brake MAZDA MX-5 1994 Owner's Manual

FUEL SYSTEM 1. Fuel filler hoses 7. Rear crossmem ber assembly 2. Fuel hoses Removal Note ............. page F-112 3. Evaporative hoses 8. Fuel tank unit 4. Fuel filter bolts 9. Two-way check valve ~4 Removal Note ............. page F-112 10. Fuel vapor valve 5. Brake pipe joint 11. Fuel pump Removal Note ............. page F-112 6. Battery cable Removal Note ............. page F-112 Removal note Fuel filter bolts 1. Remove the fuel filter cover. 2. Remove the fuel filter bolts. (MT) 3. Remove the fuel filter nuts. (AT) 4. Remove the fuel filter with the fuel hoses still connected. Brake pipe joint 1. Remove the brake pipe joint nuts. 2. Remove the brake pipe joint with the brake pipe and brake hose still connected. Battery cable Remove the battery cable clamp as shown in the figure. Rear crossmember assembly 1. Support the rear crossmember assembly with a trans- mission jack. 2. Remove the rear crossmember mounting bolts and nuts. 3. Lower the rear crossmember assembly. Gartner Banana

CONTROL SYSTEM F Terminal voltage B+: Battery positive voltage Test condition I Voltage I Remark - - - - - - - - - - - - - - - - - - Connection to Battery Constant Ignition switch OFF Main relay - B+ OV lgnition switch (Start position) For backup - Ignition switch ON While cranking Lamp illuminated for 3 sec. after 1 4.5-5.5V ianition switch OFF+ON 1 B+ Approx. 1 OV Ignition switch ON - - OV Data link connector (MEN terminal) Test switch at "SELF-TEST" .. Lamp not illuminated after 3 sec. Test switch at "02 MONITOR" at idle Monitor lam illuminated & 4.5-5.5v . . I Malfunction indicator IighVData link connector (FEN ter- minal) With Self-Diagnosis Checker and System Selector Test switch at "02 MONITOR" at idle Monitor lamp not illuminated Light illuminated and buzzer sounded for 3 sec. after ignition switch OFF-ON B+ tor tesiswitch at "SELF-TEST" With Self-Diagnosis checker and system selector Below 2.5V 1 Light illuminated and buzzer sounded 1 Below 2.5V I With System Selec- Light not illuminated and buzzer not sounded after 3 sec. I Light not illuminated and buzzer 1 n. 1 B+ not sound I D+ 1 - #I, 4 lgniter (in IG COIL) #2,3 Igniter (in IG COIL) Powertrain control module (transmis- sion) - Ignition switch ON Idle Ignition switch ON Idle lgnition switch ON (Engine coolant temp, below 60°C {I 40°F)) Ignition switch ON AtC relay Air conditioning sensor ON at idle Air conditioning sensor OFF at idle Ground (MT) - OV Approx. 0.2V OV Approx. 0.2V Below 1 .OV B+ Below 2.5V B+ - - - - , * Open (AT) - Ignition switch ON ( Below 1 .O V I Engine coolant temp. I Below .OV I ldle Above 97°C (206.6OF1 Ignition switch ON I I B+ Ignition switch ON Coolant fan relay B+ . - Other conditions lgnition switch On dround data link connector TEN terminal I Blow 1.0" I B+ Vehicle speed sensor ldle switch OFF While driving Vehicle sto~wed ldle switch (in throttle position sensor) 2-5V 1 or 7V . , Accelerator pedal released Accelerator ~edal de~ressed - Stoplight switch OV B+ Brake pedal released Brake ~edal deoressed lgnition switch ON Steering pressure sensor OV B+ I I - Ignition switch ON B+ - PIS ON (at idle) PIS OFF (at idle) Air conditioning sensor Air conditioning sensor ON (Igni- tion switch ON) Air conditioning sensor OFF (Igni- tion switch ON) OV B+ - Below 2.5V B+ Blower motor ON Gartner Banana

