MAZDA MX-5 1994 Workshop Manual

K TRANSMISSION 5. Tighten the transmission-side bolts. Tightening torque: 104--123 N.m (10.6-12.6 kgf-m, 76.7-91.1 ft-lbf} 6. Tighten the differential-side bolts. Tightening torque: lO4--123 N.m {10.6-1 2.6 kgf-m, 76.7-91.1 ft-lbf} 7. Remove the jack. 8. Measure distance A with a straightedge and vernier cali- pers. Distance A: 51.5-61 Smm (2.023--2.417 in} 9. If the distance is not within specification, reposition the power plant frame at the transmission. Gartner Banana

OIL COOLER K OIL COOLER REMOVAL / INSPECTION / INSTALLATION 1. Remove in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to lnstallation Note. 45UOKX-57 1. Connector bolts 4. Oil pipe Inspect for clogging ins~ect for damaae or cracks -- - - 2. Packing installation Note ................ below 3. Transmission 5. Oil hose Removal ................. page K- 45 Inspect for damage or cracks Installation ............... page K-148 6. Radiator I UP SIDE DOWN SlDE lnstallation Note Oil pipe 1. Align the marks, and slide the oil cooler hose onto the oil cooler pipe until it contacts the ridge. 2. Install the hose clamp onto the hose at the center of the mark and at the angle shown. If reusing the hose, posi- tion the new hose clamp in the mark left by the previous hose clamp. 3. Verify that the hose clamp does not interfere with any other parts. Gartner Banana

K DRIVE PLATE DRIVE PLATE PREPARATION SST Brake set, ring gear 49 EOll 104 Collar (Part of 49 E011 1AO) For holding ring gear For holding ring gear 49 EOll 103 Shaft (Part of - - 49 EOl 1 1 AO) Stopper (Part of 49 EOll 1AO) REMOVAL I INSPECTION I INSTALLATION 1. Remove in the order shown in the figure, referring to Removal Note. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to Installation Note. For holding ring gear For holding ring gear 1. Transmission 4. Drive plate Removal ................. page K- 45 Removal Note ............ page K-153 Installation ............... page K-148 Inspect for cracks. Inspect ring gear for .J 2. Bolts wear and damage 3. Backing plate Installation Note .......... page K-153 5. Adapter Gartner Banana

DRIVE PLATE K Removal Note Drive plate Hold the drive plate by using the SST or equivalent, for removal of the mounting bolts. Installation Note Drive plate 1. Assemble the adapter, drive plate, and backing plate. 2. Install the SSl or equivalent, and tighten the bolts in the order shown. Tightening torque: 97-102 N-m (9.8-10.5 kgf-m, 71-75.9 ft-lbf) Gartner Banana

K SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) SHIFT-LOCK SYSTEM COMPONENTS Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K TROUBLESHOOTING Circuit Diagram - 1-21 AT SHIFT-LOCK SYSTEM Diagnosis chart Problem -- Selector lever cannot be moved from P range with brake pedal depressed and ignition switch ON Possible cause ROOM 1 OA fuse burned or not installed METER 10A fuse burned IG1 system malfunction Wire harness broken Poor connection IG 80A fuse burned Ignition switch malfunction Stop light switch remains OFF Stop light system malfunction Wire harness broken Poor connection STOP 15A fuse burned P range switch remains OFF P range switch system malfunction Wire harness broken (poor ground) Poor connection Shift-lock actuator malfunction Wire harness broken Poor connection Misadjustrnent of selector lever or improper assembly of shift-lock actuator Action I Page Repair or replace Connect firmly Replace Install or replace Replace K-155 K-155 Repair or replace K-155 Connect firmly K-155 Replace K-155 Inspect and replace Adjust or replace section T section T Repair or replace Connect firmly Inspect and replace Repair or replace Connect firmly Adjust or repair K-155 K-I55 K-155 K-155 K-159 Gartner Banana

K ' SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) Problem Possible cause Selector lever can be ROOM 1OA fuse burned or not installed moved lrom nnp. [stop light switch remains ON with ignition switch ON, but without brake pedal I Shift-lock actuator malfunction depressed Misadjustment of selector lever or improper assembly of shift-lock actuator Selector lever can be ROOM 10A fuse burned or not installed range Ignition switch malfunction with ignition switch OFF and brake pedal de- Shift-lock actuator malfunction pressed Misadjustrnent of selector lever or improper assembly of shift-iock actuator Shift-lock actuator op- P range switch remains ON eration heard when brake pedal depressed ' Misadjustment of selector lever or improper assembly with ignition switch ON of shift-lock actuator in other than P range Action -- Install or replace Adjust or replace lnspect and replace Adjust or replace Install or replace Inspect and replace inspect and replace Adjust or replace Inspect and replace Adjust or replace section T K-159 Selector lever remains locked when emergency override button oper- ated Emergency override button not pushed fully down Broken emergency override button lgnitlon key can be turned to lock position with selector lever in other than P range Push down fully and hold emergency override but- Misadjustment of indicator pedal ROOM 10A fuse burned or not installed Key interlock solenoid malfunction Wire harness broken Poor connection P range switch remains ON P range switch system malfunction Wire harness broken Poor connection lnspect and replace Repair or replace Connect firmly Adjust Install or replace K-161 - K-151 Inspect and replace Repair or replace Connect firmly I lanition kev cannot be I P ranae switch remains OFF I lns~ect and replace 1 K-158 I K-159 K-166 K-166 Key cylinder (push switch) malfunction Wire harness broken Poor connection Key interlock unit malfunction I ~~~~~$1~~~~ I Key iierlock solenoid malfunction I' I I Inspect and replace I K-158 I range Inspect and replace Repair or replace Connect firmly Inspect and replace Key cylinder (push switch) malfunction I Inspect and replace I section T section T K-155 K-155 section T I I Misadjustment of selector lever 1 Adjust I K-160 ] 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

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) Replacement 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key interlock solenoid connector. 4. Remove the screws and the key interlock solenoid. 5. Install the key interlock solenoid and tighten the screws. Tightening torque: 6.S-13 N-m (70-1 30 kgf-m, 61-11 3 ft-lbf} I I I 6. Verify that the key interlock solenoid operates. (Refer to 45UOKX-576 "Inspection" above.) 7. Connect the key interlock solenoid connector. 8. Install the column cover. 9. Connect the negative battery cable. KEY INTERLOCK UNIT Inspection 1. Remove the column cover. 2. Turn the ignition switch ON, and check terminal volt- ages, referring to the chart below. 3. If not as specified, repair the wiring harness andlor key -, interlock unit. B+: Battery positive voltage - - - Within 2 seconds of twning the P-range switch ON, and either the ACC or IG ON. Except above conditions Correct measurement valve 0 B+ E Condition Terminal I I I I terminal connected to I Ground 1 Constant M 0 Ignition switch ON Ignition switch OFF P-range switch and ACC are ON, or IG is ON Except above condition I B+ 0 S 0 B+ P-range switch ON P-range switch OFF I 0 B+ - ACC switch ON ACC switch OFF B+ 0 Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K TO GROUND FROM SHIFT-LOCK ACTUATOR Replacement 1. Disconnect the negative battery cable. 2. Disconnect the key interlock unit connector. 3. Remove the key interlock unit. 4. Install the new key interlock unit. 5. Connect the key interlock unit connector. 6. Connect the negative battery cable. P RANGE SWITCH Inspection Continuity 1. Disconnect the negative battery cable. 2. Remove the rear console. 3. Remove the screws and lift up the indicator panel. 4. Disconnect the P range switch connector. 5. Check continuity between the terminals. I Range I Selector lever release button I Continuity I 6. If not as specified, replace the P range switch. (Refer to page K-166.) I 7. Connect the P range switch connector. 8. Adjust the indicator panel. (Refer to page K-161.) Install the screws in the order shown in the figure. 9. Install the rear console. 10. Connect the negative battery cable. 11. Verify correct operation of the shift-lock system. SHIFT-LOCK ACTUATOR Inspection Terminal voltage and continuity 1. Remove the rear console 2. Remove the selector knob and indicator panel screws. Released Depressed Yes No Gartner Banana