SECTION T MAZDA MX-5 1994 Manual PDF

CHARGING SYSTEM B TE S TERMINAL 1. Remove the battery cover. 2. Disconnect the battery cable from the battery. 3. Remove the battery from the vehicle. 4. Place the battery in a pan of the water to prevent it from ,-, over heating, but keep water away from the top of bat- tery. 5. Charge the battery. Replacement Note When replacing the battery, replace it with the same style Mazda genuine battery (with vent manifold). ALTERNATOR Caution Obtain the code number and deactivate the audio anti-theft system before disconnecting the bat- tery. (Refer to section T.) Caution Reversing the battery connections or using high- voltage testers will damage the rectifier. Caution Do not start the engine while the connector is dis- connected from L and S terminals. It can damage the alternator. Note .--,' Positive voltage is always present at alternator B ter- minal. Removal l Installation 1. Disconnect the negative battery cable. 2. Disconnect the steering pressure sensor connector. 3. Disconnect the water thermoswitch connector. 4. Disconnect the IAC valve connector. 5. Remove the intake air pipe. 6. Disconnect the wire and connector from the alternator. 7. Remove the alternator bolts and nut. 8. Remove the alternator. 9. Install in the reverse order of removal. Tightening torque Bolt 0: 38-51 N.m (3.8-5.3 kgf-m, 27-38 ftelbf) Bolt @ : 19-25 N.m j1.9-2.6 kgfem, 14--18 ft-lbf) Nut @I: 9.9--14 N.m (100-150 kgf-cm, 87-1 30 in-lbf) Gartner Banana

IGNITION SYSTEM TROUBLESHOOTING Misfire I 1 Check 1 NO NO 1. Turn ignition switch ON 2. Connect data link connector terminals (TEN) and (GND) with a jumper wire 3. Check if MIL illuminates I Check if resistance of secondary windings is OK Replace ignition coil (Refer to page G-19) (Refer to page G-19) I Refer to section F Check 2 Check if resistance of Replace high-tension lead (Refer to page G-20) (Refer to page G-20) I I Check 3 Check if spark plug is OK ( I Check 4 1 YES I Check PCME terminals (Refer to section F) a 1 G, 1 H (Igniter) 0 2E, 2G (Crankshaft position sensor) Repair or replace (Refer to section F) ( 2F, 20 ass airflow sensor) YES Replace ignition coil (igniter malfunction) 1 Check 1 Check 3 Check 2 PLUG WEAR AND CARBON BUILDUP BURNS DAMAGE AND DETERIORATION DAMAGE Gartner Banana

IGNITION SYSTEM G GND TEN I I I IGNITION TIMING 1. Check the condition of the engine (spark plugs, leaks in hoses, etc.). 2. Verify that all accessories are OFF. 3. Warm up the engine to the normal operating tempera- ture. Note When using an externally powered timing light and/or tachometer connect it to the power connector (Blue: l-pin). Warning Do not ground the power connector. terminal (Blue: l-pin); some fuses will be burned. 4. Connect a timing light and tachometer to the data link connector terminal (IG-). 5. Connect the SST and set TEST SW to "SELF TEST" or connect data link connector terminals TEN and GND with a jumper wire. 6. Check the idle speed, and set it to specification if neces- sary (Refer to section F.) ' Idle speed (rpm):800-900 (MT) 75-50 (AT) 7. Verify that the timing mark (white) on the crankshaft pulley is aligned with the indicator pin. Ignition timing: 9"-11" BTDC (at idle) 8. If the marks are not aligned, remove the ignition coil bracket and push the ignition coil aside for easy access and then loosen the crankshaft position sensor lock bolts, and turn the crankshaft position sensor to make the adjustment. 9. Tighten the crankshaft position sensor lock bolts to the specified torque. Tightening torque: 19-25 N-m (1 3-2.6 kgf~m, l4--19 ft.lbf) 10. After adjusting the ignition timing, disconnect the jumper wire or SST from the data link connector. 11. Increase the engine speed and verify that the ignition timing advances. Gartner Banana

