fuel pressure MAZDA MX-5 1994 Workshop Manual

SAE STANDARDS SAE STANDARDS In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have 4 been used in Mazda manuals up to now and their SAE equivalents. 46UGIX-047 Engine and Emission Systems Accelerator Pedal Air Cleaner Housing I Mixture Control Solenoid I F2 Carburetor ] Abbreviation AP ACH MCS VAF M AF Abbreviation - - - - - Volume Airflow Sensor I I Name Accelerator Pedal Air Cleaner AirlFuel (NF) Solenoid Valve Airflow Meter Airflow Sensor I Mass Airflow Sensor I I Alternator I I - - - -~ I Barometric Absolute Pressure I I Sensor I I Alternator Atmospheric Pressure Sensor I - 1 Carburetor CARB 1 Catalytic Converter OC ALT BAR0 Carburetor 1 Oxidation Catalvst I - - - - - I Direct Ignition I DL1 EG I 1 Electronic Gasoline lniection Svstem I CIS Three Way Catalyst Warm Up Three Way Catalyst Fuel Pump Relay Coolant Fan Control Crankshaft Position Sensor Data Link Connector Circuit Opening Relay Cooling Fan Control Crank Angle Sensor Diaanosis Connector Distributorless Ignition I Continuous Fuel lniection Svstem I 1 #1 #2 FPR C FC CPS DLC I Previous Standard SAE Standard Name I Remark - ( Electronic Spark Ignition EGR Gas Sensor EGR Position Sensor EGR Position Switch El Electronic Ignition 1 #3 EGR Function Control I - I EGR Modulator Solenoid I EGRC 4 ECU I Evaporative Emission Control Svstem I EVAP - - I -,--- I - I Exhaust Gas Recirculation System I EGR Engine Control Unit PCM PCME Engine Modification Ennine Speed EM RPM - - - - - Feedback System Flexible Fuel - I Intercooler Powertrain Control Module I #5 I EGR Function Sensor CLS FF Fuel Pump IC Regulator Intake Air Thermosensor CAC I Powertrain Control Module (Engine) I #4 FP VR IATS - I ISC Solenoid Valve I IACV Engine Modification I Engine Speed - Fuel Evaporative System I Exhaust Gas Recirculation 1 System name 1 Closed Loop System I Flexible Fuel Knock Sensor I I - ( Knock Sensor I KS I Malfunction Indicator Light I I - I Malfunction Indicator Liaht MIL Multiport Fuel Injection Oxidation Catalyst - 1 Multiport Fuel Injection #1: Directy connected to exhaust manifold #2: In some models, there is a "Fuel Pump Relay" that controls pump speed. That relay is now called the 'Fuel Pump Relay (Speed)". #3: Controlled by the PCME (PCM) 4 #4: EGR valve controller device name #5: Device that controls engine and powertrain MFI - 1 Oxidizina Converter OC Gartner Banana

SAE STANDARDS Engine and Emission Systems (cont'd) I Previous Standard I SAE Standard b I - Abbreviation ( Name I Oxvaen Sensor - .w- - I I ." I 02s I Oxygen Sensor I - PTC Reed Valve Relief 1 Solenoid Valve Secondary Air lnjection System - Seauential Fuel lniection SMFl L - Service Code(s) DTC - Spark Ignition Dl - Supercharger SC Abbreviation I Name Open Loop Positive Temperature Coefficient Hnatar Secondarv Air Pulse Valve Remark . .--.-. Pressure Sensor Secondary Air Bypass valve Pulsed Secondarv Air lniection H02S I Heated Oxvaen Sensor I With heater OL EFE Secondary Air lnjection Sequential Multipoint Fuel lnjection Diagnostic Trouble Code(s) Open Loop Early Fuel Evaporation MAP MVS Distributor lgnition Supercharger Manifold Absolute Pressure Sensor Manifold Vacuum Sensor I - - - - - - Checks vacuum only Pulsed iniection - Switching Solenoid Valve Test Mode(s) Three Way Catalyst Throttle Body Throttle Sensor Turbocharaer .. Maifold Differential Pressure Manifold Vacuum Zone Switch , - I - 1 VAC I MDP 1-1 Water Thermosensor L - I Vacuum Switch I ECTS I Engine Coolant Temperature Sensor I SASV DTM TWC TB TPS TC MVZS #6: Supplies air to three way catalyst #7: Diagnostic trouble codes depend on the test mode - Secondary Air Switching Valve Diagnostic Test Mode(s) Three Way Catalyst Throttle Body Throttle Position Sensor Turbocharaer Transmission (Transaxle) and Steering System L - - Previous Standard I I I I Abbreviation - - - SAE Standard Fully Open Inhibitor Switch - I Lock-up Position - - Name Clutch Position EC-AT Control Unit Fullv Closed Abbreviation CPP PCMT CTP TCC I Torque Converter Clutch - - - WOT PNS Output Signal(s) Overdrive I Name Clutch Pedal Position Powertrain Control Module (Transaxle) Powertrain Control Module (Transmission) Closed Throttle Position Wide Open Throttle ParWNeutral Switch Power Steering Pressure Switch Pulse Generator Vehicle Speed Sensor - 1 3rd Gear Remark FF FR PTCS 4GR 3GR I Third Gear Powertrain Control Signal(@ Fourth Gear SPS VSPG VSS Steering Pressure Sensor Vehicle Speed Pulse Generator Vehicle Speed Sensor Gartner Banana

PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE The following items may be done at any time prior to delivery to your customer. INSPECT and ADJUST, if necessary, the following items to specification: 0 Glass, exterior bright metal and paint for damage 0 Convertible top and detachable hardtop (if equipped) for damage 0 Wheel lug nuts and locks 89-117 N.m (9-1 2 kgf.m, 66-86 ft4bf) 0 All weatherstrips for damage or detachment Operation of hood release and lock Operation of fuel lid 0 Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps (if equipped) 0 Outside mirror(s) 0 Mast antenna (if equipped) UNDER HOOD-ENGINE OFF INSPECT and ADJUST, if necessary, the following items to specification : Fuel, coolant, and hydraulic lines, fittings, connections, and components for leaks Engine oil level 0 Power steering fluid level (if equipped) Brake and clutch master cylinder fluid level 0 Windshield washer reservoir fluid level 0 Radiator coolant level and specific gravity 0 Tightness of battery terminals pKiq INSTALL the following parts: CHECK operation of the following items: 0 Seat controls (sliding and reclining) 0 Door locks 0 Seat belts and warning system 0 Air bag system using indicator light (Refer to section T) Ignition switch and steering lock 0 Starter interlock switch (clutch pedal) All lights, including warning, and indicator lights 0 Audible warning system 0 Horn, wipers, and washers Audio system 0 Cigarette lighter Power windows (if equipped) 0 Power outside mirrors (if equipped) 0 Heater, defroster, and air conditioner at all mode selections (if equipped) CHECK the following items: Presence of spare fuses 0 Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: 0 Pedal height and free play of brake and clutch pedals I Pedal height mm {in} I Ft: $iy I Clutch pedal {6.89--7.28) (with carpet) Parking brake 7-9 notchesil96 N (20 kgf, 44 Ibf) 0.63.1 (0.024. 12) Brake pedal RUNNING AT OPERATING TEMPERATURE CHECK the following items: 0 Automatic transmission oil level 171-181 (6.73--7.13) (with carpet) I ON HOIST I 4--7 {0.16-0.28} CHECK the following items: 0 Underside fuel, coolant, and hydraulic lines, fittings, con- nections, and components for leaks 4 Tires for cuts or bruises 0 Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage Manual transmission oil level Differential oil level I ROAD TEST I CHECK the following items: Brake operation Clutch operation 0 Steering control 0 Operation of meters and gauges Squeaks, rattles and unusual noises 0 Overall engine performance Seat belt emergency locking retractors 0 Cruise control system (if equipped) I AFTER ROAD TEST I CHECK for necessary owner information materials, tools and spare tire in vehicle The following items must be done just before the delivery to your customer. 0 Load test battery and charge if necessary -1 Install fuses for accessories Adjust tire pressure to specification Load test fesuk 0 Remove seat and floor mat protective covers (Refer to Door Label) 0 Vacuum and clean interior of vehicle Clean outside of vehicle Inspect installation of option parts with invoice 45UOAX-002 Gartner Banana

OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS Engine Item Tv~e BP DOHC Gasoline, 4-cvcle . . I -, Dis~lacement ml kc. cu inl I 1.840 (1.840. 11 2) I Cylinder arrangement and number Combustion chamber Valve system Bore x stroke mm {in) I 83.0 x 85.0 (3.27 x 3.35) I In-line, 4-cylinders Pentroof DOHC, belt-driven Com~ression ratio I 9.0 I Compression pressure kPa (kgf/cm2, psi)-rpm .- . 1 open (BTDCO) 1,255 {I 2.8, 182)-300 5 Valve timing TROUBLESHOOTING GUIDE tX Valve clearance Problem .. . -. . Difficult starting ' With System Selector (49 B019 9AO) test switch at SELF TEST. 45uo~x-003 Close (ATDCO) IN mm {in) EX mm {in) Poor idling Close (ABDCO) Open (BBDCO) 14 0: Maintenance-free 0: Maintenance-free Excessive oil consumption 48 56 Possible Cause Malfunction of engine-related components Burned valve Worn piston, piston ring, or cylinder Failed cylinder head gasket Malfunction of fuel system Malfunction of ignition system Malfunction of engine-related components Malfunction of HLA' Poor valve-to-valve seat contact Failed cvlinder head aasket Oil leakage I Refer to section D I I Remedy Malfunction of fuel system Malfunction of ignition system Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder Oil working down Worn valve seal Worn valve stem or guide Page Replace Replace or repair Replace Refer to section F Refer to section G Replace Replace or repair Re~lace 8-48 B-53,55 B-1 6 B-20 B-50 B-1 6 Refer to section F Refer to section G Replace Replace or repair Replace Replace B-55 B-53,55 B-39,70 8-48 Gartner Banana

REMOVAL 6 Removal Note PIS oil pump 1. Remove the PIS oil pump with the hoses still connected. 2. Position the pump away from the engine and affix it with wire. 45UOBX-051 AIC compressor (If equipped) 1. Remove the NC compressor with the hoses still con- nected. 2. Position the compressor away from the engine and affix it with wire. I I 45UOBX-052 Step 2 Disconnect the harness connectors shown in the figure. 6 1. Steering pressure sensor 2. Throttle position sensor 3. Idle air control valve 4. Heated oxygen sensor 5. Ignition coil 6. Crankshaft position sensor 7. Ground 8. Fuel injector 9. Alternator 10. Oil pressure switch 11. Starter Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . FUEL AND EMISSION CONTROL SYSTEMS INDEX ............................ F- 2 ......................... OUTLINE F- 5 .............. SYSTEM DIAGRAM F- 5 VACUUM HOSE ROUTING DIAGRAM ...................... F- 6 WIRING DIAGRAM ............... F- 7 SPECIFICATIONS ............... F- 8 COMPONENT DESCRIPTIONS ... F- 9 ....... TROUBLESHOOTING GUIDE F- 11 ENGINE CONTROL OPERATION CHART ........................ F- 11 RELATIONSHIP CHART .......... F- 12 USING THIS SECTION ........... F- 13 DIAGNOSTIC INDEX ............. F- 15 SYMPTOM TROUBLESHOOTING . F- 17 PREPARATION ................... F- 75 ............. BASIC INSPECTION F- 75 .................. ADJUSTMENT F- 76 ON-BOARD DIAGNOSIS SYSTEM . . F- 78 DESCRIPTION .................. F- 78 PREPARATION .................. F- 79 DIAGNOSTIC TROUBLE CODE NUMBER ...................... F- 79 ... SWITCH MONITOR FUNCTION F- 95 INTAKE AIR SYSTEM .............. F- 98 COMPONENTS .................. F- 98 SYSTEM OPERATION ............ F-100 THROTTLE BODY ............... F-101 INTAKE MANIFOLD .............. F-102 ACCELERATOR PEDAL AND CABLE ........................ F-103 IDLE SPEED CONTROL SYSTEM ... F-104 DESCRI PTlON .................. F-104 PREPARATION .................. F-105 BAC VALVE ..................... F-105 IDLE AIR CONTROL VALVE ....... F-106 FUEL SYSTEM .................... F-107 DESCRIPTION .................. F-107 PREPARATION .................. F-108 SYSTEM OPERATION ............ F-109 FUEL TANK ..................... F-111 FUEL FILTER .................... F-113 FUEL PUMP .................... F-114 FUEL PUMP RELAY .............. F-117 PRESSURE REGULATOR ........ F-118 FUEL INJECTOR ................ F-119 PRESSURE REGULATOR CONTROL SYSTEM ......................... F-122 PRC SOLENOID VALVE .......... F-123 EXHAUST GAS RECIRCULATION (EGR) ........................... F-124 PREPARATION .................. F-124 .................. DESCRIPTION F-124 SYSTEM OPERATION F-125 ............ EGR SOLENOID VALVE (VACUUM) F-125 EGR SOLENOID VALVE (VENT) ... F-126 ......... EGR FUNCTION SENSOR F-126 ........... EGR CONTROL VALVE F-127 ................ EXHAUST SYSTEM F-128 .................. COMPONENTS F-128 OUTLINE OF EMISSION CONTROL ......................... SYSTEM F-129 ............. STRUCTURAL VIEW F-129 POSITIVE CRANKCASE VENTILATION ................... (PCV) SYSTEM F-130 ' DESCRIPTION .................. F-I ..................... PCV VALVE F-1 ..... FUEL EVAPORATIVE SYSTEM F- .................. DESCRIPTION F- ....... PURGE SOLENOID VALVE F- ........ TWO-WAY CHECK VALVE F- ...... THREE-WAY CHECK VALVE F- ............. FUEL VAPOR VALVE F- .......... CHARCOAL CANISTER F- CATALYTIC CONVERTER SYSTEM . F- .................. DESCRIPTION F- .......... THREE-WAY CATALYST F- AIC CUT-OFF CONTROL SYSTEM . . F- .................. DESCRIPTION F- ........... SYSTEM INSPECTION F- ...................... A/c RELAY F-1 36 ..... DECHOKE CONTROL SYSTEM F-137 .................. DESCRIPTION F-137 ......... COOLANT FAN CONTROL F-138 ....................... OUTLINE F-138 .................. COOLANT FAN F-139 ............... CONDENSER FAN F-139 ........... SYSTEM INSPECTION F-140 ........... COOLANT FAN RELAY F-140 ........ CONDENSER FAN RELAY F-140 ............... CONTROL SYSTEM F-141 .................. PREPARATION F-141 ............. STRUCTURAL VIEW F-142 POWERTRAIN CONTROL MODULE .............. (ENGINE) (PCME) F-143 ........ MASS AIRFLOW SENSOR F-152 CRANKSHAFT POSITION SENSOR F-153 ENGINE COOLANT TEMPERATURE ...................... SENSOR F-154 THROTTLE POSITION SENSOR . . F-154 HEATED OXYGEN SENSOR ...... F-156 MAIN RELAY .................... F-157 ............... CLUTCH SWITCH F-157 NEUTRAL SWITCH .............. F-157 STEERING PRESSURE SENSOR . F-158 45UOFX-001 Gartner Banana

