AIR BAG MAZDA MX-5 1994 User Guide

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 . STEERING SYSTEM INDEX ....................................... N- 2 OUTLINE ..................................... N- 4 SPECIFICATIONS ........................... N- 4 MANUAL STEERING .......................... N- 4 PREPARATION ............................. N- 4 ................ TROUBLESHOOTING GUIDE N- 5 BOOT ...................................... N- 6 STEERING WHEEL AND COLUMN ........... N- 8 ............. STEERING GEAR AND LINKAGE N-12 ENGINE SPEED SENSING POWER STEERING .......................... N-18 PREPARATION ............................. N-18 TROUBLESHOOTING GUIDE ................ N-20 AIR BLEEDING ............................. N-21 POWER STEERING FLUID ................... N-22 STEERING WHEEL AND COLUMN ........... N-24 STEERING GEAR AND LINKAGE ............. N-25 POWER STEERING OIL PUMP ............... N-33 DRIVE BELT ................................ N-37 25UONX-001 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

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . BRAKING SYSTEM INDEX ....................................... P- 2 OUTLINE ..................................... P- 4 SPEClFlCATlONS ........................... P- 4 BRAKE SYSTEM ............................. P- 5 PREPARATION ............................. P- 5 TROUBLESHOOTING GUIDE ................ P- 6 AIR BLEEDING ............................. P- 7 BRAKE HYDRAULIC LINE ................... P- 7 BRAKE FLUID .............................. P- 8 ............................. BRAKE PEDAL P- 9 MASTER CYLINDER (STANDARD) ............ P-11 MASTER CYLINDER (ABS) .................. P-14 POWER BRAKE UNIT ....................... P-20 PROPORTIONING BYPASS VALVE ........... P-23 FRONT BRAKE (DISC) ...................... P-25 CALIPER ................................... P-28 REAR BRAKE (DISC) ........................ P-29 CALIPER ................................... P-32 PARKING BRAKE SYSTEM .................... P-34 TROUBLESHOOTING GUIDE ................ P-34 PARKING BRAKE LEVER .................... P-34 PARKING BRAKE CABLE .................... P-36 ANTILOCK BRAKE SYSTEM (ABS) ............ P-37 DESCRIPTION .............................. P-37 PREPARATION ............................. P-37 TROUBLESHOOTING GUIDE ................ P-38 CIRCUIT DIAGRAM ......................... P-52 HYDRAULIC UNIT ........................... P-53 ........................ ABS CONTROL UNIT P-55 RELAYS .................................... P-56 ABS WHEEL SPEED SENSOR (FRONT) ....... P-58 ABS SENSOR ROTOR (FRONT) .............. P-59 ABS WHEEL SPEED SENSOR (REAR) ........ P-60 ABS SENSOR ROTOR (REAR) ............... P-61 25UOPX-001 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 . INDEX ....................................... R- 2 OUTLINE ..................................... R- 4 SPECIFICATIONS ........................... R- 4 TROUBLESHOOTING GUIDE .................. R- 5 WHEEL ALIGNMENT .......................... R- 6 PRE-INSPECTION .......................... R- 6 FRONT WHEEL ALIGNMENT ................. R- 6 .................. REAR WHEEL ALIGNMENT R- 9 FRONT SUSPENSION (DOUBLE-WISHBONE) ... R-11 PREPARATION ............................. R-11 SHOCK ABSORBER AND SPRING ............ R-11 LOWER ARM ............................... R-15 UPPER ARM ............................... R-17 STABILIZER ................................ R-19 CROSSMEMBER ........................... R-20 REAR SUSPENSION (DOUBLE-WISHBONE) .... R-21 PREPARATION ............................. R-21 SHOCK ABSORBER AND SPRING ............ R-22 LOWER ARM ............................... R-23 UPPER ARM ............................... R-24 STABILIZER ................................ R-25 CROSSMEMBER ........................... R-26 25UORX-001 Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . BODY INDEX ............................. S- 2 HOOD ............................. S- 5 COMPONENTS ................... S- 5 DOOR ............................. S- 7 COMPONENTS ................... S- 7 WINDOW REGULATOR. GLASS. AND GUIDE ....................... S- 9 COMPONENTS ................... S- 9 ......... DOOR LOCK AND OPENER S-15 ................... COMPONENTS S-15 TRUNK LID ........................ S-16 COMPONENTS ................... S-16 .... TRUNK LID LOCK AND OPENER S-18 COMPONENTS ................... S-18 ......... POWER WINDOW SYSTEM S-19 .............. STRUCTURAL VIEW S-19 TROUBLESHOOTING ............. S-20 ........ b POWER WINDOW SWITCH S-22 ... POWER WINDOW REGULATOR S-22 ......... FUEL-FILLER LID OPENER S-23 COMPONENTS ................... S-23 FRONT BUMPER ................... S-24 COMPONENTS ................... S-24 REAR BUMPER .................... S-25 COMPONENTS ................... S-25 ........... MOLDING AND GARNISH S-27 COMPONENTS ................... S-27 OUTSIDE MIRROR ................. S-30 STRUCTURAL VIEW .............. S-30 ............. TROUBLESHOOTING S-31 POWER OUTSIDE MIRROR ....... S-33 POWER OUTSIDE MIRROR SWITCH ........................ S-33 COMPONENTS ................... S-34 WINDSHIELD WIPER AND WASHER . S-35 TROUBLESHOOTING ............. S-35 WIPER MOTOR .................. S-38 ................ WASHER MOTOR S-38 FRONT WIPER AND WASHER ........................ SWITCH S-38 ................... COMPONENTS S39 WINDSHIELD ...................... S-44 PREPARATION ................... S-44 ................... COMPONENTS S-44 REAR WINDOW GLASS ......... (DETACHABLE HARDTOP) S-48 PREPARATION ................... S48 ................... COMPONENTS S48 REAR WINDOW .............. (CONVERTIBLE TOP) S-52 ................... COMPONENTS S-52 ....... DASHBOARD AND CONSOLE S-56 ................... COMPONENTS S56 TRIM .............................. S-59 COMPONENTS ................... S-59 ................. FLOOR COVERING S-62 ................... COMPONENTS -21 SEAT BELT ........................ S-63 COMPONENTS ................... S-63 ...................... SEAT BELT S-64 ................ BUCKLE SWITCH S-64 SEAT .............................. S-65 ................... COMPONENTS S-65 ................ CONVERTIBLE TOP S-67 PREPARATION ................... S-67 ................... COMPONENTS S-67 ........... DETACHABLE HARDTOP S-81 COMPONENTS ................... S-81 BRACE BAR ....................... S-84 ................... COMPONENTS S-84 ......... UNDERBODY DIMENSIONS S-85 PROJECTED DIMENSIONS ........ S-85 ..... STRAIGHT-LINE DIMENSIONS S-87 45uoSx-001 Gartner Banana

