key battery MAZDA MX-5 1994 Workshop Manual

ON-VEHICLE MAINTENANCE B Steps After Installation 1. Connect the neaative batterv cable. Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. Installation Note Oil seal 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly with a pipe and a hammer until it is flush with the edge of the oil pump body. Note Oil seal outer diameter: 50.5mm (1.99 in} Oil seal inner diameter: 36.5mm (1.44 in} Timing belt pulley 1. Install the timing belt pulley. 2. Install the pulley woodruff key with the tapered side to- ward the oil pump body. 2. Start the enginsand check, and if necessary, adjust the ignition timing. 3. Connect the negative battery cable. 4. Start the engine and check follows: (1) Engine coolant leakage (2) Ignition timing (Refer to page B-9.) 5. Recheck the engine coolant levels. Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K POSSlBLt TO SHIFT c3 BRAKEPEDAL DEPRESSED 45UOKX42! EMERGENCY OVERRIDE BUTTON '
+ I SHIFT TO P RANGE 1 SHIFT-LOCK lnspection 1. Turn the ignition switch to ON engine OFF. 2. Verify that the selector lever is in P range. 3. Without the brake pedal depressed, verify that the selec- tor lever cannot be shifted from P range. 4. Depress the brake pedal and verify that the selector le- ver can be shifted from P range. 5. If not as specified, check the P range switch continuity andlor shift-lock actuator terminal voltage and continu- ity. (Refer to pages K-159.) EMERGENCY OVERRIDE BUTTON lnspection 1. Verify that the engine is off. 2. Verify that the selector is locked in P range. 3. Remove the indicator panel cover with the screwdriver as shown. 4. Insert the screwdriver into the emergency override hole, push down, and verify that the selector lever can be shifted from P range. 5. If not as specified, inspect and repair as necessary, re- ferring to the Troubleshooting diagnosis chart. (Refer to pages K-155.) KEY INTERLOCK lnspection 1. Turn the ignition switch to ON engine OFF. 2. Shift the selector lever to R range. 3. Verify that the ignition key cannot be turned to the LOCK position. 4. Shift the selector lever to P range. 5. Verify that the ignition key can be turned to the LOCK position. 6. If not as specified, inspect and repair as necessary, re- ferring to Troubleshooting. (Refer to pages K-155.) KEY INTERLOCK SOLENOID lnspection 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key interlock solenoid connector. 4. Insert the ignition key in the key cylinder. 5. Apply battery voltage between terminals 6 and C, and verify that the solenoid operates. 6. If not as specified, replace key interlock solenoid. 7. Connect the key interlock solenoid connector. 8. Install the column cover. 9. Connect the negative battery cable. Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) Replacement 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key interlock solenoid connector. 4. Remove the screws and the key interlock solenoid. 5. Install the key interlock solenoid and tighten the screws. Tightening torque: 6.S-13 N-m (70-1 30 kgf-m, 61-11 3 ft-lbf} I I I 6. Verify that the key interlock solenoid operates. (Refer to 45UOKX-576 "Inspection" above.) 7. Connect the key interlock solenoid connector. 8. Install the column cover. 9. Connect the negative battery cable. KEY INTERLOCK UNIT Inspection 1. Remove the column cover. 2. Turn the ignition switch ON, and check terminal volt- ages, referring to the chart below. 3. If not as specified, repair the wiring harness andlor key -, interlock unit. B+: Battery positive voltage - - - Within 2 seconds of twning the P-range switch ON, and either the ACC or IG ON. Except above conditions Correct measurement valve 0 B+ E Condition Terminal I I I I terminal connected to I Ground 1 Constant M 0 Ignition switch ON Ignition switch OFF P-range switch and ACC are ON, or IG is ON Except above condition I B+ 0 S 0 B+ P-range switch ON P-range switch OFF I 0 B+ - ACC switch ON ACC switch OFF B+ 0 Gartner Banana

SHIFT MECHANISM (WITH SHIFT-LOCK SYSTEM) K TO GROUND FROM SHIFT-LOCK ACTUATOR Replacement 1. Disconnect the negative battery cable. 2. Disconnect the key interlock unit connector. 3. Remove the key interlock unit. 4. Install the new key interlock unit. 5. Connect the key interlock unit connector. 6. Connect the negative battery cable. P RANGE SWITCH Inspection Continuity 1. Disconnect the negative battery cable. 2. Remove the rear console. 3. Remove the screws and lift up the indicator panel. 4. Disconnect the P range switch connector. 5. Check continuity between the terminals. I Range I Selector lever release button I Continuity I 6. If not as specified, replace the P range switch. (Refer to page K-166.) I 7. Connect the P range switch connector. 8. Adjust the indicator panel. (Refer to page K-161.) Install the screws in the order shown in the figure. 9. Install the rear console. 10. Connect the negative battery cable. 11. Verify correct operation of the shift-lock system. SHIFT-LOCK ACTUATOR Inspection Terminal voltage and continuity 1. Remove the rear console 2. Remove the selector knob and indicator panel screws. Released Depressed Yes No Gartner Banana