INDEX INDEX 1. Air cleaner housing 5. Idle air control valve Removal 1 Inspection / Inspection . . . . . . . . . . . . . . . . . . page F-106 lnstallation . . . . . . . . . . . . . . . . . page F-99 6. Pressure regulator 2. Throttle body Inspection . . . . . . . . . . . . . . . . . . page F-118 Removal . . . . . . . . . . . . . . . . . . . . page F-99 Replacement . . . . . . . . . . . . . . . page F-119 lnspection . . . . . . . . . . . . . . . . . . . page F-99 7. Fuel injector Installation . . . . . . . . . . . . . . . . . . page F-99 Inspection . . . . . . . . . . . . . . . . . . page F-119 3. Intake manifold Removal . . . . . . . . . . . . . . . . . . . page F-119 Removal . . . . . . . . . . . . . . . . . . . . page F-99 Installation . . . . . . . . . . . . . . . . . page F-121 Installation . . . . . . . . . . . . . . . . . . page F-99 8. PCV valve 4. Accelerator pedal and cable Inspection . . . . . . . . . . . . . . . . . . page F-130 1 lnspection . . . . . . . . . . . . . . . . . . . page F-99 9. Purge solenoid valve Replacement . . . . . . . . . . . . . . . . page F-99 On-vehicle inspection . . . . . . . . page F-132 lnspection . . . . . . . . . . . . . . . . . . page F-132 Gartner Banana