H CLUTCH UNIT CLUTCH UNlT PREPARATION SST 49 E011 1AO Brake set, ring gear 49 E011 104 Collar (Part of 49 EOll 1AO) 49 SEOl 310A 0 Clutch disc centering tool 49 1285 073 Chuck (Part of 49 1285 071) For holding ring gear For holding ring gear For removal and installation of clutch disc For removal of pilot bearing 49 EOll 103 Shaft (Part of 49 EOll 1AO) 49 E011 105 Stopper (Part of 49 E011 1 AO) 49 1 285 071 Puller, bearing For holding ring gear For holding ring gear For removal of pilot bearing REMOVAL / INSTALLATION Note The clutch release cylinder can be removed from the transaxle with the clutch pipe connected. 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to Installation Note. 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 . AUTOMATIC TRANSMISSION INDEX ................................ K- 2 OUTLINE ............................. K- 3 SPECIFICATIONS ................... K- 3 ........... CROSS-SECTIONAL VIEW K- 4 POWER FLOW DIAGRAM ............ K- 5 OPERATION OF COMPONENTS ...... K- 5 FLUID PASSAGE LOCATIONS ........ K- 6 TROUBLESHOOTING .................. K- 8 GENERAL NOTES ................... K- 8 .......... QUICK DIAGNOSIS CHART K- 9 ON-BOARD DIAGNOSIS SYSTEM ...... K- 11 DESCRIPTION ...................... K- 11 PREPARATION ...................... K- 11 ....... DIAGNOSTIC TROUBLE CODE K- 11 .......... MECHANICAL SYSTEM TEST K- 22 PREPARATION ...................... K- 22 STALL TEST ........................ K- 22 TIME LAG TEST ..................... K- 25 LINE PRESSURE TEST .............. K- 26 ROAD TEST .......................... K- 29 D-RANGE TEST ..................... K- 29 S-RANGE TEST ..................... K- 31 ..................... L-RANGE TEST K- 32 . P-RANGE TEST ..................... K- 33 AUTOMATIC TRANSMISSION FLUID (ATF) ................................ K- 35 ATF ................................ K- 35 REPLACEMENT ..................... K- 37 ELECTRICAL SYSTEM COMPONENTS . . K- 38 PREPARATION ...................... K- 38 HOLD SWITCH ...................... K- 38 PARWNEUTRAL SWITCH ............ K- 39 .............. ATF THERMOSENSOR K- 41 VEHICLE SPEED PULSE GENERATOR ...................... K- 41 1-2 SHIFT. 2-3 SHIFT. 3-4 SHIFT. ... 3-2 CONTROL SOLENOID VALVE K- 42 LOCKUP CONTROL SOLENOID ....... VALVE ............................ K- 42 POWERTRAIN CONTROL MODULE (TRANSMISSION) .................. K- 43 TRANSMISSION ....................... K- 46 TRANSMISSION UNIT (REMOVAL) .... K- 46 TRANSMISSION UNlT (DISASSEMBLY) ................... K- 50 TORQUE CONVERTER .............. K- 61 OILPUMP .......................... K- 62 FOURTH GEAR CONNECTING SHELL AND FOURTH GEAR PLANETARY GEAR UNIT (FOURTH GEAR SUN GEAR. FOURTH GEAR PLANETARY PINION CARRIER. FOURTH GEAR CLUTCH HUB) ...... K- 67 DIRECT CLUTCH .................... K- 70 FOURTH GEAR BAND SERVO ........ K- 76 DRUM SUPPORT. ACCUMULATOR. AND FOURTH GEAR CASE ......... K- 79 2ND BAND SERVO .................. K- 83 FRONT CLUTCH .................... K- 86 REAR CLUTCH ...................... K- 91 CONNECTING SHELL AND FRONT PLANETARY GEAR UNlT (REAR CLUTCH HUB. FRONT PLANETARY PINION CARRIER. REAR SUN GEAR) ................. K- 96 REAR PLANETARY GEAR UNlT (CONNECTING DRUM. REAR PLANETARY PINION CARRIER. ONE-WAY CLUTCH) K- 98 LOW AND REVERSE BRAKE K-102 ................ ......... EXTENSION HOUSING AND PARKING MECHANISM ............. K-107 OIL SEAL ........................... K-ill CONTROL VALVE BODY ............. K-112 UPPER VALVE BODY ................ K-116 LOWER VALVE BODY ............... K-120 CONTROL VALVE BODY ............. K-125 VACUUM DIAPHRAGM ............... K-130 TRANSMISSION UNIT (ASSEMBLY) ... K-132 TRANSMISSION UNIT (INSTALLATION) ................... K-147 OIL COOLER .......................... K-151 REMOVAL I INSPECTION I INSTALLATION ..................... K-151 DRIVE PLATE ......................... K-152 PREPARATION ...................... K-152 REMOVAL 1 INSPECTION I INSTALLATION ..................... K-152 SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) ......... K-154 SHIFT-LOCK SYSTEM COMPONENTS K-154 TROUBLESHOOTING ................ K-155 SHIFT-LOCK ........................ K-157 EMERGENCY OVERRIDE BUTTON ... K-157 KEY INTERLOCK .................... K-157 KEY INTERLOCK SOLENOID ......... K-157 KEY INTERLOCK UNIT ............... K-158 P RANGE SWITCH .................. K-159 SHIFT-LOCKACTUATOR ............. K-159 SELECTOR LEVER .................. K-161 HYDRAULIC CIRCUIT .................. K-168 P RANGE ........................... K-168 R RANGE ........................... K-169 N RANGE; BELOW 7 kmlh I4.34 mph) . K-170 N RANGE; ABOVE 9 kmlh (5.58 mph} . K-171 D RANGE; 1 ST GEAR ................ K-172 D RANGE; 2ND GEAR ............... K-173 D RANGE; THIRD GEAR ............. K-174 D RANGE; FOURTH GEAR. LOCKUP ON ....................... K-175 S RANGE; 1 ST GEAR ................ K-176 S RANGE; 2ND GEAR ............... K-177 S RANGE; THIRD GEAR ............. K-178 L RANGE; 1 ST GEAR ................ K-179 L RANGE; 2ND GEAR ................ K-180 Gartner Banana

