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MX-5Miata
Hands-on maintenance & repairFull step-by-step stripdown & rebuild
Easy to use! Over 350 pages & over 1600 illustrations!
Rod’s
Mazda
1.8
Enthusiast’s Workshop ManualTM
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MAZDA
MIATAMX-5
1.8EUNOS ROADSTER
ENTHUSIAST’S SHOP MANUAL
By Rod Grainger & Pete Shoemark
VELOCE PUBLISHINGTHE PUBLISHER OF FINE AUTOMOTIVE BOOKS
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CHAPTER 1: GENERAL ADVICE & USING THIS MANUAL
1. Using this manual ___________________________________ 1:1Conventions _____________________________________ 1:1Symbols & cross-references ___________________________ 1:1Hey! Watch out! ___________________________________ 1:2
2. Working procedures _________________________________ 1:2General _________________________________________ 1:2Work area & storage facilities __________________________ 1:2Hose connections __________________________________ 1:2Gaskets & seals ___________________________________ 1:3Screws, bolts & nuts ________________________________ 1:4Torque tightening by feel _____________________________ 1:4Electrical connections & wire color coding _________________ 1:4Wrestling with two-piece plastic panel fasteners _____________ 1:5
3. Jacking & supporting the car ___________________________ 1:54. Cleaning components ________________________________ 1:65. Buying new parts ___________________________________ 1:76. Tools & equipment __________________________________ 1:77. Dealing with breakdowns ______________________________ 1:88. Technical specifications _______________________________ 1:9
General _________________________________________ 1:9Dimensions ______________________________________ 1:9Transmission _____________________________________ 1:9Chassis _________________________________________ 1:9Engine - detail ____________________________________ 1:9Lubrication system (engine) __________________________ 1:12Cooling system ___________________________________ 1:12Fuel & emission control systems _______________________ 1:13Electrical system (engine) ___________________________ 1:13Clutch _________________________________________ 1:14Transmission (gearbox), manual _______________________ 1:14Transmission, automatic ____________________________ 1:15Driveshaft (propshaft) ______________________________ 1:15Front axle ______________________________________ 1:16Rear axle _______________________________________ 1:16Differential ______________________________________ 1:16Steering ________________________________________ 1:16Braking system ___________________________________ 1:16Wheels & tires ___________________________________ 1:17Suspension _____________________________________ 1:17Wheel alignment__________________________________ 1:18Electrical system (body) _____________________________ 1:18
CHAPTER 2: TUNE-UP & MAINTENANCE
1. Introduction _______________________________________ 2:12A. Maintenance schedule: USA __________________________ 2:22B. Maintenance schedule: USA (abnormal operating conditions) ___ 2:32C. Maintenance schedule: Canada ________________________ 2:42D. Maintenance schedule: UK & rest of world ________________ 2:63. Engine oil & oil filter - changing _________________________ 2:74. Drivebelts (external) - inspection, replacement & adjustment _____ 2:85. Air cleaner (filter) element - replacement __________________ 2:96. Sparkplugs - checking, cleaning & adjusting _________________ 2:97. Idle speed - checking & adjustment______________________ 2:108. Transmission (manual) oil - checking level & changing ________ 2:109. Transmission (auto) fluid - checking level & changing _________ 2:1110. Differential oil - checking level & changing ________________ 2:1111. Battery - checking charge, specific gravity & electrolyte level ___ 2:1212. Ignition timing - checking & adjusting ___________________ 2:1313. Driveaxles (halfshafts), rear - checking ___________________ 2:1314. Engine coolant - topping-up & changing _________________ 2:1415. Lights, horn, wipers & washers - checking ________________ 2:1516. Tires - checking pressures & condition __________________ 2:1517. Body - general maintenance __________________________ 2:1618. Steering & suspension- checking ______________________ 2:1719. Exhaust system - checking ___________________________ 2:1820. Brake & clutch fluid - checking level & replacing ___________ 2:18
CHAPTER 3: ENGINE & CLUTCH
1. Major work possible with engine in car ____________________ 3:12. Major work requiring engine removal _____________________ 3:13. Engine removal methods & preparation ___________________ 3:1
4. Engine - removal (with transmission) ______________________ 3:15. Engine - removal (without transmission) __________________ 3:126. Engine dismantling - general advice _____________________ 3:127. Engine dismantling _________________________________ 3:13
Intake manifold & wiring removal ______________________ 3:13Fuel rail removal __________________________________ 3:14Starter motor removal ______________________________ 3:14Engine mounting removal ___________________________ 3:14Oil filter & oil cooler removal _________________________ 3:14Alternator removal ________________________________ 3:14Exhaust manifold removal ___________________________ 3:15Clutch removal ___________________________________ 3:16Sparkplug wires & coils removal _______________________ 3:16Thermostat removal _______________________________ 3:16Cambox cover removal _____________________________ 3:17Camshaft drivebelt removal __________________________ 3:17Camshaft drivebelt tensioner wheel & tensioner spring removal _ 3:18Camshaft pulleys removal ___________________________ 3:18Cylinder head front sealing plate removal ________________ 3:19Thermostat housing removal _________________________ 3:19Water pump removal ______________________________ 3:19Crankshaft inner pulley removal _______________________ 3:19Camshaft removal ________________________________ 3:20Cam followers removal _____________________________ 3:20Cylinder head removal _____________________________ 3:20Valves removal ___________________________________ 3:21Valve guides removal & installation ____________________ 3:21Oil pan removal __________________________________ 3:22Oil pump, pickup pipe & oil pan baffle removal ____________ 3:22Oil pump & oil pressure relief valve teardown _____________ 3:23Flywheel (driveplate - auto trans) removal ________________ 3:23Engine backplate removal ___________________________ 3:23Crankshaft rear oil seal housing removal _________________ 3:23Connecting rod (big end) caps, con rods & pistons removal ___ 3:24Main bearing caps & crankshaft removal _________________ 3:24Piston oil jets removal ______________________________ 3:25Pistons removal from connecting rods ___________________ 3:25Piston rings removal _______________________________ 3:25Engine teardown conclusion _________________________ 3:26
8. Engine components - checking & repair __________________ 3:26Checking & repair general ___________________________ 3:26Cylinder head & valves removing carbon ________________ 3:26Cylinder head checking & repair ______________________ 3:26Valves, guides & valve seats checking, repair & valve lapping __ 3:26Valve springs checking & repair _______________________ 3:27Camshafts & camshaft bearings checking & repair __________ 3:28Cam followers checking & repair ______________________ 3:28Cylinder block checking & repair: core plug renewal _________ 3:29Pistons: removing carbon ___________________________ 3:29Pistons, piston rings & piston pins checking & repair_________ 3:29Connecting rods checking & repair _____________________ 3:30Crankshaft & crankshaft bearings checking & repair _________ 3:30Cam drivebelt, tensioner, idler & pulleys checking & repair ____ 3:31Oil pump checking & repair __________________________ 3:31Oil jets checking & repair ____________________________ 3:31Flywheel, pilot bearing & starter ring gear checking & repair ___ 3:31Driveplate (auto-trans) & starter ring gear checking & repair ___ 3:32Clutch cover, disc, release bearing & fork checking & repair ___ 3:32
