MAZDA MX-5 1994 Workshop Manual

T CRUISE CONTROL SYSTEM TROUBLESHOOTING Before troubleshooting the system, check the following items: 1. Is the customer using the system correctly? 2. Is the fuse burnt? If it is, replace it after checking and repairing the wiring harness. d Symptom: Vehicle speed cannot be set. (Cruise control unit will not hold vehicle speed.) 45UOTX-189 ("pj") SRUISE MAIN Step 1 1. Turn the ignition switch ON. 2. Turn the cruise control main switch ON. 3. Check that the main switch indicator light comes ON. 4. If the light does not come ON, go to Step 2. 5. If the light comes ON, go to Step 3. Step 2 1. Check for continuity between the terminals of the cruise control main switch. Neutral OFF I Position M: Continuity 2. If not as specified, replace the switch. 3. If the switch is OK, repair the wiring harness. (METER 15A fuse - Cruise control main switch - GND) Terminal A~B~D~F~G~H Step 3 1. Measure the voltage at the following terminal wires of the cruise control unit connector. Disconnect the CIS control unit connector before measuring the voltage at terminal J. 2. If all terminal voltage are OK, replace the cruise control unit. -- / Gartner Banana

CRUISE CONTROL SYSTEM B+: Battery Dositive voltage erminall Win color . . .. Action Connected to Cruise actuator Cruise actuator Test condition Main switch OFF Main switch ON Cruise A\actuator Specification Main switch OFF Main switch ON PCMT OV 9V Main switch OFF . Main switch ON Brake switch Go to Step 8 OV . 9V Ignition switch OFF lanition switch ON ParklNeutral switch Cruise control Main switch ON switch (Set switch and coast switch) Check main switch OV 9V - Brake pedal depressed Brake ~edal released Clutch switch Check main switch OV B+ Shift to "N" or "P" range Shift to other ranae Go to section K OV 9V Clutch pedal depressed Clutch pedal released Stoplight switch Go to Step 4 OV 5V Cruise control switch (Resume switch and accel switch) speed I While rotating rear tires I beMeenM,, sor Run I GO to Step 9 Go to section K OV B+ Brake pedal depressed Brake pedal released Cruise actuator I I I Battery 1 Constant I B+ I Repair wiring harness Go to Step 5 Main switch ON While turning resume switch after main switch ON B+ OV Main switch OFF Step 4 - Inspection of brake switch 1. Disconnect the brake switch connector. 2. Check for continuity between terminals of the switch. Go to Step 7 B+ OV OV GND 1 Constant Pedal position Go to Step 6 OV I Repair wiring harness Terminal A B 1 I Main switch ON 9V 45UOTX-19 Go to Step 8 3. If not as specified, replace the brake switch. 4. If the switch is OK, repair the wiring harness (fuse - brake switch - control unit). Pedal released Pedal depressed M: Continuity 0 0 Gartner Banana

T CRUISE CONTROL SYSTEM ~~UOTX-195 3. If not as specified, replace the clutch switch. 4. If the switch is OK, repair the wiring harness (fuse - clutch switch - control unit). w B A CRUISE CONTROL UNIT I Step 5 - lnspection of clutch switch 1. Disconnect the clutch switch connector. 2. Check for continuity between terminals of the switch. I RESUMUACCEL I 0 I 0 I m: Continuity Step 6 - lnspection of cruise control switch 1. Remove the knee protector and disconnect the com- bination switch connector. 2. Check for continuity between terminals of the combina- tion switch connector. ./ 3. If not as specified, replace the cruise control switch. 4. If the switch is OK, repair the wiring harness (cruise con- trol switch - control unit). Pedal position Pedal released Pedal depressed Switch Step 7 - lnspection of stoplight switch 1. Disconnect the stoplight switch. 2. Check for continuity between terminals of the switch. W: Continuity Terminal Terminal A 0 SE Pedal position 3. If not as specified, replace the stoplight switch. 4. If the switch is OK, repair the wiring harness (cruise con- trol unit - stoplight switch). B 0 RE I E Terminal A B i Pedal released Pedal depressed m: Continuity 4 0 0 Gartner Banana

CRUISE CONTROL SYSTEM Step 8 - lnspection of actuator 1. Measure the cruise actuator solenoid resistance by us- ing an ohmmeter. Check terminals C-A 2. If not as soecified. redace the actuator. Resistance C-B C-D 3. If continuiiv is OK: ad to Ster, 84. Approx. 25 to 55R 4. ~isconne4 the actiator cabie from the accelerator ped- al. 5. Run the engine at idle speed. 6. Apply battery positive voltage to the following terminals, and check actuator operation. B+: Batterv aositive voltaae I Order 1 2 7. If not as specified, replace the actuator. Terminal condition AlBlClD 3 4 Step 9 - lnspection of vehicle speed sensor 1. Remove the instrument cluster. 2. Check for continuity between terminals 2D and 2F while rotating the speedometer cable. 3. If there are not four pulses per shaft rotation, replace the vehicle speed sensor. (Refer to page T-32.) 4. If there are four pulses per rotation, check the wiring har- ness. (instrument cluster - control unit). 5. If the wiring is OK, replace the cruise control unit. Operation of control cable GND GND GND - GND - - B+ B+ B+ - GND GND Pull Hold - - Extend Release Gartner Banana

