engine MAZDA MX-5 1994 Workshop Manual

ROAD TEST (Hold) shift diagram LOCKUP AVAILABLE WHEN COASTING 818 718 - 618 - 518 ' 418 - 3/8 ' 218 - 118 - 018 0 20 (1 2) 40 (25) 60 (37) 80 (50) 100 (63) 120 (75) 140 (87) 160 (99) VEHICLE SPEED kmh {mph} Noise and Vibration Drive the vehicle in 2nd (Hold) and listen closely for any out of the ordinary noise or vibration. The torque converter, propeller shift, and differential can be sources of abnormal noise and vibration if they are not functioning properly. Check these when searching for sources of noise and vibration. L-RANGE TEST Shift Pattern For this test it is not necessary to inspect shift shock and shift points, since they are almost exactly the same as those for the D-range test. However, in the D-range (Normal) shift diagram, the shift points are different. ,, In L-range, the shift patterns for Normal mode are the same. 1. Shift the selector lever to L-range and select the Normal mode. 2. Accelerate the vehicle and verify that 1-2 up and downshifts are obtained, and that no third gear, no fourth gear, and no lockup are obtained. 3. Drive in 1 st gear, then decelerate and verify that engine braking effect is felt. 4. While driving in D-range (Hold mode) and third gear, shift the selector lever to L-range and verify that third gear is held until the 3-2 downshift point as shown in the L-range (Hold) shift diagram, and that 2nd gear is held until 2-1 downshift point is achieved. 5. Accelerate the vehicle in L-range (Hold mode) and verify that 1 st gear is held. L-range (Power) shift diagram LOCKUP AVAILABLE WHEN COASTING o 20 (12) 40 (25) 60 (37) 80 (50) 100 163) i 20 (75) 14dp7) 160 pgj VEHICLE SPEED kwh {mph) Gartner Banana

AUTOMATIC TRANSMISSION FLUID (ATF) K AUTOMATIC TRANSMISSION FLUID (ATF) ATF Inspection Level 1. Park the vehicle on level ground. 2. Apply the parking brake and position wheel chocks se- curely to prevent the vehicle from rolling. 3. Warm up the engine until the ATF reaches 60-70°C (1 40-1 58°F). 4. While depressing the brake pedal, shift the selector lever to each range (P-L), pausing momentarily in each range. 5. Shift back to P. Note In some cases it may be necessary to inspect the ATF in the cool range 15-25°C (59-77"F) before warm- ing up the engine. 6. Ensure that the ATF level is in the HOT (65°C) range. Add ATF to the specification, if necessary. ATF type: DexronQII or M-I11 Condition Determine whether the transmission should be disas- sembled by noting. 1. If the ATF is muddy or varnished. 2. If the ATF smells strange or unusual. Gartner Banana

K ELECTRICAL SYSTEM COMPONENTS ELECTRICAL SYSTEM COMPONENTS PREPARATION SST 49 GO1 8 904 Sheet 49 9200 162 Monitor, Engine Signal - 49 DO1 9 902 Adapter Harness For inspection of powertrain control module (transmission) terminal voltage For inspection of powertrain control module (transmission) terminal voltage p@ HOLD For inspection of powertrain control module (transmission) terminal voltage HOLD SWITCH lnspection lnspection of operation 1. Turn the ignition switch from OFF to ON. 2. Verify that the hold indicator light is not illuminated. De- press the hold switch and verify that the hold indicator -J light illuminates. 3. If not as specified, check the terminal voltage of the hold switch. lnspection of voltage 1. Remove the front console. 2. Turn the ignition switch ON. 3. Measure voltage at the hold switch connector. B+: Battery positive voltage Position (V): Voltage Normal (V) Depressed (V) 4. If not as specified, check the continuity of the hold switch. Connector terminal A B+ 0 B 0 0 Gartner Banana

ELECTRICAL SYSTEM COMPONENTS K I POWERTRAIN CONTROL POWERTRAIN CONTROL MODULE (TRANSMISSION) lns~ection 1. kemove the powertrain control module (Transmission). (Refer to page K-45.) 2. Disconnect the control module connectors. 3. Connect the SSTs (Engine Signal Monitor and Adapt- er Harness) to the powertrain control module (Transmis- sion) as shown. 4. Place the SST (sheet) on the Engine Signal Monitor. 5. Turn the ignition switch ON. 6. Measure the terminal voltage at each terminal. 7. If any control module terminal voltage is incorrect, check the related input of output devices and wiring. If no prob- lem is found, replace the powertrain control module (Transmission). Caution Applying voltage to terminals A and B of this SST will damage the SST. Gartner Banana

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

TRANSMISSION K Transmission Caution Shaking the transmission could damage the crank angle sensor on the engine. When remov- ing the transmission, do not shake it up and down or side to side. Remove the transmission. Gartner Banana

K TRANSMISSION TRANSMISSION UNIT (ASSEMBLY) Preparation SST 49 01 07 680A Engine stand 49 H075 4958 Body (Part of U019 OAOA) 49 GO32 355 Adjustment gauge For assembly of transmission For assembly of transmission For adjustment of vacuum diaphragm rod 49 UOI 9 OAOA Transmission hanger 49 U019 003 Holder (Part of U019 OAOA) For assembly of transmission For assembly of transmission Precaution 1. If the drive plates or brake bands are replaced with new ones, soak the new ones in ATF for at least two hours before installation. 2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts. 3. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit. u 4. Use petroleum jelly, not grease, during reassembly. 5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing. 6. Assemble the housing within 10 minutes after applying sealant, and allow it to cure at least 30 minutes after assembly before filing the transmission with ATF. Gartner Banana

K TRANSMISSION 52. Apply ATF to a new O-ring and install it onto the vehicle speed pulse generator. 53. Apply locking compound to the mounting bolt threads, then install the vehicle speed pulse generator. Tightening torque: 7.9-10.7 N-m (80-110 kgtcm, 70-95.4 inmlbf) 54. Apply ATF to the new O-rings and install them into the transmission case. 55. Install the lockup control solenoid. 56. Rotate the manual shaft fully rearward; then return it two notches to the N position. 57. Loosely tighten the parwneutral switch nuts. 58. Remove the screw on the switch body and move the parklneutral switch so that the screw hole on the switch body is aligned with the small hole inside the switch. - Check their alignment by inserting a 2.0mm (0.0079 in) diameter pin into the holes. 59. Tighten the switch attaching nuts. 60. Remove the pin, and tighten the screw into the hole. Tightening torque: 5.0--6.8 Nem (50-70 kgfecrn, 44-60 in-lbf) 61. Ensure that the torque converter is installed correctly by measuring the distance (A) between the end of the torque converter and the end of the converter housing. "A": 22.5mm (0.89 in) 62. Remove the transmission from the engine stand. Gartner Banana

TRANSMISSION K TRANSMISSION UNIT (INSTALLATION) Preparation SST Wrench d b For installation of torque converter bolts 1. On level ground, raise the vehicle and support it evenly on safety stands. 2. Install in the order shown in figure, referring to Installation Note. 3. Fill the transmission with the specified amount and type of the ATF after installation. 4. Warm up the engine, inspect for oil leakage, and verify correct transmission operation. 49 0259 440 Holder, rnainshaft For prevention of oil leakage 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