Mazda MX-5 Miata - Workshop Manual

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Contents1
Vehicle Identification Numbers (VIN)2
Warning3
General Information4
How to Use this Manual5
Range of Topics5
Repair Procedure6
Symbols7
Upper and Lower Limits7
Basic Flow of Troubleshooting7
On-Board Diagnosis7
Diagnostic Index8
Procedures for Use8
Using the Basic Inspection8
Using the Diagnostic Index8
Using the Quick Diagnosis Chart9
Using the Symptom Troubleshooting10
Text Sequence10
Units11
SAE Standards12
Fundamental Procedures14
Installation of Radio System16
Electrical System Procedures17
Electrical Troubleshooting Tools19
Jacking Positions20
Vehicle Lift (2 Supports) and Safety Stand (Rigid Rack) Position20
Towing21
Tiedown Hooks21
Identification Number Locations21
Abbreviations22
Pre-Delivery Inspection23
Scheduled Maintenance24
Scheduled Maintenance Chart Symbols25
Schedule 2 (Unique Driving Conditions)25
Scheduled Maintenance Table (Canada)26
Engine28
Troubleshooting (Engine Control)29
Engine On-Board Diagnosis29
Simulation Test30
Diagnostic Support Procedure (Engine)30
New Generation Start (NGS) Tester Hook-Up Procedure30
Dtcs Reading Procedure30
Pending Trouble Code Access Procedure31
Freeze Frame PID Data Access Procedure32
On-Board System Readiness Tests Access Procedure33
PID/DATA Monitor and Record Procedure33
Playback of Stored Pids Procedure34
Diagnostic Monitoring Test Results Access Procedure34
Diagnostic Support Procedure35
Oxygen Sensor Test Results Access Procedure36
Simuilation Test Procedure36
Idling Test36
Ignition on Test37
After Repair Procedure38
OBD II Drive Mode Procedure38
Failure Indication Function/Diagnostic Trouble Code Table (Engine)42
Diagnostic Trouble Code Troubleshooting45
DTC P0102 Mass Air Flow Circuit Low Input45
DTC P0103 Mass Air Flow Circuit High Input45
DTC P0106 Barometric Pressure Circuit Performance Problem46
DTC P0107 Barometric Pressure Circuit Low Input47
DTC P0108 Barometric Pressure Circuit High Input48
DTC P0111 Intake Air Temperature Circuit Performance Problem49
DTC P0112 Intake Air Temperature Circuit Low Input49
DTC P0113 Intake Air Temperature Circuit High Input50
DTC P0117 Engine Coolant Temperature Circuit Low Input51
DTC P0118 Engine Coolant Temperature Circuit High Input52
DTC P0122 Throttle Position Circuit Low Input52
DTC P0123 Throttle Position Circuit High Input53
DTC P0125 Excessive Fuel Control Time to Enter Closed Loop54
DTC P0130 Front Heated Oxygen Sensor Circuit Malfunction55
DTC P0134 Front Heated Oxygen Sensor Circuit no Activity Detected58
DTC P0138 Rear Heated Oxygen Sensor Circuit High Input61
DTC P0140 Rear Heated Oxygen Sensor Circuit no Activity Detected62
DTC P0171 Fuel Trim System too Lean65
DTC P0172 Fuel Trim System too Rich68
DTC P0300 Random Misfire Detected70
DTC P0301, P0302, P0303, P0304 Cylinder 1 - 4 Misfire Detected74
DTC P0325 Knock Sensor Circuit Malfunction78
DTC P0335 Crankshaft Position Sensor Circuit Malfunction78
DTC P0339 Crankshaft Position Sensor Circuit Intermittent79
DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected80
DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected82
DTC P0420 Warm up Catalyst System Efficiently below Threshold83
DTC P0421 Warm up Catalyst System Efficiently below Threshold84
DTC P0442 Evaporative Emission Control System Malfunction (Leak Check)85
DTC P0443 Evaporative Emission Control System Purge Control Valve Circuit Malfunction (Equip Leak Check)87
DTC P0446 Evaporative Emission Control System Malfunction (Vent Control Malfunction)88
DTC P0452 Evaporative Emission Control System Pressure Sensor Low Input90
DTC P0453 Evaporative Emission Control System Pressure Sensor High Input91
DTC P0455 Evaporative Emission Control System Malfunction (Con. Leak Detected)92
DTC P0461 Fuel Level Sensor Circuit Range/Performance95
DTC P0462 Fuel Level Sensor Circuit High Input96
DTC P0463 Fuel Level Sensor Circuit Low Input97
DTC P0500 Vehicle Speed Sensor Malfunction97
DTC P0506 Idle Control System RPM Is Lower than Expected98
DTC P0507 Idle Control System RPM Is Higher than Expected99
DTC P0550 P/S SW Malfunction100
DTC P0703 Brake Switch Input Malfunction100
DTC P0704 Clutch Switch Input Circuit Malfunction101
DTC P0705 Neutral Switch Circuit Malfunction (MT)101
DTC P1102 Mass Air Flow Inconsistent with Throttle Position Sensor (Lower than Expected)102
DTC P1103 Mass Air Flow Inconsistent with RPM (Greater than Expected)103
DTC P1122 Throttle Position Is Closed Stuck104
DTC P1123 Throttle Position Is Open Stuck105
DTC P1135 Front Heated Oxygen Sensor Heater Circuit Low106
DTC P1136 Front Heated Oxygen Sensor Heater Circuit High106
DTC P1141 Rear Heated Oxygen Sensor Heater Circuit Low107
DTC P1142 Rear Heated Oxygen Sensor Heater Circuit High108
DTC P1170 Heated Oxygen Sensor (Front) (Inversion)109
