Mazda MIATA - Service Manual

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Contents1
General Information1
Repair Procedure3
Symbols4
Advisory Messages4
Upper and Lower Limits4
Troubleshooting Procedures4
Diagnostic Index5
Quick Diagnosis Chart5
Procedures for Use5
Using the Basic Inspection5
Using the Quick Diagnosis Chart6
Using the Symptom Troubleshooting7
Text Sequence7
Units8
Conversion to si Units8
Rounding off8
SAE Standards9
Fundamental Procedures11
Protection of the Vehicle11
Preparation of Tools and Measuring Equipment11
Disconnection of the Negative Battery Cable11
Arrangement of Parts12
Cleaning of Parts12
Reassembly12
Adjustments12
Installation of Radio System13
Rubber Parts and Tubing13
Hose Clamps13
Torque Formulas13
Electrical System14
Electrical Parts14
Battery Cable14
Data Link Connector14
Terminals Inspection15
Terminals Replacement15
Sensors, Switches and Relays15
Wiring Harness15
Fuse Replacement16
Electrical Troubleshooting Tools16
Jumper Wire16
Voltmeter16
Jacking Positions17
Vehicle Lift and Safety Stand Position17
Towing18
Identification Number Locations18
Vehicle Identification Number (VIN)18
Engine Identification Number18
Abbreviations19
Pre-Delivery Inspection20
Pre-Delivery Inspection Table20
Exterior20
Under Hood - Engine off20
Scheduled Maintenance21
Chart Symbols22
Remarks22
Engine25
Engine Troubleshooting25
Engine On-Board Diagnosis26
Pending Trouble Codes26
Freeze Frame Data26
On-Board System Readiness Test26
Simulation Test27
Diagnostic Support Procedure27
On-Board Diagnosis Test27
Dtcs Reading Procedure27
Pending Trouble Code Access Procedure28
Freeze Frame PID Data Access Procedure29
On-Board System Readiness Tests Access Procedure30
PID/DATA Monitor and Record Procedure30
Playback of Stored Pids Procedure31
Diagnostic Monitoring Test Results Access Procedure31
Oxygen Sensor Test Results Access Procedure33
Simulation Test Procedure33
Idling Test33
Ignition on Test34
OBD II Drive Mode Procedure35
After Repair Procedure35
Engine Speed Table36
Mode 136
Mode 237
Mode 337
Mode 438
Failure Indication Function39
Diagnostic Trouble Codes Table39
Diagnostic Trouble Code Troubleshooting42
DTC P0102 Mass Air Flow Circuit Low Input42
DTC P0103 Mass Air Flow Circuit High Input42
DTC P0106 Barometric Pressure Circuit Performance Problem43
DTC P0107 Barometric Pressure Circuit Low Input44
DTC P0108 Barometric Pressure Circuit High Input45
DTC P0111 Intake Air Temperature Circuit Performance Problem46
DTC P0112 Intake Air Temperature Circuit Low Input46
DTC P0113 Intake Air Temperature Circuit High Input47
DTC P0117 Engine Coolant Temperature Circuit Low Input48
DTC P0118 Engine Coolant Temperature Circuit High Input49
DTC P0122 Throttle Position Circuit Low Input49
DTC P0123 Throttle Position Circuit High Input50
DTC P0125 Excessive Fuel Control Time to Enter Closed Loop51
DTC P0130 Front Heated Oxygen Sensor Circuit Malfunction52
DTC P0134 Front Heated Oxygen Sensor Circuit no Activity Detected55
DTC P0138 Rear Heated Oxygen Sensor Circuit High Input58
DTC P0140 Rear Heated Oxygen Sensor Circuit no Activity Detected59
DTC P0171 Fuel Trim System too Lean62
P0172 Fuel Trim System too Rich65
P0300 Random Misfire Detected67
P0301, P0302, P0303, P0304 Cylinder 1-4 Misfire Detected71
P0325 Knock Sensor Circuit Malfunction75
P0335 Crankshaft Position Sensor Circuit Malfunction75
P0339 Crankshaft Position Sensor Circuit Intermittent76
P0401 Exhaust Gas Recirculation Flow Insufficient Detected77
P0402 Exhaust Gas Recirculation Flow Excessive Detected79
P0420 Warm up Catalyst System Efficiency below Threshold80
P0421 Warm up Catalyst System Efficiency below Threshold81
P0442 Evaporative Emission Control System Malfunction (Leak Check)82
P0443 Evaporative Emission Control System Purge Control Valve Circuit Malfunction (Equip Leak Check)84
P0446 Evaporative Emission Control System Malfunction (Vent Control Malfunction)85
P0452 Evaporative Emission Control System Pressure Sensor Low Input87
P0453 Evaporative Emission Control System Pressure Sensor High Input88
P0455 Evaporative Emission Control System Malfunction (Con. Leak Detected)89
P0461 Fuel Level Sensor Circuit Range/Performance92
P0462 Fuel Level Sensor Circuit High Input93
P0463 Fuel Level Sensor Circuit Low Input94
P0500 Vehicle Speed Sensor Malfunction94
P0506 Idle Control System RPM Is Lower than Expected95
P0507 Idle Control System RPM Is Higher than Expected96
P0550 P/S SW Malfunction97
P0703 Brake Switch Input Malfunction97
P0704 Clutch Switch Input Circuit Malfunction98
P0705 Neutral Switch Malfunction (MT)98
P1102 Mass Air Flow Inconsistent with Throttle Position Sensor (Lower than Expected)99
P1103 Mass Air Flow Inconsistent with RPM (Grater than Expected)100
P1122 Throttle Position Is Closed Stuck101
P1123 Throttle Position Is Open Stuck102
P1135 Front Heated Oxygen Sensor Heater Circuit Low103
P1136 Front Heated Oxygen Sensor Heater Circuit High103
P1141 Rear Heated Oxygen Sensor Heater Circuit Low104
P1142 Rear Heated Oxygen Sensor Heater Circuit High105
P1170 Heated Oxygen Sensor (Front) (Inversion)106
P1345 no SGC Signal109
P1449 Canister Drain Cut Valve (CDCV) Open or Short109
P1450 Evaporative Emission Control System Malfunction110
P1487 EGR Boost Sensor Solenoid Valve Open or Short112
P1496 EGR Valve Motor Coll 1 Open or Short113
P1497 EGR Valve Motor Coil 2 Open or Short113
P1498 EGR Valve Motor Coil 3 Open or Short114
P1499 EGR Valve Motor Coil 4 Open or Short115
P1504 Idle Air Control Circuit Malfunction116
