Mazda MX-5 1997 Workshop Manual

Document

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

GENERATOR & REGULATOR

1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

DESCRIPTION & OPERATION

Generator is a conventional 3-phase, self-rectifying type with 6 diodes (3 positive and 3 negative) that rectify current. Internal regulator is solid-state type.

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

New Belt

Used Belt

(1) With 22 lbs. (10 kg) applied to belt.

(1)

Deflection - In. (mm)

0.22-0.28 (5.5-7.0)

0.24-0.30 (6.0-7.5)

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.

TROUBLE SHOOTING PRECAUTIONS

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



Obtain code number and deactivate audio anti-theft system before disconnecting battery (if equipped).



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

DO NOT use high voltage type testers.



Battery voltage should always exist at generator terminal "B".

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



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

DO NOT apply battery voltage to terminal "L".

ON-VEHICLE TESTING

* PLEASE READ FIRST *

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

NOTE: Check generator 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 generator terminal "B" does not contact ground.

GENERATOR OUTPUT

1. Connect an ammeter (100-amp minimum) in-line between generator terminal "B" connector and terminal

"B" of wiring harness connector. See Fig. 1 . Turn headlights and all accessories on. Depress brake pedal.

Operate engine at 2500-3000 RPM.

2. Measure and record generator output. See GENERATOR MAXIMUM RATED OUTPUT table. If amperage is as specified, go to next step. If amperage is not as specified, repair or replace generator.

3. Turn off headlights and all accessories. Release brake pedal. Operate engine at 2500-3000 RPM and measure amperage under no-load condition. No-load amperage should be 5 amps or greater. If amperage is as specified, go to next step. If amperage is not as specified, repair or replace generator.

4. Operate engine at 2500-3000 RPM. Measure voltage between ground and terminals "S" and "L". If 14.1-

14.7 volts does not exist, repair or replace generator. If 14.1-14.7 volts exists, generator output is okay.

GENERATOR MAXIMUM RATED OUTPUT

Application

A/T

M/T

Amps

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 1: Identifying Generator Terminals

Courtesy of MAZDA MOTORS CORP.

BENCH TESTING

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

RECTIFIER/DIODE ASSEMBLY

1. Using an ohmmeter, check continuity of each diode in both directions (polarity). See Fig. 2 thru Fig. 4 . 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, diode is shorted. If diode shows high resistance in both directions, diode is open. If any diode is defective, replace rectifier assembly.

ROTOR & SLIP RINGS

Measure resistance between rotor slip ring contacts. See Fig. 5 thru Fig. 9 . If resistance is not within specification, replace rotor. See ROTOR RESISTANCE SPECIFICATIONS table. Check continuity between individual slip rings and rotor core/shaft. If continuity exists, replace rotor.

ROTOR RESISTANCE SPECIFICATIONS

Application

Miata

(1) If continuity does not exist, replace rotor.

(1)

Ohms

3.5-4.5

STATOR

Check continuity between stator coil leads and stator core. See Fig. 5 thru Fig. 9 . If continuity exists, replace stator. Check continuity between leads of stator coil. If continuity does not exist, replace stator.

BRUSHES

Replace brushes if worn to limit line. See Fig. 5 thru Fig. 9 . Replace brush springs if corroded. For brush replacement procedure, see OVERHAUL .

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 2: Testing Rectifier Diodes

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 3: Rectifier Schematic

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 4: Rectifier Continuity Test Chart

Courtesy of MAZDA MOTORS CORP.

Fig. 5: Testing Generator Stator, Rotor & Brushes

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 6: Checking Stator Winding Continuity

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 7: Measuring Brush Wear

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 8: Checking Rotor For Shorts

Courtesy of MAZDA MOTORS CORP.

Fig. 9: Checking Rotor Resistance

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

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. 10 thru Fig. 15 and

Fig. 17 .

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. 16 . 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. 10 thru Fig. 15 . Note reading on spring scale. Replace spring if tension is not 5.6-15.5 ozs. (160-440 g).

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 10: Heating Rear Bearing Housing

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 11: Removing Rear Bearing

Courtesy of MAZDA MOTORS CORP.

Fig. 12: Unsoldering Rectifier From Regulator

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 13: Replacing Brushes

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 14: Measuring Brush Spring Tension

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 15: Inserting Wire To Retain Brushes For Reassembly

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 16: Measuring Installed Depth Of Brush

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 17: Exploded View Of Generator

Courtesy of MAZDA MOTORS CORP.

WIRING DIAGRAMS

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Microsoft

1997 Mazda MX-5 Miata

GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

Fig. 18: Charging System Wiring Diagram

Microsoft

CLUTCH 1997-98 CLUTCHES Mazda - RWD

CLUTCH

1997-98 CLUTCHES Mazda - RWD

DESCRIPTION

All models use a hydraulically operated clutch. On all models except Miata, the clutch release bearing and clutch release cylinder are combined into a single unit. No routine adjustments are necessary on B2300, B2500,

B3000 and B4000 models.

ADJUSTMENTS

CLUTCH PEDAL FREE PLAY

Miata

Measure clutch pedal free play. See Fig. 1 . See CLUTCH PEDAL FREE PLAY table. If free play is not within specification, inspect hydraulic and mechanical system components. If adjustment is required, loosen lock nut and rotate master cylinder push rod to obtain specified free play. Tighten lock nut.

CLUTCH PEDAL FREE PLAY

(1)

Application

Miata

In. (mm)

0.2-0.5 (5-13)

(1) See Fig. 1 .

CLUTCH PEDAL HEIGHT

Miata

Measure clutch pedal height from bulkhead to front side of pedal pad. See Fig. 1 . See CLUTCH PEDAL

HEIGHT table.

CLUTCH PEDAL HEIGHT

(1)

Application

Miata

In. (mm)

6.89-7.28 (175-185)

(1) Measure to carpet on bulkhead. See Fig. 1 .

CLUTCH DISENGAGEMENT HEIGHT

Miata

Measure clutch disengagement height, where clutch disengages, from pedal pad to bulkhead. See Fig. 1 . See

CLUTCH DISENGAGEMENT HEIGHT (MINIMUM) table.

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

CLUTCH DISENGAGEMENT HEIGHT (MINIMUM)

(1)

Application

Miata

(1) Measure to carpet on bulkhead. See Fig. 1 .

In. (mm)

2.68 (68)

Fig. 1: Adjusting Clutch Pedal (Miata)

Courtesy of MAZDA MOTORS CORP.

HYDRAULIC SYSTEM BLEEDING

B2300, B2500, B3000 & B4000

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

1. Using Clutch Disconnect Tool (T88T-70522-A), disconnect hydraulic line at transmission. See Fig. 2 .

Clean reservoir cap area. Fill reservoir with DOT 3 brake fluid. Maintain fluid level in reservoir during bleeding procedure.

2. Using small screwdriver, press and hold internal mechanism of male coupler to open valve. While holding valve open, have an assistant slowly press and hold clutch pedal to floor.

3. Remove screwdriver to allow valve to close. Release clutch pedal. Refill reservoir.

4. Repeat steps 2) and 3). Install reservoir cap. Reconnect hydraulic line. Tug hydraulic line lightly to verify secure connection.

5. As rapidly as possible, operate clutch pedal for full 5-10 strokes. Wait 3 minutes. Repeat this step at least

3 more times.

6. Loosen bleed screw, located next to release cylinder connection. Have an assistant press and hold clutch pedal. Tighten bleed screw. Release pedal. Refill reservoir. Check clutch operation.

Fig. 2: Removing Hydraulic Line (B2300, B2500, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.

Miata

1. Remove bleeder screw cap located at clutch release cylinder. Install vinyl hose onto bleeder screw.

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Submerge other end of hose in container of brake fluid.

2. Fill reservoir with DOT 3 brake fluid. Have an assistant press and release clutch pedal several times, then hold pedal down. With pedal pressed, loosen bleeder screw to let air and fluid escape.

3. Repeat step 2) until no more air bubbles emerge from hose. Tighten bleeder screw. Fill reservoir. Operate clutch while inspecting for leaks. Check clutch and brake operation.

REMOVAL & INSTALLATION

CLUTCH ASSEMBLY

Removal (B2300, B2500, B3000 & B4000)

1. Disconnect negative battery cable. Shift transmission into Neutral. Remove gearshift lever. Raise and support vehicle. Mark drive shaft flanges for installation reference. Remove drive shaft. Using Clutch

Disconnect Tool (T88T-70522-A), disconnect hydraulic line at transmission. See Fig. 2 . Plug hydraulic line to prevent contamination. Disconnect wiring at transmission.

2. Remove starter. Remove exhaust components as necessary for clearance. On 4WD models, remove skid plate and transfer case. On all models, secure transmission jack under transmission. Remove transmission mount-to-crossmember nuts and bolts.

3. Remove nuts securing crossmember to frame side rails, and remove crossmember. Lower transmission enough to gain access to transmission-to-engine block bolts. Remove transmission-to-engine block bolts.

Remove transmission.

4. If clutch parts are going to be reused, mark clutch cover and flywheel for reassembly reference. Loosen pressure plate bolts evenly in crisscross pattern until springs are not under tension. Remove clutch cover and clutch disc.

Inspection (B2300, B2500, B3000 & B4000)

1. Inspect disc for loose rivets, worn or defective springs, excessive wear, or oil contamination. Inspect flywheel and clutch cover for burns, scoring, or grooves.

2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond specification. See CLUTCH RUNOUT (MAXIMUM) table.

3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT

(MAXIMUM) table. Inspect disc hub and input shaft splines for excessive wear. Hub must slide smoothly on input shaft splines.

4. Inspect pilot bearing for wear. Apply inward pressure while rotating pilot bearing. If bearing sticks or has excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect release bearing for smooth operation, wear, damage, or looseness. Replace bearing as necessary.

CLUTCH RUNOUT (MAXIMUM)

Application

Disc

Flywheel

In. (mm)

0.028 (0.7)

0.008 (0.20)

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Installation (B2300, B2500, B3000 & B4000)

1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a crisscross pattern to specification. See TORQUE SPECIFICATIONS .

2. Raise transmission into position. Install and tighten transmission-to-engine block bolts. See TORQUE

SPECIFICATIONS . Install crossmember.

3. On 4WD models, install NEW transfer case gasket. Install transfer case. Tighten transfer case bolts to specification is sequence. See Fig. 3 . See TORQUE SPECIFICATIONS .

4. On all models, to complete installation, reverse removal procedure. Bleed hydraulic clutch system. See

HYDRAULIC SYSTEM BLEEDING under ADJUSTMENTS.

Fig. 3: Tightening Transfer Case Bolts (B2300, B2500, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.

Removal (Miata)

1. Disconnect negative battery cable. Remove gearshift knob, console, and shift lever. See Fig. 4 . Raise and support vehicle. Remove engine undercover. Disconnect exhaust pipe from manifold. Mark drive shaft flanges for installation reference. Remove drive shaft.

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Fig. 4: Exploded View Of Drive Line (Miata)

Courtesy of MAZDA MOTORS CORP.

2. Remove clutch release cylinder. Remove starter. Disconnect speedometer cable from transmission. Note locations, and disconnect wiring harness from Power Plant Frame (PPF).

3. Remove PPF bracket from rear transmission extension housing. Remove PPF-to-differential side bolts.

Pry out spacer. Remove PPF/differential mounting spacer. See Fig. 5 .

4. Thread M14 X 1.5 bolt into sleeve. See Fig. 6 . Twist bolt side to side while pulling it downward. Thread

M6 X 1 bolt into hole in housing block to hold sleeve. Remove long bolt. Remove short bolt.

NOTE: Do not remove spacers attached to top of Power Plant Frame (PPF). If they are removed, replace PPF.

5. Remove PPF side bolts. Remove PPF. Remove transmission-to-engine block bolts. Remove transmission.

Remove clutch cover bolts evenly in crisscross pattern. Remove clutch cover and disc. See Fig. 7 .

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Fig. 5: Installing & Removing Power Plant Frame (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Fig. 6: Removing Reamer Bolt Sleeve (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Fig. 7: Exploded View Of Clutch Assembly (Typical)

Courtesy of MAZDA MOTORS CORP.

Inspection (Miata)

1. Inspect disc for loose rivets, worn springs, excessive wear, or oil contamination. Inspect flywheel and clutch cover for burns, scoring, or grooves.

2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond specification. See CLUTCH RUNOUT (MAXIMUM) table. If flywheel ring gear is replaced, ensure chamfer on flywheel teeth faces engine.

3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT

(MAXIMUM) table. Inspect disc hub and input shaft splines for excessive wear. Hub must slide smoothly on input shaft splines.

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Installation (Miata)

2. Place a wooden block on jack, and position jack under front of oil pan. Raise front of engine to ease transmission installation. Install transmission. Tighten transmission-to-engine block bolts to specification.

See TORQUE SPECIFICATIONS . Place jack (from front of engine) under transmission.

3. Raise transmission until level with engine. Position Power Plant Frame (PPF) in place. Install

PPF/differential mounting spacer, and tighten bolts to 27-38 ft. lbs. (37-51 N.m). Install and tighten PPF side mounting bolts.

NOTE: Front PPF-to-differential side mounting bolt is the reamer bolt, used to align frame.

4. Install sleeve into PPF housing block. Install spacer and bolts. Install reamer bolt into front hole, and tighten bolt. See Fig. 5 .

5. Install transmission-to-PPF bracket. Install remaining PPF bolts, and tighten to specification. See

TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

RELEASE BEARING & FORK

Removal (B2300, B2500, B3000 & B4000)

With transmission removed, twist release bearing and carrier assembly until preload spring pushes bearing assembly from slave cylinder. See Fig. 8 .

NOTE: Use only lithium base grease on release bearing. DO NOT use petroleum base lubricants.

Installation

Lubricate bearing bore and bearing carrier with NIGI No. 2 (lithium base) grease. Push release bearing assembly onto clutch slave cylinder.

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Fig. 8: Servicing Clutch Release Bearing (B2300, B2500, B3000 & B4000)

Courtesy of FORD MOTOR CO.

Removal & Installation (Miata)

1. Remove transmission. See CLUTCH ASSEMBLY . Remove release bearing and fork. Turn release bearing in both directions. Replace bearing if rough or noisy.

2. Inspect release fork for wear and damage. Replace if necessary. Apply molybdenum disulfide grease to release bearing contact and sliding surfaces. To complete installation, reverse removal procedure.

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

CLUTCH MASTER CYLINDER

Removal (B2300, B2500, B3000 & B4000)

1. Disengage master cylinder push rod from clutch pedal. Disconnect clutch/starter interlock switch connector. See Fig. 9 .

2. Using Clutch Disconnect Tool (T88T-70522-A), disconnect hydraulic line. See Fig. 2 . Pull hydraulic line to disconnect line from clutch slave cylinder. Remove master cylinder, reservoir, and hydraulic line.

Plug lines.

Fig. 9: Removing Clutch/Starter Interlock Switch (B2300, B2500, B3000 & B4000)

Courtesy of FORD MOTOR CO.

Microsoft

CAUTION: Disconnect master cylinder push rod if slave cylinder is to be disconnected from release lever or bearing. Permanent damage to master cylinder will occur if master cylinder is activated with slave cylinder

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD disconnected.

Installation

Insert master cylinder push rod through opening in bulkhead. Install master cylinder. Connect hydraulic lines.

Install fluid reservoir. Install push rod on clutch pedal. Bleed hydraulic system. See HYDRAULIC SYSTEM

BLEEDING .

Removal & Installation (Miata)

Disconnect hydraulic line and master cylinder mounting nuts. Disengage push rod from clutch pedal. Remove master cylinder. To install, reverse removal procedure and bleed hydraulic system. See HYDRAULIC

SYSTEM BLEEDING .

CLUTCH RELEASE CYLINDER

Removal & Installation (B2300, B2500, B3000 & B4000)

Release cylinder is removed with clutch. See CLUTCH ASSEMBLY.

Removal & Installation (Miata)

Raise and support vehicle. Disconnect and plug hydraulic line. Remove clutch release cylinder. To install, reverse removal procedure. Bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING .

OVERHAUL

NOTE: Overhaul procedures for B2300, B2500, B3000 and B4000 are not available.

CLUTCH MASTER CYLINDER

NOTE: Use exploded view of clutch master cylinder for overhaul procedure. See Fig.

10 .

Microsoft

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Fig. 10: Exploded View Of Clutch Master Cylinder (Miata)

Courtesy of MAZDA MOTORS CORP.

CLUTCH RELEASE CYLINDER

Microsoft

NOTE:

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

Use exploded view of clutch release cylinder for overhaul procedure. See Fig.

11 .

Fig. 11: Exploded View Of Clutch Release Cylinder (Miata)

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Application

B2300, B2500, B3000 & B4000

Clutch Cover Bolts

(1)

Crossmember Nuts

Drive Shaft Bolts

Flywheel-To-Crankshaft Nuts

Gearshift Lever Bolt

Starter Mounting Bolts

Transfer Case Bolts (4WD)

(2)

Transmission-To-Engine Block Bolts

Miata

Clutch Cover Bolts

(1)

Drive Shaft Nuts

Flywheel-To-Crankshaft Bolts

PPF-To-Differential Mounting Spacer Bolt (Short)

PPF-To-Differential Side Mounting Bolts (Long)

PPF-To-PPF Bracket Bolt

Microsoft

Sunday, July 05, 2009 1:36:47 PM

Ft. Lbs. (N.m)

17-24 (23-32)

39-53 (53-72)

65-87 (88-119)

54-67 (73-91)

20-30 (27-40)

17-20 (23-27)

35-46 (47-62)

37-50 (50-68)

13-19 (18-26)

37-43 (50-58)

71-76 (96-103)

27-38 (37-51)

77-91 (104-123)

27-40 (37-54)

1997 Mazda MX-5 Miata

CLUTCH 1997-98 CLUTCHES Mazda - RWD

PPF-To-Transmission Side Mounting Bolts (Long)

Starter Mounting Bolts

Transmission-To-Engine Block Bolts

Transmission-To-PPF Bracket Bolts

(1) Tighten in a crisscross pattern.

(2) Tighten in sequence. See Fig. 3 .

77-91 (104-123)

28-38 (38-51)

48-65 (64-89)

27-40 (37-54)

Microsoft

GENERAL INFORMATION Computer Relearn Procedures

GENERAL INFORMATION

Computer Relearn Procedures

COMPUTER RELEARN PROCEDURES

Vehicles equipped with engine or transmission computers may require a relearn procedure after vehicle battery is disconnected. Many vehicle computers memorize and store vehicle operation patterns for optimum driveability and performance. When vehicle battery is disconnected, this memory is lost. The computer will use default data until new data from each key start is stored. As computer memorizes vehicle operation for each new key start, driveability is restored. Vehicle computers may memorize vehicles operation patterns for 40 of more key starts.

Customers often complain of driveability problems during relearn stage because vehicle acts differently then before being serviced. Depending on type and make of vehicle and how it is equipped, the following complaints

(driveability problems) may exist:



Harsh Or Poor Shift Quality



Rough Or Unstable Idle

Hesitation Or Stumble



Rich Or Lean Running



Poor Fuel Mileage

These symptoms and complaints should disappear after a number of drive cycles have been memorized. To reduce the possibility of complaints, after any service which requires battery power to be disconnected, vehicle should be road tested.

GENERIC COMPUTER RELEARN PROCEDURES

Some manufacturers identify a specific relearn procedure which will help establish suitable driveability during relearn stage. These procedures are especially important if vehicle is equipped with and electronically controlled automatic transmission or transaxle. Always complete procedure before returning vehicle to customer. The following general procedures are to be used if driveability problems are encountered after power loss or battery has been disconnected. These procedures may provide an aid in eliminating these problems.

Automatic Transmission



Set parking brake, start engine in "P" or "N" position. Warm-up vehicle to normal operating temperature or until cooling fan cycles.



Allow vehicle to idle for one minute in "N" position. Select "D" and allow engine to idle for one minute.

Accelerate at normal throttle position (20-50%) until vehicle shifts into top gear.



Cruise at light to medium throttle.

Decelerate to a stop, allowing vehicle to downshift, and use brakes normally.



Process may be repeated as necessary.

1997 Mazda MX-5 Miata

GENERAL INFORMATION Computer Relearn Procedures

Manual Transmission



Place transmission in Neutral position.



Ensure emergency brake has been set and all accessories are turned off.



Start engine and bring to normal operating temperature.

Allow vehicle to idle in Neutral for one minute.



Initial relearn is complete, and process will be completed during normal driving.

Microsoft

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

1997-98 DRIVE AXLES

Differentials & Drive Axles - MPV & MX-5 Miata

AXLE RATIO & IDENTIFICATION

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

AXLE RATIO SPECIFICATIONS

Number Of Teeth Pinion/Ring

Gear Ratio Application

Miata

A/T

M/T

MPV

2WD

4WD (Front & Rear)

N/A

11/43

10/41

4.10:1

4.30:1

3.91:1

4.10:1

DESCRIPTION

NOTE: For models with independent suspension, see AXLE SHAFTS - REAR or AXLE

SHAFTS - FRONT article for axle shaft overhaul.

A Limited Slip Differential (LSD) is optional on Miata. On MPV, rear axle bearings are held in place by a pressed-on collar. Front axle on MPV 4WD and rear axle on Miata use CV joints to connect differential to axle hubs.

LUBRICATION

CAPACITY

DIFFERENTIAL CAPACITY SPECIFICATIONS

Application

Miata

MPV 2WD

MPV 4WD

Front

Rear

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

(1)

Qts. (L)

1.06 (1.00)

1.60 (1.50)

1.80 (1.70)

1.60 (1.50)

FLUID TYPE

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

DIFFERENTIAL LUBRICATION SPECIFICATIONS

Application

Warmer Than 0°F (-18°C)

Cooler Than 0°F (-18°C)

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

(1)

Specification

GL-5/SAE 90W

GL-5/SAE 80W

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

FRONT DIFFERENTIAL OIL SEAL REPLACEMENT (MPV)

1. Jack up the vehicle and support it on safety stands.

2. Drain the differential oil.

3. Mark front drive shaft flange for reassembly reference. Remove drive shaft.

4. Before loosening the locknut, measure the rotation starting torque of the drive pinion (within the range of the drive pinion and ring gear backlash).

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 1: Measuring Rotation Starting Torque (MPV)

Courtesy of MAZDA MOTORS CORP.

5. Hold the companion flange by using Flange Holder (49 S120 710), and remove the locknut.

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 2: Holding Companion Flange (MPV)

Courtesy of MAZDA MOTORS CORP.

6. Remove the companition flange by using Puller (49 0839 425C).

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 3: Removing Companion Flange (MPV)

Courtesy of MAZDA MOTORS CORP.

7. Remove the oil seal.

8. Apply a thin coat of lithium-based grease to the lip of a new oil seal, and install it by using the Seal

Installer (49 U027 003).

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 4: Installing Oil Seal (MPV)

Courtesy of MAZDA MOTORS CORP.

9. Install the companion flange and tighten the locknut to get the starting torque measured in step 4 .

10. Install the drive shaft. Tighten bolts to specfiication. See TORQUE SPECIFICATIONS . Add differential oil to the specified level. See FLUID TYPE .

REAR AXLE SHAFTS & BEARINGS

Removal (MPV)

1. Raise and support vehicle. Remove rear wheel and tire assembly. Remove brake caliper and support aside. Remove brake disc plate. See Fig. 5 . Using dial indicator, measure axle bearing play. Replace axle bearing if play exceeds .023" (.57 mm).

2. Remove hold pin from parking brake shoe assembly and remove parking brake shoe assembly.

Disconnect parking brake cable. Using Flare Nut Wrench (49-0259-770B), disconnect brake pipe. Plug brake pipe openings.

3. Remove rear axle shaft assembly-to-axle shaft housing retaining nuts. Using Puller (49-0223-630B) and

Attachment (49-8501-631A), remove rear axle shaft, backing plate and dust cover as an assembly from

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata axle shaft housing. Remove axle oil seal. See Fig. 5 . With axle shaft removed, remove retaining ring.

Remove ABS sensor rotor.

4. To remove bearing collar, grind collar until a section about .02" (.50 mm) remains. Using chisel, cut remaining bearing collar from axle shaft. Using Puller (49-S121-520A), remove axle bearing from axle shaft. Remove dust shield and backing plate.

