headlights MAZDA MX-5 1994 Workshop Manual

TROUBLESHOOTING GUIDE ldle speed control malfunction Engine speed feedback control malfunction ldle air control valve stuck 12 INSPECTION LOW IDLE SPEED - WHEN AIC, PIS, OR EIL ON Check if "00" is displayed on Self-Diagnosis Check- er with ignition switch ON @? page F-79 SELECT SWA SYSTEM SELECT 1 I Check switches for correct operation with Self- Diagnosis Checker Monitor Lamp and ignition switch ON page F-95 SELECT SW A DESCRIPTIOH MONITOR [LAMP &\L SYSTEM SELECT 1 : Engine speed decreases at idle when NC, PIS, or EIL ON NC, PIS, headlights, blower fan and electric coolant fan operate normally Check if continuity exists between data link con- nector terminal TEN and ground --., rrROUBLESHOOTlNG HINTS] Disconnect idle air control valve connector at idle and check if engine condition is changed IAC VALYE CONNECTOR /' Yes - No Yes Yes No - Yes - No - ACTION Go to next step Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) US= page F-81 "88" flashes Check PCME terminal 1 E voltage * page F-145 Specification: Battery positive voltage (Ignition switch ON) 6 If OK, replace PCME page F-143 G If not OK, check wiring between PCME and Self-Diagno- sis Checker page F-7 Go to next step Lamp not ONIOFF with specified switch Check for cause (Refer to specified check sequence) as page F-96 Lamp always ON Check wiring between PCME terminal I D and Self-Diag- nosis Checker @T page F-7 Check for short circuit in wiring between data link connec- tor terminal TEN and ground as page F-7 Go to next step Try known good PCME page F-144 Check idle air control valve @? page F-106 Gartner Banana

F CONTROL SYSTEM B+: Battery positive voltage Connection to 1 Test condition 1 Voltage I Remark I -- EGR solenoid valvi Idle B+ Blower switch -- EGR solenoid valve (vacuum) :vent) Initial acceleration* Blower switch at mid, high or su- per high position Blower switch OFF or low Headlight switch Neutral or clutch switch (MT) B+ Idle ParWneutral switch (AT) Ground (Injector) Ground (Output) Ground (PCME) Approx. OV - Approx. 12V B+ Headlights ON (Tail, parking, low beamfhigh beam) Headlights OFF Neutral position or clutch pedal de- pressed Other conditions Ground (Input) Crankshaft position (SGT-signal) Ignition switch ON N or fJ range Other conditions Constant Constant Constant -. Mass airflow sensor .. . . EGR function sensor I while running Approx. 0-5v Initial acceleration* Approx, 2V OV ov B+ Constant Ignition switch ON Idle Crankshaft position sensor (SGC-signal) Data link connector (TEN terminal) Igniter I I I Vre f I lanition switch ON 1 4.5-5.9.' 1 - B+ - OV B+ OV OV OV Ignition switch ON Idle - - - OV OV or 5V ADD~OX. 2V - - Ignition switch ON Idle System Selector test switch at "02 MONITOR" System Selector test switch at "SELF-TEST" Ignition switch ON Idle lanition switch ON I . . I I 1 Ignition switch ON I Below 1 .OV I I - - . . Below 1 .OV Below 1 .OV ear window defrost- er relay Throttle position sensor Heated oxygen sensor - OV or 5V Approx. 1.5V B+ ov Below 0.5V Approx. 1 V Approx. 1 .OV - - - " Rear window defroster switch OFF Rear window defroster switch ON Accelerator pedal released Accelerator ~edal fullv de~ressed Mass airflow sensor B+ Below 1 .OV 0.1-1 .o 3.14.5 Intake air temperature sensor Engine coolant tem- perature sensor lgnition switch ON lgnition switch ON Ignition switch ON Idle ireen and red lamps flash At 200C {680Fj Engine coolant temperature 20°C {680F) After warm-up Below 1 .OV 1 .O-2.0 - Approx. 2.5V Approx. 2.5V Approx. 0.4V Built in mass airflow lgnition switch ON Gartner Banana