P1523 VICS Circuit Malfunction116
P1562 PCM+BB Voltage Is Low117
P1601 Communication Line Error (PCM - TCM)117
P1608, P1609118
P1631 Generator Output Voltage Signal no Electricity118
P1632 Battery Voltage Monitor Signal Circuit Malfunction119
P1633 Battery Overcharge119
P1634 Generator Terminal B Circuit Open120
Engine Symptom Troubleshooting121
Quick Diagnostic Chart123
Description of Drivability Problems125
Fuel Pressure Release and Servicing Fuel System125
Fuel Line Safety Procedures125
Symptom Troubleshooting126
Melts Main or Other Fuse126
Will Not Crank127
Hard Start/Long Crank/Erratic Start/Erratic Crank128
Engine Stalls - after Start, at Idle130
Cranks Normally but will Not Start133
Slow Return to Idle135
Engine Runs Rough/Rolling Idle136
Fast Idle/Runs on139
Low Idle/Stalls During Deceleration140
Engine Stalls/Quits - Acceleration/Cruise141
Engine Runs Rough - Acceleration/Cruise141
Misses - Acceleration/Cruise141
Buck/Jerk - Acceleration/Cruise/Deceleration141
Lack/Loss of Power - Acceleration/Cruise144
Knocking/Pinging - Acceleration/Cruise147
Poor Fuel Economy148
Emission Compliance149
Mil Never on151
High Oil Consumption/Leakage151
Cooling System Overheating152
Cooling System Runs Cold154
Exhaust Smoke155
Fuel Odor (in Engine Compartment)156
Engine Noise157
Vibration Concerns (Engine)158
A/C Does Not Work158
A/C Always On/A/C Compressor Runs Continuously159
A/C Does Not Cut off under Wide Open Throttle Conditions160
Exhaust Sulphur Smell161
Intermittent Concerns162
Fuel Refill Concerns163
Fuel Filling Shut off Issues163
Constant Voltage164
Engine Diagnostic Inspection166
Spark Plug Condition Inspection Purpose166
Wet/Carbon Stuck on Specific Plug166
Grayish White with Specific Plug167
Wet/Carbon Stuck on All Plugs167
Grayish White with All Plugs168
Input Signal System Investigation Procedure169
Finding Unusual Signals169
Locating the Source of Unusual Signals169
Variable Resistance Type 1169
Investigate the Electrical Supply System170
Investigate the GND System170
Thermistor Type170
Vehicle Speed Sensor170
Inspection Using an Oscilloscope (Reference)171
Fuel Tank Pressure, Graph Recording Procedure171
Engine System Inspection173
Intake Manifold Vacuum Inspection173
BAC Valve Operation Inspection173
Idle Air Control Inspection173
Engine Speed174
VICS Operation Inspection174
Rod Operation174
Fuel Line Pressure Inspection175
Fuel Line Pressure175
Fuel Hold Pressure Inspection175
Fuel Pump Operation Inspection176
Fuel Pump Control Inspection176
Evaporative Emission Control System Inspection177
Whole System Inspection177
Inspection from Charcoal Canister to Fuel Tank178
Inspection from Charcoal Canister to Purge Solenoid Valve180
Purge Control Inspection180
EGR Control Inspection180
Main Relay Operation Inspection181
Ignition Timing Control Inspection181
A/C Cut Control Inspection181
Cooling Fan Control System Inspection182
Cooling Fan182
Condenser Fan Relay182
Spark Test183
Fuel Injector Operation Inspection183
Fuel Cut Control Inspection184
Troubleshooting (Cruise Control System)185
Cruise Control System On-Board Diagnosis185
Inspection of Diagnostic Trouble Codes for Operation Mode185
Using the Cruise Set Indicator Light185
Using the SST (NGS Set)186
New Generation Star (NGS) Tester Hookup Procedure186
Reading Dtcs Procedure186
Operation Code List187
Inspection of Diagnostic Trouble Codes188
DTC 21 Cruise Control Switch (Set/Coast Switch)188
DTC 22 Cruise Control Switch (Resume/Accel Switch)188
DTC 31 Brake Switch188
DTC 35 Clutch Switch (At: Transmission Range Switch)189
DTC 37 Vehicle Speed Sensor190
Inspection of Diagnostic Trouble Codes for Condition Detection Mode191
Condition Code List193
DTC 05 Brake Switch194
DTC 07 Brake Switch194
DTC 11 Cruise Control Switch (Set/Coast Switch)195
DTC 12 Cruise Control Switch (Resume/Accel Switch)195
DTC 15 Cruise Control Module195
Mechanical196
Drive Belt Inspection196
Drive Belt Deflection Check196
Drive Belt Tension Check196
Drive Belt Adjustment197
Valve Clearance Inspection198
Valve Clearance Adjustment199
Compression Inspection200
Timing Belt Removal/Installation201
Pulley Lock Bolt Removal/Installation Note202
Timing Belt Removal Note202
Tensioner and Tensioner Spring Installation Note202
Timing Belt Installation Note203
Cylinder Head Cover Installation Note204
Cylinder Head Gasket Replacement205
Tappet and Adjustment Shim Removal/Installation206
Cylinder Head Removal Note206
Cylinder Head Installation Note206
Camshaft Installation Note207
Camshaft Pulley Installation Note207
Front Oil Seal Replacement208
Front Oil Seal Removal Note208
Front Oil Seal Installation Note208
Rear Oil Seal Replacement209
Rear Oil Seal Removal Note209
Rear Oil Installation Note209
Engine Removal/Installation210
Engine Disassembly/Assembly211
Engine Mount Installation Note211
Engine Tune-Up Procedure212
Ignition Timing Inspection212
Idle-Up Speed Inspection213
Idle Mixture Inspection213
Lubrication System214
Engine Oil Level Inspection214
Engine Oil Replacement214
Oil Filter Replacement215
Oil Pressure Inspection215
Oil Cooler Removal/Installation216
Oil Pan Removal/Installation217
Engine Mount Nut Removal Note218
Crossmember Bolt and Nut Removal Note218
Oil Pan Removal Note218
Oil Baffle Removal Note218
Oil Pan Installation Note219
Cooling System220
Cooling System Service Warnings220
Engine Coolant Level Inspection220
Engine Coolant Replacement221
Antifreeze Solution Mixture Percentage221
Engine Coolant Leakage Inspection222
Radiator Cap Inspection222
Radiator Removal/Installation223