9. Engine rebuild ____________________________________ 3:32Engine rebuild general______________________________ 3:32Piston rings installation _____________________________ 3:32Pistons & connecting rods rebuild & installation ____________ 3:33Oil jets rebuild & installation _________________________ 3:33Crankshaft & bearing shells installation __________________ 3:33Connecting rods & caps fitting to crankshaft ______________ 3:34Crankshaft rear cover: oil seal installation ________________ 3:34Crankshaft rear cover installation ______________________ 3:34Oil pump rebuild & fitting new oil seal___________________ 3:35Oil pump installation _______________________________ 3:35Oil pan baffle, oil pump pickup pipe & oil pan installation _____ 3:35Engine backplate installation _________________________ 3:36Flywheel (driveplate - auto trans) installation ______________ 3:36Water pump installation _____________________________ 3:36Valves, springs & valve stem oil seals installation ___________ 3:36Cylinder head installation ___________________________ 3:37
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Mazda Miata, MX-5, Eunos & RoadsterThermostat housing installation _______________________ 3:37Cylinder head seal plate installation ____________________ 3:38Cam followers installation ___________________________ 3:38Camshafts installation ______________________________ 3:38Camshaft oil seals installation _________________________ 3:38Camshaft pulleys installation _________________________ 3:38Cam drivebelt idler & tensioner wheels & spring installation ___ 3:39Crankshaft inner (cam drivebelt) pulley installation __________ 3:39Camshaft drivebelt installation & valve timing _____________ 3:39Cam drivebelt covers, w/pump & crankshaft pulley installation _ 3:40Cambox cover installation ___________________________ 3:41Thermostat & thermostat housing cover installation _________ 3:41Engine mounting bracket (right-hand) installation ___________ 3:41Oil pressure gauge sender unit installation ________________ 3:41Alternator installation ______________________________ 3:42Oil cooler & oil filter installation _______________________ 3:42Starter motor installation ____________________________ 3:42Heater outlet cover installation ________________________ 3:43Ignition coils & sparkplug wires installation _______________ 3:43Clutch cover & disc installation _______________________ 3:43Engine mounting bracket (left-hand) installation ____________ 3:43Power steering pump bracket installation _________________ 3:43Coolant inlet casting installation _______________________ 3:44Dipstick tube installation ____________________________ 3:44Engine lifting eyes installation _________________________ 3:44Camshaft position sensor installation ____________________ 3:44Manifolds installation special note ______________________ 3:44
10. Transmission (gearbox) - installation (engine out of car) ______ 3:4511. Engine & transmission - installation as a unit ______________ 3:4512. Engine - installation (without transmission)________________ 3:5513. Camshaft drivebelt (timing belt) - replacement (engine in car) __ 3:5614. Camshafts & followers - removal & installation (engine in car) __ 3:5715. Cylinder head - removal & installation (engine in car) ________ 3:57
Cylinder head checking _____________________________ 3:5816. Crankshaft front oil seal - replacement (engine in car) ________ 3:5817. Crankshaft rear oil seal - replacement (engine in car) ________ 3:5918. Camshaft oil seal - replacement (engine in car) _____________ 3:5919. Starter ring gear - replacement (engine in car) _____________ 3:6020. Engine mountings - replacement (engine in car) ____________ 3:6021. Clutch & release bearing - removal & installation (engine in car) 3:6022. Clutch master cylinder - removal & installation _____________ 3:6023. Clutch master cylinder - overhaul ______________________ 3:6124. Clutch release (slave) cylinder - removal & installation _______ 3:6225. Clutch release (slave) cylinder - overhaul _________________ 3:62
Dismantling & checking _____________________________ 3:62Rebuild ________________________________________ 3:63
26. Clutch hydraulic system - bleeding _____________________ 3:6327. Clutch hydraulic lines/hoses - replacement ________________ 3:6328. Clutch pedal height & free play - checking & adjustment ______ 3:6429. Clutch pedal removal & installation _____________________ 3:65
CHAPTER 4: TRANSMISSION & DRIVELINE
1. Transmission (gearbox) - preparation for removal _____________ 4:12. Transmission (gearbox), manual - removal _________________ 4:13. Transmission (gearbox), automatic - removal ________________ 4:44. Transmission (gearbox), manual - dismantling & rebuild general __ 4:55. Transmission (gearbox), manual - teardown ________________ 4:66. Transmission (gearbox), manual - components checking & repair 4:13
Mainshaft gear pinions _____________________________ 4:13Mainshaft _______________________________________ 4:14Input shaft & countershaft ___________________________ 4:14Clutch/selector hubs & forks _________________________ 4:14Synchro rings ____________________________________ 4:14Bearings _______________________________________ 4:14Springs ________________________________________ 4:14Casings ________________________________________ 4:15
7. Transmission (gearbox), manual - rebuild _________________ 4:158. Transmission (gearbox), manual - installation _______________ 4:249. Transmission (gearbox), automatic - installation _____________ 4:2410. Driveshaft (propshaft) - removal, checking, repair & installation _ 4:2511. Transmission (gearbox) rear oil seal - replacement __________ 4:2612. PPF (Power Plant Frame) - removal & installation __________ 4:2613. Driveaxles - removal, checking, repair & installation _________ 4:2614. Driveaxle - dismantling, rebuild & new boots ______________ 4:27
15. Differential unit & carrier - removal & installation ___________ 4:2716. Differential side (driveaxle) oil seals - replacement __________ 4:2817. Differential nose (pinion) oil seal - replacement ____________ 4:2818. Differential unit carrier mountings - replacement ____________ 4:2819. Differential unit - teardown & rebuild ___________________ 4:2820 Transmission (gearbox), automatic - troubleshooting _________ 4:28
CHAPTER 5: ENGINE MANAGEMENT, FUEL, IGNITION & EXHAUSTSYSTEMS
1. Introduction _______________________________________ 5:12. PCM system - component summary ______________________ 5:1
Air cleaner (ACL) __________________________________ 5:1Air valve (BAC valve) _______________________________ 5:2Camshaft position sensor (CMP) _______________________ 5:2Catalytic converter _________________________________ 5:2Charcoal canister __________________________________ 5:2Clutch switch _____________________________________ 5:2Coolant temperature sensor ___________________________ 5:2Crankshaft position sensor (CKP) _______________________ 5:2Data link connector (DLC) ____________________________ 5:2Exhaust gas recirculation (EGR) system ___________________ 5:2Fuel pump relay (FPR) ______________________________ 5:2Fuel filter ________________________________________ 5:2Fuel pump _______________________________________ 5:2Fuel vapor valve ___________________________________ 5:2Heated oxygen sensor _______________________________ 5:2Idle air control (IAC) valve ____________________________ 5:2Ignition coil ______________________________________ 5:2Ignition control module ______________________________ 5:2Ignition switch ____________________________________ 5:2Injector _________________________________________ 5:2Intake air temperature (IAT) sensor______________________ 5:2Main relay _______________________________________ 5:2Malfunction indicator lamp ___________________________ 5:2Mass airflow sensor (MAF) ____________________________ 5:2Neutral switch ____________________________________ 5:2On board diagnostic (OBD) system ______________________ 5:2Positive crankcase ventilation (PCV) valve _________________ 5:3Power steering pressure (PSP) switch ____________________ 5:3Powertrain control module (PCM) ______________________ 5:3Pressure regulator __________________________________ 5:3Pressure regulator control (PRC) solenoid valve _____________ 5:3Purge solenoid valve ________________________________ 5:3Resonance chamber ________________________________ 5:3Stoplight switch ___________________________________ 5:3Throttle body _____________________________________ 5:3Throttle sensor ____________________________________ 5:3Two port check valve (three port, automatic trans) ___________ 5:3