MANUAL STEERING , N Removal / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. ,, 3. Inspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal. 5. Tighten all necessary nuts and bolts to the specified torque. 6. After installation, check if the horn sounds. If the horn does not sound, remove the air bag module and connect the module connectors. (Refer to section T.) 1. Air bag module 6. Lower panel Removal 1 Installation .......... section T 7. Key interlock cable (Automatic transmission) 2. Locknut 8. Intermediate shaft bolt 3. Steering wheel 9. Steering shaft w ............... Removal Note page N-10 Disassembly 1 Inspection / 4. Column cover Assembly .................. page N-10 5. Combination switch Removal / Installation .......... section T Gartner Banana

DOOR LOCK AND OPENER s DOOR LOCK AND OPENER COMPONENTS Removal 1 lnstallation 1. Raise the door glass fully. 2. Disconnect the negative battery cable. Note Remove the door screen carefully so that it may be reused. 3. Remove in the order shown in the figure, referring Removal Note. 4. Install in the reverse order of removal, referring Installation Note. 1. Regulator handle 5. Inner handle Removal Note ............. page S-10 6. Sealing pad Installation Note ........... page S-10 7. Door screen - 2. Inner handle cover 8. Door lock assembly 3. Pull handle 9. Outer handle 4. Door trim 10. Key cylinder Removal Note ............. page S-61 Gartner Banana