Thermostat Removal/Installation224
Thermostat Inspection224
Thermostat Cover Gasket Installation Note224
Water Pump Removal/Installation225
Cooling Fan Motor Inspection225
P/S Oil Pump Removal Note225
Water Pump Installation Note225
Cooling Fan Motor Removal/Installation226
Cooling Fan Relay Inspection226
Intake-Air System227
Vacuum Hose Routing Diagram227
Intake-Air System Removal/Installation228
Idle Air Control Valve Removal/Installation229
Idle Air Control Valve Inspection229
Intake Manifold Gasket Installation Note229
Dynamic Chamber Gasket Installation Note229
VICS Check Valve (One-Way) Removal/Installation230
VICS Check Valve (One-Way) Inspection230
VICS Shutter Valve Actuator Removal/Installation231
VICS Shutter Valve Actuator Inspection231
VICS Solenoid Valve Removal/Installation232
VICS Solenoid Valve Inspection232
Airflow Inspection232
Short Circuit232
Accelerator Pedal Removal/Installation233
Accelerator Cable Inspection/Adjustment233
Accelerator Cable Installation Note233
Fuel System234
Before Repair Procedure234
Fuel Line Safety Procedure234
Fuel Hose Installation235
Fuel Leakage Inspection235
Fuel Tank Removal/Installation236
Fuel Drawing Note237
Rear Crossmember Component Removal Note237
Plastic Fuel Hose Disassembly Note237
Nonreturn Valve Installation Note237
Breather Hose, Evaporative Hose Installation Note238
Joint Hose Installation Note238
Plastic Fuel Hose Assembly Note238
Fuel Tank Side238
Nonreturn Valve Inspection239
Fuel Pump Removal/Installation239
Fuel Pump Disassembly/Assembly240
Fuel Pump Assembly Note240
Fuel Hose Assembly Note240
Fuel Pump Inspection241
Continuity Inspection241
Fuel Pump Maximum Pressure Inspection241
Fuel Pump Hold Pressure Inspection242
Fuel Pump Maximum Pressure242
Fuel Pump Hold Pressure243
Fuel Filter (High-Pressure) Removal/Installation244
Fuel Filter (High-Pressure) Removal Note245
Fuel Filter (High-Pressure) Installation Note245
Replacing the Fuel Filter245
Replacing the Fuel Filter Bracket245
Fuel Injector Removal/Installation246
Fuel Injection Installation Note246
Fuel Injection Inspection247
On-Vehicle Inspection247
Resistance Inspection247
Fuel Leakage Test247
Volume Test248
Pressure Regulator Inspection249
Pulsation Damper No.1 Removal/Installation251
Pulsation Damper No.1, No.2 Inspection251
Fuel Pump Relay Inspection252
Fuel Pump Malfunction252
Vent Cut Valve Inspection253
Exhaust System254
Exhaust System Inspection254
Exhaust System Removal/Installation255
California Emission Regulations Applicable Model256
Exhaust Manifold Insulator No1, Exhaust Manifold Insulator Removal Note256
Exhaust Manifold Gasket Installation Note256
Emission System257
Evaporative Emission Control System Components Location258
Emission System (Engine Compartment Side) Component Location260
Rollover Valve Removal/Installation261
Rollover Valve Inspection261
Air Filter Inspection261
Tank Pressure Control Valve (TPCV) Inspection262
Charcoal Canister Inspection263
Canister Drain Cur Valve (CDCV) Removal/Installation263
Canister Drain Cut Valve (CDCV) Inspection263
Catch Tank Inspection264
Purge Solenoid Valve Removal/Installation264
Purge Solenoid Valve Inspection265
Evaporative Chamber Inspection265
EGR Valve Removal/Installation266
EGR Valve Inspection266
EGR Boost Sensor Solenoid Valve Inspection267
PCV Valve Inspection268
Charging System269
Battery Removal/Installation269
Battery Inspection269
Battery Recharging270
Dark Current270
Generator Removal/Installation271
Generator Inspection271
Generator Warning Light271
Generator Voltage271
Current272
Standard Current (Reference)272
Ignition System273
Ignition Coil Removal/Installation273
Ignition Coil Inspection273
High-Tension Lead Removal/Installation276
High-Tension Lead Inspection276
Secondary Coil Winding276
Insulation Resistance of Case276
Spark Plug Removal/Installation277
Spark Plug Inspection277
Starting System278
Starter Removal/Installation278
Starter Installation Note278
Starter Inspection279
Magnetic Switch Operation Inspection279
Pull-Out Test279
Pinion Gap Inspection280
Starter Inner Parts Inspection280
Standard Commutator Diameter280
Minimum Commutator Diameter280
Magnetic Switch281
Brush and Brush Holder281
Standard Brush Length281
Minimum Brush Length281
Starter Disassembly/Assembly282
Starter Interlock Switch Inspection (MT)282
Cruise Control System283
Cruise Control Module Removal/Installation283
Cruise Control Module Inspection283
Terminal Voltage List (Reference)284
Cruise Actuator Removal/Installation285
Cruise Actuator Inspection286
Actuator Cable Adjustment287
Actuator Cable Removal/Installation287
Cruise Control Main Switch Removal/Installation288
Cruise Control Main Switch Inspection288
Cruise Control Switch Inspection289
Control System290
Control System Component Location291
PCM Removal/Installation292
Pid/Data Monitor Inspection293
FTP V PID Inspection Procedure296
BARO V PID Inspection Procedure296
Vref Terminal Circuit Inspection297
Ground Circuit Inspection297
Intake Air Temperature Sensor Inspection298
Power Supply Circuit Inspection298
Serial Communication Terminal Inspection298
Inspection of Resistance298
Mass Air Flow Sensor Inspection299
Throttle Position Sensor Inspection300
Throttle Position Sensor Replacement300
Engine Coolant Temperature Sensor Inspection301
Water Temperature Sender Unit Inspection301
Crankshaft Position Sensor Inspection302
Crankshaft Position Sensor Adjustment303
Crankshaft Position Sensor Removal/Installation303
Plate Removal/Installation303
Camshaft Position Sensor Inspection304