IGNITION SYSTEM IGNITION COIL lnspection Secondary coil winding 1. Remove the high-tension leads. u 2. Measure resistance of the secondary coil winding of each coil with an ohmmeter. Secondary coil winding resistance (at 20°C (68°F)): 8.7-1 2.9 kR 3. If not within specification, replace the ignition coil. 45UOGX-030 I I Insulation resistance of case 1. Remove the high-tension leads and disconnect the con- nectors. 2. Use a 500V megger tester to measure the insulation resistance between the primary terminal and the coil case. Resistance : Above 10 MR 3. If not within specification, replace the ignition coil. L I 45UOGX-031 Replacement 1. Disconnect the high-tension leads and ignition coil con- nector. 2. Remove the installation bolts and the ignition coil. 3. Install in the reverse order of removal. L Tightening torque: 19-25 N.m (1.9--2.6 kgf-m, 14--18 ft-lbf) 45UOGX-032 IGNITER Inspection 1. Check the poor connection of ignition coil, high-tension leads and PCME. 2. Check the ignition coil, and high-tension leads. 3. Mesure the voltage of the PCME terminal as follows. (Refer to section F.) 1 G igniter (Nos.1, 4) 1 H igniter (Nos.2, 3) 2E, 2G crankshaft position sensor (SGT) 2F, 20 mass airflow sensor 4. If all are normal, but misfire still occurs, replace the igni- tion coil. Gartner Banana

STARTING SYSTEM G STARTING SYSTEM CIRCUIT DIAGRAM I TROUBLESHOOTING Check 1 1 No Magnetic switch gE only clicks when ignition switch is at START Check starter (Refer to page G-23) Check wire harness Check 2 NO MT . . . . 1. Depress clutch pedal 2. Check if voltage between interlock switch (starter side) and ground is approx. 12V AT . . . . 1. Shift into P or N range Check wire harness 2. Check if voltage between parwneutral switch (starter side) and ground is approx. 12v 1. Turn ignition switch to START position 2. Check if voltage between S terminal and ground is approx. 12V Check 3 1 No Check starter magnetic switch (Refer to page G-27) I I Check wire harness I MT . . . . Check if voltage between interlockswitch (igni- tion switch side) and ground is approx. 12V AT . . . . . Check if voltage between parwneutral switch (ignition switch side) and ground is approx. 12v Check starter interlock switch (Refer to page G-28) Check parwneutral switch (Refer to section K) Gartner Banana

G STARTING SYSTEM Check 1 Check 3 Check 2 STARTER Caution Obtain the code number and deactivate the audio anti-theft system before disconnecting the bat- tery. (Refer to section T.) Removal / Installation 1. Disconnect the negative battery cable. 2. Disconnect the wiring from the starter. 3. Remove the starter bracket. (MT only) 4. Raise the front of the vehicle and support it with safety stands. 5. Remove the bolts and the starter. 6. Install in the reverse order of removal. Tightening torque Nut O: 10-11 N.m (100-120 kgfam, 87-100 in4bf) Bolt, Nut O: 38-51 N.m (3.8-53 kgf-m, 28-38 ft4bf) Bolt 0: 16-22 N.m (1.6-2.3 kgf.m, 12-16 ft-lbf) Bolt 0: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnlngs and audio antitheft system alarm conditions . i, CLUTCH INDEX ....................................... H- 2 OUTLINE ..................................... H- 3 SPECIFICATIONS ........................... H- 3 TROUBLESHOOTING GUIDE .................. H- 3 CLUTCH FLUID ............................... H- 4 ............................. PREPARATION H- 4 ............................ REPLACEMENT H- 4 .............................. CLUTCH PEDAL H- 5 .............................. ADJUSTMENT H- 5 REMOVAL / INSPECTION / INSTALLATION .... H- 6 ................. CLUTCH MASTER CYLINDER H- 7 PREPARATION ............................. H- 7 REMOVAL / INSTALLATION .................. H- 8 AIR BLEEDING ............................. H- 9 OVERHAUL ................................ H-10 CLUTCH RELEASE CYLINDER ................ H-12 PREPARATION ............................. H-12 REMOVAL / INSTALLATION .................. H-12 AIR BLEEDING (REFER TO PAGE H-9.) OVERHAUL ............................... H-13 CLUTCH UNIT ................................ H-14 PREPARATION ............................. H-14 REMOVAL / INSTALLATION .................. H-14 CLUTCH RELEASE COLLAR .................. H-17 INSPECTION ............................... H-17 CLUTCH COVER ............................. H-17 INSPECTION ............................... H-17 CLUTCH DISC ................................ H-17 INSPECTION ............................... H-17 PILOT BEARING .............................. H-18 INSPECTION ............................... H-18 FLYWHEEL ................................... H-18 INSPECTION ............................... H-18 35UOHX-001 Gartner Banana

