battery MAZDA MX-5 1994 Manual PDF

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

FUEL SYSTEM SYSTEM OPERATION Fuel Pressure Hold Inspection 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 "Fuel Line Safety Procedures" on page F-108. 1. Disconnect the negative battery terminal. 2. Install a fuel pressure gauge between the fuel pipe and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Connect data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON for 10 sec. to operate the fuel Pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min. Fuel pressure: More than 147 kPa (1.5 kgf/cm2, 21 psi) 8. If not as specified, perform the following inspections. Fuel pump hold pressure (Refer to page F-114.) Pressure regulator hold pressure (Refer to page F-118.) Fuel injector fuel leakage (Refer to page F-120.) Gartner Banana

FUEL SYSTEM Fuel Line Pressure Inspection 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 "Fuel Line Safety Procedures" on page F-108. 1. Disconnect the negative battery terminal. 2. Install a fuel pressure gauge between the fuel pipe and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Connect data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON. 6. Measure the fuel line pressure. Fuel line pressure: 265-31 4 kPa {2.7-3.2 kgf/cm2, 38-46 psi) Pressure low- Check fuel pump maximum pressure. (Refer to page F-115.) If as specified, fuel line or fuel filter might be clogged or restricted. Pressure high- Replace the pressure regulator. (Refer to page F-118.) Gartner Banana

FUEL SYSTEM FUEL TANK Removal 1 Inspection / Installation b Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. 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 "Fuel Line Safety Procedures" on page F-108. Warning Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before re- pairing it. 1. Disconnect the negative battery terminal. 2. Drain the fuel from the fuel tank. 3. Remove the main silencer. (Refer to page F-128.) 4. Remove the power plant frame. (Refer to section J.) 5. Remove in the order shown in the figure, referring to Removal note. 6. Install in the reverse order of removal, referring to Installation note. Gartner Banana

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

F FUEL SYSTEM FUEL PUMP Inspection Fuel pump operation 1. Connect the data link connector terminals F/P and GND , with a jumper wire. 2. Remove the fuel filler cap. 3. Turn the ignition switch ON. 4. Listen for operational sound of the fuel pump at the filler inlet. 5. Install the fuel filler cap. 6. If no sound was heard, measure the voltage between the fuel pump connector wire to ground. Voltage: Battery positive voltage 7. If not correct, check the fuel pump relay and its circuits. (Refer to page F-116.) 8. If the voltage is normal, check for continuity between fuel pump connector (6) and a ground. 9. If there is continuity, replace the fuel pump. 10. If no continuity, repair the ground circuit. Hold pressure Perform this inspection if the fuel pressure hold inspec- tion is not as specified. (Refer to page F-109.) Warning Fuel line spills and leaks can be dangerous. Fuel can ignite and cause serious injuries or death and can damage the vehicle. Fuel can also irritate skin and eyes. To prevent this from happening, release the fuel pressure according to "Fuel Line Safety Procedures" on page F-108. 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge to the fuel main pipe and plug the outlet of the fuel pressure gauge as shown. (Install clamps as shown.) 3. Connect the negative battery terminal. Gartner Banana

FUEL SYSTEM 4. Connect data link connector terminals FIP and GND with a jumper wire. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min. Fuel pressure: More than 343 kPa (3.5 kgf/cm2, 50 psi) 8. If not as specified, replace the fuel pump. Fuel pump maximum pressure Warning Fuel line spills and leaks can be dangerous. Fuel can ignite and cause serious injuries or death and can damage the vehicle. Fuel can also irritate skin and eyes. To prevent this from happening, release the fuel pressure according to "Fuel Line Safety Procedures" on page F-108. 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge to the fuel main pipe and plug the outlet of the fuel pressure gauge as shown. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Connect data link connector terminals FIP and GND with a jumper wire. 5. Turn the ignition switch ON to operate the fuel pump. 6. Measure the pump maximum pressure. Fuel pump maximum pressure: 480-657 kPa (4.9-6.7 kgf/cm2, 69-95 psi) 7. Turn the ignition switch OFF and disconnect the jumper wire. 8. If not as specified, replace the fuel pump. Replacement Warning Fuel line spills and leaks can be dangerous. Fuel can ignite and cause serious injuries or death and can damage the vehicle. Fuel can also irritate skin and eyes. To prevent this from happening, release the fuel pressure according to "Fuel Line Safety Procedures" on page F-108. Gartner Banana

FUEL SYSTEM F FUEL PUMP RELAY Inspection Apply battery positive voltage and a ground to the termi- nals below and check the fuel pump relay operation as described. If not as specified, replace the fuel pump relay. B+: Battery positive voltage Replacement 1. Remove the undercover. B+ A 2. Remove the fuel pump relay. 3. Install in the reverse order of removal. Grounded B Correct result C - E: Continuity Gartner Banana

F FUEL SYSTEM PRESSURE REGULATOR Inspection Fuel line pressure d Warning Fuel line spills and leaks can be dangerous. Fuel can ignite and cause serious injuries or death and can damage the vehicle. Fuel can also irritate skin and eyes. To prevent this from happening, release the fuel pressure according to "Fuel Line Safety Procedures" on page F-108. 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge between the fuel main pipe and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Start the engine and run it at idle. 5. Measure the fuel line pressure. Fuel line pressure: 21 6-264 kPa (2.2-2.7 kgf/cm2, 32-38 psi) Hold pressure Perform this inspection if the fuel pressure hold inspec- tion is not as specified. (Refer to page F-104.) Warning Fuel line spills and leaks can be dangerous. Fuel ,-, can ignite and cause serious injuries or death and can damage the vehicle. Fuel can also irritate skin and eyes. To prevent this from happening, release the fuel pressure according to "Fuel Line Safety Procedures" on page F-108. 1. Disconnect the negative battery terminal. 2. Install a fuel pressure gauge between the fuel pipe and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Connect data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Block the outlet of the pressure regulator. 8. Observe the fuel pressure for 5 min. Fuel pressure: More than 147 kPa {I .5 kgf/cm2, 21 psi) 9. If pressure is as specified, replace the pressure regula- tor. Gartner Banana

FUEL SYSTEM 1. Disconnect the negative battery terminal. 2. Remove the PCV hose. 3. Disconnect the vacuum hose. 4. Disconnect the fuel injector connectors. 5. Remove the fuel distributor and the pressure regulator. 6. Remove the grommets, fuel injectors, and insulators. Inspection Fuel leakage test 1. Firmly affix the fuel injectors to the fuel distributor with wire. 2. Disconnect the fuel injector connectors. 3. Remove the fuel distributor and fuel injectors together with the fuel hoses connected. 4. Connect data link connector terminals FIP and GND with a jumper wire. 5. Turn the ignition switch ON. 6. Tilt the fuel injectors approx. 60 degrees and verify that no fuel leaks from the fuel injector nozzles. 7. If fuel leaks from an fuel injector, replace it. Leakage Specification If there is more than one drop per 2 minutes, replace the fuel injector. d 8. Turn the ignition switch OFF and remove the jumper wire. Gartner Banana