Visual Inspection304
Frequency Inspection304
Camshaft Position Sensor Removal/Installation306
Knock Sensor Inspection306
Knock Sensor Removal/Installation306
Heated Oxygen Sensor Inspection307
Inspection of Voltage307
Heated Oxygen Sensor Heater Inspection308
EGR Boost Sensor Inspection309
Clutch Switch Inspection309
Neutral Switch Inspection310
Power Steering Pressure Switch Inspection310
Main Relay Inspection311
Fuel Tank Pressure Sensor Inspection311
Technical Data312
Service Tools315
Suspension316
General Procedures316
Brake Pipe Flare Nuts Tightening316
Blade Lines Disconnection/Connection316
Wheel Alignment317
Wheel Alignment Preinspection317
Front Wheel Alignment317
Maximum Steering Angle Adjustment318
Caster Adjustment318
Camber Adjustment318
Rear Wheel Alignment319
Total Toe-In Adjustment319
Front Suspension321
Front Shock Absorber and Coil Spring Removal/Installation321
Front Shock Absorber and Coil Spring Removal322
Piston Rod Nut Removal Note322
Bound Stopper Installation Note322
Coil Spring Installation Note323
Front Shock Absorber and Coil Spring Installation Note323
Front Shock Absorber Inspection324
Front Shock Absorber Disposal324
Front Lower Arm Removal/Installation325
Lower Arm Ball Joint Removal Note326
Dust Boot Removal Note326
Lower Arm Blushing (Front and Rear) Removal Note326
Lower Arm Bushing (Front and Rear) Installation Note326
Front Lower Arm Inspection327
Front Upper Arm Removal/Installation327
Upper Arm Ball Joint Removal Note328
Upper Arm Bushing (Front and Rear) Removal Note328
Upper Arm Bushing (Front and Rear) Installation Note328
Dust Boot Installation Note328
Front Upper Arm Inspection329
Front Stabilizer Removal/Installation329
Stabilizer Bushing Installation Note330
Stabilizer Control Link Inspection330
Front Crossmember Removal/Installation331
Rear Suspension332
Rear Shock Absorber and Coil Spring Removal/Installation332
Rear Shock Absorber Inspection333
Rear Shock Absorber Disposal333
Rear Shock Absorber and Coil Spring Removal Note333
Rear Shock Absorber and Coil Spring Installation Note333
Rear Lower Arm Removal/Installation334
Lower Arm Bushing (Crossmember Side) Removal Note334
Lower Arm Bushing (Knuckle Side) Removal Note334
Lower Arm Bushing (Knuckle Side) Installation Note335
Lower Arm Bushing (Crossmember Side) Installation Note335
Rear Upper Arm Removal/Installation336
Upper Arm Bushing Removal Note336
Upper Arm Bushing Installation Note336
Rear Stabilizer Removal/Installation337
Rear Crossmember Removal/Installation338
Suspension SST341
Driveline/Axle342
Precaution (Driveline/Axle)342
Front Axle343
Wheel Hub, Steering Knuckle Preinspection343
Wheel Hub Bolt Replacement343
Wheel Bearing Play343
Wheel Hub, Steering Knuckle Removal/Installation344
ABS Sensor Rotor Removal Note345
Wheel Hub Bolt Removal Note345
Wheel Hub Bolt Installation Note345
ABS Sensor Rotor Installation Note345
Rear Axle346
Wheel Hub, Knuckle Preinspection346
Wheel Hub, Knuckle Removal/Installation347
Rear Wheel Hub Removal Note348
Wheel Bearing Removal Note348
Dust Cover Removal Note348
Bushing Removal Note348
Dust Cover Installation Note349
Wheel Bearing Installation Note349
Rear Wheel Hub Installation Note349
Oil Seal Installation Note349
Drive Shaft Preinspection350
Drive Shaft Removal/Installation351
Drive Shaft Removal Note351
Drive Shaft Installation Note352
Drive Shaft Disassembly/Assembly352
Boot Bands Disassembly Note353
Clip Disassembly Note353
Snap Ring Disassembly Note353
Balls, Inner Ring, Cage Disassembly Note353
ABS Sensor Rotor (with ABS) Disassembly Note354
ABS Sensor Rotor (with ABS) Assembly Note354
Boots Assembly Note354
Cage, Inner Ring, Balls Assembly Note354
Boot Bands Assembly Note355
Differential356
Differential Oil Inspection356
Differential Oil Replacement356
Oil Seal Replacement357
Differential Removal/Installation358
Power Plant Frame (PPF), Differential Mounting Spacer Removal Note359
Differential Removal Note359
Differential Disassembly/Assembly360
Differential Case Disassembly Note361
Differential Gear Component Disassembly Note361
Knock Pin (Standard) Disassembly Note361
Bearing Inner Races (Side Bearing) Disassembly Note361
Locknut (Companion Flange) Disassembly Note362
Companion Flange Disassembly Note362
Drive Pinion Disassembly Note362
Differential Mount Disassembly Note362
Differential Mount Assembly Note363
Oil Seal Assembly Note363
Bearing Outer Race (Front Bearing) Assembly363
Bearing Outer Race (Rear Bearing) Assembly Note363
Standard Backlash365
Thrust Washer Thickness365
Propeller Shaft368
Propeller Shaft Removal/Installation368
Propeller Shaft Inspection369
Driveline/Axle Technical Data370
Driveline/Axle SST371
Brakes Troubleshooting373
Antilock Brake System On-Board Diagnosis374
Conditions that Are Not ABS Malfunctions374
On-Board Diagnostic (OBD) Test Description374
New Generation Star (NGS) Tester Hook-Up Procedure374
DCT 05 Brake Switch378
Dct 11, Dct 12, Dct 13, Dct 14378
DCT 15 ABS Wheel-Speed Sensor, ABS Sensor Rotor378
DCT 22 Right Front Pressure Reduction Valve, DCT 23 Right Front Pressure Retension Valve, DCT 24 Left Front Pressure Reduction Valve, DCT 25 Left Fron379
DTC 41 Right Front ABS Wheel-Speed Sensor, DTC 42 Left Front ABS Wheel-Speed Sensor, DTC 43 Right Rear ABS Wheel-Speed Sensor, DTC 44 Left Rear ABS Wheel-Speed Sensor379
DTC 51 Valve Relay380
DTC 53 ABS Motor, Motor Relay380
Antilock Brake System Symptom Troubleshooting381
DTC 61 ABS Control Module381
DTC 63 Power Supply, Ground381
IG Switch Is Turned ON, but ABS Warning Light Does Not Illuminate382