3. PCM system - overview _______________________________ 5:3Fuel system ______________________________________ 5:4Air intake system __________________________________ 5:4Emission control system _____________________________ 5:4
4. Powertrain control system - troubleshooting tips ______________ 5:5Fault codes ______________________________________ 5:5
5. Engine compression check _____________________________ 5:66. Air intake system checks ______________________________ 5:67. Throttle body - removal, inspection & installation _____________ 5:68. Accelerator cable & pedal - adjustment & cable replacement _____ 5:79. Intake manifold - removal, checking & installation ____________ 5:910. Air intake control (IAC) valve - checking _________________ 5:1111. Air (BAC) valve - removal, checking & installation __________ 5:1112 Fuel system - description ____________________________ 5:1113. Fuel system - safety, depressurizing & repressurizing _________ 5:11
Releasing fuel system pressure ________________________ 5:11Disconnecting fuel lines _____________________________ 5:11Priming fuel system ________________________________ 5:12
14. Fuel system - checking______________________________ 5:12Fuel pump relay checking ___________________________ 5:12Fuel pump checking _______________________________ 5:12Fuel pressure checking _____________________________ 5:12Fuel pressure hold checking __________________________ 5:12Fuel maximum pressure checking ______________________ 5:13Fuel line pressure checking __________________________ 5:13Pressure regulator control (PRC) valve checking ___________ 5:13
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Injector operation checking __________________________ 5:13Fault not located? _________________________________ 5:13
15. Fuel tank - removal, checking & installation _______________ 5:13Draining the fuel tank ______________________________ 5:14Inspection & repair ________________________________ 5:16
16. Fuel pump/fuel gauge sender - removal & installation ________ 5:1817. Fuel pump relay - removal & installation _________________ 5:2018. Fuel pressure regulator - removal & installation ____________ 5:2019. Fuel injectors & rail - removal, leak testing & installation ______ 5:2020. Fuel filter - removal & installation ______________________ 5:2121. Emissions control system - introduction __________________ 5:2222. PCV valve - checking & replacement ___________________ 5:2223. EVAP/EGR systems - component checking & replacement ____ 5:22
Fuel vapor valve __________________________________ 5:23Two-way check valve (three-way check valve, auto trans) _____ 5:23EVAP system hoses _______________________________ 5:24Charcoal canister _________________________________ 5:24Purge solenoid valve _______________________________ 5:24EGR valve ______________________________________ 5:24EGR solenoid valves _______________________________ 5:24EGR boost sensor _________________________________ 5:25EGR valve position sensor ___________________________ 5:25
24. Dechoke control system - description ___________________ 5:2525. Ignition system - introduction _________________________ 5:2526. Ignition timing - checking & adjusting ___________________ 5:2527a. Ignition system checks _____________________________ 5:26
Self-diagnosis (OBD system) checks ____________________ 5:26Sparkplugs ______________________________________ 5:26Sparkplug leads __________________________________ 5:27Ignition coils _____________________________________ 5:27
27b. Ignition coils - removal & installation ___________________ 5:2728. PCM (powertrain control module)______________________ 5:2829a. Camshaft position sensor - removal, checking & installation ___ 5:2929b. Crankshaft position sensor - adjustment, removal & installation 5:2930. Mass airflow (MAF) sensor - removal, checking & installation ___ 5:3031. Engine coolant temp. sensor - removal, checking & installation _ 5:3032. TPS unit - checking, adjustment, removal & installation ______ 5:3133. Heated oxygen sensor - checking, removal & replacement ____ 5:3134. Power steering pressure switch - checking, removal & installation 5:3235. Main (fuel injection) relay - checking & replacement _________ 5:3236. Clutch switch - checking, removal & installation ____________ 5:3337. Neutral switch - checking, removal & installation ___________ 5:3338. Exhaust system - checking, removal & replacement _________ 5:3439. Exhaust manifold removal & installation _________________ 5:36
CHAPTER 6: COOLING, HEATING & AIR CONDITIONING SYSTEMS
1. Introduction _______________________________________ 6:12. Engine coolant - topping-up & changing ___________________ 6:1
Mixing engine coolant _______________________________ 6:2Topping up the cooling system _________________________ 6:2Changing the coolant _______________________________ 6:2
3. Cooling system - checking _____________________________ 6:24. Cooling system - hose replacement _______________________ 6:3
Top hose ________________________________________ 6:3Bottom hose _____________________________________ 6:3Coolant inlet casting & hose connections __________________ 6:4Heater hose connections _____________________________ 6:4Intake manifold hose connections _______________________ 6:4After fitting new hoses _______________________________ 6:4
5. Radiator - removal & installation ________________________ 6:46. Thermostat - removal, testing & installation _________________ 6:57. Water pump - removal & installation ______________________ 6:68. Radiator fan/s - testing, removal & installation _______________ 6:6
Checking coolant temperature sensor ____________________ 6:7Fan motor testing __________________________________ 6:7Fan motor removal & installation _______________________ 6:7Fan relay testing ___________________________________ 6:7
9. Heating & ventilation system - how it works _________________ 6:810. Blower unit - checking _______________________________ 6:8
Checking the circuit breaker or fuse _____________________ 6:8Checking the blower motor voltage ______________________ 6:8Checking the blower resistor __________________________ 6:8
11. Blower unit - resistor removal & installation ________________ 6:812. Blower motor - removal & installation ____________________ 6:9
13. Blower unit - removal & installation _____________________ 6:914. Heater unit - removal, inspection & installation _____________ 6:915. Heater/air con control assy - removal, inspection & installation _ 6:11
Checking the blower & air conditioning switch _____________ 6:1116. Air conditioning system - checking _____________________ 6:12
Precautions _____________________________________ 6:12Visual check of refrigerant charge ______________________ 6:13Checking thermoswitch operation ______________________ 6:13Checking system fittings & refrigerant lines _______________ 6:13Checking the condenser cooling fan ____________________ 6:13Checking the air conditioning relay _____________________ 6:13Magnetic clutch checks _____________________________ 6:13
CHAPTER 7: ELECTRICAL SYSTEM
1. Introduction _______________________________________ 7:12. Electrical system - procedures, precautions & jump starting ______ 7:1