DTC P1345 no SGC Signal112
DTC P1449 Canister Drain Cut Valve (CDCV) Open or Short112
DTC P1450 Evaporative Emission Control System Malfunction113
DTC P1487 EGR Boost Sensor Solenoid Valve Open or Short115
DTC P1496 EGR Valve Motor Coil 1 Open or Short116
DTC P1497 EGR Valve Motor Coil 2 Open or Short116
DTC P1498 EGR Valve Motor Coil 3 Open or Short117
DTC P1499 EGR Valve Motor Coil 4 Open or Short118
DTC P1504 Idle Air Control Circuit Malfunction119
DTC P1523 VICS Circuit Malfunction119
DTC P1562 PCM + BB Voltage Is Low120
DTC P1601 Communication Line Error (PCM-TCM)120
Dtc P1608, P1609121
DTC P1631 Generator Output Voltage Signal no Electricity121
DTC P1632 Battery Voltage Monitor Signal Circuit Malfunction122
DTC P1633 Battery Overcharge122
DTC P1634 Generator Terminal B Circuit Open123
Engine Symptom Troubleshooting124
Quick Diagnostic Chart (Engine)126
Description of Drivability Problems128
Fuel Pressure Release and Servicing Fuel System128
Fuel Line Safety Procedures128
Symptom Troubleshooting (Engine)129
Melts Main or Other Fuse129
Will Not Crank130
Hard Start/Long Crank/Erratic Start/Erratic Crank131
Engine Stalls - after Start, at Idle133
Cranks Normally but will Not Start136
Slow Return to Idle138
Engine Runs Rough/Rolling Idle139
Fast Idle/Runs on142
Low Idle/Stalls During Deceleration143
Engine Stalls/Quits - Acceleration/Cruise; Engine Runs Rough - Acceleration/Cruise; Misses - Acceleration/Cruise; Buck/Jerk - Acceleration/Cruise/Dece144
Lack/Loss of Power - Acceleration/Cruise147
Knocking/Pinging - Acceleration/Cruise150
Poor Fuel Economy151
Emission Compliance152
Mil Never on154
High Oil Consumption/Leakage154
Cooling System Overheating155
Cooling System Runs Cold157
Exhaust Smoke158
Fuel Odor (in Engine Compartment)159
Engine Noise160
Vibration Concerns (Engine)161
A/C Does Not Work161
A/C Always On/ A/C Compressor Runs Continuously162
A/C Does Not Cut off under Wide Open Throttle Conditions163
Exhaust Sulphur Smell164
Intermittent Concerns165
Fuel Refill Concerns166
Fuel Filling Shut off Issues166
Constant Voltage167
Engine Diagnostic Inspection169
Spark Plug Condition Inspectin Purpose169
Wet/Carbon Stuck on Specific Plug169
Grayish White with Specific Plug170
Wet/Carbon Stuck on All Plugs170
Grayish White with All Plugs171
Input Signal System Investigation Procedure172
Finding Unusual Signals172
Investigate the Input Signal System172
Investigate the GND System172
Investigate the Electrical Supply System173
Thermistor Type (Intake Air Temperature and Engine Coolant Temperature Sensors)173
Vehicle Speed Sensor173
Inspection Using an Oscilloscope (Reference) Purpose174
When Plunger Stuck174
Fuel Tank Pressure, Graph Recording Procedure174
Engine System Inspection176
Intake Manifold Vacuum Inspection176
BAC Valve Operation Inspection176
Idle Air Control Inspection176
VICS Operation Inspection177
Fuel Line Pressure Inspection178
Fuel Hold Pressure Inspection178
Fuel Pump Operation Inspection179
Fuel Pump Control Inspection179
Evaporative Emission Control System Inspection - Whole System Inspection180
Inspection from Charcoal Canister to Fuel Tank181
Inspection from Charcoal Canister to Purge Solenoid Valve183
Purge Control Inspection183
EGR Control Inspection183
Main Relay Operation Inspection184
Ignition Timing Control Inspection184
A/C Cut Control Inspection184
Cooling Fan Control System Inspection185
Cooling Fan Operation185
Condenser Fan Relay185
Spark Test186
Fuel Injector Operation Inspection186
Fuel Cut Control Inspection187
Troubleshooting (Cruise Control System)188
Cruise Control System On-Board Diagnosis188
Inspection of Diagnostic Trouble Codes for Operation Mode188
Using the Cruise Set Indicator Light188
Using the SST (NGS Set) - New Generation Star (NGS) Tester Hookup Procedure189
Reading Dtcs Procedure189
Operation Code List190
Inspection of Diagnostic Trouble Codes191
DTC 21 Cruise Control Switch (Set/Coast Switch)191
DTC 22 Cruise Control Switch (Resume/Accel Switch)191
DTC 31 Brake Switch191
DTC 35 Clutch Switch (AT: Transmission Range Switch)192
DTC 37 Vehicle Speed Sensor193
Inspection of Diagnostic Trouble Codes for Condition Detection Mode Using the Cruise Set Indicator Light194
Condition Code List196
DTC 01 Cruise Actuator196
DTC 05 Brake Switch197
DTC 07 Brake Switch197
DTC 11 Cruise Control Switch (Set/Coast Switch)198
DTC 12 Cruise Control Switch (Resume/Accel Switch)198
DTC 15 Cruise Control Module198
Mechanical199
Drive Belt Inspection199
Drive Belt Deflection Check199
Drive Belt Tension Check199
Drive Belt Adjustment200
Valve Clearance Inspection201
Valve Clearance Adjustment202
Compression Inspection203
Timing Belt Removal/Installation204
Cylinder Head Cover Installation Note207
Cylinder Head Gasket Replacement208
Tappet and Adjustment Shim Removal/Installation209
