warning MAZDA MX-5 1994 Workshop Manual

SRS AIR BAG SYSTEM T L Possible cause Flowchart No.8 Defective air bag module Defective clock spring Defective wiring harness Defective diagnostic module Warning Handling the air bag module improperly can accidently deploy the air bag, which may seri- ously injure you. Read SERVICE WARNINGS, page T-159, before handling the air bag module. Symptom Step 1 Carry out "Before Servicing" procedure under GEN- ERAL PROCEDURES, page T-1 60. Service Code 32 Step 2 1. Remove the air bag module. 2. Install a 1 -ohm (rated power 1 W) resistor between termi- nals B and C of the air bag module connector. 3. Connect the negative battery cable. 4. Turn the ignition switch to ON and check the service code. 1 Other I Replace air baa module (Refer to paae T-206) I Service code 32 Step 3 1. Disconnect the clock spring connector. 2. Install a 1-ohm (rated power 1 W) resistor between termi- nals B and C of the clock spring connector. 3. Connect the negative battery cable. 4. Turn the ignition switch to ON and check the service code. I Service code Action I Action Remove 1 -ohm resistor and go to Step 3 I 32 I Remove 1 -ohm resistor and ao to Ste~ 4 I 1 Other Replace combination switch (Refer to page T-19) Step 4 1. Turn the ignition switch to LOCK. 2. Disconnect the negative battery cable. 3. Disconnect the diagnostic module connector. 4. Measure the resistance between terminals 2D (GNV) and 2F (GY) of the diagnostic module connector. Resistance 1 R More than 1R Action Replace diagnostic module (Refer to page T-208) Replace wiring harness Gartner Banana

T SRS AIR BAG SYSTEM I Flowchart No.9 I Symptom I Service Code 34 I Possible cause Defective air bag module Defective clock spring Defective wiring harness Defective diagnostic module Warning Handling the air bag module improperly can accidently deploy the air bag, which may seri- ously injure you. Read SERVICE WARNINGS, page T-159, before handling the air bag module. Step 1 Carry out "Before Servicing" procedure under GEN- ERAL PROCEDURES, page T-1 60. Step 2 1. Remove the air bag module. 2. Make sure the shorting bars at the diagnostic module connector, clock spring connectors, and air bag module are properly installed. Note An engaged shorting bar or poorly mated connector can cause code 34 to set. 3. Connect the negative battery cable. 4. Turn the ignition switch to ON and check the service code. -- Step 3 1. Turn the ignition switch to LOCK. 2. Disconnect the clock spring connector. 3. Turn the ignition switch to ON and check the service code. Service code 32 34 Action Replace air bag module (Refer to page T-206) Go to Step 3 Step 4 1. Turn the ignition switch to LOCK. 2. Disconnect the negative battery cable. 3. Disconnect the diagnostic module connector. 4. Measure the resistance between terminals 2D (GNV) and 2F (GY) of the diagnostic module connector. Service code 32 Action Replace combination switch (Refer to page T-19) 1 Less than 1 R I Replace wiring harness I Resistance 1 a Action Replace diagnostic module (Refer to page T-208) d Gartner Banana

SRS AIR BAG SYSTEM DRIVER-SIDE AIR BAG MODULE Removal I Installation Warning 4 Handling the air bag module improperly can accidently deploy the air bag, which may serious- ly injure you. Read SERVICE WARNINGS, page T-159, before handling the air bag module. 1. Carry out "Before Servicing" procedure under GENERAL PROCEDURES, page T-160. 2. Remove in the order shown in the figure. 3. Install in the reverse order of removal. 4. Follow the troubleshootina flowchart (page T-160) to verify that the air bag system is operating normally. 1. Bolts 2. Support rope 3. Driver-side air bag module Installation note . . . . . . . . . . . . . . . . . below Installation note Driver-side air bag module 1. Connect the blue and orange clock spring connectors. 2. Connect the negative battery cable. 3. Turn the ignition switch to ON and verify that service code 32 is set. 4. If another service code is set, troubleshoot the system. 5. If service code 32 is set, turn the ignition switch to OFF and disconnect the negative battery cable. 6. Disconnect the orange and blue clock spring connec- tors. 7. Install the driver-side air bag module. Gartner Banana

