battery MAZDA MX-5 1994 Workshop Manual

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K TO GROUND FROM SHIFT-LOCK ACTUATOR Replacement 1. Disconnect the negative battery cable. 2. Disconnect the key interlock unit connector. 3. Remove the key interlock unit. 4. Install the new key interlock unit. 5. Connect the key interlock unit connector. 6. Connect the negative battery cable. P RANGE SWITCH Inspection Continuity 1. Disconnect the negative battery cable. 2. Remove the rear console. 3. Remove the screws and lift up the indicator panel. 4. Disconnect the P range switch connector. 5. Check continuity between the terminals. I Range I Selector lever release button I Continuity I 6. If not as specified, replace the P range switch. (Refer to page K-166.) I 7. Connect the P range switch connector. 8. Adjust the indicator panel. (Refer to page K-161.) Install the screws in the order shown in the figure. 9. Install the rear console. 10. Connect the negative battery cable. 11. Verify correct operation of the shift-lock system. SHIFT-LOCK ACTUATOR Inspection Terminal voltage and continuity 1. Remove the rear console 2. Remove the selector knob and indicator panel screws. Released Depressed Yes No Gartner Banana

K SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) CONNECTOR B CONNECTOR A 3. Lift up slightly on the selector lever, selector sleeve, and indicator panel, and disconnect the hold switch connec- tor. 4. Disconnect the HOLD switch connector. .--' 5. Shift the selector lever to P range. 6. Turn the ignition switch ON, and check terminal voltages and continuity, referring to the chart below. Disconnect the shift-lock actuator connector to check continuity be- tween terminal c (harness side) and ground. 7. If not as specified, repair the wiring harness and/or shift- lock actuator. I ~~UOKX-477 B+: Battery positive voltage I Connector I Terminal connectd to l terminal I Condition I Correct measurement vaive I I 1 I I A a B-C I P range, selector lever release button not depressed I OR I lBl e I B I P ranae, selector lever release button not depressed I OV I A B B B B 8. Grasp the HOLD switch wiring harness and pull it while pushing the selector knob down fully onto the selector le- ver. 9. Connect the HOLD switch connector. 10. Adjust the indicator panel. (Refer to page K-161.) Install the screws in the order shown in the figure. 11. Apply locking compound to the selector knob screw threads after the threads have been cleaned. Tighten the screws. Tightening torque: 2.0-2.9 N-m (20-30 kgf-cm, 18-26 in-lbf) b a b C (harness side) d 12. Install the rear console. 13. Connect the negative battery cable. 14. Verify correct operation of the shift-lock system. B-C B-C B-C Body B-C Constant Ignition switch OFF Ignition switch ON Constant Brake pedal released -t depressed OR B+ El+ on OV -+ B+ -1 Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K BUTTON NEED NOT BEDEPRESSED BUTTON MUST BE DEPRESSED 0.9--1.0mm 0.64.7mm i0.035--0.039 in} (0.024-0.028 in) I 0.5-0.6mm (0.02-0.024 in) 45UOKX-48 HEAVY-GAUGE WIRE , SLIDER '22EEL SELECTOR LEVER Inspection 1. Verify that the selector lever can only be shifted as shown in the figure. When shifting from P range, do so with the ignition switch ON and the brake pedal de- pressed. 2. Verify there is a click at each range when shifted from P -+ L range. 3. Verify that the positions of the selector lever and the indi- cator are aligned. 4. Verify that the button returns smoothly when pushed to shift. Adjustment Lever position 1. Disconnect the negative battery cable to deactivate the shift-lock. 2. Remove the rear console, selector knob, selector sleeve, and indicator panel. (Refer to "Shift-lock actuator inspection"; page K-159, steps 1-45.) 3. Loosen the locknut. 4. Shift the transmission to P range by pushing the adjust- ment lever forward. 5. Adjust the lever so that the clearance between the guide plate and the guide pin in P range with the push rod light- ly depressed is as shown. 6. Tighten the locknut. Tightening torque: 18-24 Nem (1.8-2.5 kgf-m, 14--18 ft-lbf) 7. Move the selector lever to N and D ranges and verify that there is the same clearance between the guide plate and the guide pin. 8. If not as specified, readjust the lever. 9. lnstall the indicator panel, selector sleeve, selector knob, and rear console in the reverse order of removal. 10. Check the selector lever operation. (Refer to "lnspec- tion"; page K-161.) Indicator panel 1. Remove the rear console. 2. Shift the selector lever to P range. 3. Loosen the indicator screws. 4. Align the alignment hole in the slider with the hole in the indictor panel. Install suitable heavy-gauge wire to hold the slider. 5. Tighten the indicator mounting screws in the order shown in the figure. 6. Remove the wire from the slider. 7. Verify that the selector lever properly aligns with the indi- cator in each range. 8. Verify correct operation of the emergency override but- ton. Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K Removal / Inspection / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. i, 3. Inspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal, referring to Installation Note. 45UOKX-5E 1. Rear console 5. Shift-lock actuator connector 2. Center panel 6. Selector lever 3. Audio unit 4. Spring pin Removal Note ............ page K-164 .......... Installation Note page K-164 Gartner Banana