5. Using dial indicator and "V" blocks, check axle shaft for straightness. Maximum axle shaft runout is .059" (1.50 mm). Also check axle shaft splines for wear and damage. Use a press to replace wheel studs as necessary. DO NOT reuse wheel studs if removed.

Installation

To install, reverse removal procedure. Lubricate oil seal lip before replacement. Use Attachment (49-1011-748) and a press to install axle bearing onto axle shaft. DO NOT lubricate bearing collar before replacement. Use

Attachment (49-1011-748) and a press to install NEW bearing collar. If press fit of collar requires less than 2.7 tons (2699 kg) to install, replace axle shaft. Tighten nuts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 5: Exploded View Of Rear Axle Shaft (MPV)

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL ASSEMBLY

Removal (Front MPV 4WD)

1. Raise and support vehicle. Remove engine skid plate. See Fig. 6 . Drain front differential fluid. Remove tie rod ends and lower control arms. Remove front axle shafts. See AXLE SHAFTS - FRONT article.

2. Mark drive shaft and differential carrier flanges for reassembly reference, and remove drive shaft from differential carrier. See Fig. 6 . Disconnect Automatic Free Wheel (AFW) vacuum hoses and electrical connector.

3. Place floor jack under differential assembly. Remove differential-to-chassis mounting bolts and AFW extension housing mounting nuts. Remove differential and AFW extension housing from vehicle.

Remove AFW assembly from left side of differential housing. Pull drive coupler from carrier. Remove differential carrier-to-housing bolts. Remove differential carrier.

Installation

To install, reverse removal procedure. Apply sealant to carrier mating flange. Align marks made during removal. Refill differential with lubricant. Tighten all nuts and bolts to specification. See TORQUE

SPECIFICATIONS.

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 6: Removing & Installing Front Differential (MPV 4WD)

Courtesy of MAZDA MOTORS CORP.

Removal (Rear MPV)

1. Raise and support vehicle. Remove wheel and tire assembly. Drain rear differential fluid. Remove axles.

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

See REAR AXLE SHAFTS & BEARINGS.

2. Remove ABS wheel speed sensor. Mark drive shaft and differential carrier flanges for reassembly reference and remove drive shaft from differential carrier. Remove differential carrier-to-housing bolts.

Remove differential carrier.

Installation

SPECIFICATIONS .

Removal (Miata)

1. Raise and support vehicle. Remove wheel and tire assembly. Drain differential. Remove differential mounting pipe. Remove exhaust pipe. Mark drive shaft and differential carrier flanges for reassembly reference and remove drive shaft from differential carrier. See Fig. 7 . Disconnect speedometer cable from transmission. Noting locations, disconnect wiring harness from Power Plant Frame (PPF).

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 7: Exploded View Of Differential Components (Miata)

Courtesy of MAZDA MOTORS CORP.

2. Support transmission using a jack. Remove PPF bracket from rear transmission extension housing (M/T only). Remove PPF-to-differential side bolts. Pry out spacer. Remove PPF/differential mounting spacer.

See Fig. 8 . Install bolt (M14 X 1.5) into sleeve. See Fig. 9 .

3. Twist bolt from side to side while pulling it 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. Remove caliper assembly. Remove lower arm bolt. Mark and disconnect CV joint axle shafts from differential assembly, and support aside.

5. Support differential assembly and remove differential-to-chassis mounting nuts. Remove differential from vehicle. Remove drive axle output shafts from carrier. Remove differential carrier-to-housing bolts.

Remove differential carrier.

Fig. 8: View Of Power Plant Frame (PPF) Components (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 9: Removing Reamer Bolt Sleeve (Miata)

Courtesy of MAZDA MOTORS CORP.

Installation

1. To install, reverse removal procedure. Apply sealant to carrier mating flange. Align marks made during removal and install axle shafts. Install differential. Raise transmission until engine and transmission are level.

2. Position Power Plant Frame (PPF) in place. Install PPF/differential mounting spacer. Tighten bolts to 27-

38 ft. lbs. (37-52 N.m). Install and tighten PPF-to-transmission side mounting bolts.

3. Ensure sleeve is installed into PPF housing block. Install spacer and bolts. Ensure reamer bolt is installed into front hole and tighten bolt. See Fig. 8 .

NOTE: Front PPF-to-differential side mounting bolt is reamer bolt which aligns

PPF. See Fig. 8 .

4. Install transmission-to-PPF bracket (M/T only). Install remaining PPF bolts. Refill differential with

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata lubricant. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

OVERHAUL

DIFFERENTIAL

NOTE: Mark positions of all components before disassembly.

NOTE: Overhaul procedure for Limited Slip Differential (LSD) is not available.

Disassembly (Standard Type)

1. Mount carrier in Differential Carrier Hanger (49-M005-561). Mark side bearing caps for reassembly reference. Remove adjuster lock plates (if equipped). See Fig. 10 .

2. Loosen side bearing cap bolts and slightly back off adjusters. Remove side bearing caps. Remove differential assembly from carrier. Mark side bearing races for reassembly reference. Remove adjusters and side bearing races from differential.

3. Remove drive pinion lock nut and washer. Remove companion flange using Puller (49-0839-425C).

Remove oil seal, spacer, front bearing and collapsible spacer from carrier. Remove drive pinion, spacer and rear bearing assembly from carrier. Remove bearing races using a drift and hammer in slots provided on inner lip (as necessary).

4. Remove ring gear retaining bolts. Separate ring gear from differential case. Mark side bearings for reassembly reference. Using Puller (49-0839-425C), remove side bearings from differential case. Remove knock pin. Remove pinion shaft, pinion gears, thrust washers, and side gears. See Fig. 10 .

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 10: Exploded View Of Standard Differential & Carrier Assembly

Courtesy of MAZDA MOTORS CORP.

Reassembly & Adjustment (Standard Type)

1. Install side gears, thrust washers, pinion gears and pinion shaft. Position dial indicator against pinion gear. See Fig. 11 . Secure one side gear.

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 11: Measuring Side Gear & Pinion Gear Backlash

Courtesy of MAZDA MOTORS CORP.

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

See THRUST WASHER SPECIFICATIONS table. Install and stake knock pin. Noting marks made during disassembly, press side bearings onto differential assembly using Bearing Installer (49-G030-338 or 49-UB71-525) and Body (49-F401-331).

THRUST WASHER SPECIFICATIONS

Identifying Mark Thickness - In. (mm)

0 .0787 (2.000)

.0807 (2.050)

.0827 (2.100)

.0846 (2.150)

.0866 (2.200)

3. 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). Using appropriate bearing installer set and press, install drive pinion bearing races into differential carrier.

4. Put original spacer, rear bearing and Collar (49-H027-001) on Dummy Drive Pinion (49-8531-565). See

Fig. 12 . Secure collar with "O" ring. Install assembly into differential carrier.

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

5. Install front bearing and collar on dummy drive pinion. See COLLAR SELECTION table. Install companion flange, washer and original drive pinion lock nut. Tighten drive pinion lock nut so dummy drive pinion assembly can be turned by hand.

COLLAR SELECTION

Application Collar No.

Miata 49-8531-567

MPV 49-U027-001

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 12: Checking Drive Pinion Installation & Position

Courtesy of MAZDA MOTORS CORP.

6. Install 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 dummy drive pinion assembly. See GAUGE

BLOCK SELECTION table.

GAUGE BLOCK SELECTION

Application Gauge Block No.

Front Differential

MPV

4WD

Rear Differential

Miata

MPV

49-0305-555

49-0660-555

7. Place pinion height gauge on top of gauge block. Position dial indicator to measure distance to a point where side bearing sits. Measure lowest point. See Fig. 12 . Measure both sides. Add both measurements together and divide by 2.

8. If result is not zero, replace pinion spacer. Spacers are available in a range of .1213-.1366" (3.080-3.470 mm) in .001" (.03 mm) increments. Remove dummy drive pinion. Press rear bearing onto drive pinion.

9. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential carrier.

DO NOT install pinion oil seal yet. DO NOT exceed one-ton force; collapsible spacer will be damaged.

10. Install washer and drive pinion lock nut. Temporarily tighten drive pinion lock nut. Turn companion flange by hand to seat bearing. Using torque wrench, tighten drive pinion lock nut to specification. See

TORQUE SPECIFICATIONS . Check pinion bearing preload at drive pinion lock nut. See PINION

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

PINION PRELOAD SPECIFICATIONS

Application INCH Lbs. (N.m)

Miata

MPV 2WD

MPV 4WD

7.8-12.1 (0.9-1.3)

11.3-15.6 (1.3-1.8)

Front

Rear

7.8-12.2 (0.9-1.4)

11.3-15.6 (1.3-1.8)

11. Remove drive pinion lock nut, washer and companion flange. Install pinion oil seal. Lubricate oil seal lip with differential oil. Install companion flange and washer. Install NEW drive pinion lock nut and tighten to specification. See TORQUE SPECIFICATIONS . Recheck pinion bearing preload. Lubricate end of companion flange with grease.

12. Position differential assembly into differential carrier. Install side bearing adjusters. Position side bearing caps. Align marks made during disassembly. Install side bearing cap bolts and hand-tighten bolts.

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

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

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

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

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

15. To set differential bearing preload, tighten adjusters equally until distance between measuring points on carrier bearing caps is within specification. See Fig. 13 . See DIFFERENTIAL CARRIER

DIMENSIONS table.

16. Ensure backlash did not change when preload was set. Tighten side bearing cap bolts to specification. See

TORQUE SPECIFICATIONS. Check ring gear tooth patterns. See GEAR TOOTH CONTACT

PATTERNS article in GENERAL INFORMATION.

17. To complete reassembly, reverse disassembly procedure. Tighten all nuts and bolts to specification. See

TORQUE SPECIFICATIONS .

DIFFERENTIAL CARRIER DIMENSIONS

Application

Miata

MPV 2WD

MPV 4WD

Front

Rear

(1) See illustration for measuring point. See Fig. 13 .

(1)

In. (mm)

7.300-7.303 (185.43-185.50)

8.022-8.050 (203.78-204.50)

7.275-7.303 (184.78-185.50)

8.022-8.050 (203.78-204.50)

Microsoft

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Fig. 13: Measuring Carrier Case Spread

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (MIATA)

Application

Differential Carrier Bearings Cap Bolts

Differential Carrier Bearings Lock Plate Bolt

Differential Carrier-To-Housing Bolts

Differential-To-Chassis Mount Nuts

Inner Nut

Outer Nuts (2)

Drive Axle Inner CV Joint Flange Nuts

Drive Pinion Lock Nut

Drive Shaft Companion Flange Nuts

Exhaust Pipe Mount Nuts

Filler Plug

Power Plant Frame Bracket

To-Power Plant Frame Bolt (M/T)

To-Transmission Bolts (M/T)

Microsoft

Sunday, July 05, 2009 1:52:42 PM

Ft. Lbs. (N.m)

28-38 (38-52)

13-18 (18-25)

17-19 (23-26)

61-72 (83-98)

13-20 (18-27)

40-47 (54-64)

94-209 (128-284)

20-22 (27-30)

30-41 (40-55)

29-40 (39-54)

Page 22

77-91 (104-123)

27-40 (37-54)

1997 Mazda MX-5 Miata

1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata

Power Plant Frame-To-Differential

Side Mounting Bolts (Long)

Spacer Bolt (Short)

Power Plant Frame-To-Transmission Side Mounting Bolts (Long)

Ring Gear Retaining Bolts

Wheel Lug Nuts

TORQUE SPECIFICATIONS (MPV)

Application

AFW Extension Housing Mount Nut (4WD)

Brake Pipe Union

Differential Carrier Bearings Cap Bolts Front Differential

Differential Carrier Bearings Cap Bolts Rear Differential

Differential Carrier Bearings Lock Plate Bolt

Differential Carrier-To-Housing Nuts/Bolts

Differential-To-Chassis Mount Nuts (4WD)

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 ABS Wheel Speed Sensor Bolt

Rear Axle Shaft Assembly-To-Axle Shaft Housing Retaining Nuts

Rear Brake Caliper Bolts

Ring Gear Retaining Bolts

Skid Plate Bolts (4WD)

Tie Rod End Nut (4WD)

Wheel Lug Nuts

77-91 (104-123)

27-38 (37-52)

77-91 (104-123)

51-61 (69-83)

65-87 (88-118)

Ft. Lbs. (N.m)

49-72 (66-98)

10-16 (14-22)

27-38 (37-52)

54-78 (73-106)

13-19 (18-26)

17-19 (23-26)

49-72 (66-98)

94-210 (127-284)

37-43 (50-58)

29-40 (39-54)

75-101 (102-137)

94-127 (127-172)

12-16 (16-22)

40-49 (54-66)

37-43 (50-58)

51-61 (69-83)

12-17 (16-23)

43-58 (58-78)

65-87 (88-118)

Microsoft

1997 MAZDA MX-5 Miata

1997 MAZDA

MX-5 Miata

BUZZERS, RELAYS & TIMERS

Component

A/C Relay

Condenser Fan Relay

Cooling Fan Relay

Flasher Unit

Fuel Pump Relay

Headlamp Relay

Horn Relay

INT Relay

Main Relay

Power Antenna Relay

Rear Window Defogger

Relay

Retractable Headlamp Relay

TNS Relay

Warning Unit

Component Location

In right front of engine compartment, near radiator. See Fig. 1 .

In main fuse/relay block.

Behind left side of dash. See Fig. 2 .

Under left side of dash. See Fig. 2 .

On left rear corner of front inner fender panel. See Fig. 1 .

Integral with windshield wiper & washer switch.

In left rear corner of engine compartment, in main fuse/relay block.

In right rear of vehicle, attached to power antenna.

In center rear of trunk compartment. See Fig. 3 .

Behind left side of dash.

In left rear corner of engine compartment, on inner fender panel. See Fig.

1 .

Behind left side of dash. See Fig. 2 .

CIRCUIT PROTECTION DEVICES

Component

Fuse Block (Front)

Fuse Block (Rear)

Main Fuse Block

Component Location

Behind left side of dash. See Fig. 2 .

On right rear side of luggage compartment. See Fig. 3 .

On right rear corner of engine compartment, near firewall. See Fig. 1 .

CONTROL UNITS

Component

ABS Control Module

ABS Control Unit

Cruise Control Module

Daytime Running Lamp (DRL) Control Module

Engine Control Module (ECM)

Component Location

Behind passenger's seat. See Fig. 3 .

In right rear corner of engine compartment.

Under left side of dash above fuse block. See Fig. 2 .

On bracket, behind left side of dash. See Fig. 2 .

Behind passenger's seat. See Fig. 3 .

1997 Mazda MX-5 Miata

1997 MAZDA MX-5 Miata

Key Interlock Unit

SAS Unit

Transmission Control Module (TCM)

MOTORS

Component

Blower Motor

Condenser Fan Motor

Cooling Fan Motor

Cruise Control Actuator

Fuel Pump

Power Antenna Motor

Retractable Headlamp Actuators

Shift Lock Actuator

Windshield Washer Motor

Windshield Wiper Motor

Behind left side of dash. See Fig. 2 .

Behind center of dash. See Fig. 2 .

Under left side of dash, near fuse block. See Fig. 2 .

Component Location

Under right side of dash. See Fig. 2 .

In front of engine compartment.

On left side of engine compartment.

In fuel tank.

In right front of trunk.

Behind respective headlamp.

Under center console, on base of gear selector.

On bottom of washer fluid reservoir.

On right side of firewall.

SENDING UNITS & SENSORS

Component

ABS Wheel Speed Sensor (Left Front)

ABS Wheel Speed Sensor (Left Rear)

ABS Wheel Speed Sensor (Right Front)

ABS Wheel Speed Sensor (Right Rear)

Brake Fluid Level Sensor

Camshaft Position Sensor

Crankshaft Position Sensor

EGR Boost Sensor

EGR Valve Position Sensor

Engine Coolant Temperature Sensor

Fuel Gauge Sender Unit

Heated Oxygen Sensor (Front)

Heated Oxygen Sensor (Rear)

Input/Turbine Speed Sensor

Mass Air Flow Sensor

Throttle Position (TP) Sensor

Transmission Fluid Temperature Sensor

Microsoft

Sunday, July 05, 2009 1:54:00 PM

Component Location

On back of left front wheel spindle assembly. See Fig. 1 .

On back of left rear wheel hub assembly. See Fig. 3 .

On back of right front wheel spindle assembly. See Fig. 1 .

On back of right rear wheel hub assembly. See Fig. 3 .

In brake fluid reservoir. See Fig. 1 .

In center rear of engine compartment. See Fig. 1 .

On front of engine.

On right side of engine compartment.

On right side center, rear of engine compartment.

On right side center, rear of engine compartment. See Fig. 1 .

On rear of engine. See Fig. 1 .

In fuel tank.

In rear of engine compartment. See Fig. 1 .

On underside of vehicle, on exhaust pipe.

On left side of transmission.

On top of air filter housing. See Fig. 1 .

On side of throttle body. See Fig. 1 .

On left side of transmission.

1997 Mazda MX-5 Miata

1997 MAZDA MX-5 Miata

Vehicle Speed Sensor (VSS)

Water Temperature Sender Unit

Washer Fluid Level Sensor

On speedometer assembly.

On center of engine. See Fig. 1 .

On washer fluid reservoir. See Fig. 1 .

SOLENOIDS & SOLENOID VALVES

Component

AT Interlock Solenoid

EC-AT Solenoid Valve

EGR Solenoid Valve (Vacuum)

EGR Solenoid Valve (Vent)

Fourth Gear Solenoid Valve

Idle Air Control Valve

PRC Solenoid Valve

Purge Solenoid Valve

Component Location

In steering column, near ignition switch. See Fig. 2 .

On left side of transmission.

On right side of engine compartment. See Fig. 1 .

On left side of transmission.

On right side, front of engine compartment. See Fig. 1 .

On right side, front of engine. See Fig. 1 .

On right strut tower. See Fig. 1 .

SWITCHES

Component

Back-Up Lamp Switch (M/T)

Brake Switch

Buckle Switch

Clutch Switch (M/T)

Hold Switch

Key Reminder Switch

Neutral Switch (M/T)

Oil Pressure Switch

"P" Range Switch

Parking Brake Switch

Power Steering Pressure Switch

Refrigerant Pressure Switch

Starter Interlock Switch (M/T)

Thermoswitch

Transmission Range Switch

MISCELLANEOUS

Component

Microsoft

Sunday, July 05, 2009 1:54:00 PM

Component Location

On right side of transmission. See Fig. 1 .

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

On driver side seat belt buckle. See Fig. 3 .

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

Under right side of center console.

In steering column, near ignition switch.

On right side of transmission. See Fig. 1 .

On right side of engine. See Fig. 1 .

Under center console, on base of gear selector.

On base of parking brake lever. See Fig. 4 .

On power steering pump assembly.

In front of engine compartment, near radiator support. See Fig. 1 .

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

Under right side of dash.

On left side of transmission.

Page 3

Component Location

Data Link Connector (DLC)

Data Link Connector (DLC) No. 2

Ignition Coil

Power Connector

Resistor (A/C-Heater)

CONNECTORS

Component

X-06 (White, 1 Pin)

X-07 (White, 1 Pin)

X-08 (White, 3 Pin)

X-09 (Green, 4 Pin)

X-10 (White, 6 Pin)

X-12 (A/T) (White, 4 Pin)

X-12 (M/T) (Black, 1 Pin)

X-13 (Black, 10 Pin)

X-14 (Black, 8 Pin)

X-15 (Gray, 4 Pin)

X-16 (White, 20 Pin)

X-17 (White, 20 Pin)

X-18 (White, 24 Pin)

X-19 (White, 20 Pin)

X-20 (White, 20 Pin)

X-21 (White, 24 Pin)

X-22 (White, 2 Pin)

X-23 (White, 16 Pin)

X-24 (White, 12 Pin)

X-25 (White, 12 Pin)

X-26 (White, 4 Pin)

X-27 (White, 3 Pin)

X-28 (White, 4 Pin)

X-29 (White, 3 Pin)

X-30 (White, 8 Pin)

X-31 (White, 2 Pin)

X-36 (White, 2 Pin)

GROUNDS

Microsoft

Sunday, July 05, 2009 1:54:00 PM

1997 Mazda MX-5 Miata

1997 MAZDA MX-5 Miata

On left inner fender panel. See Fig. 1 .

Under left side, center of dash, near console. See Fig. 4 .

On center rear of engine compartment.

On left inner fender panel.

Under right side of dash. See Fig. 2 .

Component Location

At right rear of engine compartment.

At right rear of engine compartment. See Fig. 1 .

At right rear of engine. See Fig. 1 .

At right kick panel. See Fig. 2 .

At left side of dash. See Fig. 4 .

At right side of dash. See Fig. 4 .

At left kick panel. See Fig. 2 .

At right kick panel. See Fig. 2 .

Forward of right rear wheelwell. See Fig. 3 .

At right front corner of trunk.

At left kick panel.

1997 Mazda MX-5 Miata

1997 MAZDA MX-5 Miata

Component

G10

G11

Component Location

At left rear corner of engine compartment. See Fig. 1 .

At left side of dash. See Fig. 2 .

At front of engine compartment. See Fig. 1 .

At right upper end of dash. See Fig. 2 .

At right rear corner of engine compartment. See Fig. 1 .

At right end of dash. See Fig. 4 .

At left end of dash. See Fig. 4 .

At center rear of trunk. See Fig. 3 .

Above left rear wheelwell. See Fig. 3 .

Forward of right rear wheelwell. See Fig. 3 .

COMPONENT LOCATION GRAPHICS

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

Microsoft

1997 Mazda MX-5 Miata

1997 MAZDA MX-5 Miata

Fig. 1: Engine Compartment

Microsoft

1997 Mazda MX-5 Miata

1997 MAZDA MX-5 Miata

Fig. 2: Dash

Microsoft

1997 Mazda MX-5 Miata

1997 MAZDA MX-5 Miata

Fig. 3: Left Side Of Vehicle

Microsoft

1997 Mazda MX-5 Miata

1997 MAZDA MX-5 Miata

Fig. 4: Dash

Microsoft

1997-98 ENGINES 1.8L 4-Cylinder

1997-98 ENGINES

1.8L 4-Cylinder

ENGINE IDENTIFICATION

NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL

PROCEDURES article in GENERAL INFORMATION.

Engines can be identified by engine model and number. See ENGINE IDENTIFICATION CODE . On Miata, engine model and number are stamped on flange at upper right rear of cylinder block deck, as viewed from flywheel. On Protege, engine model and number are stamped on flange at upper left rear of cylinder block deck, as viewed from flywheel.

ENGINE IDENTIFICATION CODE

Application

Miata & Protege (1.8L DOHC)

Code

ADJUSTMENTS

VALVE CLEARANCE ADJUSTMENT

NOTE: Valve clearance is not adjustable. Some Hydraulic Lash Adjuster (HLA) noise may occur during engine start-up. Noise should disappear after engine reaches normal operating temperature. If noise persists and oil level is okay, change engine oil. If oil change does not reduce noise, check with manufacturer for modified HLA.

REMOVAL & INSTALLATION

NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE & PRIMING

Releasing Pressure (Miata)

Locate and remove fuel pump relay from under left side of dash, near steering column. Start engine and allow to stall. After engine stalls, attempt to restart engine to ensure no residual pressure exists. Turn ignition off and reinstall fuel pump relay. When disconnecting fuel hoses, cover connection with shop rag to catch fuel leakage.

To avoid excessive cranking after servicing, prime fuel system before starting engine.

Releasing Pressure (Protege)

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Remove rear seat cushions. Disconnect fuel pump connector. Start engine and allow to stall. After engine stalls, attempt to restart engine to ensure no residual pressure exists. Turn ignition off and reconnect fuel pump connector. When disconnecting fuel hoses, cover connection with shop rag to catch fuel leakage. To avoid excessive cranking after servicing, prime fuel system before starting engine.

Priming System

Ensure fuel system is closed. Connect jumper wire between F/P and GND terminals of data link connector. See

Fig. 1 . Turn ignition on for about 10 seconds and check for fuel leaks. Turn ignition off and disconnect jumper wire.

Fig. 1: Identifying Data Link Connector Terminals (Typical)

Courtesy of MAZDA MOTORS CORP.

