation
=> Gear sliding
force caused
<> by thrust force ) !
N
^У Y
| N A
| \ NN
pd >
THRUST WASHER / THRUST WASHER
| |
FAST | SLOW
THRUST WASHERS
* The figure above shows the differential operation in the driving condition.
When the engine brake is applied, all gears move in the opposite direction ofthe arrows andthe side gears are pressed
against the differential case.
Limited-Slip Operation
When one the driving wheels is spinning and the differential operation is restricted, thrust force and radial
force are generated between the helical gears by engage reaction. Rotation torque of the spinning wheel is
reduced by friction between the planet gear teeth and the gear case, between the planet gear end surface in
axial direction and the gear case, and between the side gear and the thrust washer. The reduced torque is
transmitted to the higher traction side, and functions as the limited-slip differential. This torque is proportion-
al to the ring gear input torque.
M-4
TD
TECHNICAL DATA
TECHNICAL DATA .........e_reorenvecno TD- 2
M. FRONT AND REAR AXLES ......... TD- 2
T. BODY ELECTRICAL SYSTEM........ TD- 2
TD
TECHNICAL DATA
M. FRONT AND REAR AXLES
TECHNICAL DATA
[===
| —— Engine/Transmission | BP DOHC
DGETA | MT
Drive shaft
Wheel side Bell joint
Joint type — —
Differential side Double-offset joint
Overall length Left side 767.3—777.3 {30.20—30.60}
(air in boot at atmospheric pressure
mm {in} | Right side 767.3—777.3 {30.20—30.60}
Shaft diameter mm {in} 24.0 {0.94}
Differential
Differential type IVPEBTSD Standard
Ring gear size mm { in } 182.88 {7.20}
Final gear ratio 4.100
Reduction gear Hypoid gear
Differential gear Helical gear | Straight-bevel gear
Ring gear teeth 41
Drive pinion gear teeth 10
Grade API service GL-5
oi Viscosiy Below-18 {0 °F }. SAESO
Capacity L( US at , Imp at } 1.00 {1.06, 0.88}
T. BODY ELECTRICAL SYSTEM
Bulb Specifications
Headlight 60/55W
Front turn light 21W
Front side turn light 5W
Exterior light Licence plate light 5W @
Rear turn light 21W
Stop/taillight 21/5W
Back-up light 21W
High-mount brake light 18.4W
Interior light Interior light 8W
Generator warning light 1.4W
Brake system warning light 1.4W
Washer fluid-level warning light 1.4W
ABS warning light 1.4W |
Air bag system warning light 1.4W 1
Hazard warning light 1.4W
Warning and indicator light Rear fog light indicator light 1.4W
Retractor indicator light 1.4W
Immobilizer indicator light 1.4W
High beam indicator light 3.4W
Rear window defroster indicator light 1.4W
Turn signal indicator light 3.4Wx2
Instrument cluster illumination 3.4W x4
TD-2
e
Before beginning any service procedure, refer to section T of the
MX—5 Workshop Manual (1451—10—94L) for air bag system service
warnings.
FEATURES
OUTLINE ........eeerresoonooneoconmanarnc N- 2
OUTLINE OF CONSTRUCTION ........... N- 2
SERVICE
SUPPLEMENTAL SERVICE
INFORMATION .....e..eoerrenonvonveano N- 2
MANUAL STEERING ...................... N- 2
STEERING WHEEL AND COLUMN
DISASSEMBLY / ASSEMBLY ............ N- 2
N OUTLINE, SUPPLEMENTAL SERVICE INFORMATION, MANUAL STEERING
OUTLINE O
OUTLINE OF CONSTRUCTION
e Due to the addition of the immobilizer system, when replacing the steering lock for the steering wheel
and column, the ID coda must be input into the system, because if this is not done, the engine can not
De Starteu.
SUPPLEMENTAL SERVICE INFORMATION
The following changes and / or additions have been made since publication of the Mazda MX-5 Work-
shop Manual (1221-10-89).
Steering wheel and column
e Disassembly / Assembly procedures modified
MANUAL STEERING
STEERING WHEEL AND COLUMN DISASSEMBLY / ASSEMBLY
Caution
e After replacing the steering lock with a new one, the engine cannot be started without inputting O
the ID number of the keys. Input the ID number, referring to “key replacement or duplicate keys”
(Refer to IMMOBILIZER SYSTEM General Information, section T.)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
1. Steering lock mounting bolts and bracket
2. Steering lock assembly
3. Steering shaft O
a REPLACE 4. Intermediate shaft
N-m { kgf-m , ft-Ibf }
N—2
Before beginning any service procedure, refer to section T of the
MX-5 Workshop Manual (1451-10-94L) for air bag system service
warnings.