IG Switch Is Turned to ON, and ABS Warning Light Stays on after more than 4 Seconds383
ABS Warning Light Flashes with Vehicle Stopped and ABS Warning Light Goes off When Vehicle Is Driven383
ABS Warning Light Goes on During Driving and Stays on until IG Switch Is Turned off384
ABS Warning Light Goes on and off Intermittently, Regardless of Driving and Stopping384
ABS Warning Light Indicates Normal, However ABS Does Not Operate Correctly384
Wheels and Tires Removal/Installation385
Brake Lines Disconnection/Connection385
Connectors Disconnection385
ABS Components Operations385
Conventional Brake System386
Air Bleeding386
Vacuum Line Inspection387
Brake Pedal Inspection387
Brake Pedal Height Inspection387
Brake Pedal Play Inspection387
Brake Pedal Adjustment388
Brake Pedal Height Adjustment388
Pedal Play Adjustment388
Brake Pedal Removal/Installation389
Brake Switch Inspection390
Master Cylinder Removal/Installation390
Master Cylinder Installation Note391
Non ABS Model391
Brake Fluid Level Sensor Inspection393
Master Cylinder Disassembly/Assembly394
Power Brake Unit Inspection395
Stop Screw and O-Ring Assembly Note395
Stop Pin and O-Ring Assembly Note395
Inspection for Vacuum Loss395
Power Brake Unit Removal/Installation396
Inspection for Hydraulic Pressure396
Proportioning Bypass Valve Inspection397
Proportioning Bypass Valve Replacement397
Front Brake (Disc) Inspection398
Disc Pad Thickness Inspection398
Disc Plate Thickness Inspection398
Disc Plate Runout Inspection398
Front Brake (Disc) Removal/Installation399
Disc Plate Removal Note399
Disc Plate Installation Note399
Disc Pad (Front) Replacement400
Disc Pad Installation Note400
Caliper (Front) Disassembly/Assembly401
Rear Brake (Disc) Inspection402
Rear Brake (Disc) Removal/Installation403
Disc Pad (Rear) Replacement404
Caliper (Rear) Disassembly/Assembly405
Piston Disassembly Note406
Piston Assembly Note406
Parking Brake System407
Parking Brake Inspection407
Parking Brake Adjustment407
Parking Brake Lever Removal/Installation407
Parking Brake Cable Removal/Installation408
Antilock Brake System409
ABS Hydraulic Unit Inspection409
ABS Motor Inspection410
Solenoid Valve Inspection Including the Valve Relay410
ABS Hydraulic Unit Removal/Installation411
Solenoid Valve Inspection411
ABS Hydraulic Unit Installation Note412
ABS Control Module Removal/Installation412
ABS Harness and Input Signal Inspection413
ABS Relay Removal/Installation415
ABS Relay Inspection415
Valve Relay Inspection415
Motor Relay Inspection416
Front ABS Wheel-Speed Sensor Removal/Installation417
Front ABS Wheel-Speed Sensor Inspection418
Clearance Inspection418
Rear ABS Wheel-Speed Sensor Removal/Installation419
Rear ABS Wheel-Speed Sensor Inspection419
Brakes Technical Data420
Brakes SST421
Transmission/Transaxle Troubleshooting422
Automatic Transmission On-Board Diagnostic423
Diagnostic Trouble Code Inspection423
Diagnostic Trouble Code Table423
P0715 Input/Turbine Speed Sensor Circuit Malfunction427
P0720 Output Speed Sensor Circuit Malfunction428
P0725 Engine Speed Input Circuit Signal429
P0741 Torque Converter Clutch Solenoid Valve Stuck off430
P0742 Torque Converter Clutch Solenoid Valve Stuck on430
P0751 Shift Solenoid a Stuck off431
P0752 Shift Solenoid a Stuck on431
P0756 Shift Solenoid B Stuck off432
P0757 Shift Solenoid B Stuck on432
P1740 Torque Converter Clutch Control Solenoid Valve Open433
P1742 Torque Converter Clutch Control Solenoid Valve Short433
P1751 Shift Solenoid a Circuit Open434
P1752 Shift Solenoid a Circuit Short434
P1756 Shift Solenoid B Circuit Open435
P1757 Shift Solenoid B Circuit Short435
P1771 Throttle Position Sensor Open436
P1772 Throttle Position Sensor Short436
Automatic Transmission Basic Inspection437
Automatic Transmission Symptom Troubleshooting438
Vehicle Does Not Move in D, 2, 1 Ranges, or in R Position442
Vehicle Moves in N Position443
Vehicle Moves in P Position, or Parking Gear Does Not Disengage When P Is Disengaged443
Excessive Creep443
No Creep at All444
Low Maximum Speed and Poor Acceleration445
No Shift446
Fail-Safe Function446
No TCC Function447
Abnormal Shift448
Frequent Shifting449
Shift Point Is High or Low449
No Kickdown449
Engine Flares up or Slips When Upshifting or Downshifting450
Engine Flares up or Slips When Accelerating Vehicle450
Judder Upon During TCC Operation451
Excessive N to D or N to R Position/Range Shift Shock452
Excessive Shift Shock When Upshifting and Downshifting453
Excessive TCC Shift Shock453
Noise at Idle When Vehicle Is Stopped in All Positions/Ranges454
Noise at Idle When Vehicle Is Stopped in D, 2, 1 Range or in R Position454
No Engine Braking in 1, 2, or 3 Gear454
Transmission Overheats455
Engine Stalls When Shifted to D, 2, 1 Ranges, And/Or in R Position456
Engine Stalls When Driving at Slow Speeds or Stopping456
O/D off Indicator Light Does Not Illuminate When O/D off Switch Is Turned on457
O/D off Indicator Light Illuminates When O/D Switch Is Not Turned on457
Clutch458
Clutch Pipe458
Clutch Fluid Inspection458
Clutch Fluid Replacement459
Clutch Fluid Air Bleeding459
Clutch Pedal Inspection460
Clutch Pedal Height Inspection460
Clutch Pedal Free Play Inspection460
Clutch Pedal Adjustment461
Clutch Pedal Height Adjustment461
Clutch Pedal Free Play Adjustment461
Clutch Pedal Removal/Installation462
Clutch Master Cylinder Removal/Installation463
Spring Removal Note463
Spring Installation Note463
Clutch Master Cylinder Disassembly/Assembly464
Gasket Installation Note464