COOLING SYSTEM BLEEDING

CAUTION: If engine overheats during procedure, system contains excessive air. Stop engine and allow it to cool, then repeat step 1).

1. Slowly pour coolant into radiator at a rate of 1.1 qt. (1.0L) per minute maximum until coolant is level with filler port. Fill coolant reservoir to "F" mark. Securely install radiator cap. Start engine.

2. Operate engine at idle until normal operating temperature is reached. If coolant level warning light illuminates during warm-up, turn engine off and check drain plug and coolant hoses for leaks. Operate engine at 2200-2800 RPM for 5 minutes. Stop engine and allow to cool.

3. Repeat steps 1) and 2). Check coolant level. If engine coolant is not level with filler neck, repeat entire procedure. If engine coolant is level with filler neck, fill reservoir to "F" mark.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

ENGINE

NOTE: On Miata with audio anti-theft system, radio will not operate if power to radio is cut. Obtain code from customer to reactivate radio. To reactivate radio after reconnecting power supply, turn ignition switch to ACC position. Press and hold FF and REW buttons until CODE is displayed. Again press and hold FF and

REW buttons until bars (----) are displayed. Use preset button No. 1 to enter first number. Use preset buttons No. 2 to enter second number, 3 for third number, etc. Press FF and REW buttons for about 1.5 seconds until a beep is heard.

After 5 seconds, flashing CODE will disappear and radio will operate.

Removal (Miata)

1. Release residual pressure from fuel system. See FUEL PRESSURE RELEASE & PRIMING .

Disconnect negative battery cable from trunk-mounted battery. Reference mark and remove hood. Raise vehicle and remove engine undercover. See Fig. 2 . Drain engine, transmission and cooling system fluids.

2. Remove transmission. For automatic transmission removal procedure, see REMOVAL &

INSTALLATION article in TRANSMISSION SERVICING. For manual transmission removal procedure, see appropriate article in CLUTCHES.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 2: Removing & Installing Drive Train Components (Miata)

Courtesy of MAZDA MOTORS CORP.

3. Remove all cooling system hoses and A/T oil cooler hoses at radiator (if equipped). Remove radiator and cooling fans as an assembly. Remove all drive belts. DO NOT disconnect power steering hoses or A/C compressor hoses. Unbolt power steering pump and A/C compressor from engine, and wire aside.

4. Remove air cleaner assembly. See Fig. 3 . Remove throttle cable. Note locations and disconnect all necessary electrical connectors, ground wires, vacuum hoses, fuel hoses, coolant hoses and control cables for engine removal. Plug all fuel hoses to prevent leakage. Remove engine mount nuts and remove engine.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 3: Removing Engine Components (Miata)

Courtesy of MAZDA MOTORS CORP.

NOTE: Proper installation of Power Plant Frame (PPF) is critical for aligning drive shaft and eliminating harmonic vibrations.

Installation

1. To install, reverse removal procedure. After installing engine mount nuts, mount PPF to transmission and tighten long bolts by hand. Ensure bolt sleeve and PPF/differential mounting spacer are installed to

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder differential housing block.

2. Tighten PPF/differential mounting spacer bolts to 28-38 ft. lbs. (38-52 N.m). See Fig. 4 . Install PPF to differential. Hand-tighten long bolts. Ensure PPF-to-differential large shank reamer bolt and spacer are properly installed.

NOTE: Reamer bolt is the front long bolt attaching PPF to differential. This bolt aligns PPF with drive train.

3. When PPF is properly aligned between transmission and differential, tighten all long mounting bolts to specification. Install rear transmission-to-PPF bracket and tighten to specification. See TORQUE

SPECIFICATIONS . To complete installation, reverse removal procedure. Before installing M/T shift lever, add gear oil to transmission through shifter hole. Fill all fluids to correct level. Prime fuel system before attempting to start engine. See FUEL PRESSURE RELEASE & PRIMING. Bleed cooling system.

See COOLING SYSTEM BLEEDING.

Fig. 4: Locating PPF-To-Differential Reamer Bolt, Sleeve & Spacer

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (Protege)

1. Release residual pressure from fuel system. See FUEL PRESSURE RELEASE & PRIMING .

Disconnect negative battery cable. Reference mark and remove hood. Raise vehicle. Remove engine undercover and side covers. See Fig. 5 . Drain engine, transaxle and cooling system fluids. Remove front wheels.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 5: Removing Engine Components (Protege)

Courtesy of MAZDA MOTORS CORP.

2. Lower vehicle. Remove air cleaner assembly. Remove battery/carrier assembly. Remove throttle cable and air intake duct across radiator (if equipped).

3. Remove all drive belts. DO NOT disconnect power steering hoses or A/C compressor hoses. Unbolt power steering pump and A/C compressor from engine, and wire aside.

4. Note locations and disconnect all necessary electrical connectors, ground wires, vacuum hoses, fuel hoses, coolant hoses and control cables for engine removal.

5. Plug all fuel hoses to avoid leakage. Attach engine support bar or engine hoist to secure engine. Raise vehicle. Disconnect exhaust manifold down pipe and exhaust brackets from engine. On A/T models, remove shift control cable.

6. On M/T models, remove shift control linkage and extension bar. Remove clutch release cylinder and fluid line bracket from transaxle housing, leaving fluid line connected to cylinder. Secure cylinder away from transaxle.

7. On all models, remove transmission wiring harness connectors and speedometer cable. Remove axle shaft nuts from hubs. Disconnect stabilizer bar from lower control arms. Separate lower ball joints and steering tie-rod ends from steering knuckles.

8. Pry axle shafts out of transaxle. Remove and discard circlip from axle shafts. For further information on axle shafts, see appropriate article in DRIVE AXLES.

9. Remove transaxle mount nuts from crossmember and loosen crossmember bolts. See Fig. 6 . Lower vehicle and attach engine hoist for engine removal. Remove engine front mount and transaxle top mount from inner fender panels. Remove transaxle crossmember. Remove engine and transaxle assembly from top of vehicle.

10. To install, reverse removal procedure. Tighten bolts and nuts to specifications. See TORQUE

SPECIFICATIONS . Fill all fluids to correct level. Prime fuel system before attempting to start engine.

See FUEL PRESSURE RELEASE & PRIMING . Bleed cooling system. See COOLING SYSTEM

BLEEDING.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 6: Removing Engine Mounts (Protege)

Courtesy of MAZDA MOTORS CORP.

INTAKE MANIFOLD

Removal

1. Release residual pressure from fuel system. See FUEL PRESSURE RELEASE & PRIMING .

Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and ducting. See

Fig. 3 or Fig. 5 . Mark and disconnect coolant hoses, vacuum hoses and electrical connectors from intake manifolds.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

2. Disconnect throttle cable. Remove fuel lines from fuel rail and pressure regulator. Remove throttle body intake duct housing and throttle body. Remove by-pass air control valve and solenoid valves. Remove upper intake manifold (if equipped).

3. Remove intake manifold support bracket from underneath manifold. Disconnect injector harness connectors, and remove injectors/fuel rail assembly. Remove intake manifold and gasket.

Installation

1. Ensure all gasket surfaces are clean and flat. Using NEW gasket, install intake manifold to cylinder head.

Tighten manifold bolts/nuts evenly to specification, starting from center bolt and alternating outward. See

TORQUE SPECIFICATIONS . Install support bracket underneath intake manifold.

2. Install gasket and upper intake manifold (if equipped). Tighten bolts/nuts evenly to specification, alternating from top to bottom. See TORQUE SPECIFICATIONS .

3. To complete installation, reverse removal procedure. Ensure throttle cable has .04-.12" (1-3 mm) free play. Ensure injectors twist freely and are not cocked in insulator "O" rings. Refill engine with coolant.

EXHAUST MANIFOLD

Removal & Installation

1. Remove air cleaner intake duct from top of radiator/fan assembly (if equipped). Disconnect oxygen sensor. Remove heat shields. Disconnect down pipe from exhaust manifold. Remove exhaust manifold.

2. To install, reverse removal procedure. Ensure all mating surfaces are clean and flat. Install NEW exhaust manifold gasket to cylinder head. Tighten manifold bolts evenly to specification, starting from center bolt and alternating outward. See TORQUE SPECIFICATIONS .

CYLINDER HEAD

Removal

1. Release residual pressure from fuel system. See FUEL PRESSURE RELEASE & PRIMING . Drain engine coolant. Note locations and disconnect all necessary electrical connectors, ground wires, vacuum hoses, fuel hoses, coolant hoses and control cables for cylinder head removal. Plug all fuel hoses to avoid leakage.

2. Remove spark plug wires from spark plugs. Remove all drive belts. Remove water pump pulley. Remove timing belt. See TIMING BELT . Remove camshaft/rocker cover.

3. Remove front exhaust pipe. Remove intake manifold support bracket. Loosen all cylinder head bolts evenly, in 3 steps, in reverse of tightening sequence. See Fig. 7 . Remove bolts and cylinder head assembly.

Inspection

Carefully clean carbon and gasket material from all mating surfaces. Clean threads of cylinder head bolts. Use a tap to clean threads in engine block. Check cylinder head for warpage. Resurface or replace head if it is not within specification. Check valve train components. Replace or resurface components if they are not within

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder specification. See CYLINDER HEAD and VALVES & VALVE SPRINGS tables under ENGINE

SPECIFICATIONS .

Installation

Install cylinder head gasket, cylinder head assembly and bolts. Tighten cylinder head bolts in 2 steps, and in sequence, to specification. See Fig. 7 . See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Fig. 7: Cylinder Head Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

CRANKSHAFT FRONT SEAL

Removal

Disconnect negative battery cable. Remove drive belts and crankshaft pulley. Remove water pump pulley, timing belt covers and timing belt. See TIMING BELT . Use Crankshaft Lock Tool (49-D011-102) to lock crankshaft sprocket into position. Remove crankshaft sprocket bolt. Remove crankshaft sprocket using steering

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder wheel puller. Pry out seal.

Installation

1. Apply light oil coat to seal lip. Using a hammer and seal installer, tap seal into oil pump body until it is flush with edge of pump body. DO NOT bottom seal in pump body. Align keyway slots, and install crankshaft sprocket and Woodruff key with tapered side toward oil pump body. Install crankshaft sprocket bolt.

2. Using Crankshaft Lock Tool (49-D011-102), lock crankshaft sprocket into position. Tighten lock bolt to specification. See TORQUE SPECIFICATIONS .

3. Install timing belt. See TIMING BELT under REMOVAL & INSTALLATION. Install timing belt covers, pulleys and drive belts. Reconnect negative battery cable and ensure timing is correct.

TIMING BELT

NOTE: For 1997-98 vehicles, the manufacturer recommends the belt be replaced at

60,000 mile intervals for vehicles sold outside of California and Massachusetts.

For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

Removal (Miata)

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 between throttle body and air cleaner filter housing.

2. Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at

TDC of compression stroke. Hold crankshaft pulley stationary. Remove crankshaft pulley bolts and 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. 8 . Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully expanded. Remove timing belt.

Removal (Protege)

1. Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right side cover and undercover.

2. Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at

TDC of compression stroke. Hold crankshaft stationary. Remove crankshaft pulley bolts and pulley.

Remove crankshaft pulley hub bolt and hub.

Fig. 8 . Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully expanded. Remove timing belt.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Inspection (All Models)

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 sprockets. See Fig. 8 . Ensure crankshaft timing mark is at TDC. Install belt around crankshaft sprocket, then working in a counterclockwise direction, route belt around camshaft sprockets.

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. Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 9 . Ensure timing belt deflection is within specification. See TIMING BELT DEFLECTION .

TIMING BELT DEFLECTION

Application

Miata & Protege

(1)

Deflection In. (mm)

.35-.45 (9.0-11.5)

(1) Deflection measurement is with 22 lbs. (10 kg) of pressure applied to timing belt. See Fig. 9 .

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 8: Aligning Camshaft Timing Marks

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 9: Measuring Timing Belt Deflection

Courtesy of MAZDA MOTORS CORP.

HYDRAULIC LASH ADJUSTER (HLA)

NOTE: If hydraulic lash adjusters are persistently noisy, check with manufacturer for availability of modified adjusters.

Removal

Disconnect negative battery cable. Remove camshaft. See CAMSHAFT . Mark location of each HLA for reassembly reference. Remove HLA from cylinder head.

Inspection

Place HLA in palm of hand. Attempt to compress HLA plunger with thumb. If plunger compresses, replace

HLA.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Installation

Insert HLA in original location. To complete installation, reverse removal procedure. Tighten camshaft bearing caps evenly in sequence to specification. See Fig. 10 or Fig. 11 . See TORQUE SPECIFICATIONS .

CAMSHAFT

NOTE: On Miata, exhaust camshaft has a slot for camshaft position sensor drive. On

Protege, exhaust camshaft has a slot for distributor drive. On all models, match mark camshafts and sprockets for installation reference.

Removal

Remove cylinder head cover. Remove timing belt. See TIMING BELT . Remove distributor/camshaft position sensor. Reference mark camshafts, caps and sprockets, and remove sprockets. Loosen camshaft bearing cap bolts evenly in 5-6 steps, in sequence. See Fig. 10 or Fig. 11 . Remove camshafts.

Inspection

Check camshaft end play. Check camshaft journal diameters and bearing clearances. Check camshaft lobes for wear. See CAMSHAFT under ENGINE SPECIFICATIONS. If any measurement is not within specification, replace camshaft and/or cylinder head.

Installation

To install, reverse removal procedure. On both camshafts, apply small amount of silicone sealant to contact area of cylinder head/camshaft seal cover cap. Tighten camshaft bearing cap bolts evenly in sequence to specification. See Fig. 10 or Fig. 11 . See TORQUE SPECIFICATIONS .

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 10: Camshaft Bearing Cap Bolt Removal & Installation Sequence (Miata) Removal

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 11: Camshaft Bearing Cap Bolt Removal & Installation Sequence (Miata) Installation

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 12: Camshaft Bearing Cap Bolt Removal & Installation Sequence (Protege) Removal

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 13: Camshaft Bearing Cap Bolt Removal & Installation Sequence (Protege) Installation

Courtesy of MAZDA MOTORS CORP.

CRANKSHAFT REAR OIL SEAL

Removal & Installation

1. Disconnect negative battery cable. Remove transmission/transaxle and flywheel. For automatic transmission removal procedure, see REMOVAL & INSTALLATION article in TRANSMISSION

SERVICING. For manual transmission removal procedure, see appropriate article in CLUTCHES. On all models, pry out rear oil seal.

2. To install, apply light coat of oil to seal lip and push seal over crankshaft. Tap seal into rear cover until it is flush with edge of rear cover. DO NOT bottom seal in cover.

3. Completely remove used sealant from flywheel bolts. Apply lock-type sealant to bolts and install flywheel to crankshaft. Tighten bolts to 71-76 ft. lbs. (96-103 N.m) in a star-pattern sequence. Install clutch assembly (if equipped) and tighten cover bolts to 13-20 ft. lbs. (18-26 N.m) in a star-pattern sequence. Install transmission/transaxle. See appropriate article in TRANSMISSION SERVICING or

CLUTCHES.

WATER PUMP

Removal & Installation

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

1. Drain engine coolant. Disconnect battery cable. Position No. 1 cylinder at TDC of compression stroke.

On Protege, remove right side cover and undercover.

2. On Miata, remove air cleaner intake duct from between throttle body and air cleaner/filter assembly. On all models, remove upper radiator hose and by-pass hoses from thermostat housing.

3. Remove drive belts and water pump pulley. Remove power steering pump with hoses attached and secure pump away from engine (if necessary). Remove timing belt, tensioner and idler. See TIMING BELT.

4. Unbolt water inlet pipe from water pump. Water pump inlet pipe has lower radiator hose and by-pass pipe attached to it. Remove bolts from water pump. To install, reverse removal procedure. Tighten bolt to specification. See TORQUE SPECIFICATIONS .

NOTE: For further information on cooling systems, see SPECIFICATIONS & ELECTRIC

COOLING FANS article in ENGINE COOLING.

OIL PAN

NOTE: On Miata, engine must be supported in order to remove oil pan.

Removal & Installation (Miata)

1. Disconnect negative battery cable. Drain engine oil. Remove dipstick, tube and "O" ring. Raise vehicle on hoist. Remove engine undercover. Disconnect steering column shaft at steering rack coupling. See Fig.

14 . Remove engine mount nuts. Lift and support engine using jack.

2. Support crossmember using transmission jack and remove crossmember bolts. Slowly and carefully lower crossmember until clearance between oil pan and steering rack is about 4 inches. Remove oil pan bolts from engine block and transmission.

3. DO NOT damage sealant contact surfaces. Remove oil pan by prying between oil pan and transmission support. Remove oil pan baffle by prying it from engine. See Fig. 14 . DO NOT deform oil pan baffle.

Replace oil pan baffle if deformed. Clean sealant from oil pan, bolts, engine block and both sides of oil pan baffle.

4. To install, apply oil resistant sealant to engine block and oil pan. Install oil pan baffle and oil pan within 5 minutes of applying sealant. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill engine with oil to specification. See ENGINE

LUBRICATION SYSTEM under ENGINE OILING.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 14: Removing Crossmember & Oil Pan (Miata)

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (Protege)

1. Disconnect negative battery cable. Remove engine undercovers. Drain engine oil. Remove exhaust header downpipe and brackets from front exhaust system. Remove oil pan retaining bolts.

2. DO NOT damage sealant contact surfaces. Remove oil pan by prying between oil pan and mounting surface. On Protege, remove stiffener by prying between stiffener and cylinder block. On all models, clean all sealant from oil pan, bolts, engine block and both sides of stiffener (Protege).

CAUTION: If reusing old oil pan bolts, remove old sealant from bolt threads.

Failure to remove old sealant may result in cracked block at bolt holes.

3. On Protege, apply oil resistant sealant to engine block and stiffener. Install stiffener. On all models, apply sealant and install oil pan within 5 minutes of applying sealant. To complete installation, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS . Fill engine with oil to specification. See ENGINE LUBRICATION SYSTEM under ENGINE OILING.

OVERHAUL

CYLINDER HEAD

Cylinder Head

Clean carbon and gasket material from all mating surfaces. Using a tap, clean cylinder head threads. Check cylinder head warpage. If warpage exceeds specification, resurface head, but DO NOT exceed grinding limit.

See CYLINDER HEAD under ENGINE SPECIFICATIONS. After resurfacing cylinder head, check cylinder head height. Replace cylinder head if height is less than minimum specification.

Valve Springs

Ensure valve spring free length, out-of-square and compressed length are within specification. See VALVES &

VALVE SPRINGS under ENGINE SPECIFICATIONS. Replace valve spring if necessary.

NOTE: Intake and exhaust valve stem seals are different. Exhaust seals can be identified by ridges molded into top of seal. Intake seals do not have identifying ridges. Incorrect installation of valve stem seals will cause premature failure.

Valve Stem Oil Seals

1. On Miata, use Installer Set (49-L012-0A0) to install valve seals. See Fig. 15 . Adjust installer dimension

"L" to seal depth of .720-.744" (18.3-18.9 mm). Using hand pressure ONLY, install seal until it contacts cylinder head. Lightly oil valve seal lip.

2. On Protege, use Installer Set (49-L012-0A0) to install valve seals. See Fig. 15 . Adjust installer dimension "L" to seal depth of .783" (19.9 mm). Using hand pressure, install seal until it contacts cylinder

Microsoft

head. Lightly oil valve seal lip.

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 15: Installing Valve Guide Seals

Courtesy of MAZDA MOTORS CORP.

NOTE: On Miata, use only NEW exhaust valve guides to replace intake or exhaust valve guides.

Valve Guides

1. Check valve stem-to-valve guide oil clearance. Ensure valve guide inside diameter is within specification.

See CYLINDER HEAD under ENGINE SPECIFICATIONS.

2. Completely disassemble cylinder head. Gradually heat cylinder head in water to 194°F (94°C). Using

Valve Guide Remover (49-B012-005), drive valve guide out, working from combustion chamber side of cylinder head. Repeat procedure if required, keeping cylinder head hot so aluminum head will not warp.

3. If required, install new circlip on guide. Using proper components of Valve Guide Installer (49-L012-

0A0), adjust installer guide depth (dimension "L") to specification using depth micrometer or caliper. See

VALVE GUIDE INSTALLED HEIGHT . See Fig. 16 .

4. Insert guide into pre-adjusted installer and drive guide into cylinder head from camshaft side until guide circlip, and/or installer contact cylinder head. Measure dimension "L" (guide installed height). See Fig.

16 or Fig. 15 . If installed height is not within specification, adjust or replace valve guide or cylinder head as necessary. See VALVE GUIDE INSTALLED HEIGHT .

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

VALVE GUIDE INSTALLED HEIGHT

Application

Miata & Protege

In. (mm)

.720-.744 (18.30-18.90)

Fig. 16: Adjusting Valve Guide Installer & Installing Guide

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 17: Measuring Installed Valve & Guide Height

Courtesy of MAZDA MOTORS CORP.

Valve Seat

1. Service valve guide before valve seat. Valve seat replacement information is not available from manufacturer. Inspect valve seat for roughness and damage. Check valve seat angle and seat width.

2. Measure seat contact width on valve and ensure seat contact position is in center of valve face. Service seat if angle and width are not within specification. See CYLINDER HEAD under ENGINE

SPECIFICATIONS. Measure valve installed height after servicing valve seat. See Fig. 17 . See VALVE

INSTALLED HEIGHT .

3. If valve installed height is within serviceable range, install adjusting shim on spring seat. If installed height exceeds serviceable range, replace cylinder head.

VALVE INSTALLED HEIGHT

Application

Miata & Protege

Microsoft

Sunday, July 05, 2009 1:55:15 PM Page 26

In. (mm)

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Normal

Serviceable

1.772-1.791 (45.00-45.50)

1.733-1.772 (45.60-46.50)

Valves

Check valve face angle, head diameter, margin thickness and stem diameter. Service or replace valves if measurements are not within specifications. See VALVES & VALVE SPRINGS under ENGINE

SPECIFICATIONS.

Valve Seat Correction Angles

Measure seat contact width on valve. See VALVE SEAT. If seat width is not within specification or if valve face does not contact center of valve seat, correct seat using a 70-degree grinding stone. After correcting seat, lightly finish seat with 45-degree grinding stone.

VALVE TRAIN

Hydraulic Lash Adjusters

1. Remove camshaft cover. Check movement of each Hydraulic Lash Adjuster (HLA) by pushing downward using hand pressure only. If HLA compresses, replace HLA. To remove HLA, remove camshafts. See CAMSHAFT under REMOVAL & INSTALLATION. Mark location of HLA before removing from bore. Lift HLA from cylinder head.

NOTE: If hydraulic lash adjusters are persistently noisy, check with manufacturer for availability of modified adjusters.

2. Inspect HLA friction surfaces for wear and damage. Replace HLA if required. Coat HLA with engine oil and install in original location. Ensure HLA moves smoothly in bore by using small magnet attached to

HLA.

CYLINDER BLOCK ASSEMBLY

NOTE: During disassembly, match mark components for reassembly reference.

Piston & Connecting Rod Assembly

1. Before removing rod cap from crankshaft, measure and record rod side play. See CONNECTING RODS under ENGINE SPECIFICATIONS. Before removing connecting rods, measure and record connecting rod bearing oil clearance. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS under

ENGINE SPECIFICATIONS.

2. Before separating piston from connecting rod, mark piston in relation to connecting rod. Check oscillation movement of piston and rod assembly (hold piston horizontally, lift rod and allow rod to drop by its own weight). If pin binds in pin bore (rod does not drop), replace piston and/or pin as necessary.

3. To separate components, press piston pin out of piston and rod assembly, noting pressure required to

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder remove piston pin. If piston pin can be pressed out with less than 1100 lbs. (500 kg) of pressure, replace piston and/or connecting rod.

4. Ensure piston pin diameter, piston fit and rod fit are within specification. See PISTONS, PINS &

RINGS under ENGINE SPECIFICATIONS. Using 1100-3300 lbs. (500-1500 kg) of pressure, install piston pin through side of piston that has an "F" mark near pin bore. See Fig. 18 . Install piston and rod assembly so "F" mark on side of piston is facing front of engine.