T CRUISE CONTROL SYSTEM SELF-DIAGNOSTIC INSPECTION Self-diagnostic Function The Self-diagnostic function integrated within the cruise control unit diagnoses the condition of the cruise control system. 4 Conditionfoperation codes are indicated by flashing of the test light connected to the control unit. (Refer to condition code numbers on pages T-101, 102.) This operation continues until canceled. 45UOTX-201 Principle of Code Cycle Condition and operation codes are determined by flashing of the test light connected to the control unit as shown below. 03UOTX-140 1. Code cycle break The time between conditionloperation code cycles is 4.0 seconds (the time the light is off). CONDITION/OPERATION * ODE CYCLE BREAK - - 4.0 sec 2. Second digit of conditionloperation code (ones position) The digit in the ones position of the conditionloperation code represents the number of times the light is on 014 second during one cycle. - CONDITION/OPERATION 1 CYCLE CODE CODE: 03 ON OFF .. ... 4.0 4.0 4.0 SeC sec sec 3. First digit of conditionloperation code (tens position) The digit in the tens position of the conditionloperation code represents the number of times the light is on 1.2 seconds during one cycle. The light remains off for 1.6 seconds between the long and short flashes. MALFUNCTION 1 CYCLE MALFUNCTION CODE CODE: 22 FIRST DlGlT SECOND DIGIT 45UOTX-204 - - 1.2- 0.4. 1.6 - -- - C CYCLE BREAK * C 4.0 sec sec Gartner Banana

CRUISE CONTROL SYSTEM T Inspection Procedure Self-diagnosis 1. Connect a 1.4W test light between terminals D and F, of the cruise control unit connector. Note There is no wire in terminal D of the connector. Push the test light through the connector and touch the cor- responding pin on the control unit. 2. Turn the ignition switch to ON. 3. Turn the cruise control on by pressing the MAlN switch. The MAlN indicator light will come on. 4. Press and hold the RESUMEIACCEL switch for more than 3 seconds. The test light will illuminate for 3 se- conds and go out for 2 seconds. 5. The on-board diagnosis system is activated and the test light will flash if there is a problem. Refer to the chart be- low to obtain the problem code number. Note The cruise control system will not operate in self-diag- nosis mode. 6. After retrieving the code(s), drive the vehicle at more than 16 kmlh (10 MPH) or press the MAlN switch to deactivate self-diagnosis. The MAlN indicator light will go off. 7. Follow the action corresponding to the problem code. Service Code Table If there are two or more problems in the system, the problem with the highest priority will be indicated. Priority Pattern of output signal ON 2 OFF n 4 OFF ON 5 OFF I No. Code I Possible cause Defective wiring (Cruise actuator- Cruise control unit, Stoplight switch-Cruise control unit) 01 Defective actuator Defective stoplight switch (For O5 1 Defective wiring (Fuse - Cruise control unit) Both stoplight and brake switch (for 07 vehicle and cruise) are ON simulta- neously Defective SETICOAST, or RESUMEIACCEL switch l5 1 Defective cruise control unit Action Repair harness lnspect actuator (Refer to page T-107) Inspect brake switch (Refer to page T-105) Replace fuse Repair harness Inspect stoplight and brake switch (Refer to pages T-105 and T-56) Inspect cruise control switch (Refer to page T-106) Go to troubleshooting Gartner Banana

T 2 CRUISE CONTROL SYSTEM PRESS 45UOTX-209 Inspection Procedure Quick inspection 1. Connect a 1.4W test light between terminals D and F, of the cruise control unit connector. u Note There is no wire in terminal D of the connector. Push the test light through the connector and touch the cor- responding pin on the control unit. 2. Turn the ignition switch to ON. 3. Shift the selector lever to D or R range. 4. Verify that the MAlN switch is off. (The MAlN indicator light will be off .) 5. Turn the RESUMEIACCEL switch and the MAlN switch simultaneously to activate the system inspection. The MAlN indicator light will come on. 6. Operate each switch as described below and obtain the problem code numbers. Note The cruise control system will not operate in self-diag- nosis mode. 7. After retrieving the code(s), press the MAlN switch to deactivate the system inspection. The MAlN indicator light will go off. 8. Follow the action corresponding to the problem code. --, Service Code Table Press SETICOAST switch Procedure Press RESUMEIACCEL switch Pattern of output signal (Test light) ON OFF nn M nn Depress brake pedal ON OFF ON Drive vehicle above 40 km/h (25 MPH) Turn ignition switch to ON and shift the selector lever to P or N range (For AT) Depress clutch pedal (For MT) Code No. oN OFF Action lnspect cruise control switch (Refer to page T-106) lnspect cruise control switch (Refer to page T-106) lnspect stoplight switches (Refer to pages T-105 and T-56) lnspect parwneutral switch (Refer to section K) or clutch switch (Refer to page T-105) lnspect vehicle speed sensor or wire harness (Refer to page T-106) Gartner Banana