Isolating & reconnecting battery ________________________ 7:1Electrical test equipment _____________________________ 7:1Wiring connectors __________________________________ 7:2Wiring & color coding _______________________________ 7:2Fuses & relays ____________________________________ 7:3Power point ______________________________________ 7:3Booster (Jump) starting ______________________________ 7:3
3. Fuses & relays - location, removal & replacement ____________ 7:44. Charging system - general _____________________________ 7:65. Battery - removal, checking, charging & installation ___________ 7:6
Removal & cleaning ________________________________ 7:7Battery voltage check _______________________________ 7:7Battery charging ___________________________________ 7:7Battery installation _________________________________ 7:8Installing a new battery ______________________________ 7:8
6. Charging system - troubleshooting _______________________ 7:87. Alternator - checking _________________________________ 7:8
Checking the terminal voltages _________________________ 7:8Checking alternator operation _________________________ 7:8Checking the dark current ____________________________ 7:8
8. Alternator - removal, overhaul & installation ________________ 7:89. Starter system - description & troubleshooting ______________ 7:10
Initial checks ____________________________________ 7:10Interlock switch - checking (manual trans) ________________ 7:11Range switch checking & adjustment (auto trans) ___________ 7:11
10. Starter motor - removal, overhaul & installation ____________ 7:12Testing ________________________________________ 7:12
11a. Ignition switch - t/shooting, removal & installation __________ 7:1411b. Key (ignition) reminder switch - troubleshooting ___________ 7:1412. Combination switch - t/shooting, removal & installation _______ 7:1413. H/light retract & haz. warn. switch - removal, t/shooting & install. 7:1514. Instrument panel - removal, t/shooting & installation _________ 7:16
Removal _______________________________________ 7:16Bulb replacement _________________________________ 7:17Speedometer ____________________________________ 7:17Tachometer (rev counter) ___________________________ 7:18Engine temperature sender unit & gauge _________________ 7:18Fuel gauge sender & fuel gauge _______________________ 7:18Oil pressure gauge ________________________________ 7:18General checks ___________________________________ 7:18Installation ______________________________________ 7:18
15. Warning lamps, switches & sensors - location & t/shooting ____ 7:19Brake warning circuit ______________________________ 7:19Hazard warning indicator light circuit (not fitted on all models) __ 7:19“Hold” circuit (auto transmission models) ________________ 7:19Seatbelt warning circuit (where fitted) ___________________ 7:19Windshield washer fluid level sensor circuit (where fitted) _____ 7:20
16. Lighting system - initial troubleshooting __________________ 7:2017. Headlight circuit - troubleshooting______________________ 7:2018. Headlight raise/retract system - troubleshooting ____________ 7:2119. Headlight dim-dip system (if fitted) - troubleshooting ________ 7:2220. Headlight passing light (flasher) system - troubleshooting ______ 7:2221. Headlight beam - adjustment _________________________ 7:2222. Headlamp deck height - adjustment ____________________ 7:2323. Headlight retractor motor - t/shooting, removal & installation ___ 7:2324. Headlight unit - removal, installation & bulb replacement _____ 7:2525. Parking light (sidelight) circuit -troubleshooting _____________ 7:26
Parking front & rear, side marker & license plate lights. _______ 7:26
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Mazda Miata, MX-5, Eunos & Roadster26. Daytime running lights (DRL) circuit - troubleshooting________ 7:2627. Stop (brake) light circuit - troubleshooting ________________ 7:2828. Turn signal & hazard warning circuit - troubleshooting _______ 7:2829. Backup (reversing) light circuit -troubleshooting ____________ 7:3030. Tail light unit - bulb & lens replacement __________________ 7:3231. Front combination light unit - bulb replacement ____________ 7:3232. Side marker lights (where fitted) - bulb replacement _________ 7:3333. Turn signal side repeater lights (where fitted) - bulb replacement 7:3334. License plate light - bulb replacement ___________________ 7:3335. Foglight, rear (where fitted) - bulb replacement ____________ 7:3336. Driving/foglights, front (where fitted) - bulb replacement ______ 7:3337. Interior lights - troubleshooting & bulb replacement _________ 7:3438. Trunk (boot) light - troubleshooting & bulb replacement ______ 7:3539. Panel light control switch (where fitted) - testing ____________ 7:3540. Horn circuit - troubleshooting & horn replacement __________ 7:3541. Rear window defogger (where fitted) - troubleshooting & repair _ 7:3642. Cruise control system - self-diagnosis function _____________ 7:3743. Cruise control system - troubleshooting __________________ 7:3844. Airbag system - working procedures, disarming & re-arming ___ 7:40
Description _____________________________________ 7:40Working procedures _______________________________ 7:40Disarming/re-arming airbag system _____________________ 7:41
45. Airbag system - troubleshooting _______________________ 7:4146. Airbag module (driver’s) - removal & installation ___________ 7:4147. Airbag module (passenger’s) - removal & installation ________ 7:4248. Windshield wiper & washer system - troubleshooting ________ 7:4349. Wiper motor - t/shooting, removal, o/haul & installation ______ 7:4350. Wiper mechanism - removal, installation & adjustment _______ 7:4651. Windshield washer pump motor - testing & replacement ______ 7:4752. Headlight washer system (if fitted) - troubleshooting _________ 7:4753. Cigarette lighter - removal & installation _________________ 7:4854. Audio unit ______________________________________ 7:49
Removal & installation _____________________________ 7:49Security ________________________________________ 7:49Audio system troubleshooting ________________________ 7:49Nothing works ___________________________________ 7:49System works on one stereo channel only ________________ 7:49System won’t play cassette tapes ______________________ 7:49Radio inoperative (cassette tape player OK) _______________ 7:49CD player inoperative - disc will not load _________________ 7:50CD skips during play _______________________________ 7:50
55. Antenna (manual) - removal & installation ________________ 7:5056. Antenna (power) - removal & installation ________________ 7:5057. Alarms & immobilisers - general _______________________ 7:5158. Wiring diagrams - general ___________________________ 7:51
CHAPTER 8: SUSPENSION & STEERING
1. Introduction _______________________________________ 8:12. Wheel alignment - general _____________________________ 8:13. Wheel alignment - checking & adjustment __________________ 8:3
Toe-in (front wheels) - adjustment ______________________ 8:3Caster angle (front wheels) - adjustment __________________ 8:3Camber angle (front wheels) - adjustment _________________ 8:4Toe-in (rear wheels) adjustment ________________________ 8:4Camber angle (rear wheels) adjustment ___________________ 8:4
4. Shock absorber & spring (front) - removal, o/haul & installation ___ 8:5Checking ________________________________________ 8:6
5. Wishbone, lower front - removal, o/haul & installation _________ 8:76. Wishbone, upper front - removal, o/haul & installation _________ 8:97. Stabilizer bar (front) - removal, checking & installation ________ 8:118. Crossmember (front) - removal & installation _______________ 8:119. Steering (manual) - description _________________________ 8:1210. Steering (manual) - checking _________________________ 8:1311. Steering wheel & column - removal, checking & installation ___ 8:1312. Tie rod ball joint & rack dust boot - removal & installation _____ 8:1613. Steering (manual) rack - removal, o/haul & installation _______ 8:1714. Steering (power) - description ________________________ 8:1815. Steering (power) - fluid level check & air bleeding __________ 8:1816. Steering (power) - checking for leaks ____________________ 8:1817. Steering (power) - pressure check ______________________ 8:1918. Steering (power) - checking __________________________ 8:1919. Steering (power) rack - removal, o/haul & installation ________ 8:1920. Steering (power) pump - removal & installation ____________ 8:2121. Steering (power) pump - dismantling, o/haul & reassembly ____ 8:21