CONTROL SYSTEM B+: Battery positive voltage Terminal 1 M 7 1 N 10 1 P 1 Q 1 R 1 S 1 T 1 U Connection to Abnormal voltage Always approx. 1 V Always approx. 7V Possible cause r Vehicle speed sensor malfunction r Short circuit in wiring from vehicle speed sensor to PCME terminal 1 M Vehicle speed sensor - r Vehicle speed senso~malfunction r Open circuit in wiring from vehicle speed sensor to PCME terminal 1 M r Throttle position sensor misadjustment (Refer to page F-154) r Short circuit in wiring from PCME terminal 1 N to throttle position sensor 6 PCME malfunction Always OV Throttle position sensor (idle terminal) Always B+ r Throttle position sensor misadjustment (Refer to page F-154) r Open circuit in wiring from PCME terminal 1 N to throttle position sensor r Open circuit in wiring from throttle position sensor to ground Stoplight switch Always OV (Stoplights OK) r Open circuit in wiring from stoplight switch to PCME terminal 10 r Steering pressure sensor malfunction (Refer to page F-158) Short circuit in wiring from PCME terminal 1 P to steering pressure sensor r PCME malfunction r Steering pressure sensor malfunction (Refer to F-158) r Open circuit in wiring from PCME terminal 1 P to steering pressure sensor Open circuit in wiring from steering pressure sensor to ground r Air conditioning sensor malfunction (Refer to section U) r Short circuit in wiring from PCME terminal 1 Q to air conditioning sensor r Poor connection at PCME connector r PCME malfunction Always OV Steering pressure sensor Always B+ -- Air conditioning sensor Always OV (with blower switch ON) Air conditioning sensor malfunction (Refer to section U) Open circuit in wiring from PCME terminal 1Q to air conditioning sensor Open circuit in wiring from air conditioning sensor to blower switch Always B+ (with blower switch ON) (Blower fan OK) EGR solenoid valve (vent) Always OV r Refer to Code No.29 Troubleshooting (Refer to page F-92) Short circuit in wiring from blower switch to PCME terminal 1 S r Poor connection at PCME connector PCME malfunction Always OV (Blower fan OK) Blower switch Always B+ (Blower fan OK) Open circuit in wiring from blower switch to PCME terminal IS EGR solenoid (vacu- um) Always OV r Refer to Code No.28 Troubleshooting (Refer to paae F-92) Headlight switch Always OV (Headlights OK) r Open or short circuit in wiring from headlight relay to PCME terminal 1 U Gartner Banana

s FRONT BUMPER FRONT BUMPER COMPONENTS Removal 1 Installation 1. Raise the headlights. 2. Disconnect the negative battery cable. 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. Front combination light 6. Set plate Removal .................... Section T 7. Front fascia Front side marker light 8. Retainer Removal .................... Section T 9. Bumper reinforcement 3. Fender bracket 10. Spacer 4. Mud guard 11. Front bumper retainer 5. Grille cover 12. Front bumper bracket Gartner Banana

