stop start MAZDA MX-5 1994 User Guide

TROUBLESHOOTING GUIDE F 18 ENGINE STALLS DURING START-UP DESCRIPTKlN I Engine unexpectedly stops running while starting VROUBLESHOOTING HINTS] @ Misfire occurs when depressing accelerator Q Lack of engine torque for start-up AirIFuel mixture too rich or too lean AirIFuel mixture too rich or too lean Incorrect ignition timing Weak ignition INSPECTION Check if brakes are dragging Section P Check if "00 is displayed on Self-Diagnosis Check- er with ignition switch ON * page F-79 SELECT SW A Check switches for correct operation with Self- Diagnosis Checker Monitor Lamp and ignition switch ON @ page F-95 Disconnect heated oxygen sensor connector and :heck if condition improves SENSOR CONNECTOR -3 I I - Yes - No Yes Yes No - Yes Low intake air amount Low en~ine com~ression ACTION Repair us Section P Go to next step Go to next step -- Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) page F-81 "88" flashes Check PCME terminal 1 E voltage us page F-145 Specification : Battery positive voltage (Ignition switch ON) If OK, replace PCME rc+r page F-143 6 If not OK, check wiring between PCME and Self-Diagno- sis Checker e page F-7 Go to next step Lamp not ONIOFF with specified switch Check for cause (Refer to specified check sequence) uw page F-96 Lamp always ON Check wiring between PCME terminal 1 D and Self-Diag- nosis Checker page F-7 Check heated oxygen sensor @s page F-156 Go to next step Gartner Banana

TROUBLESHOOTING GUIDE DESCRIPTION I Engine intermittently stops running Before stallina, ennine condition OK 21 [TRO~ESHOOTING HINTS] O Intermittently no spark or no fuel injection Poor connection in wiring harness ENGINE STALLS SUDDENLY (INTERMITTENT) INSPECTION Check if "00" is displayed on Self-Diagnosis Check- er with ignition switch ON page F-79 Tap, move, and wiggle harness and connectors to check if PCME terminal voltages are OK (1 B, 2A, 2B and 2C) @ page F-146 ACTION Go to next step Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) @S page F-81 When checking wiring harness and connectors, tap, move, and wiggle suspect sensor and/or harness to recre- ate problem "88" flashes Check PCME terminal 1 E voltage @S page F-145 Specification: Battery positive voltage (Ignition switch ON) 0 If OK, replace PCME page F-143 0 If not OK, check wiring between PCME and Self-Diagno- sis Checker IS= page F-7 Go to Troubleshooting No.2 "CRANKS NORMALLY BUT WILL NOT START (NO COM- BUSTION)" page F-17 Check for cause (Refer to "Check Point for Each Termi- nal") page F-148 Gartner Banana

EXHAUST GAS RECIRCULATION (EGR) Operation Cold Engine (Coolant temperature less than 55°C (1 31 OF)) EGR operation is stopped to improve driveability when the engine temperature is cold. u Warm Engine The powertrain control module (engine) controls the solenoid valves (vacuum side and vent side) to sup- ply EGR gases as described below. Remark Operating condition Idle Deceleration High speed Heavy load EGR SOLENOID VALVE (VACUUM) I I EGR operation Acceleration Warming up Other SYSTEM OPERATION 1. Connect the SSTs to the PCME as shown. 2. Start the engine. 3. Drive the vehicle and verify that PCME terminals 1 R and 1 T voltage is battery positive voltage (B+) while the en- gine is still cold. 4. Warm up the engine to normal operating temperature and let it idle. 5. Drive the vehicle and verify that the Engine Signal Moni- tor green and red lamps flash when the SST is set to 1 R and 1 T. 6. Ground the PCME terminal IT by using a jumper wire. 7. Verify that the engine runs roughly or stalls at idle. Stopped EGR SOLENOID VALVE (VACUUM) Inspection 1. Disconnect the vacuum hoses. 2. Blow into the EGR solenoid valve (vacuum) and verify that air does not flow. 3. Disconnect the EGR solenoid valve (vacuum) connec- tor. 4. Apply battery positive voltage and a ground to the sole- noid valve as shown. 5. Blow through the EGR solenoid valve (vacuum) and verify that air flows. 6. If not as specified, replace the EGR solenoid valve (vac- uum) assembly. Idle switch: ON Above 3,125 rpm - Reduced EGR gas amount Control supply of EGR gas amount by using signal from EGR function sensor - Coolant temperature: Between 55OC (1 31 OF) and 60°C {140°F) - Gartner Banana

