MAZDA MX-5 1994 Workshop Manual

K ON-BOARD DIAGNOSIS SYSTEM DIAGNOSTIC TROUBLE CODE N0.64 3-2 CONTROL SOLENOID VALVE ACTION STEP I INSPECTION Yes 1 3epair or replace connector Are there any poor connections at sole- noid valve and powertrain control module (transmission) connectors? 30 to next step shown Is output voltage of 3-2 control solenoid valve at powertrain control module (trans- mission) OK? Yes ;heck wiring and go to step 5 page K-45 B4 (-) term, Battery positive voltage Voltage (V) Condition downshift Other condition (+) term. 2M 30 to next step Grounc I I I I I 3 1 Disconnect 20-pin powertrain control Yes 30 to step 5 module (transmission) connector Is resistance between terminal 2M and ground Resistance: 13-2752 30 to next step Disconnect solenoid connector Is resistance between ground and termi- nal A of 3-2 control solenoid valve OK? page K-42 Yes ;heck wiring and connectors form powertrain control module transmission) to 3-2 control solenoid valve If OK, go to next step If not OK, repair wiring and/or connector Resistance: 13-2752 qeplace 3-2 control solenoid valve Disconnect the negative battery cable for at least 20 seconds and depress the brake pedal Connect the battery cable and recheck for code Is diagnostic trouble code displayed? page K-21 Yes 3eplace powertrain control module (transmission) page K-45 ntermittent poor connection :heck for cause Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM K DRIVE AT 50 kmlh (31 mph) I STOP VEHICLE After-Repair Procedure 1. Cancel the memory of diagnostic trouble codes by dis- connecting the negative battery cable for at least 20 se- conds and the depressing the brake pedal. Reconnect the battery cable. 2. Remove the SST (Self-Diagnosis Checker) if con- nected. 3. Drive the vehicle at 50 kmlh (31 mph), and depress the accelerator pedal fully to activate kickdown. Stop the ve- hicle gradually. 4. Connect the SST (Self-Diagnosis Checker) to the data link connector. 5. Turn the ignition switch to ON. 6. Verify that no codes are displayed. Gartner Banana

K MECHANICAL SYSTEM TEST MECHANICAL SYSTEM TEST PREPARATION SST STALL TEST 49 0378 400A Gauge set, oil pressure 49 801 9 901 Gauge, oil pressure For oil pressure test For oil pressure test This test is performed to determine if there is slippage of the friction elements or malfunction of the hy- draulic components. Preparation 1. Check the engine coolant, engine oil, and ATF levels before testing. 2. Warm the engine thoroughly to raise the ATF temperature to operating level (50--80°C, 122-176°F). 3. Engage the parking brake and use wheel chocks at the front and rear of the wheels. ENGAGE PARKING BRAKE WARM UP ENGINE COOLANT LEVEL ENGINE OIL LEVEL TEMPERATURE 60-70°C (1 40-1 58°F) ATF LEVEL Gartner Banana

MECHANICAL SYSTEM TEST K Procedure ENGAGE PARKING BRAKE IDLE SPEED 1. Connect a tachometer to the engine. 2. Start the engine and check the idle speed in P range. (Refer to section F.) Idle speed: 750-450 rpm 3. Shift the selector lever to R range. Caution If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is pressed, the transmission could be damaged. Therefore, do steps 4 and 5 within 5 seconds of each oth- er. 4. Firmly depress the foot brake with the left foot, and gently depress the accelerator pedal with the right. 5. When the engine speed no longer increases, quickly read the engine speed and release the accelerator. 6. Shift the selector to N and let the engine idle for 1 minute or more to cool the ATF. 7. Perform the stall test for the following ranges in the same manner. (1 ) D range u (2) S range (3) L range Engine stall speed: 1,90&2,lOO rpm Gartner Banana

K MECHANICAL SYSTEM TEST Evaluation of Stall Test 4bove specification Nithin specification In all ranges In D (Normal), and L ranges In D (Normal) range only In R range only 3elow specification Possible cause I Worn oil Dumo Oil leakage from oil pump, control Insufficient line pressure Direct clutch and overdrive one-way clutch sli~~ina Rear clutch slipping One-way clutch slipping Low and reverse brake slipping Front clutch slipping Perform road test to determine if this is caused by low and reverse brake or front clutch as follows: a) Effective engine braking in L range . . . . . . . . . . Front clutch b) No enaine brakina in L range . . . . . Low and reverse brake All ~hiftcont~elements within transmission are functioning normally Engine out of tune One-wav clutch sli~~ina within toraue converter 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