Fig. 18: Installing Piston & Connecting Rod Assembly

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fitting Pistons

1. Ensure pistons are not scored or damaged. Measure piston diameter on piston skirt at 90-degree angle from piston pin, .65" (16.5 mm) below lowest ring groove. See PISTONS, PINS & RINGS under

ENGINE SPECIFICATIONS.

2. Check piston-to-cylinder wall clearance in 3 different vertical places of piston travel. If clearance is not within specification, re-bore cylinders to fit oversize pistons. Using NEW piston rings, measure piston ring side clearance around entire piston circumference. If clearance is not within specification, replace piston. See PISTONS, PINS & RINGS .

NOTE: Pistons and rings are available in .010" (.25 mm) and .020" (.50 mm) oversize.

Piston Rings

1. If ring end gap and side clearance are not within specification, replace piston and/or rings as necessary.

See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS.

2. Install oil ring spacer. Ensure ends DO NOT overlap. See Fig. 19 . Upper and lower rails are the same and are interchangeable. In stall rails, ensuring rails are expanded by spacer tangs (oil rings when assembled should rotate freely). Install rings No. 1 (top) and No. 2 (second) with "R" mark toward top of piston. Ensure ring end gaps are properly positioned around piston. See Fig. 20 .

Fig. 19: Identifying Oil Rings

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Courtesy of MAZDA MOTORS CORP.

Fig. 20: Identifying Piston Rings & Positioning Ring End Gaps

Courtesy of MAZDA MOTORS CORP.

Crankshaft & Main Bearings

1. Check crankshaft connecting rod journals for wear, out-of-round, taper and undersize. Machine or replace crankshaft and/or bearings as necessary. See CRANKSHAFT, MAIN & CONNECTING ROD

BEARINGS under ENGINE SPECIFICATIONS.

2. Before removing main cap, measure and record crankshaft end play by prying crankshaft forward, then rearward. Using Plastigage method, measure and record main bearing oil clearance. Remove crankshaft.

Measure and record each main journal diameter in 2 places. See CRANKSHAFT, MAIN &

CONNECTING ROD BEARINGS under ENGINE SPECIFICATIONS.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

3. Install main bearing caps with square mark facing front of engine. Tighten main bearing cap bolts in 2-3 step, working outward from center bearing. Tighten bolts to specification. See TORQUE

SPECIFICATIONS . Thrust Bearing - Install thrust bearing before installing crankshaft. Check crankshaft end play with crankshaft bearings and caps installed, but without connecting rods attached to crankshaft. DO NOT turn crankshaft until bearings are lubricated. If crankshaft end play exceeds specification, grind crankshaft and replace thrust bearings with oversize thrust bearings, or replace crankshaft and thrust bearings. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS under ENGINE SPECIFICATIONS.

Cylinder Block

Check cylinder bore out-of-round, taper, ridge and piston-to-cylinder bore clearance. Check head gasket surface for warpage. If warpage is not within specification, machine or replace cylinder block as necessary. See

CYLINDER BLOCK under ENGINE SPECIFICATIONS. Remove, clean and install oil jets for piston oil spraying.

ENGINE OILING

ENGINE LUBRICATION SYSTEM

NOTE: See cross-sectional view of engine oil circuit. See Fig. 21 .

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 21: Cross-Sectional View Of Engine Oil Circuit

Courtesy of MAZDA MOTORS CORP.

Crankcase Capacity

See ENGINE OIL CRANKCASE CAPACITY .

Oil Pressure

With engine at operating temperature, oil pressure should be 15-28 psi (1.0-2.0 kg/cm

) at 1000 RPM, and 43-

57 psi(3.0-4.0 kg/cm

) at 3000 RPM.

Oil Pressure Relief Valve

Pressure relief valve opening pressure is 50-64 psi (3.5-4.5 kg/cm

2 body and is not adjustable.

). Pressure relief valve is located in oil pump

ENGINE OIL CRANKCASE CAPACITY

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Application

Miata & Protege

W/O Filter Qts. (L)

3.8 (3.6)

W/Filter Qts. (L)

4.0 (3.8)

OIL PUMP

Removal & Disassembly

1. Disconnect negative battery cable. Remove dipstick, tube and "O" ring. Drain engine oil and coolant.

Remove drive belts, crankshaft and water pump pulleys. Remove generator, A/C compressor and mounting bracket. Without disconnecting A/C hoses, secure A/C compressor away from engine. Remove timing belt and related components. See TIMING BELT under REMOVAL & INSTALLATION.

2. Hold crankshaft sprocket in place and remove crankshaft sprocket bolt. Remove crankshaft sprocket using steering wheel puller. Leave crankshaft Woodruff key in place.

3. Remove oil pan and oil pump pick-up tube. See OIL PAN under REMOVAL & INSTALLATION.

Remove oil pump housing assembly. Using a screwdriver protected with a rag, drive oil seal out from inside of oil pump housing assembly.

4. Remove pump cover screws (use a manual impact screwdriver, if necessary). See Fig. 22 . Remove pump cover. Note location of alignment marks on inner and outer rotors. Remove inner and outer rotors. To remove pressure relief valve, remove spring seat, pressure spring and control plunger.

Inspection

Replace pressure relief valve spring if length is not as specified. See OIL PUMP SPECIFICATIONS . Ensure plunger slides freely in bore. Replace oil pump housing assembly if clearances are not as specified. See OIL

PUMP SPECIFICATIONS .

Reassembly & Installation

1. Apply oil to friction surfaces. Install inner and outer rotors with marks aligned. See Fig. 23 . Install pressure relief valve components. Apply oil to lip of NEW oil seal. Press oil seal into bore until even with face of oil pump housing assembly.

2. Install pump cover. Tighten screws to 53-78 INCH lbs. (6-9 N.m). To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

OIL PUMP SPECIFICATIONS

Application

Maximum Rotor Tip Clearance

(1)

Maximum Rotor-To-Pump Body Clearance

(2)

Maximum Rotor Side Clearance

(3)

Pressure Relief Spring Free Length

(1) See Fig. 23 .

(2) Insert feeler gauge between outer rotor and pump body.

Maximum Clearance In. (mm)

.0079 (.20)

.0055 (.14)

1.809 (45.94)

Place straightedge across pump body and check clearance between straightedge and both rotors.

Microsoft

(3)

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 22: Exploded View Of Oil Pump

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Fig. 23: Aligning Marks On Inner & Outer Rotor

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Application

Axle Shaft Nut (Protege)

Camshaft Sprocket Bolt

Compressor Bracket-To-Engine Bolt

Connecting Rod Cap Nut

Crankshaft Pulley Bolts

Crankshaft/Timing Belt Sprocket Bolt

Crossmember-To-Frame Bolt

Cylinder Head Bolt

(2)

Distributor Bolt

Drive Shaft Bolts (Miata)

Engine Mount Nut

Engine Mount-To-Engine Bolt

Engine Mount-To-Frame Nut

Miata

Protege

Exhaust Header Pipe-To-Exhaust

Microsoft

Sunday, July 05, 2009 1:55:15 PM Page 35

Ft. Lbs. (N.m)

174-235 (235-319)

36-45 (49-61)

28-38 (38-51)

35-37 (48-50)

9-13 (12-18)

116-123 (157-167)

47-66 (63-89)

56-60 (76-81)

14-19 (19-26)

37-43 (50-58)

42-58 (57-79)

27-40 (37-54)

42-57 (57-77)

28-38 (38-51)

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Manifold Nut

Exhaust Manifold Nut

Flywheel Bolt

Fuel Rail Bolt

Generator Top Bolt

Intake Manifold Bolt/Nut

Intake Manifold Support Bracket

Main Bearing Cap Bolt

Step 1

Step 2 (Final)

Oil Pan-To-Transaxle Bolt (Protege)

Oil Pan-To-Transmission Bolt (Miata)

Oil Pump-To-Block Bolt

Power Steering Pump-To-Bracket Bolt

PPF/Differential Spacer Mounting Bolt

(2)

PPF-To-Differential Long Mounting Bolt

(2)

PPF-To-Transmission Side Mounting Bolt

(2)

PPF/Transmission Rear Bracket Mounting Bolt

Spark Plug

Timing Belt Tensioner Bolt

Water Pump Bolt

Camshaft Bearing Cap Bolt

Cylinder Head Cover Bolt

Oil Jet

Oil Pan-To-Engine Block Bolt

(Miata & Protege)

Oil Pump Cover Screws

Oil Strainer Bolt

Rear Cover Bolt

Water Pump Pulley Bolt

(1) Tighten evenly to specification in alternating sequence.

(2) Tighten in sequence. See Fig. 7 .

(3) Tighten in sequence. See Fig. 10 or Fig. 11 .

ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

Microsoft

23-34 (31-46)

(1)

28-34 (38-46)

71-76 (96-103)

14-19 (19-26)

27-38 (37-51)

(1)

14-19 (19-26)

14-18 (19-25)

(1)

22-27 (30-37)

(1)

40-43 (54-58)

28-38 (38-51)

48-65 (64-88)

14-19 (19-26)

28-38 (38-51)

27-38 (37-51)

77-91 (104-123)

27-40 (37-54)

11-16 (15-22)

27-38 (37-51)

14-19 (19-26)

INCH Lbs. (N.m)

(3)

100-125 (11.3-14.1)

43-78 (5-9)

104-156 (12-18)

70-95 (8-11)

53-78 (6-9)

70-95 (8-11)

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Application

Displacement

Bore

Stroke

Compression Ratio

Miata

Protege

Fuel System

Horsepower @ RPM

Miata

Protege

Torque Ft. Lbs. @ RPM

Miata

Protege

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application

Crankshaft

End Play

Standard

Maximum

Maximum Runout

Main Bearings

Journal Diameter

Standard Bearings

Journal Out-Of-Round

Oil Clearance

Standard

Maximum

Connecting Rod Bearings

Journal Diameter

Standard Bearings

Journal Out-Of-Round

Oil Clearance

Standard

Maximum

CONNECTING RODS

Microsoft

Sunday, July 05, 2009 1:55:15 PM

Specification

112.2 Cu. In. (1.8L)

3.27" (83.0 mm)

3.35" (85.0 mm)

9.0:1

8.9:1

PFI

128 @ 6500

103 @ 5500

110 @ 5000

111 @ 4000

In. (mm)

.0032-.0111 (.080-.282)

.0118 (.30)

.0016 (.04)

1.9661-1.9667 (49.938-49.956)

.002 (.05)

.0008-.0014 (.020-.036)

.004 (.10)

1.7693-1.7699 (44.940-44.956)

.002 (.05)

.0008-.0027 (.020-.068)

.0039 (.100)

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

CONNECTING RODS

Application

Bore Diameter

Crankpin Bore

Pin Bore

Center-To-Center Length

Maximum Bend

Side Play

Standard

Maximum

(1) Bend must not exceed .003" per 1.97" (.075 mm per 50 mm).

PISTONS, PINS & RINGS

Application

Pistons

Clearance

Standard

Miata

Protege

Maximum

Diameter

Standard

Oversize

.010" (0.25 mm)

.020" (0.50 mm)

Pins

Diameter

Piston Fit

Rings

No. 1

End Gap

Standard

Maximum

Side Clearance

Standard

Maximum

Microsoft

Sunday, July 05, 2009 1:55:15 PM

In. (mm)

1.8898-1.8904 (48.000-

48.016)

.7876-.7879 (20.003-20.014)

5.231-5.234 (132.85-132.95)

(1)

.0044-.0103 (.110-.262)

.012 (.30)

In. (mm)

.0013-.0023 (.032-.059)

.0010-.0014 (.024-.037)

.006 (.15)

3.2660-3.2666 (82.954-82.974)

3.2761-3.2762 (83.211-

83.217)

3.2859-3.2860 (83.461-

83.467)

.7869-.7871 (19.987-19.993)

-.0002-.0005 (-.005-.013)

.006-.011 (.15-.30)

.039 (1.0)

Page 38

.0012-.0025 (.030-.065)

.006 (.15)

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

No. 2

End Gap

Standard

Maximum

Side Clearance

Standard

Maximum

No. 3 (Oil)

End Gap

Standard

Maximum

.006-.011 (.15-.30)

.039 (1.0)

.0012-.0027 (.030-.070)

.006 (.15)

.008-.027 (.20-.70)

.039 (1.0)

CYLINDER BLOCK

Application

Cylinder Bore

Standard

In. (mm)

3.2678-3.2684 (83.000-

83.019)

Oversize

.010" (0.25 mm)

.020" (0.50 mm)

Maximum Taper & Out-Of-Round

Minimum Deck Height

(1)

Maximum Deck Warpage

(1) DO NOT machine more than .008" (.20 mm) from cylinder block deck surface.

3.2778-3.2780 (83.256-

83.263)

3.2877-3.2879 (83.506-

83.513)

.0007 (.019)

8.720 (221.5)

.006 (.15)

CYLINDER HEAD

Application

Cylinder Head

Height

Grinding Limit

Maximum Warpage

Valve Seats

Intake Valve

Seat Angle

Seat Width

Microsoft

Sunday, July 05, 2009 1:55:15 PM Page 39

Specification

5.268-5.275" (133.8-134.0 mm)

.004" (.10 mm)

45°

.032-.055" (0.80-1.40 mm)

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

Exhaust Valve

Seat Angle

Seat Width

Valve Guides

Intake Valve

Valve Guide I.D.

Valve Guide Installed

Height

Valve Stem-To-Guide Oil Clearance

Standard

Maximum

Exhaust Valve

Valve Guide I.D.

Valve Guide Installed

Height

Valve Stem-To-Guide Oil Clearance

Standard

Maximum

VALVES & VALVE SPRINGS

Application

Valves

Face Angle

Installed Height

Normal

Serviceable

Minimum Margin

Intake

Exhaust

Refinish Length

Miata

Intake

Standard

Minimum

Exhaust

Standard

Minimum

Protege

Intake

Microsoft

Sunday, July 05, 2009 1:55:15 PM

45°

.032-.055" (0.80-1.40 mm)

.2367-.2374" (6.01-6.03 mm)

.721-.744" (18.3-18.9 mm)

.0010-.0023" (.025-.060 mm)

.008" (.20 mm)

.2367-.2374" (6.01-6.03 mm)

.721-.744" (18.3-18.9 mm)

.0012-.0025" (.030-.065 mm)

.008" (.20 mm)

Specification

45°

1.772-1.791" (45.00-45.50 mm)

1.733-1.772" (45.60-46.50 mm)

.035" (0.9 mm)

.039" (1.0 mm)

4.0114" (101.89 mm)

3.9524" (100.39 mm)

4.0153" (101.99 mm)

3.9563" (100.49 mm)

Standard

Minimum

Exhaust

Standard

Minimum

Stem Diameter

Intake

Standard

Minimum

Exhaust

Standard

Minimum

Valve Springs

Free Length

1.821" (46.26 mm)

Maximum Out-Of-Square

.064" (1.62 mm)

Compressed Length

Minimum

CAMSHAFT

Application

End Play

Standard

Maximum

Journal Diameter

Maximum Journal Out-Of-Round

Maximum Journal Runout

Journal Oil Clearance

Standard

Maximum

Lobe Height

Standard

Intake

Exhaust

Minimum

Microsoft

Sunday, July 05, 2009 1:55:15 PM

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

3.9741-4.0055" (100.94-

101.74 mm)

3.9701" (100.84 mm)

3.9780-4.0094" (101.04-

101.84 mm)

3.9661" (100.74 mm)

.2351-.2356" (5.970-5.985 mm)

.2331" (5.920 mm)

.2349-.2354" (5.965-5.980 mm)

.2329" (5.915 mm)

Lbs. @ In. (kg @ mm)

51-55 @ 1.555 (23-25 @ 39.50)

In. (mm)

.0028-.0074 (.07-.19)

.008 (.20)

1.0213-1.0222 (25.940-25.965)

.0012 (.03)

.0014-.0031 (.035-.081)

.006 (.15)

1.7360 (44.094)

1.7559 (44.600)

Intake

Exhaust

VALVE LIFTERS

Application

Bore Diameter

Lifter Diameter

Oil Clearance

Standard

Maximum

1997 Mazda MX-5 Miata

1997-98 ENGINES 1.8L 4-Cylinder

1.7281 (43.894)

1.7480 (44.400)

In. (mm)

1.1811-1.1821 (30.000-30.025)

1.1795-1.1802 (29.959-29.975)

.0010-.0026 (.025-.066)

.0071 (.180)

Microsoft

Miata & Protege

1994-98 ENGINE COOLING

Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5 Miata &

Protege

APPLICATION

Information presented in this article applies to the following years and models. See YEAR & MODEL

APPLICATION .

YEAR & MODEL APPLICATION

Years

1997

1998

1997-98

1994-97

1995-98

Model

B2300

B4000

B2500, B3000 & B4000

Millenia

MPV

MX-5 Miata

Protege

ADJUSTMENTS

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

B4000 & MILLENIA (2.3L)

NOTE: "B" Series Pickup and Millenia 2.3L are equipped with serpentine belts that are automatically adjusted by tensioner. Millenia is equipped with 2 serpentine belts

(alternator and power steering pump). Replace belts if tensioner indicates belt is out of adjustment range. See Fig. 1 - Fig. 3 . DO NOT apply belt dressing to serpentine belt.

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 1: Checking Serpentine Belt Tension (B4000)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 2: Checking Alternator Serpentine Belt Tension (Millenia, 2.3L)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 3: Checking Power Steering Pump Serpentine Belt Tension (Millenia, 2.3L)

Courtesy of MAZDA MOTORS CORP.

MILLENIA

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

Alternator (2.5L)

Loosen idler pulley locknut and adjust belt deflection by turning adjusting bolt. See Fig. 4 and Fig. 19 . See

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

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 4: Adjusting Alternator Belt (Millenia, 2.5L)

Courtesy of MAZDA MOTORS CORP.

Power Steering Pump (2.5L)

Loosen idler pulley locknut and adjust belt deflection by turning adjusting bolt. See Fig. 5 and Fig. 20 . See

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

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 5: Adjusting Power Steering Pump Belt (Millenia, 2.5L)

Courtesy of MAZDA MOTORS CORP.

MPV

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

Alternator

Loosen alternator bolts and adjust belt deflection by levering generator outward and applying tension. See Fig.

6 and Fig. 21 . See ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE

SPECIFICATIONS .

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 6: Adjusting Alternator Belt (MPV)

Courtesy of MAZDA MOTORS CORP.

A/C Compressor

Loosen locknut and adjust belt deflection by turning adjusting bolt. See Fig. 7 and Fig. 23 . See

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

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 7: Adjusting A/C Compressor Belt (MPV)

Courtesy of MAZDA MOTORS CORP.

Power Steering Pump

Loosen locknut and adjust belt deflection by turning adjusting bolt. See Fig. 8 and Fig. 22 . See

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

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 8: Adjusting Power Steering Pump Belt (MPV)

Courtesy of MAZDA MOTORS CORP.

MX-5 MIATA

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

Alternator

Loosen alternator bolts and adjust belt deflection by turning adjusting bolt. See Fig. 9 and Fig. 25 . See

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

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 9: Adjusting Alternator Belt (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

A/C Compressor

Loosen locknut and adjust belt deflection by turning adjusting bolt. See Fig. 10 and Fig. 26 . See

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

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 10: Adjusting A/C Compressor Belt (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

Power Steering Pump

Loosen power steering pump nut and bolt, and adjust belt deflection by turning adjusting bolt. See Fig. 11 and

Fig. 25 . See ADJUSTMENT SPECIFICATIONS . Tighten bolts to specification. See TORQUE

SPECIFICATIONS .

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 11: Adjusting Power Steering Pump Belt (MX-5 Miata)

Courtesy of MAZDA MOTORS CORP.

PROTEGE

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

Alternator

Loosen bolts and adjust belt deflection by turning adjusting bolt. See Fig. 12 and Fig. 27 . See ADJUSTMENT

SPECIFICATIONS . Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 12: Adjusting Alternator Belt (Protege)

Courtesy of MAZDA MOTORS CORP.

Power Steering Pump

Loosen nuts and bolts and adjust belt deflection by turning adjusting bolt. See Fig. 13 , Fig. 14 and Fig. 28 . See

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

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 13: Adjusting Power Steering Pump Belt (Without A/C, Protege)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 14: Adjusting Power Steering Pump Belt (With A/C, Protege)

Courtesy of MAZDA MOTORS CORP.

DRIVE BELT ROUTING

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 15: Identifying Drive Belt Routing (B2300 & B2500)

Courtesy of FORD MOTOR CO.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 16: Identifying Drive Belt Routing (B3000)

Courtesy of FORD MOTOR CO.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 17: Identifying Drive Belt Routing (B4000)

Courtesy of FORD MOTOR CO.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 18: Identifying Drive Belt Routing (Millenia, 2.3L)

Courtesy of FORD MOTOR CO.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 19: Identifying Drive Belt Routing & Deflection Check Point (Millenia, 2.5L, 1 Of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 20: Identifying Drive Belt Routing & Deflection Check Point (Millenia, 2.5L, 2 Of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 21: Identifying Drive Belt Routing & Deflection Check Point (MPV, 1 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 22: Identifying Drive Belt Routing & Deflection Check Point (MPV, 2 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 23: Identifying Drive Belt Routing & Deflection Check Point (MPV, 3 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 24: Identifying Drive Belt Routing & Deflection Check Point (MX-5 Miata, 1 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 25: Identifying Drive Belt Routing & Deflection Check Point (MX-5 Miata, 2 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 26: Identifying Drive Belt Routing & Deflection Check Point (MX-5 Miata, 3 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 27: Identifying Drive Belt Routing & Deflection Check Point (Protege, 1 Of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 28: Identifying Drive Belt Routing & Deflection Check Point (Protege, 2 Of 2)

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENT SPECIFICATIONS

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

DEFLECTION SPECIFICATIONS (MILLENIA, 2.5L)

Application

New Belt

(2)

Alternator

Power Steering Pump

Used Belt

Alternator

Power Steering Pump

Wear Limit

Alternator

Power Steering Pump

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

Microsoft

Sunday, July 05, 2009 1:57:32 PM Page 29

(1)

Specification - In. (mm)

0.22-0.25 (5.5-6.5)

0.24-0.27 (6-7)

0.25-0.29 (6.5-7.5)

0.27-0.31 (7-8)

0.31 (8)

0.35 (9)

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

(2) Used on for less than 5 minutes.

DEFLECTION SPECIFICATIONS (1996, MPV)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

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

(2) Used on for less than 5 minutes.

DEFLECTION SPECIFICATIONS (1997-98, MPV)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

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

(2) Used on for less than 5 minutes.

(1)

Specification - In. (mm)

0.36-0.39 (9-10)

0.16-0.17 (4-4.5)

0.28-0.29 (7-7.5)

0.39-0.47 (10-12)

0.17-0.21 (4.5-5.5)

0.30-0.32 (7.5-8.2)

0.71 (18)

0.33 (8.5)

0.53 (13.5)

Specification - In. (mm)

0.36-0.39 (9-10)

0.18-0.19 (4.5-5)

0.28-0.29 (7-7.5)

0.39-0.47 (10-12)

0.20-0.22 (5-5.6)

0.30-0.32 (7.5-8.2)

0.71 (18)

0.33 (8.5)

0.53 (13.5)

DEFLECTION SPECIFICATIONS (MX-5 MIATA)

Application

Microsoft

Sunday, July 05, 2009 1:57:32 PM Page 30

(1)

Specification - In. (mm)

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

Alternator

A/C Compressor

Power Steering Pump

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

(2) Used on for less than 5 minutes.

0.22-0.27 (5.5-7)

0.32-0.35 (8-9)

0.24-0.29 (6-7.5)

0.35-0.39 (9-10)

0.31 (8)

0.45 (11.5)

DEFLECTION SPECIFICATIONS (PROTEGE)

Application

New Belt

(2)

Alternator

Power Steering Pump

Used Belt

Alternator

Power Steering Pump

Wear Limit

Alternator

Power Steering Pump

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

(2) Used on for less than 5 minutes.

(1)

Specification - In. (mm)

0.22-0.27 (5.5-7)

0.32-0.35 (8-9)

0.24-0.29 (6-7.5)

0.35-0.39 (9-10)

0.31 (8)

0.45 (11.5)

TENSION SPECIFICATIONS (MILLENIA, 2.5L)

Application

New Belt

(2)

Alternator

Power Steering Pump

Used Belt

Alternator

Power Steering Pump

Wear Limit

Microsoft

Sunday, July 05, 2009 1:57:32 PM Page 31

(1)

Specification - Lbs. (kg)

160-190 (70-90)

130-150 (55-70)

110-150 (50-70)

88-120 (40-55)

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Alternator

Power Steering Pump

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

(2) Used on for less than 5 minutes.

