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MX-5 Miata
Workshop manual
Mazda MX-5 MIATA Workshop Manual
1999
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Also See for MX-5 MIATA
:
Workshop manual
(743 pages)
,
Owner's manual
(609 pages)
,
Workshop manual supplement
(120 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
Vehicle Identification Numbers (VIN)
Warning
General Information
How to Use this Manual
Range of Topics
Repair Procedure
Symbols
Upper and Lower Limits
Basic Flow of Troubleshooting
On-Board Diagnosis
Diagnostic Index
Procedures for Use
Using the Basic Inspection
Using the Diagnostic Index
Using the Quick Diagnosis Chart
Using the Symptom Troubleshooting
Text Sequence
Units
SAE Standards
Fundamental Procedures
Installation of Radio System
Electrical System Procedures
Electrical Troubleshooting Tools
Jacking Positions
Vehicle Lift (2 Supports) and Safety Stand (Rigid Rack) Position
Towing
Tiedown Hooks
Identification Number Locations
Abbreviations
Pre-Delivery Inspection
Scheduled Maintenance
Scheduled Maintenance Chart Symbols
Schedule 2 (Unique Driving Conditions)
Scheduled Maintenance Table (Canada)
Engine
Troubleshooting (Engine Control)
Engine On-Board Diagnosis
Simulation Test
Diagnostic Support Procedure (Engine)
New Generation Start (NGS) Tester Hook-Up Procedure
Dtcs Reading Procedure
Pending Trouble Code Access Procedure
Freeze Frame PID Data Access Procedure
On-Board System Readiness Tests Access Procedure
PID/DATA Monitor and Record Procedure
Playback of Stored Pids Procedure
Diagnostic Monitoring Test Results Access Procedure
Diagnostic Support Procedure
Oxygen Sensor Test Results Access Procedure
Simuilation Test Procedure
Idling Test
Ignition on Test
After Repair Procedure
OBD II Drive Mode Procedure
Failure Indication Function/Diagnostic Trouble Code Table (Engine)
Diagnostic Trouble Code Troubleshooting
DTC P0102 Mass Air Flow Circuit Low Input
DTC P0103 Mass Air Flow Circuit High Input
DTC P0106 Barometric Pressure Circuit Performance Problem
DTC P0107 Barometric Pressure Circuit Low Input
DTC P0108 Barometric Pressure Circuit High Input
DTC P0111 Intake Air Temperature Circuit Performance Problem
DTC P0112 Intake Air Temperature Circuit Low Input
DTC P0113 Intake Air Temperature Circuit High Input
DTC P0117 Engine Coolant Temperature Circuit Low Input
DTC P0118 Engine Coolant Temperature Circuit High Input
DTC P0122 Throttle Position Circuit Low Input
DTC P0123 Throttle Position Circuit High Input
DTC P0125 Excessive Fuel Control Time to Enter Closed Loop
DTC P0130 Front Heated Oxygen Sensor Circuit Malfunction
DTC P0134 Front Heated Oxygen Sensor Circuit no Activity Detected
DTC P0138 Rear Heated Oxygen Sensor Circuit High Input
DTC P0140 Rear Heated Oxygen Sensor Circuit no Activity Detected
DTC P0171 Fuel Trim System too Lean
DTC P0172 Fuel Trim System too Rich
DTC P0300 Random Misfire Detected
DTC P0301, P0302, P0303, P0304 Cylinder 1 - 4 Misfire Detected
DTC P0325 Knock Sensor Circuit Malfunction
DTC P0335 Crankshaft Position Sensor Circuit Malfunction
DTC P0339 Crankshaft Position Sensor Circuit Intermittent
DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected
DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected
DTC P0420 Warm up Catalyst System Efficiently below Threshold
DTC P0421 Warm up Catalyst System Efficiently below Threshold
DTC P0442 Evaporative Emission Control System Malfunction (Leak Check)
DTC P0443 Evaporative Emission Control System Purge Control Valve Circuit Malfunction (Equip Leak Check)
DTC P0446 Evaporative Emission Control System Malfunction (Vent Control Malfunction)
DTC P0452 Evaporative Emission Control System Pressure Sensor Low Input
DTC P0453 Evaporative Emission Control System Pressure Sensor High Input
DTC P0455 Evaporative Emission Control System Malfunction (Con. Leak Detected)
DTC P0461 Fuel Level Sensor Circuit Range/Performance
DTC P0462 Fuel Level Sensor Circuit High Input
