stop start MAZDA MX-5 1994 Workshop Manual

ENGINE TUNE-UP HLA TROUBLESHOOTING GUIDE Problem 1. Noise when engine is started immediately af- ter oil is changed 2. Noise when engine is started after setting approx. one day 3. Noise when engine is started after cranking for 3 seconds or more 4. Noise when engine is started after new HLA is installed 5. Noise continues more than 10 minutes 5. Noise occurs during idle after high speed run- ning Possible Cause Oil leakage in oil passage Oil leakage in HLA Faulty HLA Action Run engine 2000-3000 rpm. If noise stops after 2 second-10 minutes(') HLA is normal. If not, replace HLA. Time required for engine oil to circulate withir engine, includes tolerance for engine oi condition and ambient temperature. Insufficient oil pressure (Refer to page 8-53) Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. Check oil pressure. If lower than specification, check for cause. Oil pressure; 295-392 kPa I3.0-4.0 kgf/cm2, 43-56 psil-3000 rpm Deteriorated oil Check oil quality. If deteriorated, replace with specified type and amount of oil. Incorrect oil amount IGNITION TIMING, IDLE SPEED Preparation 1. Check the condition of the engine (spark plugs, leaks in hoses, etc.). 2. Make sure all accessories are OFF. 3. Warm up the engine to normal operating temperature. 4. Connect a timing light and a tachometer to the data link connector terminal IG-. When using an externally pow- ered timing light and/or tachometer, connect it to the power connector (Blue: 1 -pin). Measure valve clearance. If more than Omm {0 in}, replace HLA. Check oil level. Drain or add oil as necessary. Caution Grounding the power connector terminal (Blue: 1-pin) will burn out the 20A wiper fuse. 5. Make sure coolant fan does not operate. Gartner Banana

E ENGINE COOLANT REFILLING Use the proper amount and mixture of ethylene-glycol based coolant. (Refer to Coolant Protection, page E-5.) 1. Slowly pour the coolant into the radiator up to the coolant filler port. Filling pace: 1.0 L (1.1 US qt, 0.9 Imp qt}/min. max 2. Fill the coolant reservoir up to the FULL level. 3. Fully install the radiator cap. 4. Start the engine and let it idle until it warms up. 5. If the temperature increases beyond normal, there is ex- cessive air in the system. Stop the engine and allow it to cool; then repeat step 1-3. 6. Run the engine at 2,200-2,800 rpm for five seconds; re- peat several times. 7. Stop the engine and allow it to cool. Warning Remove the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding cool- ant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press ii down on the cap -still using a cloth - turn it, and remove it. 8. Remove the radiator cap and check the coolant level. If the coolant level has dropped, repeat the procedure from step 1. 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

OUTLINE F COMPONENT DESCRIPTIONS Component Air cleaner housing Air valve Remark Function Filters air entering throttle body When cold, supplies bypass air into dynamicchamber w Engine speed increased to shorten warm-up period Thermowax type Barometric absolute pressure sensor Detects barometric absolute pressure; sends signal to powertrain control module (engine) 3uilt-in PCME Charcoal canister Clutch switch (MT) Stores gas tank fumes while engine stopped Detects in-gear condition: sends signal to powertrain control module (engine) --- ~witch OFF when clutch pedal released Crankshaft position sen- sor Detects No.1 cylinder TDC; sends signal to powertrain control module (engine) Detects crank angle at 180" intervals; sends signal to powertrain control module (engine) Data link connector Concentrated service connector Concentrated terminals are: 1. CIS on-board diagnosis terminal 2. Initial set terminal 3. Fuel pump check terminal Dynamic chamber Interconnects all cylinders Detects coolant temperature; sends signal to powertrain control module (engine) Recircurates oortion of exhaust aas Engine coolant temperature sensor EGR control valve lnstalled in EGR control valve EGR function sensor Detects EGR control valve operating position; send sig- nal to PCME EGR solenoid valve (vent) Controls vacuum to EGR control valve (vent side) Controlled by duty signal from PCME . - EGR solenoid valve (vac- Controls vacuum to EGR control valve (vacuum side) 0 Controlled by duty signal from PCME uum) Fuel filter Filters particles from fuel Injects fuel into intake port Fuel injector Controlled by signals from powertrain control module (engine) High-ohmic injector 0 Sinale port injector nozzle Fuel pump Provides fuel to fuel injectors 0 operates while engine running lnstalled in fuel tank Fuel pump relay Voltage for fuel pump while engine running Fuel vapor valve Prevents fuel from entering canister during vehicle roll over Heated oxygen sensor Detects oxygen concentration; sends signal to power- train control module (engine) 0 Zirconia ceramic and platinum coating ldle air control valve Controls bypass air amount Controlled by duty signal from powertrain control module (engine) Controls idle-up lnstalled in throttle position sensor lnstalled in ignition coil ldle switch Igniter Detects idle condition; sends signal to PCME Receives spark signal from powertrain control module (engine) and generates high voltage in ignition coil Detects high voltage ignition; sends substitute ignition signal to powertrain control module (engine) Ignition switch (START position) Sends engine cranking signal to powertrain control mod- ule (engine) Intake air temperature sensor Detects intake air temperature: sends signal to powertrain control module (engine) Installed in mass airflow sensor Main relay Supplies electric current to fuel injectors, powertrain control module (engine), etc. Gartner Banana