K MECHANICAL SYSTEM TEST LINE PRESSURE TEST This test measures line pressures for checking the hydraulic components and inspecting for oil leakage. Preparation d 1. Perform the preparation procedure shown in the STALL TEST. (Refer to page K-22.) 2. Connect a tachometer to the engine. Warning Removing the square-head plug when the ATF is hot is dangerous. Hot ATF can come out of the opening and badly burn. Before removing the square-head plug, allow the ATF to cool. 3. Connect the SST to the line pressure inspection hole(s). Procedure 1. Start the engine and check the idle speed in P range. (Refer to section F.) Idle speed: 750--850 rpm * 2. Shift the selector lever to D range and read the line pressure at idle. Caution If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is pressed, the transmission could be damaged. Therefore, do steps 3 and 4 within 5 seconds of each oth- er. 3. Depress the brake pedal firmly with the left foot and gradually depress the accelerator pedal with the right foot. 4. Read the line pressure as soon as the engine speed becomes constant, then release the accelerator .- pedal. 5. Shift the selector to N and let the engine idle for 1 minute or more to cool the ATF. 6. Read the line pressure at idle and at the engine stall speed for each range in the same manner. Gartner Banana

MECHANICAL SYSTEM TEST K Specified line pressure: 7. Cool the transmission and reconnect the SST to the line pressure inspection hole. 8. Connect a vacuum pump to the vacuum diaphragm and place the pump inside the vehicle. 9. Shift the selector lever to R range. 10. Read the line pressure at idle as described below. Range D range S range L range R range Specified line pressure: Pressure kPa {kgflcm2, psi] Idle 285--362 i2.9-3.7,42-52) 785--921 (8.G9.4, 11 4--133) 295-392 {3.0-4.0,43--56) 775--970 (7.9--9.9, 1 1 S140) Vacuum Atmospheric pressure 1 400 mmHg (15.7 inHg} I 393490 (4.0-5.0,57-71) I Stall 79S912 18.1-9.3, 11 &I321 795--91 2 {8.1-9.3, 11 6--132) 883-1,078 l9.0-11 .O, 128-1 56) 1,972-2,167 (20.1-22.1,286--314) Line pressure kPa {kgf/cm2, psi) 883-1,078 {9.&11 .O, 128--156) 200 mmHg (7.87 inHg) - Evaluation of Line Pressure Test 687-784 17.0-4.0, 10-113) Below specification I Excessive line pressure Condition I Possible Cause In all ranges Worn oil pump Fluid leakage from the oil pump, control valve body, and/or transmission case Stuck pressure regulator valve Fluid leakage from the direct clutch and/or fourth gear band servo release side hydraulic circuit In D (Normal), S (Normal), and L Fluid leakage from the rear clutch hydraulic circuit ranaes I Stuck pressure modifier valve In S (Normal & Hold) and L ranges I Fluid leakage from the throttle backup valve hydraulic circuit In L and R ranges I Fluid leakage from the low and reverse hydraulic circuit In S range (Hold) In R range only Stuck throttle backup valve Stuck backup control valve Backup control function (electronic) not operating properly Stuck pressure modifier valve Stuck backup control valve Fluid leakage from the front clutch and/or 2nd band servo release side hydraulic circuit Below specification Excessive pressure In all ranges Same as Line Pressure Test Leaking or disconnected vacuum hose Leaking vacuum diaphragm Diaphragm rod too long Stuck vacuum throttle valve Stuck Dressure renulator valve I In S ranae (Hold) I Stuck pressure modifier valve Gartner Banana

K MECHANICAL SYSTEM TEST Incorrect line pressure with specified vacuum at vacuum diaphragm Condition No variation Possible Cause Missing diaphragm rod lncorrect variation (Above or below specification) Incorrect diaphragm rod length Stuck vacuum throttle valve Stuck pressure regulator valve Stuck Dressure regulator ~lua Gartner Banana

ROAD TEST K ROAD TEST A road test is necessary to inspect for problems in the different gear ranges. If a range or function tar- b geted by the road test is found to have any problem, refer to the ELECTRONIC SYSTEM COMPONENT segment or the TRANSMISSION, OIL COOLER, DRIVE PLATE, and SHIFT MECHANISM segments of this section. Do the road test only when the ATF is 50-80°C (1 22-1 76°F). D-RANGE TEST Shift Point, Shift Pattern, and Shift Shock 1. Shift the selector lever to D range and select the Normal mode. 2. Accelerate the vehicle with half-and wide open throttle opening. 3. Verify that 1-2, 2-3, and 3-4 upshifts, downshifts, and lockup are obtained. The shift points must be as shown in the D range (Normal) shift diagram. Note There is fourth gear is any of the following conditions. A The cruise control is operating, and there is an 8kmIh (5 mph} difference between the preset cruise speed and the vehicle speed. B The SET or RESUME switch is ON. There is no lockup when water temperature is below 50°C (1 22°F) or in the throttle valve closed posi- tion. 4. Check the upshifts for shift shock or slippage in the same manner. 5. While driving in overdrive, shift the selector lever to S range and verify that 4-3 downshift immediately occurs, then decelerate and verify that engine braking effect is felt in only third gear and 2nd gears. D-range (Normal) shift diagram p'yJ ..,,*sw.. LOCKUP AVAILABLE WHEN ACCELERATING AND CRUSING LOCKUP AVAILABLE WHEN COASTING 0 20 (1 2) 40 (25) 60 (37) 80 {50) 100 (63) 1 20 (75) 140 (87) 1 60 (99) VEHICLE SPEED kmlh {mph) Gartner Banana