DTC P0463 Fuel Level Sensor Circuit Low Input
DTC P0500 Vehicle Speed Sensor Malfunction
DTC P0506 Idle Control System RPM Is Lower than Expected
DTC P0507 Idle Control System RPM Is Higher than Expected
DTC P0550 P/S SW Malfunction
DTC P0703 Brake Switch Input Malfunction
DTC P0704 Clutch Switch Input Circuit Malfunction
DTC P0705 Neutral Switch Circuit Malfunction (MT)
DTC P1102 Mass Air Flow Inconsistent with Throttle Position Sensor (Lower than Expected)
DTC P1103 Mass Air Flow Inconsistent with RPM (Greater than Expected)
DTC P1122 Throttle Position Is Closed Stuck
DTC P1123 Throttle Position Is Open Stuck
DTC P1135 Front Heated Oxygen Sensor Heater Circuit Low
DTC P1136 Front Heated Oxygen Sensor Heater Circuit High
DTC P1141 Rear Heated Oxygen Sensor Heater Circuit Low
DTC P1142 Rear Heated Oxygen Sensor Heater Circuit High
DTC P1170 Heated Oxygen Sensor (Front) (Inversion)
DTC P1345 no SGC Signal
DTC P1449 Canister Drain Cut Valve (CDCV) Open or Short
DTC P1450 Evaporative Emission Control System Malfunction
DTC P1487 EGR Boost Sensor Solenoid Valve Open or Short
DTC P1496 EGR Valve Motor Coil 1 Open or Short
DTC P1497 EGR Valve Motor Coil 2 Open or Short
DTC P1498 EGR Valve Motor Coil 3 Open or Short
DTC P1499 EGR Valve Motor Coil 4 Open or Short
DTC P1504 Idle Air Control Circuit Malfunction
DTC P1523 VICS Circuit Malfunction
DTC P1562 PCM + BB Voltage Is Low
DTC P1601 Communication Line Error (PCM-TCM)
Dtc P1608, P1609
DTC P1631 Generator Output Voltage Signal no Electricity
DTC P1632 Battery Voltage Monitor Signal Circuit Malfunction
DTC P1633 Battery Overcharge
DTC P1634 Generator Terminal B Circuit Open
Engine Symptom Troubleshooting
Quick Diagnostic Chart (Engine)
Description of Drivability Problems
Fuel Pressure Release and Servicing Fuel System
Fuel Line Safety Procedures
Symptom Troubleshooting (Engine)
Melts Main or Other Fuse
Will Not Crank
Hard Start/Long Crank/Erratic Start/Erratic Crank
Engine Stalls - after Start, at Idle
Cranks Normally but will Not Start
Slow Return to Idle
Engine Runs Rough/Rolling Idle
Fast Idle/Runs on
Low Idle/Stalls During Deceleration
Engine Stalls/Quits - Acceleration/Cruise; Engine Runs Rough - Acceleration/Cruise; Misses - Acceleration/Cruise; Buck/Jerk - Acceleration/Cruise/Dece
Lack/Loss of Power - Acceleration/Cruise
Knocking/Pinging - Acceleration/Cruise
Poor Fuel Economy
Emission Compliance
Mil Never on
High Oil Consumption/Leakage
Cooling System Overheating
Cooling System Runs Cold
Exhaust Smoke
Fuel Odor (in Engine Compartment)
Engine Noise
Vibration Concerns (Engine)
A/C Does Not Work
A/C Always On/ A/C Compressor Runs Continuously
A/C Does Not Cut off under Wide Open Throttle Conditions
Exhaust Sulphur Smell
Intermittent Concerns
Fuel Refill Concerns
Fuel Filling Shut off Issues
Constant Voltage
Engine Diagnostic Inspection
Spark Plug Condition Inspectin Purpose
Wet/Carbon Stuck on Specific Plug
Grayish White with Specific Plug
Wet/Carbon Stuck on All Plugs
Grayish White with All Plugs
Input Signal System Investigation Procedure
Finding Unusual Signals
Investigate the Input Signal System
Investigate the GND System
Investigate the Electrical Supply System
Thermistor Type (Intake Air Temperature and Engine Coolant Temperature Sensors)
Vehicle Speed Sensor
Inspection Using an Oscilloscope (Reference) Purpose
When Plunger Stuck
Fuel Tank Pressure, Graph Recording Procedure
Engine System Inspection
Intake Manifold Vacuum Inspection
BAC Valve Operation Inspection
Idle Air Control Inspection
VICS Operation Inspection
Fuel Line Pressure Inspection
Fuel Hold Pressure Inspection
Fuel Pump Operation Inspection
Fuel Pump Control Inspection
Evaporative Emission Control System Inspection - Whole System Inspection
Inspection from Charcoal Canister to Fuel Tank
Inspection from Charcoal Canister to Purge Solenoid Valve
Purge Control Inspection
EGR Control Inspection
Main Relay Operation Inspection
Ignition Timing Control Inspection
A/C Cut Control Inspection
Cooling Fan Control System Inspection