INDEX, OUTLINE K 1. Hold switch lnspection . . . . . . . . . . . . . . . . page K- 38 Replacement . . . . . . . . . . . . . page K- 39 b 2. ParkINeutral switch lnspection . . . . . . . . . . . . . . . . page K- 39 Adjustment . . . . . . . . . . . . . . . page K- 40 3. Vehicle speed pulse generator lnspection . . . . . . . . . . . . . . . . page K- 41 Replacement . . . . . . . . . . . . . page K- 42 4. ATF thermosensor lnspection . . . . . . . . . . . . . . . . page K- 41 Replacement . . . . . . . . . . . . . page K- 41 5. 1-2 shift, 2-3 shift, 3-4 shift, 3-2 control solenoid valves lnspection . . . . . . . . . . . . . . . . page K- 42 6. Lockup control solenoid valve lnspection . . . . . . . . . . . . . . . . page K- 42 7. Powertrain control module (Transmission) lnspection . . . . . . . . . . . . . . . . page K- 43 Replacement . . . . . . . . . . . . . page K- 45 OUTLINE SPECIFICATIONS 8. Automatic transmission Removal . . . . . . . . . . . . . . . . . page K- 46 Disassembly . . . . . . . . . . . . . page K- 50 Assembly . . . . . . . . . . . . . . . . page K-132 lnstallation . . . . . . . . . . . . . . . page K-147 9. Oil cooler Removal 1 Inspection / lnstallation . . . . . . . . . . . . . . page K-151 10. Drive plate Removal 1 Inspection 1 lnstallation . . . . . . . . . . . . . . page K-152 11. P range switch lnspection . . . . . . . . . . . . . . . . page K-159 12. Shift-lock actuator lnspection . . . . . . . . . . . . . . . . page K-159 13. Selector lever lnspection . . . . . . . . . . . . . . . . page K-161 Adjustment . . . . . . . . . . . . . . . page K-160 Removal / Inspection / lnstallation . . . . . . . . . . . . . . page K-163 Disassembly 1 Inspection / Assembly . . . . . . . . . . . . . . . page K-166 - Model Item - Gear ratio NC4A-EL Torque converter stall torque ratio 1 st 1.900 : 1 2.458 4GR Reverse 0.720 2.182 Number of driveldriven plates Servo diameter (Piston outer diameterketainer inner diam- eter) mm{in} Direct clutch Front clutch Rear clutch Automatic transmission fluid (Am 212 315 515 Low and reverse brake Fourth gear band servo 2nd band servo 4/4 56/36 {2.205/1.417} 72/50 {2.835/1.969} Dexron@II or M-111 7.3 {7.7,6.4} 4.0 {4.2,3.5} Type Capacity L {US qt, Imp qtI Total oil pan Gartner Banana

OUTLINE K POWER FLOW DIAGRAM 1. Torque converter 2. Oil pump 3. Input shaft 4. Fourth gear sun gear 5. Internal gear - 6. Fourth gear one-way clutch (4GR OWC) 7. Fourth gear brake band (4GR Brk.) OPERATION OF COMPONENTS 8. Fourth gear planetary pinion carrier 9. Direct clutch (D/C) 10. Intermediate shaft 11. Front clutch (F/C) 12. 2nd brake band (2nd Brk.) 13. Rear clutch (R/C) 14. Front planetary pinion carrier 15. Internal gear 16. Sun gear 17. Rear planetary pinion carrier 18. Low and reverse brake (L&R Brk.) 19. Internal gear 20. One-way clutch (OWC) 21. Output shaft C3 indicates operation although the band servo remains deactivated due to the large area of the release pressure side. The lockup control solenoid valve operates only during lockup. The 3-2 control solenoid valve operates momentarily during 3-2 downshift. The Fourth gear one-way clutch operates momentarily during 4-3 downshift. Gartner Banana