BRAKING SYSTEM
FEATURES
OUTLINE ....e...ñe.eoecoconesanoonaneanooo Р- 2
OUTLINE OF CONSTRUCTION ........... Р- 2
SERVICE
SUPPLEMENTAL SERVICE INFORMATION ... P- 2
ANTILOCK BRAKE SYSTEM (ABS) ........ Р- 2
ABS CONTROL MODULE
REMOVAL / INSTALLATION ............. Р- 2
OUTLINE, SUPPLEMENTAL SERVICE INFORMATION,
P ANTILOCK BRAKE SYSTEM (ABS)
OUTLINE O
OUTLINE OF CONSTRUCTION O
e For models with the immobilizer system, the bolts which fix the ABS control module panel have been
chanyed Set bolts are now used.
SUPPLEMENTAL SERVICE INFORMATION
The following changes and / or additions have been made since publication of the Mazda MX-5 Workshop
Manual Supplement (1451-10-94L).
ABS control module
e Removal / Installation procedure modified
ANTILOCK BRAKE SYSTEM (ABS)
ABS CONTROL MODULE REMOVAL / INSTALLATION
1. Lift up the passenger side carpet.
2. Remove in the order shown in the figure.
3. Install in the reverse order of removal. O
Caution
e Connect the connector securely. If a poor contact occurs, the ABS may malfunction.
Q (1)18—26 {1.8—2.7, 14—19}
WITHOUT IMMOBILIZER ©
18—26 Ds 6
{1.8—2.7,14—19} > <> 2) @
<= N=
==
/C
17
18.6—25.5
(1.90—2.60, 13.8— 18.8)
N-m { kgf-m, ft-Ibf >
—
1. Bolt and nut 4. Control module panel
2. Nut 5. Connector
3. Set bolt 6. ABS control module
Refer to removal note
Refer to installation note
Set Boit Removai Note
(Refer to Section F2.)
Set Bolt Installation Note
(Refer to Section F2.)
P-2
Before beginning any service procedure, refer to section T of the
MX-5 Workshop Manual (1451-10-94L) for air bag system service
warnings.
BODY
FEATURES
OUTLINE ..........000000sa0n sens en san 00 S— 2
OUTLINE OF CONSTRUCTION ........... S— 2
SERVICE
SUPPLEMENTAL SERVICE INFORMATION .S- 2
REARVIEW MIRROR ..........e.ñe.eemeco.. S— 2
REARVIEW MIRROR REMOVAL /
INSTALLATION ........e.eorecnoneneco. S- 2
S OUTLINE, SUPPLEMENTAL SERVICE INFORMATION, REARVIEW MIRROR
OUTLINE O
e
OUTLINE OF CONSTRUCTION
e The rearview mirror has been redesigned.
SUPPLEMENTAL SERVICE iNFORMATION
The following changes and / or additions have been made since publication of the Mazda MX-5 Work-
shop Manual Supplement (1221-10-89I).
Rearview mirror
e Removal / Installation procedure modified
REARVIEW MIRROR
REARVIEW MIRROR REMOVAL / INSTALLATION
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal. O
SST
1. Rearview mirror 2. Base
Rearview mirror Base removalnote ............ раде 5-3
removalnote ................ page 5-3 Base installation note .......... раде S-3
5-2
REARVIEW MIRROR S
BASE
49 0305 870A
BASE
NOZZLE
3{0.12}
ct HE REPAIR SEALANT
mm { in }
CERAMIC COATING
5(0.2) /
=
BASE
\
`` mm {in}
Rearview Mirror Removal Note
1. Insert a flathead screwdriver between the mirror and the
base.
2. Push the base pin to remove the mirror.
Base Removal Note
1. Wind each end of a wire around a bar.
2. Saw through the sealant to remove the base. Use a long
sawing action to spread the work over the whole length of
wire to prevent it from breaking.
Base Installation Note
1. Cut away all of the original sealant by using a razor knife.
2. Clean and degrease the glass.
3. Apply primer to the glass and the base. Use only glass
primer on the glass and body primer on the base. Keep
the bonding area free of dirt and grease, and do not touch
the surface. Allow the primer to dry for approximately 30
minutes.
4. Applya3 mm {0.12 in } bead of repair sealant to the base.
о
5. Center the base in the ceramic coating and press it onto ES
the glass. Use ethyl alcohol to remove any excess repair
sealant.
Hardening time of repair sealant
Temperature | Surlacs hardening | Time require uni cer
5 °C {41 °F } Approx. 1.5 hr 12 hr
20 °C {68 °F } Approx. 1 hr 4 hr
35 °C {95 °F } Approx. 10 min 2 hr
5-3
Before beginning any service procedure, refer to section T of the
MX-5 Workshop Manual (1451-10-94L) for air bag system service
warnings.
FEATURES
OUTLINE neon cn T- 2
OUTLINE OF CONSTRUCTION ........... T- 2
IMMOBILIZER SYSTEM ................... T- 2
OUTLINE 22 TU T- 2
SERVICE
SUPPLEMENTAL SERVICE
INFORMATION ................. ree... T- 2
POWER SYSTEM NE T- 2
IGNITION SWITCH INSPECTION ......... T- 2
INTERIOR LIGHTING SYSTEM.............. T- 3
INTERIOR LIGHT REMOVAL/
INSTALLATION ............e..... e... T- 3
IMMOBILIZER SYSTEM ................... T- 4
STRUCTURAL VIEW оо T- 4
IMMOBILIZER UNIT REMOVAL/
INSTALLATION ....................... T- 5
OUTLINE, IMMOBILIZER SYSTEM,
T SUPPLEMENTAL SERVICE INFORMATION, POWER SYSTEM
OUTLINE O
©
OUTLINE OF CONSTRUCTION
e Immobilizer system has been added.