BODY ELECTRICAL SYSTEM ................................... INDEX T- 2 ........................... SWITCHES T- 2 FUSES AND RELAYS .................. T- 3 .............................. LIGHTS T- 4 CRUISE CONTROL SYSTEM ........... T- 5 ...................... AUDIO SYSTEM T- 6 SRS AIR BAG SYSTEM ................ T- 7 ............................... OUTLINE T- 8 TROUBLESHOOTING GUIDE ........... T- 8 ELECTRICAL SYMBOLS ............... T- 9 ................................... FUSE T- 10 STRUCTURAL VIEW ................... T- 10 ...................... SPECIFICATIONS T- 11 ........................ DESCRIPTION T- 12 ....................... REPLACEMENT T- 12 ....................... RELAY .. ....... T- 13 STRUCTURAL VIEW ................... T- 13 ........................ DESCRIPTION T- 13 RETRACTABLE HEADLIGHT RELAY .... T- 14 ....................... FLASHER UNIT T- 14 ........................... TNS RELAY T- 15 .......................... HORN RELAY T- 15 COOLANT FAN RELAY ................. T- 15 REAR WINDOW DEFROSTER RELAY ... T- 16 HEADLIGHT RELAY ................... T- 16 ................................ SWITCH T- 17 ................... STRUCTURAL VIEW T- 17 ........................ DESCRIPTION T- 17 .................... IGNITION SWITCH T- 18 COMBINATION SWITCH ............... T- 19 RETRACTOR SWITCH AND HAZARD WARNING ............................. SWITCH T- 21 ................. INSTRUMENT CLUSTER T- 22 ................... STRUCTURAL VIEW T- 22 ........................ DESCRIPTION T- 22 .................... CIRCUIT DIAGRAM T- 23 ................. TROUBLESHOOTING T- 24 ............ REMOVAL / INSTALLATION T- 29 ........... DISASSEMBLY 1 ASSEMBLY T- 29 ...................... SPEEDOMETER T- 30 ........................ TACHOMETER T- 30 WATER TEMPERATURE GAUGE ....... T- 30 ......................... FUEL GAUGE T- 31 OIL PRESSURE GAUGE ............... T- 31 .................... PRINTED CIRCUIT T- 32 VEHICLE SPEED SENSOR ............. T- 32 WATER TEMPERATURE SENDER UNlT . T- 32 FUEL GAUGE SENDER UNlT ...................... (IN FUEL TANK) T- 32 OIL PRESSURE SENSOR .............. T- 33 ............... SPEEDOMETER CABLE T- 33 WARNING LIGHT AND SENDER UNIT ..... T- 34 ................... STRUCTURAL VIEW T- 34 CIRCUIT DIAGRAM .................... T- 35 ................. TROUBLESHOOTING T- 36 BRAKE FLUID LEVEL SENSOR ......... T- 39 PARKING BRAKE SWITCH ............. T- 39 ..................... BUCKLE SWITCH T- 39 ...................... LIGHTING SYSTEM T- 40 ................... STRUCTURAL VIEW T- 40 ......................... HEADLIGHTS T- 41 ......................... STOPLIGHTS T- 53 TURN AND HAZARD WARNING LIGHTS . T- 57 ..................... BACK-UP LIGHTS T- 66 TAILLIGHTS. SIDE MARKER LIGHTS. PARKING LIGHTS AND LICENSE PLATE LIGHTS . T- 69 DAYTIME RUNNING LIGHTS (DRL) .................... (CANADA SPEC.) T- 72 ........... REAR COMBINATION LIGHT T- 76 .................... INTERIOR LIGHTS T- 78 ................ ILLUMINATION LIGHTS T- 82 .................................. HORN T- 84 ................... STRUCTURAL VIEW T- 84 .................... CIRCUIT DIAGRAM T- 85 ................. TROUBLESHOOTING T- 86 ............ REMOVAL 1 INSTALLATION T- 87 ............ REAR WINDOW DEFROSTER T- 89 ................... STRUCTURAL VIEW T- 89 ........................ DESCRIPTION T- 89 ................. TROUBLESHOOTING T- 90 ................ REPAIRING FILAMENT T- 93 ............. CRUISE CONTROL SYSTEM T- 94 ................... STRUCTURAL VIEW T- 94 .................... CIRCUIT DIAGRAM T- 95 ................. TROUBLESHOOTING T- 96 ....... SELF-DIAGNOSTIC INSPECTION T-100 ............... CRUISE CONTROL UNIT T-103 .................... ACTUATOR CABLE T-104 ..................... CLUTCH SWITCH T-105 .......... STOP LIGHTIBRAKE SWITCH T-105 ...... CRUISE CONTROL MAIN SWITCH T-106 ........... CRUISE CONTROL SWITCH T-106 ............. VEHICLE SPEED SENSOR T-106 ........................... ACTUATOR T-107 a .................................. AUDIO T-108 ................... STRUCTURAL VIEW T-108 ................... SYSTEM DIAGRAM T-109 ............................ FEATURES T-110 FUNCTION AND OPERATING ......................... PROCEDURE 1-111 ............. OPERATION DESCRIPTION T-113 .................. ANTITHEFT SYSTEM T-120 ................. TROUBLESHOOTING T-122 ............ REMOVAL I INSTALLATION T-145 .................... POWER ANTENNA T-149 ......................... INSPECTION T-153 CONNECTOR TERMINAL .................... SPECIFICATIONS T-154 SRS AIR BAG SYSTEM .................. T-156 PREPARATION ........................ T-156 ................... STRUCTURAL VIEW T-156 .......... COMPONENT DESCRIPTION T-157 SYSTEM DIAGRAM ................... T-158 ................. SERVICE WARNINGS T-159 GENERAL PROCEDURES ............. T-160 TROUBLESHOOTING ................. T-160 DRIVER-SIDE AIR BAG MODULE ....... T-206 PASSENGER-SIDE AIR BAG MODULE . . T-207 DIAGNOSTIC MODULE ................ T-208 CLOCK SPRING ....................... T-209 CRASH SENSOR (D-SENSOR) ......... T-210 CRASH SENSOR (S-SENSOR) ......... T-213 AIR BAG MODULE DISPOSAL . .. PROCEDURE ........................ T-215 INSPECTION OF SST (DEPLOYMENT TOOL) ............... T-217 Gartner Banana

T OUTLINE OUTLINE TROUBLESHOOTING GUIDE Symptom a Speedometer does not operate or indication is incorrect a Tachometer does not operate Water temperature gauge does not operate Fuel gauge does not operate a Oil pressure gauge does not operate a Brake system warning light remains illuminated Brake system warning light does not illuminate when parking brake on a Brake system warning light does not illuminate when brake fluid in reservoir is below MIN a OID off indicator light does not illuminate when OID off switch turned on Seat belt warning light remains on six seconds after ignition switch is turned on (Timer function does not operate) Seat belt warning light does not illuminate when ignition switch is first turned on a Headlights do not illuminate Headlight does not illuminate (Right or left) Retractable headlight actuator do not operate (Both sides) Retractable headlight actuator does not operate (One side) Stoplights do not illuminate (All) Stoplight does not illuminate (One only) Turn and hazard warning functions do not operate Turn signals not operate (Hazard warning function operates normally) Hazard warning function does not operate (Turn signals function normally) Back-up lights does not illuminate Taillights, side marker lights, and license plate lights do not illuminate Daytime running lights do not illuminate Daytime running light function does not cancel lnterior lights do not illuminate Interior liahts remains illuminated (Control switch: DOOR ~osition) Horn does not sound Vehicle speed cannot be set (Cruise control unit will not hold vehicle speed) Speakers do not operate (Without headrest speakers) Speakers do not operate (With headrest speakers) Poor sound quality or noise (Radio) Poor sound quality (Cassette tape player) Cassette tape will not load Cassette tape will not play Compact disc will not load Compact disc skips No sound can be heard Some speakers do not operate Bodysonic will not play Service code table (With passenger-side air bag) Service code table (With out ~assenaer-side air baa) Reference page T-24 T-25 T-26 T-27 T-28 T-36 T-37 T-37 Gartner Banana