22. Shock absorber & spring (rear) - removal, o/haul & installation _ 8:2223. Wishbone, lower rear - removal, o/haul & installation ________ 8:2324. Wishbone, upper rear - removal, o/haul & installation ________ 8:2425. Stabilizer bar (rear) - removal, checking & installation ________ 8:2426. Crossmember (rear) - removal, checking & installation _______ 8:25
CHAPTER 9: BRAKES, WHEELS & TIRES
1. Brake system - Introduction & on-vehicle checks _____________ 9:12. Brake hydraulic system - topping-up fluid & bleeding __________ 9:13. Brake system hydraulic fluid - replacement _________________ 9:24. Brake lines & hoses - checking & replacement _______________ 9:2
Rigid line replacement _______________________________ 9:2Flexible hose replacement ____________________________ 9:3
5. Brake pedal - removal, installation & adjustment _____________ 9:36. Brake master cylinder & servo - removal, installation & adjustment 9:4
Master cylinder removal _____________________________ 9:4Vacuum servo (power brake) unit removal ________________ 9:4Vacuum servo (power brake) unit installation _______________ 9:4Master cylinder installation ____________________________ 9:5Special notes: ABS equipped cars ______________________ 9:5
7. Brake master cylinder - overhaul ________________________ 9:68. Brake servo - checking (in-situ) _________________________ 9:79. Brake proportioning bypass valve - checking (in-situ) __________ 9:710. Brake pads (front) - wear check ________________________ 9:711. Brake pads (front) - removal & installation _________________ 9:812. Brake disc (front) - checking, removal & installation __________ 9:913. Brake caliper (front) - removal & installation ______________ 9:1014. Brake caliper (front) - overhaul ________________________ 9:1015. Brake pads (rear) - wear check ________________________ 9:1116. Brake pads (rear) - removal & installation ________________ 9:1217. Brake disc (rear) - checking, removal & installation __________ 9:1418. Brake caliper (rear) - removal & installation _______________ 9:1419. Brake caliper (rear) - overhaul ________________________ 9:1520. Parking brake - checking & adjustment __________________ 9:1621. Parking brake lever - removal, checking & installation ________ 9:1622. Parking brake cable - removal, checking & installation _______ 9:17
Lever to compensator cable - replacement _______________ 9:17Compensator to brake cables - replacement ______________ 9:17
23. ABS (anti-lock brake system) - checking _________________ 9:1824. Tires - checking __________________________________ 9:18
Tread wear _____________________________________ 9:18Tire damage _____________________________________ 9:18Matching tires ____________________________________ 9:19Tire size & ratings _________________________________ 9:19
25. Wheel changing (with car’s toolkit) _____________________ 9:1926. Tires - rotation ___________________________________ 9:2027. Tire pressures - checking & adjusting ___________________ 9:2028. Tire fitting & wheel balancing _________________________ 9:2029. Wheels - checking & maintenance _____________________ 9:2030. Wheel hubs & bearings - checking & overhaul _____________ 9:2031. Wheel studs - removal & installation ____________________ 9:23
CHAPTER 10: INTERIOR
1. Introduction ______________________________________ 10:12. Console, rear (between seats) - removal & installation ________ 10:13. Dash center panel - removal & installation _________________ 10:24. Dash panel - removal, checking & installation ______________ 10:35. Interior trim - removal & installation _____________________ 10:7
Front header rail trim & sun visors _____________________ 10:7A-pillar trim _____________________________________ 10:7Front side (footwell) trim ____________________________ 10:7Scuff plate ______________________________________ 10:8Quarter trim _____________________________________ 10:8Door speaker & grille ______________________________ 10:9Door trim _______________________________________ 10:9
6. Door glass & lifter mechanism - removal & installation _______ 10:117. Window lift system (power) - checking & overhaul __________ 10:138. Window lift system (manual) - checking & overhaul _________ 10:159. Door glass alignment - checking & adjustment _____________ 10:15
Height adjustment _______________________________ 10:15Inward/outward adjustment _________________________ 10:15Fore/aft adjustment _______________________________ 10:16Adjustment checks _______________________________ 10:16
0:7
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Contents
Visit Veloce on the Web - www.veloce.co.uk
10. Door latch & lock assembly - removal, overhaul & installation _ 10:16Aftermarket central locking _________________________ 10:17
11. Seats - removal, checking, overhaul & installation _________ 10:1712. Carpets - removal & installation ______________________ 10:1913. Trunk (boot) carpet & trim - removal & installation _________ 10:2014. Seatbelts - removal, checking & installation ______________ 10:2115. Brace bar - removal & installation _____________________ 10:21
Removal ______________________________________ 10:21Installation _____________________________________ 10:21
CHAPTER 11: BODY
1. Introduction ______________________________________ 11:12. Body - maintenance & cosmetic care ____________________ 11:1
Why maintenance matters ___________________________ 11:1Washing _______________________________________ 11:1Polishing _______________________________________ 11:2Vinyl trim cleaners & polishes ________________________ 11:2Tar spots _______________________________________ 11:2Color restorers ___________________________________ 11:2
3. Paintwork - damage repair ____________________________ 11:24. Body - damage repair & painting _______________________ 11:2
Assessing the damage ______________________________ 11:3Pulling out a dent _________________________________ 11:3Repairing holed or gashed areas _______________________ 11:3Filling _________________________________________ 11:4Sanding ________________________________________ 11:4Painting ________________________________________ 11:4Finishing _______________________________________ 11:5
5. Hood (bonnet) - removal & installation ___________________ 11:66. Trunk (boot) lid, fittings & rear panel - removal & installation ___ 11:6
Trunk lid removal & installation _______________________ 11:7Trunk latch - removal, installation & adjustment ____________ 11:7Rear finisher (license plate) panel & trunk lock barrel - removal _ 11:8Trunk lid balance springs - removal, installation & adjustment __ 11:9Trunk lid hinges - removal & installation ________________ 11:10
7. Fuel filler cable & lid - removal, installation & emergency opening11:108A. Door mirror - removal & installation ___________________ 11:118B. Door mirror (power) - checking ______________________ 11:119. Door - removal, installation & adjustment ________________ 11:1210. Bumper (rear) - removal & installation _________________ 11:1311. Bumper (front) - removal & installation _________________ 11:1512. Fender (wing), front - removal & installation _____________ 11:1713. Windshield - removal & installation ____________________ 11:1814. Hard top - installation & adjustment ___________________ 11:1915. Convertible top - removal, installation & adjustment ________ 11:1916. Convertible top rear window & rain rail - removal & installation 11:2117. Convertible top fabric - removal & installation ____________ 11:2218. Convertible top - fabric repairs _______________________ 11:25
CHAPTER 12: UNDERBODY & RUSTPROOFING