Clutch Release Cylinder Removal/Installation465
Snap Ring Disassembly/Assembly Note465
Clutch Release Cylinder Disassembly/Assembly466
Clutch Unit Removal/Installation467
Clutch Cover and Clutch Disc Removal Note468
Flywheel Installation Note468
Pilot Bearing Note468
Pilot Bearing Installation Note468
Clutch Cover Inspection469
Clutch Disc Inspection469
Clutch Cover Installation Note469
Clutch Release Collar Inspection470
Pilot Bearing Inspection470
Flywheel Inspection470
Manual Transmission471
Transmission Oil Inspection471
Transmission Oil Replacement472
Oil Seal (Rear) Replacement472
Vehicle Speedometer Sensor Removal/Installation473
Vehicle Speedometer Sensor Inspection473
Manual Transmission Removal/Installation473
Power Plant Frame (PPF) Removal Note474
Transmission Removal Note475
Transmission Installation Note475
Power Plant Frame (PPF) Installation Note475
Shift Lever Component Installation Note476
Automatic Transmission478
Mechanical System Test479
Line Pressure Test479
Evaluation of Line Pressure Test479
Specified Line Pressure479
Stall Test480
Evaluation of Stall Test480
Time Lag Test480
Road Test Preparation481
Shift Diagram481
Range Test481
Vehicle Speed at Shift Point Table482
2 Range Test482
Automatic Transmission Fluid (ATF) Inspection483
ATF Condition Inspection483
ATF Condition483
Automatic Transmission Fluid (ATF) Replacement484
ATF Level Inspection484
Throttle Cable Inspection485
Throttle Cable Adjustment485
Throttle Cable Removal/Installation486
O/D off Switch Inspection488
O/D off Switch Removal/Installation488
Inspection of Operation488
Inspection of Continuity488
Transmission Range Switch Inspection489
Transmission Range Switch Removal/Installation490
Transmission Range Switch Adjustment490
Input/Turbine Speed Sensor Inspection491
Input/Turbine Speed Sensor Removal/Installation491
Output Speed Sensor Inspection492
Output Speed Sensor Removal/Installation492
Solenoid Valves Inspection493
Fail Safe Function493
Solenoid Valves Removal/Installation494
Transmission Control Module Inspection495
Terminal Voltage Chart (Reference Data)495
Transmission Control Module Removal/Installation497
Automatic Transmission Removal/Installation497
Torque Converter Bolts Installation Note499
Power Plate Frame (PPF) Installation Note499
Extension Housing Removal/Installation500
Oil Seal (Transmission) Replacement501
Control Valve Body Removal/Installation502
On-Vehicle Removal502
On-Vehicle Installation502
Torque Converter Removal/Installation503
Elbow Installation Note504
Drive Plate Removal/Installation505
Radiator Installation Note505
Oil Hose Installation Note505
Drive Plate Mounting Bolts Installation Note506
Automatic Transmission Shift Mechanism507
Emergency Override Button Inspection507
Key Interlock Solenoid Inspection507
Key Interlock Solenoid Removal/Installation508
Key Interlock Unit Inspection508
Key Interlock Unit Removal/Installation509
P Position Switch Inspection509
Shift-Lock Actuator Inspection509
Shift-Lock Actuator Removal/Installation511
Selector Lever Inspection511
Selector Lever Adjustment512
Lever Position Adjustment512
Indicator Panel Adjustment512
Selector Lever Removal/Installation513
Spring Pin Installation Note513
Selector Lever Disassembly/Assembly514
Cam Assembly Note515
Indicator Panel Assembly Note515
Transmission/Transaxle Technical Data516
Transmission/Transaxle Service Tools517
Steering518
Steering Precaution518
Power Steering Components Removal/Installation518
Manual Steering519
Steering Wheel and Column Inspection519
Steering Wheel Looseness Inspection519
Steering Wheel Inspection519
Steering Wheel and Column Removal/Installation520
Steering Wheel Removal Note520
Steering Shaft Disassembly/Assembly521
Steering Lock Mounting Bolts and Bracket Disassembly Note521
Steering Lock Mounting Bolts and Bracket Assembly Note521
Steering Shaft Inspection522
Steering Gear and Linkage Removal/Installation522
Steering Gear and Linkage Disassembly/Assembly523
Tie-Rod End Ball Joint Removal Note523
Tie-Rod Disassembly Note524
Adjusting Cover Disassembly Note524
Steering Rack Disassembly Note524
Lower Bearing Disassembly Note524
Rack Bushing Disassembly Note525
Bushing Disassembly Note525
Tie-Rod End Boot Disassembly Note525
Mounting Rubber Assembly Note525
Tie-Rod End Boot Assembly Note526
Bushing Assembly Note526
Rack Bushing Assembly Note526
Lower Bearing Assembly Note526
Pinion Shaft Assembly Note527
Rear Cover Assembly Note527
Adjusting Cover Assembly Note527
Steering Gear and Linkage Inspection528
Tie Rod Inspection528
Steering Rack Inspection528
Engine Speed Sensing Power Steering529
Power Steering Fluid Inspection529
Fluid Level Inspection529
Fluid Leakage Inspection530
Fluid Pressure Inspection530
Steering Wheel Effort Inspection532
Steering Wheel Effort532
Pinion Shaft Component Disassembly Note536
Holder Disassembly Note536
Oil Seal, Inner Guide Disassembly Note536
Upper Bearing, Oil Seal Disassembly Note536
Oil Seal, Inner Guide Assembly Note537
Holder Assembly Note537
Upper Bearing Assembly Note537
Seal Ring Assembly Note537
Hermetic Sealing Inspection538
Power Steering Oil Pump Removal/Installation539
Power Steering Oil Pump Disassembly/Assembly540
Power Steering Oil Pump Disassembly Note541
Rotor Assembly Note541
Cam Ring Assembly Note541
Blade Assembly Note541
Steering Technical Data542
Steering SST543
HVAC Troubleshooting545
Refrigerant System555
Refrigerant System Service Warnings555
Refrigerant System Service Cautions555
Refrigerant System General Procedures556
Refrigerant System Performance Test556