Front Oil Seal Replacement211
Rear Oil Seal Replacement212
Engine Removal/Installation213
Engine Disassembly/Assembly214
Engine Tune-Up215
Ignition Timing Inspection215
Idle Speed Adjustment215
Idle-Up Speed Inspection216
Idle Mixture Inspection216
Lubrication System217
Engine Oil Level Inspection217
Engine Oil Replacement217
Oil Filter Replacement218
Oil Pressure Inspection218
Oil Cooler Removal/Installation219
Oil Pan Removal/Installation220
Engine Mount Nut Removal Note221
Oil Pan Removal Note221
Crossmember Bolt and Nut Removal Note221
Oil Baffle Removal and Installation Note221
Oil Pan Installation Note222
Cooling System223
Engine Coolant Level Inspection223
Engine Coolant Replacement224
Antifreeze Solution Mixture Percentage224
Engine Coolant Leakage Inspection225
Radiator Cap Inspection225
Radiator Removal/Installation226
Thermostat Removal/Installation227
Thermostat Inspection227
Water Pump Removal/Installation228
Cooling Fan Motor Inspection228
Cooling Fan Motor Removal/Installation229
Cooling Fan Relay Inspection229
Intake-Air System230
Vacuum Hose Routing Diagram230
Intake-Air System Removal/Installation231
Idle Air Control Valve Removal/Installation232
Idle Air Control Valve Inspection232
Resistance Inspection232
VICS Check Valve (One-Way) Removal/Installation233
VICS Check Valve (One-Way) Inspection233
VICS Shitter Valve Actuator Removal/Installation234
VICS Shutter Valve Actuator Inspection234
VICS Solenoid Valve Removal/Installation235
VICS Solenoid Valve Inspection235
Accelerator Pedal Removal/Installation236
Accelerator Cable Inspection/Adjustment236
Fuel System237
Fuel Line Safety Procedure237
Fuel Hose Installation238
Fuel Leakage Inspection238
Fuel Tank Removal/Installation239
Fuel Drawing Note240
Rear Crossmember Component Removal Note240
Plastic Fuel Hose Disassembly Note240
Nonreturn Valve Installation Note240
Breather Hose, Evaporative Hose Installation Note241
Joint Hose Installation Note241
Plastic Fuel Hose Assembly Note241
Nonreturn Valve Inspection242
Fuel Pump Removal/Installation242
Fuel Pump Disassembly/Assembly243
Fuel Pump Inspection244
Fuel Pump Maximum Pressure Inspection244
Fuel Pump Hold Pressure Inspection245
Fuel Filter (High-Pressure) Removal/Installation247
Fuel Filter (High-Pressure) Removal Note248
Replacing the Fuel Filter Bracket248
Fuel Injector Removal/Installation249
Fuel Injector Inspection250
Fuel Leakage Test250
Volume Test251
Pressure Regulator Inspection252
Pulsation Damper No.1 Removal/Installation254
Pulsation Damper No.1, No.2 Inspection254
Fuel Pump Relay Inspection255
Vent Cut Valve Inspection256
Exhaust System Inspection257
Exhaust System Removal/Installation258
California Emission Regulations Applicable Model259
Emission System260
Evaporative Emission Control System Components Location261
Emission System (Engine Compartment Side) Component Location263
Rollover Valve Removal/Installation264
Rollover Valve Inspection264
Air Filter Inspection264
Tank Pressure Control Valve (TPCV) Inspection265
Evaporative Hose Improper Routing, Kinks or Leakage265
Charcoal Canister Inspection266
Canister Drain Cut Valve (CDCV) Removal/Installation266
Canister Drain Cut Valve (CDCV) Inspection266
Catch Tank Inspection267
Purge Solenoid Valve Removal/Installation267
Purge Solenoid Valve Inspection268
Evaporative Chamber Inspection268
EGR Valve Removal/Installation269
EGR Valve Inspection269
EGR Boost Sensor Solenoid Valve Inspection270
PCV Valve Inspection271
Charging System272
Battery Removal/Installation272
Battery Inspection272
Battery Positive Voltage with Load272
Battery Recharging273
Dark Current273
Generator Removal/Installation274
Generator Inspection274
Generator Warning Light274
Generator Voltage274
Current275
Igniton System276
Ignition Coil Removal/Installation276
Ignition Coil Inspection276
High-Tension Lead Removal/Installation279
High-Tension Lead Inspection279
Secondary Coil Winding279
Insulation Resistance of Case279
Spark Plug Removal/Installation280
Spark Plug Inspection280
Starting System281
Starter Removal/Installation281
Starter Inspection282
Magnetic Switch Operation Inspection282
Pinion Gap Inspection283
Starter Inner Parts Inspection283
Magnetic Switch284
Brush and Brush Holder284
Starter Disassembly/Assembly285
Starter Interlock Switch Inspection (MT)285
Cruise Control System286
Cruise Control Module Removal/Installation286
Cruise Control Module Inspection286
Terminal Voltage List (Reference)287
Cruise Actuator Removal/Installation288
Cruise Actuator Inspection289
Actuator Cable Adjustment290
Actuator Cable Removal/Installation290
Cruise Control Main Switch Removal/Installation291
Cruise Control Main Switch Inspection291
Cruise Control Switch Inspection292
Control System293
Control System Component Location294
PCM Removal/Installation295
Pid/Data Monitor Inspection296