TENSION SPECIFICATIONS (1996, MPV)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

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.

(1)

99 (45)

77 (35)

Specification - Lbs. (kg)

124-143 (56-65)

115-129 (52-59)

77-85 (35-39)

104-123 (47-56)

97-112 (44-51)

66-74 (30-34)

59 (27)

55 (25)

TENSION SPECIFICATIONS (1997-98, MPV)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

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.

Microsoft

Sunday, July 05, 2009 1:57:32 PM Page 32

(1)

Specification - Lbs. (kg)

124-143 (56-65)

115-129 (52-59)

77-85 (35-39)

104-123 (47-56)

97-112 (44-51)

66-74 (30-34)

59 (27)

55 (25)

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

TENSION SPECIFICATIONS (MX-5 MIATA)

Application

New Belt

(2)

Alternator

A/C Compressor

Power Steering Pump

Used Belt

Alternator

A/C Compressor

Power Steering Pump

Wear Limit

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.

TENSION SPECIFICATIONS (PROTEGE)

Application

New Belt

(2)

Alternator

Power Steering Pump

Used Belt

Alternator

Power Steering Pump

Wear Limit

Alternator

Power Steering Pump

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

(2) Used on for less than 5 minutes.

(1)

Specification - Lbs. (kg)

110-167 (50-76)

110-132 (50-60)

110-158 (50-72)

95-110 (43-50)

77 (35)

55 (25)

Specification - Lbs. (kg)

110-160 (50-76)

110-130 (50-60)

110-150 (50-72)

95-110 (43-50)

77 (35)

55 (25)

TROUBLE SHOOTING

NOTE: Ensure drive belts are not worn, cracked or frayed and are correctly mounted on pulleys. See Fig. 29 .

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Fig. 29: Identifying Correct Belt Mounting

Courtesy of MAZDA MOTORS CORP.

B2500, B3000 & B4000

CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause drive belt to come off drive pulleys.

NOTE: Replace belts if tensioner indicates belt is out of adjustment range. DO NOT apply belt dressing to serpentine belt. Use illustration to help align serpentine belt and to check belt routing and tension. See Fig. 15 through Fig. 17 .

To check drive belt for proper operation, with engine running, check drive belt tracking (position of drive belt on one of the grooveless pulleys, idlers or drive belt tensioner). If edge of drive belt rides beyond edge of pulley, noise and premature wear may result. If a drive belt tracking condition exists, visually check drive belt tensioner for damage, especially mounting pad surface. If drive belt tensioner is not installed correctly with locating pins in locating holes, mounting surface pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal noises.

If above procedures do not correct drive belt noise, try replacing drive belt with a known good drive belt.

However, drive belt noise may return, with mileage, if one of above conditions still exists uncorrected.

Microsoft

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

With engine running, visually observe grooves in pulleys (not pulley flanges) for excessive wobble. Replace components as required. Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent component from mounting properly. Correct any interference conditions and recheck belt tracking. Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification.

Replace drive belt is excessive cracking or wear, severe glazing or frayed cords are present. Minor cracks in back of drive belt are considered acceptable.

SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS (1997 2300)

Model

B2300

Coolant Replacement

Interval

Specification

(1)

50,000 Miles Or 48

Months

Coolant Capacity

With A/C

Without A/C

Pressure Cap

Thermostat Open Temperature

Starts

Fully Open

Thermostat Open Lift

(1) Every 30,000 miles, and every 36 months thereafter.

7.2 Qts. (6.8L)

6.5 Qts. (6.2L)

12 psi

192°F (89°C)

212°F (100°C)

.13" (3.2 mm)

COOLING SYSTEM SPECIFICATIONS (1998 B2500, B3000 & B4000)

Model

B2500

Coolant Replacement

Interval

Coolant Capacity

With A/C

Without A/C

Pressure Cap

Thermostat Open Temperature

Starts

Fully Open

Thermostat Open Lift

Microsoft

Sunday, July 05, 2009 1:57:33 PM

Specification

(1)

50,000 Miles Or 48

Months

7.2 Qts. (6.8L)

6.5 Qts. (6.2L)

14.4-17.6 psi

Page 35

183-190°F (84-88°C)

212°F (100°C)

.13" (3.2 mm)

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

B3000

Coolant Replacement

Interval

Coolant Capacity

With A/C

Without A/C

Pressure Cap

Thermostat Open Temperature

Starts

Fully Open

Thermostat Open Lift

B4000

Coolant Replacement

Interval

Coolant Capacity

With A/C

Without A/C

Pressure Cap

1997

1998

Thermostat Open Temperature (1997)

Starts

Fully Open

Thermostat Open Lift (1997)

Thermostat Open Temperature (1998)

Starts

Fully Open

Thermostat Open Lift (1998)

(1) Every 30,000 miles, and every 36 months thereafter.

(1)

183-190°F (84-88°C)

(1)

50,000 Miles Or 48

Months

10.2 Qts. (9.6L)

9.5 Qts. (9.0L)

14.4-17.6 psi

212°F (100°C)

.13" (3.2 mm)

50,000 Miles Or 48

Months

8.6 Qts. (8.1L)

7.8 Qts. (7.4L)

12 psi

14.4-17.6 psi

192°F (89°C)

212°F (100°C)

.13" (3.2 mm)

183-190°F (84-88°C)

212°F (100°C)

.13" (3.2 mm)

COOLING SYSTEM SPECIFICATIONS (1994-97 MIATA)

Model

Miata

Coolant Replacement

1994-95

Interval

1996-97

Interval

Microsoft

Sunday, July 05, 2009 1:57:33 PM Page 36

Specification

24,000 Miles Or 30 Months

(1)

45,000 Miles Or 36

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Coolant Capacity

Pressure Cap

Thermostat Open Temperature

Starts

Main Valve

Sub Valve

Fully Open

Thermostat Open Lift

Main Valve

Sub Valve

(1) Every 30,000 miles, and every 24 months thereafter.

COOLING SYSTEM SPECIFICATIONS (1997-98 MILLENIA)

Model

Millenia

Coolant Replacement

Interval

Coolant Capacity

Pressure Cap

Thermostat Open Temperature

Starts

Fully Open

Thermostat Open Lift

(1) Every 30,000 miles, and every 24 months thereafter.

188-193°F (86.5-89.5°C)

183-188°F (83.5-86.5°C)

(1)

Months

6.3 Qts. (6.0L)

10.7-14.9 psi

212°F (100°C)

.31" (8 mm)

.06" (1.5 mm)

Specification

45,000 Miles Or 36

Months

7.9 Qts. (7.5L)

13.5-17.7 psi

176-183°F (80-84°C)

203°F (95°C)

.33" (8.5 mm)

COOLING SYSTEM SPECIFICATIONS (1997-98 MPV)

Model

MPV

Coolant Replacement

Interval

Coolant Capacity

Pressure Cap

Thermostat Open Temperature (1997)

Starts

Fully Open

Thermostat Open Lift (1997)

Thermostat Open Temperature (1998)

Microsoft

Sunday, July 05, 2009 1:57:33 PM

Specification

(1)

45,000 Miles Or 36

Months

10.3 Qts. (9.7L)

10.7-14.9 psi

179-184°F (81.5-84.5°C)

205°F (96°C)

.35" (9.0 mm)

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

Starts

Fully Open

Thermostat Open Lift (1998)

(1) Every 30,000 miles, and every 24 months thereafter.

COOLING SYSTEM SPECIFICATIONS (1995-98 PROTEGE)

Model

Protege

Coolant Replacement

1995

Interval

1996-98

Interval

Coolant Capacity

Pressure Cap

Thermostat Open Temperature (1995)

Starts

Main Valve

Sub Valve

Fully Open

Thermostat Open Lift (1995)

Main Valve

Sub Valve

Thermostat Open Temperature (1996-98)

Starts

Fully Open

Thermostat Open Lift (1996-98)

(1) Every 30,000 miles, and every 24 months thereafter.

176-183°F (80-84°C)

203°F (95°C)

.33" (8.5 mm)

Specification

24,000 Miles Or 30 Months

(1)

45,000 Miles Or 36

Months

6.3 Qts. (6.0L)

10.7-14.9 psi

188-193°F (86.5-89.5°C)

183-188°F (83.5-86.5°C)

212°F (100°C)

.31" (8 mm)

.06" (1.5 mm)

183-193°F (83.5-89.5°C)

212°F (100°C)

.33" (8.5 mm)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (MILLENIA, 2.5L)

Application

Alternator Locknut

Power Steering Pump Locknut

TORQUE SPECIFICATIONS (MPV)

Application

Alternator Adjusting Bolt

Microsoft

Sunday, July 05, 2009 1:57:33 PM

Ft. Lbs. (N.m)

24-33 (32-46)

Ft. Lbs. (N.m)

1997 Mazda MX-5 Miata

1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5

Miata & Protege

"A"

"B"

A/C Compressor Locknut

Power Steering Pump Locknut

TORQUE SPECIFICATIONS (MX-3 MIATA)

Application

Alternator Adjusting Bolt

"A"

"B"

A/C Compressor Locknut

Power Steering Pump Bolt

"A"

"B"

"C"

TORQUE SPECIFICATIONS (PROTEGE)

Application

Alternator Adjusting Bolt

"A"

"B"

Power Steering Pump Bolt

"A"

"B"

"C"

14-18 (19-25)

28-38 (38-51)

Ft. Lbs. (N.m)

14-18 (19-25)

28-38 (38-51)

24-33 (32-46)

27-39 (37-53)

14-18 (19-25)

Ft. Lbs. (N.m)

28-38 (38-51)

14-18 (19-25)

32-44 (44-60)

28-38 (38-51)

Microsoft

1997-2000 SUSPENSION Front - Miata

1997-2000 SUSPENSION

Front - Miata

DESCRIPTION

NOTE: Mazda did not produce 1998 Miata models.

Front suspension is an independent, double wishbone design using upper and lower control arms. A spring over shock is mounted between lower control arm and upper fender panel. Upper and lower control arms pivot at crossmember and are connected by ball joints to steering knuckle. A stabilizer bar attaches to each lower control arm and frame. See Fig. 1 . Upper coil over shock mount plate has been redesigned for 1999-2000. New design incorporates a urethane bumper and improves ride and cornering.

Fig. 1: Identifying Front Suspension Components

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

NOTE: See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

WHEEL BEARING ADJUSTMENT

Raise and support vehicle. Remove wheel assembly. Remove brake caliper and ABS wheel speed sensor.

Remove rotor. Attach dial indicator to axle hub, and measure bearing play. Check bearing axial play by rocking hub assembly by hand. Maximum axial play should be .002" (.05 mm). If play exceeds specification, check and adjust lock nut torque or replace hub and bearing assembly. See TORQUE SPECIFICATIONS .

1997 Mazda MX-5 Miata

1997-2000 SUSPENSION Front - Miata

INSPECTION

BALL JOINT CHECKING

Lower Ball Joint

Remove lower control arm. See LOWER CONTROL ARM & BALL JOINT under REMOVAL &

INSTALLATION. Rotate ball joint stud 4-5 times. Install Preload Attachment (49-0180-510B) to ball joint stud. Measure ball joint preload using spring scale. See LOWER BALL JOINT PRELOAD

SPECIFICATIONS table. If preload is not as specified, replace lower ball joint.

LOWER BALL JOINT PRELOAD SPECIFICATIONS

Application

1997

1999 & 2000

Lbs. (kg)

1.1-3.3 (0.5-1.5)

0.78-4.29 (0.35-1.95)

Upper Ball Joint

Remove upper control arm. See UPPER CONTROL ARM & BALL JOINT under REMOVAL &

INSTALLATION. Rotate ball joint stud 4-5 times. Install Preload Attachment (49-0180-510B) to ball joint stud. Measure ball joint preload using spring scale. See UPPER BALL JOINT PRELOAD

SPECIFICATIONS table. If preload is not as specified, replace upper control arm.

UPPER BALL JOINT PRELOAD SPECIFICATIONS

Application

1997

1999 & 2000

Lbs. (kg)

0.9-3.9 (0.4-1.8)

0.7-5.0 (0.3-2.3)

REMOVAL & INSTALLATION

NOTE: Refer to illustration during removal and installation. See Fig. 1 .

WHEEL BEARING

NOTE: Wheel bearing is not serviceable. If bearing is defective, replace hub and bearing assembly as a unit.

Removal

Raise and support vehicle. Remove wheel assembly. Remove brake caliper and ABS wheel speed sensor, and wire aside. Remove grease cap and axle lock nut. Remove brake rotor. Remove hub and bearing assembly.

Remove wheel speed sensor rotor from hub.

Inspection

Microsoft

1997 Mazda MX-5 Miata

1997-2000 SUSPENSION Front - Miata

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. Replace components as necessary.

Installation

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

ADJUSTMENT under ADJUSTMENTS. Stake axle nut.

LOWER CONTROL ARM & BALL JOINT

Removal

1. Raise and support vehicle. Remove wheel assembly. Remove engine splash shield (if equipped). Separate tie rod end from steering knuckle (as necessary). Remove stabilizer bar from lower control arm.

2. Remove shock lower mounting bolt and separate lower shock from lower control arm. Remove lower control arm ball joint cotter pin and nut. Separate lower control arm ball joint stud from knuckle using

Puller (49 T028 3A0). Remove lower control arm pivot bolts and 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 components as necessary.

Bushing Replacement

Cut or press old bushing from control arm. Coat NEW bushing with paraffin-based oil. Press new bushing into control arm.

Installation (All Models)

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

UPPER CONTROL ARM & BALL JOINT

Removal

Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor harness band. Remove shock lower mounting bolt, and separate lower shock from lower control arm. Remove upper control arm ball joint cotter pin and nut. Separate upper control arm ball joint stud from knuckle using

Puller (49-0118-850C). Remove upper control arm pivot bolts and 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 components as necessary.

Microsoft

1997 Mazda MX-5 Miata

1997-2000 SUSPENSION Front - Miata

Bushing Replacement

Cut or press old bushing from control arm. Coat new bushing with paraffin-based oil. Press new bushing into control arm.

Installation (All Models)

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

SHOCK ASSEMBLY

Removal (1997)

Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor harness band. Remove stabilizer link bolt. Remove upper control arm ball joint cotter pin and nut. Separate upper control arm ball joint stud from knuckle using Puller (49-0118-850C). Loosen lower control arm pivot bolts. Remove shock upper mount nuts and lower bolt. Move lower control arm just enough to remove shock assembly. DO NOT damage brake line.

Removal (1999 & 2000)

Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor.

Remove stabilizer link bolt. Separate lower control arm ball joint stud from knuckle using Puller (49-T028-

3A0). Loosen lower control arm pivot bolts. Inside engine compartment, on 1999 models, remove strut bar. See

FRONT STRUT BAR (1999) . On 2000 models, remove shock upper mount nuts. On all models, under car, remove lower bolt. Move lower control arm just enough to remove shock assembly. DO NOT damage brake line.

Disassembly

Clamp upper shock mount in vise. Loosen piston lock nut 2 turns only. Compress coil spring using coil spring compressor. Remove piston lock nut. Slowly release compressor tension. Remove components. Remove coil spring. Remove shock from vise.

Inspection

Check shock tube for damage, oil leakage and abnormal noise. Check rubber components for deterioration or damage. Inspect coil spring for signs of fatigue or damage. Replace components as necessary.

Reassembly (1997)

Clamp shock in vise. Install coil spring and components in reverse order of disassembly. Ensure coil spring is well seated in upper and lower spring seats. See Fig. 2 . Tighten piston rod nut. See TORQUE

SPECIFICATIONS .

Microsoft

1997 Mazda MX-5 Miata

1997-2000 SUSPENSION Front - Miata

Fig. 2: Cross-Sectional View Of Upper Coil Over Shock Assembly (1997)

Courtesy of MAZDA MOTORS CORP.

Reassembly (1999 & 2000)

Clamp shock in vise. Install spring and upper spring retainer in original orientation to shock. Tighten lower piston rod nut so that exposed thread of piston rod is 0.62-0.69" (15.7-17.7mm). See Fig. 3 . Tighten upper nut to 12-17 ft. lbs. (16-23 N.m).

CAUTION: Using air tool will damage piston rod thread. DO NOT use air tool.

Microsoft

1997 Mazda MX-5 Miata

1997-2000 SUSPENSION Front - Miata

Fig. 3: Cross-Sectional View Of Upper Coil Over Shock Assembly (1999-2000)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2000 SUSPENSION Front - Miata

Installation

To install, reverse removal procedure. Fully tighten all bolts with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS . Check front wheel alignment. See SPECIFICATIONS &

PROCEDURES article in WHEEL ALIGNMENT.

STABILIZER BAR

Removal & Installation

Raise and support vehicle. Remove engine splash shield. Remove frame brackets and bushings. Remove stabilizer control links. Align bushing with installation mark on stabilizer. Reverse removable procedure for installation. See TORQUE SPECIFICATIONS .

FRONT STRUT BAR (1999)

Removal & Installation

1. To remove strut bar located in engine compartment mounted on top of shock towers, loosen lock nuts on joint bolt and loosen joint bolt. Remove nut, washer and bolt retaining strut bar to strut plate. Remove strut bar from vehicle.

2. To install, reverse removal procedure. Rotate joint bolt counterclockwise to 3.5-5.2 INCH lbs. (.4-.6 N.m) to set tension. Tighten lock nuts to 87-121 INCH lbs. (10-14 N.m). Tighten strut bar-to-strut plate nut.

See TORQUE SPECIFICATIONS .

TORQUE SPECIFICATIONS

Application

Axle Lock Nut

Brake Caliper Bracket Bolts

Lower Ball Joint-To-Knuckle Nut

Lower Ball Joint-To-Lower Control

1997

1999 & 2000

Bolt & Nut

Bolt

Lower Control Arm-To-Frame

1997

Front Adjusting Bolt Lock Nut

Rear Adjusting Bolt Lock Nut

1999 & 2000

Shock Assembly-To-Lower Control Arm Bolt/Nut

1997

Microsoft

Sunday, July 05, 2009 1:38:08 PM Page 7

Ft. Lbs. (N.m)

123-159 (167-215)

37-50 (50-68)

42-57 (57-77)

54-69 (73-94)

69-86 (94-117)

54-69 (73-94)

69-83 (94-112)

62-75 (84-102)

69-83 (94-112)

54-68 (73-93)

1999 & 2000

Shock Piston Rod Nut

1997

Shock Upper Mount Nuts

Stabilizer Bar Bracket-To-Frame Bolts

Stabilizer Link Bolts

1997

1999 & 2000

Tie Rod-To-Knuckle Nut

1997

1999 & 2000

Upper Ball Joint-To-Knuckle Nut

Upper Control Arm Pivot Bolt/Nut

Wheel Lug Nuts

Wheel Speed Sensor Bolt

1997

1999 & 2000

1997 Mazda MX-5 Miata

1997-2000 SUSPENSION Front - Miata

69-86 (94-117)

24-33 (32-46)

22-26 (30-36)

14-19 (19-26)

27-39 (37-53)

32-44 (43-60)

22-32 (30-43)

32-41 (43-56)

31-44 (42-60)

87-101 (118-137)

66-86 (89-117)

12-16 (16-22)

14-18 (19-25)

Microsoft

1997 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

1997 ELECTRICAL

Fuses & Circuit Breakers - MX-5 Miata

IDENTIFICATION

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN

PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

MAIN FUSE BLOCK

Main fuse block is located on passenger's side of engine compartment. See Fig. 1 .

Fig. 1: Locating Main Fuse Block

1997 Mazda MX-5 Miata

1997 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Fig. 2: Identifying Main Fuse Block Components

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 3: Main Fuse Block Legend

Courtesy of MAZDA MOTORS CORP.

FUSE BLOCK

Fuse block is located under driver's side of instrument panel. See Fig. 4 .

Fig. 4: Locating Fuse Block

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 5: Identifying Fuse Block Components

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 6: Fuse Block Legend

Courtesy of MAZDA MOTORS CORP.

TRUNK FUSE BOX

Trunk fuse block is located in passenger's side of the trunk. See Fig. 7 .

Microsoft

1997 Mazda MX-5 Miata

1997 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 7: Locating Trunk Fuse Box

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997 ELECTRICAL Fuses & Circuit Breakers - MX-5 Miata

Fig. 8: Identifying Trunk Fuse Box Components & Legend

Courtesy of MAZDA MOTORS CORP.

Microsoft

HEATER SYSTEM 1997 Heater System

DESCRIPTION & OPERATION

HEATER SYSTEM

1997 Heater System

WARNING: To avoid injury from accidental air bag deployment, read and follow all

SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG

SYSTEM procedures in AIR BAG RESTRAINT SYSTEM article in the

ACCESSORIES/SAFETY EQUIPMENT section.

CAUTION: When battery is disconnected, radio will go into anti-theft protection mode. Obtain radio anti-theft protection code from owner prior to servicing vehicle.

Heater case, mounted under center of instrument panel, contains airflow mode doors and air-mix (temperature blend) doors. See Fig. 1 . Blower case, mounted under right side of instrument panel, contains blower motor, blower resistor and fresh/recirculated air door. All doors are controlled manually from control panel by cable.

Blower resistors, located on bottom of blower case, determine blower speed.

1997 Mazda MX-5 Miata

HEATER SYSTEM 1997 Heater System

Fig. 1: Exploded View Of Heater Unit

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

AIRFLOW MODE DOOR

Set airflow mode control lever at vent position. Disconnect control cable at airflow mode door lever. See Fig.

1 . Extend airflow mode door lever until it stops. Attach control cable to door lever. Secure cable using clip.

Ensure control lever slides freely between defrost and vent positions.

AIR-MIX (TEMPERATURE BLEND) DOOR

Set temperature control lever at maximum hot setting. Disconnect control cable at air-mix door lever. See Fig.

1 . Extend air-mix door lever until it stops. Attach control cable to door lever. Secure cable using clip. Ensure control lever slides freely between hot and cold settings.

FRESH/RECIRCULATED AIR DOOR

Set fresh/recirculated air control lever at fresh air setting. Disconnect control cable at fresh/recirculated air door lever. Retract recirculated/fresh air door lever until it stops. Attach control cable to door lever. Secure cable using clip. Ensure control lever slides freely between recirculated air and fresh air settings.

TESTING

WARNING: To avoid injury from accidental air bag deployment, read and follow all

SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG

SYSTEM procedures in AIR BAG RESTRAINT SYSTEM article in the

ACCESSORIES/SAFETY EQUIPMENT section.

BLOWER MOTOR CIRCUIT

1. Check 30-amp HEATER fuse in passenger compartment fuse block. If fuse is okay, go to next step. If fuse is burnt, check for short circuit in wiring harness and repair as necessary. Replace fuse.

2. Turn ignition on. Turn blower switch to 4th position (high). Using voltmeter, backprobe Blue wire terminal of blower motor connector on bottom of blower case. If battery voltage exists, go to next step. If battery voltage is not present, repair wiring harness between circuit breaker or fuse and blower motor.

3. Ensure ignition is on. Backprobe Blue wire terminal of blower resistor 1-pin connector. If battery voltage exists, go to next step. If battery voltage is not present, replace blower motor.

4. Backprobe Blue/White wire terminal, Blue/Red wire terminal, Blue/Green wire terminal and Blue/Yellow wire terminal of blower resistor 4-pin connector. If battery voltage exists, go to next step. If battery voltage is not present at any terminal, replace blower resistor.

5. Turn blower switch to 4th position (high). Backprobe Black wire terminal of blower switch connector. If battery voltage is not present, go to next step. If battery voltage exists, repair Black wire between blower switch and chassis ground.

Microsoft

1997 Mazda MX-5 Miata

HEATER SYSTEM 1997 Heater System

6. Turn ignition blower switch off. Backprobe Blue/White wire terminal, Blue/Red wire terminal,

Blue/Green wire terminal and Blue/Yellow wire terminal of blower switch connector If battery voltage is not present, repair open wire(s) between blower resistor and blower switch. If battery voltage exists, check blower motor.