Cooling Fan Operation
Condenser Fan Relay
Spark Test
Fuel Injector Operation Inspection
Fuel Cut Control Inspection
Troubleshooting (Cruise Control System)
Cruise Control System On-Board Diagnosis
Inspection of Diagnostic Trouble Codes for Operation Mode
Using the Cruise Set Indicator Light
Using the SST (NGS Set) - New Generation Star (NGS) Tester Hookup Procedure
Reading Dtcs Procedure
Operation Code List
Inspection of Diagnostic Trouble Codes
DTC 21 Cruise Control Switch (Set/Coast Switch)
DTC 22 Cruise Control Switch (Resume/Accel Switch)
DTC 31 Brake Switch
DTC 35 Clutch Switch (AT: Transmission Range Switch)
DTC 37 Vehicle Speed Sensor
Inspection of Diagnostic Trouble Codes for Condition Detection Mode Using the Cruise Set Indicator Light
Condition Code List
DTC 01 Cruise Actuator
DTC 05 Brake Switch
DTC 07 Brake Switch
DTC 11 Cruise Control Switch (Set/Coast Switch)
DTC 12 Cruise Control Switch (Resume/Accel Switch)
DTC 15 Cruise Control Module
Mechanical
Drive Belt Inspection
Drive Belt Deflection Check
Drive Belt Tension Check
Drive Belt Adjustment
Valve Clearance Inspection
Valve Clearance Adjustment
Compression Inspection
Timing Belt Removal/Installation
Cylinder Head Cover Installation Note
Cylinder Head Gasket Replacement
Tappet and Adjustment Shim Removal/Installation
Front Oil Seal Replacement
Rear Oil Seal Replacement
Engine Removal/Installation
Engine Disassembly/Assembly
Engine Tune-Up
Ignition Timing Inspection
Idle Speed Adjustment
Idle-Up Speed Inspection
Idle Mixture Inspection
Lubrication System
Engine Oil Level Inspection
Engine Oil Replacement
Oil Filter Replacement
Oil Pressure Inspection
Oil Cooler Removal/Installation
Oil Pan Removal/Installation
Engine Mount Nut Removal Note
Oil Pan Removal Note
Crossmember Bolt and Nut Removal Note
Oil Baffle Removal and Installation Note
Oil Pan Installation Note
Cooling System
Engine Coolant Level Inspection
Engine Coolant Replacement
Antifreeze Solution Mixture Percentage
Engine Coolant Leakage Inspection
Radiator Cap Inspection
Radiator Removal/Installation
Thermostat Removal/Installation
Thermostat Inspection
Water Pump Removal/Installation
Cooling Fan Motor Inspection
Cooling Fan Motor Removal/Installation
Cooling Fan Relay Inspection
Intake-Air System
Vacuum Hose Routing Diagram
Intake-Air System Removal/Installation
Idle Air Control Valve Removal/Installation
Idle Air Control Valve Inspection
Resistance Inspection
VICS Check Valve (One-Way) Removal/Installation
VICS Check Valve (One-Way) Inspection
VICS Shitter Valve Actuator Removal/Installation
VICS Shutter Valve Actuator Inspection
VICS Solenoid Valve Removal/Installation
VICS Solenoid Valve Inspection
Accelerator Pedal Removal/Installation
Accelerator Cable Inspection/Adjustment
Fuel System
Fuel Line Safety Procedure
Fuel Hose Installation
Fuel Leakage Inspection
Fuel Tank Removal/Installation
Fuel Drawing Note
Rear Crossmember Component Removal Note
Plastic Fuel Hose Disassembly Note
Nonreturn Valve Installation Note
Breather Hose, Evaporative Hose Installation Note
Joint Hose Installation Note
Plastic Fuel Hose Assembly Note
Nonreturn Valve Inspection
Fuel Pump Removal/Installation
Fuel Pump Disassembly/Assembly
Fuel Pump Inspection
Fuel Pump Maximum Pressure Inspection
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Table of Contents
Troubleshooting
Symbols
7
Using the symptom troubleshooting
10
Electrical Troubleshooting Tools
19
Troubleshooting (engine control)
29
Diagnostic Trouble Code Troubleshooting
45
Engine symptom troubleshooting
124
Symptom Troubleshooting (Engine)
129
Troubleshooting (cruise control system)
188
Brakes
376
Antilock Brake System symptom troubleshooting
384
Automatic transmission symptom troubleshooting
441
HVAC Symptom Troubleshooting
549
Air bag system symptom troubleshooting
591
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This manual is also suitable for:
Mx5 miata 1999
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