DASHBOARD AND CONSOLE DASHBOARD AND CONSOLE COMPONENTS Removal l Installation 1. Disconnect the negative battery cable. Warning Handling the air bag module improperly can accidently deploy the air bag, which may seri- ously injure you. Read SERVICE WARNINGS, section T, before handling the air bag module. 2. Remove in the order shown in the figure, referring to Removal Note. To remove the dashboard, remove the control wires of the heater unit and blower unit. 3. Install in the reverse order of removal. 1. Ashtray 2. Change lever knob 3. Rear console assembly a. Back plate b. Shift lever boot 7. Speedometer cable 8. Instrument cluster 9. Center louver Removal Note ............. page S-57 10. Center an el assemblv c. Power window switch Removal Note ............. page S-58 d. Cover (Without power window) 1 1. Glove box assembly e. Console lock assembly 12. Passenger-side airbag module (if equipped) 4. Center lower panel assembly Removal 1 Installation ......... section T Removal Note ............. page S-57 13. Hood release knob -1 5. Steering shaft 14. Center hole cover 6. Meter hood assembly 15. Side cover Removal Note ............. page $57 16. Dashboard Gartner Banana

BODY ELECTRICAL SYSTEM ................................... INDEX T- 2 ........................... SWITCHES T- 2 FUSES AND RELAYS .................. T- 3 .............................. LIGHTS T- 4 CRUISE CONTROL SYSTEM ........... T- 5 ...................... AUDIO SYSTEM T- 6 SRS AIR BAG SYSTEM ................ T- 7 ............................... OUTLINE T- 8 TROUBLESHOOTING GUIDE ........... T- 8 ELECTRICAL SYMBOLS ............... T- 9 ................................... FUSE T- 10 STRUCTURAL VIEW ................... T- 10 ...................... SPECIFICATIONS T- 11 ........................ DESCRIPTION T- 12 ....................... REPLACEMENT T- 12 ....................... RELAY .. ....... T- 13 STRUCTURAL VIEW ................... T- 13 ........................ DESCRIPTION T- 13 RETRACTABLE HEADLIGHT RELAY .... T- 14 ....................... FLASHER UNIT T- 14 ........................... TNS RELAY T- 15 .......................... HORN RELAY T- 15 COOLANT FAN RELAY ................. T- 15 REAR WINDOW DEFROSTER RELAY ... T- 16 HEADLIGHT RELAY ................... T- 16 ................................ SWITCH T- 17 ................... STRUCTURAL VIEW T- 17 ........................ DESCRIPTION T- 17 .................... IGNITION SWITCH T- 18 COMBINATION SWITCH ............... T- 19 RETRACTOR SWITCH AND HAZARD WARNING ............................. SWITCH T- 21 ................. INSTRUMENT CLUSTER T- 22 ................... STRUCTURAL VIEW T- 22 ........................ DESCRIPTION T- 22 .................... CIRCUIT DIAGRAM T- 23 ................. TROUBLESHOOTING T- 24 ............ REMOVAL / INSTALLATION T- 29 ........... DISASSEMBLY 1 ASSEMBLY T- 29 ...................... SPEEDOMETER T- 30 ........................ TACHOMETER T- 30 WATER TEMPERATURE GAUGE ....... T- 30 ......................... FUEL GAUGE T- 31 OIL PRESSURE GAUGE ............... T- 31 .................... PRINTED CIRCUIT T- 32 VEHICLE SPEED SENSOR ............. T- 32 WATER TEMPERATURE SENDER UNlT . T- 32 FUEL GAUGE SENDER UNlT ...................... (IN FUEL TANK) T- 32 OIL PRESSURE SENSOR .............. T- 33 ............... SPEEDOMETER CABLE T- 33 WARNING LIGHT AND SENDER UNIT ..... T- 34 ................... STRUCTURAL VIEW T- 34 CIRCUIT DIAGRAM .................... T- 35 ................. TROUBLESHOOTING T- 36 BRAKE FLUID LEVEL SENSOR ......... T- 39 PARKING BRAKE SWITCH ............. T- 39 ..................... BUCKLE SWITCH T- 39 ...................... LIGHTING SYSTEM T- 40 ................... STRUCTURAL VIEW T- 40 ......................... HEADLIGHTS T- 41 ......................... STOPLIGHTS T- 53 TURN AND HAZARD WARNING LIGHTS . T- 57 ..................... BACK-UP LIGHTS T- 66 TAILLIGHTS. SIDE MARKER LIGHTS. PARKING LIGHTS AND LICENSE PLATE LIGHTS . T- 69 DAYTIME RUNNING LIGHTS (DRL) .................... (CANADA SPEC.) T- 72 ........... REAR COMBINATION LIGHT T- 76 .................... INTERIOR LIGHTS T- 78 ................ ILLUMINATION LIGHTS T- 82 .................................. HORN T- 84 ................... STRUCTURAL VIEW T- 84 .................... CIRCUIT DIAGRAM T- 85 ................. TROUBLESHOOTING T- 86 ............ REMOVAL 1 INSTALLATION T- 87 ............ REAR WINDOW DEFROSTER T- 89 ................... STRUCTURAL VIEW T- 89 ........................ DESCRIPTION T- 89 ................. TROUBLESHOOTING T- 90 ................ REPAIRING FILAMENT T- 93 ............. CRUISE CONTROL SYSTEM T- 94 ................... STRUCTURAL VIEW T- 94 .................... CIRCUIT DIAGRAM T- 95 ................. TROUBLESHOOTING T- 96 ....... SELF-DIAGNOSTIC INSPECTION T-100 ............... CRUISE CONTROL UNIT T-103 .................... ACTUATOR CABLE T-104 ..................... CLUTCH SWITCH T-105 .......... STOP LIGHTIBRAKE SWITCH T-105 ...... CRUISE CONTROL MAIN SWITCH T-106 ........... CRUISE CONTROL SWITCH T-106 ............. VEHICLE SPEED SENSOR T-106 ........................... ACTUATOR T-107 a .................................. AUDIO T-108 ................... STRUCTURAL VIEW T-108 ................... SYSTEM DIAGRAM T-109 ............................ FEATURES T-110 FUNCTION AND OPERATING ......................... PROCEDURE 1-111 ............. OPERATION DESCRIPTION T-113 .................. ANTITHEFT SYSTEM T-120 ................. TROUBLESHOOTING T-122 ............ REMOVAL I INSTALLATION T-145 .................... POWER ANTENNA T-149 ......................... INSPECTION T-153 CONNECTOR TERMINAL .................... SPECIFICATIONS T-154 SRS AIR BAG SYSTEM .................. T-156 PREPARATION ........................ T-156 ................... STRUCTURAL VIEW T-156 .......... COMPONENT DESCRIPTION T-157 SYSTEM DIAGRAM ................... T-158 ................. SERVICE WARNINGS T-159 GENERAL PROCEDURES ............. T-160 TROUBLESHOOTING ................. T-160 DRIVER-SIDE AIR BAG MODULE ....... T-206 PASSENGER-SIDE AIR BAG MODULE . . T-207 DIAGNOSTIC MODULE ................ T-208 CLOCK SPRING ....................... T-209 CRASH SENSOR (D-SENSOR) ......... T-210 CRASH SENSOR (S-SENSOR) ......... T-213 AIR BAG MODULE DISPOSAL . .. PROCEDURE ........................ T-215 INSPECTION OF SST (DEPLOYMENT TOOL) ............... T-217 Gartner Banana