FTP V PID Inspection Procedure299
BARO V PID Inspection Procedure299
Vref Terminal Circuit Inspection300
Ground Circuit Inspection300
Intake Air Temperature Sensor Inspection301
Power Supply Circuit Inspection301
Mass Air Flow Sensor Inspection302
Throttle Position Sensor Inspection303
Throttle Position Sensor Replacement303
Engine Coolant Temperature Sensor Inspection304
Water Temperature Sender Unit Inspection304
Crankshaft Position Sensor Inspection305
Inspection of Air Gap305
Crankshaft Position Sensor Adjustment306
Crankshaft Position Sensor Removal/Installation306
Plate Removal/Installation306
Camshaft Position Sensor Inspection307
Camshaft Position Sensor Removal/Installation309
Knock Sensor Inspection309
Knock Sensor Removal/Installation309
Heated Oxygen Sensor Inspection310
Heated Oxygen Sensor Heater Inspection311
EGR Boost Sensor Inspection312
Clutch Switch Inspection312
Neutral Switch Inspection313
Power Steering Pressure Switch Inspection313
Main Relay Inspection314
Fuel Tank Pressure Sensor Inspection314
Technical Data315
Engine Data315
Service Tools318
Suspension319
Precaution (Suspension)319
Wheel Alignment Preinspection320
Front Wheel Alignment320
Maximum Steering Angle Adjustment321
Caster Adjustment321
Camber Adjustment321
Rear Wheel Alignment322
Total Toe-In Adjustment322
Front Suspension324
Front Shock Absorber and Coil Spring Removal/Installation324
Front Shock Absorber and Coil Spring Removal Note325
Piston Rod Nut Removal Note325
Bound Stopper Installation Note325
Coil Spring Installation Note326
Front Shock Absorber and Coil Spring Installation Note326
Front Shock Absorber Inspection327
Front Shock Absorber Disposal327
Front Lower Arm Removal/Installation328
Front Lower Arm Inspection330
Front Upper Arm Removal/Installation330
Front Upper Arm Inspection332
Front Stabilizer Removal/Installation332
Stabilizer Control Link Inspection333
Front Crossmember Removal/Installation334
Rear Suspension335
Rear Shock Absorber and Coil Spring Removal/Installation335
Rear Shock Absorber Inspection336
Rear Shock Absorber Disposal336
Rear Lower Arm Removal/Installation337
Rear Upper Arm Removal/Installation339
Rear Stabilizer Removal/Installation340
Rear Crossmember Removal/Installation341
Suspension Technical Data342
Suspension SST344
Driveline/Axle345
Wheels and Tires Removal/Installation - Precautions345
Suspension Arm Removal/Installation - Precautions345
Front Axle346
Wheel Hub, Steering Knuckle Preinspection346
Wheel Hub Bolt Replacement346
Wheel Hub, Steering Knuckle Removal/Installation347
ABS Sensor Rotor Removal Note348
ABS Sensor Rotor Installation Note348
Wheel Hub Bolt Removal Note348
Locknut Installation Note348
Rear Axle349
Wheel Hub, Knuckle Preinspection349
Wheel Bearing Play349
Wheel Hub, Knuckle Removal/Installation350
Rear Wheel Hub Removal Note351
Dust Cover Removal Note351
Wheel Bearing Removal Note351
Bushing Removal Note351
Dust Cover Installationi Note352
Rear Wheel Hub Installation Note352
Wheel Bearing Installation Note352
Drive Shaft Preinspection353
Drive Shaft Removal/Installation354
Drive Shaft Disassembly/Assembly355
Outer Diameter of Large Boot End357
Differential359
Differential Oil Inspection359
Differential Oil Replacement359
Oil Seal Replacement360
Differential Removal/Installation361
Differential Disassembly/Assembly363
Thrust Washer Thickness Table368
Propeller Shaft Removal/Installation371
Propeller Shaft Inspection372
Driveline/Axle Techical Data373
Driveline/Axle SST374
Brakes376
Troubleshooting Note (Brakes)376
Conditions that Are Not ABS Malfunctions377
Antilock Brake System On-Board Diagnisis377
On-Board Diagnostic (OBD) Test Description377
Reading Dtcs Procedure (Brakes)378
Clearing Dtcs Procedure (Brakes)379
Diagnostic Trouble Code Table (Brakes)380
DTC 05: Brake Switch381
DTC 11 - 14 Right/Left Front ABS Wheel-Speed Sensor / Right/Left Rear ABS Wheel-Speed Sensor381
DTC 15 ABS Wheel-Speed Sensor, ABS Sensor Rotor381
DTC 22 - 27 Reduction Valves382
DTC 41 - 44 ABS Wheel-Speed Sensors382
DTC 51 Valve Relay383
DTC 53 ABS Motor, Motor Relay383
Antilock Brake System Symptom Troubleshooting384
DTC 61 ABS Control Module384
DTC 63 Power Supply, Ground384
IG Switch Is Turned to on but ABS Warning Light Does Not Illuminate385
IG Switch Is Turned to on but ABS Warning Light Stays on after more than 4 Seconds386
ABS Waring Light Flashes with Vehicle Stopped and ABS Warning Light Goes off When Vehicle Is Driven386
ABS Waring Light Goes on During Driving and Stays on until IG Switch Is Turned off387
ABS Waring Light Goes on and off Intermittently, Regardless of Driving and Stopping387
ABS Warning Light Indicates Normal; However, ABS Does Not Operate Correctly387
Brakes: General Procedures388
Precaution (Brakes)388
Conventional Brake System389
Air Bleeding389
