Mazda MX-5 1991 Workshop Manual

Document

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

AIR BAG RESTRAINT SYSTEM

MAZDA 1990-91 AIR BAGS

DESCRIPTION & OPERATION

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all WARNINGS and SERVICE PRECAUTIONS.

The air bag restraint system, when used in conjunction with seat belt, provides increased protection for the driver in a collision. The air bag restraint system consists of the following: AIR BAG warning light, air bag module, clockspring connector, diagnostic module, crash sensors, back-up battery, and wiring harnesses.

The air bag is designed to deploy when rear safing sensor and at least one front impact sensor close in a collision, and ignition switch is in the ON position. The back-up battery supplies current for the ignitor if the vehicle battery or fuses fail during a collision. The diagnostic module monitors the air bag system for failures. If any failures are detected by the module, the driver is warned of such failure(s) through the activation or flashing of the AIR BAG warning light.

SERVICE PRECAUTIONS

NOTE: The following precautions should be observed when working with air bag systems.



Disable air bag system before servicing any air bag system or steering column component. See

DISABLING & ACTIVATING AIR BAG SYSTEM

Wait about 10 MINUTES after disabling air bag system before servicing. Air bag system voltage is maintained for about 10 MINUTES after system is disabled. Failure to wait 10 MINUTES before servicing system may cause accidental air bag deployment and possible personal injury.



On Miata, obtain radio code number from customer and deactivate radio anti-theft function before disconnecting battery.

Because of the critical system operating requirements, DO NOT service any air bag system component.

Corrections are made by replacement only.



DO NOT use an ohmmeter to check resistance of air bag module, as it may cause air bag deployment.

When carrying a live (undeployed) module, ensure trim cover is pointed away from your body. This minimizes chance of injure in the event ofaccidental air bag deployment.



When placing a live air bag module on any surface, always face trim cover upward to reduce motion of module if it is accidentally deployed.

If an open circuit is present, replace entire wiring harness. DO NOT attempt wire repair.



Impact sensors must always be installed with arrow marks facing front of vehicle. Also, check sensors for cracks, defects or rust before installation. Replace impact sensor(s) if required.

Air bag system clockspring MUST be aligned in the neutral position, since its rotation ability is limited.

DO NOT turn steering wheel or column after removal of steering gear.

1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS



A double-lock mechanism is used on clockspring connectors. DO NOT use excessive force when disconnecting connectors, as damage to connector may occur.

DISABLING & ACTIVATING AIR BAG SYSTEM

AIR BAG SYSTEM

WARNING: Wait about 10 MINUTES after disabling air bag system before servicing.

Air bag system voltage is maintained for about 10 MINUTES after system is disabled. Failure to wait 10 MINUTES before servicing system may cause accidental air bag deployment and possible personal injury.

DISABLING SYSTEM

On Miata, obtain radio code number from customer, and deactivate audio anti-theft function. On all models, turn ignition switch off. Disconnect and shield negative battery cable. Remove knee protector. Disconnect

Orange and Blue clockspring connectors at base of steering column. See Fig. 1 .

ACTIVATING SYSTEM

Reconnect battery and clockspring connectors. Turn ignition switch to RUN position. Check AIR BAG indicator light to ensure system is operating properly. See SYSTEM OPERATION CHECK.

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 1: Locating Clockspring Connector

Courtesy of MAZDA MOTORS CORP.

POST-COLLISION AIR BAG SAFETY INSPECTION

Replace After Deployment

Inspect & If Damaged, Replace Component (Even

If Air Bag Did Not Deploy)

Comments

 Air Bag Module(s)



Clockspring



Air Bag Diagnosis Control Unit

 Impact Sensors & Sensors Mountings



Steering Column



Steering Wheel

Wiring Harness



DO NOT attempt wiring harness repairs.

Replace entire wiring harness.



Impact sensors must always be installed with arrow on sensor facing front of vehicle.

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

ADJUSTMENTS

CLOCKSPRING CENTERING

Set front wheels in straight-ahead position. Turn clockspring connector clockwise until it stops (do not force).

Return connector 2 3/4 turns counterclockwise. Rotate clockspring connector further, if necessary, to align marks on connector and outer housing.

DISPOSAL PROCEDURES

DEPLOYED AIR BAG

Dispose deployed air bag module as you would any other part. Wear gloves and safety glasses when handling air bag module.

SCRAPPED VEHICLE

NOTE: Perform the following procedures when scrapping a vehicle with undeployed air bag.

1. Ensure vehicle is outside, and away from other vehicles and people. Open convertible top and doors.

Disconnect negative battery cable.

2. Ensure air bag module is firmly mounted to steering wheel. Remove knee protector and disconnect

Orange and Blue clockspring connectors at base of steering column. See Fig. 1 . Cut clockspring connector Blue wires.

3. Connect 2 jumper wires (20 feet long) to cut clockspring wires. Connect other ends of wires to a 12-volt battery to deploy air bag. Because of heat, wait 10 MINUTES before touching deployed air bag.

REMOVAL & INSTALLATION

WARNING: Follow air bag service precautions to prevent accidentalair bag deployment and personal injury. See SERVICE PRECAUTIONS.

NOTE: After component replacement, check system to ensure proper operation. See

SYSTEM OPERATION CHECK.

CRASH SENSORS

NOTE: Crash sensor orientation and mounting is important for proper operation. All sensors must be positioned so that arrow points forward. If there is sheet metal damage near sensor mounting point, inspect body structure at sensor mounting point for deformation. If damaged, restore to original shape. Ensure sensor mounting bolts or nuts are tightened to specification. See TORQUE

SPECIFICATIONS table.

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Removal (Front Impact Sensors)

1. Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM.

2. Front impact sensors are located in left front and right front of vehicle. See Fig. 2 or Fig. 3 . To remove left or right sensor, remove wheelwell undercover, and disconnect connector(s). Remove retaining clips and bolts. Remove sensor(s).

Fig. 2: Locating Crash Sensors (Miata)

Courtesy of MAZDA MOTORS CORP.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 3: Locating Crash Sensors (RX7 Convertible)

Courtesy of MAZDA MOTORS CORP.

Installation

To install, reverse removal procedure. Position sensor with arrow toward front of vehicle. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS table. Reactivate air bag system. See DISABLING &

ACTIVATING AIR BAG SYSTEM. Check AIR BAG indicator light to ensure system is functioning properly.

See SYSTEM OPERATION CHECK.

Removal (Rear Safing Sensor)

Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS. Disable air bag system.

See DISABLING & ACTIVATING AIR BAG SYSTEM. Rear safing sensor is located under center of instrument panel. Remove instrument panel. Locate and disconnect safing sensor connectors. See Fig. 2 or Fig.

3 . Remove sensor and cover.

CAUTION: A double-lock mechanism is used on clockspring connectors. DO NOT use excessive force when disconnecting connectors, as damage to connector may occur.

Installation

To install, reverse removal procedure. Position sensor with arrow toward front of vehicle. Tighten mounting nuts to specification. See TORQUE SPECIFICATIONS table. Reactivate air bag system. See DISABLING &

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

ACTIVATING AIR BAG SYSTEM. Check AIR BAG indicator light to ensure system is functioning properly.

See SYSTEM OPERATION CHECK.

AIR BAG MODULE

Removal & Installation

1. Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM.

2. Air bag module is located on center of steering wheel. See Fig. 4 or Fig. 5 . Remove air bag module nuts and remove module from steering wheel. To install, reverse removal procedure. Tighten air bag module mounting nuts to specification. See TORQUE SPECIFICATIONS table. Reactivate air bag system. See

DISABLING & ACTIVATING AIR BAG SYSTEM. Check AIR BAG indicator light to ensure system is functioning properly. See SYSTEM OPERATION CHECK.

Fig. 4: Identifying Air Bag System Components (Miata)

Courtesy of MAZDA MOTORS CORP.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 5: Identifying Air Bag System Components (RX7 Convertible)

Courtesy of MAZDA MOTORS CORP.

STEERING WHEEL

Removal & Installation

Remove air bag module. See AIR BAG MODULE. Remove steering wheel nut. DO NOT strike steering shaft with a hammer, or steering shaft may collapse. Remove steering wheel with steering wheel puller. To install, reverse removal procedure. Tighten steering wheel nut to specification. See TORQUE SPECIFICATIONS table.

CLOCKSPRING CONNECTOR ASSEMBLY

NOTE: Clockspring connector assembly is part of the combination switch. When replacing clockspring, replace clockspring and combination switch as an assembly.

Installation

1. To install, reverse removal procedure. Before installing steering wheel, center clockspring. See

CLOCKSPRING CENTERING under ADJUSTMENTS. Tighten steering wheel nut to specification. See

TORQUE SPECIFICATIONS table.

2. After installing clockspring connector and combination switch assembly, reactivate air bag system. See

DISABLING & ACTIVATING AIR BAG SYSTEM. Check AIR BAG indicator light to ensure system is functioning properly. See SYSTEM OPERATION CHECK.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Removal

1. Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM.

2. Clockspring connector assembly is located under steering wheel, in steering column. See Fig. 4 or Fig. 5 .

Remove air bag module. See AIR BAG MODULE. Remove steering wheel nut and remove steering wheel with steering wheel puller. Remove column covers. Remove screws. Remove clockspring connector and combination switch as an assembly.

DIAGNOSTIC MODULE & BACK-UP BATTERY

Removal & Installation

1. Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM.

2. Diagnostic module and back-up battery is located under left side of instrument panel. See Fig. 4 or Fig.

5 . Disconnect diagnostic module and back-up battery connectors. Remove nuts. Remove diagnostic module and back-up battery as an assembly. To install, reverse removal procedure. After diagnostic module and back-up battery are installed, reactivate air bag system. See DISABLING & ACTIVATING

AIR BAG SYSTEM. Check AIR BAG indicator light to ensure system is functioning properly. See

SYSTEM OPERATION CHECK.

SYSTEM OPERATION CHECK

Turn ignition switch to the ON or START position. AIR BAG warning light in instrument cluster should illuminate for approximately 6 seconds then go out. This indicates that the air bag system is functioning properly. If any of the following conditions exists, air bag system is malfunctioning and needs repair.



AIR BAG warning light does not illuminate as described.



AIR BAG warning light stays on for more than 6 seconds.

 AIR BAG warning light illuminates while driving.

If air bag system components are replaced for any reason, air bag system must be checked for proper function after repair. Turn ignition on. AIR BAG warning light should illuminate for approximately 6 seconds then go out. If AIR BAG warning light does not illuminate as described, air bag system is malfunctioning and needs repair. If warning light functions as described, check horn operation. If horn does not sound, remove air bag module and check air bag module and horn switch connections. Always follow service precautions and deactivate air bag system before performing repairs. See DISABLING & ACTIVATING AIR BAG

SYSTEM .

WIRE REPAIR

DO NOT repair air bag system wiring. If air bag harness connectors are faulty, replace faulty wiring harness.

TORQUE SPECIFICATIONS

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

TORQUE SPECIFICATIONS

Application

Air Bag Module Nuts

Steering Wheel Nut

Ft. Lbs. (N.m)

12-15 (16-20)

29-36 (39-49)

INCH Lbs. (N.m)

78-113 (9-13) Front Impact Sensor Bolts

Rear Safing Sensor Nuts

Miata

RX7

78-113 (9-13)

61-87 (7-10)

DIAGNOSIS & TESTING

WARNING: Follow air bag service precautions to prevent accidentalair bag deployment and personal injury. See SERVICE PRECAUTIONS.

NOTE: After component replacement, check system to ensure proper operation. See

SYSTEM OPERATION CHECK.

SELF-DIAGNOSTIC SYSTEM

Trouble Shooting

AIR BAG warning light flashes are used to diagnose air bag system. The number of warning light flashes depends on the type of fault being detected. Codes are prioritized so that if 2 or more faults are present, the highest test-priority fault indication will remain until corrected.

Warning Light Does Not Illuminate

Check for blown fuses, burned-out bulb, disconnected diagnostic module, or open circuit between warning light and diagnostic module.

Warning Light Flashes Or Remains On

Check code output of AIR BAG warning light. See AIR BAG FLASH CODES table.

AIR BAG FLASH CODES

Priority

Flash Code

Remains On

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Flashes 3 Times

Page 10

Cause/Diagnosis



Faulty Diagnostic Module



Poor Connection Of Diagnostic

Module Connector (See

DIAGNOSTIC TEST NO. 1)



Open Circuit



Poor Connection Of Power Source

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

(1)

Flashes 5 Times

Flashes 10 Times

Flashes 4 Times

Flashes 6 Times

Flashes 7 Times

Flashes 8 Times

Flashes 9 Times

Flashes 2 Times

Circuit (See DIAGNOSTIC TEST

NO. 2)



Faulty Front Impact Sensor (See

DIAGNOSTIC TEST NO. 3)



Faulty Diagnostic Module (System

Down-Fused Burned) (See

DIAGNOSTIC TEST NO. 4)

 Faulty Rear safing Sensor (See

DIAGNOSTIC TEST NO. 5)



Faulty Air Bag Module



Poor Connection Of Clockspring

Connector (See DIAGNOSTIC

TEST NO. 6)



Poor Wiring Harness Ground (See

DIAGNOSTIC TEST NO. 8)



Poor Ground Of Front Impact

Sensor (See DIAGNOSTIC TEST

NO. 8)

 Open Circuit Between Diagnostic

Module and Front Impact Sensor

(See DIAGNOSTIC TEST NO. 3)



Poor Ground Of All Front Impact

Sensors (See DIAGNOSTIC TSET

NO. 7)

(1) Code 7 Does not apply to 1990 Miata

DIAGNOSTIC TEST NO. 1

Warning Light Remains On

Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Ensure diagnostic module connectors are properly connected. If connector is okay, replace diagnostic module.

DIAGNOSTIC TEST NO. 2

Warning Light Flashes 3 Times

1. Measure battery voltage. If voltage is less than 9 volts, charge battery. If battery voltage is okay, check fuses/relays in order given in FUSE/RELAY LOCATION table. See Fig. 6 or Fig. 7 .

2. If fuses and relays are okay, disable air bag system. See DISABLING & ACTIVATING AIR BAG

SYSTEM. Ensure back-up battery connector is properly connected. If connection is okay, disconnect back-up battery connector.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

3. Reconnect negative battery cable. Measure voltage between Green/Red wire of back-up battery connector and ground. See Fig. 8 or Fig. 9 . If voltage is zero volt, replace wire harness assembly.

4. If battery voltage is present, disconnect negative battery cable and diagnostic module Black and Gray connectors. See Fig. 10 or Fig. 11 . Reconnect negative battery cable. Measure voltage between

White/Green wire of Gray diagnostic module connector and ground. If voltage is zero volt, replace wire harness assembly.

5. If battery voltage is present, measure voltage between Green/Yellow wire of Gray diagnostic module connector and ground. If voltage is zero volt, replace wire harness assembly. If battery voltage is present, replace diagnostic module.

FUSE/RELAY LOCATION

Fuse/Relay

Miata

Air Bag (15 Amps)

Air Bag (10 Amps)

Engine (15 Amps)

INJ (30 Amps)

RX7

Air Bag (15 Amps)

Air Bag (30 Amps)

Engine (30 Amps)

Wiper (15 Amps)

Location

In Fuse Block

In Main Fuse Block

In Fuse Block

In Main Fuse Block

In Fuse Block

In Main Fuse Block

In Fuse Block

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 6: Identifying Fuses & Relays (Miata)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 7: Identifying Fuses & Relays (RX7)

Courtesy of MAZDA MOTORS CORP.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 8: Checking Back-Up Battery Connector (Miata)

Courtesy of MAZDA MOTORS CORP.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 9: Checking Back-Up Battery Connector (RX7)

Courtesy of MAZDA MOTORS CORP.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 10: Locating Diagnostic Module Black & Gray Connectors (Miata)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 11: Locating Diagnostic Module Black & Gray Connectors (RX7)

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC TEST NO. 3

Warning Light Flashes 5 Or 9 Times

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Disconnect front impact sensor connectors (center, left, and right), and measure resistance of each sensor. See Fig. 12 .

Resistance should be approximately 1.2 k/ohms. If resistance is not as specified, replace sensor.

2. If resistance is about 1.2 k/ohms, reconnect all front impact sensor connectors. Disconnect diagnostic module Black and Gray connectors. See Fig. 10 or Fig. 11 . Measure resistance between diagnostic module Gray connector Brown/Green wire and ground. If resistance is 1.2 k/ohms, go to next step. If resistance is not 1.2 k/ohms, replace wire harness.

3. Measure resistance between diagnostic module Gray connector Brown/Red wire and ground. If resistance is 1.2 k/ohms, go to next step. If resistance is not 1.2 k/ohms, replace wire harness.

4. Measure resistance between diagnostic module Black connector Brown/Black wire and ground. If resistance is 1.2 k/ohms, replace diagnostic module. If resistance is not 1.2 k/ohms, replace wire harness.

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 12: Checking Impact Sensor Resistance

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC TEST NO. 4

Warning Light Flashes 10 Times

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Disconnect front impact sensor connectors (center, left, and right), and measure resistance of each sensor. See Fig. 12 .

Resistance should be approximately 1.2 k/ohms. If resistance is not as specified, replace sensor and go to step 5).

3. Measure resistance between diagnostic module Gray connector Brown/Red wire and ground. If resistance is 1.2 k/ohms, go to next step. If resistance is not 1.2 k/ohms, replace wire harness.

4. Measure resistance between diagnostic module Black connector Brown/Black wire and ground. If resistance is 1.2 k/ohms, go to next step. If resistance is not 1.2 k/ohms, replace wire harness and go to next step.

5. If disconnected, reconnect diagnostic module and clockspring connectors. Reconnect negative battery

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS cable. Turn ignition switch to ON position and check warning light operation. If warning light flashes 10 times, replace diagnostic module.

DIAGNOSTIC TEST NO. 5

Warning Light Flashes 4 Times

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Disconnect diagnostic module Black and Gray connectors. See Fig. 10 or Fig. 11 . Check continuity between Black connector

Green/White wire terminals. If continuity is not present, replace wire harness.

2. If continuity is present, check continuity between Black connector Green wire and ground (1990 Miata), or between Gray connector Red/Black wire terminal and ground (all others). If continuity is not present, go to step 4). If continuity is present, check continuity between Black connector Green wire terminal and

Gray connector Green/Black wire terminal. If continuity is present, go to step 4) (1990 Miata), or step 5)

(all others).

3. If continuity is not present, disconnect rear safing sensor connectors. Check continuity between sensor terminals "B" and "E". See Fig. 13 . If continuity is present, replace wire harness. If continuity is not present, replace rear safing sensor.

4. Check rear safing sensor installation; repair as necessary. If installation is okay, disconnect rear safing sensor connectors. Check continuity between sensor terminal "A" and ground. If continuity is not present, replace rear safing sensor. If continuity is present, replace wire harness.

5. Disconnect diagnostic connector. Check continuity between Black connector Green/White wire and ground. If continuity is present, replace wire harness. If continuity is not present, repeat step 4).

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 13: Identifying Rear Safing Sensor Terminals

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC TEST NO. 6

Warning Light Flashes 6 Times

1. Disconnect negative battery cable. Check connection of Orange/Blue clockspring connector; repair as necessary.

2. If connection is okay, disconnect air bag module and clockspring connector. Check continuity, as shown in illustration, for both terminals of Blue side of clockspring connector. See Fig. 14 . If continuity is not present, replace Orange/Blue clockspring connector.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 14: Checking Resistance at Clockspring Terminal

Courtesy of MAZDA MOTORS CORP.

3. If continuity is present, disconnect diagnostic module Black and Gray connectors. See Fig. 10 or Fig. 11 .

Check continuity between diagnostic module Black connector Green/White wire and clockspring connector Red wire. Also check continuity between diagnostic module Black connector Green/Yellow wire and clockspring connector Green/Yellow wire. If continuity is not present, replace wire harness assembly.

4. If continuity is present, check continuity between diagnostic module Black connector Green/Yellow wire and ground. If continuity is present, replace wire harness assembly. If continuity is not present, replace air bag module.

DIAGNOSTIC TEST NO. 7

Warning Light Flashes 2 Or 8 Times

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Disconnect diagnostic module Black and Gray connectors. See Fig. 10 or Fig. 11 . Check continuity between Black connector

Brown/Yellow wire and ground. If continuity is not present, go to step 4). If continuity is present, go to next step.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

2. Check continuity between Black connector Brown/White wire and ground. If continuity is not present, go to step 5). If continuity is present, go to next step.

3. Check continuity between Black connector Brown wire and ground. If continuity is present, replace diagnostic module. If continuity is not present, go to step 6).

4. Disconnect right front impact sensor connector. Check continuity between ground and each harness sensor terminal. See Fig. 15 . If continuity is present, replace wire harness assembly. If continuity is not present, go to step 7).

Fig. 15: Checking Continuity at Right Front Impact Sensor Connector

Courtesy of MAZDA MOTORS CORP.

5. Disconnect center front impact sensor connector. Check continuity between ground and each harness sensor terminal. If continuity is present, replace wire harness assembly. If continuity is not present, go to step 7).

6. Disconnect left front impact sensor connector. Check continuity between ground and each harness sensor terminal. If continuity is present, replace wire harness assembly. If continuity is not present, go to step 7).

7. Ensure all front impact sensors are correctly installed. If all front impact sensors are installed correctly, replace defective front impact sensor.

DIAGNOSTIC TEST NO. 8

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Warning Light Flashes 7 Times

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM. Disconnect diagnostic module Black and Gray connectors. See Fig. 10 or Fig. 11 .

2. Check continuity between Black connector Black wire and ground. If continuity is present, replace diagnostic module. If continuity is not present, replace wire harness.

WIRING DIAGRAMS

Fig. 16: Air Bag System Wiring Diagram (1990 Miata)

Courtesy of MAZDA MOTORS CORP.

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AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 17: Air Bag System Wiring Diagram (1990 RX7)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 18: Air Bag System Wiring Diagram (1991 Miata)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM MAZDA 1990-91 AIR BAGS

Fig. 19: Air Bag System Wiring Diagram (1991 RX7)

Courtesy of MAZDA MOTORS CORP.

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ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

ANTI-LOCK BRAKE SYSTEM

1988-91 BRAKES Mazda Anti-Lock Brake System

DESCRIPTION

The Anti-Lock Brake System (ABS) control unit senses reductions in front and rear wheel speed, and modulates hydraulic pressure to the brakes to prevent wheel lock-up. The ABS consists of a hydraulic unit, 4 wheel speed sensors and sensor rotors, valve relay, motor relay, pump motor, and ABS control unit. An ANTI-LOCK warning light is located on the instrument panel. See Fig. 1 thru Fig. 3 .

Fig. 1: Locating Motor Relay & Valve Relay

Courtesy of MAZDA MOTORS CORP.

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 2: Locating ABS Components (RX7 Shown; Miata Similar)

Courtesy of MAZDA MOTORS CORP.

Fig. 3: Locating ABS Components (929)

Courtesy of MAZDA MOTORS CORP.

NOTE: For more information on brake system, see BRAKE SYSTEM article in the

BRAKES Section.

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1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

OPERATION

Under normal driving conditions, the anti-lock brake system functions as a standard brake system. When vehicle speed reaches 3.8 MPH, the ABS system will diagnose pump motor by briefly operating motor. Pump motor operation may be heard inside vehicle.

The Electronic Control Unit (ECU) controls ABS by detecting speed sensor signals and activating solenoid valve in hydraulic unit. Control unit also controls pump motor and self-diagnostic function. If a problem in the

ABS system is detected, ABS system functions as a conventional brake system. The ANTI-LOCK brake warning light will also come on.

With detection of wheel lock-up, short pedal pulsations, occurring in rapid succession, will be felt in brake pedal and steering wheel. Vehicle body may also vibrate slightly. These conditions are normal. Pedal pulsation will continue until there is no longer a need for anti-lock function or until vehicle is stopped.

CAUTION: See ANTI-LOCK BRAKE SAFETY PRECAUTIONS below.

ANTI-LOCK BRAKE SAFETY PRECAUTIONS

WARNING: Refer to appropriate Anti-Lock Brakes (ABS) article for description, operation, depressurizing, testing, system bleeding, trouble shooting and system service. Failure to depressurize ABS could lead to physical injury.



NEVER open a bleeder valve or loosen a hydraulic line while ABS is pressurized.



NEVER disconnect or reconnect any electrical connectors while ignition is on. Damage to ABS control unit may result.

DO NOT attempt to bleed hydraulic system without first referring to the appropriate article.



Only use specially designed brake hoses/lines on ABS-equipped vehicles.

DO NOT tap on speed sensor components (sensor, sensor rings). Speed rings must be pressed, NOT hammered into hubs. Striking these components can cause demagnetization or a loss of polarization, affecting the accuracy of the speed signal returning to the ABS control unit.



DO NOT mix tire sizes. Increasing the width, as long as tires remain close to the original diameter, is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.

DO NOT contaminate speed sensor components with grease. Only use recommended anti-corrosion coating.



When speed sensor components have been removed, ALWAYS check sensor-to-ring air gaps when applicable. These specifications can be found in each appropriate article.

ONLY use recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.



When installing transmitting devices (CB's, telephones, etc.) on ABS-equipped vehicles, DO NOT locate the antenna near the ABS control unit (or any control unit).

Disconnect all on-board computers, when using electric welding equipment.

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1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System



DO NOT expose the ABS control unit to prolonged periods of high heat (185°F/85°C for 2 hours is generally considered a maximum limit).

BLEEDING BRAKE SYSTEM

NOTE: See BRAKE BLEEDING article in the BRAKES Section.

For ABS hydraulic unit bleeding, see HYDRAULIC UNIT under REMOVAL & INSTALLATION.