H INDEX INDEX 1 . Clutch pedal ................ Adjustment page H- 5 Removal / Inspection / ............... Installation page H- 6 2. Clutch master cylinder ....... Removal I Installation page H- 8 .................. Overhaul page H-10 ............... Air bleeding page H- 9 3. Clutch release cylinder ....... Removal I Installation page H-12 .................. Overhaul page H-13 ............... Air bleeding page H- 9 4. Clutch release collar ....... Removal / Installation page H-14 ................. Inspection page H-17 SERVICE, SECTION F 5. Clutch release fork ....... Removal / Installation page H-14 6. Clutch cover ....... Removal / Installation page H-14 ................. Inspection page H-17 7. Clutch disc ....... Removal 1 Installation page H-14 ................. Inspection page H-17 8. Pilot bearing ....... Removal I Installation page H-14 ................. Inspection page H-18 9. Flywheel Removal / Installation ....... page H-14 ................. Inspection page H-18 Gartner Banana

OUTLINE, TROUBLESHOOTING GUIDE H OUTLINE SPECIFICATIONS I Clutch control L' Clutch cover Clutch disc Clutch pedal - Enginerrransmission BP DOHC item - M15M-D 1 Master cvlinder inne I Hydraulic Inner diameter mm {in) I 150 (5.91) I Pressure plate side I n n rn cr Tvpe . . Set load N {kgf, Ibf) Outer diameter mm {in) Pedal ratio 6.13 Full stroke mm {in) I 120 (4.72) Diaphraam spring .-.- 4,310 (440,968) 21 5 18.46) . - Height mm {in) * diameter mm {in) TROUBLESHOOTING GUIDE . - I 75--185 i6.89--7.283 15.87 (0.625) . - Release cylinder inner diameter mm {in) Clutch fluid I Problem I Possible Cause 19.05 i0.750) FMVSS116 DOT-3 Clutch disc facing surface hardened or oil on surface Pressure plate damaged u Diaphragm spring damaged or weak lnsufficient clutch pedal play I Slipping I Clutch disc facing worn excessively I Flywheel damaged Faulty disengagement I Clutch disc damaged or excessive runout Clutch disc spines rusted or worn Oil on clutch disc facing Diaphragm spring weak Excessive clutch pedal play Insufficient clutch fluid Leakage of clutch fluid I 1 Clutch disc facing hardened or damaged Clutch vibrates when accelerating I I Clutch disc facing rivets loose Oil on clutch disc facing Torsion dampers weak Clutch pedal stlcks Abnormal noise Pressure plate damaged or excessive runout Flywheel surface hardened or damaged Loose or worn engine mount Pedal shaft not pro~erlv lubricated Clutch release collar damaged Poor lubrication of release collar sleeve Torsion dampers weak Excessive crankshaft end play I I Pilot bearing worn or damaged I I Worn ~ivot points of release fork Action Replace Repair or replace Repair or replace Replace Adjust ~ebair or replace Replace Remove rust or replace Repair or replace Replace Adjust Add fluid Locate and repair or replace Repair or replace Replace Repair or replace Replace Replace Repair or replace Tighten or replace Lubricate or replace Replace Lubricate or replace Replace Repair Replace Repair or replace Page H-14 H-14 H-14 H-14 H-14 H-14 section B H- 6 H-14 H-14 H-14 section B H-14 H-14 45UOHX-OC Gartner Banana

H CLUTCH FLUID CLUTCH FLUID PREPARATION 49 0259 7708 For air bleeding Whench, flare nut REPLACEMENT Caution Clutch fluid will damage painted surfaces. If clutch fluid does get on a painted surface, wipe it off immediately. 1. Drain the fluid from the reservoir by using a suction pump. (Refer to section P.) 2. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder screw. 3. Insert the other end of the vinyl hose into a clear contain- er. 4. Loosen the bleeder screw by using the SST. 5. With another person slowly pumping the clutch pedal, drain the fluid from the clutch system. 6. Repeat step 5 until all the fluid is drained. 7. Modify the bleeder screw tightening torque to allow for ,-, a torque wrench-SST combination (Refer to section GI "Torque Formulas".) 8. Tighten the bleeder screw by using the SST. Tightening torque: 5.9--8.8 N.m (60-90 kgf.cm, 53-78 in4bf) 9. Fill the reservoir to MAX with new fluid of the specified type. 10. Bleed the air from the clutch. (Refer to page H-9.) 11. Check for correct clutch operation. 12. Verifv that there is no fluid leakaae. Gartner Banana