ignition MAZDA MX-5 1994 Workshop Manual

K ELECTRICAL SYSTEM COMPONENTS Terminal Voltage Chart (Reference Data) C Terminal B+: Battery positlve voltage y Hold indicator light Condition Connected to 16 (Output) B+ Below 1.5V - - - No hold mode Hold mode FAT terminal (data link connector) I IC Voltage - - Voltmeter B+ Below 1.5V or B+ I C (Output) - - -- -- - - - -- -- - - - - - - - A- +terminal Normal If malfunction resent Ground (fluctuating) I Code Sianal I TAT terminal wounded -terminal Powertrain control module (Engine) (terminal R) TAT terminal (data link connector) - I - Below 2.5V 1 N or P range 1 D (Output) I Bt ]Other ranges I 1 E (lnput) 1 F 1 G I ATF thermosensor I 1G 3.3V ATF temperature 25OC {77"F) Ground B+ Switch depressed .-,/ -~ - 1 H (Input) 1 I Hold switch 1 OV ] Switch released I I 1 J (Output) 1 K 1 M (lnput) Cruise control unit I lM 1 N (lnput) Powertrain control module (Engine) (terminal 3M) 1 lN Idle switch B+ OV - -- Ve Accelerator pedal released I ADDrox. 4V While drivina Water temperature above 60°C {I 40°F) Accelerator pedal de~ressed Below 1.5V Vehicle speed sensor 1 P (lnput) 1 P I Approx' I Ignition switch ON I 4.4-5.5V 2A (Input) Throttle position sensor 1 2A . . . - . - . OV I lanition switch OFF 1 ParWneutral switch (N and P ranges) I OV I N or P ranae I 26 (Input) I B+ I Other ranaes I Gartner Banana

ELECTRICAL SYSTEM COMPONENTS K Terminal 2D (Input) 2E (Output) 2F (Input) 2G (Output) 2H (Input) - !I (Output) !J (Input)' - !K (Output) - !L (Ground)' 'M (Output) 1-2 shift solenoid valve 1 2E (S range) 2-3 shift solenoid valve Connected to Voltmeter I I +terminal . ParWneutral switch (D range) 2D - - (L range) 3-4 shift solenoid lalve Jehicle speed pulse 2J lenerator .ockup control ;olenoid valve 2K lehicle speed pulse 2L lenerator - 1 - I I - , - Z - 1 d - _4 3 V - - ower) E P (Ground) - 2P Ground ov - Q (Battery sattery 2Q B+ lgnition switch ON ower) OV Ignition switch OFF R - - - - - s (Battery Battery 2s B+ lgnition switch ON ~wer) Ground OV lgnition switch OFF Throttle position sen- 2T 'I- (Input) sor Approx. Throttle valve closed throttle position to wide 0.44.1 V open throttle Checked with AC range 1-2 control solenoid 'alve I 2M 1 ( Blow l.5V I 1 B+ 3-2 or 4-2 downshift OV Other conditions - - - I I I I lattery 20 B+ Constant Replacement Disconnect the negative battery cable. Disconnect the powertrain control module (Transmis- sion) connector. Remove the bolt and nut shown in the figure, and re- move the powertrain control module (Transmission). Install the new powertrain control module (Transmis- sion). Tightening torque: 19-25 N-m (1 .S2.6 kgf-m, 14--18 ftslbf) Connect the powertrain control module (Transmission). Connect the negative battery cable. Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K TROUBLESHOOTING Circuit Diagram - 1-21 AT SHIFT-LOCK SYSTEM Diagnosis chart Problem -- Selector lever cannot be moved from P range with brake pedal depressed and ignition switch ON Possible cause ROOM 1 OA fuse burned or not installed METER 10A fuse burned IG1 system malfunction Wire harness broken Poor connection IG 80A fuse burned Ignition switch malfunction Stop light switch remains OFF Stop light system malfunction Wire harness broken Poor connection STOP 15A fuse burned P range switch remains OFF P range switch system malfunction Wire harness broken (poor ground) Poor connection Shift-lock actuator malfunction Wire harness broken Poor connection Misadjustrnent of selector lever or improper assembly of shift-lock actuator Action I Page Repair or replace Connect firmly Replace Install or replace Replace K-155 K-155 Repair or replace K-155 Connect firmly K-155 Replace K-155 Inspect and replace Adjust or replace section T section T Repair or replace Connect firmly Inspect and replace Repair or replace Connect firmly Adjust or repair K-155 K-I55 K-155 K-155 K-159 Gartner Banana

K ' SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) Problem Possible cause Selector lever can be ROOM 1OA fuse burned or not installed moved lrom nnp. [stop light switch remains ON with ignition switch ON, but without brake pedal I Shift-lock actuator malfunction depressed Misadjustment of selector lever or improper assembly of shift-lock actuator Selector lever can be ROOM 10A fuse burned or not installed range Ignition switch malfunction with ignition switch OFF and brake pedal de- Shift-lock actuator malfunction pressed Misadjustrnent of selector lever or improper assembly of shift-iock actuator Shift-lock actuator op- P range switch remains ON eration heard when brake pedal depressed ' Misadjustment of selector lever or improper assembly with ignition switch ON of shift-lock actuator in other than P range Action -- Install or replace Adjust or replace lnspect and replace Adjust or replace Install or replace Inspect and replace inspect and replace Adjust or replace Inspect and replace Adjust or replace section T K-159 Selector lever remains locked when emergency override button oper- ated Emergency override button not pushed fully down Broken emergency override button lgnitlon key can be turned to lock position with selector lever in other than P range Push down fully and hold emergency override but- Misadjustment of indicator pedal ROOM 10A fuse burned or not installed Key interlock solenoid malfunction Wire harness broken Poor connection P range switch remains ON P range switch system malfunction Wire harness broken Poor connection lnspect and replace Repair or replace Connect firmly Adjust Install or replace K-161 - K-151 Inspect and replace Repair or replace Connect firmly I lanition kev cannot be I P ranae switch remains OFF I lns~ect and replace 1 K-158 I K-159 K-166 K-166 Key cylinder (push switch) malfunction Wire harness broken Poor connection Key interlock unit malfunction I ~~~~~$1~~~~ I Key iierlock solenoid malfunction I' I I Inspect and replace I K-158 I range Inspect and replace Repair or replace Connect firmly Inspect and replace Key cylinder (push switch) malfunction I Inspect and replace I section T section T K-155 K-155 section T I I Misadjustment of selector lever 1 Adjust I K-160 ] Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K POSSlBLt TO SHIFT c3 BRAKEPEDAL DEPRESSED 45UOKX42! EMERGENCY OVERRIDE BUTTON '
+ I SHIFT TO P RANGE 1 SHIFT-LOCK lnspection 1. Turn the ignition switch to ON engine OFF. 2. Verify that the selector lever is in P range. 3. Without the brake pedal depressed, verify that the selec- tor lever cannot be shifted from P range. 4. Depress the brake pedal and verify that the selector le- ver can be shifted from P range. 5. If not as specified, check the P range switch continuity andlor shift-lock actuator terminal voltage and continu- ity. (Refer to pages K-159.) EMERGENCY OVERRIDE BUTTON lnspection 1. Verify that the engine is off. 2. Verify that the selector is locked in P range. 3. Remove the indicator panel cover with the screwdriver as shown. 4. Insert the screwdriver into the emergency override hole, push down, and verify that the selector lever can be shifted from P range. 5. If not as specified, inspect and repair as necessary, re- ferring to the Troubleshooting diagnosis chart. (Refer to pages K-155.) KEY INTERLOCK lnspection 1. Turn the ignition switch to ON engine OFF. 2. Shift the selector lever to R range. 3. Verify that the ignition key cannot be turned to the LOCK position. 4. Shift the selector lever to P range. 5. Verify that the ignition key can be turned to the LOCK position. 6. If not as specified, inspect and repair as necessary, re- ferring to Troubleshooting. (Refer to pages K-155.) KEY INTERLOCK SOLENOID lnspection 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key interlock solenoid connector. 4. Insert the ignition key in the key cylinder. 5. Apply battery voltage between terminals 6 and C, and verify that the solenoid operates. 6. If not as specified, replace key interlock solenoid. 7. Connect the key interlock solenoid connector. 8. Install the column cover. 9. Connect the negative battery cable. Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) Replacement 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key interlock solenoid connector. 4. Remove the screws and the key interlock solenoid. 5. Install the key interlock solenoid and tighten the screws. Tightening torque: 6.S-13 N-m (70-1 30 kgf-m, 61-11 3 ft-lbf} I I I 6. Verify that the key interlock solenoid operates. (Refer to 45UOKX-576 "Inspection" above.) 7. Connect the key interlock solenoid connector. 8. Install the column cover. 9. Connect the negative battery cable. KEY INTERLOCK UNIT Inspection 1. Remove the column cover. 2. Turn the ignition switch ON, and check terminal volt- ages, referring to the chart below. 3. If not as specified, repair the wiring harness andlor key -, interlock unit. B+: Battery positive voltage - - - Within 2 seconds of twning the P-range switch ON, and either the ACC or IG ON. Except above conditions Correct measurement valve 0 B+ E Condition Terminal I I I I terminal connected to I Ground 1 Constant M 0 Ignition switch ON Ignition switch OFF P-range switch and ACC are ON, or IG is ON Except above condition I B+ 0 S 0 B+ P-range switch ON P-range switch OFF I 0 B+ - ACC switch ON ACC switch OFF B+ 0 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

K SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) POSSIBLE TO SHIFT BRAKEPEDAL DEPRESSED P RANGE POSSIBLE TO TURN IN LOCK POSITION I Shift-lock System Operation Inspection Shift-lock system 1. Turn the ignition switch ON, engine OFF 2. Verify that the selector lever is in P range. u 3. Without the brake pedal depressed, verify that the selec- tor lever cannot be shifted from P range. 4. Depress the brake pedal. Verify that the selector lever can be shifted from P range. 5. Shift the selector lever to R range. 6. Verify that the ignition key cannot be turned to the LOCK position. 7. Shift the selector lever to P range. 8. Verify that the ignition key can be turned to the LOCK position. 9. If not as specified, inspect and repair as necessary, re- ferring to "Troubleshooting". Emergency override button 1. Verify that the engine is off. 2. Verify that the selector is locked in P range. 3. Remove the indicator panel cover with the screwdriver as shown. 4. Insert the screwdriver into the emergency override hole, ,, push down, and verify that the selector lever can be shifted from P range. 5. If not as specified, inspect and repair as necessary, re- ferring to "Troubleshooting". Gartner Banana

PARKING BRAKE SYSTEM P Removal 1 Inspection / lnstallation 1. Block the wheels firmly. 2. Release the parking brake. - 3. Remove in the order shown in the figure. 4. lnspect all parts and repair or replace as necessary. 5. Install in the reverse order of removal, referring to lnstallation Note. 6. After installation, adiust the arki in^ lever stroke. (Refer to page P-34.) 1. Screw 6. Release button 2. Cover 7. Spring 3. Bolt Inspect for weakness 4. Parking brake switch 8. Bolt lnstallation Note . . . . . . . . . . . . . . . . . below 9. Parking brake lever lnspect for damage and cracks 5. Adjusting nut and clip lnstallation note Parking brake switch 1. Install the parking brake switch so that it contacts the parking brake lever when the lever is fully released. 2. Turn the ignition switch ON, and verify that the parking brake warning light illuminates with the lever pulled up one notch. Gartner Banana