1. Introduction ______________________________________ 12:12. Rustproofing - why it’s a good idea ______________________ 12:13. Rustproofing procedure ______________________________ 12:1
CHAPTER 13: TROUBLESHOOTING
Introduction ________________________________________ 13:1Engine problems ____________________________________ 13.1
Won't start/stops suddenly ___________________________ 13:1Does not crank when starter operated ___________________ 13:1Cranks very slowly when starter operated ________________ 13:1Cranks normally, but does not start ____________________ 13:2Difficult to start when cold ___________________________ 13:2Difficult to start when warm __________________________ 13:2Starts, but doesn’t run normally _______________________ 13:2Idle (tickover) erratic or rough ________________________ 13:2Stalls __________________________________________ 13:2
Hesitates or stumbles during acceleration ________________ 13:2Power surges/losses when gas pedal held steady ___________ 13:2Lacks power ____________________________________ 13:3Engine runs roughly during deceleration _________________ 13:3Abnormal fuel consumption __________________________ 13:3Low oil pressure __________________________________ 13:3Excessive oil consumption ___________________________ 13:3
Clutch problems _____________________________________ 13:3Clutch does not release when pedal depressed_____________ 13:3Clutch slipping ___________________________________ 13:3Clutch judder ____________________________________ 13:3Unusual noise ___________________________________ 13:3
Transmission (manual) problems _________________________ 13:3Gear engagement difficult or noisy _____________________ 13:3Transmission jumps out of gear _______________________ 13:4Unusual noises ___________________________________ 13:4Abnormal vibration ________________________________ 13:4Transmission (automatic) problems _____________________ 13:4General ________________________________________ 13:4
Final drive problems __________________________________ 13:4Engine runs normally, & gears engage, but car does not move __ 13:4Abnormal noise or vibration __________________________ 13:4
Cooling system problems ______________________________ 13:4Overheating indicated &/or steam from under hood (bonnet) __ 13:4Coolant ejected from overflow pipe/oil in coolant ___________ 13:4Temperature gauge needle does not reach ‘normal’ sector ____ 13:4Coolant loss _____________________________________ 13:4
Steering & suspension problems _________________________ 13:4Car wanders off line _______________________________ 13:4Excessive steering free play __________________________ 13:4Steering excessively stiff or heavy (manual steering) _________ 13:4Steering excessively stiff or heavy (power steering) __________ 13:4Wheel (front) wobble or vibration ______________________ 13:4Wheel (rear) wobble or vibration ______________________ 13:5Car rolls excessively or wallows in corners ________________ 13:5Abnormal tire wear ________________________________ 13:5
Abnormal smells, noises or vibration _______________________ 13:5Fuel smells in or around car __________________________ 13:5Smell of burning __________________________________ 13:5Sulfur (sulphur) smell from exhaust ____________________ 13:5
Unusual noises ______________________________________ 13:5Pinging or knocking sound when engine under load _________ 13:5Light tapping or rattling noise from engine ________________ 13:5Rumbling or knocking noises from engine ________________ 13:5Squealing or screeching from under hood (bonnet) _________ 13:5Whistling noises from under hood (bonnet) _______________ 13:5Exhaust system noises ______________________________ 13:5Droning or rumbling from wheel area ___________________ 13:5Clutch noises ____________________________________ 13:5Suspension noises ________________________________ 13:5
Brake system problems ________________________________ 13:5Poor brake performance ____________________________ 13:5Brakes pull to one side _____________________________ 13:6Brakes dragging __________________________________ 13:6Excessive pedal movement __________________________ 13:6Brake noise or vibration ____________________________ 13:6Anti-lock braking system (ABS) malfunction ______________ 13:6Parking brake ineffective ____________________________ 13:6
Electrical problems ___________________________________ 13:6Battery becomes discharged frequently __________________ 13:6Headlights dim or inoperative ________________________ 13:6Turn signals inoperative on one side only ________________ 13:6Turn signals inoperative on both sides of car ______________ 13:6Burned out fuses or circuit breaker open _________________ 13:6
INDEX
Index __________________________________________ 14:1
2:10
Mazda Miata, MX-5, Eunos & Roadster
D8/4 CORRECT OIL LEVEL FOR MANUALTRANSMISSION.
A = Filler/level plug.
6 Once you’ve checked and cleaned the
plug electrodes, or before new plugs are installed,
check the electrode gap. It is worth buying a plug
gapping tool for this task; these have wire-type
feeler gauges and special tools for setting the gap
by bending the ground (earth) electrode. Note that
you should never attempt to bend the center
electrode; if you do, you’re likely to break the
insulator nose. Set the electrode gap to 1.0-1.1mm/
0.040-0.043in.
7 Before installing the new or cleaned
plugs, apply a small trace of copper-based, anti-
seize compound or molybdenum disulfide grease
to the plug threads; this will make removal easier
next time, and lessens the risk of a frozen (seized)
plug tearing out the plug threads in the cylinder
head. Caution! Do not overtighten the sparkplugs,
the correct torque is 15-22Nm/1.5-2.3kgf m/11-
16Ibf ft. Reconnect the sparkplug wires (HT leads).
7. IDLE SPEED - CHECKING & ADJUSTMENT
1/1, 2 & 2/1.
1 The correct idle speed for an engine at
normal temperature with the transmission in neutral
(manual trans) or P (auto trans) is 800-900rpm
(MT) or 750-850 (AT). With air conditioning on,
idle should increase to 1000rpm (MT only).
2 The onboard rev counter (tachometer) is
not very accurate at measuring these sort of engine
speeds, so you should assume that the idle speed
is OK if the engine does not seem to be running
excessively fast at idle, nor so slowly that it stalls at
the least provocation.
3 Idle speed can be altered by small
adjustments of the air adjusting screw (see diagram).
However, as this action may be illegal in some
territories, we advise you to leave it to your Mazda
dealer to set idle speed using the appropriate SSTs
(special service tools). Do not attempt to adjust the
throttle adjusting screw, which is factory set and
should never be disturbed.
8. TRANSMISSION (MANUAL) OIL -CHECKING LEVEL & CHANGING
1/1, 2 & 2/1.
1 Checking or changing the transmission oil
requires the car to be raised so you can get access
to the filler and drain plugs. Place the car on jack
(axle) stands, or on fabricated steel wheel ramps.
Caution! The car must be raised to a level position
to ensure the oil level reading is correct. If you have
access to a vehicle lift, or can get the oil changed by
a Mazda dealer or service station, we suggest that
you do so. Unless you need to do other work under
the car, you need to do a lot of preparatory work to
gain access. For details of jacking and supporting
the car 1/3.
CHECKING LEVEL2 With the car safely supported, unscrew
and remove the transmission oil level/filler plug A,
which is situated halfway up the transmission cas-
ing on the left-hand side.
3 You’ll need a syringe, or transmission
oil in a pack with a built-in tube. Add fresh oil
through the filler/level plug hole until the oil is level
with the hole - allow any excess to drain out for at
least ten minutes. The correct oil grade, which will
be marked on the container, is most commonly API
Service GL-4 or GL-5 SAE 75W-90. Where
temperatures are constantly above 10 degrees C/
50 degrees F, you can use API Service GL-4 or GL-
5 SAE 80W-90. These gearboxes respond well to
synthetic oils of the appropriate grade, particularly
if you feel the gearchange is too notchy.