BRAKE LINE BLEEDING SEQUENCE

(1)

Application

Miata & 929

Sequence

Longest Line First

RX7 RR, LR, RF, LF

(1) If rear caliper has not been disassembled, open upper bleed valve only.

DIAGNOSIS

ABS system can only be diagnosed using ABS Tester (0000-42-0010). See Fig. 13 . An Adapter Harness

(49N0-66-001) is also required to test Miata ABS system. ABS tester cannot diagnose ABS control unit. If a malfunction is detected in ABS and all other components in brake system are okay, replace ABS control unit.

If ABS tester is unavailable, test each component of ABS. See test procedures under TESTING. If all ABS components test okay, replace control unit with a known good unit, and retest system for correct operation.

PRE-DIAGNOSIS INSPECTION

Perform a visual inspection of ABS components that could cause anti-lock problem. Visual inspection may help identify cause of simple problem.

DIAGNOSTIC PROCEDURE WITH ABS TESTER

ABS tester uses one display window and 2 switches for reading information from unit. Become thoroughly familiar with ABS tester displays and operation before proceeding. See Fig. 13 . To diagnose ABS system, go to TESTING SEQUENCE charts under DIAGNOSING ABS SYSTEM. When diagnosing ABS system, complete tests in order given under TESTING SEQUENCE. If ABS tester does not operate, check fuses, ignition switch and ignition circuit.

TESTING

NOTE: Before testing ABS components, ensure battery and charging system are functioning properly. To prevent damage to ABS control unit connector, use very thin pins when probing connector.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

ABS DIODE

Continuity Test

1. Unplug hydraulic unit 12-pin connector. On Miata, connect positive lead of DVOM to Blue/Yellow wire terminal and negative lead to Gray wire terminal of hydraulic unit. On RX7, connect positive lead of

DVOM to Red wire terminal and negative lead to Yellow/Red wire terminal of hydraulic unit.

2. On 929, connect positive lead of DVOM to Violet wire terminal and negative lead to Yellow/Red wire terminal of hydraulic unit. Ensure continuity is present between terminals. Reverse DVOM leads.

Continuity should not be present with leads reversed. If ABS diode does not test as described, replace

ABS diode.

ABS SYSTEM GROUND

Continuity Test (Miata)

Using a DVOM, check for continuity between terminals "D", "S", and "f" of control unit harness connector and ground. See Fig. 4 or Fig. 5 . If continuity is not present, repair harness.

Continuity Test (RX7 & 929)

Use DVOM to check continuity. ON RX7, check between control unit harness connector terminal "D" and JC-

02 connector. See Fig. 4 and Fig. 6 or Fig. 5 and Fig. 7 . On 929, check between control unit harness connector terminal "T" and JC-02 connector. If continuity is not present, repair harness.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 4: Identifying Control Unit Harness Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Fig. 5: Identifying Control Unit Harness Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 6: Locating JC-02 Connector

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 7: Locating JC-02 Connector

Courtesy of MAZDA MOTORS CORP.

ANTI-LOCK WARNING LIGHT

Operational Test (Miata)

See Fig. 8 . Using a jumper wire, connect terminal 1K of instrument cluster to ground. ANTI-LOCK light should illuminate. If light does not illuminate, check bulb. If bulb is okay, check meter fuse and wiring harness.

2. Install instrument cluster, and recheck warning light operation. If light still does not illuminate for a few seconds, check wiring harness between ANTI-LOCK light and control unit and between ANTI-LOCK light and hydraulic unit. Check operation of hydraulic unit valve relay.

Operational Test (RX7)

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

1. Start engine, and observe ANTI-LOCK light. Light should illuminate for a few seconds. If light does not illuminate as described, remove clock and bezel assembly from dashboard. Slide warning and clock unit from instrument panel. Connect terminal "E" to ground. See Fig. 9 . ANTI-LOCK light should illuminate.

If light does not illuminate, check bulb. If bulb is okay, check meter fuse and wiring harness.

2. Install instrument cluster, and recheck warning light operation. If light still does not illuminate for a few seconds, check wiring harness between ANTI-LOCK light and control unit, and ANTI-LOCK light and hydraulic unit. Check operation of hydraulic unit valve relay.

Operational Test (929)

1. Start engine, and observe ANTI-LOCK light. Light should illuminate for a few seconds. If light does not illuminate as described, remove instrument cluster. Connect 12 volts to terminal "J" of instrument cluster connector I-06. See Fig. 10 . Using a jumper wire, connect terminal "E" of instrument cluster connector I-

08 to negative ground. ANTI-LOCK light should illuminate. If light does not illuminate, check bulb. If bulb is okay, check meter fuse and wiring harness.

Fig. 8: Testing ANTI-LOCK Warning Light (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 9: Testing ANTI-LOCK Warning Light (RX7)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 10: Testing ANTI-LOCK Warning Light (929)

Courtesy of MAZDA MOTORS CORP.

STOPLIGHT SWITCH

Continuity Test

Disconnect stoplight switch connector. Using a DVOM, check continuity between Green or Green/White wire and White/Green wire with brake pedal depressed. Ensure continuity exists. Release pedal, and note reading on

DVOM. Continuity should not be present. If continuity is not as specified, replace switch.

FRONT & REAR VALVES

Resistance Test (Miata)

1. Disconnect hydraulic unit 12-pin connector. Using a DVOM, measure resistance between the following wires: Yellow/Green wire and Black wire; Brown wire and Black wire; Black/White wire and Black wire.

Resistance should be 1-1.2 ohms in each measurement.

2. If resistance is not as specified, replace hydraulic unit. If resistance is as specified, check wiring harness between ABS control unit and hydraulic unit.

Resistance Test (RX7 & 929)

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

1. Disconnect hydraulic unit 12-pin connector. Using a DVOM, measure resistance between Green/Black and Yellow/Red wires, Green/White and Yellow/Red wires and Yellow and Yellow/Red wires.

Resistance should be 1-1.2 ohms in each measurement.

2. If resistance if not as specified, replace hydraulic unit. If resistance is as specified, check wiring harness between ABS control unit and hydraulic unit.

HYDRAULIC UNIT

Only serviceable parts of hydraulic unit are motor relay and valve relay. If other parts of unit malfunction, replace hydraulic unit assembly.

MOTOR RELAY

Continuity Tests

1. Disconnect negative battery cable. Remove motor relay from hydraulic unit. Ensure continuity exists between terminals "B" and "C" of motor relay. See Fig. 11 . Connect 12 volts to terminal "C", and ground terminal "B". Ensure continuity exists between terminals "A" and "D".

2. Replace relay if continuity is not as specified. If continuity is as specified, check wiring harness between motor relay and ABS control unit fuse (60 amps).

Fig. 11: Identifying Motor & Valve Relay Terminals

Courtesy of MAZDA MOTORS CORP.

PUMP MOTOR

Continuity Test (Miata)

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Disconnect 2-pin connector at hydraulic unit. Check continuity at hydraulic control between Red/Yellow wire terminal and ground. If continuity is not present, replace hydraulic control unit. If continuity is present, pump is okay. Check wiring between hydraulic control and ABS control unit.

Continuity Test (RX7 & 929)

1. Disconnect 12-pin hydraulic unit connector. Using a DVOM, check continuity between Black wire and ground. If there is continuity, check continuity between Black wire terminal at hydraulic unit connector and Green wire terminal at 2-pin hydraulic unit connector.

2. If continuity exists, connect hydraulic unit connectors. If continuity is not present, replace wiring harness between control unit and body ground.

3. Disconnect ABS control unit connector. Check continuity between Green wire of ABS control unit harness connector and ground. If continuity is present, check for poor connection of ABS control unit connector or faulty ABS control unit. If continuity is not present, repair open circuit.

VALVE RELAY

Continuity Tests

1. Disconnect negative battery cable. Remove valve relay from hydraulic unit. Using a DVOM, check continuity between relay terminals "C" and "E" and between terminals "B" and "D". See Fig. 11 .

2. Ensure continuity exists. Connect 12 volts to terminal "B", and ground terminal "D". Check continuity between terminals "A" and "E". Ensure continuity exists. If continuity is not as specified, replace valve relay.

WHEEL SPEED SENSORS

Sensor Resistance Test

Disconnect speed sensor connector. Using a DVOM, measure resistance between sensor terminals. Resistance should be 800-1200 ohms. If resistance is not as specified, replace speed sensor.

Harness Continuity & Voltage Tests

1. With ignition off and speed sensors connected, disconnect ABS control unit connector. Using a DVOM, check continuity between indicated terminals of ABS control unit harness connector. See WHEEL

SPEED SENSOR TESTS TABLE.

2. If reading on DVOM is not 800-1200 ohms, check wiring harness between wheel speed sensor and ABS control unit. If DVOM reading is 800-1200 ohms, check voltage between indicated terminals in WHEEL

SPEED SENSOR TESTS TABLE.

3. Turn ignition on. Rotate appropriate wheel one revolution per second by hand to check voltage. If DVOM does not indicate 50-60 millivolts, replace wheel speed sensor.

WHEEL SPEED SENSOR TESTS

Microsoft

Sunday, July 05, 2009 2:17:32 PM Page 13

Test Between Control Unit

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Application

Miata

Left Front

Left Rear

Right Front

Right Rear

RX7

Left Front

Left Rear

Right Front

Right Rear

929

Left Front

Left Rear

Right Front

Right Rear

(1) See Fig. 4 or Fig. 5 to identify ABS control unit terminals.

Connector Terminals

(1)

"K" & "G"

"O" & "Q"

"U" & "F"

"L" & "P"

"D" & "F"

"H" & "I"

"U" & "W"

"X" & "Z"

"K" & "G"

"O" & "Q"

"J" & "F"

"L" & "P"

WHEEL SPEED SENSOR ROTORS

Inspection

Perform a comprehensive visual inspection of sensor rotor. If any damage is noted, replace sensor rotor. Sensor rotors are attached to wheel hubs.

REMOVAL & INSTALLATION

HYDRAULIC UNIT

Removal

Remove hydraulic lines from unit. Disconnect hydraulic unit connectors. Remove nuts securing unit. Remove hydraulic unit.

Bleeding Hydraulic Unit

Before bleeding hydraulic unit, bleed brake system in appropriate sequence. See BRAKE LINE BLEEDING

SEQUENCE TABLE under BLEEDING BRAKE SYSTEM. Bleed hydraulic unit by opening bleeder screw on unit. See Fig. 12 .

Installation

To install, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

SPECIFICATIONS TABLE at end of article.

Fig. 12: Locating Hydraulic Unit Bleeder Screw

Courtesy of MAZDA MOTORS CORP.

WHEEL SPEED SENSOR ROTOR

Removal (Miata)

Remove brake caliper. Remove wheel hub. On rear axle, carefully remove sensor rotor from axle using a chisel.

On front rotor, remove sensor rotor using Puller (49- 0839-425C).

Installation

Press sensor rotor onto axle using Installer (49- H026-101A). Install sensor rotor on front rotor with chamfered edge toward hub using Press Adapter (49-F001-95). To complete installation, reverse removal procedure.

Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS TABLE at end of article.

Removal & Installation (RX7)

Remove brake caliper and wheel hub. On rear hub, remove wheel hub from outer toe control hub using Puller

(49-F026-103) and Installer (49-F026-102). On front rotor, remove rotor-to-hub bolts using Allen wrench. On rear rotor, remove rotor-to-hub screws. To install, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS TABLE at end of article.

Removal & Installation (929)

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Remove brake caliper and wheel hub. On rear axle, carefully remove sensor rotor from axle using chisel. On front rotor, remove sensor rotor using Puller (49-0839-425C). To install, press sensor rotors onto axle and front rotor using Installer (49-H026-101A). On front rotor, install sensor rotor with chamfered edge toward hub. To complete installation, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE

SPECIFICATIONS TABLE at end of article.

WHEEL SPEED SENSOR

Removal & Installation

Unplug wheel sensor connector. Remove sensor bolt. Remove wheel sensor from vehicle. To install, reverse removal procedure. On RX7, adjust wheel sensor so clearance between sensor and rotor is .016-.039" (.40-1.0 mm). Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS TABLE at end of article.

DIAGNOSING ABS SYSTEM

ABS TESTER OPERATION

Fig. 13: Operating ABS Tester

Courtesy of MAZDA MOTORS CORP.

TESTING SEQUENCE

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

TEST 1. CONNECTION POWER UP

CONNECTION/POWER-UP

1. Locate ABS Control Unit.

2. Disconnect Control Unit Harness from Control Unit.

3. Connect ABS Tester Harness to Control Unit Harness Connector.

4. Turn Ignition Key to "ON" position.

TEST 2 ALTERNATOR TEST

ALTERNATOR TEST START ENGINE (ALTERNATOR TESTED BY RUNNING ENGINE)

Tester will rapidly display several messages during an Initial Segment Check.

Fig. 14: Test 2 Alternator Test

Courtesy of MAZDA MOTORS CORP.

TEST 3 ABS SYSTEM TEST

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

ABS SYSTEM TEST TURN IGNITION KEY ON (DO NOT RUN ENGINE

Tester will rapidly display several messages during an Initial Segment Check.

Fig. 15: Test 3 ABS System Test

Courtesy of MAZDA MOTORS CORP.

TEST 4 SYSTEM VOLTAGE TEST

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 16: Test 4 System Voltage Test

Courtesy of MAZDA MOTORS CORP.

TEST 5A. ANTI-LOCK LIGHT TEST

Fig. 17: Test 5A. Anti-Lock Light Test

Courtesy of MAZDA MOTORS CORP.

TEST 5B. BRAKE LIGHT SWITCH TEST

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 18: Test 5B. Brake Light Switch Test

Courtesy of MAZDA MOTORS CORP.

TEST 5C. PUMP TEST

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 19: Test 5C. Pump Test

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Courtesy of MAZDA MOTORS CORP.

6A. DYNAMIC WHEEL SELECTION TEST OR EXIT

WHEEL SELECTION TEST

These three messages will alternate on the dispaly screen at 3 1/2 second intervals. Now, select one of the four wheels to begin the dynamic test sequence.

EXIT

Press either switch under "PUSH TO EXIT" Display to return to "STAT TEST DYNAM" Selection.

NOTE: When entering the dynamic test sequence, you will select one of four wheels to begin. When you have finished with that wheel test, you should return to 6A.

WHEEL SELECTION TEST to select another wheel, and repeat these test procedures for all four wheels

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 20: 6A. Dynamic Wheel Selection Test

Courtesy of MAZDA MOTORS CORP.

6B. DYNAMIC WHEEL SENSOR TEST

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 21: 6B. Dynamic Wheel Sensor Test (1 of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 22: 6B. Dynamic Wheel Sensor Test (2 of 2)

Courtesy of MAZDA MOTORS CORP.

6C. SOLENOID TEST

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 23: 6C. Solenoid Test (1 of 4)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 24: 6C. Solenoid Test (2 of 4)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 25: 6C. Solenoid Test (3 of 4)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 26: 6C. Solenoid Test (4 of 4)

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

PEDAL FREE PLAY

Depress pedal several times to release vacuum. Pedal free play should be .16-.28" (4-7 mm).

PEDAL HEIGHT & STOPLIGHT SWITCH

1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.

Disconnect stoplight switch. Move switch away from pedal. Adjust brake pedal push rod until correct released pedal height is obtained. See BRAKE PEDAL HEIGHT SPECIFICATIONS TABLE.

2. Adjust pedal free play. See PEDAL FREE PLAY under ADJUSTMENTS. Tighten push rod lock nut.

Rotate stoplight switch until it contacts pedal, then rotate an additional 1/2 turn. Tighten stoplight switch lock nut. Reconnect stoplight switch.

3. The applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.

Start engine. Depress brake pedal with 132-lb. (60 kg) pressure.

4. Measure the applied pedal height. If distance is not as specified, check brake adjustment, or check for air in system. See BRAKE PEDAL HEIGHT SPECIFICATIONS TABLE.

BRAKE PEDAL HEIGHT SPECIFICATIONS

Application

Pedal Released

Miata & 929

RX7

Pedal Applied

Miata & 929

RX7

(1) Minimum height.

(1)

In. (mm)

6.7-7.1 (171-181)

7.2-7.4 (184-189)

3.7 (95)

3.9 (100)

TORQUE SPECIFICATIONS

Application

Brake Caliper Mounting Bolts

Miata

RX7

Front

Rear

929

Front

Microsoft

Sunday, July 05, 2009 2:17:32 PM

Ft. Lbs. (N.m)

36-51 (49-69)

58-72 (79-98)

33-40 (45-54)

Page 31

61-69 (83-94)

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Rear

Brake Line Nuts

Hydraulic Unit Mounting Nuts

Miata & 929

RX7

Speed Sensor Bolt

Union Bolt

Wheel Bearing Nut

(1)

Miata

Front

Rear

RX7

Front

Rear

929

Front

Rear

(1) Tighten and loosen 2 or 3 times to seat bearing.

WIRING DIAGRAMS

12-17 (16-23)

10-16 (14-22)

14-19 (19-26)

12-21 (16-28)

12-17 (16-23)

14-22 (19-30)

123-159 (167-216)

159-217 (216-294)

(1) 14-22 (19-30)

174-231 (235-314)

72-130 (98-176)

174-231 (235-314)

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 27: Anti-Lock Brake System Wiring Diagram (Miata)

Microsoft

1991 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System

Fig. 28: Anti-Lock Brake System Wiring Diagram (RX7)

Fig. 29: Anti-Lock Brake System Wiring Diagram (929)

Microsoft

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

1990-93 DRIVE AXLES

Axle Shafts - MX-5 Miata

DESCRIPTION

The axle shaft is a double offset, constant velocity joint type.

TROUBLE SHOOTING

NOTE:

Check dust boot on axle shaft for cracks, damage, leaking grease, and loose boot bands. Check axle shaft for bending, cracks, and wear of joints or splines. Repair or replace axle shaft if necessary.

REMOVAL & INSTALLATION

AXLE SHAFTS

Removal

1. Raise vehicle and support with safety stands. Remove wheel and tire assembly. See Fig. 1 . Loosen axle shaft lock nut until flush with end of axle shaft. Mark differential and axle shaft flanges for installation reference. See Fig. 2 . Remove axle shaft flange nuts.

NOTE:

See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL

INFORMATION.

Manufacturer recommends using new axle shaft lock nut during installation.

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 1: Removing Axle Shaft

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 2: Identifying Differential-To-Axle Shaft Flange Mark

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 3: Removing Axle Shaft From Hub Assembly

Courtesy of MAZDA MOTORS CORP.

2. Remove upper control arm bolt, and pull knuckle/hub assembly outward. Remove inner CV joint from differential flange. Remove axle shaft from knuckle/hub assembly. If axle shaft is stuck in knuckle/hub assembly, use plastic or soft-faced hammer to tap axle shaft from knuckle/hub assembly. See Fig. 3 .

Remove axle shaft lock nut.

Installation

NOTE: Manufacturer recommends using new axle shaft lock nut during installation.

To install, reverse removal procedure. Align marks on differential and axle shaft flanges. Check rear wheel alignment. See appropriate article in WHEEL ALIGNMENT. Tighten all bolts and nuts to specification. See

TORQUE SPECIFICATIONS . Stake axle shaft lock nut. See Fig. 4 .

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 4: Installing Axle Shaft Lock Nut

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

AXLE SHAFTS

NOTE: Before disassembling axle shaft, verify that joint moves smoothly. If a problem is found, repair parts or replace axle shaft.

NOTE: DO NOT wash joint unless it is being disassembled.

Disassembly

1. Place axle shaft assembly in soft-jawed vise. Keep axle shaft assembly clean during disassembly and reassembly. To remove boot bands, pry up locking clip by using a screwdriver, then raise end of band.

See Fig. 5 .

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 5: Removing Boot Band

Courtesy of MAZDA MOTORS CORP.

2. Mark axle shaft and outer ring with paint as shown. See Fig. 6 . Using a screwdriver, remove clip. Mark axle shaft end and inner ring with paint as show. See Fig. 7 . Remove snap ring by using snap ring pliers.

See Fig. 8 .

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 6: Identifying Outer Ring-To-Axle Shaft Marks

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 7: Removing Snap Ring

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 8: Exploded View Of Axle Shaft Assembly

Courtesy of MAZDA MOTORS CORP.

3. Insert a screwdriver between inner ring and cage to remove balls. See Fig. 9 . Mark inner ring and cage with paint.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 9: Removing Balls From Inner Ring

Courtesy of MAZDA MOTORS CORP.

4. Turn cage approximately 30 degrees and pull it away from inner ring. See Fig. 10 . Wrap shaft splines with tape and remove boot. See Fig. 11 .

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 10: Separating Inner Ring From Cage

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 11: Removing CV Joint Boot

Courtesy of MAZDA MOTORS CORP.

Reassembly

CAUTION: When reassembling axle shaft, ensure to install cage with larger diameter facing snap ring groove. If incorrectly installed, axle shaft may become disengaged.

NOTE: Inner and outer CV joint boots differ in design and/or diameter. Ensure correct boot is installed at proper end when reassembling axle shaft. See Fig. 12 . See

REAR AXLE SHAFT BOOT IDENTIFICATION .

1. To reassemble, reverse disassembly procedure. Wrap tape around drive axle shaft ends before sliding CV joint boots onto drive axle shaft. See Fig. 13 .

2. Align marks on cage and inner ring. Install balls to inner ring. Install cage, inner ring and ball assembly to axle shaft in direction shown. See Fig. 14 . Larger diameter of cage should be facing snap ring groove.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 12: Measuring Axle Shaft & Identifying Boots

Courtesy of MAZDA MOTORS CORP.

Fig. 13: Installing CV Joint Boot

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 14: Installing Balls In To Inner Ring

Courtesy of MAZDA MOTORS CORP.

3. Install a NEW snap ring in axle shaft snap ring groove. Apply specified amount of grease to joints and boots. See LUBRICATION SPECIFICATION table. Aling marks and install NEW clip.

LUBRICATION SPECIFICATION

Application

Wheel Side CV Joint Boot

Differential Side CV Joint Boot

Quantity

1.9-2.7 oz. (55-75 g)

2.7-3.4 oz. (75-95 g)

4. Ensure that boots are not dented or twisted. Set axle shaft to standard length. See AXLE SHAFT

LENGTH table. Release any trapped air from boots by carefully lifting up small end of each boot with a cloth-wrapped screwdriver. See Fig. 15 . Ensure that axle shaft length is within standard. If drive shaft length is not within standard, repeat this step.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 15: Releasing Trapped Air

Courtesy of MAZDA MOTORS CORP.

5. Fold NEW band back by pulling on end with pliers. See Fig. 16 . Band should be folded in direction opposite forward revolving direction of axle shaft. Lock end of band by bending locking clips.

Microsoft

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 16: Installing Boot Band

Courtesy of MAZDA MOTORS CORP.

AXLE SHAFT LENGTH

Application

1990

On Vehicle

Off Vehicle

1991-93

On Vehicle

Off Vehicle

REAR AXLE SHAFT BOOT IDENTIFICATION

Application

Wheel Side Diameter

Differential Side Diameter

TORQUE SPECIFICATIONS

Microsoft

Sunday, July 05, 2009 2:16:33 PM

In. (mm)

25.96 (659.3)

25.97-26.37 (695.7-669.7)

25.87 (657)

25.30-26.68 (642.6-677.7)

In. (mm)

3.58 (90.8)

3.44 (87.4)

1991 Mazda MX-5 Miata

1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata

Application

Axle Shaft Lock Nut

(1)

Differential-To-Axle Shaft Flange Nuts (4)

Upper Control Arm Bolt/Nut

Wheel Lug Nuts

Ft. Lbs. (N.m)

159-217 (216-294)

40-47 (54-64)

34-49 (46-66)

65-87 (88-118)

(1) Non-reuseable part. Manufacturer recommends replacing axle shaft lock nut on installation.

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BRAKE SYSTEM 1991 BRAKES Mazda Brake System

BRAKE SYSTEM

1991 BRAKES Mazda Brake System

DESCRIPTION & OPERATION

NOTE: For information on anti-lock brake systems, see appropriate ANTI-LOCK BRAKE

SYSTEM article in the BRAKES Section.

All models use hydraulic-operated brake system with a tandem master cylinder and a power brake unit.

BRAKE SYSTEM BLEEDING

NOTE: See BRAKE BLEEDING article in the BRAKES Section.

BRAKE LINE BLEEDING SEQUENCE

Application

Protege & 323

RX7

(1)

All Others

(1) If rear caliper has not been disassembled, open upper bleed valve only.

Sequence

RR, LR, LF, RF

RR, LR, RF, LF

Longest Line First

ADJUSTMENTS

MASTER CYLINDER PUSH ROD (NAVAJO)

NOTE: Push rod has an adjustment screw to maintain correct distance between booster push rod and master cylinder piston. If push rod is adjusted too long, it prevents master cylinder piston from completely releasing hydraulic pressure, causing brakes to drag. If push rod is adjusted too short, it causes excessive pedal travel and an undesirable clunk in booster area.

1. Remove master cylinder to gain access to push rod. To check screw adjustment, fabricate a gauge. See

Fig. 1 .

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 1: Adjusting Brake Booster Push Rod (Navajo)

Courtesy of FORD MOTOR CO.

2. Place gauge against master cylinder mounting surface of booster. Adjust push rod screw by turning it until end of screw just touches inner edge of gauge slot.

REAR BRAKE SHOES

NOTE: Self-adjusting rear brakes only require manual adjustment when brake shoe is replaced or operating lever is moved during service operations.

B2200 & B2600i 2WD

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

1. Raise and support rear of vehicle. Ensure parking brake is released. Remove plugs from rear of backing plate (one below wheel cylinder, other near outer diameter of backing plate). Insert a screwdriver through hole below wheel cylinder. Rotate star wheel adjuster in direction of arrow stamped on backing plate until wheel locks.

