warning lights MAZDA MX-5 1994 Workshop Manual

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

TROUBLESHOOTING GUIDE Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system is under high pressure when the engine is not running. 4 Warning Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". 35UOFX-008 F-73 F-73 F-74 Fuel Line Safety Procedures A. Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. u 2. Disconnect the fuel pump relay connector. 3. After the engine stalls, turn the ignition switch to OFF. 4. Reconnect the fuel pump relay connector. B. Avoid leakage. 1. When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage. 2. Plug the hose after removal. C. Install hose clamps to secure the fuel pressure gauge connections. Self-Diagnosis Checker does not indicate Diagnostic Trouble Code No. but MIL comes on Self-Diagnosis Checker indicates Diagnostic Trouble Code No, of input device but MIL never comes ON Blower fan operates but no cool air is discharged 32 33 34 Pinching Hose When pinching an air hose or fuel hose with pliers, wrap the hose with a rag to prevent damage. MIL always ON MIL never ON NC does not work Checking ignition spark When checking ignition spark condition, hold the high- tension lead with insulated pliers. Note If a timing light is used to check for spark, some lights do not light at the number 2 and 4 cylinders even if the ignition system is normal. J 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 INDEX LIGHTS 1. Retractable headlight 7. Back-up light Aiming ..................... page T-50 Removal / Installation ... page T-68 Removal I Installation ........ page T-49 8. License plate light 2. Retractable headlight actuator Removal / Installation ... page T-71 Inspection .................. page T-51 9. Side marker light 3. Stoplight Removal / Installation ... page T-71 Removal / Installation ........ page T-55 10. Taillight 4. High-mount stoplight Removal / Installation ... page T-71 Removal / Installation ........ page T-55 11. Rear combination light 5. Turn and hazard warning light Removal / Installation ... page T-49 d Removal I Installation ........ page T-64 Disassembly / Assembly pages T-76,77 6. Parking lights 12. Interior light Removal / Installation ........ page T-71 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

RELAY T RELAY STRUCTURAL VIEW 1. Headlight relay 2. TNS relay 3. Retractable headlight relay 4. EGI main relay 5. Circuit-opening relay 6. Rear window defroster timer unit 7. Coolant fan relay 8. Horn relay 9. Flasher unit 10. Rear window defroster relay DESCRIPTION The DRL control unit (Canada only) controls the operation of the turn signal lights. When the ignition switch is at ON or START, the front turn signal lights illuminate as running lights, except when one of the following switches is on: Headlight switch. Turn signal light switch. Hazard warning switch. Parking brake switch. Gartner Banana

RELAY TIMER a 45UOTX-01 FLASHER UNIT Inspection 1. Turn the ianition switch to ON. RETRACTABLE HEADLIGHT RELAY Inspection 1. Disconnect the relay. 2. Apply battery positive voltage and check for continuity .- between terminals of the relay. B+: Batterv ~ositive voltaae Step -- -- M: Continuity Terminal A I H I G I B I D 1 2 3. If not as specified, replace the relay. 2. Operate the following switches and check the operation of the turn signal and hazard warning lights. 0 0 3. If not as specified, troubleshoot the circuit., 0 Switch Turn signal switch Hazard warning switch HAZARD WARNING SW - - 0 Procedure Right side ON Left side ON ON 0 B+ Operation Right turn signal lights flash Left turn signal lights flash All turn signal lights flash 0 GND V Gartner Banana

T INSTRUMENT CLUSTER INSTRUMENT CLUSTER STRUCTURAL VIEW 1. Speedometer 2. Tachometer 3. Water temperature gauge 4. Fuel gauge 5. Oil pressure gauge 6. Warning and indicator lights 7. Trip meter 8. Odometer DESCRIPTION Speedometer Two scales are shown on the speedometer face. The main scale for U.S. specification vehicles is MPH (0-140 MPH); the main scale for Canada specification vehicles is kmlh (0-220 kmlh). The odometer indication is the same as the main scale. Tachometer The tachometer has a RED STRIPED ZONE (6,500-7,000 rpm) that indicates momentary allowable engine speed. The engine should not be operated in the RED ZONE (7,000-8,000 rpm). Fuel Gauge 2 The fuel gauge continues to indicate the amount of fuel remaining in the fuel tank after the ignition switch has been turned OFF. Gartner Banana

RtAH TURN ANU HAZARO WARNING LIGHTS . .. . 1 156 (27W) . .. I I 6 tiAzAmJ B ' ORL CONTROL UNIT (F) (F) I (SECTICN E-2) I I I '-1 FLASHER WIT =TURN AND HAZARD WARNING LIGHTS G/B G/W G/B G/W B (A) (R) AZARO ARVING WITCH E-19 1 I HAZARO INSTRUclENT CLUSTER 0 (SECTION C-b) (:I Gartner Banana

LIGHTING SYSTEM T Hazard Warning Switch Inspection 1. Remove the hazard warning switch. 2. Check for continuity between terminals of the switch. I off 0---0 : Continuity Switch On 3. If not as specified, replace the hazard warning switch and retractor switch as an assembly. Flasher Unit Inspection 1. Turn the ignition switch to ON. 2. Operate the following switches and check the operation of the turn signal and hazard warning lights. Terminal Switch G 0 Turn signal switch H 0 Hazard warning switch Procedure Operation I --- -- - ON 1 All turn signal lights flash I Right side ON Left side ON 3. If not as specified, troubleshoot the circuit. Right turn signal lights flash Left turn signal lights flash I > L R ? TURN SIGNAL SWITCH HAZARD WARNING LIGHT LIGHT SW Gartner Banana