Neutral swltch (MT) 7 PCV valve Powertrain control mod- ule (engine) (PCME) Purge solenoid valve Resonance chamber Steering pressure sen- Stoplight swltch I Throttle posltion sensor r [Two-way check valve Function jetects amount of intake air; sends signal to powertrain :ontrol module (engine) Li~ht illuminates when input device malfunctions - Light flashes to indicate trouble code number of input and output devices Detects in-gear condition; sends signal to powertrain :ontrol module (engine) - Controls blow by aas amount introduced into engine Detects the followlng: 1. A/C operation 2. Airlfuel ratio (Oxygen concentration) 3. Barometric absolute pressure 4. Braking signal 5. Cranking signal 6. EIL operation 7. Engine coolant temperature 8. Engine speed 9. In-gear condition 10. lntake air amount 11, lntake air temperature 12. No.1 piston TDC 13. PIS operation 14. Initial set signal 15. Throttle valve opening angle Controls operatlon of the followlng: 1. AIC (Cut off) 2. Fail-safe function 3. Fuel injection system 4. ldle speed control 5. Ignition timing control system 6. Monitor function 7. Purge control system 8. Lockup control svstem Controls vacuum to pressure regulator -- Adjusts fuel pressure supplied to fuel injectors Controls evaporative fumes from canister to intake man- ifold -- lm~roves mid-ranae torque characteristics -. Detects PIS operation; sends signal to powertrain con- trol module (engine) -- Detects braking operation (deceleration); sends signal to powertrain control module (engine) Reduces HC, CO, and NOx by chemical reaction Controls pressurein fuel tank Controls intake air quantity Detects position of the throttle valve closed throttle posi- tion; sends signal to powertrain control module (engine) Detects the throttle valve opening at a preset angle; sends si~nal to powertrain control module (engine) controls pressure in fuel tank Remark lntake air temperature sensor and fuel pump switch included Use Vref (5 volt) as power source ' Data link connector terminal TEN ' Data link connector terminal TEN Switch ON when in neutral 1, Air conditioning sesnor 2. Heated oxygen sensor 3. Barometric absolute pressure sensor 4. Stoplight switch 5. Ignition switch (START position) 6. Coolant fan relay Light and turn relay Blower switch 7. Engine coolant temperature sensor 8. Crankshaft position sensor (SGT-signal) 9. Neutral and dutch switches (MT) Parklneutral switch (AT) 10. Mass airflow sensor 11, lntake air temperature sensor 12. Crankshaft position sensor (SGC-signal) 13. Steering pressure switch 14. Data link connector 15. Throttle position sensor 1. NC relay 2. Self-diagnosis checker and MIL 3. Fuel injector 4. IAC valve 5. Igniter 6. Monitor lamp (Self-diagnosis checker) 7. Purge solenoid valve 8. Powertrain control module (transmission) (AT) D Controlled by duty signal from powertrain control module (engine) D PIS: ON when steering wheel turned Monolith type D Integrated throttle position sensor, Idle air control valve, and dashpol Gartner Banana

TROUBLESHOOTING GUIDE RELATIONSHIP CHART Fuel injector TEN Terminal (Data link connector) Ignition Switch (Start Position) Steering Pressure Sensor X X X X X X X X X X X X X X X xoo Blower Switch Headlight Switch Stoplight Switch Neutral and Clutch Switches (MT) Parklneutral switch (AT) Air Conditioning Sensor Idle Switch Throttle I BDL) Position Sensor I Sensor (NO) Barometric Absolute Pres- sure Sensor IGF Signal Heated Oxygen Sensor Engine Coolant Temperature Sensor Sensor Mass Air- flow Sensor Intake Air Temperature Sensor Crankshaft SGTSignal Position Sensor SGC-Signal Gartner Banana