LIGHTING SYSTEM T HEADLIGHTS Circuit Diagram Gartner Banana

T LIGHTING SYSTEM Description The headlight system consists of two halogen headlights mounted on retractable mechanisms, a head- light switch in the combination switch, and a retractor switch between the center ventilation outlets. When the headlight switch is rotated to the second position, the headlights are activated and the retract- able headlight actuator lift the headlights. If only the retractor switch is turned ON, the headlights will raise to the upright position, but all lights will be off. An emergency manual retractor knob is located on top of each retractable headlight actuator. 45UOTX-080 Troubleshooting A retractor indicator light is included in the instrument cluster. The indicator light illuminates when the re- tractable headlight actuator is operating and should go out when the headlights are fully raised or retracted. if the indicator light remains on, small objects, such as pebbles or pieces of ice, may lodged between the headlight and the vehicle body. Use the following procedure to correct this. Turn the ignition switch to OFF. Obtain the code number and deactivate the audio antitheft function. (Refer to page T-120.) Disconnect the negative battery cable or remove the RETRACTOR 30A fuse in the main fuse block. Raise or lower the headlight by turning the emergency retractor knob. Remove the obstruction. After verifying that the headlight switch and the retractor switch are off, reconnect the negative battery cable. Verify operation of the retractable headlight and the retractor indicator light. 45UOTX-095 --- Symptom: Headlights do not illuminate. HEAD 30A MAIN FUSE BLOCK Step 1 1. Check HEAD 30A fuse in the main fuse block. 2. If the fuse is burned, replace it. Check and repair the wir- ing harness, if necessary. 3. If the fuse is OK, go to Step 2. Gartner Banana

T LIGHTING SYSTEM I Symptom: Retractable headlight actuators do not operate (Both sides). I Activate the headlight switch and retractor switch and follow the approximate action. d Switch I Headlight switch ON / 'RECTOR Retractor rnotor(s) operate Retractor switch ON Step 1 1. Check RETRACTOR 30A and HEAD 30A fuses in the main fuse block. 2. If a fuse is burned, replace it. Check and repair the wire harness, if necessary. 3. If the fuses are OK, go to Step 2. Actlon Yes No Step 2 1. Disconnect the negative battery cable. 2. Retract the headlights fully by using the manual knobs. 3. Disconnect the retractable headlight actuator connec- tors. 4. Reconnect the negative battery cable. 5. Turn on the headlight switch and retractor switch. 6. Measure the voltage at the following terminal wires of the retractable headlight actuator connectors. Begin troubleshooting from Step 5 Next, turn ON retractor switch 45UOTX-087 Yes No B+: Batterv ~ositive voltage Begin troubleshooting from Step 4 Begin troubleshooting from Step 1 . . - Step 3 1. Disconnect the retractable headlight actuator connec- tors. 2. Check for continuity between the A terminal wire of the retractable headlight actuator connectors and ground. Retractable headlight actuator Left and Right I~ontinui~l headlight actuator Action Voltage (RN) Repair wiring harness (Retractable headlight actuator - GND) Left and Right Check retractable headlight actuator (Refer to oaon T-51) Action B+ Other Go to Step 3 Go to Step 4 Gartner Banana

LIGHTING SYSTEM ADJUSTMENT VERTICAL ADJUSTMENT RETRACTABLE HEADLIGHT ACTUATOR I Adjustment Headlight aiming 1. Adjust the tire air pressure to specification. 2. Turn on the retractor switch to raise the retractable head- 4 lights. 3. Position the unloaded vehicle on a flat level surface. 4. Adjust the headlights to meet local regulations by turning the two adjusting screws. Retractor hinge 1. Fully retracted the headlights. 2. Obtain the code number and deactivate the audio anti- theft function. (Refer to page T-120.) 3. Disconnect the negative battery cable. 4. Disconnect the actuator link. 5. Lower the retractor hinge until the hinge is stopped by the stop. 6. Adjust the stop so that the headlight lid is flush with the fender and hood. Gartner Banana