Vacuum Line Inspection390
Brake Pedal Inspection390
Brake Pedal Play Inspection390
Brake Pedal-To-Floor Clearance Inspection390
Brake Pedal Adjustment391
Brake Pedal Height Adjustment391
Pedal Play Adjustment391
Brake Pedal Removal/Installation392
Brake Switch Inspection393
Master Cylinder Removal/Installation393
Brake Fluid Level Sensor Inspection396
Master Cylinder Disassembly/Assembly397
Power Brake Unit Inspection398
Inspection for Vacuum Loss (Unloaded Condition)398
Power Brake Unit Removal/Installation399
Inspection for Hydraulic Pressure399
Proportioning Bypass Valve Inspection400
Proportioning Bypass Valve Replacement400
Front Brake (Disc) Inspection401
Front Brake (Disc) Removal/Installation402
Disc Pad (Front) Replacement403
Caliper (Front) Disassembly/Assembly404
Rear Brake (Disc) Inspection405
Rear Brake (Disc) Removal/Installation406
Disc Pad (Rear) Replacement407
Caliper (Rear) Disassembly/Assembly408
Piston Disassembly Note409
Piston Assembly Note409
Parking Brake System410
Parking Brake Inspection410
Parking Brake Adjustment410
Parking Brake Lever Removal/Installation410
Parking Brake Cable Removal/Installation411
Antilock Brake System412
ABS Hydraulic Unit Inspection412
ABS Motor Inspection413
Solenoid Valve Inspection Including the Valve Relay413
Solenoid Valve Inspection414
ABS Hydraulic Unit Removal/Installation414
ABS Control Module Removal/Installation415
ABS Harness and Input Signal Inspection416
ABS Relay Removal/Installation418
ABS Relay Inspection418
Motor Relay Inspection419
Front ABS Wheel-Speed Sensor Removal/Installation420
Front ABS Wheel Speed Sensor Inspection421
Rear ABS Wheel Speed Sensor Removal/Installation422
Rear ABS Wheel Speed Sensor Inspection422
Brakes Techincal Data423
Brakes Service Tools424
Transmission/Transaxle425
Automatic Transmission On-Board Diagnostic426
DTC P0705 Transmission Range Switch Circuit Malfunction429
DTC P0706 Transmission Range Switch Circuit Malfunction (Open Circuit)429
DTC P0715 Input/Turbine Spread Sensor Circuit Malfunction430
DTC P0720 Output Speed Sensor Circuit Malfunction431
DTC P0725 Engine Speed Input Circuit Signal432
DTC P0741/P0742 Torque Converter Clutch Solenoid Valve Stuck Off/On433
DTC P0751/P0752 Shift Solenoid a Stuck Off/On434
DTC P0756/P0757 Shift Solenoid B Stuck Off/On435
DTC P1740/P1742 Torque Converter Clutch Control Solenoid Valve Open/Short436
DTC P1751/P1752 Shift Solenoid a Circuit Open/Short437
DTC P1756/P1757 Shift Solenoid B Circuit Open/Short438
DTC P1771/P1772 Throttle Position Sensor Open/Short439
Automatic Transmission Basic Inspection440
Automatic Transmission Symptom Troubleshooting441
Quick Diagnosis Chart443
Vehicle Does Not Move in D, 2, 1 Ranges or in R Position445
Vehicle Moves in N Position446
Vehicle Moves in P Position or Parking Gear Does Not Disengage When P Is Disengaged446
Excessive Creep446
No Creep at All447
Low Maximum Speed and Poor Acceleration448
No Shift449
Fail-Safe Function449
No TCC Function450
Abnormal Shift451
Frequent Shifting452
Shift Point Is High or Low452
No Kickdown452
Engine Flares up or Slips When Upshifting or Downshifting453
Engine Flares up or Slips When Accelerating Vehicle453
Judder Upon During TCC Operation454
Excessive N to D or to R Position/Range Shift Shock455
Excessive Shift Lock When Upshifting and Downshifting456
Excessive TCC Shift Shock456
Noise at Idle When Vehicle Is Stopped in All Positions/Ranges457
Noise at Idle When Veicle Is Stopped in D, 2, 1 Ranges or in R Position457
No Engine Braking in 1, 2, or 3 Gear457
Transmission Overheats458
Engine Stalls When Shifted to D, 2, 1 Ranges, And/Or in R Position459
Engine Stalls When Driving at Slow Speeds or Stopping459
O/D off Indicator Light Does Not Illuminate When O/D Switch Is Turned on460
O/D off Indicator Light Illuminates When O/D off Switch Is Not Turned on460
Clutch461
Clutch Pipe - Precautions461
Clutch Fluid Inspection461
Clutch Fluid Replacement462
Clutch Fluid Air Bleeding462
Clutch Pedal Inspection463
Clutch Pedal Adjustment464
Clutch Pedal Height Adjustment464
Clutch Pedal Free Play Adjustment464
Clutch Pedal Removal/Installation465
Clutch Master Cylinder Removal/Installation466
Clutch Master Cylinder Disassembly/Assembly467
Clutch Release Cylinder Removal/Installation468
Clutch Release Cylinder Disassembly/Assembly469
Clutch Unit Removal/Installation470
Clutch Cover Inspection472
Clutch Disc Inspection472
Clutch Release Collar Inspection473
Pilot Bearing Inspection473
Flywheel Inspection473
Manual Transmission474
Transmission Oil Inspection474
Transmission Oil Replacement475
Oil Seal (Rear) Replacement475
Vehicle Speedometer Sensor Removal/Installation476
Vehicle Speedometer Sensor Inspection476
Manual Transmission Removal/Installation476
Automatic Transmission481
Mechanical System Test482
Line Pressure Test482