BLOWER MOTOR

Disconnect blower motor 2-pin connector from bottom of blower case. Apply battery voltage across blower motor terminals. Replace blower motor if it does not operate.

BLOWER RESISTOR

Disconnect blower resistor connectors from blower case. Check continuity, in turn, between Blue wire terminal of 1-pin connector and each terminal of 4-pin connector. Ensure continuity exists. Replace resistor if continuity does not exist.

BLOWER SWITCH

Disconnect blower switch connector. Place blower switch in indicated positions, and check continuity between specified blower switch terminals. See BLOWER SWITCH TEST table. See Fig. 2 . If continuity is not as specified, replace blower switch.

BLOWER SWITCH TEST

Switch Position

Off

Low

Medium-Low

Medium-High

High

(1) There should not be continuity between any terminals.

Continuity Between Terminals

(1)

"A" & "G"

"C", "G" & "H"

"E", "G" & "H"

"B", "G" & "H"

Microsoft

1997 Mazda MX-5 Miata

HEATER SYSTEM 1997 Heater System

Fig. 2: Identifying Blower Switch Terminals

Courtesy of MAZDA MOTORS CORP.

REMOVAL & INSTALLATION

WARNING: To avoid injury from accidental air bag deployment, read and follow all

SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG

SYSTEM procedures in AIR BAG RESTRAINT SYSTEM article in the

ACCESSORIES/SAFETY EQUIPMENT section.

BLOWER UNIT

Removal & Installation

Remove glove box. Disconnect electrical connectors. Loosen seal plate between blower unit and evaporator unit

(if equipped). Remove blower unit bolts and blower unit. Disassemble blower unit to remove blower motor and blower resistor. To install, reverse removal procedure.

CONTROL PANEL

Removal & Installation

Remove rear center console. Remove vent outlets from center panel. Remove center panel. Remove control panel screws, and pull control panel from center panel. Disconnect heater control cables. To install, reverse removal procedure.

HEATER CORE

Removal & Installation

Microsoft

1997 Mazda MX-5 Miata

HEATER SYSTEM 1997 Heater System

Drain coolant. Disconnect heater hoses at engine compartment firewall. Remove grommets from holes (if equipped). Remove instrument panel. See INSTRUMENT PANEL . Remove heater unit. Disassemble heater unit to remove heater core. See Fig. 1 . To install, reverse removal procedure. Fill cooling system.

INSTRUMENT PANEL

Removal & Installation

Before disconnecting negative battery cable, obtain radio anti-theft code from vehicle owner. Disconnect negative battery cable. Remove components in the 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

1997 Mazda MX-5 Miata

HEATER SYSTEM 1997 Heater System

Microsoft

1997 Mazda MX-5 Miata

HEATER SYSTEM 1997 Heater System

Fig. 4: Heater System Wiring Diagram

Microsoft

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

A/C-HEATER SYSTEM - MANUAL

1997 Manual A/C-Heater System

A/C SYSTEM SPECIFICATIONS

WARNING: To avoid injury from accidental air bag deployment, read and follow all

SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG

SYSTEM procedures in AIR BAG RESTRAINT SYSTEM article in the

ACCESSORIES/SAFETY EQUIPMENT section.

CAUTION: When battery is disconnected, radio will go into anti-theft protection mode. Obtain radio anti-theft protection code from owner prior to servicing vehicle.

A/C SYSTEM SPECIFICATIONS

Application

Compressor Type

Specifications

Nippondenso TV12 Rotary

Vane

Compressor Belt Deflection

(1)

New

Used

Compressor Oil Capacity

(2)

Refrigerant Capacity

System Operating Pressures

High Side

5/16-23/64" (8-9 mm)

23/64-25/64" (9-10 mm)

4.4-5.7 ozs.

21.2 ozs.

Low Side

200-227 psi (14.0-16.0 kg/cm

)

22-35 psi (1.5-2.5 kg/cm

)

(1) Measure with 22-lb. (10 kg) pressure applied halfway between crankshaft pulley and Power Steering

(P/S) pulley or idler pulley (without P/S).

(2) Use ND-Oil 9 refrigerant oil.

DESCRIPTION

Blower assembly, mounted under right side of instrument panel, contains blower motor, blower resistor and fresh/recirculated air door. Evaporator unit, located left of blower case, contains evaporator, evaporator thermoswitch and expansion valve. Heater unit, located left of evaporator case, contains heater core, airflow mode door and air-mix (temperature blend) door.

ELECTRICAL COMPONENT LOCATIONS

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

ELECTRICAL COMPONENT LOCATIONS

Component

A/C Relay

Condenser Fan

Blower Resistor

Evaporator Thermoswitch

Pressure Switch

Location

Right Front Corner Of Engine Compartment

Bottom Of Blower Case

On Evaporator Upper Case

In High-Pressure Line, Between Receiver-Drier &

Evaporator

OPERATION

All air control doors are controlled manually by cable from control panel. Blower resistor determines blower speed. With blower switch in high position, blower motor is grounded directly through blower switch. With blower switch in all other positions, blower motor is grounded through blower resistor and blower switch.

A/C compressor clutch circuit is completed when A/C relay is energized and pressure switch is closed. A/C relay is energized when Powertrain Control Module (PCM) grounds the solenoid circuit of the relay. The PCM energizes A/C relay if evaporator thermoswitch is closed and A/C and blower switches are on. The PCM also controls A/C relay operation according to engine load.

ADJUSTMENTS

NOTE: For door control cable adjustments, see ADJUSTMENTS in HEATER SYSTEM article.

TESTING

WARNING: To avoid injury from accidental air bag deployment, read and follow all

SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG

SYSTEM procedures in AIR BAG RESTRAINT SYSTEM article in the

ACCESSORIES/SAFETY EQUIPMENT section.

NOTE: For test procedures not covered in this article, see TESTING in HEATER

SYSTEM article.

A/C SYSTEM PERFORMANCE

1. Connect manifold gauge set. Operate engine at 1500 RPM. Operate A/C at maximum cooling, recirculate, fan on high, vent mode. Close all doors and windows. Place thermometer at center vent outlet.

2. Allow A/C to stabilize. Ensure high pressure is 200-227 psi (14.0-16.0 kg/cm

). Read temperature at center vent outlet. Ensure temperature is within 39-43°F (3-6°C)

A/C COMPRESSOR CLUTCH CIRCUIT

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

1. Check WIPER fuse (20-amp) in passenger compartment fuse block. Check AD FAN (additional fan) fuse

(20-amp) in engine compartment fuse block. If fuses are okay, go to next step. If either fuse is blown, check for shorted wiring harness before replacing fuse.

2. Operate engine at idle. Turn A/C and blower on. Using voltmeter, backprobe Black/Red wire terminal of compressor clutch connector. If battery voltage exists, replace compressor clutch. If battery voltage is not present, go to next step.

3. Ensure engine is running. Ensure A/C and blower are on. Using a voltmeter, backprobe Blue/Yellow wire terminal of the A/C relay connector. If battery voltage exists, go to next step. If battery voltage does not exist, repair open Blue/Yellow wire between AD FAN fuse and A/C relay.

4. Backprobe Blue wire terminal of A/C relay connector. If battery voltage exists, go to next step. If battery voltage is not present, repair open Blue wire between WIPER fuse and A/C relay.

5. Backprobe Black/Red wire terminal of A/C relay connector. If battery voltage exists, repair open

Black/Red wire between A/C relay and compressor clutch. If battery voltage is not present, go to next step.

6. Backprobe Blue/Black wire terminal of A/C relay connector. If voltage is Zero volts, replace A/C relay. If voltage is not Zero volts, repair open Blue/Black wire between A/C relay and PCM. If wire is okay, check

PCM operation.

CONDENSER (ADDITIONAL) FAN CIRCUIT

1. Check ENGINE fuse (30-amp) in passenger compartment fuse block. Check AD FAN fuse (20-amp) in engine compartment fuse block. If fuses are okay, go to next step. If either fuse is blown, check for shorted wiring harness before replacing fuse.

2. Start engine. Turn A/C and blower switches on. Using voltmeter, backprobe Black/Yellow wire terminal of condenser fan motor. If battery voltage exists, go to next step. If battery voltage is not present, go to step 4).

3. Turn ignition switch off. Disconnect condenser fan connector. Using ohmmeter, check continuity between Black wire of condenser fan connector and ground. If continuity exists, replace condenser fan. If continuity is not present, repair open Black wire between condenser fan and ground.

4. Turn ignition on. Ensure A/C and blower switches are on. Using voltmeter, backprobe Black/White wire terminal of condenser fan relay connector. If battery voltage exists, go to next step. If battery voltage is not present, repair open Black/White wire between ENGINE fuse and condenser fan relay.

5. Backprobe Blue/Yellow wire terminal of condenser fan relay connector. If battery voltage exists, go to next step. If battery voltage is not present, repair open Blue/Yellow wire between AD FAN fuse and condenser fan relay.

6. Backprobe Black/Yellow wire terminal of condenser fan relay connector. If battery voltage exists, repair open Black/Yellow wire between condenser fan relay and condenser fan. If battery voltage is not present, go to next step.

7. Backprobe Blue/White wire terminal of condenser fan relay connector. If battery voltage exists, repair

Blue/White wire between condenser fan relay and PCM. If wire is okay, check PCM operation. If battery voltage is not present, replace condenser fan relay.

A/C SWITCH

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

Disconnect A/C switch connector. Turn A/C switch on. Check continuity between indicated terminals. See A/C

SWITCH TEST table. See Fig. 1 . Replace A/C switch if continuity is not as specified.

A/C SWITCH TEST

Terminal

"D" & "A"

"F" & "A"

(1) Continuity exists in only one direction.

Continuity

(1)

Yes

(1)

Yes

Fig. 1: Identifying A/C Switch Terminals

Courtesy of MAZDA MOTORS CORP.

A/C RELAY

Remove relay. Check continuity between indicated relay terminals. See A/C RELAY TEST table. See Fig. 2 .

Replace relay if continuity is not as specified.

A/C RELAY TEST

Test Between Terminals

"A" & "B"

"C" & "D"

(1) With no voltage applied.

(2) With battery voltage applied to terminals "A" and "B".

Continuity

(1)

(2)

Yes

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

Fig. 2: Identifying A/C Relay Terminals

Courtesy of MAZDA MOTORS CORP.

CONDENSER FAN RELAY

Remove condenser fan relay. Check continuity between indicated relay terminals. See CONDENSER FAN

RELAY TEST table. See Fig. 3 . If continuity is not as specified, replace relay.

CONDENSER FAN RELAY TEST

Test Between Terminals

"A" & "B"

"C" & "E"

"C" & "F"

"C" & "E"

(1) With no voltage applied.

(2) With battery voltage applied to terminals "A" and "B".

Continuity

(1)

(2)

Yes

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

Fig. 3: Identifying Condenser Fan Relay Terminals

Courtesy of MAZDA MOTORS CORP.

CONDENSER FAN MOTOR

Disconnect condenser fan motor connector. Connect positive battery lead to condenser fan motor Black/Yellow wire terminal, and ground Black wire terminal. Replace condenser fan motor if it does not operate.

EVAPORATOR THERMOSWITCH

1. Remove glove box. Operate engine at idle. Turn A/C off. Turn blower switch to 4th position (high) for a few minutes to ensure evaporator temperature is greater than 32°F (0°C). Turn blower switch and engine off.

2. Disconnect evaporator thermoswitch connector. Check continuity between thermoswitch terminals. If continuity exists, go to next step. If there is no continuity, replace thermoswitch.

3. Submerge thermoswitch sensing bulb in ice cold water of less than 32°F (0°C). Ensure continuity does not exist between thermoswitch terminals. Replace thermoswitch if continuity is not as specified.

PRESSURE SWITCH

1. Turn ignition off. Connect manifold pressure gauge set to system. If high-side pressure is 37-310 psi (2.6-

22.0 kg/cm

), go to next step. If pressure is not as specified, check refrigerant level.

2. Disconnect pressure switch connector. Check continuity between switch terminals. If continuity exists, pressure switch is okay. If there is no continuity, replace pressure switch.

REMOVAL & INSTALLATION

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

WARNING: To avoid injury from accidental air bag deployment, read and follow all

SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG

SYSTEM procedures in AIR BAG RESTRAINT SYSTEM article in the

ACCESSORIES/SAFETY EQUIPMENT section.

NOTE: For removal and installation procedures not covered in this article, see HEATER

SYSTEM article.

COMPRESSOR

Removal & Installation

1. Before disconnecting negative battery cable, obtain radio anti-theft code from vehicle owner. Disconnect negative battery cable.

2. Raise and support front of vehicle with safety stands. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove splash shield and air guide.

3. Disconnect compressor clutch connector. Disconnect refrigerant lines from compressor, and plug open fittings. Remove compressor drive belt. Remove compressor bolts and compressor. To install, reverse removal procedure. Adjust drive belt deflection. Apply clean compressor oil to "O" ring before connecting fittings. DO NOT apply compressor oil to fitting nuts. Evacuate and charge A/C system.

Check for leaks.

CONDENSER & RECEIVER-DRIER

Removal

Raise and support front of vehicle with safety stands. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove splash shield and air guide. Remove condenser. Remove receiver-drier.

Plug open fittings.

Installation

To install, reverse removal procedure. Apply clean compressor oil to "O" rings before connecting fittings. DO

NOT apply compressor oil to fitting nuts. If installing new condenser, add 1.0 ounce of compressor oil to A/C compressor. If installing new receiver-drier, add .3 ounce of compressor oil to A/C compressor. Evacuate and charge A/C system. Check for leaks.

EVAPORATOR UNIT

Removal

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant pipes from evaporator tubes at engine compartment firewall and plug open fittings. Remove passengerside instrument panel undercover. Remove glove box.

2. Disconnect electrical connectors. Loosen seal plates between evaporator unit, heater unit and blower unit.

Remove evaporator unit. Disassemble evaporator unit to remove evaporator core and thermo-switch. See

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

Fig. 4 .

Installation

To install, reverse removal procedure. Apply clean compressor oil to "O" rings before connecting fittings. DO

NOT apply compressor oil to fitting nuts. If installing new evaporator, add 1.7 ounces of compressor oil to A/C compressor. Evacuate and charge A/C system. Check for leaks.

Fig. 4: Exploded View Of Evaporator Unit

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

TORQUE SPECIFICATIONS

Application

Compressor Bracket-To-Engine Bolt

Compressor-To-Compressor Bracket Bolt

Refrigerant Pipe Fittings

Condenser Inlet

Evaporator Outlet

Evaporator Unit Nut

Refrigerant Pipe Fittings

Compressor Inlet & Outlet

Evaporator Inlet

Receiver-Drier Inlet & Outlet

Steering Wheel Nut

WIRING DIAGRAM

Ft. Lbs. (N.m)

28-38 (38-51)

11-15 (15-21)

11-18 (15-24)

15-21 (20-29)

INCH Lbs. (N.m)

71-97 (8-11)

89-132 (10-15)

89-168 (10-19)

79-121 (9-14)

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

Microsoft

1997 Mazda MX-5 Miata

A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System

Fig. 5: Manual A/C-Heater System Wiring Diagram

Microsoft

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

MAINTENANCE INFORMATION

1997 MAINTENANCE Mazda Maintenance Information

MODEL IDENTIFICATION

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

Fig. 1: VIN Code ID Explanation

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

MAINTENANCE SERVICE INFORMATION

SEVERE & NORMAL SERVICE DEFINITIONS

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on following primary operating conditions:

Normal Service



Driven More Than 10 Miles Daily

No Operating Conditions From Severe Service Schedule

Severe Service (Unique Driving Conditions)

NOTE: Use the Severe Service schedule if the vehicle to be serviced is operated under

ANY (one or more) of these conditions:



Repeated Short Distance Driving

Dusty Conditions



Extended Use Of Brakes

Salt Or Other Corrosive Materials On The Roads



Rough Or Muddy Roads

Extended Idling Or Low Speed Operation



Extended Operation In Extreme Temperatures

CAMSHAFT TIMING BELT

Replace camshaft timing belt at 60,000 mile intervals.

CAUTION: Failure to replace a faulty camshaft timing belt may result in serious engine damage.

The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called "Free Wheeling".

Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.

Belts or components should be inspected and replaced if any of the following conditions exist:

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information



Cracks Or Tears In Belt Surface



Missing, Damaged, Cracked Or Rounded Teeth

Oil Contamination



Damaged Or Faulty Tensioners

Incorrect Tension Adjustment

SERVICE POINT LOCATIONS

Fig. 2: Service Point Locations

Courtesy of MAZDA MOTOR OF AMERICA, INC.

LUBRICATION SPECIFICATIONS

Material

Engine Oil

(1)

Engine Oil

(1)

Condition

Ambient Temperature Above -10°

F (-23°C) To Over 100°F (38°C)

Ambient Temperature Less Than -

10°F (-23°C) To 60°F (16°C)

Engine Coolant Above 3°F (-16°C) Above -15°F

(-26°C) Above -40°F (-40°C)

Brake Fluid

Automatic Transaxle Fluid

Manual Transaxle Fluid

A/C Refrigerant

Microsoft

Sunday, July 05, 2009 1:41:19 PM

All

Page 3

Specification

SAE 10W-30

SAE 5W-30

35/65 Mixture 45/55 Mixture

55/45 Mixture Distilled Water

Ethylene Glycol

DOT 3

ATF M-III or DEXRON II

Hypoid Gear Oil API

Classification GL-4 or GL-5 SAE

75W-90 Above 50°F (10°C):

80W-90

R-134a

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

(1) Energy conserving oils are recommended, API classification SG", "SH".

FLUID CAPACITIES

Item

Engine Oil

Engine Coolant

Automatic Transaxle Fluid

Manual Transaxle Fluid

Rear Axle Oil

A/C Refrigerant

Fuel Tank

Condition

Drained, With Filter

Drained

Capacity

Evacuated

Capacity

Specification

(1)

4.0 Qts. (3.8L)

3.8 Qts. (3.6L)

6.3 Qts. (6.0L)

7.1 Qts. (6.7L)

2.1 Qts. (2.0L)

1.1 Qts. (l.0L)

1 lb. 3.4 oz. (0.6kg)

12.6 Gal. (48.0L)

(1) Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.

WHEEL & TIRE SPECIFICATIONS

WHEEL TIGHTENING

Tighten wheel lug nuts to 65-87 ft. lbs. (88-118 N.m).

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 BAG RESTRAINT SYSTEM 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

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information 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 BAG

RESTRAINT SYSTEM 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 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

CAUTION: 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

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

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

CAUTION: 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

CAUTION: Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

CAUTION: Continued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.

CAUTION: 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

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

WARNING: Relieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

WARNING: 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.

WARRANTY INFORMATION

CAUTION: Always refer to customer's copy of warranty information for specific model application and/or coverage limitations.

BASIC NEW CAR WARRANTY

Basic components are warranted against defects in materials and workmanship for 36 months or 50,000 miles, whichever occurs first. Tires are covered by a separate warranty offered by tire manufacturer.

ANTI-PERFORATION WARRANTY

Covers body sheet metal panels for 60 months, regardless of mileage, against perforation due to corrosion.

SAFETY RESTRAINT SYSTEM WARRANTY

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

Supplemental air bag system, seat belts and related components are warranted for 5 years or 60,000 miles, whichever comes first, against defects in materials and workmanship.

REPLACEMENT PARTS & ACCESSORIES

Manufacturer-supplied parts and accessories are warranted against defects in material or workmanship for 12 months without regard to mileage. If installed by a Mazda dealer, part or accessory will be repaired or replaced without charge during warranty period. If not installed by a dealer, part or accessory will be repaired or replaced without charge for parts, but labor cost will be responsibility of owner.

EMISSION DEFECT WARRANTY (EXCEPT CALIFORNIA)

Warrants that vehicle was designed, built and equipped to conform with applicable Federal emission regulations at time of sale and that vehicle is free of defects in materials and workmanship which may cause vehicle to fail to conform with applicable regulations for 5 years or 50,000 miles, whichever occurs first.

EMISSION PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)

Covers all repairs, adjustments and replacements if vehicle fails to conform to applicable emission standards and such failure results in vehicle owner bearing a penalty or other sanction under local, state or Federal law.

Warranty period is 5 years or 50,000 miles, whichever comes first. After 2 years or 24,000 miles, manufacturer will make necessary adjustments, repairs and replacements at no cost to owner only when noncompliance is caused by failure of components which have been installed in vehicle for sole or primary purpose of reducing vehicle emissions. See copy of warranty for specific components covered.

EMISSION DEFECT WARRANTY (CALIFORNIA)

For 3 years or 50,000 miles, whichever occurs first, any defective emission-related part on vehicle will be repaired or replaced by manufacturer at no cost to owner. Certain emission-related parts are covered for repair or replacement for 7 years or 70,000 miles, whichever occurs first. See copy of warranty for specific components covered.

EMISSION PERFORMANCE WARRANTY (CALIFORNIA)

For 3 years or 50,000 miles, manufacturer will make all necessary repairs and adjustments to ensure vehicle passes a required Smog Check inspection.

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.

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

MAIN FUSE BLOCK IDENTIFICATION

Fig. 3: 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



1 - 30 Amp (Pink) Headlights

2 - 30 Amp (Pink) Fuel Injection, Alternator



3 - 80 Amp (Black) Protection Of All Circuits



4 - 40 Amp (Green) Refer to HAZARD (15A), STOP (15A), ROOM (10A), TAIL (15A)

5 - 30 Amp (Pink) Anti-Lock Brake System



6 - 30 Amp (Pink) Cooling Fan

7 - Empty



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

9 - 10 Amp (Red) Fuel Injection



10 - 30 Amp (Green) Headlight Retractor

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

TRUNK MOUNTED FUSE PANEL IDENTIFICATION

Fig. 4: Trunk Mounted Fuse Panel Identification

Courtesy of MAZDA MOTOR OF AMERICA, INC.

Fuse & Circuit Breaker Identification



1 - 10 Amp (Red) Rear Defroster



2 - 10 Amp (Red) Auto Antenna

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information

INTERIOR FUSE PANEL IDENTIFICATION

Fig. 5: Interior Fuse Panel Identification

Courtesy of MAZDA MOTOR OF AMERICA, INC.

Fuse & Circuit Breaker Identification



1 - 10 Amp (Red) Interior Light, Warning Buzzers, Radio/Cassette and Compact Disc Player and Clock



2 - Empty

3 - Empty



4 - 15 Amp (Blue) Tail Lights

5 - 15 Amp (Blue) Shift Lock, Cruise Control, Horn, Brakelights



6 - 15 Amp (Blue) Hazard Warning Lights



7 - Empty

8 - Empty



9 - 15 Amp (Blue) Radio/Cassette and Compact Disc Player and Clock, Cigarette Lighter

10 - Empty



11 - 20 Amp (Yellow) Wipers, Washer

Microsoft

1997 Mazda MX-5 Miata

MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information



12 - 30 Amp (Green) Power Windows



13 - Empty

14 - Empty 15 - 15 Amp (Blue) Gauges, Warning Lights, Turn-Signal Lights, Cruise Control



16 - 15 Amp (Blue) Cooling Fan

17 - 30 Amp (Pink) Heater



18 - Empty



19 - Empty

20 - 10 Amp Defog (Some Models)



21 - 10 Amp Antenna (Some Models)

22 - Empty

Microsoft

1997-98 MANUAL TRANSMISSION SERVICING Mazda

1997-98 MANUAL TRANSMISSION SERVICING

Mazda

APPLICATION

TRANSMISSION APPLICATIONS

Vehicle Application

B2300, B2500, B3000 & B4000

Miata

MX-6 & 626

Protege

Transmission/Transaxle Model

M50D-R1

M15M-D

G25M-R

F25M-R

NOTE: Mazda B2300, B2500, B3000 and B4000 are referred to as B-Series throughout this article.

LUBRICATION

SERVICE INTERVALS

Fluid Inspection & Replacement

Check fluid level(s) at least once a year. Change transmission/transaxle and transfer case fluids every 60,000 miles for normal driving conditions and every 30,000 miles for severe driving conditions.

CHECKING FLUID LEVEL

Transaxle Fluid

Remove fill plug from transaxle. Fluid should be up to bottom of fill hole on side of case.

Transmission Fluid (RWD Models)

Remove fill plug from transmission. Fluid should be up to bottom of fill hole on side of case.