INDEX T SRS AIR BAG SYSTEM 1. Driver-side air bag module ...... Removal / Installation page T-206 ........ Disposal procedure page T-215 2. Passenger-side air bag module ...... Removal / Installation page T-207 ........ Disposal procedure page T-215 3. Clock spring ...... Removal / Installation page T- 19 ................ Inspection page T-209 I 45UOTX-007 4. Diagnostic module ...... Removal / Installation page T-208 5. Crash sensor (D-sensor) ...... Removal / Installation page T-210 ................ Inspection page T-212 6. Crash sensor (S-sensor) Removal / Installation ...... page T-213 ................ Inspection page T-214 Gartner Banana

T OUTLINE OUTLINE TROUBLESHOOTING GUIDE Symptom a Speedometer does not operate or indication is incorrect a Tachometer does not operate Water temperature gauge does not operate Fuel gauge does not operate a Oil pressure gauge does not operate a Brake system warning light remains illuminated Brake system warning light does not illuminate when parking brake on a Brake system warning light does not illuminate when brake fluid in reservoir is below MIN a OID off indicator light does not illuminate when OID off switch turned on Seat belt warning light remains on six seconds after ignition switch is turned on (Timer function does not operate) Seat belt warning light does not illuminate when ignition switch is first turned on a Headlights do not illuminate Headlight does not illuminate (Right or left) Retractable headlight actuator do not operate (Both sides) Retractable headlight actuator does not operate (One side) Stoplights do not illuminate (All) Stoplight does not illuminate (One only) Turn and hazard warning functions do not operate Turn signals not operate (Hazard warning function operates normally) Hazard warning function does not operate (Turn signals function normally) Back-up lights does not illuminate Taillights, side marker lights, and license plate lights do not illuminate Daytime running lights do not illuminate Daytime running light function does not cancel lnterior lights do not illuminate Interior liahts remains illuminated (Control switch: DOOR ~osition) Horn does not sound Vehicle speed cannot be set (Cruise control unit will not hold vehicle speed) Speakers do not operate (Without headrest speakers) Speakers do not operate (With headrest speakers) Poor sound quality or noise (Radio) Poor sound quality (Cassette tape player) Cassette tape will not load Cassette tape will not play Compact disc will not load Compact disc skips No sound can be heard Some speakers do not operate Bodysonic will not play Service code table (With passenger-side air bag) Service code table (With out ~assenaer-side air baa) Reference page T-24 T-25 T-26 T-27 T-28 T-36 T-37 T-37 Gartner Banana

FUSE SPECIFICATIONS Main Fuse Block u I Fuse Amperes Protected circuit HEAD INJ MAIN BTN 30A 30A COOLING FAN (AD FAN) 1 ABS I 60A I Antilock brake svstem I Headlight relay, Headlight switch Alternator, Diagnostic module (for air bag system) 80A 40A ST SIG RETRACTOR Fuse Box No.1 Except circuits protected in main fuse block: INJ 30A, HEAD 30A, RETRACTOR 30A TNS relay, Headlight switch 30A 20A EGI main relay, Coolant fan relay A/C relay 10A 30A Park l Neutral switch, Circuit-opening relay Retractable headlight actuator Fuse ENGINE METER (POWER WIND) Amperes 15A WIPER TAIL ROOM I 10A I PCME, Key reminder switch, Audio unit I Protected circuit EGI main relay, Coolant fan relay 15A 30A STOP HAZARD CIGAR 15A I Cigarette lighter, Audio unit 1 Instrument cluster, Turn signal switch, Timer and buzzer unit, Cruise control main switch Power window switch 20A 15A Fuse Box No.2 Blower switch, Wiper switch Taillights, Side marker lights, License plate lights, Parking lights 15A 15A Fuse Amperes Protected circuit I Stoplight switch, Horn switch, Cruise control unit Flasher unit Fuse Color Code (DEFOG) (ANTENNA) I Fuse amperes I Color code Fuse type 25UOTX-013 20A 20A I I 10A Red 1 I Rear window defroster Power antenna Plate type 15A 20A Light blue Yellow 30A 30A 80A Light green Pink Black Cartridge type Gartner Banana