F TROUBLESHOOTING GUIDE Troubleshooting chart F TROUBLESHOOTING GUIDE 7 I - page F-79 CRANKS NORMALLY BUT HARD TO START - AFTER WARM-UP 1 Check if PCME terminal voltaoes are OK Check If '00" is displayed on Sell-Diagnosis Check- er wilh lonillon switch ON I (2D* 2R and *) page 6145 'SCRIPTION Enginecranks at normal speed but requires excessive cranking time (more than 5 sec.) before starting after run- ning and hot soaked Battery In normal condition Engine starts normally when cold TROUBLESHOOTING HINTS] D AidFuel mixture too rich @ Vapor lock Fuel injection control malfunction . Fuel pressure not held In fuel line after engine stop Fuel injector fuel leakage . High RVP (winter) fuel used In warm weather ITEP I INSPECTlON Yes "88" flashes I Check PCME terminal I E ~Itg " p8gO F-I45 1 ACVON Go to next slep No Speclflcatlon: Baltery porltlve voltage (Ignition rwltch 1 ON) Diagnostic Trouble Code No. dlrplayed Check lor cause (Refer lo specified check sequence) a page F-81 If OK, replace PCME rr F-143 I:, if not OK, check wiring between PCME and Sell-Diagno- sis Checker LQ page M I No Check for cause (Refer to 'Check Pdnt for Each Terml- nal') page F-1 I -- ~ Yes Go lo next step I p- / Yes DESCRIPTION: Further describes the symptom. Confirm that the chart addresses the actual symptom before beginning troubleshooting. Go to next slep TROUBLESHOOTING HINTS: This describes the possible point of malfunction. STEP: This shows the order of troubleshooting. Proceed with troubleshooting as indicated. INSPECTION: This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is nec- essary to perform the INSPECTION, refer to the page shown by the "UW' mark. ACTION: This recommends the appropriate action to take as a result (YesINo) of the INSPECTION. How to per- form the action is described on the reference page shown by the "=" mark. Gartner Banana

TROUBLESHOOTING GUIDE DIAGNOSTIC INDEX Cranks normally but will not start (No com- Engine cranks at normal speed but shows no sign of bustion) I #firingN I F-17 I No. 1 TROUBLESHOOTING ITEM Will not crank or cranks slowly -- -- Cranks normally but will not start (Partial combustion) -When engine is cold Cranks normally but will not start (Partial combustion) - After warm-up Cranks normally but hard to start - Always Cranks normally but hard to start - When engine is cold - Engine cranks at normal speed but shows partial com- bustion and will not continue to run Engine cranks at normal speed but shows partial com- bustion and will not continue to run after running and hot soaked Engine cranks at normal speed but requires excessive cranking time (more than 5 sec.) before starting Same condition as No.5 when engine is cold Restarts OK after warm-up 8 DESCRIPTION Refer to Engine Electrical System Low idle speed1Rough idle - Before warm- UP Low idle speed/Rough idle -After warm-up PAGE SECTION G Cranks normally but hard to start - After warm-up Rough idle - Always Engine speed low or engine vibrates excessively at idle during warm-up Engine runs normally at idle during warm-up but vi- brates excessively after warm-up High idle speed - After warm-up Low idle speed - When NC, PIS, or EIL ON l5 1 Engine stalls at idle - Always Engine starts normally but vibrates excessively and stalls at idle in every condition I F40 1 13 14 Same condition as No.5 after running and hot soaked Starts normally when cold Engine vibrates excessively at idle in every condition Engine idle excessive for operation mode Engine speed decreases at idle when NC, PIS, or EIL is ON 18 1 Engine stalls during start-up 1 Engine unexpectedly stops running while starting I F-45 F-26 F-27 F-34 F-36 Rough idle just after starting Idle moves up and down 16 17 l9 1 Engine stalls on deceleration I Engine unexpectedly stops running while decelerating or after deceleration Engine starts normally but vibrates excessively only just after starting Engine speed up and down periodically at idle Engine stalls at idle - Before warm-up Engine stalls at idle - After warm-up Engine stalls at idle -When AIC, PIS, or EIL running at idle when 1 20 1 ON I F-50 1 F-37 F-38 I I . . I 21 1 Engine stalls suddenly (Intermittent) I Engine intermittently stops running I F-52 Engine starts normally but vibrates excessively and stalls at idle before warm-up Engine runs normally at idle during warm-up but be- comes rouclh and stalls after warm-up F-43 F-44 24 1 Lack of power Performance is poor under load Maximum speed re- 1 duced I F-57 I Hesitates/Stumbles on acceleration Surges while cruising I I I 25 / Poor acceleration I Performance is poor while accelerating 1 F-61 I Flat spot occurs just after accelerator is depressed or mild jerking occurs during acceleration Unexpected, usually repetitive change in engine speed Knocking F-53 F-55 Runs rough on deceleration1Afterburn Abnormal combustion accompanied by audible "ping- ing" noise I F-67 I Engine runs rough while decelerating and abnormal combustion in exhaust system 1 30 1 High oil consumption I Oil consumption excessive I F-70 1 F-65 28 1 Fuel odor 29 / Exhaust sulfur smell 1 31 1 Poor fuel economy I Fuel economy unsatisfactory I F-71 I Gasoline odor in cabin Exhaust gas smells abnormal (rotten egg smell) F-69 F-70 Gartner Banana