Refrigerant Charge Check556
Refrigerant Pressure Check557
Refrigerant Charging557
Basic System Structural View560
Blower Unit Removal/Installation561
Blower Unit Disassembly/Assembly561
Cooling Unit Removal/Installation562
Cooling Unit Installation Note562
Cooling Unit Disassembly/Assembly563
Evaporator Inspection563
Expansion Valve Assembly Note563
Thermoswitch Assembly Note563
Heater Unit Removal/Installation564
Heater Unit Disassembly/Assembly564
Heater Core Inspection565
A/C Compressor Removal/Installation565
A/C Compressor Installation Note565
Condenser Removal/Installation566
Condenser Inspection566
Receiver/Driver Removal/Installation567
Refrigerant Lines Removal/Installation568
Control System Structural View569
Resistor Removal/Installation570
Resistor Inspection570
Magnetic Clutch Inspection570
Magnetic Clutch Adjustment571
Magnetic Clutch Disassembly/Assembly571
Condenser Fan Inspection572
Condenser Fan Removal/Installation572
Blower Motor Inspection573
Blower Motor Removal/Installation573
Refrigerant Pressure Switch Inspection573
Refrigerant Pressure Switch Removal/Installation574
Thermoswitch Inspection574
To Determine if the Switch Is Functioning574
To Inspect On/Off Points of the Thermoswitch574
Heater Control Unit Removal575
Heater Control Unit Installation575
Heater Control Unit Disassembly/Assembly576
Heater Control Unit Inspection576
A/C Switch576
Fan Switch576
Heater Control Unit Wire Adjustment577
A/C Relay and Condenser Fan Relay Removal/Installation577
Air Intake Wire577
Air MIX Wire577
A/C Relay and Condenser Fan Relay Inspection578
Blower Relay Removal/Installation578
Blower Relay Inspection578
HVAC Technical Data579
Hvac Sst580
Restraints581
Air Bag System On-Board Diagnosis581
DTC 1 SAS Control Module Connector Poor Connection582
DTC 2 SAS Control Module583
DTC 3 Battery583
DTC 6 Driver-Side Air Bag Module584
DTC 7 Passenger-Side Air Bag Module586
DTC 49 Passenger-Side Air Bag Cut-Off System587
Air Bag System Symptom Troubleshooting588
Air Bag System596
Air Bag System Service Warnings596
Air Bag Module Inspection596
Air Bag Module Handling597
SAS Control Module Handling597
Driver-Side Air Bag Module Removal/Instlallation598
Passenger-Side Air Bag Module Removal/Installation599
Bolt Installation Note599
Clock Spring Adjustment600
Clock Spring Removal/Installation600
Clock Spring Inspection601
Passenger Air Bag Deactivation (Pad) Switch Removal/Installation601
Passenger Air Bag Deactivation (Pad) Switch Inspection602
SAS Control Module Removal/Installation603
Air Bag Module Deployment Authorization Procedures603
Air Bag Module Deployment Procedures604
Deployment Procedures for Inside of Vehicle604
Driver-Side Air Bag Module604
Passenger-Side Air Bag Module604
Deployment Procedures for Outside of Vehicle605
Air Bag Module Disposal Procedures607
Inspection of SST (Deployment Tool)608
Seat Belt Inspection609
Belt609
Elr609
Alr609
Seat Belt Removal/Installation610
Buckle Removal/Installation610
Restraints SST611
Body & Accessories612
Body Panels612
Fuelfiller Lid Adjustment612
Fuel-Filler Lid Removal/Installation613
Hood Adjustment613
Gap Adjustment613
Height Adjustment613
Hood Removal/Installation614
Trunk Lid Adjustment614
Trunk Lid Removal/Installation615
Front Bumper Removal/Installation616
Balance Spring Removal Note616
Rear Bumper Removal/Installation617
Front Fender Panel Removal/Installation618
Doors and Liftgate619
Door Adjustment619
Door Removal/Installation620
Connector Removal Note620
Connector Installation Note620
Door Disassembly/Assembly621
Glass/Windows/Mirrors622
Door Glass Adjustment622
Vertical Adjustment623
Convertible Top623
Detachable Hardtop623
Forward/Backward Adjustment624
Inward/Outward Adjustment625
Door Glass and Guide Removal/Installation626
Power Window Regulator Removal/Installation627
Power Window Regulator Disassembly627
Power Window Regulator Assembly628
Power Window Motor Inspection629
Manual Window Regulator Removal/Installation630
Power Window Switch Removal/Installation630
Power Window Switch Inspection631
Regulator Handle Removal631
Regulator Handle Installation632
Rear Window Glass Removal632
Rear Window Glass Installation633
Windshield Removal634
Non Reusing Windshield634
Windshield Installation635
Reusing Windshield635
Filament Inspection637
Filament Repair638
Rear Window Defroster Switch Removal/Installation638
Rear Window Defroster Switch Inspection638
Rear Window Defroster Power-Cut Switch Removal/Installation639
Rear Window Defroster Power-Cut Switch Inspection639
Rear Window Defroster Relay Removal/Installation640
Rear Window Defroster Relay Inspection640
Power Outside Mirror Inspection640
Power Outside Mirror Removal/Installation641
Manual Outside Mirror Removal/Installation642
Outside Mirror Glass Removal642
Outside Mirror Glass Installation643
Power Outside Mirror Switch Removal/Installation643
Power Outside Mirror Switch Inspection644
Rearview Mirror Removal644
Rearview Mirror Installation645
Base Removal645
Base Installation645
Seat Removal/Installation647
Seat Disassembly/Assembly648
Security and Locks649
Door Lock and Opener Removal/Installation649
Door Lock Actuator Inspection649
Door Lock-Link Switch Inspection650
Door Lock Striker Removal/Installation650
Door Lock Control Module Inspection651
Terminal Voltage List651
Door Lock Control Module Removal/Installation652
Fuel-Filler Lid Opener Removal/Installation653
Hood Lock and Opener Removal/Installation654
Trunk Lid Lock and Opener Removal/Installation654