2. Insert a drift through other hole in backing plate. Push pawl back from adjuster and back off adjuster 6-7 notches. Ensure wheel rotates freely. Perform same procedure on both sides. Adjust parking brake.

B2600i 4WD & MPV

1. Raise and support rear of vehicle. Ensure parking brake is released. Remove plugs from rear of backing plate. Insert a screwdriver through hole for star wheel. Rotate adjuster in direction of arrow stamped on backing plate until wheel locks.

2. Insert a drift through other hole in backing plate. Push pawl back from adjuster and back off adjuster 8-10 notches (13-15 notches on MPV). Ensure wheel rotates freely. Perform same procedure on both sides.

Adjust parking brake.

MX-6, Protege, 323 & 626

1. Raise and support rear of vehicle. Remove wheel. Release parking brake. Remove lock nut from axle shaft. Remove brake drum. Insert screwdriver between adjusting plate and quadrant. Twist screwdriver to disengage teeth. See Fig. 2 or Fig. 3 .

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 2: Moving Quadrant on Rear Brake Adj. (MX-6 & 626)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 3: Moving Quadrant on Rear Brake Adj. (Typical Protege & 323)

Courtesy of MAZDA MOTORS CORP.

2. Push adjusting lever toward backing plate. Install brake drum. Install new lock nut, and secure by crimping. Operate parking brake a few times to reset adjuster. Adjust parking brake.

Navajo

1. Raise and support rear of vehicle. If drums are installed on vehicle, remove cover from adjusting hole at bottom of brake backing plate. Turn adjusting screw with a brake adjusting tool until shoes drag against brake drum and lock drum.

2. When shoes are against drum, loosen adjusting screw an additional 10-12 notches so drum rotates freely.

If drum does not rotate freely, remove wheel and drum and vacuum dust and dirt from linings. Use sandpaper and remove rust from points where shoes touch backing plate. Apply a light coating of molybdenum grease to brake shoe-to-backing plate contact points. Install wheel and drum and adjust shoes.

3. To adjust brakes with rear drums removed, first clean all rust and dirt on points where shoes touch backing plate and apply a small amount of molybdenum grease to those areas. Use a brake shoe adjustment gauge and adjust brakes to inside diameter of drum braking surface.

4. Reverse tool and adjust brake shoes until they touch gauge. Gauge contact points on shoes must be parallel to vehicle with center line through center of axle. Hold automatic adjusting lever out of

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System engagement while rotating adjusting screw to prevent burring screw slots. Ensure adjusting screw rotates freely.

PARKING BRAKE

B2200 & B2600i

1. Depress brake pedal several times while vehicle is moving in Reverse. Ensure brakes are properly adjusted. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 7-12 notches, parking brake is properly adjusted.

2. If stroke is not 7-12 notches, raise and support rear of vehicle. Release parking brake lever. Loosen cable lock nut at lever end of cable. Rotate adjusting nut until correct stroke is obtained. Operate parking brake several times and ensure rear wheels rotate freely. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

Navajo

1. Adjust service brakes before adjusting parking brake cable. Ensure brake drums are cold. Apply parking brake to fully depressed position. Grip threaded rod to prevent it from spinning.

2. Thread equalizer nut 6 full turns past its original position on threaded rod. See Fig. 4 . Check cable tension at rear of equalizer assembly using Cable Tension Gauge (021-00018). If tension is not 400-600 lbs. (182-272 kg), repeat step 2).

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 4: Adjusting Parking Brake (Navajo)

Courtesy of FORD MOTOR CO.

3. Release pedal, and check rear wheel drag. If drag is noted, remove drums, and check for clearance between parking brake lever and cam plate. Cables should be tight enough to allow full application of rear brakes and loose enough to allow full release of rear brakes.

NOTE: Tension limiter will reset parking brake tension any time system is disconnected if distance between bracket and cinch strap hook is reduced during adjustment. When adjustment has been performed so cinch strap contacts bracket, system tension will increase greatly. This may cause an overtension condition. When available adjustment travel has been used, replace tension limiter.

929

1. Depress brake pedal several times. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 6-8 notches, parking brake is properly adjusted. If stroke is not 6-8 notches, adjust parking brake shoes. See

PARKING BRAKE SHOES under ADJUSTMENTS .

NOTE: If rear brake shoes are removed for any reason, parking brake cable

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System tension should be checked and adjusted.

2. Release parking brake lever. Using a screwdriver, reach through parking brake handle hole in console and rotate adjusting screw until stroke is 6-8 notches. Ensure rear wheels rotate freely. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

Miata, MX-6, MPV, Protege, RX7, 323, 626

1. On models with rear disc brakes, depress brake pedal several times. On models with rear drum brakes, start engine and depress brake pedal several times while vehicle is moving in Reverse. Stop engine.

2. On all models, pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 5-7 notches, parking brake is properly adjusted. If stroke is not 5-7 notches, raise and support rear of vehicle. Release parking brake lever.

3. Rotate cable adjusting nut at lever end of cable (under console cover) until stroke is within specification.

On models equipped with rear disc brakes, ensure clearance between stopper and lever (at each caliper) is not less than .08" (2 mm) on RX7, or zero on all other models. On all models, ensure parking brake warning light illuminates when brake lever is pulled one notch.

PARKING BRAKE SHOES

929

Raise and support vehicle. Remove rear wheels. Remove service plug from rotor. Using a screwdriver, rotate star wheel adjuster toward axle until rotor locks. Rotate adjuster in opposite direction 3-5 notches. Ensure rotors turn freely and parking brake functions properly. Install service plug and rear wheels.

PEDAL FREE PLAY

Depress pedal a few times to eliminate vacuum. Pedal free play should be .16-.28" (4-7 mm). Adjust play by loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut.

PEDAL HEIGHT & STOPLIGHT SWITCH

NOTE: Pedal height and stoplight switch information is not available for Navajo.

1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.

Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Move switch away from pedal. Loosen push rod lock nut. Turn rod until correct pedal height is obtained. See BRAKE

PEDAL HEIGHT SPECIFICATIONS .

2. Adjust pedal free play. See PEDAL FREE PLAY under ADJUSTMENTS. Tighten push rod lock nut.

Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight switch lock nut. Reconnect stoplight switch electrical connector.

3. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.

Start engine. On B2200, B2600i and MPV, depress brake pedal with 33 lbs. (15 kg) pressure. On all other models, depress brake pedal with 132 lbs. (60 kg) pressure.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

4. On all models, measure applied pedal height. If distance is not as specified, check brake adjustment or system for air. See BRAKE PEDAL HEIGHT SPECIFICATIONS TABLE.

BRAKE PEDAL HEIGHT SPECIFICATIONS

Application

Pedal Released

B2200 & B2600i

Miata, MX-6, 626 & 929

MPV

Protege & 323

RX7

Pedal Applied

(1)

B2200 & B2600i

Miata, MX-6, 626 & 929

MPV

Protege & 323

RX7

(1) Minimum height.

In. (mm)

7.1-7.3 (180-185)

6.7-7.1 (171-181)

7.5-7.9 (191-201)

7.6-7.7 (193-196)

7.2-7.4 (184-189)

4.1 (105)

3.7 (95)

5.2 (133)

2.8 (70)

3.9 (100)

TESTING

POWER BRAKE UNIT

1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal does not move as specified, go to next step.

2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is operating. If length of strokes is equal, test check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary, and go to next step.

3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal height remains at same height, power brake unit is operating. If pedal height recedes, test check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal & Installation (Protege & 323)

Raise and support front of vehicle. Remove wheels. Remove spring "A". See Fig. 5 . Remove spring "B".

Remove pad pins. Remove pads, shims and anti-squeak shim. Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE. To install, reverse removal

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procedure.

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 5: Exploded View of Front Disc Brake Assembly (Protege & 323)

Courtesy of MAZDA MOTORS CORP.

Removal (Navajo)

1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake fluid from master cylinder. Raise vehicle, and support using safety stands.

2. Remove front wheel assembly. Place a large "C" clamp on caliper. See Fig. 9 . Tighten clamp to bottom piston in cylinder bore. Remove clamp.

3. Remove dirt around caliper pin tabs. Tap upper caliper pin toward inboard side of vehicle until pin tabs

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System touch spindle face.

4. Insert screwdriver into slot provided behind pin tabs on inboard side of pin. Using pliers, compress end of pin while using screwdriver to pry until tabs slip into spindle groove.

5. Place a 7/16" diameter punch on end of pin, and drive caliper pin out of caliper slide groove. Repeat procedure for lower pin. Remove caliper from rotor. Remove outer brake pad. Compress anti-rattle spring clip, and remove inner brake pad. Support caliper aside. Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE.

CAUTION: During installation, DO NOT tap caliper pin too far into spindle groove. If this happens, tap pin in other direction until tabs snap back into place.

Tabs on each end of caliper pin must be free to catch on spindle flanks.

Installation

Use "C" clamp to push caliper piston into piston bore until it bottoms out. To install, reverse removal procedure.

Bleed air from brake system.

Removal & Installation (RX7 With 4-Piston Caliper)

Raise and support front of vehicle. Remove wheels. Remove pad pins and pad springs. See Fig. 6 . Remove brake pads and shims. Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING

SPECIFICATIONS (FRONT) . To install, reverse removal procedure.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 6: Front Disc Brake Assembly (RX7 with 4-Piston Caliper)

Removal & Installation (All With Single-Piston Caliper)

Raise and support front of vehicle. Remove wheels. Remove lower lock pin/guide bolt. See Fig. 7 , Fig. 8 , Fig.

10 , Fig. 11 , or Fig. 12 . Pivot caliper upward, and support using rope. Remove brake pads. Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE.

To install, reverse removal procedure.

MINIMUM PAD LINING SPECIFICATIONS (FRONT)

Application

B2200, B2600i & Navajo

Thickness In. (mm)

.12 (3.0)

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Miata

MPV, MX-6, Protege, RX7, 323, 626 & 929

NOTE: The following figures are Courtesy Mazda Motors Corp.

.04 (1.0)

.08 (2.0)

Fig. 7: View of Front Disc Brake Assembly B2200 & B2600I

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 8: View of Front Disc Brake Assembly, Miata Shown; MPV Similar.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 9: View of Front Brake Disc Assembly Navajo.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 10: View of Front Brake Disc Assembly MX-6 & 626.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 11: View of RX7 Single-Piston Caliper Front Brake Assembly

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 12: View of Front Disc Brake Assembly 929

FRONT DISC BRAKE CALIPER

NOTE: For removal and installation of front disc brake caliper for Navajo, see FRONT

DISC BRAKE PADS under REMOVAL & INSTALLATION.

Removal & Installation

Raise and support front of vehicle. Remove wheel and disconnect brake hose. Plug all openings. Remove brake disc pads. Remove remaining bolt(s). Remove caliper body from vehicle. To install, reverse removal procedure.

Bleed hydraulic system.

FRONT BRAKE ROTOR

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Removal & Installation (B2200 & B2600i 2WD)

1. With caliper assembly removed, remove wheel hub grease cap, cotter pin, lock plate and ring adjusting lock nut. Remove thrust washer and outer bearing from hub. Slide hub and rotor assembly from spindle.

2. Mark rotor-to-hub position. Separate rotor from hub. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC

BRAKE SPECIFICATIONS at end of article.

3. To install, reverse removal procedure and evenly tighten rotor-to-hub bolts. Adjust wheel bearings.

Removal & Installation (B2600i 4WD) 1) Remove front caliper. Set hub to FREE position. Remove hub bolts. Remove hub as an assembly. Install 2 bolts and nuts to retain hub assembly together. Remove snap ring and spacer.

4. Remove set bolt and plate. Remove nut. Remove rotor and hub assembly. Mark rotor-to-hub position.

Remove rotor from hub. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS at end of article. To install, reverse removal procedure.

Removal & Installation (Miata, MPV, MX-6, Protege, RX7, 323 & 626)

1. Raise and support front of vehicle. Remove wheel. Remove caliper with brake hose connected. Support caliper using rope. Remove 2 rotor-to-hub screws. Remove rotor.

2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS at end of article. To install, reverse removal procedure.

Removal & Installation (Navajo 2WD)

1. Raise vehicle, and support using safety stands. Remove wheel and caliper assemblies. Remove dust cap, cotter pin, nut, washer and outer bearing. Carefully remove hub and rotor assembly. Remove inner bearing and seal.

2. To install, reverse removal procedure. Adjust front wheel bearings. While rotating rotor, tighten adjusting nut to 17-25 ft. lbs. (23-34 N.m). Back off adjusting nut 120-180 degrees. Install bearing retainer and new cotter pin.

Removal (Navajo 4WD With Automatic Locking Hubs)

1. Raise vehicle, and support using safety stands. Remove wheel assembly and caliper. See FRONT DISC

BRAKE PADS under REMOVAL & INSTALLATION. Remove retainer washers from lug nut studs.

Remove automatic locking hub housing from spindle.

2. Remove snap ring from end of spindle shaft. Remove axle spacer. See Fig. 13 . Carefully pull plastic moving cam off wheel bearing adjusting nut. Remove 2 plastic thrust spacers from adjusting nut. Using a magnet, remove locking key.

CAUTION: DO NOT pry on plastic cam or spacers during removal as damage may result. To prevent damaging spindle threads, remove locking key before removing adjusting nut.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 13: Removing Front Rotor (Navajo with Automatic Locking Hubs)

Courtesy of FORD MOTOR CO.

3. If necessary, rotate adjusting nut slightly to relieve pressure on locking key. Using Hex Lock Nut Wrench

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

(T70T-4252-B), remove wheel bearing adjusting nut. Remove outer wheel bearing, and then remove rotor.

Installation

When installing rotor, outer bearing and adjusting nut, tighten adjusting nut to 35 ft. lbs (47 N.m) to seat bearings. Spin rotor, and back off adjusting nut 1/4 turn. Tighten adjusting nut to 16 INCH lbs. (1.8 N.m). To install remaining components, reverse removal procedure. See Fig. 13 . After assembly is complete, wheel to spindle end play should be .001-.003" (.02-.08 mm).

CAUTION: Extreme caution must be used when aligning adjusting nut lug with spindle locking key slot to prevent damage to locking key. Extreme caution must be used when aligning fixed cam key with spindle key slot to prevent damage to fixed cam.

Removal (Navajo 4WD With Manual Locking Hubs)

1. Raise and support vehicle. Remove wheel assembly and caliper. See FRONT DISC BRAKE PADS under REMOVAL & INSTALLATION. Remove retainer washers from lug nut studs. Remove manual locking hub housing from spindle.

2. Remove snap ring from end of spindle shaft. Remove axle spacer. See Fig. 14 . Using Lock Nut Wrench

(T86T-1197-A), remove outer wheel bearing lock-nut. Remove lock washer. Using Lock Nut Wrench

(T86T-1197-A), remove inner wheel bearing lock nut, outer wheel bearing and rotor.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 14: Removing Front Rotor (Navajo with Manual Locking Hubs)

Courtesy of FORD MOTOR CO.

Installation

When installing rotor, outer bearing and inner lock nut, tighten inner lock nut to 35 ft. lbs (47 N.m) to seat bearings. Spin rotor, and back off inner lock nut 1/4 turn. Tighten inner lock nut to 16 INCH lbs. (1.8 N.m). To

Microsoft

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System install remaining components, reverse removal procedure. See Fig. 14 . After assembly is complete, wheel to spindle end play should be .001-.003" (.02-.08 mm).

Removal & Installation (929)

1. Raise and support front of vehicle. Remove wheel. Remove caliper with brake hose connected. Support caliper with rope. Remove hub cap, wheel bearing lock nut and washer. Remove hub and rotor assembly.

2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS at end of article.

3. To install, reverse removal procedure. Replace wheel bearing lock nut, and tighten to 72-130 ft. lbs. (98-

177 N.m). Check hub end play. If end play exceeds .002" (.05 mm), replace bearing. If end play is within specification, stake lock nut at groove in axle shaft.

REAR DISC BRAKE PADS

Removal & Installation (Miata, Protege & 323)

1. Raise and support rear of vehicle. Remove wheel. Remove manual adjustment gear concealment plug from caliper. See Fig. 15 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 15: Rear Disc Brake Assembly (Miata, Protege & 323)

2. Remove lower guide bolt from caliper. Rotate caliper upward, and support using rope. Remove "M" spring. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04" (1.0 mm).

To install, reverse removal procedure.

Removal & Installation (MX-6 & 626)

1. Raise and support rear of vehicle. Remove wheel. Release parking brake and disconnect parking brake cable from caliper. Remove upper guide bolt from caliper. Rotate caliper downward and secure with rope.

Remove "V" springs. Remove pads and shims.

2. To install, turn caliper piston clockwise using Disc Brake Piston Wrench (49-FA18-602) to retract caliper piston. Ensure groove in piston aligns with alignment pin on back of inner pad. Replace pad if lining thickness is less than .04" (1.0 mm). To complete installation, reverse removal procedure.

Removal & Installation (RX7)

1. Raise and support rear of vehicle. Remove wheel. Remove lower guide bolt from caliper. Rotate caliper upward, and secure using rope. Remove "V" springs. Remove pads and shims. Replace pad if lining thickness is less than .04" (1.0 mm).

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

2. To install, turn caliper piston clockwise using Disc Brake Piston Wrench (49-FA18-602) to retract caliper piston. Ensure groove in piston aligns with alignment pin on back of inner pad. To install remaining components, reverse removal procedure.

Removal & Installation (929)

Raise and support rear of vehicle. Remove wheel. Remove lower guide bolt from caliper. Rotate caliper upward and secure with rope. Remove pads and shims. Replace pad if lining thickness is less than .08" (2.0 mm). To install, reverse removal procedure.

REAR BRAKE CALIPER

Removal & Installation

1. Raise and support rear of vehicle. On all models except 929, release parking brake and disconnect parking brake cable from caliper. On all models, disconnect brake hose from caliper.

2. On Miata, Protege and 323, remove manual adjustment gear concealment plug from caliper. See Fig. 15 .

Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.

3. On all models, remove lower guide bolt from caliper. Rotate caliper upward. Pull caliper toward center of vehicle to slide it off of caliper mount. To install, reverse removal procedure. Bleed hydraulic system.

REAR BRAKE ROTOR

Removal & Installation (Miata, Protege, RX7, 323 & 929)

Remove rear brake caliper. Remove rotor-to-hub screws. Remove rotor. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE

SPECIFICATIONS at end of article. To install, reverse removal procedure.

Removal & Installation (MX-6 & 626)

1. Remove rear caliper, and wire aside. Remove grease cap. Remove lock nut. Remove rotor. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS at end of article.

2. To install, reverse removal procedure. Tighten lock nut to 73-131 ft. lbs. (99-178 N.m). Check end play at grease cap. If end play exceeds .008" (.20 mm), replace wheel bearings.

REAR BRAKE SHOES

Removal (B2200, B2600i & MPV)

With brake drum removed, remove brake shoe return springs, retaining springs and guide pins. See Fig. 16 or

Fig. 17 . Remove brake shoes. Remove parking brake strut, and disconnect parking brake cable from operating lever of secondary shoe. Minimum lining thickness is .04" (1 mm).

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 16: Rear Drum Brake Assembly (B2200 & B2600i 2WD)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 17: Rear Drum Brake Assembly (B2600i 4WD & MPV)

Courtesy of MAZDA MOTORS CORP.

Installation

1. Apply brake grease to the adjusting screw threads and shoe contact points on backing plate. Install parking brake operating lever to secondary shoe and secure with clip. Engage operating lever with parking brake cable.

2. Position operating strut between slots of shoes. Mount assembly to backing plate so slots in shoes are toward adjusting screws. Install return springs and retainer springs.

Removal (MX-6, Protege, 323 & 626)

1. Remove brake drum. Remove trailing shoe hold-down spring and pin. Remove trailing shoe assembly.

2. Remove return spring, anti-rattle spring, and leading shoe hold-down spring and pin. Remove leading shoe assembly. See Fig. 18 . Minimum lining thickness is .04" (1 mm).

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 18: View of Rear Drum Brake Assembly (Typical)

Courtesy of MAZDA MOTORS CORP.

Installation

1. Apply brake grease to brake shoe contact areas on backing plate. When installing adjuster between shoes, insert a flat-tipped screwdriver between adjuster quadrant and meshing teeth on MX-6 and 626, or between quadrant and knurled pin on Protege and 323. See Fig. 2 .

2. To fully retract adjuster, move quadrant until it touches backing plate. To complete installation, reverse removal procedure. Adjust wheel bearings and stake lock nut.

Removal (Navajo)

1. Remove wheel assembly and drum. Place a wheel cylinder clamp over ends of wheel cylinder. Disengage adjusting lever from adjusting screw by pulling backwards on lever cable. See Fig. 19 .

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 19: Examining Rear Brake Assemblies (Navajo)

Courtesy of FORD MOTOR CO.

2. Move outboard side of adjusting screw upward, and back off pivot nut as far as possible. Pull adjusting lever, cable and adjusting spring down and toward rear to unhook pivot hook from large hole in secondary shoe. DO NOT pry pivot hook from hole.

3. Remove adjusting spring and adjusting lever. Remove secondary shoe-to-anchor spring. Remove primary

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System shoe-to-anchor spring. Unhook cable anchor, and remove anchor pin plate.

4. Remove cable guide, shoe hold-down springs, brake shoes, adjusting screw, pivot nut and socket.

Remove parking brake link spring and link. Note color and position of springs for reassembly.

5. Disconnect parking brake cable from lever. Remove secondary shoe. Disassemble parking brake lever from shoe by removing retaining clip and spring washer. See Fig. 20 .

Fig. 20: Exploded View of Rear Drum Brake Assembly (Navajo)

Courtesy of MAZDA MOTORS CORP.

Installation

Clean and sand brake shoe contact points on backing plate. Apply a light coating of lithium base grease to contact points. Lubricate adjusting cable eye and anchor pin area. Lubricate adjusting screw, pivot and socket.

To install, reverse removal procedure.

PARKING BRAKE SHOES

Removal (929)

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1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Raise and support vehicle. Remove rear wheels. Remove brake rotor. Remove upper and lower return springs.

See Fig. 21 . Remove hold-down springs and pins. Remove parking brake shoes. Separate adjuster and operating lever. Minimum lining thickness is .04" (1 mm).

Fig. 21: Exploded View of Parking Brake Assembly (929)

Courtesy of MAZDA MOTORS CORP.

Installation

Connect operating lever to parking brake cable. Set marked side (with arrow) of operating lever to front side.

Position shoes and adjuster. Ensure threaded side of adjuster faces forward on left wheel and rearward on right wheel. To complete installation, reverse removal procedure. Adjust parking brake. See PARKING BRAKE under ADJUSTMENTS at beginning of article.

REAR AXLE BEARING & OIL SEAL

NOTE: For information on models with sealed wheel bearings, see appropriate article in the SUSPENSION Section.

Removal (B2200 & B2600i)

1. Remove wheel and brake drum. Disconnect parking brake cable and brake line. Remove backing plate bolts. Remove backing plate and rear axle assembly. Remove axle bearing lock nut using Holder (49-

Microsoft

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

S120-645A) and Wrench (49-0603-635A).

NOTE: Left wheel lock nut has left-hand threads.

2. Using Puller (49-S120-520A) and Adapter (49-S120-523A), remove rear axle bearings. Remove oil seal from axle housing.

Installation

1. Install oil seal in axle housing. Install bearing inner race. Install and position oil seal flush with end of axle casing. Apply multipurpose grease to oil seal lip. Install spacer with concave side facing backing plate.

2. Press axle bearing onto axle shaft. Using wrench, install and tighten lock nut to 145-217 ft. lbs. (197-295

N.m). Install axle shaft assembly. Install backing plate. Reconnect brake line and parking brake cable.

Install brake drum and wheel. Bleed brake system.

MASTER CYLINDER

Removal

1. Disconnect fluid level sensor coupler (if equipped). Disconnect and plug hydraulic lines at master cylinder to prevent entry of dirt and loss of fluid.

2. Remove nuts attaching master cylinder to firewall or power brake unit. Remove master cylinder from vehicle. On RX7, remove proportioning valve by-pass bolt.

Installation

1. Place Adjustment Gauge (49-F043-001) onto master cylinder. Turn screw on adjuster gauge until it contacts piston. Remove adjuster gauge. Apply 19.7 in. Hg to power brake unit.

2. Invert adjuster gauge and place it on power brake unit. Adjust push rod on power brake unit until there is no clearance between push rod and adjuster gauge screw. Install master cylinder. Bleed hydraulic system.

POWER BRAKE UNIT

Removal & Installation

1. Remove master cylinder from power brake unit. See MASTER CYLINDER under REMOVAL &

INSTALLATION . Disconnect vacuum line at power brake unit. From inside vehicle, remove cotter pin and clevis pin. Separate push rod from brake pedal.

2. Remove power brake unit-to-firewall nuts. Remove power brake unit. See Fig. 22 To install, reverse removal procedure. Bleed hydraulic system.

Microsoft

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 22: Removing Master Cylinder & Power Brake Unit (Typical)

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

Microsoft

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 23: Rear Caliper Assembly (Miata, Protege & 323)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 24: Master Cylinder (Navajo).

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 25: Master Cylinder (929).

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Fig. 26: Typical Master Cylinder (Except Navajo & 929)

Courtesy of MAZDA MOTORS CORP.

SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Backing Plate (Rear)

B2200 & B2600i 2WD

B2600i 4WD

Navajo

All Others

Caliper Guide Bolt

B2200 & B2600i

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Sunday, July 05, 2009 2:18:09 PM Page 37

Ft. Lbs. (N.m)

72-87 (98-118)

65-80 (88-108)

25-35 (34-47)

33-43 (45-58)

23-30 (31-41)

Miata

Front

Lower

Upper

Rear

MPV

MX-6 & 626

Front

Rear

Protege & 323

Front

Rear

RX7

Front

Single-Piston Caliper

4-Piston Caliper

Rear

929

Front

Rear

Caliper Mounting Bracket Bolt

B2200, B2600i & MPV

Miata

Front

Rear

MX-6 & 626

Front

Rear

Protege & 323

Front

Rear

RX7

Front

Single-Piston Caliper

4-Piston Caliper

Rear

929

Front

Rear

Hub Bolt (4WD)

Microsoft

Sunday, July 05, 2009 2:18:09 PM

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

58-65 (78-88)

33-40 (45-54)

33-43 (45-59)

61-69 (83-93)

23-30 (31-41)

12-17 (16-24)

(1)

33-43 (45-59)

23-30 (31-41)

(1)

12-17 (16-24)

61-69 (83-93)

12-17 (16-24)

65-80 (88-108)

36-51 (49-69)

33-43 (45-59)

58-72 (78-98)

33-49 (45-67)

(1)

33-43 (45-59)

58-72 (78-98)

(1)

33-40 (45-54)

Page 38

58-86 (78-117)

33-50 (45-68)

22-25 (30-34)

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Rotor-To-Hub Bolt

B2200 & B2600i

MX-6 & 626

323

Wheel Bearing Lock Nut

B2200 & B2600i (Rear)

323 (Front)

Wheel Lug Nut

B2200 & B2600i

Standard Wheel

Styled Wheel

Navajo

All Others

40-51 (54-69)

36-43 (49-58)

33-40 (45-54)

145-217 (197-295)

116-174 (158-237)

65-87 (88-118)

87-108 (118-147)

85-115 (115-155)

65-87 (88-118)

INCH Lbs. (N.m)

Parking Brake Cable Lock Nut

B2200 & B2600i

All Others

Wheel Cylinder Mounting Bolt

B2200 & B2600i 2WD

B2600i 4WD

Except B2200, B2600i & Navajo

(2)

60-84 (7-10)

168-252 (19-29)

108-144 (12-16)

180-216 (20-24)

84-108 (10-12)

(1) These bolts secure caliper directly to steering knuckle. On Protege, tighten to 29-36 ft. lbs. (39-49

N.m). On RX7, tighten to 58-72 ft. lbs. (78-98 N.m).

(2) Information is not available from manufacturer for Navajo.

DISC BRAKE SPECIFICATIONS

Application

B2200 & B2600i 2WD Front

(1)

Original Thickness

Discard Thickness

B2600i 4WD Front

(1)

Original Thickness

Discard Thickness

Miata

Front

(2)

Original Thickness

Discard Thickness

Microsoft

Sunday, July 05, 2009 2:18:09 PM

In. (mm)

.79 (20)

.71 (18)

.87 (22)

.79 (20)

.71 (18)

.63 (16)

Rear

(2)

Original Thickness

Discard Thickness

MPV Front

(2)

Original Thickness

Discard Thickness

MX-6 & 626

Front

(2)

Original Thickness

Discard Thickness

Rear

(2)

Original Thickness

Discard Thickness

Navajo Front

(3)

Original Thickness

Discard Thickness

Protege & 323

Front

(2)

Original Thickness

Discard Thickness

Rear

(2)

Original Thickness

Discard Thickness

RX7

Front

(2)

Original Thickness

Discard Thickness

Rear

(2)

Solid Rotor

Original Thickness

Discard Thickness

Ventilated Rotor

Original Thickness

Discard Thickness

929

Front

(2)

Original Thickness

Discard Thickness

Rear

(2)

Microsoft

Sunday, July 05, 2009 2:18:09 PM

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

.35 (9)

.28 (7)

.94 (24)

.87 (22)

.94 (24)

.87 (22)

.39 (10)

.31 (8)

.94 (24)

.81 (21)

.87 (22)

.79 (20)

.35 (9)

.28 (7)

.87 (22)

.79 (20)

.39 (10)

.31 (8)

.79 (20)

.71 (18)

.87 (22)

.79 (20)

1991 Mazda MX-5 Miata

BRAKE SYSTEM 1991 BRAKES Mazda Brake System

Discard Thickness

(1) Maximum lateral runout is .006" (.15 mm).

(2) Maximum lateral runout is .004" (.10 mm).

(3) Maximum lateral runout is .003" (.08 mm).

DRUM BRAKE SPECIFICATIONS

Application

B2200 & B2600i

Drum Diameter

Original

Minimum

Wheel Cylinder Bore Diameter

B2200 & B2600i 2WD

B2600i 4WD

MPV

Drum Diameter

Original

Minimum

Wheel Cylinder Bore Diameter

MX-6 & 626

Drum Diameter

Original

Minimum

Wheel Cylinder Bore Diameter

Navajo

Drum Diameter

Original

10"

Minimum

10"

Protege & 323

Drum Diameter

Original

Minimum

Wheel Cylinder Bore Diameter

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Sunday, July 05, 2009 2:18:09 PM

.71 (18)

.63 (16)

In. (mm)

10.24 (260.0)

10.30 (261.5)

0.750 (19.05)

0.688 (17.46)

10.24 (260)

10.30 (261.5)

0.690 (17.50)

9.00 (228.6)

9.06 (230.1)

0.875 (22.22)

9.00 (228.6)

10.00 (254.0)

9.09 (230.8)

10.09 (256.3)

Page 41

9.00 (228.6)

9.04 (229.6)

0.875 (22.22)

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

ALTERNATOR & REGULATOR

1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

DESCRIPTION

Alternators are conventional 3-phase, self-rectifying type units containing 6 diodes (3 positive and 3 negative) which are used to rectify current. See Fig. 1 . An internally-mounted, Integrated Circuit (IC) regulator is used on all models.

Fig. 1: Charging System Wiring Schematic

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

BELT DEFLECTION

Measure belt deflection in center of longest pulley-to-pulley span. See BELT DEFLECTION

SPECIFICATIONS table. If belt deflection is not as specified, adjust as necessary.

BELT DEFLECTION SPECIFICATIONS

Application Deflection - In. (mm)

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

B2200

New Belt

Used Belt

B2600i

New Belt

Used Belt

Miata

New Belt

Used Belt

MPV

4-Cylinder Engine

New Belt

Used Belt

V6 Engine

New Belt

MX-3

Used Belt

4-Cylinder Engine

New Belt

Used Belt

V6 Engine

New Belt

Used Belt

MX-6 & 626

New Belt

Used Belt

Protege & 323

New Belt

Used Belt

RX7

929

New Belt

Used Belt

New Belt

Used Belt

- With 22 lbs. (98N) applied to belt.

TROUBLE SHOOTING

CHARGING SYSTEM

Microsoft

0.28-0.31 (7.0-8.0)

0.31-0.35 (8.0-9.0)

0.39-0.47 (10.0-12.0)

0.43-0.51 (11.0-13.0)

0.31-0.35 (8.0-9.0)

0.35-0.39 (9.0-10.0)

0.39-0.47 (10-12)

0.43-0.57 (11-13)

0.35-0.39 (9-10)

0.39-0.47 (10-12)

0.31-0.35 (8.0-9.0)

0.35-0.39 (9.0-10.0)

0.24-0.28 (6.0-7.0)

0.28-0.31 (7.0-8.0)

0.24-0.31 (6.0-8.0)

0.28-0.35 (7.0-9.0)

0.31-0.35 (8.0-9.0)

0.35-0.39 (9.0-10.0)

0.47-0.59 (12.0-15.0)

0.55-0.67 (14.0-17.0)

0.35-0.39 (9.0-10.0)

0.39-0.47 (10.0-12.0)

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

CHARGING SYSTEM TROUBLE SHOOTING

PROBLEM Possible Cause

NO START CONDITION

Dead Battery

Bad Cable Connections

Ignition Switch/Circuit Fault

CHARGING SYSTEM WARNING LIGHT STAYS ON

Loose/Worn Alternator Belt

Loose Alternator Connections

Warning Light Wiring

Faulty Stator/Diodes

Faulty Voltage Regulator

WARNING LIGHT OFF WITH IGNITION SWITCH ON

Blown Fuse

Faulty Alternator

Bad Warning Light Bulb

WARNING LIGHT ON WITH IGNITION SWITCH OFF

Alternator Wiring Short

Faulty Rectifier Bridge

AMMETER INDICATES DISCHARGE

Loose/Worn Alternator Belt

Loose Alternator Connections

Faulty Ammeter

NOISY Defective Battery

Defective Alternator

Defective Regulator

TROUBLE SHOOTING PRECAUTIONS

Action

Check/Replace Battery

Clean/Replace Cables

Check Switch/Circuit

Tighten/Replace Belt

Check/Repair

Connections

Check/Repair Wiring

Test/Repair Alternator

Test/Repair Regulator

Check/Replace Fuse

Test Alternator

Test/Replace Bulb

Check/Repair Wiring

Test/Repair Alternator

Tighten/Replace Belt

Check/Repair

Connections

Test/Replace Ammeter

Replace Battery

Test/Repair Alternator

Test/Repair Regulator

NOTE: Observe the following precautions when trouble shooting or testing charging system:

Miata



Obtain code number and deactivate audio anti-theft system before disconnecting battery.

All Models



DO NOT reverse battery cable connections. Rectifier will be damaged.

DO NOT use high voltage type testers.

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi



Battery voltage is always applied to terminal "B".



DO NOT ground terminal "L" while engine is running.

DO NOT start engine with connector disconnected from terminals "L" and "S".



DO NOT apply battery voltage to terminal "L".

ON-VEHICLE TESTING

NOTE: Check alternator wiring harness connections and drive belt tension. Battery must be fully charged before testing. Wait at least 30 seconds after starting engine before measuring system voltage.

CAUTION: Ensure alternator terminal "B" does not contact ground.

ALTERNATOR OUTPUT

1. Connect an ammeter (80-amp minimum) in-line between terminal "B" connector and wire. See Fig. 2 ,

Fig. 3 and Fig. 4 . Turn all headlights and accessories on and depress brake pedal. With engine operating at 2500-3000 RPM, measure output amperage.

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

Fig. 2: Identifying Alternator Terminals

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

Fig. 3: Identifying Alternator Terminals (1992 B2200, B2600i & MPV)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

Fig. 4: Identifying Alternator Terminals (1992 All Other Models)

Courtesy of MAZDA MOTORS CORP.

2. If output amperage is not equal to or more than amount specified in ALTERNATOR OUTPUT table, repair or replace alternator as necessary.

3. Turn off all accessories and release brake pedal. With engine operating at 2500-3000 RPM, measure output amperage. If output amperage is not at least 5 amps, repair or replace alternator as necessary.

4. With engine operating at 2500-3000 RPM, measure voltage between terminal "S" and ground. If reading is not 14.1-14.7 volts, repair or replace alternator as necessary.

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

ALTERNATOR OUTPUT

Application

B2200

B2600i

Miata

A/T

M/T

MPV

MX-6 & 626

Non-Turbo

Turbo

A/T

M/T

MX-3

4-Cylinder

Protege & 323

RX7

929

Amps

BENCH TESTING

Rectifier/Diode Assembly

1. Using an ohmmeter, check continuity of each diode in both directions (polarity). See Fig. 5 and Fig. 6 . If diode shows high resistance in one direction and low resistance in other direction, diode is okay.

2. If diode shows low resistance in both directions, it is shorted. If diode shows high resistance in both directions, diode is open. If any diode is defective, replace rectifier assembly.

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

Fig. 5: Testing Alternator Rectifier & Diodes

Courtesy of MAZDA MOTORS CORP.

Fig. 6: Testing Alternator Rectifier & Diodes (1992)

Courtesy of MAZDA MOTORS CORP.

Rotor & Slip Rings

Measure resistance between rotor slip ring contacts. See Fig. 7 . If resistance is not within specification, replace rotor. See ROTOR RESISTANCE SPECIFICATIONS table. Check continuity between individual slip rings and rotor core/shaft. If there is continuity, replace rotor.

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

Fig. 7: Testing Alternator Stator, Rotor & Brushes

Courtesy of MAZDA MOTORS CORP.

ROTOR RESISTANCE SPECIFICATIONS

Application

MPV

RX7

All Others

Ohms

2.7-2.9

2.0-4.0

3.5-4.5

Stator

Check continuity between stator coil leads and stator core. See Fig. 7 . If there is continuity, replace stator.

Check continuity between leads of stator coil. If there is no continuity, replace stator.

Brushes

Replace brushes if worn to limit line. See Fig. 7 . Replace brush springs if corroded. For brush replacement procedure, see OVERHAUL.

OVERHAUL

DISASSEMBLY

1. Place a 200-watt soldering iron against rear bearing for 3-4 minutes to heat rear cover to 122-140°F (50-

60°C). Carefully separate front case and rotor from rear cover and stator. See Fig. 8 , Fig. 10 and Fig. 11 .

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

Fig. 8: Overhauling Alternators

Courtesy of MAZDA MOTORS CORP.

2. Position rotor in vise. Remove pulley. Disassemble pulley, rotor and front case. Remove front bearing from front case. Using a bearing puller, remove rear bearing.

3. Remove "B" terminal nut and bushing from rear cover. Remove screws from brush holder and rectifier.

Separate rear cover and stator. When unsoldering rectifier and stator leads, disconnect as quickly as possible (5 seconds maximum) to avoid damage to rectifier. To remove brushes from holder, unsolder pigtail from terminal.

REASSEMBLY

Brush Installation

1. Install brush and spring into holder. Allow brush to extend out of holder until wear limit line extends .08-

.16" (2-4 mm) beyond end of brush holder. See Fig. 9 . Solder pigtail onto brush holder.

2. Insert spring and brush into brush holder. Using a spring scale, pull brush into holder until end of brush protrudes .08" (2.0 mm) from holder. See Fig. 9 . Note reading on spring scale. Replace spring if tension is not 5.6-15.5 ozs. (160-440 g).

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

Fig. 9: Measuring Installed Depth of Brush

Courtesy of MAZDA MOTORS CORP.

Fig. 10: Exploded View of Alternators

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

Fig. 11: Exploded View of Alternators

Courtesy of MAZDA MOTORS CORP.

Microsoft

1990-91 ENGINE COOLING Cooling System Specifications - MX-5 Miata

1990-91 ENGINE COOLING

Cooling System Specifications - MX-5 Miata

COOLING SYSTEM SPECIFICATIONS

Application

Coolant Replacement Interval

Coolant Capacity

Pressure Cap

Thermostat Open Temperature

Starts

Main Valve

Sub Valve

Fully Open

Thermostat Open Lift

Main Valve

Sub Valve

Specification

30 Months Or 30,000 Miles

6.3 qts. (6.0L)

11-15 psi (0.75-1.05 kg/cm

)

188-193°F (86.5-89.5°C)

182-188°F (83.5-86.5°C)

212°F (100°C)

0.31" (8 mm)

0.06" (1.5 mm)

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

1990-91 DRIVE AXLES

Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

AXLE RATIO & IDENTIFICATION

See AXLE RATIO SPECIFICATIONS . To determine axle ratio, divide number of ring gear teeth by number of pinion teeth.

AXLE RATIO SPECIFICATIONS

No. of Teeth

Pinion/Ring Gear

11/43

Ratio

3.91:1

Application

B2200

B2600i

Front & Rear

Miata

MPV (Front & Rear)

A/T

M/T

Protege & 929

RX7

A/T

(1)

M/T Non-Turbo

M/T Turbo

(1) Non-Turbo convertible only.

11/41

N/A

10/41

11/43

N/A

11/43

N/A

3.73:1

4.30:1

4.01:1

3.91:1

N/A

3.9:1 or 4.1:1

4.1:1 or 4.3:1

4.1:1

DESCRIPTION

NOTE: For models with independent suspension, see REAR AXLE SHAFTS (vehicles that are normally only FWD), or AXLE SHAFTS - FRONT article in this section for axle shaft overhaul.

An optional Limited Slip Differential (LSD) is available on Miata and RX7 models. Rear drive axles are retained in the housing by tapered bearings and bearing retainers at axle housing outer ends on B2200 and

B2600i. Rear drive axle bearings on MPV 4WD are held in place by a pressed-on collar.

On front axle on B2600i (4WD) and MPV 4WD, and rear axle on Miata, Protege 4WD, RX7 and 929, drive axles use CV joints to connect differentials to drive hubs.

LUBRICATION

CAPACITY

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

DIFFERENTIAL CAPACITY SPECIFICATIONS

(1)

Application

B2200 (Front & Rear)

B2600i

Front

Rear

Miata

MPV 2WD

MPV 4WD

Front

Rear

Protege 4WD

RX7

Non-Turbo

Turbo

929

(1) Fill to lower edge of filler plug hole.

FLUID TYPE

DIFFERENTIAL LUBRICATION SPECIFICATIONS

(1)

Application

Above 0°F (-18°C)

Below 0°F (-18°C)

(1) Fill to lower edge of filler plug hole.

Qts. (L)

1.3 (1.2)

1.6 (1.5)

1.8 (1.7)

.69 (.65)

1.6 (1.5)

1.8 (1.7)

1.6 (1.5)

.69 (.65)

1.4 (1.3)

1.5 (1.4)

1.4 (1.3)

Specification

GL-5/SAE 90W

GL-5/SAE 80W

TROUBLE SHOOTING

See TROUBLE SHOOTING - BASIC PROCEDURES article in the TROUBLE SHOOTING Section.

REMOVAL & INSTALLATION

REAR AXLE SHAFTS & BEARINGS

Removal (B2200 & B2600i)

1. Raise and support vehicle. Remove rear wheels. Remove brake drum and shoes. Using a dial indicator, measure axle flange lateral movement. If bearing play is not within specification, bearing shim must be adjusted during installation. See END PLAY SPECIFICATIONS .

2. Disconnect brake line from wheel cylinder. Plug line openings. Disconnect parking brake cable. Remove backing plate retaining nuts. Remove axle shaft and backing plate as an assembly.

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

NOTE: On B2200 and B2600i, left axle bearing lock nut has left-hand threads.

3. Using Bearing Nut Wrench (49 0603 635A ) and Shaft Holder (49 S120 645A ), remove bearing lock nut from axle shaft. Remove bearing and bearing retainer from axle using Puller (49 S120 520A ). Remove outer race from hub.

END PLAY SPECIFICATIONS

(1)

In. (mm) Application

B2200 & B2600i

One Axle Installed

Both Axles Installed

.026-.037 (.65-.95)

.002-.010 (.05-.25)

(1) Check at axle flange with dial indicator.

Installation

1. Press new oil seal and bearing outer race into bearing retainer. Coat bearing race and outer seal with grease. Tap inner oil seal flush with end of axle housing. Coat inner seal lip with grease.

2. Position brake backing plate onto axle shaft. Install spacer against backing plate with chamfer facing backing plate. Using Press Attachment (49 S120 748 ) and a press, install wheel bearing onto axle shaft.

Standard press force is 4.6-6.7 tons (4200-6100 kg). If press fit force is too high or too low, replace the bearing collar or shaft.

3. Using Bearing Nut Wrench (49 0603 635A ), install bearing lock nut to axle shaft and tighten to 145-217 ft. lbs. (196-245 N.m). Bend tab up into groove. Install one axle shaft into axle housing. Tighten backing plate nuts to specification. Install dial indicator on backing plate and check drive axle end play.

NOTE: Ensure end play for first drive axle is within specification before inserting second drive axle. Use shims to adjust end play if necessary.

4. To adjust end play, remove axle and insert appropriate size adjustment shim between axle hub and housing. End play for second drive axle installed should be set to normal end play clearance of .002-

.010" (.05-.25 mm), with both axles installed.

5. Install parking brake cable, attaching pin and brake line. Install brake shoes and actuating hardware.

Bleed brake system. Install wheel and tire.

BEARING RETAINER SHIMS (B2200 & B2600i)

Part Number

083 26 165

083 26 166

083 26 167

083 26 168

Thickness In. (mm)

.004 (.10)

.006 (.15)

.020 (.50)

.030 (.75)

MPV 4WD

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

1. Raise and support vehicle. Remove rear wheels. Remove brake drum and shoes. Using a dial indicator, measure axle flange lateral movement. Replace bearing if play exceeds If bearing play exceeds .023" (.57 mm). Disconnect brake line from wheel cylinder. Plug line openings. Disconnect parking brake cable.

2. Remove backing plate retaining nuts. Remove axle shaft and backing plate as an assembly. Use puller or slide hammer to pull axle and bearing from axle housing. With axle removed, remove retaining ring and bearing collar. See Fig. 1 .

Fig. 1: Exploded View of Rear Drive Axle (MPV; Others Similar)

Courtesy of MAZDA MOTORS CORP.

3. To remove bearing collar, grind collar until a section of it is .020" (.5 mm) and cut through it with a chisel. Use a puller or press to remove bearing and brake backing plate. Check axle shaft for straightness.

Maximum runout is .059" (1.5 mm).

4. Use a press to replace wheel studs (if necessary), never use a previously used wheel stud as a replacement. Lubricate seal lips before replacement. DO NOT lubricate bearing retainer collar before replacement. Use a press to install bearing collar. If press-fit of collar requires less than 2.7 tons (2699 kg.) replace collar or axle shaft. Reverse removal procedures to complete installation.

DIFFERENTIAL ASSEMBLY

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Removal (Front - B2600i & MPV 4WD)

1. Raise and support vehicle. Remove engine skid plate. Drain differential. On MPV 4WD, remove tie rod end and lower arm. Remove front axle shafts. See AXLE SHAFTS - FRONT article. Mark drive shaft position, and remove drive shaft.

2. On B2600i, remove differential subframe mounting bolts and nuts. Remove differential, Remote Free

Wheel (RFW) and subframe assembly from vehicle. Remove RFW assembly from right side of differential housing. Pull drive coupler from carrier. Remove differential carrier retaining bolts. Remove differential carrier.

3. On MPV 4WD, remove differential housing mounting bolts and mount at end of Remote Free Wheel

(RFW) extension housing. Remove differential and extension housing from vehicle. Remove RFW assembly from right side of differential housing. Pull drive coupler from carrier. Remove differential carrier retaining bolts. Remove differential carrier.

Installation

To install, reverse removal procedure. See Fig. 2 or Fig. 3 . Apply Sealant (8527 77 739 ) to carrier mating flange. Align marks made during removal. Refill differential with lubricant. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Fig. 2: Installing Front Differential (B2600i)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Fig. 3: Installing Front Differential (MPV 4WD)

Courtesy of MAZDA MOTORS CORP.

Removal; Rear - B2200, B2600i, MPV 2WD, PROTEGE 4WD, RX7, 929

1. Raise and support vehicle. Drain differential. Mark drive axles and drive shaft positions. On B2200,

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

B2600i and MPV, remove brake drum and drive axles. See REAR AXLE SHAFTS & BEARINGS . On

Protege 4WD, RX7 and 929, disconnect CV joint drive axles from differential assembly and wire aside.

2. On all models, mark flanges and disconnect drive shaft. Remove ABS sensor (if equipped). On RX7, remove rear exhaust system and differential mount on left side of pinion flange. Remove hanger mounts and allow left side to hang down. Disconnect sublinks and remove differential.

3. On Protege 4WD and 929 models, remove differential housing assembly-to-chassis mounting bolts.

Remove differential housing assembly from vehicle. On all models, remove differential carrier-tohousing nuts. Remove differential carrier.

Installation

To install, reverse removal procedure. Apply Sealant (8527 77 739 ) to carrier mating flange. Align marks made during removal. Refill differential with correct type and amount of lubricant. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

Fig. 4: Exploded View of Differential Assembly (RX7)

Courtesy of MAZDA MOTORS CORP.

Removal (Miata)

1. Raise and support vehicle. Drain differential. Mark flanges and remove drive shaft. Note locations and disconnect wiring harness from Power Plant Frame (PPF). See Fig. 5 .

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

2. Support transmission with a jack. Remove PPF bracket from rear transmission extension housing.

Remove PPF-to-differential side bolts and pry out spacer. Remove PPF/differential mounting spacer. See

Fig. 6 . Install metric bolt (M14 X 1.5) into sleeve. See Fig. 7 .

3. Twist bolt side-to-side while pulling bolt downward. Install a metric bolt (M6 X 1) into hole in housing block to hold sleeve and remove long bolt (M14 X 1.5). Remove short bolt (M6 X 1).

4. Remove PPF-to-transmission side bolts and remove PPF. Mark and disconnect CV joint drive axles from differential assembly and wire aside. Remove differential carrier-to-housing nuts. Remove differential carrier.

INSTALLATION

1. To install, reverse removal procedure. Apply Sealant (8527 77 739 ) to carrier mating flange. Align marks made during removal and install differential carrier. Install differential. Raise transmission until engine and transmission are level.

2. To install Power Plant Frame (PPF), position PPF in place. Install PPF/differential mounting spacer and tighten bolts to 27-38 ft. lbs. (37-52 N.m). Install PPF-to-transmission side mounting bolts and tighten.

3. Ensure sleeve is installed into PPF housing block. Install spacer and bolts. Ensure reamer bolt is installed into front hole and tighten. See Fig. 6 .

4. Install transmission-to-PPF bracket. Install remaining PPF bolts and tighten all bolts to specification. See

TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

NOTE: On Miata, front PPF-to-differential side mounting bolt is reamer bolt, which aligns power plant frame. See Fig. 6 .

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Fig. 5: Exploded View of Differential Components (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Fig. 6: View of Power Plant Frame Components (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Fig. 7: Removing Reamer Bolt Sleeve (Miata)

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

DIFFERENTIAL HOUSING & DRIVE PINION

NOTE: Mark position of all components before disassembly.

Disassembly

1. Mount carrier in repair stand. Mark side bearing caps for reassembly purposes. Remove adjuster lock plates. See Fig. 8 .

2. Loosen side bearing and slightly back off adjusters. Remove bearing caps and adjusters. Withdraw differential assembly from carrier. Ensure side bearing races remain with their respective bearings.