F A/C CUT-OFF CONTROL SYSTEM D B AIC RE LAY SYSTEM INSPECTION 1. Turn the ignition switch ON. 2. Turn the blower switch and air conditioning sensor ON. 3. Start the engine. d 4. Verify that the A/C stops for approx. 2 sec. after the en- gine start. 5. Rotate the throttle link to fully open position. 6. Verify that the A/C stops for approx. 5 sec. after the throttle link to fully open position. 7. If not specified, inspect as following. PCME 1Q terminal voltage A/C relay Throttle position sensor AIC RELAY Inspection 1. Remove the A/C relay. 2. Check the continuity between the terminals of the relay. 3. If not specified, replace the A/C relay. B+: Battery positive voltage Terminal A - B Apply B+ B+ not applied Terminal C - D Yes No Gartner Banana

CONTROL SYSTEM F Terminal voltage B+: Battery positive voltage Test condition I Voltage I Remark - - - - - - - - - - - - - - - - - - Connection to Battery Constant Ignition switch OFF Main relay - B+ OV lgnition switch (Start position) For backup - Ignition switch ON While cranking Lamp illuminated for 3 sec. after 1 4.5-5.5V ianition switch OFF+ON 1 B+ Approx. 1 OV Ignition switch ON - - OV Data link connector (MEN terminal) Test switch at "SELF-TEST" .. Lamp not illuminated after 3 sec. Test switch at "02 MONITOR" at idle Monitor lam illuminated & 4.5-5.5v . . I Malfunction indicator IighVData link connector (FEN ter- minal) With Self-Diagnosis Checker and System Selector Test switch at "02 MONITOR" at idle Monitor lamp not illuminated Light illuminated and buzzer sounded for 3 sec. after ignition switch OFF-ON B+ tor tesiswitch at "SELF-TEST" With Self-Diagnosis checker and system selector Below 2.5V 1 Light illuminated and buzzer sounded 1 Below 2.5V I With System Selec- Light not illuminated and buzzer not sounded after 3 sec. I Light not illuminated and buzzer 1 n. 1 B+ not sound I D+ 1 - #I, 4 lgniter (in IG COIL) #2,3 Igniter (in IG COIL) Powertrain control module (transmis- sion) - Ignition switch ON Idle Ignition switch ON Idle lgnition switch ON (Engine coolant temp, below 60°C {I 40°F)) Ignition switch ON AtC relay Air conditioning sensor ON at idle Air conditioning sensor OFF at idle Ground (MT) - OV Approx. 0.2V OV Approx. 0.2V Below 1 .OV B+ Below 2.5V B+ - - - - , * Open (AT) - Ignition switch ON ( Below 1 .O V I Engine coolant temp. I Below .OV I ldle Above 97°C (206.6OF1 Ignition switch ON I I B+ Ignition switch ON Coolant fan relay B+ . - Other conditions lgnition switch On dround data link connector TEN terminal I Blow 1.0" I B+ Vehicle speed sensor ldle switch OFF While driving Vehicle sto~wed ldle switch (in throttle position sensor) 2-5V 1 or 7V . , Accelerator pedal released Accelerator ~edal de~ressed - Stoplight switch OV B+ Brake pedal released Brake ~edal deoressed lgnition switch ON Steering pressure sensor OV B+ I I - Ignition switch ON B+ - PIS ON (at idle) PIS OFF (at idle) Air conditioning sensor Air conditioning sensor ON (Igni- tion switch ON) Air conditioning sensor OFF (Igni- tion switch ON) OV B+ - Below 2.5V B+ Blower motor ON Gartner Banana