Transfer Case Fluid (4WD)

Remove fill plug from transfer case. Fluid should be up to bottom of fill hole on side of transfer case.

RECOMMENDED FLUID

FLUID SPECIFICATIONS

Application

Transmission

Recommended Fluid

1997 Mazda MX-5 Miata

1997-98 MANUAL TRANSMISSION SERVICING Mazda

B-Series

All Other Models

All-Season Usage

Temp. Greater Than 50°F (10°C)

Transfer Case

B-Series

(1) API GL-4 or GL-5.

MERCON Or M-III

ATF

(1)

SAE 75W-90

(1)

SAE 80W-90

Dexron-II Or MERCON

ATF

FLUID CAPACITIES

TRANSMISSION/TRANSAXLE REFILL CAPACITIES

Application

B-Series

Miata

MX-6 & 626

Protege

TRANSFER CASE REFILL CAPACITY

Application

B-Series

ADJUSTMENTS

GEARSHIFT LINKAGE

No external linkage adjustment is required.

TORQUE SPECIFICATIONS

Application

Drain Plug

(1)

B-Series

Miata, MX-6, Protege & 626

Fill Plug

B-Series

Miata

MX-6, Protege & 626

Transfer Case Plug (B-Series)

Microsoft

Sunday, July 05, 2009 1:37:16 PM Page 2

Qts. (L)

2.8 (2.6)

2.1 (2.0)

2.9 (2.7)

Qts. (L)

1.3 (1.2)

Ft. Lbs. (N.m)

30-43 (40-58)

18-29 (24-39)

30-43 (40-58)

14-22 (19-30)

Speedometer Gear Bolt (FWD)

(1) Install NEW washer.

1997 Mazda MX-5 Miata

1997-98 MANUAL TRANSMISSION SERVICING Mazda

INCH Lbs. (N.m)

69-95 (8-11)

Microsoft

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

STEERING SYSTEM - POWER RACK & PINION

1997 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 lines.

TESTING

HYDRAULIC SYSTEM PRESSURE TEST

Pump Fluid Pressure Test

1. Disconnect pressure line from steering gear and steering pump. Connect pressure gauge/valve between steering pump and steering gear. See Fig. 1 . Bleed air from system.

2. Completely open valve. Start engine and operate at idle. Turn steering wheel from 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. Measure oil pump fluid pressure. 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.

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 1: Connecting Pressure Gauge/Valve (Typical)

Courtesy of MAZDA MOTORS CORP.

Gear Fluid Pressure Test

1. Ensure steering pump pressure is within specification. See PUMP FLUID PRESSURE TEST . 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. Measure steering gear fluid pressure. Ensure gear pressure is within specification. See HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS table. If pressure is not within specification, replace gear.

HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS

(1)

Application

Miata & MPV

MX-3 psi (kg/cm

)

1102-1209 (77-85)

1138-1152 (80-81)

Millenia, MX-6 & 626

Protege

RX7

929

1209-1280 (85-90)

1244-1350 (87-95)

1110-1209 (78-85)

1066-1137 (75-80)

(1) Specifications are measured at 1000-1500 RPM, with fluid temperature at 122-140°F (50-60°C).

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

LUBRICATION

FLUID CAPACITY

POWER STEERING FLUID CAPACITY

Application

Miata & Protege

MPV

MX-3

4-Cylinder

Millenia, MX-6 & 626

RX7

929

Qts. (L)

.85 (.80)

.95 (.90)

.85 (.80)

1.27 (1.20)

1.32 (1.25)

1.01 (.96)

1.80 (1.70)

FLUID TYPE

Dexron-II or Mazda M-III fluid is recommended for all models.

FLUID LEVEL CHECK

Check fluid level on oil pump dipstick (if equipped) or reservoir. Fluid should be between marks on level gauge dipstick (if equipped) or reservoir. If fluid level is low, fill as necessary. Recheck fluid level. DO NOT overfill.

HYDRAULIC SYSTEM BLEEDING

1. Raise and support front of vehicle. With ignition off, turn steering wheel from lock to lock several times.

Check fluid level. Add fluid as necessary. Repeat procedure until fluid level no longer decreases.

2. Start engine and operate at idle. Turn steering wheel from 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

PINION PRELOAD

NOTE: Pinion preload should be checked when steering gear assembly has been disassembled or overhauled. Check preload after steering gear assembly has been reassembled, but tie rods have not yet been installed.

Miata & Protege

1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten adjusting cover to 43 INCH lbs. (4.9 N.m), then loosen adjusting cover. See Fig. 2 . Repeat loosening and tightening procedure 3 times. After tightening adjusting cover the third time, loosen adjusting cover 25

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion degrees.

2. Center steering rack. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3 . Measure pinion preload using spring scale. Pinion preload should be 2.2-2.6 lbs. (1.0-1.2 kg).

3. If preload is not as specified, repeat steps 1) and 2). If preload is as specified, apply thread sealant to adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 29-36 ft. lbs.

(39-49 N.m) on Protege or 44-54 ft. lbs. (60-73 N.m) on Miata.

Fig. 2: Tightening Adjusting Cover (Miata Shown; Others Are Similar)

Courtesy of FORD MOTOR CO.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 3: Checking Pinion Preload (Miata Shown; Others Are Similar)

Courtesy of FORD MOTOR CO.

Millenia

1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten adjusting cover 14-22 ft. lbs. (19-30 N.m), then loosen cover. Again, tighten adjusting cover to 15 ft. lbs.

(20 N.m), then loosen adjusting cover 25-35 degrees.

2. Apply thread sealant to exposed adjusting cover threads. Install and tighten adjusting cover lock nut 37-

50 ft. lbs. (50-68 N.m). Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3 . Measure pinion preload using spring scale. Pinion preload shoul d be 1.8-3.3 lbs. (.8-1.5 kg). If preload is not as specified, repeat steps 1) and 2).

MPV

1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten adjusting cover to 15 ft. lbs. (20 N.m), then loosen cover. Again, tighten adjusting cover to 15 ft. lbs. (20

N.m) then loosen cover.

2. Tighten adjusting cover 44-56 INCH lbs. (5.0-6.3 N.m), then loosen adjusting cover 35-45 degrees.

Apply thread sealant to exposed adjusting cover threads. Install and tighten adjusting cover lock nut 37-

43 ft. lbs. (50-58 N.m).

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

MX-3 (4-Cylinder)

1. Install and temporarily tighten adjusting cover to 95 INCH lbs. (10.7 N.m). Move steering rack back and forth about 3 times, then loosen adjusting cover. Tighten adjusting cover 40-47 INCH lbs (4.5-5.3 N.m) then loosen adjusting cover 0-40 degrees. Apply thread sealant to adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m).

2. Center steering rack. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3 . Measure pinion preload using spring scale. With steering rack in center position, pinion preload should be 2.2-3.0 lbs. (1.0-1.4 kg). With steering rack in any other position, pinion preload should be a maximum of 3.7 lbs.

(1.7 kg). If preload is not as specified, repeat steps 1) and 2).

MX-3 (V6)

1. Center steering rack. Install and temporarily tighten adjusting cover to 100 INCH lbs. (11.3 N.m), then loosen cover. Tighten adjusting cover 40-47 INCH lbs. (4.5-5.3 N.m), then loosen cover 45 degrees.

2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3 . Measure pinion preload using spring scale. With steering rack in center position (plus or minus 90 degrees), preload should be 2.2-2.6 lbs. (1.0-1.2 kg). With steering rack in any other position, preload should be a maximum of 3.7 lbs. (1.7 kg).

3. If preload is as specified, apply thread sealant to adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m). If preload is not as specified, repeat steps 1) and 2).

MX-6 & 626

1. Center steering rack. Install and temporarily tighten adjusting cover to 87 INCH lbs. (9.8 N.m), then loosen adjusting cover. Tighten adjusting cover 39-48 INCH lbs (4.4-5.4 N.m) then loosen adjusting cover 20 degrees. Apply thread sealant to adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m).

2.8-3.3 lbs. (1.3-1.5 kg). If preload is not as specified, repeat steps 1) and 2).

RX7

1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten adjusting cover 87 INCH lbs. (9.8 N.m), then loosen adjusting cover 20-25 degrees. See Fig. 2 .

2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3 . Measure pinion preload using spring scale. Pinion preload should be 3.3 lbs. (1.5 kg) maximum.

(50-68 N.m).

929

1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion adjusting cover 15-21 ft. lbs. (20-28 N.m), then loosen adjusting cover 25 degrees. See Fig. 2 .

2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3 . Measure pinion preload using spring scale. Pinion preload should be 3.3 lbs. (1.5 kg) maximum.

(50-68 N.m).

PINION SHAFT & VALVE HOUSING ASSEMBLY

Miata

1. With steering rack assembly secured in a vise, pull steering rack out until distance between end of rack and end of rack housing is 2.38" (60.5 mm). See Fig. 4 .

2. If reusing original gear housing, pinion shaft and valve housing, install same number of shims that were removed during disassembly procedure. If installing a NEW gear housing, pinion shaft and/or valve housing, install same number of shims that were removed during disassembly procedure, and go to next step.

3. Install and tighten valve housing bolts 15-21 ft. lbs. (20-28 N.m). Using a feeler gauge, measure clearance between gear housing and valve housing. See Fig. 5 . Add or remove necessary shims until clearance is zero.

Fig. 4: Centering Steering Rack (Miata Shown; Others Are Similar)

Courtesy of FORD MOTOR CO.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 5: Measuring Gear Housing To Valve Housing Clearance (1996-97 Miata)

Courtesy of FORD MOTOR CO.

POWER STEERING PUMP BELT

BELT ADJUSTMENT SPECIFICATIONS

Application

Miata & Protege

New Belt

Used Belt

Millenia

2.3L

2.5L

New Belt

Used Belt

MPV

New Belt

Microsoft

Sunday, July 05, 2009 1:39:26 PM Page 8

(1)

Deflection In. (mm)

.31-.35 (8.0-9.0)

.35-.39 (9.0-10.0)

(2)

.23-.27 (6.0-7.0)

.27-.31 (7.0-8.0)

.27-.35 (7.0-7.5)

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Used Belt

MX-3

4-Cylinder

New Belt

Used Belt

New Belt

Used Belt

MX-6 & 626

4-Cylinder

New Belt

Used Belt

New Belt

Used Belt

RX7

New Belt

Used Belt

929

New Belt

Used Belt

.35-.33 (7.5-8.2)

.31-.35 (8.0-9.0)

.35-.39 (9.0-10.0)

.23-.27 (6.0-7.0)

.27-.31 (7.0-8.0)

.30-.35 (7.5-9.0)

.32-.37 (8.1-9.4)

.24-.27 (6.0-7.0)

.27-.31 (7.0-8.0)

.14-.16 (3.5-4.0)

.18-.20 (4.5-5.0)

.23-.25 (5.8-6.3)

.27-.30 (6.9-7.7)

(1) Belt deflection is measured at midpoint between idler pulley and pump, with 22 lbs. (10 kg.) of pressure applied.

(2) Serpentine belt with an automatic tensioner is used. No adjustment is necessary. If pointer on tensioner is not within wear gauge limit, replace belt.

REMOVAL & INSTALLATION

STEERING GEAR

NOTE: Use a suitable container or rags to collect fluid when disconnecting pressure and return lines.

Removal & Installation (Miata & MPV)

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.

Remove cotter pins and castle nuts from tie rod ends.

2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. Mark steering column intermediate shaft-to-steering column gear pinion for installation reference. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Place reference marks on steering gear and pressure line fitting for reassembly.

3. Disconnect pressure and return line connections from steering gear. On Miata, remove steering gear-to-

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion frame mounting bolts. Remove steering gear and linkage from vehicle. On MPV, remove steering gear bracket-to-frame mounting bolts. Remove steering gear and linkage with steering bracket from vehicle.

Remove 4 steering gear-to-bracket bolts and separate gear from bracket.

4. On all models, to install, reverse removal procedure. Tighten bolts to specification. See TORQUE

SPECIFICATIONS table. On MPV, tighten steering gear-to-bracket bolts in sequence: left front, right front, left rear, right rear. On all models, fill and bleed power steering system. Check and adjust front wheel alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Removal & Installation (Millenia)

1. Disconnect negative battery cable. Support engine using Engine Support (49-G017-5A0 ). Raise and support front of vehicle. Remove front wheel assemblies. Remove cotter pins and castle nuts from tie rod ends.

2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. Remove transverse member bolts and remove transverse member. See Fig. 6 Disconnect pressure and return line connections from steering gear. Remove intermediate shaft pinch bolt.

3. Reference mark lower steering column-to-intermediate shaft. Remove engine mount member. Remove

No. 1 engine mount bolts. Remove upper lateral link bolt and separate upper lateral link from crossmember. Remove lower control arm-to-crossmember mounting bolt and gusset. Separate lower control arm from crossmember.

4. Remove stabilizer link-to-lower control arm nut. Separate stabilizer link from lower control arm. Using a jack, support front suspension crossmember. Remove crossmember retaining nuts. Carefully lower crossmember. Disconnect stabilizer link from stabilizer bar. Remove stabilizer bar brackets, bushings and stabilizer bar. Remove steering gear mounting nuts. Remove steering gear assembly.

5. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Tighten steering gear mounting nuts in sequence: right front, left rear, right rear, left front. Fill and bleed power steering system. Check and adjust front wheel alignment. See SPECIFICATIONS &

PROCEDURES article in WHEEL ALIGNMENT.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 6: Removing Steering Gear Assembly (Millenia)

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (MX-3 & Protege)

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.

Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends.

2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. On MX-3 DOHC, remove support bracket bolt, nut and rubber insulator. Remove steering gear insulator bolts and remove insulator.

On all models, remove intermediate shaft dust cover.

3. Mark steering column intermediate shaft-to-steering column gear pinion for installation reference.

Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Disconnect pressure and return line connections from steering gear.

4. On M/T, remove mounting nuts and bolts from extension bar and control rod. Remove extension rod and control rod. On all models, remove steering gear mounting nuts. Remove steering gear and linkage from

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion vehicle through passenger side wheelwell.

5. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE

SPECIFICATIONS table. Tighten steering gear mounting nuts in sequence: left rear, right rear, left front, right front. Fill and bleed power steering system. Check and adjust front wheel alignment. See

SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Removal & Installation (MX-6 & 626)

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.

Remove cotter pins and castle nuts from tie rod ends.

2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. On 2.5L engines, remove transverse member bolts and remove transverse crossmember. Remove front exhaust pipe and catalytic converter assembly nuts and remove assembly.

3. On all models, support engine using Engine Support (49-G017-5A0 ), and remove engine mount. Mark steering column intermediate shaft-to-steering column gear pinion for installation reference. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt.

4. Disconnect pressure and return line connections from steering gear. Remove steering gear mounting nuts.

Remove steering gear and linkage from vehicle through passenger's side wheelwell.

5. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Tighten steering gear mounting nuts in sequence: left front, right front, right rear, left rear. Fill and bleed power steering system. Check and adjust front wheel alignment. See SPECIFICATIONS &

PROCEDURES article in WHEEL ALIGNMENT.

Removal & Installation (RX7)

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.

Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends. Using Puller Set (49-

T028-3A0 ), separate tie rod ends from steering knuckles.

2. Remove stabilizer bar-to-frame bolts and brackets. Disconnect pressure and return line connections from steering gear. Mark steering column intermediate shaft-to-steering column gear pinion for installation reference.

3. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Remove steering gear mounting bolts. Support crossmember with jack and remove crossmember nuts and bolts. Slowly lower jack and remove steering gear and linkage from vehicle.

4. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE

SPECIFICATIONS table. Tighten steering gear mounting bolts in sequence: left rear, right rear, left front, right front. Fill and bleed power steering system. Check and adjust front wheel alignment. See

SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Removal & Installation (929)

1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.

Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends. Using Puller Set (49-

T028-3A0 ), separate tie rod ends from steering knuckles.

2. Disconnect pressure and return line connections from steering gear. Mark steering column intermediate

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion shaft-to-steering column gear pinion for installation reference. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Remove steering gear mounting nuts. Remove steering gear and linkage from vehicle.

3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE

SPECIFICATIONS table. Tighten steering gear mounting nuts in sequence: left rear, left front, right front, right rear. Fill and bleed power steering system. Check and adjust front wheel alignment. See

SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

POWER STEERING PUMP

NOTE: Use a suitable container or rags to collect fluid when disconnecting pressure and return lines.

Removal & Installation

1. Remove drive belt. On Millenia, MPV, MX-6, RX7, 626 and 929, remove pulley lock nut and remove pulley from pump. On all models, disconnect power steering pressure switch electrical connector (if equipped).

2. Place reference marks on steering pump and pressure line fitting for reassembly. Disconnect pressure and return line connections from steering pump. Remove pump-to-bracket bolts and nuts. Remove pump from vehicle.

3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE

SPECIFICATIONS table. Adjust belt tension. See POWER STEERING PUMP BELT under

ADJUSTMENTS. Bleed air from system. Inspect system for leaks.

OVERHAUL

STEERING GEAR

Disassembly & Reassembly

1. Remove steering gear assembly. See STEERING GEAR under REMOVAL & INSTALLATION. As an aid to disassembly and reassembly, use illustrations. See Fig. 7 -16 . For reassembly reference, keep components in order of disassembly. Replace worn or damaged components as necessary.

2. On 1996-97 Miata, after installing valve housing, check clearance between gear housing and valve housing. See PINION SHAFT & VALVE HOUSING ASSEMBLY under ADJUSTMENT. Adjust clearance as necessary. On all models, after steering rack reassembly, but before installing tie rods, check pinion preload. See PINION PRELOAD under ADJUSTMENTS.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 7: Exploded View Of Rack & Pinion Steering Gear (1995 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 8: Exploded View Of Rack & Pinion Steering Gear (1996-97 Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 9: Exploded View Of Rack & Pinion Steering Gear (Millenia)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 10: Exploded View Of Rack & Pinion Steering Gear (1995-96 MPV)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 11: Exploded View Of Rack & Pinion Steering Gear (1997 MPV)

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Courtesy of MAZDA MOTORS CORP.

Fig. 12: Exploded View Of Rack & Pinion Steering Gear (MX-3 1.6L & Protege)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 13: Exploded View Of Rack & Pinion Steering Gear (MX-3 1.8L)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 14: Exploded View Of Rack & Pinion Steering Gear (MX-6 & 626)

Courtesy of MAZDA MOTORS CORP.

Fig. 15: Exploded View Of Rack & Pinion Steering Gear (RX7)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 16: Exploded View Of Rack & Pinion Steering Gear (929)

Courtesy of MAZDA MOTORS CORP.

POWER STEERING PUMP

NOTE: See Fig. 17 -22 for exploded views of power steering pumps.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 17: Exploded View Of Power Steering Pump (Miata Shown; MX-3 1.6L & Protege Are Similar)

Courtesy of MAZDA MOTORS CORP.

Fig. 18: Exploded View Of Power Steering Pump (MPV)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 19: Exploded View Of Power Steering Pump (MX-3 1.8L)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Fig. 20: Exploded View Of Power Steering Pump (MX-6 & 626 Shown; Millenia Is Similar)

Courtesy of MAZDA MOTORS CORP.

Fig. 21: Exploded View Of Power Steering Pump (RX7)

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Courtesy of MAZDA MOTORS CORP.

Fig. 22: Exploded View Of Power Steering Pump (929)

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Microsoft

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Application

Miata

Adjusting Cover Lock Nut

Intermediate Shaft-To-Pinion Shaft Bolt

Pinion Shaft Lock Nut (1995)

Power Steering Pump Mounting Bolts/Nuts

Pressure Line Fitting-To-Power Steering Pump

Pressure Line Fitting-To-Steering Gear

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

Tie Rod Castle Nuts

Tie Rod End-To-Tie Rod Lock Nut

Valve Housing Bolts (1996-97)

Wheel Lug Nuts

Millenia

Adjusting Cover Lock Nut

Intermediate Shaft-To-Pinion Shaft Bolt

Engine Mount Member

Bolts

Nut

No. 1 Engine Mount Bolt

Power Steering Pump Mounting Bolts/Nuts

Power Steering Pump Pulley Lock Nut

Pressure Line Fitting-To-Power Steering Pump

Pressure Line Fitting-To-Steering Gear

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

Tie Rod Castle Nuts

Tie Rod End-To-Tie Rod Lock Nut

Transverse Member Nuts (Millenia)

Valve Housing Bolts

Wheel Lug Nuts

MPV

Adjusting Cover Lock Nut

Intermediate Shaft-To-Pinion Shaft Bolt

Pinion Shaft Lock Nut

Power Steering Pump Mounting Bolts/Nuts

Power Steering Pump Pulley Lock Nut

Pressure Line Fitting-To-Power Steering Pump

Pressure Line Fitting-To-Steering Gear

Microsoft

Sunday, July 05, 2009 1:39:27 PM Page 29

Ft. Lbs. (N.m)

(1)

13-19 (18-26)

22-29 (30-39)

27-40 (37-54)

23-35 (31-47)

34-43 (46-58)

58-72 (79-98)

22-32 (30-44)

25-29 (34-39)

15-21 (20-29)

66-86 (89-117)

(1)

13-19 (18-26)

50-69 (67-93)

55-77 (75-104)

32-44 (44-60)

24-33 (33-45)

36-43 (49-58)

23-35 (41-47)

(2)

32-44 (44-60)

58-72 (79-98)

41-59 (55-80)

58-72 (79-98)

40-56 (54-76)

13-18 (17-25)

66-94 (89-127)

(1)

13-19 (18-26)

29-36 (39-49)

23-34 (31-46)

29-43 (39-58)

23-35 (31-47)

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Steering Bracket-To-Frame Mounting Bolt

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

Tie Rod Castle Nuts

Tie Rod End-To-Tie Rod Lock Nut

Wheel Lug Nuts

MX-3

Adjusting Cover Lock Nut

Intermediate Shaft-To-Pinion Shaft Bolt

Pinion Shaft Lock Nut

Power Steering Pump Mounting Bolts/Nuts

Bolt

Nut

Pressure Line Fitting-To-Power Steering Pump

4-Cylinder

Pressure Line Fitting-To-Steering Gear

4-Cylinder

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

4-Cylinder

Tie Rod Castle Nuts

Tie Rod End-To-Tie Rod Lock Nut

Wheel Lug Nuts

MX-6 & 626

Adjusting Cover Lock Nut

Intermediate Shaft-To-Pinion Shaft Bolt

Power Steering Pump Mounting Bolts/Nuts

Power Steering Pump Pulley Lock Nut

Pressure Line Fitting-To-Power Steering Pump

Pressure Line Fitting-To-Steering Gear

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

Tie Rod Castle Nuts

Tie Rod End-To-Tie Rod Lock Nut

Wheel Lug Nuts

Protege

Adjusting Cover Lock Nut

Microsoft

Sunday, July 05, 2009 1:39:27 PM Page 30

46-69 (62-94)

55-69 (75-94)

87-101 (118-137)

44-58 (60-79)

51-58 (69-79)

65-87 (88-118)

(1)

13-19 (18-26)

29-36 (39-49)

27-40 (37-54)

14-19 (19-26)

12-17 (16-23)

18-26 (24-35)

21-25 (28-34)

26-32 (35-44)

27-38 (37-52)

43-58 (58-79)

91-105 (123-142)

31-42 (42-57)

25-37 (34-50)

65-87 (88-118)

(1)

13-19 (18-26)

23-34 (31-46)

36-43 (49-58)

22-32 (30-44)

25-33 (34-45)

28-38 (38-51)

91-105 (123-142)

23-33 (31-45)

51-72 (69-98)

65-87 (88-118)

(1)

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

Intermediate Shaft-To-Pinion Shaft Bolt

Pinion Shaft Lock Nut

Power Steering Pump Mounting Bolts/Nuts

Bolt

Nut

Pressure Line Fitting-To-Power Steering Pump

Pressure Line Fitting-To-Steering Gear

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

Tie Rod Castle Nuts

Tie Rod End-To-Tie Rod Lock Nut

Wheel Lug Nuts

RX7

Adjusting Cover Lock Nut

Intermediate Shaft-To-Pinion Shaft Bolt

Pinion Shaft Lock Nut

Power Steering Pump Mounting Bolts/Nuts

Power Steering Pump Pulley Lock Nut

Pressure Line Fitting-To-Power Steering Pump

Pressure Line Fitting-To-Steering Gear

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

Tie Rod Castle Nuts

929

Tie Rod End-To-Tie Rod Lock Nut

Wheel Lug Nuts

Adjusting Cover Lock Nut

Intermediate Shaft-To-Pinion Shaft Bolt

Pinion Shaft Lock Nut

Power Steering Pump Mounting Bolts/Nuts

Power Steering Pump Pulley Lock Nut

Pressure Line Fitting-To-Power Steering Pump

Pressure Line Fitting-To-Steering Gear

Steering Gear Mounting Bolts/Nuts

Steering Rack-To-Tie Rod

Tie Rod Castle Nuts

Tie Rod End-To-Tie Rod Lock Nut

Valve Housing Bolts

Wheel Lug Nuts

(1) For adjusting cover lock nut tightening procedure, see ADJUSTMENTS .

