MAZDA MX-5 1994 Workshop Manual

F ON-BOARD DIAGNOSIS SYSTEM CODE NO. I 28 (EGR SOLENOID VALVE(VACUUM)) I I iTEP I INSPECTION ACTION (vacuum) circuit? valve (vacuum) connector disconnected OK? - Yes Repair or replace connector I Go to next step Yes Go to next step No - Yes - No 3 Check for open or short circuit in wiring from EGR solenoid valve (vacuum) terminal A to main relay terminal I Condition 1 Voltage IG switch ON I Battery positive voltage Is continuity between EGR solenoid valve (vacu- um) terminal B and PCME terminal IT OK? Check for short circuit in wiring from EGR solenoid valve (vacuum) terminal B to PCME terminal IT 0 If OK, go to next step 0 If not OK, repair or replace wiring harness Repair or replace wire harness Yes - No 4 Replace PCME Replace EGR solenoid valve (vacuum) Is EGR solenoid valve (vacuum) OK? CODE No. I - 29 (EGR SOLENOID VALVE(VENT)) I iTEP I INSPECTION ACTION I I If there a poor connection in EGR solenoid valve (vent) circuit? Repair or replace connector Go to next step Go to next step 1 Is connector terminal A voltages with EGR solenoid valve (vent) connector disconnected OK? Check for open or short circuit in wiring from EGR solenoid valve (vent) terminal A to main relay terminal I Condition I Voltage G switch ON I Battery positive voltage 1 Yes 3 Check for short circuit in wiring from EGR solenoid valve (vent) terminal B to PCME terminal 1 R Is continuity between EGR solenoid valve (vent) terminal B and PCME terminal 1 R OK? 0 If OK, go to next step s If not OK, repair or replace wiring harness Re~air or reolace wire harness I 4 Replace PCME I Replace EGR solenoid valve (vent) 39UOFX-110 Is EGR solenoid valve (vent) OK? No Yes No Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM INSPECTION Are there any poor connections in idle air control valve circuit? CODE NO. Is resistance of idle air control valve OK? 34 (IDLE AIR CONTROL VALVE) 1 Resistance: 11.5 + 0.8R (20°C (68°F)) Is there battery positive voltage at terminal A of idle air control valve circuit? Is there continuity between idle air control valve and PCME? Idle air control valve I PCME B 2W Is PCME terminal 2W voltage OK? page F-147 Circuit Diagram No 1 Go to next ste~ I Yes ACTION Repair or replace connector Yes No Yes Go to next step I I Go to next step Replace idle air control valve page F-106 Yes No No Check for open circuit in wiring from idle air control valve I to PCME Go to next step Check for open circuit in wiring from idle air control valve to main relay SOLENOID VALVE pRc c Yes No PURGE SOLENOID VALVE Replace PCME page F-143 Check for short circuit in wiring from idle air control valve to PCME t PCME 15UOFX-036 TO IGNITION - rVF, SWITCH A - - EGR TO BATTERY - O?! SOLENOIC t 4 I, VALVE (VACUUM) SOLENOI VALVE (VENT) Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM SELECT SW A Af ter-repair Procedure 1. Cancel the memory of malfunctions by disconnecting the negative battery cable at least 20 seconds and de- press the brake pedal. Reconnect the negative battery cable. 2. Connect the SST to the data link connector as shown. 3. Turn the ignition switch ON, but do not start the engine for six seconds. 4. Start and warm up the engine, then run it at 2,000 rpm for three minutes. 5. Verify that no code numbers are displayed. Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM SWITCH MONITOR FUNCTION Inspection Procedure POWERTRAIN CONTROL MODULE (ENGINE) NEUTRAL SWITCH CLUTCH SWITCH 1 STOPLIGHT SWITCH HEADLIGHT SWITCH REAR WINDOW DEFROSTER SWITCH PARKINEUTRAL SWITCH IDLE SWITCH (IN THROTTLE POSITION SENSOR) BLOWER SWITCH AIR CONDITIONING SENSOR I ' SYSTEM MONITOR LAMP (SELF-DIAGNOSIS 1 Clutch switch (MT) 1 Pedal released I Pedal depressed I In gear I Switch Self-Diagnosis Checker (Monitor lamp) I Liaht ON Liaht OFF . . I I I - I Idle switch (in throttle position sensor) I Pedal depressed I Pedal released 1 Remark ParWneutral switch (AT) I L, S, D and R range I N and P range I I I Stoplight switch (MT) Pedal depressed I Pedal released - I Neutral I Clutch pedal released Neutral switch (MT) - In gear I I Blower switch Headlight switch OFF Blower motor position: "medium" "high" or "super hiah" position I I ON 1. Connect the SST to the data link connector as shown. 2. Turn the ignition switch ON. Check if the monitor lamp il- luminates when each switch is made to function as de- scribed below. If any switch remains activated, the monitor lamp will be illuminated. 3. Connect the SST to the data link connector as shown. 4. Turn the ignition switch to ON (engine off). Check if the monitor lamp illuminates when each switch is adjusted as described above. 45UOFX-173 OFF 1 Air conditioning sensor Rear window defroster switch - ON ON OFF OFF Fan speed control: Low position - Gartner Banana