IMMOBILIZER SYSTEM
OUTLINE
e The immobilizer system of the Mazda MX-5 is basically the same as that for the Mazda 323, 626, MX-6,
XEDOS 6, and XEDOS 9.
SUPPLEMENTAL SERVICE INFORMATION
The following changes and / or additions have been made since publication of the Mazda MX-5 Workshop
Manual (1221-10-891), Mazda MX-5 Workshop Manual Supplement (1246—-10-90G), Mazda MX-5 Work-
shop Manual Supplement (1372-10-93l), and Mazda MX-5 Workshop Manual Supplement
(1451—10—94L).
Ignition switch
e Inspection procedure added
Interior light
e Removal / Installation procedure modified
Immobilizer unit
e Removal / Installation procedure added
POWER SYSTEM
IGNITION SWITCH INSPECTION O
= — = Vehicles equipped with immobilizer system
E С А 1. Disconnect the ignition switch connector.
2. Check for continuity between the terminals of the switch
F D B O—O : Contin
Terminal
B A E
Switch position
LOCK
ACC
ON
START
3. If not as specified, replace the steering lock.
(Refer to section N, MANUAL STEERING, STEERING
WHEEL AND COLUMN DISASSEMBLY/ASSEMBLY.)
T-2
|
1 INTERIOR LIGHTING SYSTEM T
INTERIOR LIGHTING SYSTEM
INTERIOR LIGHT REMOVAL / INSTALLATION
1. Insert a flathead screwdriver which has been wrapped in
tape as shown in the figure.
2. Twist the screwdriver to remove the lens.
3. Remove the screw.
4. Disconnect the interior light connector.
5. Remove the housing.
6. Remove the bulb.
7. Install in the reverse order of removal.
INTERIOR LIGHT
CONNECTOR
7 HOUSING
SCREW
LENS BULB
T IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
Caution
¢ When an immobilizer system component (such as the ECM (PCM), immobilizer unit. coil and
pre-amplifier, or the key) has failed, it must be accurately determined according to the trouble-
shooting procedures or by the display of the diagnostic trouble codes prior to carrying out the
service procedures. If a normal component is mistakenly replaced and the ID number and / or
code word are input into the new component, then neither component can be reused on other
vehicles.
STRUCTURAL VIEW
< ——
À
O80
IER)
1. Coil 3. Immobilizer unit
2. Pre-amplifier
Note
e The coil and the pre-amplifier are part of the assembly with the steering lock. When the coil and/or pre-
amplifier must be replaced, replace the steering lock.
SEMBLY on N, MANUAL STEERING, STEERING WHEEL AND COLUMN DISASSEMBLY / AS-
Note
e The following service procedure for the Mazda MX-5 are basically the same as for the Mazda 3>@
626, MX-6, XEDOS 6, and XEDOS 9.
* Coil and pre-amplifier inspection
* Immobilizer unit inspection
© ID number input procedure
CODE WORD input procedure
T-4
IMMOBILIZER SYSTEM T
BRACKET
ob
IMMOBILIZER UNIT
IMMOBILIZER UNIT REMOVAL / INSTALLATION
. Remove the center lower panel assembly.
. Remove the nut.
. Remove the bracket.
. Disconnect the connector.
. Remove the screws.
. Remove the immobilizer unit.
. Install in the reverse order of removal.
NOOSE © ГО —
Caution |
e After replacing the immobilizer unit with a new one,
the engine cannot be started without inputting the
ID number of the keys and the code word of the new
immobilizer unit. Input the ID number and code
word.
SPECIAL TOOLS
SPECIAL TOOLS ..........e.eereasooeoo ST- 2
GENERAL INFORMATION ............. ST- 2
CHECKERS AND OTHER EQUIPMENT . ST- 2
ST
ST
SPECIAL TOOLS
SPECIAL TOOLS
GENERAL INFORMATION
A..... inaispensabie
The tools ranked À in this list are indispensable for performing operations satisfactorily, easily, safely, and
efficiently. It is therefore advisable that all service shops have these tools.
B..... Selective
The tools ranked B is this list are not as necessary as tools ranked A, but all service shops should have them
to perform repairs more easily and efficiently.
CHECKERS AND OTHER EQUIPMENT
TOOL NUMBER
& DESCRIPTION
PRIORITY
ILLUSTRATION
49 G018 906
Sheet
(B6)
49 0088 008
Harness adapter
power
TOOL NUMBER
& DESCRIPTION | PRIORITY | ILLUSTRATION
49 9200 162A
Engine signal A
monitor
49 T018 902
Harness adapter A
49 H018 9A1
Self-Diagnosis A
checker
76MIN DOG
49 F018 903 == E
Sheet A Fox =
(BP) = te
SE
Ц
ala
49 B019 9A0
System selector
ST-2
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