4 Once the oil level is correct, install the
filler/level plug (A) and tighten it to 25-39Nm/2.5-
4.0kgf m/18-28lbf ft.
CHANGING TRANSMISSION OIL5 With the car safely supported, position a
drain tray under the transmission drain plug, then
remove the filler plug A (diagram D8/2), followed
by the drain plug B. The transmission holds 2.0
liters/2.1 US or 1.8 Imp quarts of oil, so have ready
a container of at least this capacity. The transmission
D8/2 LOCATION OF MANUAL TRANSMISSIONDRAIN AND LEVEL/FILLER PLUGS.
6/6 Measuring sparkplug electrode gap.
6/7 Correct connection of sparkplug wires.
D7/3 USING AIR ADJUSTING SCREW TO ADJUSTIDLE SPEED.(See text.)
7/3 Air adjusting screw (see text).
3:3
3
3: Engine & clutch
where there are three fixings on each side. You’ll
also have to remove the 10mm nut that holds the
stay (or stays) to the lower part of the front wing (or
wings). Note that on some right-hand drive cars the
windscreen washer reservoir is mounted forward
of the left-hand wheelarch, in which case one of the
undertray fixings will be a deeply recessed 10mm
nut near the reservoir body. Remove the two
10mm bolts at the rear of the undertray and three
at the front; then lift the undertray out from beneath
the car.
16 The next step is to drain the radiator.
Unscrew and remove the crosshead drain screw
from the bottom of the radiator, having first placed
a suitable receptacle underneath. If you use a clean
receptacle you can retain the coolant for re-use.
17 + Place a drainer can under the sump
and then, using a 19mm socket, loosen and remove
the sump drain plug.
18 + Manual transmission cars only: loosen
and remove the 24mm transmission drain plug
once a suitable receptacle is in place to catch the oil.
19 Working from above the engine
compartment and starting at the right-hand side of
the engine proceed as follows -
20 First, disconnect the hose from the
4/12 Disconnect washer hose.
4/13 Remove four hinge bolts.
4/14 Remove front wheels.
4/15a Three bolts each side ...
4/15b ... one of which secures stay ...
4/15c ... some cars have this front left fixing ...
4/15d ... two bolts at rear ...
4/15e ... and three at front secure undertray.
4/15f Lift away undertray.
4/16 Drain coolant into suitable receptacle.
4/17a Remove drain plug and ...
4/17b ... drain the engine oil.
4/18a Remove drain plug and ...
4:5
4
4: Transmission (gearbox) & driveline
section of the small bore vacuum pipe (7) to the
left-hand side of the casing. Pull the rubber section
of the pipe from its union stub.
10 Also on the left of the unit you’ll see the oil
cooler feed and return pipes (13). Both are secured
to the transmission casing and bellhousing by clips
and then at their unions by banjo bolts. Remove
the bolts securing the clips and the banjo bolts, then
tie the loose pipes out of harm’s way.
11 Detach the wiring harness (14) and remove
PPF (15) 4/2/17-23.
12 At the front of the unit on the right-hand
side you’ll see the transmission dipstick tube.
Remove the dipstick, unscrew the nut and bolt
securing the tube’s support bracket and then pull
the tube from the transmission case.
13 Remove the cover (16) of the access hole
in the bottom of the bellhousing. With a blob of
paint or an indelible marker, mark the relative
positions of the driveplate and torque convertor so
that they can be reattached in the same positions
on reassembly.
14 Reach up into the bellhousing and unscrew
and remove the four nuts or bolts (17), as applicable,
fixing the torque convertor to the driveplate. You
can lock the driveplate by jamming a large screw-
driver into the starter ring gear teeth and simultane-
ously wedging it against the side of the access hole.
15 Release bellhousing bolts and nuts 4/
2/25-27.
16 Lower the transmission as far as it will go
until the jack pad just comes free and then jack it
back up just 13mm/half-an-inch so that the engine
mountings are not too strained.
17 There should now be sufficient room above
the transmission to reach and separate the five
electrical connector blocks (8, 9, 10, 11, 12).
Caution! Before disconnecting, check the color
coding of the wires each side of each connector: if
necessary, tag wires so you know what goes with
what on refit. The wiring harness can now be pulled
to the side and tied to the brake pipes out of harm’s
way.
18 Carefully undo and remove the last two
bellhousing bolts.
19 Using a wooden packing piece, place a
jack under the rear end of the engine oil pan/sump
adjacent to the bellhousing and jack upwards until
the weight of the transmission is just released from
the existing jack. Caution! Don’t jack the sump any
higher than this. The jack which was used to
support the transmission should now be removed
(unless it's a wheeled jack).
20 With the help of a strong assistant, or by
supporting the weight of the transmission on a
wheeled jack, pull the transmission backward whilst
supporting the weight of the unit - which we think
is around 70kg (155lb). Warning! If you and your
assistant are doing this job without a wheeled jack,
neither of you should position yourselves directly
beneath the transmission in case it drops. Once the
spigots in the bellhousing joint face are clear, the
whole transmission unit can be lowered to the
ground and then removed from beneath the car.
Caution! It is essential that the automatic transmis-
sion unit is kept the right way up at all times,
otherwise sediment and debris from the oil pan
(which will still contain fluid) can be dislodged and
allowed to contaminate fine drillings and valves.
4. TRANSMISSION (GEARBOX), MANUAL -DISMANTLING & REBUILD GENERAL
First read 1/1, 2.
1 Read the text on teardown and rebuildbefore you start the job so that you have a good
idea of what’s involved 4/5, 6, 7.
2 Most of the work can be undertaken with
ordinary tools, but there are a few tasks requiring
D3/2 AUTOMATIC TRANSMISSION REMOVAL SEQUENCE1 Shift rod. 2 Engine undertray. 3 ‘Performance rod’ brace. 4 Exhaust system (except manifold).
5 Driveshaft (propshaft). 6 Speedometer cable. 7 Vacuum pipe/hose. 8 Range switchconnector. 9 Input/turbine speed sensor connection. 10 Solenoid connector. 11 ATF
temperature sensor. 12 Clutch solenoid connector. 13 Oil cooler pipes. 14 Wiring harness. 15 PPF(power plant frame). 16 Access cover. 17 Torque convertor nuts or bolts (as applicable).
18 Starter motor. 19 Bellhousing bolts. 20 Auto transmission unit. R = Replace.
D3/6 DRAINING ATF.
D4/1 CHECK THAT TORQUE CONVERTORPROPERLY ENGAGED WITH OIL PUMP
‘A’ = 22.5mm/0.89in.
5:5
5
5: Engine management, fuel, ignition & exhaust systems
exhaust manifold and the main muffler/silencer.
13 Ignition. The PCM reads the engine
operating condition and uses this data to determine
the exact point of ignition for each cylinder for
optimum efficiency. Once triggered by the PCM,
each coil generates a high voltage which fires two
sparkplugs simultaneously.