TROUBLESHOOTING GUIDE 7 CRANKS NORMALLY BUT WILL NOT START (PARTIAL COMBUSTION) -AFTER WARM-UP I ~ngine starts normally when cold TROUBLESHOOTING HINTS] D AirIFuel mixture too rich O Vapor lock Fuel pressure not held in fuel line after engine stops High RVP (winter) fuel used in warm weather 'ESCRIPTIoN Fuel injection control malfunction (Correction for coolant temperature) Fuel injector fuel leakage I INSPECTION Engine cranks at normal speed but shows partial combustion and will not continue to run after running and hol soaked Battery in normal condition :heck if "00" is displayed on Self-Diagnosis Checker with ignition switch ON @S page F-79 :heck if PCME terminal voltages are OK :2D and 20) page F-136 sonnect data link connector terminals F/P and GND ~ith jumper wire and check for correct fuel line pres- sure with ignition switch ON page F-110 Fuel Line pressure: 26-14 kPa {2.7-3.2 kgflcm2, 38-46 psi) GND F~P INSTALL CLAPS ' Yes No - Yes - No Yes ACTION Go to next step Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) page F-81 "88" flashes Check PCME terminal 1 E voltage page F-145 Specification: Battery positive voltage (Ignition switch ON) 0 If OK, replace PCME page F-143 0 If not OK, check wiring between PCME and Self-Diagno- sis Checker page F-7 Go to next step Check for cause (Refer to "Check Point for Each Terminal") page F-148 Go to next step Low pressure Check fuel line pressure while pinching fuel return hose Q If fuel line pressure quickly increases, check pressure regulator page F-118 0 If fuel line pressure gradually increases, check fuel line and filter for clogging If not clogged, check fuel pump maximum pressure page F-115 - High pressure Check if fuel return hose is clogged or restricted a If OK, replace pressure regulator page F-119 6 If not OK, repair or replace Gartner Banana

F TROUBLESHOOTING GUIDE [TROUBLESHOOTING HINTS] D AirIFuel mixture too rich 7 Q Vaoor lock CRANKS NORMALLY BUT HARD TO START - AFTER WARM-UP Fuel pressure not held in fuel line after engine stops 0 High RVP (winter) fuel used in warm weather ACTION DESCR'PnON Fuel injection control malfunction Fuel injector fuel leakage Check if "00" is displayed on Self-Diagnosis Check- er with ignition switch ON uar page F-79 Engine cranks at normal speed but requires excessive cranking time (more than 5 sec.) before starting after run- ning and hot soaked Battery in normal condition Engine starts normally when cold 1 Check if PCME terminal voltages are OK (2D,2R and 2Q) page F-145 INSPECTION Run engine at idle and check if fuel line pressure is held after ignition switch turned OFF page F-109 Fuel line pressure: More than 147 kPa (1.5 kgf/cm2, 21 psi} for 5 min. INSTALL CLAPS Try known good PCME and check if condition im- proves US page F-144 Yes - No Yes - No Yes No - Yes Go to next step Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) page F-81 "88" flashes Check PCME terminal 1 E voltage page F-145 Specification: Battery positive voltage (Ignition switch ON) 0 If OK, replace PCME @sf page F-143 G If not OK, check wiring between PCME and Self-Diagno- sis Checker page F-7 Go to next step Check for cause (Refer to "Check Point for Each Termi- nal") page F-148 Go to next step Block outlet of pressure regulator and check if fuel line pressure is held after ignition switch is turned OFF page F-117 If OK, replace pressure regulator page F-118 Q If not OK, check fuel pump hold pressure I@? page F-115 If fuel pump is OK, check fuel injector for fuel leakage page F-120 Replace PCME Change fuel to another brand Gartner Banana