sensor MAZDA MX-5 1994 Service Manual

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 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

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

PRESSURE REGULATOR CONTROL SYSTEM PRESSURE REGULATOR CONTROL SYSTEM DATA LINK CONNECTOR - CLUTCH SWITCH (MT) (TEN TERMINAL) PARKINEUTRAL SWITCH (PCMT) (AT) THROTTLE POSITION SENSOR L 1 ,,,, INTAKE AIR TEMPERATURE 1 SENSOR (IN MASS AIRFLOW SENSOR) -;- ENGINE COOLANT TEMPERATURE SENSOR PRC SOLENOID VALVE CRANKSHAFT POSITION SENSOR PRESSURE REGULATOR PCME I Above 90°C {194OF} ( Above 70°C {158'F} I Throttle valve closed throttle position or no load condition I Approx. 150 1 I Operating condition Coolant temperature I Intake air temperature I Engine condition I I To prevent percolation of the fuel during hot restart idle, vacuum to the pressure regulator is momentarily cut, and the fuel injection pressure is increased to slightly more than 284 kPa (2.9 kgf/cm2, 41.2 psi}. Operating time (sec) Gartner Banana

F EXHAUST GAS RECIRCULATION (EGR) EXHAUST GAS RECIRCULATION (EGR) PREPARATION SST I 49 9200 162 Engine Signal Monitor 49 GO1 8 904 Sheet DESCRIPTION For inspection of EGR For inspection of EGR 49 GO1 8 903 For inspection of Adapter EGR harness / TO AIR CLEANER HOUSING I THROTTLE POSITION ENGINE COOLANT SENSOR SENSOR TEMPERATURE CRANKSHAFT SENSOR POSITION SENSOR EGR SOLENOID VALVE (VACUUM) EGR SOLENOID VALVE (VENT) / PCME I This ~~st~rn~recirculates a small amount of exhaust gas into the intake manifold to reduce the combus- tion temperature, and reduce the NOx emissions. This system consists of the EGR control valve, EGR function sensor, two solenoid valves, powertrain control module (engine) (PCME) and input devices. Gartner Banana

EXHAUST GAS RECIRCULATION (EGR) Operation Cold Engine (Coolant temperature less than 55°C (1 31 OF)) EGR operation is stopped to improve driveability when the engine temperature is cold. u Warm Engine The powertrain control module (engine) controls the solenoid valves (vacuum side and vent side) to sup- ply EGR gases as described below. Remark Operating condition Idle Deceleration High speed Heavy load EGR SOLENOID VALVE (VACUUM) I I EGR operation Acceleration Warming up Other SYSTEM OPERATION 1. Connect the SSTs to the PCME as shown. 2. Start the engine. 3. Drive the vehicle and verify that PCME terminals 1 R and 1 T voltage is battery positive voltage (B+) while the en- gine is still cold. 4. Warm up the engine to normal operating temperature and let it idle. 5. Drive the vehicle and verify that the Engine Signal Moni- tor green and red lamps flash when the SST is set to 1 R and 1 T. 6. Ground the PCME terminal IT by using a jumper wire. 7. Verify that the engine runs roughly or stalls at idle. Stopped EGR SOLENOID VALVE (VACUUM) Inspection 1. Disconnect the vacuum hoses. 2. Blow into the EGR solenoid valve (vacuum) and verify that air does not flow. 3. Disconnect the EGR solenoid valve (vacuum) connec- tor. 4. Apply battery positive voltage and a ground to the sole- noid valve as shown. 5. Blow through the EGR solenoid valve (vacuum) and verify that air flows. 6. If not as specified, replace the EGR solenoid valve (vac- uum) assembly. Idle switch: ON Above 3,125 rpm - Reduced EGR gas amount Control supply of EGR gas amount by using signal from EGR function sensor - Coolant temperature: Between 55OC (1 31 OF) and 60°C {140°F) - Gartner Banana

F EXHAUST GAS RECIRCULATION (EGR) VACUUM PUMP EGR SOLENOID VALVE (VENT) lnspection 1. Disconnect the vacuum hoses. 2. Blow through the EGR solenoid valve (vent) and verify u that air flows. 3. Disconnect the EGR solenoid valve (vent) connector. 4. Apply battery positive voltage and a ground to the EGR solenoid valve (vent) as shown. 5. Blow into the EGR solenoid valve (vent) and verify that air does not flow. 6. If not as specified, replace the EGR solenoid valve (vent) assembly. EGR FUNCTION SENSOR lnspection Output voltage inspection 1. Disconnect the PCME connector. 2. Connect the SST to the PCME as shown and connect a vacuum pump. 3. Turn the ignition switch to ON (engine OFF). 4. Measure voltage at the terminals as shown in the table. I I Vacuum I Terminal 5. If not correct at terminal 2J, check the wiring harness and 'i terminal 21 of the PCME. B A C Resistance 1. Disconnect the EGR function sensor connector, and connect an ohmmeter. 2. Disconnect the vacuum hose from the EGR control valve, and connect a vacuum pump. 3. Measure the resistance between the terminals as shown while vacuum is applied. PCME Specification 2K 2 D 2J Approx. 0 kPa {O mmHg, 0 inHg} 4. If not as specified, replace the EGR control valve. Approx. 20 kPa I150 mmHg, 5.9 inHg} 4.5--5.5 V OV Terminal LC A-C A-B Approx. 0.8 V Resistance 0.1-2.4 ki2 0.5-2.7 W1 Approx. 2.7 W1 Approx. 5 V Gartner Banana

EXHAUST GAS RECIRCULATION (EGR) EGR CONTROL VALVE I EGR CONTROL VALVE Inspection 1. Start the engine and let it idle. 2. Connect a vacuum pump as shown and apply vacuum. 3. Verify that the engine runs roughly or stalls at more than the specified vacuum. Specification: 5.4--12.0 kPa (40-90 mmHg, 1.6-3.5 inHg) 4. If not as specified, replace the EGR control valve. Replacement Plug the water hoses after disconnecting them. 1. Remove the EGR control valve in the sequence shown below. (1 ) EGR hoses (2) Vacuum hose (3) EGR function sensor connector (4) EGR control valve and gasket 2. Install a new gasket, and then install the EGR control valve in the reverse order of removal. Gartner Banana