SRS AIR BAG SYSTEM T PASSENGER-SIDE AIR BAG MODULE Removal I Installation b Warning Handling the air bag module improperly can accidently deploy the air bag, which may serious- ly injure you, Read SERVICE WARNINGS, page T-159, before handling the air bag module. 1. Carry out "Before Servicing" procedure under GENERAL PROCEDURES, page T-160. 2. Remove the glove compartment. 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. 1. Bolts 2. Support rope 3. Passenger-side air bag module Installation note . . . . . . . . . . . . . . . . . below Installation note Passenger-side air bag module 1. Connect the blue and orange clock spring connectors. 2. Connect the negative battery cable. 3. Turn the ignition switch to ON and verify that service code 33 is set. 4. If another service code is set, troubleshoot the system. 5. If service code 33 is set, turn the ignition switch to OFF and disconnect the negative battery cable. 6. Disconnect the orange and blue clock spring connec- tors. 7. Install the driver-side air bag module. Gartner Banana

SRS AIR BAG SYSTEM T 2-PIN CONNECTOR I CLOCK SPRING Inspection Warning Handling the air bag module improperly can accl- dently deploy the air bag, which may seriously in- jure you. Read SERVICE WARNINGS, page T-159, before handling the air bag module. 1. Carry out "Before Servicing" procedure under GENER- AL PROCEDURES, page T-160. 2. Remove the Driver-side air bag module. (Refer to page T-206.) 3. Check for continuity between terminals of the clock spring. 4. If not as specified, replace the combination switch. (Refer to page T-18.) 5. Connect the blue and orange clock spring connectors. 6. Check if the pin B of the clock spring connector (harness- side) is broken. 7. If pin B is broken, replace the wiring harness. 8. Check if the pin B of the driver-side air bag module con- nector (on clock spring) is broken. 9. If pin B is broken, replace the combination switch. 10. Disconnect the diagnostic module connector. Terminals 11. Connect the blue and orange clock spring connectors. A 0 12. Check for continuity between terminals B and C of the clock spring. 13. If continuity exists, replace the combination switch. 1 0---0: Continuity B 0 C n 2A n 28 0 3A 0 Gartner Banana

T SRS AIR BAG SYSTEM GREEN LIGHT -+@ @ . ACTIVATION SWITCH RED ' LIGHT (3) Inspect the SST (Refer to page T-217.) (4) Connect the SST to the air bag module. 5. Connect the red clip of the SST to the positive battery ter- minal and the black clip to the negative terminal. 6. Verify that the red light on the SST is illuminated. 7. Make sure all persons are standing at least 6 m (20 ft} from the vehicle. 8. Press the activation switch on the SST to deploy the air bag. Air Bag Disposal Warning The air bag is very hot immediately after it de- ploys. You can be burned. Do not touch the air bag module for at least 15 minutes after deployment. Warning Pouring water on a deployed air bag is danger- ous. The water will mix with the residual gases to form a gas that can make breathing difficult if in- haled. Do not pour water on the deployed air bag module. Warning A deployed air bag module may contain deposits of sodium hydroxide, a caustic by-product of the gas-generated combustion. If this substance gets in your eyes or on your hands, it can cause irrita- tion and itching. When handling a deployed air bag module, wear gloves and safety glasses. 1. Put on gloves and safety glasses. 2. Place the deployed air bag module in a plastic bag, seal it, and then dispose of it. 3. Wash your hands after removing your gloves. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for I air bag system service warnings and audio antitheft system alarm conditions . HEATER AND AIR CONDITIONER SYSTEMS ....................................... INDEX U- 2 ................................... HEATER U- 2 AIR CONDITIONER ......................... U- 3 TROUBLESHOOTING ......................... U- 4 CIRCUIT DIAGRAM ......................... U- 4 TROUBLESHOOTING GUIDE ................ U- 5 ..................................... HEATER U-15 ........................ STRUCTURAL VIEW U-15 HEATER UNIT .............................. U-16 BLOWER UNIT ............................. U-18 HEATER CONTROL UNIT .................... U-20 AIR CONDITIONER ........................... U-23 PREPARATION ............................. U-23 STRUCTURAL Vl EW ........................ U-23 SERVICE WARNINGS ....................... U-24 SERVICE CAUTIONS ........................ U-24 REFRIGERANT SYSTEM SERVICE PROCEDURE .............................. U-25 COOLING UNIT ............................. U-30 CONDENSER AND RECEIVER DRIER ........ U-33 REFRIGERANT LINES ....................... U-35 CONDENSER FAN .......................... U-36 AIC RELAY ................................. U-37 ................... CONDENSER FAN RELAY U-37 REFRIGERANT PRESSURE SWITCH ......... U-37 NC COMPRESSOR ......................... U-38 45U0Ux-001 Gartner Banana