14 Power train control module (PCM). Also
known as the ECU or ECM. The main control
element in the engine management system - the
car’s brain. Tucked safely away inside the cockpit,
it constantly monitors engine operating conditions
through the battery of sensors previously described.
It uses a basic pre-programmed set of instructions
(‘maps’) overlaid by the varying conditions it reads
from the rest of the vehicle to control engine
operation
4. POWERTRAIN CONTROL SYSTEM -TROUBLESHOOTING TIPS
1 DONT PANIC! It’s too easy to assume
that, because the PCM and its associated
components and wiring make a complex system,
the slightest stumble from the engine is bound to be
caused by the failure of some mysterious little part
deep inside the PCM: this is not so.
2 The fact is that the PCM and the
components to which it is linked are designed to
last the life of the car without replacement, and are
therefore unlikely to give trouble.
3 What this means is that if the engine stops,
it’s most likely that you’re out of fuel; if it misfires,
that the sparkplug wires or sparkplugs are shot or
wet; and, if it fails to start, that the battery is flat or
the auto transmission’s in D. Keep it simple:
eliminate the most likely problems with a logical
process before hunting for extremely obscure and
unlikely faults.
4 The “Troubleshooting” chapter will point
you in the right direction; meantime those with
earlier cars just got lucky and are off to a head start
with fault diagnosis -
FAULT CODES
5 The PCM of 1994 and early 1995
models using the original OBD (on board diagnosis)
rather than the OBD II system, will report the
general nature of a fault by a sequence of flashes of
the dashboard mounted ‘Check’ light. Whenever
you turn the ignition key to the ON position (this
applies to later models, too), the ‘Check’ light
illuminates to indicate that its bulb is working. Once
the engine is started it will go out if the PCM has
detected no faults in the system. If the light stays on
when the engine is started, the PCM is telling you
that a fault exists in the PCM circuitry, componentry
controlled by/reporting to the PCM or within the
PCM itself.
6 For models with the original OBD system,
after getting the engine to normal operating
temperature, determine the nature of the fault as
follows. Switch off the engine. Switch off all
accessories (eg: air conditioning, lights, radio, etc.)
and put the transmission in neutral. Do not press
the accelerator or clutch pedals during the test.
7 Open the data link connector on the left-
hand inner fender (wing) and, with a piece of stiff
copper wire, or a paperclip, bridge terminals TEN
(test engine) and GND (ground). Turn the ignition
switch to ON (do not start the engine).
8 If the PCM has stored a fault code the
check light will give a series of flashes separated by
4 second pauses. A short flash indicates a single
digit, so 3 short flashes repeating every 4 seconds
would indicate fault code 3. A long flash equates
to 10, so 2 long flashes and 3 short flashes repeating
every 4 seconds would indicate fault code 23. Got
it? If you get more than one type of flashing
sequence every four seconds, multiple faults are
being reported. Take your time to determine the
fault codes; the light sequence will continue until
you turn the ignition off.
9 Note that once a fault has been rectified,
the fault code can be cleared from the PCM (and
therefore the check light) by disconnecting the
battery negative cable and pressing the brake pedal
for at least 20 seconds.
10 The check light system reports just 16
codes, though there are many more which can be
picked up by SSTs (Special Service Tools). The
codes are as follows -
Code 01: A problem with the ignition system or
associated circuitry.
Code 03 and 04: A problem with the camshaft
position sensor or associated circuitry.
Code 08: A problem with the MAF (mass airflow)
sensor or associated circuitry.
Code 09: A problem with the engine coolant
temperature sensor or associated circuitry.
Code 10: A problem with the air temperature
sensor (within MAF unit) or associated circuitry.
Code 12: A problem with the throttle position
sensor or associated circuitry.
Code 14: A problem with the barometric pressure
sensor (located within PCM) or associated circuitry.
Code 15 and 17: A problem with the heated
oxygen sensor or associated circuitry.
Code 16: A problem with the EGR valve position
sensor, associated circuitry or hoses.
Code 25: A problem with the PRC solenoid valve,
associated circuitry or hoses.
Code 26: A problem with the purge solenoid valve,
associated circuitry or hoses.
Code 28: A problem with the EGR solenoid valve
(vacuum), associated circuitry or hoses.
Code 29: A problem with the EGR solenoid valve
(vent), associated circuitry or hoses.
Code 34: A problem with the idle air control valve,
associated circuitry or hoses.
D3/8 OVERVIEW OF THE EXHAUST GAS RECIRCULATION (EGR) SYSTEM.
D4/5 THE DASHBOARD MOUNTED ENGINE‘CHECK’ LIGHT.
6:1
6
6: Cooling, heating & air conditioning systems
1. INTRODUCTION
These cars use a conventional cooling system in
which the water-based coolant is circulated around
the engine by a small centrifugal pump driven by a
belt from the crankshaft. Engine heat is transferred
to the coolant, which is constantly circulated through
the radiator. Air passing though the radiator matrix
reduces coolant temperature before it circulates
once again through the engine. Hot air is sucked
from the engine compartment by the airstream
created by the moving car. An electric cooling fan
switches on at a predetermined coolant tempera-
ture to draw air through the radiator matrix. This
ensures adequate cooling in very hot tempera-
tures, or when in slow-moving traffic.
During cold weather, the interior of the car
is heated by a system like the engine cooling system
running in reverse: hot coolant from the engine is
diverted through the heater matrix below the
dashboard, and air is passed through the matrix to
extract heat to warm the passenger compartment.
The heater control allows the occupants to control
a combination of recirculated and fresh air, and to
boost the incoming airflow with an electric fan.
An optional air conditioning system is avail-
able. This works pretty much like a domestic refrig-
erator. An engine-driven compressor circulates
refrigerant through the condenser - effectively an-
other radiator - mounted in the nose of the car. The
condenser, backed up by an electric fan, is designed
to dump unwanted heat into the passing airstream.
Refrigerant is piped to the cooling unit (evaporator)
mounted under the dashboard. Hot air from the
car’s interior is passed through the evaporator, the
refigerant absorbing the air’s heat and thus reducing
its temperature. The warmed refrigerant evaporates
into a gas which is pumped back to the condenser,
where it cools and liquefies: the cycle is then
repeated.
2. ENGINE COOLANT - TOPPING-UP &CHANGING
1/1, 2 & 6/1.
Warning! If the engine has been run within the last
hour or so, the engine coolant will be hot and under
pressure. Removing the radiator cap or coolant
reservoir cap can result in the coolant suddenly
boiling as pressure is released, resulting in scalding
steam being ejected. Always allow the engine to
cool before removing either cap. Wear eye protec-
tion, gloves and overalls for safety. Place rag over
the radiator cap, then turn the cap slowly counter-
clockwise until it reaches the first stop position.
D1/0 ENGINE COOLING SYSTEM (SHOWING COOLANT FLOW)1 Reservoir. 2 Radiator cap. 3 Radiator. 4 Thermostat. 5 Water pump. 6 Engine coolant fan.
7 Engine coolant fan relay.
Cooling,heating and
airconditioning
systems
6
1 MX5 Decadence A4 8/29/08 3:11 PM Page 1
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Untitled-1.indd 1 21/1/10 11:54:10
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