Trunk Lid Striker Removal/Installation655
Exterior Trim656
Cowl Grille Removal/Installation656
Beltline Molding Removal/Installation656
Front Beltline Molding Removal/Installation657
Rear Window Molding Removal657
Rear Window Molding Installation657
Windshield Molding Removal659
Windshield Molding Installation659
Convertible Top Adjustment661
Convertible Top Removal/Installation662
Convertible Top Disassembly/Assembly663
Convertible Top Installation Note663
Set Plate Assembly Note666
End Plate Assembly Note666
Retainer Assembly Note666
Retainer Adjustment667
Top Fabric Repair667
Top Fabric Removal/Installation669
Top Fabric Removal Note670
Rain Rail Removal Note670
Rain Rail Installation Note670
If the Rivets will be Used671
Top Fabric Installation Note671
Detachable Hardtop Adjustment672
Top Lock672
Side Lock672
Rear Deck Lock672
Detachable Hardtop Disassembly/Assembly673
Interior Trim674
Dashboard Removal/Installation675
Dashboard Disassembly/Assembly676
Center Panel Removal/Installation677
Column Cover Removal/Installation677
Console Removal/Installation678
Console Disassembly/Assembly678
Glove Compartment Removal/Installation679
Lower Panel Removal/Installation679
Meter Hood Removal/Installation680
Door Trim Removal/Installation680
A-Pillar Trim Removal/Installation681
Front Header Trim Removal/Installation681
Quarter Trim Removal/Installation681
Rear Package Trim Removal/Installation682
Scuff Plate Removal/Installation682
Front Side Trim Removal/Installation682
Trunk End Trim Removal/Installation683
Trunk Side Trim Removal/Installation683
Floor Covering Removal/Installation684
Rear End Mat Removal/Installation684
Lighting System685
Headlight Adjustment685
Front Combination Light Removal/Installation686
Headlight Bulb Removal/Installation686
Parking Light/Front Turn Light Bulb Removal/Installation686
Front Side Marker Light Removal/Installation687
Rear Combination Light Removal/Installation687
High-Mount Brake Light Removal/Installation687
License Plate Light Removal/Installation688
Back-Up Light Switch Removal/Installation688
High-Mount Brake Light Removal Note688
License Plate Light Removal Note688
Back-Up Light Switch Inspection689
Combination Switch Removal/Installation689
Combination Switch Disassembly/Assembly690
Combination Switch Inspection690
Headlight Switch690
Hazard Warning Switch Removal/Installation691
Turn Switch691
Windshield Wiper and Washer Switch691
Hazard Warning Switch Removal Note691
Hazard Warning Switch Inspection692
Headlight Relay Removal/Installation692
Headlight Relay Inspection693
TNS Relay Removal/Installation693
TNS Relay Inspection693
Flasher Control Module Removal/Installation694
Flasher Control Module Inspection694
DRL Control Module Removal/Installation695
DRL Control Module Inspection695
Interior Light Removal and Installation696
Interior Light Inspection697
Door Switch Removal/Installation697
Door Switch Inspection697
Panel Light Control Switch Removal/Installation698
Panel Light Control Switch Inspection698
Panel Light Control Switch Removal Note698
Wiper and Washer700
Windshield Wiper Arm and Blade Adjustment700
Windshield Wiper Arm and Blade Removal/Installation700
Windshield Wiper Link Removal/Installation701
Windshield Wiper Motor Removal/Installation701
Windshield Wiper Motor Inspection701
Windshield Washer Tank Removal/Installation702
Windshield Washer Motor Removal/Installation703
Windshield Washer Motor Inspection703
Windshield Washer Nozzle Adjustment704
Windshield Washer Nozzle Removal704
Windshield Washer Nozzle Installation704
Windshield Washer Pipe Removal/Installation705
Entertainment706
Door Speaker Removal/Installation706
Door Speaer Inspection706
Tweeter Speaker Removal/Installation707
Tweeter Speaker Inspection707
Manual Antenna Removal/Installation708
Manual Antenna Inspection708
Mounting Nut Removal Note708
Power Antenna Removal/Installation709
Power Antenna Disassembly/Assembly709
Power Antenna Inspection710
Antenna Mast Removal710
Antenna Mast Installation710
Front Antenna Feeder Removal/Installation711
Front Antenna Feeder Inspection711
Rear Antenna Feeder Removal/Installation712
Rear Antenna Feeder Inspection712
Audio Unit Removal713
Audio Unit Installation713
Audio Amplifier Removal/Installation714
Audio Relay Removal/Installation714
Audio Relay Inspection715
Cigarette Lighter Removal/Installation715
Cigarette Lighter Inspection715
Socket Removal Note715
Power Systems717
Fuse Service Caution717
Main Fuse Removal/Installation717
Room Fuse Installation718
Ignition Switch Removal/Installation718
Ignition Switch Inspection718
Key Reminder Switch Inspection719
Instrumention/Driver Info720
Instrument Cluster Removal/Installation720
Instrument Cluster Disassembly/Assembly720
Instrument Cluster Inspection721
Speedometer721
Fuel Gauge721
Tachometer721
Oil Pressure Gauge722
Instrument Cluster Input/Output Check Mode723
Diagnostic Trouble Code Chart723
Operating Order723
Checking Order723
DTC 00 Transmission Range Switch (R Range) Signal724
DTC 01 Seat Belt Switch On/Off Signal724
DTC 04 Door Switch On/Off Signal724
Warning and Indicator Light Bulb Removal/Installation725
DTC 08 TNS Relay On/Off Signal725
DTC 14 Operation Signal to Buzzer725
DTC 31 Key Reminder Switch On/Off Signal725
Fuel Gauge Sender Unit Inspection726
Oil Pressure Switch Inspection726
Horn Removal/Installation726
Horn Relay Inspection726
Body & Accessories Technical Data727
Body & Accessories SST728
Alphabetical Index729

Mazda MIATA - Service Manual

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