F ON-BOARD DIAGNOSIS SYSTEM Procedure - Set conditions to deactivate each switch a All accessories OFF a Transmission in neutral a All pedals released Verify that monitor lamp does not illuminate Neutral and Clutch switches (MT) Parklneutral switch (AT) Depress clutch pedal Verify that monitor lamp does not illuminate Return transmission to neutral NO PC: a Neutral or clutch switch malfunction (Refer to F-146) a Open circuit in related wire harness a Powertrain control module (engine) terminal 1V malfunction (Refer to page F-146) - Shift transmission into gear Verify that monitor lamp illuminates with clutch pedal is re- leased PC: a Clutch switch malfunction (Refer to page F-157) 35UOFX-046 I ParWneutral switch OK Shift into P or N range Check each switch and related wire harness a Clutch and Neutral switch :Refer to page F-I57 a Idle switch (in throttle position sensor) :Refer to page F-154 a Stoplight switch :Refer to Section T Headlight switch :Refer to Section T 1 Check each switch as described I I NO - ldle switch (in throttle position sensor) a Blower switch :Refer to Section T a Air conditioning sensor :Refer to Section U a Rear window defroster switch :Refer to Section T a ParWneutral switch :Refer to Section K YES PC: a ParWneutral switch malfunction (Refer to Section K) a Open or short circuit in related wire harness a PCME terminal 1 V voltage incorrect (Refer to page F-I 46) PCME malfunction - Shift transmission into L, S, D, or P range Check that monitor lamp illuminates 35UOFX-06 NO + YES I 1 I ldle switch OK I L I PC: Throttle position sensor malfunction (Refer to page F-144) a Short circuit in wire harness from throttle position sensor to PCME a PCME terminal 1 N voltage incorrect (Refer to page F-145) a PCME malfunction - Depress accelerator pedal and check that monitor lamp illu- minates f NO --c YES PC: a Throttle position sensor malfunction (Refer to page F-144) Open circuit in wire harness from throttle position sensor to PCME PCME terminal 2M voltage incorrect (Refer to page F-146) Release acceleration pedal and check that monitor lamp does not illuminate 2 YES I I Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM Stoplight switch OK Release brake pedal Stoplight switch (MT) Headlight switch PC: Stoplight switch malfunction (Refer to Section T) 0 Open circuit in wire harness from stoplight switch to powertrain control module (engine) Powertrain control module (engine) terminal 10 malfunction (Refer to page F-145) Headlight switch OK Turn OFF headlight switch I I NO ---c L, Blower switch YES Depress brake pedal and verify that monitor lamp illuminates PC: Headlight switch malfunction (Refer to section T) Open circuit in wire harness from headlight switch to powertrain control module (engine) Powertrain control module (engine) terminal 1 U malfunction (Refer to page F-146) Turn ON headlight switch Verify that monitor lamp illuminates Verify that monitor lamp illuminates NO - I YES YES Blower switch OK Turn OFF blower switch Air conditioning sensor PC: Blower switch malfunction (Refer to section T) 0 Open circuit in wire harness from blower switch to powertrain control module (engine) 0 Powertrain control module (engine) terminal IS malfunction (Refer to page F-146) 1 I YES I ' Set fan speed control to low position Turn air conditioning sensor ON, and verify that monitor lamp illuminates PC: Air conditioning sensor malfunction (Refer to Section U) Blower switch malfunction Open circuit in wire harness from air conditioning sensor to blower switch Powertrain control module (engine) terminal 1Q malfunction (Refer to page F-146) NO' 4 Air conditioning sensor OK Turn air conditioning sensor and blower switch OFF Rear window defroster switch Turn rear window defroster switch ON Is monitor lamp illuminated? NO PC: Rear window defroster switch malfunction (Refer to Section T) Open circuit in wire harness (Rear window defroster switch - PCME) PCME terminal 2L voltage incorrect (Refer to page F-146) PCME malfunction YES Turn rear window defroster switch OFF u Rear window defroster switch OK Gartner Banana