MECHANICAL SYSTEM TEST TIME LAG TEST If the selector lever is shifted while the engine is idling, there will be a certain time lapse, or time lag, before shock is felt. This step checks this time lag for checking condition of the 1-2, N-R/2-3 and N-D L/ accumulators, front, rear and one-way clutches, 2nd brake band, and low and reverse brake. Preparation Perform the preparation procedure shown in the STALL TEST. (Refer to page K-22.) Procedure IDLE SPEED 1. Start the engine and check the idle speed in P range. (Refer to section F.) u Idle speed: 750--850 rpm 2. Shift from N range to D range. 3. Use a stopwatch to measure the time it takes from shifting until shock is felt. 4. Shift the selector to N and let the engine idle for 1 minute or more to cool the ATF. 5. Do the time lag test for the following shifts in the same manner. Make three measurements for each test and average the results. (1) N 4 D range (Normal mode) (2) N -+ D range (Hold mode) (3) N -+ R range .......................................... Specified time lag: N -t D range 0.5-46 second ..................... N -+ R range ... .............. 0.75-0.85 second Evaluation of Time Lag Test - I Condition N -c D (Hold) shifting More than specification Less than specification More than specification Less than specification N -+ R shifting I More than specification Less than specification Rear clutch slipping Excessive line pressure - lnsufficient line pressure Rear clutch slipping 2nd brake band slipping - 1-2 accumulator not operating properly Excessive line pressure lnsufficient line pressure Low and reverse brake slipping Front clutch slipping N-R/2-3 accumulator not operating properly Excessive line pressure K-25 Gartner Banana

P BRAKE SYSTEM k FIRST PEDAL VACUUM GAUG DEPRESSION FORCE GAUGE POWER BRAKE UNIT Quick Inspection, On-vehicle Power brake unit function check (Simple method) ii Step 1 1. With the engine stopped, depress the pedal a few times. 2. With the pedal depressed, start the engine. 3. If immediately after the engine starts the pedal moves down slightly, the unit is operating. Step 2 1. Start the engine and let it run 1 or 2 minutes. 2. Stop the engine. 3. Depress the pedal with the usual force. 4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating. 5. If a problem is found, inspect for damage or improper connection of the check valve or vacuum hose. Repair if necessary, and inspect it once again. Step 3 1. Start the engine. 2. Depress the pedal with the usual force. 3. Stop the engine with the pedal depressed. 4. Hold the pedal down for about 30 seconds. 5. If the pedal height does not change, the unit is operating. ,, 6. If there is a problem, check for damage or improper con- nection of the check valve or vacuum hose. Repair if necessary, and check once again. If the nature of the problem is still not clear after following the 3 steps above, follow the more detailed check described in "Method using tester," below. (Method using tester) Connect the SST, vacuum gauge, and pedal depression force gauge as shown in the figure. After bleeding the air from the SST, conduct the test as described in the 3 steps below. Inspection using gauges Connect the SST gauges, a vacuum gauge (A), and a pedal depression gauge (B) as shown. Bleed the air from the SST gauges before performing the following tests. a) Checking for vacuum loss Unloaded condition 1. Start the engine. 2. Stop the engine when the vacuum gauge indicates 66.7 kPa (500 mmHg, 19.7 inHg). 3. Observe the vacuum gauge for 15 seconds. If the gauge indicates 63.4-66.6 kPa (475-500 mmHg, ,, 18.7-19.7 inHg), the unit is operating. Gartner Banana