CRUISE CONTROL SYSTEM T T P N L JHF B T P N L JHF B CRUISE CONTROL UNIT Removal 1. Remove the passenger side kick panel. 2. Remove the nut and the control unit. Installation Install in the reverse order of removal. Inspection 1. Check the terminal voltages of the control unit. Discon- nect the CIS control unit connector before measuring the voltage at terminal J. 2. If the terminal voltages are correct, replace the control unit. B+: Battery positive voltage berminail Wire color I Connected to I Test condition 1~~ecificationl Action A B C E F (GN) ' (GIB) (G/O) (R) (YIB) G H PCMT (LGIB) J Cruise actuator Cruise actuator Cruise actuator Main switch Main switch (Y) Ignition switch OFF lanition switch ON Main switch OFF Main switch ON Main switch OFF Main switch ON Main switch OFF Main switch ON Main switch OFF Main switch ON Main switch OFF Main switch ON Brake switch (BIL) (BWW) OV B+ Shift to "N" or "P" range Shift to other range Clutch pedal depressed Clutch pedal released ParkINeutral switch Clutch switch OV 9V OV 9V ov 9V B+ OV OV B+ Check AT control unit (Refer to section K) - Brake pedal depressed Brake pedal released Check cruise actuator (Refer to page T-107) Check main switch (Refer to page T-106) OV 5V OV B+ OV 9V Check parWneutral switch (Refer to section K) Check clutch switch (Refer to page T-105) Check brake switch (Refer to page T-105) Gartner Banana

CRUISE CONTROL SYSTEM B+: Battery positive voltage L rmlnall Wire color M Specification (RIL). . N Action Connected to (G) 0 CELERATOR DAL 9MUOTX-263 Test condition Cruise control switch (Set switch and coast switch) (w) P S T ACTUATOR CABLE Removal 1. Disconnect the actuator cable from the accelerator ped- al. 2. Remove the clamp at the inside of the firewall. (P) 3. Disconnect the actuator cable from the actuator. 4. Remove the clamps and the actuator cable. Main switch ON While turning set switch after main switch ON Check stoplight switch (Refer to page T-105) Stoplight switch Cruise control switch (Resume switch and accel switch) (WIG) (B) Installation Install in the reverse order of removal. Adjustment Remove the clamp and adjust the nut so that actuator cable free play is as shown when the cable is pressed lightly. B+ OV Brake pedal depressed I B+ Main switch ON While turning resume switch after main switch ON Actuator Cable play: 1 .O-3.0mm (0.04--0.12 in) Brake pedal released OV 9V Main switch OFF Main switch ON Vehicle speed sensor Battery GND Check cruise control switch (Refer to page T-106) OV B+ OV Check actuator (Refer to page T-107) Run out betweeno-5V B+ OV rotating rear tires Constant Constant d Check cruise control switch (Refer to page T-106) Check vehicle speed sensor (Refer to page T-106) Repair wire Re~air wire Gartner Banana

CRUISE CONTROL SYSTEM T BRAKE AND STOPLIGHT SWITCH CLUTCH SWITCH Removal Loosen the locknut and remove the switch. Installation Install in the reverse order of removal. Adjustment Adjust the switch to set the specified pedal height. Pedal height: 175--185mm (6.89-7.82 in) Pedal free play: 0.6-3.lmm (0.02-4.12 in) Inspection 1. Disconnect the clutch switch connector. 2. Check for continuity between terminals of the switch. Pedal position Terminal A B 1 0-a: Continuity Pedal released 3. If not as specified, replace the clutch switch. Pedal de~ressed STOP LIGHTIBRAKE SWITCH Removal Loosen the locknut and remove the switch. 0 I 0 Installation Install in the reverse order of removal. Adjustment Adjust the switch to set the specified pedal height. Pedal height: l7l-l8l mm (6.93--7.13 in) Pedal free play: 4.0-7.0mm (0.16-0.28 in) Inspection 1. Disconnect the brake switch connector. 2. Check for continuity between terminals of the switch. I I I Pedal released I I I Pedal position w: Continuity Terminal Pedal depressed 3. If not as specified, replace the brake switch. 4. If the switch is OK, repair the wiring harness (fuse - brake switch - control unit). A 0 I 0 B Gartner Banana