3. Remove drive pinion lock nut. Remove companion flange using a gear puller. Remove drive pinion, spacer, rear bearing and collapsible spacer assembly from carrier. Remove oil seal and front bearing.

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Remove bearing outer races, using a drift and hammer in slots provided on inner lip (if necessary).

Fig. 8: Exploded View of Typical Differential & Carrier Assembly

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL ASSEMBLY & RING GEAR

Disassembly

1. Using Puller (49 0839 425C ), remove side bearings from gear case. Ensure side bearings are marked for

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7 reassembly purposes. Separate ring gear from gear case. On standard differentials, remove knock pin.

Remove pinion shaft, pinion gears, thrust washers and side gears. See Fig. 8 .

2. On Limited Slip Differentials (LSD) models, gradually loosen attaching screws until distance between left and right half of differential case is about 0.12" (3 mm). On all models, mark differential halves for reassembly reference.

3. Carefully separate differential halves. On LSD models, remove thrust washer, conical springs, friction plates, friction discs, pressure ring, side gears, carrier pinion (spider) gears and spider. See Fig. 9 . Keep parts in order for reassembly.

Fig. 9: View of Limited Slip Differential (LSD) Assembly (RX7)

Courtesy of MAZDA MOTORS CORP.

STANDARD DIFFERENTIAL

Reassembly & Adjustment

1. Install side gears, thrust washers, thrust block, pinion gears, pinion shaft and knock pin. Stake knock pin.

Press side bearings onto differential assembly. Position a dial indicator against pinion gear. Secure one side gear. See Fig. 10 .

2. Check side gear and pinion gear backlash. If backlash exceeds .004" (.10 mm), replace thrust washers.

Apply locking compound to rear face of ring gear. Install ring gear and tighten ring gear retaining bolts to

51-61 ft. lbs. (69-83 N.m). See CARRIER PINION THRUST WASHER SPECIFICATIONS .

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

CARRIER PINION THRUST WASHER SPECIFICATIONS

Identifying Mark

Thickness In. (mm)

.0787 (2.00)

.0807 (2.05)

.0827 (2.10)

.0846 (2.15)

.0866 (2.20)

Fig. 10: Measuring Carrier Gear Backlash

Courtesy of MAZDA MOTORS CORP.

LIMITED SLIP DIFFERENTIAL (RX7)

1. Check friction plate, disc and thrust washer thicknesses. See RX7 DIFFERENTIAL

SPECIFICATIONS . Measure and record thickness of 6 plate springs.

2. Measure thickness of complete clutch pack excluding conical springs. See Fig. 9 . Subtract conical spring thickness and complete clutch pack thickness from 3.583" (91.00 mm). Difference should be .004-

010" (.10-.25 mm).

3. If clearance is excessive, use oversize friction discs. Oversize friction disc thickness is .0827" (2.10 mm).

Measure thickness of side gears, pressure rings, spider, pinion gears and thrust washers in place. See Fig.

9 .

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

4. Subtract thickness from 3.701" (94.00 mm). Difference should be .004-.016" (.10-.40 mm). If clearance is not as specified, install oversize thrust washers. See RX7 DIFFERENTIAL SPECIFICATIONS .

5. Install parts in proper order. See Fig. 8 . Before installing thrust washers, coat with grease. When installing conical springs, ensure concave side faces side gears. Align differential case and cover alignment marks. Apply locking compound to rear face of ring gear. Install ring gear and tighten ring gear retaining bolts to 51-61 ft. lbs. (69-83 N.m).

RX7 DIFFERENTIAL SPECIFICATIONS (LIMITED SLIP)

Application

Friction Disc Thickness

Standard

Limit

Friction Plate

Standard

Limit

Oversize

Thrust Washer

Standard

Limit

Oversize

In. (mm)

.079 (2.0)

.075 (1.9)

.079 (2.0)

.075 (1.9)

.083 (2.1)

.063 (1.6)

.055 (1.4)

.071 (1.8)

Pinion Assembly (B2200, B2600i, Miata, Protege 4WD & 929)

1. Using a press, install pinion bearing races in differential housing. Place original spacer, rear bearing and

Bearing Collar (49 H027 001 ) onto Drive Pinion (49 8531 565 ). Secure collar with "O" ring. Install assembly into differential housing.

2. Install front bearing, Collar (49 8531 567 on 929 or 49 U027 001 on B2200 and B2600i), companion flange, washer and original drive pinion nut. See Fig. 11 . Tighten flange nut so assembly can be turned by hand.

3. Place a dial indicator on Pinion Height Gauge (49 0727 570 ). Place pinion height gauge on a flat surface and zero dial indicator. Position Gauge Block on top of Drive Pinion (49 F027 001 ). See GAUGE

BLOCK SELECTION .

GAUGE BLOCK SELECTION

Application Use Gauge Block No.

Front Differential

49 0305 555 B2600i

& MPV

4WD

Rear Differential

B2200

B2600i,

Protege

49 0305 555

49 0660 555

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

4WD &

929

Miata 49 N027 001

4. Set pinion height gauge on top of gauge block. Set dial indicator to measure distance to a point where side bearing sits. Measure lowest point. See Fig. 11 . Measure both sides. Add both measurements together and divide sum by 2.

5. If measurement is not zero, replace pinion spacer. Spacers are available in a range of .1213-

.1366" (3.081-3.470 mm), in .001" (.03 mm) increments. Remove dummy pinion shaft. Press rear pinion bearing on pinion shaft.

6. Install pinion shaft, spacer, front bearing, collapsible spacer and companion flange in differential housing.

DO NOT install pinion seal at this time. DO NOT exceed one ton force or collapsible spacer will be damaged.

7. Temporarily tighten drive pinion nut. Turn companion flange by hand to seat bearing. Tighten drive pinion nut to 94-130 ft. lbs. (128-177 N.m). Check pinion bearing preload, at drive pinion nut. See

PINION PRELOAD SPECIFICATIONS . If pinion bearing preload is not as specified, replace collapsible spacer and recheck preload.

8. Remove drive pinion nut and companion flange. Install pinion seal. Apply oil to seal lip. Install companion flange. Using a new drive pinion nut, tighten nut to 94-130 ft. lbs. (128-177 N.m). Recheck pinion bearing preload.

PINION PRELOAD SPECIFICATIONS

Application

B2200 & 929

B2600i 4WD

Front

Rear

Miata & Protege 4WD (Rear)

MPV 4WD

Front

Rear

RX7

Non-Turbo

Turbo

INCH lbs. (N.m)

11.3-15.6 (1.3-1.8)

7.8-12.2 (0.9-1.4)

2.6-6.1 (0.3-0.7)

7.8-12.2 (0.9-1.4)

11.3-15.6 (1.3-1.8)

7.8-12.1 (0.9-1.4)

11.3-15.6 (1.3-1.8)

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Fig. 11: Checking Pinion Installation & Position

Courtesy of MAZDA MOTORS CORP.

Pinion Assembly (RX7)

1. Using a press, install rear pinion bearing outer race in differential housing. Install center bearing outer race. Using original rear bearing spacer, install rear bearing on Setting Pinion (49 F027 001 ).

2. Position drive pinion in carrier and install center bearing, long collar and companion flange. Tighten pinion nut just enough so pinion can be turned by hand.

3. Place a dial indicator on Pinion Height Gauge (49 0727 570 ). Place pinion height gauge on a flat surface and zero dial indicator. Position Gauge Block (49 0305 555 ) on top of Setting Pinion (49 F027 001 ).

4. Set pinion height gauge on top of gauge block. Set dial indicator to measure distance to lowest point where side bearing sits. See Fig. 11 . Measure both sides. Add both measurements together and divide sum by 2.

5. If measurement is not zero, replace pinion spacer. Spacers are available in a range of .1213-

.1366" (3.081-3.470 mm) in .001" (.03 mm) increments. Remove setting pinion, select spacer and press rear pinion bearing on drive pinion shaft.

6. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential housing. DO NOT install pinion seal yet. Press center bearing onto drive pinion using Adapter (49 1243

465A ). DO NOT exceed one-ton force or collapsible spacer will be damaged. Two different collapsible spacers are available, ensure correct one is used.

RX7 DRIVE PINION COLLAPSIBLE SPACERS

Application

Non-Turbo

Turbo

Length In. (mm)

1.923-1.935 (48.85-49.15)

2.238-2.250 (56.85-57.15)

7. Lubricate ends of long collar with grease and install. Using a press, install front bearing using Adapter

(49 F027 009 ). Press fit with a 2-3 ton force. DO NOT install oil seal yet. Install companion flange and nut. Tighten drive pinion nut to 94 ft. lbs. (128 N.m). Turn companion flange by hand to seat bearing.

8. Pinion bearing preload at drive pinion nut should be 11.3-15.6 INCH lbs. (1.3-1.8 N.m). Adjust preload by tightening drive pinion nut. If correct preload cannot be obtained within drive pinion nut tightening range of 94-210 ft. lbs. (128-284 N.m), replace collapsible spacer and recheck preload.

9. Remove drive pinion nut and companion flange. Install pinion seal. Apply oil to seal lip. Install companion flange. Using a new drive pinion nut, tighten nut to specification established for correct preload.

Carrier Assembly (All Models)

1. Position differential assembly into differential housing. Install side bearing adjusters. Position side bearing caps. Align marks made during disassembly. Install side bearing cap bolts. DO NOT tighten yet.

2. Tighten side bearing adjusters equally until adjuster contact bearing races. Mark ring gear in 4 locations,

90 degrees apart. Position a dial indicator against ring gear to check ring gear backlash.

3. Check backlash at all 4 locations. Tighten side bearing adjusters equally until backlash is .0035-

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

.0043" (.09-.11 mm). Minimum backlash at any point is .002" (.05 mm). Difference between minimum and maximum backlash at 4 measuring points should not exceed .0028" (.07 mm).

4. To set differential bearing preload, tighten adjustment screws equally until distance between measuring points on carrier bearing caps is within specification. See Fig. 12 and DIFFERENTIAL CARRIER

DIMENSIONS .

5. Ensure backlash did not change when preload was set. Tighten side bearing cap bolts. Check ring gear tooth patterns. See GEAR TOOTH CONTACT PATTERNS article in the GENERAL

INFORMATION section.

DIFFERENTIAL CARRIER DIMENSIONS

(1)

Application In. (mm)

B2200 & B2600i

"M" Differential

"P" Differential

7.300-7.303 (185.43-185.50)

8.048-8.051 (204.43-204.50)

5.885-5.913 (149.48-150.19) Miata

MPV 4WD

Front 7.275-7.303 (184.78-185.50)

8.022-8.051 (203.78-204.50) Rear

Protege 4WD

Rear Differential 5.910-5.913 (150.13-150.20)

RX7

Non-Turbo

929

Turbo

7.300-7.306 (185.43-185.59)

8.048-8.051 (204.43-204.50)

8.023-8.051 (203.78-204.50)

(1) See Fig. 12 for measuring point.

DIFFERENTIAL LUBRICATION SPECIFICATIONS

(1)

Application

Above 0° F (-18° C)

Below 0° F (-18° C)

(1) Fill to lower edge of filler plug hole.

Specification

GL-5/SAE 90w

GL-5/SAE 80w

Microsoft

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Fig. 12: Measuring Carrier Case Spread

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

1990 TORQUE SPECIFICATIONS (B2200 & B2600i)

Application

Brake Pipe Union

Differential Assembly

Differential Carrier-to-Axle Housing

Differential Carrier Bearings Cap Bolts

"P" Series Differential

"M" Series Differential

Differential Carrier

Bearings Lock Tab

Drive Pinion Lock Nut

Filler Plug

Ring Gear Retaining Bolts

Front Suspension & Differential

Drive Shaft Companion Flange

Sub-Frame Mounting Bolts

Microsoft

Sunday, July 05, 2009 2:17:01 PM Page 21

Ft. Lbs. (N.m)

10-16 (14-22)

17-20 (23-27)

41-59 (56-80)

27-38 (37-52)

13-19 (18-26)

94-130 (127-176) 90

29-40 (39-54)

51-61 (69-83)

20-22 (27-30)

69-85 (94-115)

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Splash Shield

Rear Drive Axle

Axle Bearing Lock Nut

Backing Plate Bolt

2WD

4WD

Drive Shaft Companion Flange

Wheel Lug Nuts

Standard Wheel

Styled Wheel

1991 TORQUE SPECIFICATIONS (B2200 & B2600i)

Application

Brake Pipe Union

Differential Carrier-To-Housing Nuts

Differential Carrier Bearings Cap Bolts

"P" Series Differential

"M" Series Differential

Differential Carrier Bearings Lock Plate Bolt

Drive Pinion Lock Nut

Drive Shaft Companion Flange Nuts

Filler Plug

Front Subframe Mounting Bolts

Rear Axle Bearing Lock Nut

Rear Backing Plate Bolt

2WD

4WD

Ring Gear Retaining Bolts

Splash Shield Bolts

Wheel Lug Nuts

Standard Wheel

Styled Wheel

23-34 (31-46)

145-217 (197-294)

72-87 (98-118)

65-80 (88-109)

20-22 (27-30)

65-87 (88-118)

87-108 (118-146)

Ft. Lbs. (N.m)

10-16 (14-22)

17-20 (23-27)

41-59 (56-80)

27-38 (37-52)

13-19 (18-26)

94-210 (127-284)

20-22 (27-30)

29-40 (39-54)

69-85 (94-115)

145-217 (197-294)

72-87 (98-118)

65-80 (88-109)

51-61 (69-83)

23-34 (31-46)

65-87 (88-118)

87-108 (118-146)

1990 TORQUE SPECIFICATIONS (MIATA)

Application

Differential Assembly

Differential Carrier-to-Housing

Differential Carrier Bearings Cap Bolts

Differential Carrier Bearings Lock Tab

Differential Case Rear Mounts

Drive Pinion Lock Nut

Microsoft

Sunday, July 05, 2009 2:17:01 PM Page 22

Ft. Lbs. (N.m)

17-20 (23-27)

50-66 (68-90)

14-19 (19-26)

87-130 (118-176)

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Inner Nut

Outer Nuts (2)

Filler Plug

Ring Gear Retaining Bolts

Power Plant Frame-to-Differential Mounting

Spacer Bolt (Short)

PPF-to-Differential Side Mounting Bolts (Long)

PPF-to-PPF Bracket Bolt

Power Plant Frame-to-Transmission

Side Mounting Bolts (Long)

Transmission-to-PPF Bracket Bolts

1991 TORQUE SPECIFICATIONS (MIATA)

Application

Differential Carrier-To-Housing Nuts

Differential Carrier Bearings Cap Bolts

Differential Carrier Bearings Lock Plate Bolt

Differential Case Rear Mount Nuts

Drive Pinion Lock Nut

Inner Nut

Outer Nuts (2)

Drive Shaft Companion Flange Nuts

Filler Plug

Ring Gear Retaining Bolts

Power Plant Frame-To-Differential Mounting

Spacer Bolt (Short)

PPF-To-Differential Bolts

Side Mounting Bolts (Long)

PPF-To-PPF Bracket Bolt

Power Plant Frame-To-Transmission

Side Mounting Bolts (Long)

Transmission-To-PPF Bracket Bolts

Wheel Lug Nuts

61-72 (83-98)

13-20 (18-26)

29-40 (39-54)

51-61 (69-83)

27-38 (37-52)

77-91 (104-123)

27-40 (37-54)

77-91 (104-123)

27-40 (37-54)

Ft. Lbs. (N.m)

17-20 (23-27)

27-38 (37-52)

13-19 (18-26)

54-69 (73-94)

87-130 (118-176)

61-72 (83-98)

13-20 (18-26)

20-22 (27-30)

29-40 (39-54)

51-61 (69-83)

27-38 (37-52)

77-91 (104-123)

27-40 (37-54)

77-91 (104-123)

27-40 (37-54)

65-87 (88-118)

1990 TORQUE SPECIFICATIONS (MPV 4WD)

Application

Brake Pipe Union

Differential Assemblies

Differential Carrier Bearings Cap Bolts

Front Differential

Rear Differential

Microsoft

Sunday, July 05, 2009 2:17:01 PM Page 23

Ft. Lbs. (N.m)

10-16 (14-22)

27-38 (37-52)

54-79 (73-107)

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Differential Carrier Bearings Lock Tab

Differential Carrier-to-Housing

Drive Pinion Lock Nut

Filler Plug

Ring Gear Retaining Bolts

Front Axle Components

Differential-to-Chassis Mounts

Drive Shaft Companion Flange

Extension Housing-to-Differential Housing

Lower Ball Joint-to-"A" Frame

Splash Shield

Rear Axle Components

Axle Bearing Retainer Nuts

Brake Drum Retaining Screws

Drive Shaft Companion Flange

1991 TORQUE SPECIFICATIONS (MPV)

Application

Brake Pipe Union

Differential-To-Chassis Mount Nuts (4WD)

Differential Carrier Bearings Cap Bolts

Front Differential

Rear Differential

Differential Carrier Bearings Lock Plate Bolt

Differential Carrier-To-Housing Nuts

Drive Pinion Lock Nut

Drive Shaft Companion Flange Nuts

Filler Plug

Lower Ball Joint-To-Control Arm Bolts (4WD)

Lower Ball Joint-To-Control Arm Nut (4WD)

Rear Axle Bearing Retainer Nuts

Rear Brake Drum Retaining Screws

RFW Extension Housing Mount Nut (4WD)

Ring Gear Retaining Bolts

Splash Shield Bolts (4WD)

Tie Rod End Nut (4WD)

Wheel Lug Nuts

1990 TORQUE SPECIFICATIONS (PROTEGE 4WD)

Application

Differential Assembly

Microsoft

Sunday, July 05, 2009 2:17:01 PM Page 24

13-19 (18-26)

17-20 (23-27)

94-210 (127-285)

29-40 (39-54)

51-61 (69-83)

49-72 (66-98)

36-43 (49-58)

27-40 (36-54)

75-101 (102-137)

12-17 (16-23)

72-87 (98-118)

10-11 (14-15)

36-43 (49-58)

Ft. Lbs. (N.m)

10-16 (14-22)

49-72 (66-98)

27-38 (37-52)

54-79 (73-107)

13-19 (18-26)

17-20 (23-27)

94-210 (127-285)

36-43 (49-58)

29-40 (39-54)

75-101 (102-137)

94-127 (128-172)

72-87 (98-118)

7-11 (10-15)

149-72 (66-98)

51-61 (69-83)

12-17 (16-23)

43-58 (59-78)

65-87 (88-118)

Ft. Lbs. (N.m)

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Differential Carrier Bearing Cap Bolts

Differential Carrier Bearing Lock Tab

Differential Carrier-to-Housing

Differential Case

Front Mounts

Rear Mounts

Drive Pinion Lock Nut

Filler Plug

Ring Gear Retaining Bolts

Suspension & Mounts

Drive Axle Inner CV Joint Nut

Drive Shaft Companion Flange

Front Mount

Lateral Link

Rear Mount

Stabilizer Bar

Trailing Link

Wheel Lug Nuts

1991 TORQUE SPECIFICATIONS (PROTEGE 4WD)

Application

Differential Carrier Bearing Cap Bolts

Differential Carrier Bearing Lock Plate Bolt

Differential Carrier-To-Housing Nuts

Differential Case

Front Mounts

Rear Mounts

Drive Axle Inner CV Joint Nut

Drive Pinion Lock Nut

Drive Shaft Companion Flange Nuts

Filler Plug

Lateral Link Bolts

Ring Gear Retaining Bolts

Stabilizer Bar Bolts

Trailing Link Bolts

Wheel Lug Nuts

27-38 (37-52)

14-19 (19-26)

17-20 (23-27)

33-50 (45-68)

80-97 (109-132)

87-130 (118-176)

29-40 (39-54)

51-61 (69-83)

40-47 (54-64)

20-22 (27-30)

33-50 (45-68)

46-55 (62-75)

80-97 (109-132)

10-13 (14-18)

69-86 (94-117)

65-87 (88-118)

Ft. Lbs. (N.m)

27-38 (37-52)

13-19 (18-26)

17-20 (23-27)

39-47 (53-63)

68-86 (93-116)

40-47 (54-64)

87-130 (118-176)

20-22 (27-30)

29-40 (39-54)

46-55 (62-75)

51-61 (69-83)

31-43 (43-58)

68-93 (93-126)

65-87 (88-118)

1990-91 TORQUE SPECIFICATIONS (RX7)

Application

Differential Carrier-to-Housing

Differential Carrier

Microsoft

Sunday, July 05, 2009 2:17:01 PM Page 25

Ft. Lbs. (N.m)

17-20 (23-27)

1991 Mazda MX-5 Miata

1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7

Bearing Cap Bolts

(1)

Differential Carrier Bearing Cap Bolts

(2)

Differential Carrier Bearing Lock Tab

Differential Case Front Hanger Nut

Differential Case Rear Mounts

Differential Ring Gear Bolts

Drive Axle Inner CV Joint Nut

Drive Pinion Lock Nut

Drive Shaft Companion Flange

Filler Plug

Ring Gear Retaining Bolts

Support Strut Mounting Bolt

Wheel Lug Nuts

(1) 1990 Model.

(2) 1991 Model.

1990-91 TORQUE SPECIFICATIONS (929)

Application

ABS Sensor-to-Hub Support Bolt

Differential Carrier Bearing

Cap Bolts

Lock Tabs

Differential Carrier-to-Housing

Differential Case

Front Hanger Nut

Rear Mounts

Drive Axle Inner CV Joint Nut

Drive Pinion Lock Nut

Drive Shaft Companion Flange Bolts

Filler Plug

Ring Gear Retaining Bolts

Wheel Lug Nuts

54-79 (73-107)

50-66 (73-107)

13-19 (18-26)

65-77 (88-104)

54-69 (73-94)

51-61 (69-83)

40-47 (54-64)

94-210 (127-285)

36-43 (49-58)

29-40 (39-54)

51-61 (69-83)

54-69 (73-94)

65-87 (88-118)

Ft. Lbs. (N.m)

12-17 (16-23)

50-66 (68-90)

13-18 (18-24)

17-20 (23-27)

69-86 (94-117)

40-47 (54-64)

94-130 (127-176)

36-43 (49-58)

29-40 (39-54)

51-61 (69-83)

65-87 (88-118)

Microsoft

1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata

1990-93 ENGINE COOLING

Drive Belt Routing & Adjustment - MX-5 Miata

ADJUSTMENT

NOTE: Ensure drive belts are not worn, cracked or frayed and are correctly mounted on pulleys. See Fig. 1 .

NOTE: If a new belt is used, adjust belt deflection at midpoint of new belt specification.

Fig. 1: Identifying Correct Belt Mounting

Courtesy of MAZDA MOTORS CORP.

ALTERNATOR

Loosen alternator bolts and adjust belt deflection by turning adjusting bolt. See Fig. 2 , Fig. 6 and Fig. 7 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1991 Mazda MX-5 Miata

1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata

Fig. 2: Adjusting Alternator Belt

Courtesy of MAZDA MOTORS CORP.

A/C COMPRESSOR

Loosen locknut and adjust belt deflection by turning adjusting bolt. See Fig. 3 , Fig. 6 and Fig. 7 . See

ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1991 Mazda MX-5 Miata

1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata

Fig. 3: Adjusting A/C Compressor & Power Steering Pump Belt

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata

Fig. 4: Adjusting A/C Compressor Belt

Courtesy of MAZDA MOTORS CORP.

POWER STEERING PUMP

Loosen power steering pump bolt and nuts and adjust belt deflection by turning adjusting bolt. See Fig. 3 , Fig.

6 and Fig. 7 . See ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE

SPECIFICATIONS .

DRIVE BELT ROUTING

Microsoft

1991 Mazda MX-5 Miata

1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata

Fig. 5: Identifying Drive Belt Routing & Deflection Check Point (1 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata

Fig. 6: Identifying Drive Belt Routing & Deflection Check Point (2 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata

Fig. 7: Identifying Drive Belt Routing & Deflection Check Point (3 Of 3)

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENT SPECIFICATIONS

NOTE: Check belt deflection when engine is cold, or has bin off for 30 minutes.

DEFLECTION SPECIFICATIONS

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

(1) Deflection with 22 lbs. (10 kg) pressure applied midway on belt run.

Used on for less than 5 minutes.

Microsoft

Sunday, July 05, 2009 2:14:16 PM Page 7

(1)

Specification - In. (mm)

0.31-0.35 (8-9)

0.35-0.39 (9-10)

1991 Mazda MX-5 Miata

1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata

(2)

TENSION SPECIFICATIONS

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

(1) Measure tension using Tension Gauge (49 9200 020), or equivalent.

(2) Used on for less than 5 minutes.

TORQUE SPECIFICATIONS

Application

Alternator Adjusting Bolt

"A"

"B"

A/C Compressor Locknut

Power Steering Pump Adjusting Bolt

"A"

"B"

"C"

(1)

Specification - Lbs. (kg)

110-132 (50-60)

95-110 (43-50)

Ft. Lbs. (N.m)

14-18 (19-25)

27-38 (37-52)

23-44 (31-46)

27-40 (37-54)

14-18 (19-25)

Microsoft

ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS

ELECTRICAL COMPONENT LOCATOR

1991 MAZDA ELECTRICAL COMPONENTS

BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION

Component

ABS System

Check Valve Relay

Motor Relay

Buzzer & Timer Unit

Circuit Opening Relay

Cooling Fan Relay

Dashboard Illumination Lights Relay

EFI Main Relay

Fuel Pump Relay

Headlight Relay

Headlight Retractor Relay

Horn Relay

Ignition Relay

Turn Signal/Hazard Flasher Relay

Location

On top of ABS pump motor.

On bracket, behind left side of dash.

See Fig. 1 .

On bracket, behind left side of dash.

See Fig. 1 .

In engine compartment fuse/relay block. See Fig. 1 .