INDEX 10. Charcoal canister lnspection . . . . . . . . . . . . . . . . . . page F-133 11. Powertrain control module (engine) Removal / Installation . . . . . . . . page F-143 lnspection . . . . . . . . . . . . . . . . . . page F-143 12. Crankshaft position sensor Removal . . . . . . . . . . . . . . . . . . . page F-153 lnspection . . . . . . . . . . . . . . . . . . page F-153 lnstallation . . . . . . . . . . . . . . . . . page F-153 13. Mass airflow sensor System inspection . . . . . . . . . . . page F-152 lnspection . . . . . . . . . . . . . . . . . . page F-152 14. Engine coolant temperature sensor Removal . . . . . . . . . . . . . . . . . . . page F-154 lnspection . . . . . . . . . . . . . . . . . . page F-154 Installation . . . . . . . . . . . . . . . . . page F-154 15. Throttle position sensor lnspection . . . . . . . . . . . . . . . . . . page F-154 Adjustment . . . . . . . . . . . . . . . . . page F-155 Replacement . . . . . . . . . . . . . . . page F-156 16. Heated oxygen sensor lnspection . . . . . . . . . . . . . . . . . . page F-156 Replacement . . . . . . . . . . . . . . . page F-156 17. Main relay lnspection . . . . . . . . . . . . . . . . . . page F-157 18. Clutch switch (MT) lnspection . . . . . . . . . . . . . . . . . . page F-157 Replacement . . . . . . . . . . . . . . . page F-157 19. Neutral switch (MT) lnspection . . . . . . . . . . . . . . . . . . page F-157 Replacement . . . . . . . . . . . . . . . page F-158 20. Steering pressure sensor lnspection . . . . . . . . . . . . . . . . . . page F-158 Replacement . . . . . . . . . . . . . . . page F-158 21. Fuel pump relay lnspection . . . . . . . . . . . . . . . . . . page F-117 Replacement . . . . . . . . . . . . . . . page F-117 22. PRC solenoid valve lnspection (On-vehicle) . . . . . . page F-123 lnspection . . . . . . . . . . . . . . . . . . page F-123 23. EGR solenoid valve (Vacuum) lnspection . . . . . . . . . . . . . . . . . . page F-125 24. EGR solenoid valve (Vent) lnspection . . . . . . . . . . . . . . . . . . page F-126 25. EGR function sensor lnspection . . . . . . . . . . . . . . . . . . page F-126 26. EGR control valve lnspection . . . . . . . . . . . . . . . . . . page F-127 Replacement . . . . . . . . . . . . . . . page F-127 27. NC relay lnspection . . . . . . . . . . . . . . . . . . page F-136 28. Coolant fan relay lnspection . . . . . . . . . . . . . . . . . . page F-140 29. Condenser fan relay lnspection . . . . . . . . . . . . . . . . . . page F-140 Gartner Banana

PURGE SOLENOID VALVE 7* AlC RELAY COOLANT FAN RELAY CONDENSER FAN RELAY STARTER STEERING PRESSURE SENSOR AIR CONDITIONING SENSOR ... CHECK VALVE FUEL-FILTER (HIGH-PRESSURE SIDE) / CRANKSHAFT POSITION SENSOR HEATED OXYGEN SENSOR ltT=I THREE-WAY CATALYST - REAR WINDOW DEFROSTER SWITCH COMBINATION SrmCH BLOWER SWlTCH STOPLIGHT SWITCH (MT) CLUTCH SWITCH (MT) - NEUTRALSWrrCH (MT) TEN TERMINAL PARWEUTRAL SWITCH (AT) VEHICLE SPEED SENSOR ENGINE COOLAMTEMPERATURE SENSOR EGR SOLENOID VALVE WEM) EGR SOLENOID VALVE (VACUUM) - w TO PCME Gartner Banana

F OUTLINE SPECIFICATIONS Item Specification I Throttle body Throat diameter mm {in) I 55 I2.2) Idle speed rpm Ignition timing BTDC 800-900 (850 -+ 50)[MIb, 750-850 (800 + 50)[ATJe 9"-11" (10" k 1 ")* ~ut~~~ressure kPa {kgf/cm2, psi) 1 46-57 14.9--6.7,6%95) Fuel filter Fuel pump TY pe -- m&e regulator Impeller (in-tank) Low-pressure side Hi~h-pressure side Nylon element Paper element Fuel injector TY pe I High-ohmic Type Regulating pressure kPa {kgf/cm2, psi) Diaphragm 26S314 (2.7--3.2,38--46) ldle Air Control Valve Solenoid resistance n 1 10.7-1 2.3 (at 20°C {M°F)) Type of drive Resistance R Voltage 12-1 6 (at 20°C {68"F)) I Solenoid resistance 1 23-27 (at 20°C (68"FJ) I -- brankshaft position sensor d Air valve Opening temperature I Resistance Below 40°C {I 04°F) TY pe Capacity L {US gal, Imp gal) I 48 {12.7, 10.5) Air cleaner housing Purae solenoid valve Hall effect Engine coolant temperature sensor Free play mm (in) I 1-3 {0.0394.118) Fuel Specification 1 Unleaded regular (RON 87 or higher) Element type I I -. I *... With System Selector (49 B019 9AO) test switch at SELF TEST. 35UOFX-004 Oil permeated Accelerator cable Gartner Banana