BRAKE SYSTEM P (20 kgf, 44 Ibf) (20 kgf, 44 Ibf) Loaded condition 1. Start the engine. 2. Depress the brake pedal with a force of 196 N (20 kgf, 44 Ibf). 3. With the brake pedal depressed, stop the engine when the vacuum gauge indicates 66.7 kPa I500 mmHg, 19.7 inHg). 4. Observe the vacuum gauge for 15 seconds. If the gauge indicates 63.4-66.6 kPa (475--500 mmHg, 18.7-19.7 inHg), the unit is operating. b) Checking for hydraulic pressure 1. If with the engine stopped (vacuum 0 kPa (0 mmHg, 0 inHg}) the fluid pressure is within specification, the unit is operating. 1 Pedal force Fluid pressure 2. Start the engine. Depress the brake pedal when the vac- uum reaches 66.7 kPa (500 mmHg, 19.7 inHg). If the fluid pressure is within specification, the unit is operat- ing. 1 96 N {20 kgf, 44 Ibf) I Pedal force I Fluid pressure I 1,079-1,177 kPa {I 1-1 2 kgf/cm2, 156-1 71 psi) lnspection of Check Valve 196 N {20 kgf, 44 Ibf) Note There is an arrow on the hose to indicate direction of hose installation. 5,199--5,494 kPa {53-56 kgf/cm2, 754--796 psi} lnspection 1. Disconnect both ends of the vacuum hose. 2. Apply suction and pressure to the hose from the engine side. Verify that air flows only toward the engine. If air passes in both directions or not at all, replace the vac- uum hose (along with the check valve). Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P N. SOLENOID TEST HAST HE WHEEL STOPPED SPINNING . AND LOCKED IN PLACE IF NO FAULTS TESlERn low THEN 1 PRESS: 0 -OR- b- I STAT TEST DYNM I I ~ESTGR WILL TESTER WILL RETURN TO SA RETURN TO 8A 41% EITHER SWITCU TO START THIS TEST (mww AWLVIM ~RM pmmmr TO MAKE CCMU IE DETECTED. I W A FAULT IS DETECTED. .AWAME TESTIRmLMIICLAYEITMR STEP. &N MEW: -on- mnw: 1 (Cont .) Gartner Banana

AUDIO Name ;can button 3epeat button rrack search button Press SCAN button and beginning of tunes are played one by one (10 seconds for each) Press button during playback and scanning starts from next tune Press button during scanning and tune being scanned is played Scanning is canceled automatically when all programs in disc have been scanned Illustration Press RPT button during a tune is playing to play it repeatedly Press again to cancel repeat operation and resume normal playback Operation Press button to search for beginning of next or current program 1. PressA(up) button for less than 0.5 second during disc play and be- ginning of next tune is selected and played Tunes are changed one by one with each press of button When pressed during play of last tune, first tune is replayed 2. PressV(down) button for less than 0.5 second during disc play and current tune is replayed from beginning Tunes are changed one by one with each press of button When pressed during play of first tune, last tune is replayed Press button to fast forwardheverse disc 1. Press and hold FF (up) button for more than 0.5 second and disc play position moved ahead at high speed while button pressed When last part of last tune is reached, first tune is selected and disc stops 2. Press and hold REV (down) button for opposite operation of FF button When first part of first tune reached, disc stops reversing and starts playing Clock The clock can be set while the radio or tape/CD player is ON. Illustration Clock button (clock display) HIM button (clock setup) Operation Press button to display present radio frequency or operation mode If power supply to unit is broken (burnt fuse or disconnected battery), clock setup will be canceled When clock button is pushed for 2 seconds, clock display flashes. At this point, press H button to advance hours and M button to advance minutes Press clock button again to return to normal display If clock button is pressed again while clock display is flashing and time has not been adjusted (that is, H and M buttons have not been pressed), min- utes will be set at : 00. If time before adjustment showed 30-59 minutes, time will be set at next hour For example, nn Gartner Banana