Stall Test483
Time Lag Test483
Read Test484
Shift Diagram484
D Range Test484
2 Range Test485
1 Range Test486
ATF Condition Inspection486
Automatic Transmission Fluid (ATF) Inspection486
ATF Level Inspection487
Automatic Transmission Fluid (ATF) Replacement487
Throttle Cable Inspection488
Throttle Cable Adjustment488
Throttle Cable Removal/Installation489
O/D off Switch Inspection491
Inspection of Voltage491
Inspection of Continuity491
O/D off Switch Removal/Installation491
Transmission Range Switch Inspection492
Transmission Range Switch Removal/Installation493
Transmission Range Switch Adjustment493
Input/Turbine Speed Sensor Inspection494
Input/Turbine Speed Sensor Removal/Installation494
Output Speed Sensor Inspection495
Output Speed Sensor Removal/Installation495
Solenoid Valves Inspection496
Solenoid Valves Removal/Installation497
Transmission Control Module Inspection498
Transmission Control Module Removal/Installation500
Automatic Transmission Removal/Installation500
Power Plant Frame (PPF) Removal Note501
Extension Housing Removal/Installation503
Oil Seal (Transmission) Replacement504
Control Valve Body Removal/Installation505
Torque Converter Removal/Installation506
Oil Cooler Removal and Installation507
Drive Plate Removal/Installation508
Automatic Transmission Shift Mechanism510
Emergency Override Button Inspection510
Key Interlock Solenoid Inspection510
Key Interlock Solenoid Removal/Installation511
Key Interlock Unit Inspection511
Key Interlock Unit Removal/Installation512
P Position Switch Inspection512
Shift-Lock Actuator Inspection512
Shift-Lock Actuator Removal/Installation514
Selector Lever Inspection514
Selector Lever Adjustment515
Selector Lever Removal/Installation516
Selector Lever Disassembly/Assembly517
Transmission/Transaxle Technical Data519
Transmission/Transaxle Service Tools520
Steering521
Manual Steering522
Steering Wheel and Column Inspection522
Steering Wheel Looseness Inspection522
Steering Wheel Effort Inspection522
Steering Wheel and Column Removal/Installation523
Steering Shaft Disassembly/Assembly524
Steering Shaft Inspection525
Steering Gear and Linkage Removal/Installation525
Steering Gear and Linkage Disassembly/Assembly526
Starting Gear and Linkage Inspection531
Tie-Rod End Inspection531
Tie Rod Inspection531
Steering Rack Inspection531
Engine Speed Sensing Power Steering532
Power Steering Fluid Inspection532
Fluid Leakage Inspection533
Fluid Pressure Inspection533
Steering Wheel and Column Inspection Info535
Steering Wheel Play Inspection535
Steering Gear and Linkage Disassembly/Inspection537
Steering Gear and Linkage Inspection541
Hermetic Sealing Inspection541
Power Steering Oil Pump Removal/Installation542
Power Steering Oil Pump Disassembly/Assembly543
Steering Technical Data545
Steering - Service Tools546
Hvac548
HVAC Symptom Troubleshooting549
Insufficient Blown Air Volume And/Or no Blown Air Depending on Airflow Mode549
No Blown Air in any Airflow Mode/Blown Air Volume Does Not Change at any Fan Speed549
Ariflow Mode Does Not Change550
Improper Air Circulation And/Or no Air Circulation550
No Operation in any Temperature Setting551
Insufficient A/C Cooling552
No Cool Air554
Noise While Operating A/C System556
Refrigerant System558
Refrigerant System General Procedures559
Manifold Gauge Set Installation559
Refrigerant System Performance Test559
Refrigerant Charge Check559
Refrigerant Pressure Check560
Refrigerant Charging560
Basic System563
Blower Removal/Installation564
Blwer Unit Disassembly/Assembly564
Cooling Unit Removal/Installation565
Cooling Unit Disassembly/Assembly566
Evaporator Inspection566
Heater Unit Removal/Installation567
Heater Unit Disassembly/Assembly567
Heater Core Inspection568
A/C Compression Removal/Installation568
Condenser Removal/Installation569
Condenser Inspection569
Receiver/Drier Removal/Installation570
Refrigerant Lines Removal/Installation571
Control System Structural View572
Resistor Removal/Installation573
Resistor Inspection573
Magnetic Clutch Inspection573
Magnetic Clutch Adjustment574
Magnetic Clutch Disassembly/Assembly574
Condenser Fan Inspection575
Condenser Fan Removal/Installation575
Blower Motor Inspection576
Blower Motor Removal/Installation576
Refrigerant Pressure Switch Inspection576
Refrigerant Pressure Switch Removal-Installation577
Thermoswitch Inspection577
To Inspect On/Off Points of the Thermoswitch577
Heater Control Unit Removal578
Heater Control Unit Installation578
Heater Control Unit Disassembly/Assembly579
Heater Control Unit Inspection579
Heater Control Unit Wire Adjustment580
A/C Relay and Condenser Fan Relay Removal/Installation580
A/C Relay and Condenser Fan Relay Inspection581
Blower Relay Removal/Installation581
Blower Relay Inspection581
HVAC Technical Data582
HVAC Service Tools583
Restraints584
Air Bag System On-Board Diagnosis584
