MAZDA MX-5 1994 Workshop Manual

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

SRS AIR BAG SYSTEM T INSPECTION OF SST (DEPLOYMENT TOOL) Use the SST (deployment tool) to deploy a live air bag module before disposing of it. Before connecting the SST to the clock spring connector or air bag module connector, inspect operation b of the SST. CONNECTOR B CONNECTOR A STEP 1 RED @ STEP 2 ACTIVATION SWITCH I 29UOTX-357 lnspection Procedure 1. Inspect operation of the SST by following the steps be- low. 1 1 3 1 Press activation switch I ON I OFF I - Connect connectors A and B of ST 2. If not as specified, do not use the SST because it may cause the air bag to unexpectedly deploy upon connec- tion to the module. Connect red clip to positive bat- tery terminal and black clip to nenative battery terminal OFF ON OFF OFF 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 INDEX INDEX HEATER 1. Heater unit Removal / Installation ......... page U-16 Disassembly / Assembly ...... page U-17 Inspection ................... page U-17 2. Blower unit Removal / Installation ......... page U-18 Disassembly / Assembly ...... page U-19 Inspection ................... page U-19 3. Heater control unit Removal / Installation ......... page U-20 Disassembly 1 Assembly ...... page U-21 Inspection ................... page U-22 Adjustment .................. page U-22 Gartner Banana

INDEX u AIR CONDITIONER 1. Cooling unit 5. Condenser fan relay ................... Removal 1 Installation ......... page U-30 Inspection page U-37 Disassembly I Assembly ...... page U-31 6. A/C compressor 2. Condenser Removal 1 Installation ......... page U-38 ...... Removal I Installation ......... page U-33 Disassembly I Assembly page U-41 3. Receiver drier 7. Magnetic clutch Removal I Installation ......... page U-33 Disassembly 1 Assembly ...... page U-39 4. AIC relay Inspection ................... page U-37 Gartner Banana

Ix-ozl MAIN FUSE eLOCK MAIN AD FAN IX-071 L/Y (€1 \ G-01 G -01 FRONT (F) -A/C IAC) G-02 MAGNETIC CLUTCH (F) G-03 BLOHER WIT (F) 16-04 ?$WER&TVRE SNITCt .CONDENSOR FAN .HEATER AND AIR CONDITIONER I I '07 CONENSOR FAN (AC) G-08 REFRIGERANT PflESSURE SWITCH (AC) IG-09 A/C RELAY (ACI 16- 10 COMENSER FAN RELAY (AC) Gartner Banana

TROUBLESHOOTING u TROUBLESHOOTING GUIDE I Symptom Blower motor does not operate Reference page Below Magnetic clutch does not operate I U-7 Condenser fan does not operate e Symptom: Blower motor does not operate I U-9 Insufficient cooling No cooling Intermittent cooling Normal operation of blower motor Blower motor speed is controlled by the fan switch and a resistor in the blower unit. When the fan switch L is in the OFF position, the motor ground circuit is open and the blower motor does not operate. When the switch is in the first (Low) position, current flow from the blower motor is restricted by the three resis- tors in the resistor, and the blower motor turns at low speed. Changing the fan switch to the second (Mid), third (high), or fourth (Super-high) position causes the cir- cuit resistance to decrease, and the blower motor speed becomes correspondingly faster. I l U-10 (-1 (rn) I I I RESET BUTTON FUSE BLOCK Step 1 1. Check the circuit breaker. 2. If the reset button is not out, go to Step 2. 3. If the reset button is out, check for a short circuit in the harness. Repair as necessary; then depress the reset button to reset the circuit breaker. circuit breaker HEATER Step 2 1. Turn the ignition switch to ON. 2. Turn the fan switch to the fourth position. 3. Measure the voltage at the A terminal wire of the blower motor connector. B+: Battery positive voltage I Terminal I Voltage Action I Amperage 30A Location Fuse block A U-5 Bt Other Go to Step 3 Repair wiring harness (Circuit breaker - Blower motor) Gartner Banana

u TROUBLESHOOTING Step 3 1. Turn the ignition switch to ON. 2. Turn off the fan switch and ACS. 3. Measure the voltage at the terminal-wires of the resistor. u B+: Battery positive voltage I Terminal I Voltage I Action A (1-pin connector) A B C Step 4 1. Turn the ignition switch to ON. 2. Turn the fan switch to the fourth position. 3. Measure the voltage at the G terminal wire of the fan switch connector. .J B+: Battery positive voltage B+ , Other D CheckA terminal Replace blower motor B+ Other B+ Other B+ Other Step 5 1. Turn the ignition switch to ON. 2. Turn off the fan switch and ACS. Check B terminal Replace resistor Check C terminal Replace resistor Check D terminal Reolace resistor B+ Other Terminal G 3. Measure the voltage at the terminal-wires of the fan switch connector. Go to Step 4 Replace resistor B+: Battery positive voltage - Voltage B+ Other Action Repair wiring harness (Fan switch - GND) Go to Step 5 Gartner Banana

TROUBLESHOOTING u 7- Symptom: Magnetic clutch does not operate I Normal operation of magnetic clutch The PCME controls the operation of the condenser fan and magnetic clutch, depending on engine load. (Refer to section F.) The magnetic clutch is supplied with battery positive voltage as follows: 1. The ACS and fan switch are turned on. 2. The PCME receives a signal that the ACS and fan switch are on and creates a ground circuit. 3. The A/C relay is magnetized and the contact is closed. 4. Battery positive voltage is applied to the magnetic clutch and the clutch locks. WIPER 20A AD FAN 20A FUSE BLOCK MAIN FUSE BLOCK Step 1 1. Check the following fuses. I Fuse I Amperage I Location I I I . - I WIPER I 20A 1 In fuse block I I AD FAN I 20A 1 In main fuse block I 2. If the fuses are OK, go to Step 2. 3. If a fuse is burned, check for a short circuit in the harness before replacing it. Step 2 1. Run the engine at idle. 2. Turn on the ACS and fan switch. 3. Measure the voltage at the A terminal wire of the mag- netic clutch connector. B+: Battery positive voltage I Terminal I Voltage I Action 1 Step 3 1. Start the engine. 2. Turn on the fan switch and ACS. 3. Measure the voltage at terminal C and A of the A/C relay connector. B+: Batterv positive voltaae - -- A 1 Terminal I V0lta0e 1 Action I I C I Other I Repair wiring harness (AD FAN 20A fuse - AIC relay) I B+ Other I 1. -. B+ I GO to step 4 Replace magnetic clutch Go to Step 3 I A 1 Other I Repair wiring harness (WIPER 20A fuse - AIC relay) I Gartner Banana

u TROUBLESHOOTING Step 4 1. Remove the relay. 2. Apply battery positive voltage and check for continuity between the relay terminals. B+: Battery positive voltage 0---0 : Continuity I I I 45U0UX-013 3. If correct, repair wiring harness (AC relay - magnetic clutch). 4. If not as specified, replace the A/C relay. 1 0 10 I I I 2 1 B+ 1 GND 1 0 I Gartner Banana