INTAKE AIR SYSTEM INTAKE AIR SYSTEM COMPONENTS Removal 1 Inspection l Installation Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system is under high pressure when the engine is not running. Warning Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the follow- ing "Fuel Line Safety Procedures". Fuel Line Safety Procedures A. Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. 2. Remove the fuel pump relay. 3. After the engine stalls, turn the ignition switch to OFF. 4. lnstall the fuel pump relay. B. Avoid leakage. 1. When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage. 2. Plug the hose after removal. C. lnstall hose clamps to secure the fuel pressure gauge connections. 1. Drain the engine coolant. (Refer to section E.) 2. Remove in the order shown in the figure. 3. Check the components for damage and repair or replace as necessary. 4. lnstall in the reverse order of removal, using new gaskets. 5. Refill the engine coolant. (Refer to section E.) Gartner Banana

INTAKE AIR SYSTEM F GASKET, REPLACE 1. Air duct 6. Accelerator pedakable .... 2. Air cleaner housing Inspection / Replacement page F-103 Inspection .................. page F- 76 7. Throttle body 3. Mass airflow sensor Removal / Inspection / ................ Inspection / Replacement .... page F-142 Installation page F-101 4. Air hose 8. Intake manifold ........ 5. Resonance chamber Removal / Installation page F-102 Gartner Banana

F INTAKE AIR SYSTEM SYSTEM OPERATION Inspection of Air Leakage Check for possible air leakage and repair or replace as necessary. - 39 4 Gartner Banana

INTAKE AIR SYSTEM THROTTLE VALVE 45UOFX442 THROTTLE BODY Removal 1. Remove the negative battery terminal. 2. Remove the air pipe. 3. Remove the accelerator cable from the throttle lever. Note Before disconnecting the water hoses, drain the en- gine coolant. 4. Disconnect the water hoses. 5. Disconnect the connectors for the idle air control valve and the throttle position sensor. 6. Remove the throttle body. Inspection Do not remove the thin sealing coating from the throttle valve or bore. 1. Verify that the throttle valve is closed throttle position. 2. Verify that the throttle valve moves smoothly when the throttle lever is moved from closed throttle position to wide open throttle. 3. Replace the throttle body if necessary. Installation Install in the reverse order of removal, using a new mounting gasket. Tightening torque: 19-25 N.m (1.G2.6 kgf.m, 14--18 ftlbf) Gartner Banana