Diagnostic Trouble Code Table (Air Bag System)585
DTC 1 SAS Control Module Connector Poor Connection585
DTC 2 SAS Control Module586
DTC 3 Battery586
DTC 6 Driver-Side Air Bag Module587
DTC 7 Passenger Side Air Bag Module589
DTC 49 Passenger Side Air Bag Cut-Off System590
Air Bag System Symptom Troubleshooting591
Air Bag System Warning Light Does Not Illuminate When Ignition Switch Is Turned to on591
Air Bag System Warning Light Illuminates Immediately after Ignition Switch Is Turned to on and Remains Illuminated593
Passenger Side Air Bag Deactivation Indicator Does Not Illuminate When Passenger Side Air Bag Detection Switch Is Turned to off594
With the Passenger Side Air Bag Deactivation Switch Is at On, Passenger Side Air Bag Deactivation Indicator Illuminates Immediately after Ignition Swi596
Passenger Side Air Bag Deactivation Indicator Does Not DIM When Headlight Switch Is Turned on597
Passenger Side Air Bag Deactivation Switch Illumination Does Not Illuminate When Headlight Switch Is on598
Air Bag System599
Wiring Harness Repair599
Air Bag Module Inspection599
Air Bag Module Handling600
SAS Control Module Handling600
Air Bag System Component Handling600
Air Bag System Component Reusing600
Driver-Side Air Bag Module Removal/Installation601
Passenger Side Air Bag Module Removal/Installation602
Clock Spring Adjustment603
Clock Spring Removal/Installation603
Clock Spring Inspection604
Passenger Air Bag Deactivation (PAD) Switch Removal/Installation604
Passenger Air Bag Deactivation (PAD) Switch Inspection605
Passenger Air Bag Deactivation (PAD) Switch Warning Light Bulb and Passenger Air Bag Deactivation (PD) Switch Illumination Bulb Removal/Installation605
SAS Control Module Removal/Installation606
Air Bag Module Deployment Authorization Procedures606
Air Bag Module Deployment Procedures607
Deployment Procedures for Inside of Vehicle607
Driver-Side Air Bag Module607
Passenger-Side Air Bag Module607
Deployment Procedures for Outside of Vehicle608
Air Bag Module Disposal Procedures610
Inspection of SST (Deployment Tool)611
Seat Belt Inspection612
Elr612
Alr612
Seat Belt Switch612
Seat Belt Removal/Installation613
Buckle Removal/Installation613
Restraints Service Tools614
Body and Accessories615
Fuel-Filler Lid Adjustment615
Fuel-Filler Lid Removal/Installation616
Hood Adjustment616
Hood Removal/Installation617
Trunk Lid Adjustment617
Trunk Lid Removal/Installation618
Front Bumper Removal/Installation619
Rear Bumper Removal/Installation620
Front Fender Panel Removal/Installation621
Doors and Liftgate622
Door Adjustment622
Doors Removal/Installation623
Door Disassembly/Assembly624
Glass/Windows/Mirrors625
Door Glass Adjustment625
Door Glass Vertical Adjustment626
Convertible Top626
Detachable Hardtop626
Door Glass Forward/Backward Adjustment627
Door Glass Inward/Outward Adjustment628
Door Glass and Guide Removal/Installation629
Power Window Regulator Removal/Installation630
Power Window Regulator Disassembly630
Power Window Regulator Assembly631
Power Window Motor Inspection632
Manual Window Regulation Removal/Installation633
Power Window Switch Removal/Installation633
Power Window Switch Inspection634
Regulator Handle Removal634
Regulator Handle Installation635
Rear Window Glass Removal635
Rear Window Glass Installation636
Windshiedl Removal637
Not Reusing Windshield637
Hardening Time of Sealant637
Windshield Installation638
Reusing Windshield638
Filament Inspection640
Filament Repair641
Rear Window Defroster Switch Removal/Installation641
Rear Window Defroster Switch Inspection641
Rear Window Defroster Power-Cut Switch Removal/Installation642
Rear Window Defroster Power-Cut Switch Inspection642
Rear Window Defroster Relay Removal/Installation643
Rear Window Defroster Relay Inspection643
Power Outside Mirror Inspection643
Power Outside Mirror Removal/Installation644
Manual Outside Mirror Removal/Installation645
Outside Mirror Glass Removal645
Outside Mirror Glass Installation646
Power Outside Mirror Switch Removal/Installation646
Power Outside Mirror Switch Inspection647
Rearview Mirror Removal647
Rearview Mirror Installation648
Base Removal648
Base Installation648
Seat Removal/Installation650
Seat Disassembly/Assembly651
Security and Locks652
Door Lock and Opener Removal/Installation652
Door Lock Actuator Inspection652
Door Lock-Link Switch Inspection653
Door Lock Striker Removal/Installation653
Door Lock Control Module Inspection654
Door Lock Control Module Removal/Installation655
Fuel-Filler Lid Opener Removal/Installation656
Hood Lock and Opener Removal/Installation657
Trunk Lid Lock and Opener Removal/Installation657
Trunk Lid Striker Removal/Installation658
Exterior Trim659
Cowl Grille Removal/Installation659
Beltline Molding Removal/Installation659
Front Beltline Molding Removal/Installation660