On bracket, near master cylinder. See

Fig. 1 .

In engine compartment fuse/relay block. See Fig. 1 & Fig. 2 .

Behind left front kick panel.

On bracket, near master cylinder. See

Fig. 1 .

On bracket, near master cylinder. See

Fig. 1 .

On bracket, behind left side of dash.

See Fig. 1 .

In engine compartment fuse/relay block.

On bracket, behind left side of dash.

See Fig. 1 .

CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION

Component

Fuse Block

Fuse/Relay Block

Heater Blower Motor Circuit Breaker

Location

Behind left side of dash.

In right rear corner of engine compartment, near firewall.

See Fig. 2 .

In passenger compartment fuse block.

CONTROL UNITS

1991 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS

CONTROL UNITS LOCATION

Component

ABS Control Unit

Cruise Control Unit

Engine Control Unit (ECU)

Supplemental Safety Restraint (SRS)

Module

SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION

Component

ABS Wheel Sensors

Airflow Meter

Atmospheric Pressure Sensor

Brake Fluid Level Sensor

Coolant Temperature Sensor

Cooling Fan Thermoswitch

Crank Angle Sensor

Intake Air Thermosensor

Oil Pressure Sensor

SRS Crash/Impact Sensors

Front

Center

Throttle Position Sensor (TPS)

Location

Behind center of dash, near ECU.

Behind left side of dash, above fuse block.

Behind center of dash. See Fig. 2 .

Behind left side of dash. See Fig. 3 .

Location

On each front & rear wheel hub assembly.

Connected to air filter housing. See Fig.

2 .

Built-in ECU.

Inside brake master cylinder.

On water outlet, at left rear of engine. See

Fig. 2 .

On thermostat housing.

On right rear side of cylinder head. See

Fig. 2 .

In airflow sensor unit.

On left side of engine near oil filter.

On center, left and right front of vehicle. See Fig. 3 .

Behind center of dash. See Fig. 3 .

Mounted on side of throttle body. See

Fig. 2 .

MOTORS

MOTORS LOCATION

Component

A/C-Heater Blower Motor

Wiper Motor

SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION

Microsoft

Sunday, July 05, 2009 2:15:23 PM Page 2

Location

Behind left side of dash.

On right side of firewall.

1991 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS

Component

Idle Speed Control Solenoid

Purge Control Solenoid Valve

Location

On throttle body.

On right side of engine compartment, on shock tower.

SWITCHES

SWITCHES LOCATION

Component

A/C Pressure Switch

Back-Up Light Switch

Clutch Switch

Neutral Switch

Parking Brake Switch

Power Steering Pressure Switch

Seat Belt Buckle Switch

Stoplight Switch

Location

On high pressure refrigerant line.

On left side of transmission.

On bracket, above clutch pedal. See Fig. 2 .

On right rear side of transmission. See Fig. 2 .

On base of parking brake lever.

On power steering housing assembly. See Fig. 2 .

On driver's side seat belt buckle.

On bracket, above brake pedal. See Fig. 2 .

MISCELLANEOUS

MISCELLANEOUS LOCATION

Component

Diagnostic Check Connector

Igniter

SRS Back-Up Battery

Location

On left rear of engine compartment, near master cylinder. See Fig. 2 .

On right rear corner of engine compartment, near fuse/relay block. See

Fig. 2 .

Mounted below SRS control unit. See Fig. 3 .

COMPONENT LOCATION GRAPHICS

NOTE: Figures may show multiple component locations. Refer to appropriate table for proper figure references.

Microsoft

1991 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS

Fig. 1: Component Locations (1 Of 3)

Microsoft

1991 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS

Fig. 2: Component Locations (2 Of 3)

Microsoft

1991 Mazda MX-5 Miata

ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS

Fig. 3: Component Locations (3 Of 3)

Microsoft

SUSPENSION - FRONT 1990-91 SUSPENSION Front

SUSPENSION - FRONT

1990-91 SUSPENSION Front

DESCRIPTION

An independent front suspension with MacPherson struts is used on all models except Miata. Miata uses a double wishbone design with coil over shock absorbers. See Fig. 1 . Strut assemblies mount between steering knuckle and upper fender panels. Strut assemblies consist of inner shock absorbers and coil springs surrounding outside of strut tube housing.

The steering knuckle is connected to lower control arm and strut. Lower control arm pivots at crossmember and is connected by ball joint to steering knuckle. All models are equipped with a stabilizer bar which attaches to each lower control arm and frame. See Fig. 1 - Fig. 5 . Some models may also be equipped with Auto Adjust

Suspension (AAS). For more information on this system, see ELECTRONIC SUSPENSION article in the

SUSPENSION section.

ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

See WHEEL ALIGNMENT SPECIFICATIONS AND PROCEDURES article in the WHEEL ALIGNMENT section.

WHEEL BEARING

Miata, Protege & 323

Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Remove rotor.

Install a dial indicator against wheel hub and measure axial movement. Axial movement should be .002" (.05 mm) maximum. If specification is exceeded, check and adjust lock nut torque or replace bearing on Protege and

323 or hub and bearing assembly on Miata.

MPV & 929

Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Install a dial indicator against wheel hub and measure axial movement. Maximum axial movement should be .002" (.05 mm). If specification is exceeded, check and adjust lock nut torque or replace bearing on MPV 4WD and 929 or hub and bearing assembly on MPV 2WD.

RX7

1. Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Install a dial indicator against hub and measure axial movement. Axial movement should be zero. If specification is exceeded, adjust preload or replace wheel bearing.

2. To adjust preload, remove grease cap, cotter pin and set cover. Loosen lock nut. Tighten to 14-22 ft. lbs.

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

(20-29 N.m). Turn wheel hub a few times to seat bearings. Loosen lock nut slightly until it can be turned by hand.

3. Attach spring scale to hub bolt, and measure preload. Note value. Tighten lock nut until preload is .09-2.2 lbs. (.4-1.0 kg) more than amount measured in step 2).

MX-6 & 626

Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Install a dial indicator against wheel hub and measure axial movement. Axial movement should not exceed .008" (.2 mm). If specification is exceeded, replace wheel bearing.

BALL JOINT CHECKING

Remove lower control arm. Rotate ball joint stud 3-4 times. Install Preload Attachment (49 0180 510B) to ball joint stud. Measure ball joint preload using spring scale. Preload for all models except Miata, MPV 2WD and

929 is 4.4-7.7 lbs. (2.0-3.5 kg). Preload for Miata is 1.1-3.3 lbs. (.5-1.5 kg). Preload for MPV 2WD is 39.6 lbs.

(18. kg) or less. Preload for 929 is 1.1-2.6 lbs. (.5-1.2 kg).

Fig. 1: Exploded View of Front Suspension (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Fig. 2: Exploded View of Front Suspension (RX7)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Fig. 3: Exploded View of Front Suspension (Protege & 323)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Fig. 4: Exploded View of Front Suspension (MPV & 929)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Fig. 5: Identifying Front Suspension Components (MX-6 & 626)

Courtesy of MAZDA MOTORS CORP.

REMOVAL & INSTALLATION

NOTE: Refer to Fig. 1 - Fig. 5 during removal and installation.

WHEEL BEARING

NOTE: On Miata & MPV 2WD, replace hub and bearing assembly as a unit.

Removal (Miata & MPV 2WD)

Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Remove grease cap and lock nut. Remove brake rotor. Remove hub and bearing assembly.

Removal (MPV 4WD)

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

1. Raise and support vehicle. Remove wheel assembly. Remove axle lock nut. Remove cotter pin, and disconnect tie rod from steering knuckle. Remove and wire aside brake caliper.

2. Separate lower control arm from ball joint. Remove bolt attaching ball joint to steering knuckle. Remove bolts retaining steering knuckle to strut assembly. Separate hub and knuckle from drive shaft. Remove wheel hub and rotor from knuckle. Remove bearings and oil seals.

Removal (MX-6 & 626)

1. Raise and support vehicle. Remove wheel assembly. Disconnect tie rod end from steering knuckle.

Disconnect stabilizer bar from lower control arm. Remove axle lock nut.

2. Disconnect brake line from strut assembly. Remove and wire aside brake caliper. Remove wheel speed sensor. Remove bolt attaching ball joint to steering knuckle. Remove bolts attaching steering knuckle to strut assembly. Remove steering knuckle.

3. Remove wheel hub from knuckle using Puller Set (49-G033-1A1). Remove snap ring. Remove wheel bearing from steering knuckle using Remover (49-G033-106).

Removal (Protege, 323 & 929)

1. Raise and support vehicle. Remove wheel assembly. Remove axle lock nut. Remove cotter pin, and disconnect tie rod from steering knuckle. Remove and wire aside brake caliper. Separate lower control arm from ball joint. Remove bolts retaining steering knuckle to strut assembly.

2. On Protege and 323, separate hub and knuckle from drive shaft. Remove wheel hub and rotor from knuckle. Place alignment marks on rotor and wheel hub. Separate and remove dust cover. Remove bearings, oil seals, bearing outer races and spacer.

3. On 929, remove hub and rotor. Remove grease seal, sensor ring and circlip. Press bearing from hub assembly. DO NOT reuse old bearing once pressed from hub.

Removal (RX7)

Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Remove grease cap, cotter pin, nut lock and spindle nut. Remove washer and outer wheel bearing. Remove hub and rotor assembly.

Remove wheel speed sensor ring. Remove inner oil seal and wheel bearing.

NOTE: If bearings need to be replaced on RX7, also replace hub.

Inspection (All Models)

Wash all disassembled parts before inspection. Check for damage, excessive wear and signs of bearing seizure.

Inspect steering knuckle and hub for cracks, scoring and rust. Check for damaged dust cover and poor fit with steering knuckle.

Installation (All Models)

To install, reverse removal procedure. Adjust wheel bearing preload. See WHEEL BEARING under

ADJUSTMENTS & INSPECTION .

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

LOWER CONTROL ARM

Removal

Raise and support vehicle. Remove wheel assembly. Remove engine splash shield (if equipped). Remove stabilizer bar from lower control arm. Remove strut rod (if equipped). Remove ball joint clamp bolt or pivot nut, and separate ball joint from steering knuckle. Remove lower control arm pivot bolts. Remove lower control arm.

Inspection

Check lower control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check ball joint for excessive wear. Examine dust boot for damage. Replace parts as necessary.

NOTE: Lower control arm bushings are not replaceable on MPV 2WD models. Replace control arm assembly if bushings are worn or damaged.

Bushing Replacement (Miata)

Cut or press old bushing from control arm. Coat new bushing with paraffin-based oil. Press new bushing into control arm. To install, reverse removal procedure.

Bushing Replacement (MPV 4WD)

Cut away bushing inner collar. Using a vise and Remover/Installer (49-G033-102 and 49-FO27-009), push out front bushing. Press out rear bushing using a press and Remover/Installer (49-U034-202 and 49-GO26-103). To install front bushing, apply soapy water to bushing and use remover/installer to press in. To install rear bushing, align arrows on bushing with marks on lower arm and use remover/installer to press in.

Bushing Replacement (MX-6 & 626)

Cut away bushing inner collar. Using a vise and Remover/Installer (49-GO34-2A0), push out bushing. To install, apply soapy water to bushing and use remover/installer to press in. Always install bushing from outer side of arm. Press in bushing until collar contacts arm.

Bushing Replacement (Protege & 323)

Using a vise and Remover/Installer Set (49-BO34-2A0), push out bushing. To install, apply soapy water to bushing and use remover/installer to press in. Always install bushing from outer side of arm. Press in bushing until collar contacts arm.

Bushing Replacement (929)

Cut away bushing outer collar. Using a vise and Remover/Installer (49-HO34-202 and 49-HO34-201), remove bushing from control arm. To install, reverse removal procedure.

Bushing Replacement (RX7)

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Push out front bushing using a press and Remover (49-G030-627A). To remove rear bushing, install Bearing

Puller (49-0710-520) on bushing. DO NOT overtighten bearing puller nuts or lower arm will be distorted and damaged. Press to push out rear bushing using Remover (49-G030-627A). To install both bushings, use remover and Support Block (49-0823-146).

Installation (All Models)

To install, reverse removal procedure. Tighten lower control arm pivot bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS .

UPPER CONTROL ARM

Removal (Miata)

Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove ball joint pivot nut.

Use Puller (49-0118-850C) to separate ball joint from steering knuckle. Remove upper control arm pivot bolts.

Remove upper control arm.

Inspection

Check upper control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check ball joint for excessive wear. Examine dust boot for damage. Replace parts as necessary.

Bushing Replacement

Using a chisel, remove old bushing from control arm. Coat new bushing with grease. Press new bushing into control arm.

Installation

To install, reverse removal procedure. Tighten upper control arm pivot bolts to specification with vehicle resting on ground and suspension unloaded.

SHOCK ABSORBER

Removal (Miata)

Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove stabilizer link bolt.

Separate upper ball joint from steering knuckle. Loosen lower control arm pivot bolts. Remove shock absorber upper mount nuts and lower bolt. Move lower control arm just enough to remove shock absorber. Be careful not to damage brake line.

Disassembly

Clamp upper mount in vise. Loosen lock nut 2 turns only. Compress coil spring using coil spring compressor.

Remove lock nut and remaining components. Slowly release compressor tension.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Inspection

Check for damage, oil leakage and abnormal noise. Check rubber parts for deterioration or damage. Inspect coil spring for signs of fatigue or damage. Replace parts as needed.

Reassembly

Clamp shock absorber in vise. Install coil spring and components in reverse order of disassembly. Ensure coil spring is well seated in upper and lower spring seats.

Installation

To install, reverse removal procedure. Final tighten all bolts with vehicle resting on ground and suspension unloaded. See appropriate See SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section for checks and adjustments.

STRUT ASSEMBLY

NOTE: Prior to removing strut-to-steering knuckle bolts, make an alignment mark for reassembly reference. Note position of mounting mark on top of strut assembly before removing strut.

Removal

1. Raise and support vehicle. Remove wheel assembly. Disconnect brake line from strut assembly. Remove bolts attaching steering knuckle arm to strut assembly.

2. Disconnect harness connector from actuator (if equipped). Remove bolts, actuator and actuator mounting bracket from upper mounting block. Remove nuts attaching upper strut assembly to body panel. Remove strut assembly.

Disassembly

Clamp strut in vise. Compress coil spring using coil spring compressor. Remove piston lock nut. Slowly release compressor tension. Remove components. Remove coil spring. Remove strut from vise.

Inspection

Check strut tube for cracks, damage, oil leakage and abnormal noise. Check rubber parts for deterioration or damage. Inspect coil spring for signs of fatigue or damage. Check actuator control rod of strut assembly for smooth rotation (if equipped). Replace parts as needed.

Reassembly

Clamp strut in vise. Install coil spring and components in reverse order of disassembly. Ensure that coil spring is well seated in upper and lower spring seats. On MX-6 and 626, ensure upper spring seat positioning hole faces inside of vehicle.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Installation

To install, reverse removal procedure. Place identification mark of mounting block in its original position. See

Fig. 6 or Fig. 7 . See appropriate See SPECIFICATIONS & PROCEDURES article in the WHEEL

ALIGNMENT section for checks and adjustments.

Fig. 6: Positioning Strut for Installation (MPV, RX7 & 929)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Fig. 7: Positioning Strut for Installation (MX-6, Protege, 323 & 626)

Courtesy of MAZDA MOTORS CORP.

STABILIZER BAR

Removal & Installation

1. Raise and support vehicle. Remove engine splash shield (if equipped). Remove mounting hardware and stabilizer bar. Note position of frame bushing seam. Inspect all components for wear, bends or damage.

2. Install frame bushing so it aligns with painted line on stabilizer bar. Install and partially tighten remaining components. Final tighten all bolts with vehicle resting on ground and suspension unloaded.

TORQUE SPECIFICATIONS

Application

Miata

Brake Caliper Bracket Bolts

Drive Axle Lock Nut

Lower Ball Joint-To-Knuckle Nut

Lower Ball Joint-To-Lower Control Arm Nut

Microsoft

Sunday, July 05, 2009 2:08:54 PM Page 12

Ft. Lbs. (N.m)

36-51 (49-69)

123-159 (167-216)

43-57 (58-77)

54-69 (73-93)

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

Lower Control Arm-To-Frame

Lug Nuts

Stabilizer Bar Bolts (Frame)

Stabilizer Bar Link Bolts

Shock Absorber Assembly-To-Body Nuts

Shock Absorber Lower Bolt

Shock Absorber Lock Nut

Tie Rod-To-Knuckle Nut

Upper Ball Joint-To-Knuckle Nut

Upper Control Arm-To-Frame

MPV

Ball Joint-To-Lower Control Arm Bolt (4WD)

Ball Joint-To-Lower Control Arm Nut (4WD)

Brake Caliper Bracket Bolts

Drive Axle Lock Nut

Lower Control Arm-To-Frame (2WD)

Lower Control Arm-To-Frame (4WD)

Lug Nuts

Stabilizer Bar Bolts (Frame) (2WD)

Stabilizer Bar Bolts (Frame) (4WD)

Strut Assembly Lock Nut

Strut Assembly-To-Body Nuts

Strut Assembly-To-Knuckle Bolt

Strut Rod Body Bushing Bolt

Strut Rod-To-Body Nut

Strut Rod-To-Lower Control Arm

Tie Rod-To-Knuckle Nut

MX-6 & 626

Ball Joint-To-Steering Knuckle Nut

Brake Caliper Bracket Bolts

Drive Axle Lock Nut

Lower Control Arm-To-Frame

Lug Nuts

Stabilizer Bar Bolts (Frame)

Strut Assembly Lock Nut

Strut Assembly-To-Body Nuts

Strut Assembly-To-Knuckle Bolt

Tie Rod-To-Knuckle Nut

Wheel Speed Sensor Bolt

Protege & 323

Ball Joint-To-Lower Control Arm Nut

Microsoft

Sunday, July 05, 2009 2:08:54 PM Page 13

54-69 (73-93)

65-87 (88-118)

13-19 (18-26)

27-40 (36-54)

21-27 (29-36)

54-69 (73-93)

23-34 (31-46)

21-32 (29-44)

30-46 (41-62)

87-102 (118-138)

75-101 (102-137)

94-127 (128-172)

65-80 (88-108)

131-173 (177-235)

94-108 (127-146)

101-127 (137-172)

65-87 (88-118)

37-45 (50-61)

14-19 (19-26)

47-59 (64-80)

21-27 (29-36)

69-86 (93-117)

61-76 (83-103)

108-127 (146-172)

76-92 (103-125)

44-58 (59-78)

27-40 (36-54)

58-72 (78-98)

173-235 (235-319)

58-78 (78-106)

65-87 (88-118)

27-40 (36-54)

47-59 (64-80)

34-46 (46-63)

69-86 (93-117)

31-42 (42-57)

12-17 (16-23)

69-86 (93-117)

Brake Caliper Bracket Bolts

Drive Axle Lock Nut

Lower Control Arm-To-Frame

Front

Rear

"U" Bracket Bolts

Lug Nuts

Stabilizer Bar Bolts (Frame)

Strut Assembly Lock Nut

Strut Assembly-To-Body Nuts

Strut Assembly-To-Knuckle Bolt

Tie Rod-To-Knuckle Nut

RX7

Ball Joint-To-Steering Knuckle Nut

Brake Caliper Bracket Bolts

Lower Control Arm-To-Frame

Front

Rear

Lug Nuts

Stabilizer Bar Bolts (Frame)

Stabilizer Bar Link Bolts

Strut Assembly Lock Nut

Strut Assembly-To-Body Nuts

929

Strut Assembly-To-Knuckle Bolt

Tie Rod-To-Knuckle Nut

Ball Joint-To-Steering Knuckle Nut

Brake Caliper Bracket Bolts

Drive Axle Lock Nut

Front Wheel Bearing Nut

Knuckle Arm-To-Knuckle

Lower Control Arm-To-Frame

Lug Nuts

Stabilizer Bar Bolts (Frame)

Strut Assembly Lock Nut

Strut Assembly-To-Body Nuts

Strut Assembly-To-Knuckle Bolt

Strut Rod Body Bushing Bolt

Strut Rod-To-Body Nut

Strut Rod-To-Lower Control Arm

Microsoft

Sunday, July 05, 2009 2:08:54 PM

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

32-44 (43-59)

29-36 (39-49)

173-235 (235-319)

69-86 (93-117)

69-94 (93-127)

69-86 (93-117)

65-87 (88-118)

32-44 (43-59)

58-81 (79-110)

21-30 (29-40)

69-93 (93-127)

31-42 (42-57)

27-40 (36-54)

58-72 (78-98)

46-69 (63-93)

51-61 (69-83)

65-87 (88-118)

13-19 (18-26)

27-40 (36-54)

47-59 (64-80)

21-27 (29-36)

69-86 (93-117)

21-32 (29-44)

Page 14

69-91 (94-123)

58-86 (78-117)

72-130 (98-177)

75-101 (102-137)

55-69 (74-93)

65-87 (88-118)

37-45 (50-61)

47-59 (64-80)

25-32 (34-44)

69-86 (93-117)

64-86 (93-117)

76-92 (103-125)

1991 Mazda MX-5 Miata

SUSPENSION - FRONT 1990-91 SUSPENSION Front

21-32 (29-44)

Microsoft

FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1990-95 Mazda

FUSES & CIRCUIT BREAKERS

Fuses & Circuit Breakers 1990-95 Mazda

FUSES & CIRCUIT BREAKERS

FUSE PANEL LOCATION

Fuse box is located above driver's left knee, accessible through a removable cover. The main fuse block is located at the right rear of the engine compartment.

The Trunk Mounted Fuse Panel is located on the right side of the trunk, near the trunk hinge. (1992-95 Models)

MAIN FUSE BLOCK IDENTIFICATION

Fig. 1: Main Fuse Block Identification

Courtesy of MAZDA MOTOR OF AMERICA, INC.

WARNING: Always disconnect battery ground cable before servicing "high-current" fuses. It is recommended that "high-current" fuses be replaced by a qualified technician.

Fuse & Circuit Breaker Identification

1991 Mazda MX-5 Miata

FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1990-95 Mazda



1 - 30 Amp (Pink) Headlights



2 - 30 Amp (Pink) Fuel Injection, Alternator

3 - 80 Amp (Black) Protection Of All Circuits



4 - 40 Amp (Green) Taillights, Shift Lock, Cruise Control, Horn, Stoplights, Hazard Warning Lights,

Interior Lights, Warning Buzzers, Radio/Cassette, Compact Disc Player, Clock

5 - Empty (1990); 60 Amp (Yellow) (1991-94) Anti-Lock Brake System



6 - 30 Amp (Pink) Cooling Fan



7 - 10 Amp (Red) Air Bag

8 - 20 Amp (Yellow) A/C Additional Fan



9 - 10 Amp (Red) Fuel Injection

10 - 30 Amp (Pink) Headlight Retractor

TRUNK MOUNTED FUSE PANEL IDENTIFICATION

Microsoft

1991 Mazda MX-5 Miata

FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1990-95 Mazda

Fig. 2: Trunk Mounted Fuse Panel Identification (1992-94)

Courtesy of MAZDA MOTOR OF AMERICA, INC.

Fuse & Circuit Breaker Identification



1 - 10 Amp (Red) (1992-94) Rear Defroster

2 - 10 Amp (Red) (1992-94) Power Antenna

INTERIOR FUSE PANEL IDENTIFICATION

Microsoft

1991 Mazda MX-5 Miata

FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1990-95 Mazda

Fig. 3: Interior Fuse Panel Identification

Courtesy of MAZDA MOTOR OF AMERICA, INC.

Fuse & Circuit Breaker Identification



11 - 15 Amp (Blue) Engine Cooling Fan



12 - 10 Amp (Red) Gauges, Warning Lights, Turn Signal Lights, Cruise Control



13 - 15 Amp (Blue) Air Bag

14 - 30 Amp Heater



15 - Empty

16 - 30 Amp (Green) Power Windows



17 - 20 Amp (Yellow) Wipers, Washers

18 - Empty



19 - 15 Amp (Blue) Taillights

20 - Empty



21 - 15 Amp (Blue) Shift Lock, Cruise Control, Horn, Stoplights

 22 - 15 Amp (Blue) Hazard Warning Lights

Microsoft

1991 Mazda MX-5 Miata

FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1990-95 Mazda



23 - Empty



24 - 10 Amp (Red) Interior Lights, Warning Buzzers, Radio/Cassette, Compact Disc Player, Clock

25 - 15 Amp (Blue) Radio/Cassette, Compact Disc Player, Clock, Cigarette Lighter



26 - Empty

27 - Empty

BATTERY SPECIFICATIONS

CAUTION: When battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in the

GENERAL INFORMATION Section.

Vehicle is equipped with a special 9 9/16" x 4 3/4" x 7 3/8" 12-volt battery that is vented to outside of vehicle.

CAUTIONS & WARNINGS

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)

NOTE: See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental

Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.

CAUTION: Disconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger's side of vehicle in case of accidental air bag inflation

AIR CONDITIONING SERVICING

CAUTION: Avoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-

134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming

Microsoft

1991 Mazda MX-5 Miata

FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1990-95 Mazda service.

WARNING: R-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See AIR

CONDITIONING SERVICE article in GENERAL INFORMATION section.

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions:



DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK

BRAKE SYSTEM article in the BRAKES Section.



DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.

Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

BATTERY WARNING

WARNING: When battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL

INFORMATION section.

REPLACING BLOWN FUSES

Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

Continued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.

Microsoft

1991 Mazda MX-5 Miata

FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1990-95 Mazda

Any modification to the exhaust system on turbo models, which reduces exhaust backpressure, will lead to lean fuel mixtures and excessive spark advance. This could cause serious engine damage.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNING: Many solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not.

Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

ENGINE OIL

CAUTION: Never use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNING: Relieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

Halogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

HEADLIGHT RETRACTOR

CAUTION: If headlight retractor freezes during cold weather operation, DO NOT attempt to force mechanism. Headlights should be kept raised at all times in cold weather. To raise them, use only headlight retractor switch. DO

NOT use headlight switch.

RADIATOR CAP

CAUTION: Always disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNING: Keep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

Microsoft

HEATER SYSTEM 1990-92 Heater Systems

HEATER SYSTEM

1990-92 Heater Systems

DESCRIPTION & OPERATION

Heater case, mounted under center of instrument panel, contains airflow mode door and air-mix (temperature blend) door. See Fig. 1 . Blower case, mounted under right end of instrument panel, contains recirculated/fresh air door. All doors are controlled manually from control panel by cable.

Blower motor relay, in left rear corner of engine compartment (on relay cluster), supplies power to blower motor. Blower resistors, on bottom of blower case, determine blower speed.

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in AIR BAG article in the

ACCESSORIES/SAFETY EQUIPMENT Section.

Fig. 1: Exploded View of Heater Case

Courtesy of MAZDA MOTORS CORP.

1991 Mazda MX-5 Miata

HEATER SYSTEM 1990-92 Heater Systems

ADJUSTMENTS

AIRFLOW MODE DOOR

Set airflow mode control lever to vent position. Disconnect control cable at airflow mode door lever. Extend airflow mode door lever until it stops, and hold it there. See Fig. 1 . Attach control cable to door lever and clip.

Ensure control lever moves freely between defrost and vent positions.

AIR-MIX (TEMPERATURE BLEND) DOOR

Set temperature control lever to maximum hot position. Disconnect control cable at air-mix door lever. See Fig.

1 . Extend air-mix door lever until it stops, and hold it there. Attach control cable to door lever and clip. Ensure control lever moves freely between hot and cold positions.

RECIRCULATED/FRESH AIR DOOR

Set recirculated/fresh air control lever to fresh position. Disconnect control cable at recirculated/fresh air door lever. Retract recirculated/fresh air door lever until it stops, and hold it there. Attach control cable to door lever and clip. Ensure control lever moves freely between recirculated air and fresh air positions.

TESTING

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in AIR BAG article in the

ACCESSORIES/SAFETY EQUIPMENT Section.

BLOWER MOTOR CIRCUIT

1. Check 30-amp HEATER circuit breaker in passenger compartment fuse panel. If Red button has not popped out, go to next step. If Red button has popped out, repair short circuit and press Red button to reset circuit breaker.

2. Turn ignition on. Turn blower switch to 4th position (high). Check voltage at Blue wire terminal of 2wire blower motor connector on bottom of blower case. If no voltage is present, repair wiring between circuit breaker and blower motor.

NOTE: Blower resistor uses a 1-wire connector and a 4-wire connector. The wire in the 1-wire connector is Blue/Red, and one of the wires in the 4-wire connector is Blue/Red. Check voltage at appropriate wire.

3. If battery voltage is present, turn off blower switch and A/C switch (if equipped). Check voltage at

Blue/Red wire terminal of blower resistor 1-wire connector. If no voltage is present, replace blower motor. If battery voltage is present, check voltage at Blue/White wire terminal of blower resistor connector.

4. If no voltage is present, replace blower resistor. If battery voltage is present, check voltage at Blue/Red

Microsoft

1991 Mazda MX-5 Miata

HEATER SYSTEM 1990-92 Heater Systems wire terminal of blower resistor 4-wire connector. If no voltage is present, replace blower resistor.

5. If battery voltage is present, check voltage at Blue/Green wire terminal of blower resistor connector. If no voltage is present, replace blower resistor. If battery voltage is present, check voltage at Blue/Yellow wire terminal of blower resistor connector.

6. If no voltage is present, replace blower resistor. If battery voltage is present, turn ignition on and blower switch to 4th position (high). Check voltage at Black wire terminal of blower switch connector. If battery voltage is present, repair wiring between blower switch and ground.

7. If no voltage is present, turn ignition switch, blower switch and A/C switch off. Check voltage at

Blue/White wire terminal of blower switch connector. If no voltage is present, repair wiring between blower resistor and blower switch.

8. If battery voltage is present, check voltage at Blue/Red wire terminal of blower switch connector. If no voltage is present, repair wiring between blower resistor and blower switch. If battery voltage is present, check voltage at Blue/Green wire terminal of blower switch connector.

9. If no voltage is present, repair wiring between blower resistor and blower switch. If battery voltage is present, check voltage at Blue/Yellow wire terminal of blower switch connector. If battery voltage is present, replace blower switch. If no voltage is present, repair wiring between blower resistor and blower switch.

BLOWER MOTOR

Disconnect 2-wire connector from bottom of blower motor case. Apply battery voltage across terminals.

Replace blower motor if it does not operate.

BLOWER SWITCH

With blower switch in positions indicated, check continuity between specified terminals of blower switch connector. See Fig. 2 . If continuity is not as specified, replace blower switch.

Microsoft

1991 Mazda MX-5 Miata

HEATER SYSTEM 1990-92 Heater Systems

Fig. 2: Testing Blower Switch

Courtesy of MAZDA MOTORS CORP.

REMOVAL & INSTALLATION

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in AIR BAG article in the

ACCESSORIES/SAFETY EQUIPMENT Section.

CONTROL PANEL

Removal & Installation

Remove rear center console assembly. Remove vent outlets from center panel assembly. Remove center panel assembly. Remove control panel screws. Pull control panel from center panel and disconnect cables. To install, reverse removal procedure.

HEATER CORE

Removal & Installation

Microsoft

1991 Mazda MX-5 Miata

HEATER SYSTEM 1990-92 Heater Systems

Drain coolant. Disconnect heater hoses at engine compartment firewall. Remove grommets from holes (if equipped). Remove instrument panel. Remove heater case. Disassemble case and remove heater core. See Fig.

1 . To install, reverse removal procedure. Fill cooling system.

INSTRUMENT PANEL

Removal & Installation

Obtain code number and deactivate audio anti-theft system. Disconnect negative battery cable. Remove all components in order listed in illustration. See Fig. 3 . To install, reverse removal procedure.

Fig. 3: Exploded View of Instrument Panel

Courtesy of MAZDA MOTORS CORP.

WIRING DIAGRAM

Microsoft

1991 Mazda MX-5 Miata

HEATER SYSTEM 1990-92 Heater Systems

Fig. 4: Heater System Wiring Diagram (Miata)

Fig. 5: Heater System Wiring Diagram (1992 Miata)

Microsoft

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

A/C-HEATER SYSTEM - MANUAL

1990-92 Manual A/C-Heater Systems

A/C SYSTEM SPECIFICATIONS

Application

Compressor Type

Compressor Belt Deflection

(1) (2)

New

Used

Compressor Oil Capacity

Refrigerant (R-12) Capacity

System Operating Pressures

High Side

Specification

Nippondenso Rotary Vane

5/16-23/64" (8-9 mm)

23/64-25/64" (9-10 mm)

2.7-3.3 oz.

28 oz.

171-235 psi (12.0-16.5 kg/cm

)

21-43 psi (1.5-3.0 kg/cm

)

Low Side

(1) With 22 lbs. (10 kg) pressure applied to center of belt.

(2) On vehicles with P/S, measure midway between crankshaft pulley and P/S pump pulley. On vehicles without P/S, measure midway between crankshaft pulley and A/C idler pulley.

DESCRIPTION

Blower case, mounted under right end of instrument panel, contains blower motor and fresh/recirculated air door. Evaporator case, to left of blower case, contains evaporator, evaporator thermoswitch and expansion valve. Heater case, to left of evaporator case, contains airflow mode door and air-mix (temperature blend) door.

ELECTRICAL COMPONENT LOCATIONS

Component

A/C Relay

Blower Motor Relay

Blower Resistor

Evaporator Thermoswitch

Pressure Switch

Location

In Right Front Corner Of Engine Compartment

In Left Rear Corner Of Engine Compartment

On Bottom Of Blower Case

. On Left Side Of Evaporator Case

In High-Pressure Line, Between Receiver-Drier

And Evaporator

OPERATION

All air control doors are controlled manually by cable from control panel. Top lever controls the air-mix door, center lever controls the fresh/recirculated air door and bottom lever controls the airflow mode door.

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

Blower motor relay supplies power to blower motor. Blower resistor determines blower speed. With blower switch in highest position, blower motor is grounded through blower switch. With blower switch in all other positions, blower motor is grounded through blower resistor and blower switch.

Circuit through compressor clutch is completed when A/C relay is energized and pressure switch is closed. A/C relay is energized when Engine Control Unit (ECU) unit grounds the solenoid circuit of the relay. The ECU energizes A/C relay if evaporator thermoswitch is closed and A/C and blower switches are on. The ECU also controls A/C relay operation according to engine load.

ADJUSTMENTS

AIRFLOW MODE DOOR

Ensure control lever moves freely between defrost and vent positions.

AIR-MIX (TEMPERATURE BLEND) DOOR

Set temperature control lever to maximum hot position. Disconnect control cable at air-mix door lever. See Fig.

1 . Extend air-mix door lever until it stops, and hold it there. Attach control cable to door lever and clip. Ensure control lever moves freely between hot and cold positions.

RECIRCULATED/FRESH AIR DOOR

TESTING

AIR BAG WARNING

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in AIR BAG article in the

ACCESSORIES/SAFETY EQUIPMENT Section.

BLOWER MOTOR CIRCUIT

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

3. If battery voltage is present, turn off blower switch and A/C switch (if equipped). Check voltage at

4. If no voltage is present, replace blower resistor. If battery voltage is present, check voltage at Blue/Red wire terminal of blower resistor 4-wire connector. If no voltage is present, replace blower resistor.

7. If no voltage is present, turn ignition switch, blower switch and A/C switch off. Check voltage at

Blue/White wire terminal of blower switch connector. If no voltage is present, repair wiring between blower resistor and blower switch.

COMPRESSOR CLUTCH CIRCUIT

1. Turn ignition on. Check 20-amp WIPER fuse in passenger compartment fuse block. Check 20-amp AD

FAN (additional fan) fuse in engine compartment fuse block. If fuses are blown, repair short circuit.

2. If fuses are okay, run engine at idle. Turn A/C and blower switches on. Check voltage at compressor clutch connector (Black/Red wire terminal). If no voltage is present, go to step 5).

3. If battery voltage is present, turn ignition off. Disconnect evaporator thermoswitch connector. Check continuity between switch terminals. If there is no continuity, replace evaporator thermoswitch.

4. If there is continuity, disconnect compressor clutch connector. Set ohmmeter to X1000 scale. Check continuity between compressor clutch connector and ground. If there is no continuity, replace compressor clutch. If there is continuity, adjust compressor clutch air gap or check compressor for internal damage.

5. Run engine at idle. Turn A/C and blower switches on. Check voltage at Black/Blue wire terminal of A/C relay connector. If battery voltage is present, go to step 9).

6. If no voltage is present, check voltage at Blue/Yellow wire terminal of A/C relay connector. If no voltage is present, repair circuit between 20-amp AD FAN fuse and A/C relay.

7. If battery voltage is present, check voltage at Blue wire terminal of A/C relay connector. If no voltage is present, repair circuit between 20-amp WIPER fuse and A/C relay.

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

8. If battery voltage is present, check voltage at Blue/Black wire terminal of A/C relay connector. If no voltage is present, replace A/C relay. If battery voltage is present, check Engine Control Unit (ECU) terminal voltage.

9. Turn ignition off. Disconnect pressure switch connector. Check continuity between switch terminals. If there is continuity, repair circuit between A/C relay and compressor clutch.

10. If there is no continuity, connect manifold pressure gauges to system. If low pressure is 21-43 psi (1.5-3.0 kg/cm

) and high pressure is 171-235 psi (12.0-16.5 kg/cm

), replace pressure switch. If pressures are not as specified, check refrigerant system for proper charge.

CONDENSER (ADDITIONAL) FAN CIRCUIT

1. Turn ignition on. Turn A/C and blower switches on. Check voltage at Black/Blue wire terminal of condenser fan connector. If no voltage is present, repair circuit between A/C relay and condenser fan.

2. If battery voltage is present, check voltage at Black wire terminal of condenser fan connector. If no voltage is present, replace condenser fan motor. If battery voltage is present, repair circuit between condenser fan and ground.

A/C & BLOWER SWITCH

With switches in positions indicated, check continuity between specified terminals of A/C and blower switch connector. See Fig. 1 . If continuity is not as specified, replace A/C and blower switch.

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

Fig. 1: Testing A/C & Blower Switch

Courtesy of MAZDA MOTORS CORP.

A/C RELAY

1. Remove relay. Check continuity between specified terminals of relay connector. See A/C RELAY TEST table. See Fig. 2 . Ensure test lead polarity is correct. If continuity is not as specified, replace relay.

2. If continuity is as specified, apply battery positive lead to terminal "D" and negative lead to terminal "A".

Check continuity between terminals "E" and "C". If there is continuity, relay is okay. If there is no continuity, replace relay.

A/C RELAY TEST

Terminal (+)

(1)

Terminal (-)

(1) Connect ohmmeter positive lead to this terminal.

(2)

(2) Connect ohmmeter negative lead to this terminal.

Continuity

Yes

Fig. 2: A/C Relay Connector Terminal ID

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

BLOWER MOTOR

Disconnect 2-wire connector from bottom of blower motor case. Apply battery voltage across blower motor terminals. Replace blower motor if it does not operate.

BLOWER RESISTOR

Note 4-wire connector and 1-wire connector attached to seam where upper and lower blower cases meet. Wires in these connectors lead to blower resistor on bottom of blower case. Disconnect both connectors. If continuity does not exist between 1-wire connector terminal and each terminal of 4-wire connector, replace blower resistor.

CONDENSER (ADDITIONAL) FAN MOTOR

Disconnect condenser fan connector. Apply battery voltage across condenser fan terminals. Replace condenser fan motor if it does not operate.

EVAPORATOR THERMOSWITCH

1. Remove glove box. Run engine at idle. Turn off A/C switch. Turn blower switch to 4th position (high) for a few minutes to ensure evaporator temperature is greater than 32°F (0°C). Turn off blower switch and engine.

2. Disconnect evaporator thermoswitch connector. Check continuity between switch terminals. If there is continuity, thermoswitch is okay. If there is no continuity, replace thermoswitch.

PRESSURE SWITCH

1. Turn ignition off. Connect manifold pressure gauges to system. If high-side pressure is less than 31.2 psi

(2.2 kg/cm

), check system for proper refrigerant charge.

2. If high-side pressure is greater than 31.2 psi (2.2 kg/cm

), disconnect pressure switch connector. Check continuity between switch terminals. If there is continuity, switch is okay. If there is no continuity, replace switch.

REMOVAL & INSTALLATION

AIR BAG WARNING

WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR

BAG SYSTEM procedures in AIR BAG article in the

ACCESSORIES/SAFETY EQUIPMENT Section.

BLOWER CASE

Removal & Installation

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

Disconnect electrical connectors from blower case. Remove glove box. Loosen seal plate between blower motor case and evaporator case. Remove blower motor case nuts. Remove case and seal plate. To install, reverse removal procedure.

COMPRESSOR

Removal & Installation

1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect compressor clutch connector. Disconnect refrigerant lines from compressor.

Remove drive belt.

2. Raise and support vehicle. Remove compressor mounting bolts and remove compressor. To install, reverse removal procedure. Adjust drive belt to specified tension. Evacuate and charge system.

CONDENSER & RECEIVER-DRIER

Removal & Installation

Discharge A/C system using approved refrigerant recovery/recycling equipment. Raise and support vehicle.

Remove splash shield and air guide. Remove condenser and receiver-drier as an assembly. To install, reverse removal procedure. Evacuate and charge system.

CONTROL PANEL

Removal & Installation

Remove rear console assembly. See Fig. 4 . Remove vent outlets from center panel assembly. Remove center panel assembly. Remove control panel screws. Pull control panel from hole. Disconnect door control cables from back of control panel and remove panel. To install, reverse removal procedure.

EVAPORATOR CORE & THERMOSWITCH

Removal & Installation

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove condenser and receiver-drier as an assembly. Disconnect low-pressure and high-pressure pipes from evaporator tubes at engine compartment firewall.

2. Remove right undercover and glove box. Disconnect thermoswitch electrical connector. Loosen left seal plate (between heater case and evaporator case). Loosen right seal plate (between evaporator case and blower motor case).

3. Remove evaporator case. Disassemble evaporator case, and remove evaporator core and thermoswitch.

See Fig. 3 . To install, reverse removal procedure. Evacuate and charge system.

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

Fig. 3: Exploded View of Evaporator Case

Courtesy of MAZDA MOTORS CORP.

HEATER CORE

Removal & Installation

1 . To install, reverse removal procedure. Fill cooling system.

INSTRUMENT PANEL

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

Removal & Installation

Obtain code number and deactivate audio anti-theft system. Disconnect negative battery cable. Remove all components in order listed in illustration. See Fig. 4 . To install, reverse removal procedure.

Fig. 4: Exploded View of Instrument Panel

Courtesy of MAZDA MOTORS CORP.

WIRING DIAGRAMS

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

Fig. 5: Manual Heater-A/C System Wiring Diagram (1990)

Fig. 6: Manual Heater-A/C System Wiring Diagram (1991)

Microsoft

1991 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems

Fig. 7: Manual Heater-A/C System Wiring Diagram (1992)

Microsoft

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

STEERING GEAR - POWER RACK & PINION

1991 STEERING Mazda - Power Rack & Pinion

DESCRIPTION

Steering system is a power-assisted rack and pinion. The system consists of a rack and pinion steering gear and power-assist pump/reservoir. The steering gear and pump/reservoir are connected by flexible hoses.

TESTING

HYDRAULIC SYSTEM PRESSURE TEST

Pump Fluid Pressure Test

1. Disconnect pressure hose and connect pressure gauge/valve between steering pump and steering gear. See

Fig. 1 . Bleed air from system.

2. Open valve fully. Start engine and idle. Turn steering wheel lock-to-lock to increase fluid temperature to

122-140°F (50-60°C). To measure pump fluid pressure, close gauge valve completely.

3. Increase engine speed to 1000-1500 RPM. Ensure pump pressure is within specification. See

HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS table. If pressure is not within specification, replace pump.

CAUTION: DO NOT leave gauge valve closed for more than 15 seconds, or pump may be damaged.

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Fig. 1: Connecting Pressure Gauge (Except 4-Wheel Steering)

Courtesy of MAZDA MOTORS CORP.

Gear Fluid Pressure Test

1. Ensure pump pressure is within specification. To measure steering gear fluid pressure, open gauge/valve completely. Increase engine speed to 1000-1500 RPM.

2. Turn steering wheel from lock-to-lock. Gauge pressure must be within specification. See HYDRAULIC

SYSTEM FLUID PRESSURE SPECIFICATIONS table. If pressure is less than specification, steering gear is defective.

HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS

(1)

Application

Miata

MPV, MX-6, 626 & 929 psi (kg/cm

)

1109-1209 (78-85)

1067-1138 (75-80)

Protege

2WD

4WD

RX7

323

1067 (75)

1138 (80)

1138-1209 (80-85)

1067 (75)

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

(1) Specifications are measured at 1000-1500 RPM, with fluid temperature at 122-140°F (50-60°C).

LUBRICATION

CAPACITY

POWER STEERING FLUID CAPACITY

Application

Miata, MPV & 929

MX-6 & 626

Electronc Controlled Power Steering (ECPS)

Engine Speed (Sensing) Power Steering (ESPS)

Protege & 323

RX7

Qts. (L)

.95 (.90)

1.06 (1.0)

.95 (.90)

.63 (.60)

.85 (.80)

FLUID TYPE

Dexron-II or M-III are recommended for all vehicles.

FLUID LEVEL CHECK

Check fluid level with engine off. Remove fluid level gauge on oil pump or reservoir. Check fluid level. Fluid should be between "L" and "H" marks on level gauge dipstick. If fluid level is low, fill through gauge tube.

Recheck fluid level. DO NOT overfill.

HYDRAULIC FLUID BLEEDING

1. Raise and support front of vehicle. With ignition off, turn steering wheel lock-to-lock several times. Add fluid as necessary. Repeat procedure until fluid level no longer decreases.

2. Start engine and let idle. Turn steering wheel lock-to-lock 5 times. Check fluid level. Add fluid as necessary. Continue procedure until fluid is clear of air bubbles and does not decrease in level.

ADJUSTMENTS

NOTE: On-vehicle adjustment procedures are not available from manufacturer.

POWER STEERING BELT ADJUSTMENT

POWER STEERING BELT DEFLECTION

(1)

Application

Miata, Protege & 323

New Belt

In. (mm)

.31-.35 (7.8-8.9)

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Used Belt

MPV

New Belt

Used Belt

4-Cylinder

New Belt

Used Belt

MX-6 & 626

New Belt

Used Belt

RX7

New Belt

929

Used Belt

New Belt

Used Belt

.35-.39 (8.9-10.0)

.28-.30 (7.1-7.6)

.30-.32 (7.6-8.1)

.26-.28 (6.6-7.1)

.28-.31 (7.1-7.8)

.31-.36 (7.8-9.1)

.35-.43 (8.9-10.9)

.43-.51 (10.9-12.9)

.55-.63 (14.0-16.0)

.28-.35 (7.1-8.9)

.35-.43 (8.9-10.9)

(1) Belt deflection is measured at midpoint between idler pulley and pump, with 22 lbs. (10 kg.) of pressure applied.

REMOVAL & INSTALLATION

STEERING GEAR

Removal & Installation (Miata & MPV)

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheels. Remove cotter pins and castle nuts from tie rod ends.

2. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-tosteering gear pinion shaft bolt. Mark reference lines on pressure pipe fittings.

3. Remove pressure and return hose connections from steering gear. Remove 2 steering bracket-to-frame mounting through bolts. Remove steering gear and linkage with steering bracket attached from under the vehicle.

4. To install, reverse removal procedure. Fill and bleed system. Tighten bolts to specification. See

TORQUE SPECIFICATIONS table. Tighten steering gear-to-mounting bracket bolts (4) in the following order: left front, right front, left rear, right rear.

Removal & Installation (MX-6 & 626)

1. Disconnect negative battery cable and power steering pressure switch connectors. Raise and support front of vehicle. Remove front wheels.

2. Remove cotter pins and castle nuts from tie rod ends. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt.

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

3. Remove pressure and return hose connections from steering gear. Remove mud flap on driver's side.

Remove steering gear mounting bolts. Remove steering gear through wheelwell on driver's side.

4. To install, reverse removal procedure. Fill and bleed system. Tighten bolts to specification. See

TORQUE SPECIFICATIONS table.

Removal & Installation (Protege & 323)

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheels. Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends.

2. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-tosteering gear pinion shaft bolt. Remove pressure and return hose connections from steering gear box.

3. Remove all accessible steering gear mounting bracket upper nuts and lower bolts. On Protege, support drive train from above. Loosen stabilizer bar left mounting bracket and remove engine mount crossmember.

4. Remove transmission control cable clip. Remove transfer case mount nuts. Lower engine gradually until rear engine mount bolts can be removed. Remove lower left steering gear mounting bolt from between transaxle and transfer case.

5. On all models, remove steering gear. To install, reverse removal procedure. Fill and bleed system.

Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

Removal & Installation (RX7)

1. Remove battery. Drain cooling system. Remove fan shroud and radiator. Raise and support front of vehicle. Remove front wheels and engine undercover.

2. Remove control links and stabilizer bar. Remove cotter pins and castle nuts from tie rod ends. Remove tie rods from steering knuckles with puller.

3. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Remove pressure and return hose connections from steering gear box.

4. Remove steering gear mounting bolts. Lower steering gear brackets, steering gear and linkage from vehicle as an assembly.

5. To install, reverse removal procedure. Fill and bleed system. Tighten bolts to specification. See

TORQUE SPECIFICATIONS table.

Removal & Installation (929)

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheels. Remove engine undercover. Disconnect pressure and return hose connections in front of steering gear.

2. Drain fluid. Disconnect return hose fitting to control valve. Remove starter for access to control valve.

Disconnect control valve and pressure switch connectors. Remove control valve. Remove cotter pins and castle nuts from tie rod ends.

3. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-tosteering gear pinion shaft bolt. Remove steering gear mounting bolts. Remove steering gear from bottom of vehicle.

4. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion table. Bleed air from system. Check fluid level. Check for leaks. Adjust alignment (if necessary).

POWER STEERING PUMP

Removal & Installation

1. Raise and support front of vehicle. On MX-6 and 626, remove right wheel and splash shield. On all models remove belt, alternator and hydraulic lines from pump.

2. On Protege and 323, disconnect air cleaner duct and pressure switch. On all models, cap lines to prevent contamination. Remove bracket-to-pump bolts.

3. To install, reverse removal procedure. Adjust belt tension. See POWER STEERING BELT

DEFLECTION TABLE under ADJUSTMENTS. Bleed air from system. Check for leaks.

OVERHAUL

STEERING GEAR

NOTE: See Fig. 2 -8 for exploded views of rack and pinion steering gears.