N MANUAL STEERING STEERING WHEEL AND COLUMN Obtain the code number and deactivate the audio anti- theft system before disconnecting the battery. (Refer to section T.) On-vehicle Inspection Steering wheel play If the play exceeds specification, either the steering joints are worn or the backlash of the steering gear is excessive. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that the play is within specification. Play: 0--30mm (0-1.18 in) Looseness or play of steering wheel Move the steering wheel in directions a, 0, and @ to check for column bearing wear, steering shaft joint play, steering wheel looseness, and column looseness. Steering wheel effort 1. On level ground, jack up the front of the vehicle and sup- port it on safety stands. 2. Turn the steering wheel fully to the left and right at least 5 times. 3. Move the steering wheel to put the wheels in the straight ahead position. 4. Attach a pull scale to the outermost point of the steering wheel spoke. Then, starting with the wheels in the straight-ahead posi- tion, measure the effort required to turn the steering wheel to the left and to the right. Steering wheel effort: 5.0--29 N (0.S3.0 kgf, 1 .l--6.6 Ibf) (during one turn of steering wheel) 5. If not within specification, check the following: rotation starting torque of pinion, rotation torque of each ball joint, and steering joints. Gartner Banana

MANUAL STEERING , N Removal / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. ,, 3. Inspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal. 5. Tighten all necessary nuts and bolts to the specified torque. 6. After installation, check if the horn sounds. If the horn does not sound, remove the air bag module and connect the module connectors. (Refer to section T.) 1. Air bag module 6. Lower panel Removal 1 Installation .......... section T 7. Key interlock cable (Automatic transmission) 2. Locknut 8. Intermediate shaft bolt 3. Steering wheel 9. Steering shaft w ............... Removal Note page N-10 Disassembly 1 Inspection / 4. Column cover Assembly .................. page N-10 5. Combination switch Removal / Installation .......... section T Gartner Banana

N ENGINE SPEED SENSING POWER STEERING Caution Never hold the steering wheel to the extreme left or right for more than five seconds with the engine running. This could damage the power steering d pump- 8. Turn the steering wheel fully to the left and right and measure the fluid pressure generated by the gear hous- ing. If the pressure is not within specification, replace the gear housing assembly. Gear housing fluid pressure: 7,601--8,335 kPa (77.545.0 kgflcm2, 1,103-1,208 psi) 9. Remove the gauge set. Install and tighten the pressure hose to the specified torque. Tightening torque: 3247 N.m (3.24.8 kgf.m, 24--34 ft.lbf} 10. Bleed the air from the system. (Refer to page N-21.) STEERING WHEEL AND COLUMN Obtain the code number and deactivate the audio anti- theft system before disconnecting the battery. (Refer to section T.) On-vehicle Inspection -1 Steering wheel effort 1. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position. 2. Start the engine and warm the power steering fluid to 50--60°C (1 22-1 40°F). 3. With the engine running at idle, attach a pull scale to the outermost point of the steering wheel spoke. Then, starting with the wheels in the straight-ahead posi- tion, measure the effort required to turn the steering wheel to the left and to the right. Steering wheel effort: 2635 N (2.63.6 kgf, 5.3-7.9 Ibf) (during one turn of the steering wheel) 2 4. If not within specification, check the following: fluid level, air in system, fluid leakage at hose or connections, func- tion of oil pump and steering gear, and tire pressure. Gartner Banana

P ANTILOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING GUIDE Troubleshooting Guide with ABS Tester ABS tester ADAPTER PART No.0000-42-0010 HYDRAULIC UNIT CONNECTOR POSSlTlVE BATTERY 97UOPX469 Connecting ABS tester 1. Turn the ignition switch OFF. 2. Connect the SST harness to an extension harness, and wrap the connection with electrical tape to prevent short- ing. 3. Connect the SST between the hydraulic unit wiring har- ness connectors and to the positive battery terminal. 4. Roll back the carpet and remove the protecter. 5. Connect the ABS tester to the control unit connector at harness side .using the adaptor. Warning Driving the vehicle while the tester is connected to the ABS control unit is extremely dangerous. The brakes could fail, resulting in death or seri- / -1 ous injury. Disconnect the tester from the ABS control unit before driving the vehicle. Gartner Banana

P ANTILOCK BRAKE SYSTEM (ABS) MOTOR RELAY I I VALVE RELAY / I Check motor relay 1. Disconnect the negative battery cable. 2. Remove the motor relay. 3. Connect an ohmmeter and check for continuity at the .,i relay terminals. 4. If continuity is not as specified, replace the motor relay. 5. If OK, check the wiring harness (Motor relay - Control unit main fuse [ABS 60A1). Check pump motor Disconnect the control unit 2-pin connector and check for continuity between terminal a (FIN) wire and ground. If there is no continuity, replace the hydraulic unit. d 0 Check valve relay 1. Disconnect the negative battery cable. 2. Release the valve relay locks from the hydraulic unit and remove the valve relay. 3. Using an ohmmeter, check continuity of the relay termi- nals. M: Indicates continuity Connect to a 0 12V - c I b d 0 I I C++3: lndicates continuity Ground - b 4. If continuity is not as specified, replace the valve relay. b 0 e Connect to 12V I Ground c 0 a b c d Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P HYDRAULIC UNIT Removal 1 lnstallation 1. Disconnect the negative battery cable. - 2. Remove in the order shown in the figure, referring to Removal Note. 3. The only serviceable parts of the hydraulic unit are the valve relay and the motor relay. If there is a failure of any other part, replace the hydraulic unit assembly. 4. Install in the reverse order of removal, referring to Installation Note. 5. Add brake fluid, bleed the air, and check for fluid leakage. 1. Connectors 3. Nut bolts 2. Brake pipes 4. Hydraulic unit Removal / lnstallation Note . . . . page P-55 Gartner Banana