Rear Window Molding Removal660
Rear Window Molding Installation660
Windshield Molding Removal662
Windshield Molding Installation662
Convertible Top Adjustment664
Convertible Top Removal/Installation665
Convertible Top Disassembly/Assembly666
Retainer Adjustment670
Top Fabric Repair670
Top Fabric Removal/Installation672
Detachable Hardtop Adjustment675
Detachable Hardtop Disassembly/Assembly676
Interior Trim677
Dashboard Removal/Installation678
Dashboard Disassembly/Assembly679
Center Panel Removal/Installation680
Column Panel Removal/Installation680
Console Removal/Installation681
Console Disassembly/Assembly681
Glove Compartment Removal/Installation682
Lower Panel Removal/Installation682
Meter Hood Removal/Installation683
Door Trim Removal/Installation683
A-Pillar Trim Removal/Installation684
Front Header Trim Removal/Installation684
Quater Trim Removal/Installation684
Rear Package Trim Removal/Installation685
Scuff Plate Removal/Installation685
Front Side Trim Removal/Installation685
Trunk End Trim Removal/Installation686
Trunk Side Trim Removal/Installation686
Floor Covering Removal/Installation687
Rear End Mat Removal/Installation687
Lighting System688
Headlight Adjustment688
Front Combination Light Removal/Installation689
Headlight Bulb Removal/Installation689
Packing Light/Front Turn Light Bulb Removal/Installation689
Front Side Marker Light Removal/Installation690
Rear Combination Light Removal/Installation690
High-Mount Bracket Light Removal/Installation690
License Plate Light Removal/Installation691
Back-Up Light Switch Removal/Installation691
Back-Up Light Switch Ispection692
Combination Switch Removal/Installation692
Combination Switch Disassembly/Assembly693
Combination Switch Inspection693
Turn Switch694
Windshield Wiper and Washer Switch694
Hazard Warning Switch Removal/Installation694
Hazard Warning Switch Inspection695
Headlight Relay Removal/Installation695
Headlight Relay Inspection696
TNS Relay Removal/Installation696
TNS Relay Inspection696
Flasher Control Module Removal/Installation697
Flasher Control Module Inspection697
DRL Control Module Removal/Installation698
DRL Control Module Inspection698
Interior Light Removal/Installation699
Interior Light Inspection700
Door Switch Removal/Installation700
Door Switch Inspection700
Panel Light Control Switch Removal/Installation701
Panel Light Control Switch Inspection701
A Terminal Inspection702
Wiper and Washer703
Windshield Wiper Arm and Blade Adjustment703
Windshield Wiper Arm and Blade Removal/Installation703
Windshield Wiper Link Removal/Installation704
Windshield Wiper Motor Removal/Installation704
Windshield Wiper Motor Inspection704
Windshield Washer Tank Removal/Installation705
Windshield Washer Motor Removal/Installation706
Windshield Washer Motor Inspection706
Windshield Washer Nozzle Adjustment707
Windshield Washer Nozzle Removal707
Windshield Washer Nozzle Installation707
Windshield Washer Pipe Removal/Installation708
Entertainment709
Door Speaker Removal/Installation709
Door Speaker Inspection709
Tweeter Speaker Removal/Installation710
Tweeter Speaker Inspection710
Manual Antenna Removal/Installation711
Manual Antenna Inspection711
Power Antenna Removal/Installation712
Power Antenna Disassembly/Assembly712
Power Antenna Inspection713
Antenna Mast Removal713
Antenna Mast Installation713
Front Antenna Feeder Removal/Installation714
Front Antenna Feeder Inspection714
Rear Antenna Feeder Removal/Installation715
Rear Antenna Feeder Inspection715
Audio Unit Removal716
Audio Unit Installation716
Audio Amplifier Removal/Installation717
Audio Relay Removal/Installation717
Audio Relay Inspection718
Cigarette Lighter Removal/Installation718
Cigarette Lighter Inspection718
Power Systems720
Fuse Service Caution720
Main Fuse Removal/Installation720
Room Fuse Installation721
Ignition Switch Removal/Installation721
Ignition Switch Inspection721
Key Reminder Switch Inspection722
Instrumention/Driver Info723
Instrument Cluster Removal/Installation723
Instrument Cluster Disassembly/Assembly723
Instrument Cluster Inspection724
Tachometer724
Speedometer, Fuel Gauge724
Water Temperature Gauge724
Oil Pressure Gauge725
Instrument Cluster Input/Output Check Mode726
DTC 00 Transmission Range Switch (R Range) Signal727
DTC 01 Seat Belt Switch On/Off Signal727
DTC 04 Door Switch On/Off Signal727
DTC 08 TNS Relay On/Off Signal728
DTC 14 Operation Signal to Buzzer728
DTC 31 Key Reminder Switch On/Off Signal728
Warning and Indicator Light Bulb Removal/Installation728
Fuel Gauge Sender Unit Inspection729
Oil Pressure Switch Inspection729
Horn Removal/Installation729
Horn Relay Inspection729
Body and Accessories Technical Data730
Body and Accessories Service Tools731
Alphabetical Index732

Mazda MX-5 Miata - Workshop Manual

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