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Fig. 2: Rack & Pinion Steering Gear (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Fig. 3: Rack & Pinion Steering Gear (MPV)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Fig. 4: Engine Speed Sensing Rack & Pinion Steering Gear (MX6 & 626)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Fig. 5: Elect. Controlled Rack & Pinion Steering Gear (MX6 & 626)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Fig. 6: Exploded View of Rack & Pinion Steering Gear (Protege & 323)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Fig. 7: Exploded View of Rack & Pinion Steering Gear (RX7)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Fig. 8: Exploded View of Rack & Pinion Steering Gear (929)

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Application

Intermediate Shaft-To-Pinion Shaft Bolt

All Models Except RX7

RX7

Middle Crossmember

Front Bolt

Rear Bolt

Pinion Bearing Lock Nut

Pinion Housing Lock Nut

Miata

MPV, Protege & 323

MX-6 & 626

RX7 & 929

Stabilizer Bar-To-Control Link Nut

Microsoft

Sunday, July 05, 2009 2:10:15 PM Page 13

Ft. Lbs. (N.m)

13-19 (18-26)

12-18 (16-24)

29-40 (39-54)

58-86 (78-117)

29-36 (39-50)

29-39 (39-53)

29-36 (39-50)

33-40 (44-54)

36-51 (49-69)

27-40 (36-54)

1991 Mazda MX-5 Miata

STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion

Stabilizer Link Bolt/Nut

Steering Angle Transfer Shaft-To-Steering Gear Bolt

Steering Bracket-To-Frame Mounting Bolt

Steering Gear Mounting Bolt

Miata

MPV

MX-6 & 626

Protege, RX7, 323 & 929

Steering Rack-To-Tie Rod

Miata

MPV, MX-6, RX7 & 626

Protege, 323 & 929

Tie Rod Castle Nuts

All Models Except MPV

MPV

Valve Housing Bolt (929)

12-17 (16-23)

13-19 (18-26)

46-69 (63-93)

34-43 (46-58)

55-69 (74-93)

27-40 (36-54)

23-34 (31-46)

58-72 (78-98)

87 (118)

43-58 (60-78)

21-32 (29-44)

44-58 (59-78)

14-22 (20-29)

Microsoft

SUSPENSION - REAR 1991 SUSPENSION Rear

SUSPENSION - REAR

1991 SUSPENSION Rear

DESCRIPTION

Rear suspension consists of MacPherson-type struts, crossmember, upper and lower arms and stabilizer bar with control link. Upper and lower arms attach to crossmember and knuckle. A stabilizer bar with control link is mounted to lower arm and crossmember. Rear wheel alignment is adjusted by turning adjusting cams on lower arm.

ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

See WHEEL ALIGNMENT SPECIFICATIONS AND PROCEDURES article in the WHEEL ALIGNMENT section.

WHEEL BEARING

Raise vehicle and support. Remove wheel assembly. Remove caliper assembly and wire aside. Remove brake rotor. Attach dial indicator to axle hub and measure bearing play. Maximum bearing play is .002" (.05 mm). If play exceeds specification, check rear axle lock nut torque or replace wheel bearing.

REMOVAL & INSTALLATION

WHEEL BEARING

Removal

1. Raise and support vehicle. Remove wheel assembly. Remove drive axle lock nut. Remove brake caliper assembly, and wire aside. Remove screws and rotor. Disconnect ABS speed sensor. Remove knuckle assembly from upper and lower arms.

2. Using a press, Installer (49-G030-727) and Puller (49-F026-103), remove hub from knuckle. Remove snap ring from knuckle. Using a press, installer and Puller (49-0636-145), remove wheel bearing inner race from hub. Remove wheel bearing outer race from knuckle using a press and Adapter (49-F027-005).

Inspection

Check wheel hub and knuckle for cracks and damage. Check dust cover for deformation. Check bearing for excessive wear or seizure.

Installation

Press new wheel bearing into knuckle using Installer (49-F027-007) and Adapter (49-F027-009). Press hub into knuckle using installer. To install, reverse removal procedure. Tighten drive axle lock nut to specification. Stake

1991 Mazda MX-5 Miata

SUSPENSION - REAR 1991 SUSPENSION Rear drive axle lock nut. Check axial play. See WHEEL BEARING under ADJUSTMENTS & INSPECTION .

STRUT ASSEMBLY

Removal & Disassembly

1. Raise vehicle and remove fuel tank filler pipe protector. Remove rear wheel assembly. Remove stabilizer bar nut and bolt. Remove 2 upper strut mount-to-body nuts. Remove lower strut bolt. Loosen upper and lower arm bolts. Lower arms and remove strut assembly.

2. Clamp strut securely in soft-jawed vise. Compress coil spring. Remove lock nut and washer. Remove remaining components and note order for reassembly.

Inspection

Check strut for leaks or abnormal noise. Inspect parts for wear or damage. Check for loose installation of bolts and nuts. Replace parts as necessary.

Reassembly & Installation

To reassemble, reverse disassembly procedure. To install, reverse removal procedure. Ensure coil spring is well seated in upper and lower seats. Check rear wheel toe-in. See SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

LOWER ARM

Removal

Raise and support vehicle. Remove wheel assembly. Remove stabilizer bar control link nut and bolt. See Fig.

1 . Remove lower strut bolt. Remove lower arm-to-crossmember bolts. Remove lower arm-to-knuckle bolts.

Remove lower arm. Inspect arm for damage, cracks and deformation. Check for damaged or worn bushings.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - REAR 1991 SUSPENSION Rear

Fig. 1: Exploded View of Rear Lower Arm Assembly

Courtesy of MAZDA MOTORS CORP.

Installation

To install, reverse removal procedure. Tighten all bolts with vehicle resting on ground and suspension unloaded. Adjust rear wheel toe-in. See SPECIFICATIONS & PROCEDURES article in the WHEEL

ALIGNMENT section.

UPPER ARM

Removal

Raise and support vehicle. Remove wheel assembly. Remove upper arm-to-crossmember bolts. Remove upper arm-to-knuckle bolts. Remove upper arm. Inspect arm for damage, cracks and deformation. Check for damaged or worn bushings.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - REAR 1991 SUSPENSION Rear

Installation

To install, reverse removal procedure. Tighten all bolts with vehicle resting on ground and suspension unloaded. Adjust rear wheel toe-in. See SPECIFICATIONS & PROCEDURES article in the WHEEL

ALIGNMENT section.

STABILIZER BAR

Removal

Raise and support vehicle. Remove wheel assembly. Remove stabilizer bar-to-crossmember bolt, bracket and bushing. See Fig. 2 . Remove stabilizer bar control link-to-lower arm nut and bolt. Remove stabilizer bar and control link from vehicle. Separate stabilizer bar from control link.

Fig. 2: Exploded View of Rear Stabilizer Bar & Control Link

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

SUSPENSION - REAR 1991 SUSPENSION Rear

Installation

Inspect stabilizer bar and components for damage, cracks and deterioration. To install, reverse removal procedure. Ensure bushing is aligned with White line on stabilizer. Ensure seam faces front of vehicle. Tighten nuts and bolts to specification with vehicle resting on ground and suspension unloaded.

TORQUE SPECIFICATIONS

Application

ABS Speed Sensor Harness Bracket Bolts

Caliper Assembly-To-Knuckle Bolt

Control Link-To-Lower Arm Nut

Lower Arm-To-Crossmember Nuts

Lower Arm-To-Knuckle Nut

Rear Axle Nut

Stabilizer Bar Brackets Bolts

Stabilizer Bar-To-Control Link Bolt

Strut Piston Rod Lock Nut

Strut-To-Body Nuts

Strut-To-Lower Arm Bolt

Upper Arm-To-Crossmember Nuts

Upper Arm-To-Knuckle Bolt

Wheel Lug Nuts

Ft. Lbs. (N.m)

12-17 (16-23)

36-51 (49-69)

27-40 (36-54)

54-70 (73-95)

46-55 (63-75)

159-217 (216-294)

15-21 (20-28)

27-40 (36-54)

23-34 (31-46)

22-27 (29-36)

54-69 (73-93)

34-49 (46-67)

65-87 (88-118)

Microsoft

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

STARTER - DIRECT DRIVE

1990-92 ELECTRICAL Mazda Starters - Direct Drive

DESCRIPTION

Nippondenso direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive housing. The overrunning clutch pinion drive is mounted directly on armature shaft drive end.

NOTE: For information on B2200 and Protege models with automatic transmissions, see STARTERS - GEAR REDUCTION article.

TROUBLESHOOTING

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL

INFORMATION section.

TESTING (ON VEHICLE)

NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are clean and tight and engine grounds are good.

CIRCUIT TESTING

1. Turn ignition switch to START position, depress clutch and ensure starter operates. If starter does not operate, use voltmeter to check voltage at "S" terminal when clutch is depressed and ignition is turned to

START position. See Fig. 1 .

2. If voltage is less than 8 volts, check starter interlock switch and ignition switch to starter wiring circuit for short to ground. If voltage is greater than 8 volts and starter is inoperative, starter has an internal fault.

Repair or replace as required.

1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

Fig. 1: Direct Drive Starter Circuit Diagrams

Courtesy of MAZDA MOTORS CORP.

STARTER INTERLOCK SWITCH (CLUTCH START SWITCH)

Switch is mounted on bracket near top front of clutch pedal. Disconnect switch harness connector. Using ohmmeter, ensure continuity exists between switch connector terminals when clutch pedal is depressed. If

Microsoft

1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive continuity does not exist, adjust or replace switch.

BENCH TESTS (ASSEMBLED)

NO-LOAD TEST

Connect fully-charged 12-volt battery, voltmeter and ammeter to starter. See Fig. 2 . Using remote starter wires or jumper, engage solenoid. Starter should spin smoothly. Note/record meter readings and check no-load specification. See NO-LOAD TEST SPECIFICATIONS table. If not within specification, disassemble and inspect starter components.

NO-LOAD TEST SPECIFICATIONS

Application

B2200 (M/T), Miata, Protege (M/T) & 323

Voltage

Current

Shaft Speed

Specification

11.5 Volts

60 Amps Maximum

6500 RPM

Microsoft

1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

Fig. 2: Testing Direct Drive Starter Circuits

Courtesy of MAZDA MOTORS CORP.

SOLENOID TESTS

Microsoft

1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

NOTE: Solenoid tests must be performed with starter assembled and field lead ("M" terminal wire) disconnected at the solenoid.

CAUTION: Do not engage starter solenoid for more than 10 seconds during testing or damage to coil winding may result.

SOLENOID PULL-IN TEST

Connect positive battery lead to solenoid "S" terminal and negative battery lead to solenoid case. Starter pinion drive gear should extend quickly and maintain this position. If starter pinion drive gear does not extend, replace solenoid. See Fig. 2 .

SOLENOID RETURN TEST

Connect positive battery lead to solenoid "M" terminal and ground negative battery lead to starter body. Using screwdriver, pry overrunning clutch pinion drive outward. Release screwdriver and ensure overrunning clutch pinion drive returns to original position. See Fig. 2 .

SOLENOID

1. Disconnect all wires to solenoid. Using ohmmeter, ensure continuity between "S" and "M" terminals, and between "S" terminal and solenoid body. See Fig. 1 . If continuity does not exist between these terminals, solenoid must be replaced.

2. Next ensure continuity does not exist between "M" and "B" terminals. If continuity exists between these terminals, solenoid is shorted and must be replaced.

PINION GAP ADJUSTMENT

1. Ensure field wire is disconnected from solenoid "M" terminal. Connect positive battery lead to "S" terminal and negative battery lead to starter case. Starter pinion drive gear will extend outward and stop.

2. Quickly measure pinion gap clearance between end of pinion drive and circlip retainer. See Fig. 3 . DO

NOT operate starter solenoid for more than 10 seconds. Pinion gap clearance should be .02-.08" (0.5-2.0 mm).

3. If pinion gap clearance is not within specification, adjust by increasing or decreasing thickness of solenoid shims located between solenoid and drive housing.

Microsoft

1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

Fig. 3: Adjusting Pinion Gap

Courtesy of MAZDA MOTORS CORP.

BENCH TESTING (DISASSEMBLED)

Microsoft

1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

ARMATURE TESTING

1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.

2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If continuity exists, the armature is shorted and must be replaced. Check continuity between commutator and shaft. If continuity exists, replace armature.

3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.

COMMUTATOR TESTING

1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted, turn commutator in a lathe.

2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning. See COMMUTATOR SPECIFICATIONS table.

3. Commutator mica undercut depth should be .02 -.03" (.5 -.8 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut to standard depth.

COMMUTATOR SPECIFICATIONS

Maximum Runout In.

(mm)

Minimum Diameter

In. (mm) Application

B2200 (M/T)

Protege (M/T) & 323

Miata

.004 (.10)

.001 (.03)

1.22 (31)

BRUSH TESTING

1. Connect ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, brush holder assembly is shorted and must be replaced.

2. Check brush length. If less than specification, replace brushes. See BRUSH LENGTH

SPECIFICATIONS table. Use brush spring scale to check spring tension. Spring tension is measured at point where spring separates from brush.Tension should be greater than 2 lbs. (0.9 kg). Tension specification for a new spring is 3.1-5.7 lbs. (1.4-2.6 kg). Brushes must move freely in holders.

BRUSH LENGTH SPECIFICATIONS

Application Standard In. (mm)

All Models .67 (17.0)

Minimum In. (mm)

.45 (11.5)

FIELD COIL TESTING

1. Connect one ohmmeter lead to field coil lead ("M" terminal lead). Connect other lead to soldered portion of brush lead. If continuity does not exist, repair or replace field coil.

2. Check field coil for shorts to ground by connecting ohmmeter lead to field coil lead. Connect other lead

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1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive to field coil housing. If continuity exists, repair or replace field coil.

OVERRUNNING CLUTCH PINION DRIVE

Hold overrunning clutch housing and turn pinion gear by hand. If pinion turns in both directions, clutch is faulty and must be replaced. DO NOT clean overrunning clutch with solvent, as it is packed with grease and sealed by manufacturer.

REMOVAL & INSTALLATION

1. Disconnect negative battery cable. Raise vehicle on hoist. Remove undercover. Disconnect wiring from starter. Remove differential lock assembly (4WD models). On Protege (M/T) and 323 models, remove support brace from under intake manifold. Remove starter mounting bolts. Remove lowest mounting bolt last. Remove starter from under side of vehicle.

2. To install starter, reverse removal procedure. Tighten mounting bolts to 23-24 ft. lbs. (31-46 N.m).

Tighten battery terminal nut to 87-104 INCH lbs. (9.8-12 N.m).

OVERHAUL

DISASSEMBLY & ASSEMBLY

1. Mark rear cover, field coil housing and front drive housing for reassembly reference. Remove solenoid and shims, rear cover and brush plate. Remove field coil housing and pull armature and yoke lever from front drive housing. See Fig. 4 & Fig. 5 . Use arbor press to remove circlip, stopper and pinion drive from armature shaft. See Fig. 6 .

2. To assemble, reverse removal procedures. Lubricate solenoid plunger, yoke lever and armature bushings.

Use arbor press and pinion drive to install stopper and circlip on armature shaft. See Fig. 6 . Ensure brush plate, rear cover and field coil housing are aligned when installing through bolts.

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1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

Fig. 4: View of Direct Drive Starters (Miata, Protege, 323 & MX-3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

Fig. 5: Exploded View of Direct Drive Starters (B2200)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

Fig. 6: Removing & Installing Armature Circlip & Stopper

Courtesy of MAZDA MOTORS CORP.

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STEERING COLUMN 1991 STEERING Mazda - Steering Columns

STEERING COLUMN

1991 STEERING Mazda - Steering Columns

DESCRIPTION

The steering column consists of solid steering shaft with a lower joint assembly. Miata and RX7 convertible models are equipped with Air Bag Restraint System consisting of an air bag module and clockspring connector assembly located in the steering column.

WARNING: Wait about 10 minutes after disabling air bag system before servicing. Air bag system voltage is maintained for about 10 minutes after system is disabled. Failure to wait 10 minutes before servicing system may cause accidental air bag deployment and possible personal injury.

REMOVAL & INSTALLATION

STEERING WHEEL & HORN PAD

CAUTION: DO NOT strike steering shaft with a hammer as it may collapse.

Removal & Installation (B2200, B2600i, MPV & 929)

Unsnap horn pad cover. Remove steering wheel lock nut. Use a puller to remove steering wheel. To install, reverse removal procedure.

WARNING: Before servicing Miata and RX7 convertible models, disconnect and shield battery ground. Use caution when working around steering column as air bag could deploy.

Removal & Installation (Miata & RX7)

1. On Miata and RX7 convertible models, remove air bag module. See AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section. For all models, remove horn cap (if equipped).

2. Remove steering wheel nut. Remove steering wheel with steering wheel puller. To install, reverse removal procedure. Tighten steering wheel nut and air bag nuts to specification. See TORQUE

SPECIFICATIONS TABLE at end of article.

1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Removal & Installation (MX-6 & 626)

Pry ornament cap from horn pad with wide-blade screwdriver. Remove steering wheel nut. Use a puller to remove steering wheel. To install, reverse removal procedure.

Removal & Installation (Protege & 323)

Remove 2 horn pad screws from behind steering wheel. Remove horn pad. Remove steering wheel nut. Use a puller to remove steering wheel. To install, reverse removal procedure.

COMBINATION SWITCH

Removal (Miata & RX7 Convertible)

See STEERING WHEEL & HORN PAD under REMOVAL & INSTALLATION. Remove steering wheel.

Remove column covers. Remove screws and remove combination switch with clockspring connector assembly.

Installation

1. Install combination switch and clockspring assembly. Before installing steering wheel, center clockspring. To center clockspring, set front wheels straight ahead. Turn clockspring connector clockwise until it stops. DO NOT force it.

2. Return connector 2 3/4 turns (counterclockwise). Rotate clockspring connector further (if necessary) to align marks on connector and outer housing. See Fig. 1 .

3. Install steering wheel. Tighten steering wheel nut to specification. See TORQUE SPECIFICATIONS

TABLE at end of article. Install air bag module. See AIR BAG article in the ACCESSORIES/SAFETY

EQUIPMENT section.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 1: Aligning Clockspring Connector Alignment Marks

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (All Others)

Remove steering wheel. See STEERING WHEEL & HORN PAD under REMOVAL & INSTALLATION.

Remove steering column covers. Disconnect combination switch connectors. Remove combination switch. To install, reverse removal procedure.

IGNITION SWITCH & STEERING LOCK

Removal & Installation (All Models)

1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and

COMBINATION SWITCH.

2. Remove ignition switch connectors. Remove ignition switch-to-steering lock screw. Remove ignition switch.

3. With a hammer and chisel, make a groove on steering lock assembly shear screws. Remove 2 shear screws with screwdriver. Remove ignition switch/steering lock assembly. To install, reverse removal procedure. Tighten NEW shear screws until head breaks off.

STEERING COLUMN

CAUTION: Excessive pressure or impact to mainshaft during service may cause column to collapse.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Removal & Installation (B2200, B2600i, Miata, Protege, RX7,

323 & 929)

1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and

COMBINATION SWITCH under REMOVAL & INSTALLATION. See Fig. 2 -8. Remove steering lock assembly. See IGNITION SWITCH & STEERING LOCK under REMOVAL &

INSTALLATION.

2. Remove lower panel and air duct (if necessary). Remove steering column-to-intermediate shaft "U" joint bolt. Remove steering column-to-firewall nuts. Remove lower joint dust cover (if equipped). Remove steering column upper bracket bolts. Remove steering column.

3. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS

TABLE at end of article.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 2: Exploded View of Tilt Steering Column (B2200 & B2600i)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 3: Exploded View of Steering Column (Miata)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 4: Exploded View of Steering Column (MPV)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 5: Exploded View of Steering Column (MX-6 & 626)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 6: Exploded View of Steering Column (Protege & 323)

Courtesy of MAZDA MOTORS CORP.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 7: Exploded View of Steering Column (RX7)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 8: Exploded View of Steering Column (929)

Microsoft

1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (MPV, MX-6 & 626)

1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and

COMBINATION SWITCH under REMOVAL & INSTALLATION. Remove steering lock assembly.

See IGNITION SWITCH & STEERING LOCK under REMOVAL & INSTALLATION.

2. Remove lower dash panel and A/C duct. Remove lower column cover and steering shaft-to-intermediate shaft "U" joint bolt. On MPV with A/T, remove shift lever mechanism.

3. On all models, separate steering shaft from intermediate shaft. Remove steering column upper bracket bolts. Remove steering column. To install, reverse removal procedure. Tighten bolts to specification. See

TORQUE SPECIFICATIONS TABLE at end of article.

OVERHAUL

STEERING COLUMN

NOTE: Steering shaft dimension for 929 is not available from manufacturer.

Disassembly

Remove wiring and switches. Clamp column in vise. Turn steering shaft to remove. With a hammer and chisel, make a groove in steering lock assembly shear screws. Remove shear screws. Remove steering lock.

Inspection

Check all components for damage or wear. Check steering shaft for bends, damage or sheared plastic pins.

Check bearings for excessive play. Replace parts as necessary. Measure length of steering shaft. See Fig. 9 .

Reassembly

To reassemble, reverse disassembly procedure. Grease steering shaft, bushings and bearings. Always use NEW shear screws.

STEERING SHAFT DIMENSIONS

(1)

Application

B2200 & B2600i

Miata

Length - In. (mm)

32.69-32.99 (830.0-835.6)

22.09-23.02 (561.1-584.7)

MPV

MX-6 & 626

Protege & 323

RX7

929

24.05-24.17 (611.0-614.0)

24.00-24.05 (609.6-611.1)

23.86-23.94 (606.0-608.0)

32.05-32.17 (814.0-817.0)

(2)

See Fig. 9 for measuring points.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

(1)

(2) Information is not available.

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1991 Mazda MX-5 Miata

STEERING COLUMN 1991 STEERING Mazda - Steering Columns

Fig. 9: Measuring Steering Shaft Dimensions (Except 929)

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Application

Column Bracket Bolts/Nuts

Steering Shaft "U" Joint Bolts

Steering Wheel Nut

Tilt Lever Adjusting Nut

Ft. Lbs. (N.m)

12-17 (16-23)

13-20 (18-27)

29-36 (39-49)

INCH Lbs. (N.m)

16-25 (1.8-2.8)

Microsoft

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

MAZDA

1.6L & 1.8L 4-Cylinder - 1986-95

MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE

For 1992 and earlier model years, the manufacturer recommends the belt be replaced every 60,000 miles. For

1993-95 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

REMOVAL & INSTALLATION

TIMING BELT

Removal (MX-3, Protege & 323)

1. Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right splash panels.

2. Remove drive belts and water pump pulley. See Fig. 1 , Fig. 2 or Fig. 3 . Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft stationary, and remove crankshaft pulley bolts and pulley. Remove crankshaft pulley hub bolt and hub.

3. Remove timing belt covers. If timing belt is to be reused, mark timing belt rotation direction. Align timing marks on camshaft sprocket(s). See Fig. 4 (SOHC) or Fig. 5 (DOHC) . Loosen timing belt tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully expanded. Remove timing belt.

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Fig. 1: Exploded View Of Timing Belt & Components (1989 SOHC)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Fig. 2: Exploded View Of Timing Belt & Components (1990 & Later SOHC)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Fig. 3: Exploded View Of Timing Belt & Components (DOHC Except MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Fig. 4: Aligning Camshaft Timing Marks (SOHC Engines)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Fig. 5: Aligning Camshaft Timing Marks (DOHC 1.8L Engines)

Courtesy of MAZDA MOTORS CORP.

Removal (MX-5 Miata - DOHC)

1. Disconnect negative battery cable. Drain cooling system. Remove radiator hose and by-pass hoses from thermostat housing. Remove air cleaner intake duct assembly from throttle body to air cleaner filter housing. Remove splash shield.

2. Remove drive belt(s) and water pump pulley. See Fig. 6 . Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft pulley stationary. Remove crankshaft pulley bolts. Remove pulley. Remove crankshaft pulley hub bolt and hub.

3. Remove cylinder head cover. Remove upper, center and lower timing belt cover. If timing belt is to be reused, mark timing belt rotation direction. Ensure timing marks on camshaft sprockets are aligned. See

Fig. 7 . Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully expanded. Remove timing belt.

Microsoft

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Fig. 6: Exploded View Of Timing Belt & Components (DOHC MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Fig. 7: Aligning Camshaft Timing Marks (DOHC MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Inspection (All Models)

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1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary.

Installation (All Models)

1. Position notch on crankshaft sprocket to 12 o'clock position (aligned with mark on oil pump). Align timing marks on camshaft sprocket(s). For SOHC, see Fig. 4 . For DOHC, see Fig. 5 or Fig. 7 . Ensure crankshaft timing mark is at TDC. Install belt around crankshaft sprocket, then working in a counterclockwise direction, route belt around camshaft sprocket(s).

2. Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete turns in direction of normal engine rotation. Ensure timing marks align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure.

3. On all engines, check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 8 .

Ensure timing belt deflection is within specification. See TIMING BELT DEFLECTION table. Adjust drive belts to proper tension.

TIMING BELT DEFLECTION

Application

1986-89

1990-95

DOHC

SOHC

(1)

Deflection - In. (mm)

.47-.51 (11.9-13.0)

.35-.45 (9.0-11.5)

.43-.51 (11.0-13.0)

(1) Deflection measurement is with 22 lbs. (10 kg) of pressure applied to timing belt. See Fig. 8 .

Microsoft

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Fig. 8: Measuring Timing Belt Deflection

Microsoft

1991 Mazda MX-5 Miata

MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Application

A/C Compressor Bracket

MX-3, Protege & 323

MX-5 Miata

Alternator Top Bolt

Camshaft Sprocket Bolt

Crankshaft/Timing Belt Sprocket Bolt

1986-91

1992-95

Power Steering Pump-To-Bracket Bolt

MX-3, Protege & 323

Timing Belt Tensioner Bolt

DOHC

SOHC

Camshaft/Rocker Cover Bolt

DOHC & SOHC (Top)

SOHC (Timing Belt Cover-To-Camshaft Cover)

Crankshaft Pulley Bolts

Ft. Lbs. (N.m)

17-26 (23-35)

11-16 (15-22)

27-38 (37-52)

36-45 (49-61)

80-87 (109-118)

116-123 (157-167)

27-38 (37-52)

14-19 (19-26)

INCH Lbs. (N.m)

43-78 (5-9)

69-95 (8-11)

109-152 (12-17)

Microsoft

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