K OUTLINE FLUID PASSAGE LOCATIONS Transmission Case TO SECOND SERVO RELEASE SlDE TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE TO SECOND SERVO APPLY SI OIL PUMP DISCHARGE TORQUE CONVERTER PRESSURE TO REAR CLUTCH TO FRONT CLUTC OIL PUMP SUCTION , REAR LUBRICATION TO LOW AND REVERSE BRAKE OIL PUMP SUCTION TO FRONT CLUTCH TO DIRECT CLUTCH AND FOURTH GEAR SERVO RELEASE SlDE TO REAR CLUTCH / OIL PUMP DISCHARGE TORQUE CONVERTER PRESSURE Oil Pump OIL PUMP DISCHARGE FRONT LOCKUP CONTROL OIL PUMP SUCTION SOLENOID VALVE TORQUE CONVERTER PRESSURE 0i PUMP DISCHARGE Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM K )IAGNOSTIC TROUBLE CODE N0.06 VEHICLE SPEED SENSOR INSPECTION STEP ACTION Repair or replace connector Are there any poor connections at vehicle speed sensor and powertrain control module (Transmission) connectors? Yes Go to next step Connect a circuit tester to terminal as shown. Is input voltage of vehicle speed sensor at powertrain control module (Transmission) OK? page K-44 Yes Go to step 5 1 (+) term. I (-) term. ( Voltage (v)( Condition I Go to next step Below 1.5 While Remove instrument cluster Is there continuity between terminal 2D of meter connector and terminal 1 M of pow- ertrain control module (Transmission) Yes Go to next step Repair or replace wiring and/or connector Connect circuit tester to terminals 2D and 2A of meter connector Does pointer of circuit tester move slightly when front wheels are slowly turned? Yes Go to next step Replace vehicle speed sensor section T Disconnect the negative battery cable for at least 20 seconds and depress the brake pedal Connect the battery cable and recheck for code. Is diagnostic trouble code displayed Dane K-21 Yes Replace powertrain control module (transmission) page K-45 Intermittent poor connection check for cause Gartner Banana

K ON-BOARD DIAGNOSIS SYSTEM - -- )IAGNOSTIC TROUBLE CODE N0.12 THROTTLE POSITION SENSOR ACTION I STEP INSPECTION Are there any poor connections at throttle position sensor and powertrain control module (transmission) connector or termi- nal? Yes Repair or replace connector I Go to next step Go to step 5 Connect a circuit tester to terminal as shown Is input voltage of throttle position sensor (TVO) at powertrain control module (transmission) OK? page K-45 1 (+) term. I (-) term. I Voltage (v)/ Condition 1 Yes No lgnition Go to next step ' 2T Ground valve Approx. closed I 0.8--4.3 position to wide open 1 throttle Go to next step Connect a circuit tester to terminals as shown Is input voltage of throttle position sensor (VREF) at powertrain control module (transmission) OK? page K-44 (+) term. (-) term. Voltage (V) Condition Approx. lgnition 4.55 ;p" 2A Ground Ignition 0 switch OFF Yes Check voltage at terminal 21 of powertrain control module (En- gine) Voltage: 4.5--5.5V (Ignition switch ON) If OK, go to next step If not OK, repair wiring andlor connector Check wiring and connectors form Powertrain control module (transmission) to throttle position sensor If OK, go to next step If not OK, repair wiring andlor connector Is throttle position sensor OK? Section F Yes No Yes Adjust or replace throttle position sensor t@? section F I Replace powertrain control module (transmission) t@? page K-45 is connect the negative battery cable for at least 20 seconds and depress the brake pedal Connect the battery cable and recheck for diagnostic trouble code Is diagnostic trouble code displayed? Daae K-21 Intermittent poor connection Check for cause Gartner Banana

ON-BOARD DIAGNOSIS SYSTEM K :TIC TROUBLE CODE No.55 VEHICLE SPEED PULSE GENERATOR ACTION Repair or replace connector INSPECTION control module (transmission) connector or terminal? I (+) term. 1 (-) term. I Voltage (v)( Condition I Are there any poor connections at vehicle speed pulse generator and powertrain No ' Go to next step Connect a circuit tester to terminal as shown Is input voltage of vehicle speed pulse generator at powertrain control module (transmission) OK? page K45 Engine Yes Engine I o ( stopped ( Yes Disconnect 20-pin powertrain control module (transmission) connector Is resistance between terminal 2J and ter- minal 2L OK? Go to step 5 I No I Go to next step Yes Go to step 5 Resistance: 200--400a Disconnect vehicle speed pulse genera- tor connector Is resistance between terminal E and ter- minal F OK? page K41 Resistance: 200--400n Disconnect the negative battery cable for at least 20 seconds and depress the brake mdal Sonnect the battery cable and recheck for jiagnostic trouble code Is diagnostic trouble code displayed? page K-21 45UOKX-019 Yes No Yes No Check wiring and connectors form powertrain control module (transmission) vehicle speed pules generator If OK, go to next step If not OK, repair wiring and/or connector Replace pulse generator Replace powertrain control module (transmission) us page K-45 Intermittent poor connection Check for cause Gartner Banana