u AIR CONDITIONER SERVICE WARNINGS Storing Refrigerant The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering u metal fragments and liquid refrigerant that can seri- ously injure you. Store the refrigerant at tempera- tures below 40°C (1 04°F). Handling Refrigerant Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostabite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, im- mediately wash them with clean water and consult a doctor. SERVICE CAUTIONS Compressor oil (ND-OILS) Do not spill compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off im- mediately. b PAG compressor oil (ND-OILS) has a higher mois- ture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. There- fore, install caps immediately after using the com- pressor oil or removing refrigerant system parts to prevent moisture absorption. Gartner Banana

u AIR CONDITIONER LEAK TESTER I LEAK TESTER I 17. Check for leaks by using a leak tester. If there are no leaks, go to step 18. If a leak is found at loose joint, tighten the joint and check for leaks again. If there is still a leak at the same joint, dis- 4 charge the refrigerant and then repair the joint. Repeat the charging procedure from step 9. If there are no leaks after tightening the joint, go to step 18. Warning Running the engine with the high-pressure-side valve open is dangerous. Pressure within the ser- vice cans will increase and the cans could ex- plode, scattering metal fragments and liquid refrigerant that can seriously injure you. There- fore, do not open the high-pressure-side valve while the engine is running. 18. Open the low-pressure-side valve of the manifold gauge set and charge with the regular amount of refrigerant. 19. Close the low-pressure-side valve of the manifold gauge set. 20. Check for leaks by using a leak tester. If there are no leaks, go to step 21. If a leak is found at loose joint, tighten the joint and check for leaks again. If there is still a leak at the same joint, dis- charge the refrigerant and then repair the joint. Repeat the charging procedure from step 9. If there are no leaks after tightening the joint, go to step 21. 21. Disconnect the high and low-pressure-side quick cou- plers from the charging valves that are connected to the high and low-pressure-side cooler pipes of the refriger- ant system. 22. Install the caps to the charging valves of the cooler pipes. Gartner Banana

AIR CONDITIONER u Refilling Caution If there is too much refrigerant in the system, pressure cannot be fixed at an appropriate level to change the gas to a liquid. Do not overcharge the system. 1. Install the manifold gauge set. (Refer to page U-25.) 2. Connect the tap pin side of the charging hose to the air purge valve of the gauge set. 3. Connect the vacuum pump hose to the center joint of the gauge set. 4. Connect the vacuum pump hose to the vacuum pump. 5. Connect can puncture valves to a 4-way joint. 6. Fully open the can puncture valves and connect service cans to the valves. 7. Full close any can puncture valve that it is not connected to a service can. 8. Connect the 4-way joint to the charging hose that is con- nected the gauge set air purge valve. 9. Open only the center valve of the manifold gauge set. 10. Start the vacuum pump and let it run for 5 minutes. 11. After 5 minutes, close the center valve of the manifold gauge set. 12. Stop the vacuum pump. Warning Running the engine with the high-pressure-side valve open is dangerous. Pressure within the ser- vice cans will increase and the cans could ex- plode, scattering metal fragments and liquid refrigerant that can seriously injury you. Therefore, do not open the high-pressure-side valve while the engine is running. 13. Open the service can by using the can puncture valve. 14. Start the engine and actuate the A/C compressor. 15. Open the low-pressure-side valve and refill with refriger- ant until the bubbles in the sight glass disappear and the high and low-pressure readings of the manifold gauge set are within normal pressure limits. (Refer to page U-29.) 16. Stop the engine and the NC compressor. 17. Disconnect the high and low-pressure-side quick cou- plers from the charging valves that are connected to the high and low-pressure-side cooler pipes of the refriger- ant system. 18. Install the caps to the charging valves of the cooler pipes. 45UOUX-060 Gartner Banana