ALPHABETICAL INDEX *%* ENGLISH *** GASKET'A' ,DUST COVER----- 1-114 GAUGEIFUEL TANK---------- 1-J14 GAUGE,OIL LEVEL---------- 1-DB 1 -H3 GEAR------..-------------- GEAR SET,DRlVEN-SPEED---- 1-M7 GEAR SET,FINAL----------- 1-H11 T -1 11 A-LAA GEAR,ADJUST-------------- l-Fll GEAR, COUNTER-- ----------- 1-H6 GEAR,COUNTER REVERSE----- 1-66 GEAR,COUNl'ER SHAFT------- 1-G6 GEAR,DIFF.SIDE----------- GEAR,DRIVEN-------------- 1-111 1-06 GEAR,INNER----.----------- 1-N4 GEAR,INTERNAL------------ 1 -D9 1 -H9 GEAR,INTERNAL-STARTER---- 1-67 GEAR,MAIN DRIVE---------- GEAR,OUTER--------------- 1-E6 1-N4 GEAR,OVER DRIVE---------- 1-G9 GEAR,OLER TOP------------ 1-H6 GEAR,REVERSE--.---------- 1-66 GEAR ,REVERSE IDLE-------- 1 -H6 GEAR ,RING-FLY WHEEL------ GEAR,SHAFT--------------- 1-K3 2-J15 GEAR,SPEEDO.DRIVE-------- 1 -H6 1 -H9 GEAR,STEERING------------ 1-J12 1-L12 GEPR,suN----------------- 1 -D9 GEAR,~s~----------------- 1 -F6 GEAR,zND----------------- 1-F6 OEAR,SRD----------------- 1-E6 G€NERATOR,PULSE---------- 1 -E8 GLASS(L1,DOGR-FRT-------- 2-K9 GLASS(L1,VENTJLATOR------ 2-K9 GLASS(R1,DOOR-FRT-------- 2-J9 GLASS(R1,VENTILATOR------ 2 -K 9 GLASS,BACK WINDOW-------- 2-Nll GLASS,WINDSHIELD--------- 2-N11 GRILLE(L),OEMISTER------- 2-C8 GRILLE(R),DEMISTER-------- 2-C8 GRlLLE,COWL-------------- 2-J3 GRIPtL1,ASSIST----------- 2-HI0 GRIP(R1,ASSIST----------- 2-H10 GROMMET------------------ 1 -H4 1 - I1 2 2-Cll 2-F14 2-Jll 2- Jl3 2-N14 GROHMET,BRAKE PEDAL------ 1-M14 GROMMETIDRAIN HOSE-TOP--- 2-H12 GROMMET,KNOB-METER SET--- 2-67 GROMHET,SCREW------------ 2-E5 2-F10 GROMMET,SCREW-BAFFLE----- GROMMET,SCREW-DOOR GLASS- GROMMET,SCREW-RETAIhkU--- GROMMET,WASHER TANK------ GUIDE~B~(L),GI.AZS-------- ;-KG i GU1DE1B'(RIJGLASS-------- 2-K9 ' GUSSET N0.3(L),C.FLOOR PA 2-15 GUSSET NO.J(R),C.FLOOR PA 2-K5 ! GUS5ET( L 1 ,REAR FENDER-RR- 2- I5 I GUSSET(L1,SIDE SILL OUTER 2-15 1 GUSSET(R1,REAR FENDER-RR- 2-H5 ! GUSSET(R),SIDE SILL OUTER 2-65 ' . .-- i_ CAT .AUNA04-03 - GUSSET,FRONT FLOOR PAN--- 2-L5 HANDLE(L1,INNER---------- HANDLE(L1,OUT.----------- HANDLE(R1,INNER---------- HANDLE(R1,OUT.----------- HANDLEIJACK-------------- HANDLE,REGULATOR--------- HANDLE,SOFT TOP---------- HANGER,ENGINE------------ HANGER,ENGINE-REAR------- HANGER,SILENCER-. -------- HARNESS N0.2,REAR-------- HARNESS, DOOR-------- -----. HARNESS,ENGINE----------- HARNESS,FRONT------------ HARNESSIINSTRUFENT------- HARNESS, REAR-- -- ---- -.---- HARNESS,WIRE------------- HARNESS'NO.?' ,FRONT- ----- HEAD,CYL.-COMPRESSOR----- HEAD,CYLLNDER------------ HEAD, ZIPPER-BACK I-""QOW-- HEADER,FRONT--- .--- HEADER,FRONT-Uf --- HEATER UNIT---- .---- HINGE-----------------.--- HINGE(L1,BONNET---------- HJNGE(L),DOOR-LOWER------ HINGE(L1,DOOR-UPPER------ HINGE(L1,LID-LAMP-------- HINGE(L),TRUNK LID------- HlNGE(R1,BOHNET---------- HINGE(R1,DOOR-LOWER------ HINGE(R),DPOH-UPPER------ HINGE(R1 ,GLOVE LID---- .-- HINGE(R).LID-LAMP-------- --. HOSE NO.1,UATER---------- HOSE N0.2,BREAlHER------- 1-114 HOSE NO.2,WATER---------- 2-Cll HOSE(C1,DEFROSTER-------- 2-D8 HOSE(L1,FLEXIBLE-FRT----- 1-115 1-K15 HOSE(L1,FLEXIBLE-RR------ 1-115 1-K15 HOSE(R1,FLEXIBLE-FRT----- 1-115 1-K15 HOSE(R1,FLEXIBLE-RR------ 1-115 HOSE,AIR----------------- 1-K15 1-14 HOSE,CLUTCH FLEXIBLE----- 1-F14 HOSE,DRAIN------..-------- 1-~4 HOSE,FUEL PUMP-IN TANK--- HOSE,FUEL-€GI------------ HflSE,OIL----------------- HOSE,P,C.V.-------------- HOSE,PRESSURE------------ HDSE,REfURN-------------- HOSE, WATER BY-.PASS------- tIOSE,WATER-OIL COOLER IN. 1-C5 HOSE'C',WASH€.:----------- 2- F15 HOUSING(L1,LAMP-LID HINGE 2-H3 HOUSING(L1,LAMP-RR FENDER 2-J5 HOUSING(R1,LAMP-LID HINGE 2-M3 HOUSING(R),LAMP-!?R FENOER 2-H5 HUB SET,CLlJTCH-O.T. 8 REV 1-H6 HUB SET,CLUTCH-1ST 8 2ND- 1-F6 HUB SET,CLUTCH-3RD 8 4TH- 1-c6 HUB ,CLUTCH- ---.-- - ----- --- I 1-E6 1 1 -F6 1-H6 -- INSULATOR,DASHBOARD------ 2-N15 INSULATOR,EX.MANIFOLD---- 1-E4 INSULATOR,FRONT---------- 2-D6 INSLLATOR,FUEL D1ST.----- 1-H4 INSULATOR ,HEAT----------- 1 - E4 JACK--------------------- 1-NlZ JET,OIL------------------ JOINT-------------------- 1 -H3 1-H3 1-17 2-El5 2-M9 JOINT SET.BALL----------- 1-K12 1-Ml2 JOINT SET,INNER--------a*- 1-Dl1 JOINT SET,OUTER---------- 1-Dl1 JOINT,BACK WINDOU MOULD-- 2-Nll JOINT,BALL--------------- l-Kl2 1-M12 JOINT,ELBOW-W.TANK------- 2-C15 2-Fl! KEY SET------------------ 2-C3 KEY SUB SET(C),DOOR------ 2-C3 KEY SUB SETCR)JDOOR------ 2-C3 KEY SUB SET,GLOVE-------- 2-D3 KEY SUB SET,ST.LOCK------ 2-D3 KEY SUB SET,TRUNK-------- 2-C3 KEY,BLANK-PRIMARY-------- 2-03 KEYJBLANK-SECONDARY------ KEY,PRIWARY-------------- 2-D3 2-C3 KEY ,SECONDARY-------- ---- 2-C3 KEY,SYNCHRONILER--------- 1-E6 KEY,WOODRUFF-PULLEV------ 1-K3 KNOB---------- ----a- ----.. 2-NI! KNOB ~0.1..--------------- 2-Ell KNOB(L>,KNUCKLE---------- 2- J8 KHOB