Microsoft

Sunday, July 05, 2009 1:39:27 PM Page 31

13-19 (18-26)

29-36 (39-49)

33-44 (44-60)

28-37 (38-51)

18-26 (24-35)

22-32 (30-44)

27-38 (37-52)

44-58 (59-78)

31-42 (42-57)

25-37 (34-50)

65-87 (88-118)

(1)

13-19 (18-26)

14-22 (19-30)

12-17 (16-23)

29-43 (39-58)

17-26 (23-36)

12-17 (16-23)

27-38 (37-52)

58-72 (79-98)

22-32 (30-44)

25-37 (34-50)

65-87 (88-118)

(1)

13-19 (18-26)

14-22 (19-30)

12-17 (16-23)

29-43 (39-58)

33-40 (45-54)

29-43 (39-58)

27-38 (37-52)

58-72 (79-98)

37-47 (50-63)

51-72 (69-98)

13-18 (17-25)

65-87 (88-118)

1997 Mazda MX-5 Miata

STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion

(2) Tighten pressure line fitting-to-steering gear 76-115 INCH lbs. (8.6-13 N.m).

Microsoft

1997, 1999-2000 SUSPENSION Rear - Miata

1997, 1999-2000 SUSPENSION

Rear - Miata

DESCRIPTION

Rear suspension consists of spring over shock, 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. Upper coil over shock mount plate has been redesigned for 1999-2000. New design incorporates a urethane bumper and improves ride and cornering.

ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

NOTE: See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

WHEEL BEARING ADJUSTMENT

Raise and support vehicle. Remove rear wheel assembly. Remove caliper assembly and ABS wheel speed sensor. Remove brake rotor. Attach dial indicator to axle hub and measure bearing play. Check bearing axial play by rocking hub assembly by hand. Maximum bearing play is .002" (.05 mm). If play exceeds specification, check drive axle lock nut torque or replace wheel bearing. See TORQUE SPECIFICATIONS .

REMOVAL & INSTALLATION

WHEEL BEARING

Removal

1. Raise and support vehicle. Remove rear wheel assembly. Remove drive axle lock nut. Remove brake caliper assembly and ABS wheel speed sensor, and wire aside. Remove screws and rotor. Remove ABS speed sensor bracket. Remove knuckle assembly from upper and lower arms.

2. Using Handle (49-G030-102), Installer (49-G030-727) and Puller (49-F026-103), remove hub from knuckle. Remove snap ring from knuckle. Using handle, installer and Puller (49-0636-145), remove wheel bearing inner race from hub. Remove wheel bearing outer race from knuckle using Handle (49-

G030-797), Puller (49-F026-103) 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. Replace components as necessary.

Installation

1997 Mazda MX-5 Miata

1997, 1999-2000 SUSPENSION Rear - Miata

Press new wheel bearing into knuckle using Handle (49-G030-797), Installer (49-F027-007) and Adapter (49-

F027-009). Press hub into knuckle using adapter. To install, reverse removal procedure. Tighten drive axle lock nut to specification. See TORQUE SPECIFICATIONS . Stake drive axle lock nut. Check axial play. See

WHEEL BEARING ADJUSTMENT .

SHOCK ASSEMBLY

Removal & Disassembly

1. Raise vehicle and remove fuel tank filler pipe protector (1997). Remove rear wheel assembly. Remove stabilizer bar nut and bolt from lower control arm. Remove 2 upper shock mount-to-body nuts. Remove lower shock bolt. Lower arms, and remove shock assembly.

CAUTION: DO NOT lower arms excessively. This may damage brake hose.

2. Clamp shock securely in soft-jaw vise. Compress coil spring. Remove lock nut and washer. Remove remaining components and note order for reassembly.

Inspection

Check shock for leaks or abnormal noise. Inspect components for wear or damage. Check for loose installation of bolts and nuts. Replace components as necessary.

Reassembly (1997)

To reassemble, reverse disassembly procedure. To install, reverse removal procedure. Ensure coil spring is seated in upper and lower seats. See Fig. 1 . Tighten piston rod nut. See TORQUE SPECIFICATIONS .

Microsoft

1997 Mazda MX-5 Miata

1997, 1999-2000 SUSPENSION Rear - Miata

Fig. 1: Cross-Sectional View Of Upper Coil Over Shock Assembly (1997)

Courtesy of MAZDA MOTORS CORP.

Reassembly (1999 & 2000)

Clamp shock in vise. Install spring and upper spring retainer in original orientation to shock. Tighten lower piston rod nut so that exposed thread of piston rod is 0.62-0.69" (15.7-17.7mm). See Fig. 2 . Tighten upper nut to 12-17 ft. lbs. (16-23 N.m).

CAUTION: Using air tool will damage piston rod thread. DO NOT use air tool.

Microsoft

1997 Mazda MX-5 Miata

1997, 1999-2000 SUSPENSION Rear - Miata

Fig. 2: Cross-Sectional View Of Upper Coil Over Shock Assembly (1999-2000)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997, 1999-2000 SUSPENSION Rear - Miata

Installation

Reinstall shock in reverse order. Tighten nuts and bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS . Check rear wheel alignment. See

SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

LOWER ARM

Removal

Raise and support vehicle. Remove rear wheel assembly. Remove stabilizer bar control link nut and bolt. See

Fig. 3 . Remove lower shock 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.

Installation

To install, reverse removal procedure. Tighten all nuts/bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS . Adjust rear wheel alignment. See

SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Microsoft

1997 Mazda MX-5 Miata

1997, 1999-2000 SUSPENSION Rear - Miata

Fig. 3: Exploded View Of Rear Lower Arm Assembly

Courtesy of MAZDA MOTORS CORP.

UPPER ARM

Removal

Raise and support vehicle. Remove rear 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.

Installation

To install, reverse removal procedure. Tighten all nuts/bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS . Adjust rear wheel alignment. See

SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Microsoft

1997 Mazda MX-5 Miata

1997, 1999-2000 SUSPENSION Rear - Miata

STABILIZER BAR

Removal

Raise and support vehicle. Remove rear wheel assembly. Remove stabilizer bar-to-crossmember bolts, brackets and bushings. See Fig. 4 . 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. Inspect stabilizer bar and components for damage, cracks and deterioration.

Installation

To install, reverse removal procedure. Ensure bushing is aligned with White line on stabilizer. Tighten nuts and bolts to specification with vehicle resting on ground and suspension unloaded. See TORQUE

SPECIFICATIONS .

Fig. 4: Exploded View Of Rear Stabilizer Bar & Control Link

Microsoft

1997 Mazda MX-5 Miata

1997, 1999-2000 SUSPENSION Rear - Miata

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Application

ABS Speed Sensor Harness & Bracket Bolts

Caliper Assembly-To-Knuckle Bolt

Drive Axle Lock Nut

1997

1999 & 2000

Lower Arm-To-Crossmember Nuts

Lower Arm-To-Knuckle Nut

Shock Piston Rod Nut

1997

Shock-To-Body Nuts

Stabilizer Bar Bracket Bolts

Stabilizer Link Bolts

1997

1999 & 2000

Strut-To-Lower Arm Bolt

Upper Arm-To-Crossmember Nuts

1997

1999 & 2000

Upper Arm-To-Knuckle Bolt

1997

1999 & 2000

Wheel Lug Nuts

Ft. Lbs. (N.m)

12-16 (16-22)

37-50 (50-68)

160-216 (216-294)

174-235 (236-318)

54-70 (73-95)

46-55 (63-75)

22-27 (30-37)

22-26 (30-35)

15-20 (20-28)

27-39 (37-53)

32-44 (44-60)

54-68 (73-93)

34-49 (47-66)

40-56 (54-76)

34-49 (47-66)

40-56 (54-76)

66-86 (89-117)

Microsoft

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

STARTER - DIRECT DRIVE

1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

DESCRIPTION & OPERATION

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 end of armature shaft drive.

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING

* PLEASE READ FIRST *

NOTE: On all models with anti-theft system, obtain code number and deactivate audio anti-theft system before disconnecting battery.

NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are clean and tight, and engine grounds are good.

CIRCUIT TESTING

If starter does not operate, check voltage at starter "S" terminal with ignition switch in START position (and clutch depressed on M/T). See Fig. 1 . If voltage is greater than 8 volts, repair or replace starter as required. If voltage is 8 volts or less, check ignition switch, park/neutral switch (A/T), interlock switch (M/T) and wiring.

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

Fig. 1: Direct Drive Type Starter

Courtesy of MAZDA MOTORS CORP.

INTERLOCK SWITCH (M/T) (CLUTCH START SWITCH)

Interlock switch is mounted on bracket near top front of clutch pedal. Disconnect interlock switch wiring connector. Using ohmmeter, ensure continuity exists between interlock switch connector terminals when clutch

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive pedal is depressed. If continuity does not exist, adjust or replace interlock switch.

BENCH TESTING

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. Compare readings with specifications. See NO-

LOAD TEST SPECIFICATIONS table. If voltage is less than specified, amperage is more than specified or shaft speed is less than specified, disassemble and inspect starter components.

NO-LOAD TEST SPECIFICATIONS

Application

Voltage (Minimum)

Amperage (Maximum)

Shaft Speed (Minimum RPM)

Specification

11.5

6600

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

Fig. 2: Testing Direct Drive Starter Circuits

Courtesy of MAZDA MOTORS CORP.

SOLENOID TESTS

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

CAUTION: Perform solenoid tests with starter and solenoid assembled. 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 starter body. See Fig. 2 .

Starter pinion drive gear should extend outward and stop. If starter pinion drive gear does not extend, replace solenoid.

Solenoid Hold-In Test

After performing solenoid pull-in test, with positive battery lead connected to solenoid "S" terminal and negative battery lead connected to starter body, disconnect field lead ("M" terminal wire) at solenoid. Starter pinion drive gear should remain extended. If starter pinion drive gear returns, replace solenoid.

Solenoid Return Test

Disconnect field lead ("M" terminal wire) at solenoid. Connect positive battery lead to solenoid "M" terminal and negative battery lead to starter body. See Fig. 2 . Using screwdriver, pry overrunning clutch pinion drive outward. Release screwdriver and ensure overrunning clutch pinion drive returns to original position.

Solenoid

1. Disconnect all wires from solenoid, including "M" terminal wire between solenoid and starter. Using ohmmeter, ensure continuity exists between "S" and "M" terminals, and between "S" terminal and solenoid body. See Fig. 1 and Fig. 2 . If continuity does not exist between specified terminals, replace solenoid.

2. Using ohmmeter, ensure continuity does not exist between "M" and "B" terminals. If continuity exists, replace solenoid.

PINION GAP ADJUSTMENT

1. Disconnect field lead ("M" terminal wire) at solenoid. See Fig. 2 . Connect positive battery lead to solenoid "S" terminal and negative battery lead to starter body. Starter pinion drive gear should extend outward and stop.

2. Quickly measure pinion gap between end of pinion drive and circlip retainer. See Fig. 3 . DO NOT operate starter solenoid for more than 10 seconds. Pinion gap should be as specified. See PINION GAP

SPECIFICATIONS table.

3. If pinion gap is not within specification, adjust by increasing or decreasing thickness of solenoid shims located between solenoid and drive housing.

PINION GAP SPECIFICATIONS

Application

Miata (M/T)

In. (mm)

.02-.08 (0.5-2.0)

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

Fig. 3: Checking & Adjusting Pinion Gap

Courtesy of MAZDA MOTORS CORP.

ARMATURE TEST

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, replace armature. 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 TEST

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 .020-.030" (.50-.80 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut to standard depth.

COMMUTATOR SPECIFICATIONS

Application

Miata (M/T)

Maximum Runout In. (mm)

.001 (.03)

Minimum Diameter In.

(mm)

1.21 (30.8)

BRUSH TEST

1. Connect ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, replace brush holder assembly.

2. Check brush length. See BRUSH LENGTH SPECIFICATIONS table. If brush length is less than specified, replace brushes.

3. Using brush spring scale, measure spring tension. See BRUSH TENSION SPECIFICATIONS table. If tension is less than specified, replace brush holder assembly. Ensure brushes move freely in holders.

BRUSH LENGTH SPECIFICATIONS

Application Standard Length In. (mm)

Miata (M/T) .67 (17.0)

Minimum Length In. (mm)

.45 (11.5)

BRUSH TENSION SPECIFICATIONS

Application Standard Lbs. (Kg)

Miata (M/T)

(1)

Minimum Lbs. (Kg)

(1)

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

(1) Information is not available at time of publication.

FIELD WINDING TEST

1. Connect one ohmmeter lead to field coil lead ("M" terminal wire). Connect other lead of ohmmeter to soldered portion of brush lead. If continuity does not exist, repair or replace field coil.

2. Check field coil for short to ground by connecting one ohmmeter lead to field coil lead ("M" terminal wire) and other ohmmeter lead 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 or does not turn at all, clutch is faulty. Replace clutch. DO NOT clean overrunning clutch with solvent, as it is packed with grease and sealed by manufacturer.

REMOVAL & INSTALLATION

NOTE:

Removal & Installation

Disconnect negative battery cable. Raise vehicle on hoist. Remove engine undercover (if equipped). Disconnect wiring from starter. Remove starter mounting bolts and starter. To install, reverse removal procedure. Tighten starter mounting bolts to specification. See TORQUE SPECIFICATIONS .

OVERHAUL

NOTE:

On models with anti-theft system, obtain code number and deactivate audio anti-theft system before disconnecting battery.

Overhaul procedures are not available at time of publication. See illustration for exploded view of starter. See Fig. 4 .

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

Fig. 4: Exploded View Of Direct Drive Starter

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Application

Starter Mounting Bolts

Starter-To-Bracket Bolt

Battery Cable Nut (Solenoid Terminal "B")

WIRING DIAGRAMS

Ft. Lbs. (N.m)

28-38 (38-51)

12-16 (16-22)

INCH Lbs. (N.m)

87-104 (9.8-11.7)

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

Microsoft

1997 Mazda MX-5 Miata

STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

Fig. 5: Starting System Wiring Diagram

Microsoft

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

STARTER - REDUCTION GEAR

1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

DESCRIPTION & OPERATION

Reduction gear starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive housing.

Gear reduction is performed by coaxial planetary gear set. See Fig. 1 .

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

Fig. 1: Reduction Gear Type Starters

Courtesy of MAZDA MOTORS CORP.

TROUBLE SHOOTING

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article.

ON-VEHICLE TESTING

* PLEASE READ FIRST *

NOTE: On models with anti-theft system, obtain code number and deactivate audio anti-theft system before disconnecting battery.

NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are clean and tight, and engine grounds are good.

CIRCUIT TEST

If starter does not operate, check voltage at starter "S" terminal with ignition switch in START position. See

Fig. 2 . If voltage is greater than 8 volts and vehicle does not crank, repair or replace starter as required. If voltage is 8 volts or less, check ignition switch, park/neutral switch (A/T) and wiring.

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

Fig. 2: Testing Reduction Gear Starter Circuits

Courtesy of MAZDA MOTORS CORP.

BENCH TESTING

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

NO-LOAD TEST

LOAD TEST SPECIFICATIONS table. If voltage is less than specified, amperage is more than specified or shaft speed is less than specified, disassemble and inspect starter components.

NO-LOAD TEST SPECIFICATIONS

Application

Voltage (Minimum)

Amperage (Maximum)

Shaft Speed (Minimum RPM)

Specification

3000

SOLENOID TESTS

CAUTION: Perform solenoid tests with starter and solenoid assembled. 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 starter body. See Fig. 2 .

Starter pinion drive gear should extend outward and stop. If starter pinion drive gear does not extend, replace solenoid.

Solenoid Hold-In Test

Solenoid Return Test

Solenoid

2. Using ohmmeter, ensure continuity does not exist between "M" and "B" terminals. If continuity exists, replace solenoid.

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

PINION GAP ADJUSTMENT

SPECIFICATIONS table.

3. If pinion gap is not within specification, adjust by increasing or decreasing thickness of solenoid shims located between solenoid and drive housing.

PINION GAP SPECIFICATIONS

Application

Miata A/T

In. (mm)

.02-.08 (0.5-2.0)

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

Fig. 3: Checking & Adjusting Pinion Gap

Courtesy of MAZDA MOTORS CORP.

ARMATURE TEST

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.

3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.

COMMUTATOR TEST

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 .020 -.030" (.50 -.80 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut to standard depth.

COMMUTATOR SPECIFICATIONS

Application Maximum Runout In. (mm)

Miata A/T .001 (.03)

Minimum Diameter In. (mm)

1.21 (30.8)

BRUSH TEST

1. Connect one ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, replace brush holder assembly.

2. Check brush length. See BRUSH LENGTH SPECIFICATIONS table. If brush length is less than specified, replace brushes.

3. Using brush spring scale, measure spring tension. See BRUSH TENSION SPECIFICATIONS table. If tension is less than specified, replace brush holder assembly. Ensure brushes move freely in holders.

BRUSH LENGTH SPECIFICATIONS

Application Standard In. (mm)

Miata A/T .69 (17.5)

Minimum In. (mm)

.47 (12.0)

BRUSH TENSION SPECIFICATIONS

Application

Miata A/T

Standard Lbs. (Kg)

(1)

(1) Information is not available at time of publication.

Microsoft

Sunday, July 05, 2009 1:56:43 PM Page 8

Minimum Lbs. (Kg)

(1)

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

FIELD WINDING TEST

1. Connect one ohmmeter lead to field coil lead ("M" terminal wire). Connect other lead of ohmmeter to soldered portion of brush lead. If continuity does not exist, repair or replace field coil.

OVERRUNNING CLUTCH PINION DRIVE

REMOVAL & INSTALLATION

NOTE:

Removal & Installation

OVERHAUL

NOTE:

On models with anti-theft system, obtain code number and deactivate audio anti-theft system before disconnecting battery.

Overhaul procedures are not available at time of publication. See illustrations for exploded views of starters. See Fig. 4 .

Fig. 4: Exploded View Of Coaxial Planetary Gear Type Starter

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

TORQUE SPECIFICATIONS

Application

Starter Mounting Bolts

Starter-To-Bracket Bolt

Battery Cable Nut (Solenoid Terminal "B")

WIRING DIAGRAMS

Ft. Lbs. (N.m)

28-38 (38-51)

12-16 (16-22)

INCH Lbs. (N.m)

80-115 (9-13)

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

Microsoft

1997 Mazda MX-5 Miata

STARTER - REDUCTION GEAR 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Reduction Gear

Fig. 5: Starting System Wiring Diagram

Microsoft

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

STEERING COLUMN

1995-97 STEERING Mazda Motors Corp. - Steering Columns

DESCRIPTION & OPERATION

Steering columns are designed to be collapsible upon impact. The steering column consists of solid steering shaft with a lower joint assembly. Some models are equipped with tilt steering. Turn signal, headlight, ignition and windshield washer/wiper switches are mounted on column. Switches can be serviced by removing steering wheel and column covers. All models are equipped with air bag restraint system consisting of an driver air bag module, passenger air bag module (except 1995 MPV and 1995 Protege) and clockspring connector assembly located in the steering column.

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

SYSTEM OPERATION CHECK

1. Turn ignition switch to ON or START position. AIR BAG warning light in instrument cluster should illuminate for about 4-8 seconds, and then turn off. This indicates air bag system is functioning properly.

2. If any of the following conditions exists, air bag system is malfunctioning and requires servicing.



AIR BAG warning light does not illuminate as specified.



AIR BAG warning light remains illuminated for more than 8 seconds.

AIR BAG warning light illuminates while driving.

3. If air bag system components are replaced for any reason, air bag system must be checked for proper function after repair. Repeat step 1). If AIR BAG warning light does not illuminate as specified, air bag system is malfunctioning and servicing is required. See AIR BAG RESTRAINT SYSTEM article.

SERVICE PRECAUTIONS

Observe the following precautions when servicing air bag system.



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

DISABLING & ACTIVATING .

After disabling air bag system, wait at least one minute before servicing. Air bag system voltage is maintained for approximately one minute after system is disabled. Failure to wait one minute before servicing system may cause accidental air bag deployment and possible personal injury.



Obtain radio code number from customer and deactivate radio anti-theft function (if equipped) before disconnecting battery.

Because of the critical operation requirements of system, DO NOT service any air bag system component. Repairs 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) air bag module, ensure trim cover is pointed away from your body.

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns



This minimizes chance of injury in the event of accidental 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 to repair wire(s).

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

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



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

AIR BAG DISABLING & ACTIVATING

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

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

DISABLING SYSTEM (MIATA, MILLENIA, MPV, MX-6, PROTEGE & 626)

1. Obtain radio code from customer and deactivate audio anti-theft function (if equipped). Turn ignition off.

Disconnect and shield negative battery cable. Wait at least one minute for back-up power supply to be depleted. Remove lower cover panel(s) below left side of instrument panel.

2. On MPV, remove lower steering column shroud. On all models, disconnect Orange and Blue clockspring connectors for driver air bag module. See Fig. 1 . On all models except 1995 Protege and 1995 MPV, remove glove box compartment. Disconnect Orange and Blue connectors for passenger air bag module.

See Fig. 2 .

ACTIVATING SYSTEM (MIATA, MILLENIA, MPV, MX-6, PROTEGE & 626)

1. Ensure negative battery cable is still disconnected. On all models except 1995 Protege and 1995 MPV, reconnect Orange and Blue connector for passenger air bag module. Install glove box compartment.

2. On all models, reconnect Orange and Blue clockspring connectors for driver air bag module. Install lower cover panel(s). On MPV, install lower steering column shroud. On all models, reconnect negative battery cable.

3. Turn ignition on. Check AIR BAG warning light to ensure air bag system is operating properly. See

SYSTEM OPERATION CHECK . Activate audio anti-theft function (if equipped).

DISABLING SYSTEM (MX-3, RX7 & 929)

1. Obtain radio code from customer and deactivate audio anti-theft function. Turn ignition off. Disconnect and shield negative battery cable. Wait at least one minute for back-up power supply to be depleted.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

2. Disconnect diagnostic module connectors located at base of steering column and connect Short Circuit

Connectors (49-H066-004 ) to diagnostic module harness connectors. See Fig. 3 .

ACTIVATING SYSTEM (MX-3, RX7 & 929)

1. Ensure negative battery cable is still disconnected. Remove short circuit connectors from diagnostic module harness connectors. See Fig. 3 . Reconnect diagnostic module harness connectors to diagnostic module.

2. Reconnect negative battery cable. Turn ignition on. Check AIR BAG warning light to ensure air bag system is operating properly. See SYSTEM OPERATION CHECK . Activate audio anti-theft function

(if equipped).

Fig. 1: Disconnecting Clockspring Connectors (Typical)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 2: Disconnecting Passenger Air Bag Module Connectors (Typical)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 3: Connecting Short Circuit Connectors (Typical)

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

CLOCKSPRING CENTERING

Set front wheels in straight-ahead position. Rotate clockspring clockwise until it stops (DO NOT force). Rotate clockspring 2 3/4 turns counterclockwise. Rotate clockspring further, if necessary, to align arrows on clockspring and outer housing. See Fig. 4 .

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 4: Centering Clockspring

Courtesy of MAZDA MOTORS CORP.

REMOVAL & INSTALLATION

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

DRIVER AIR BAG MODULE

Removal

Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS . Disable air bag system. Refer to AIR BAG DISABLING & ACTIVATING . Remove air bag module bolts or nuts from back of steering wheel. Disconnect driver air bag module harness connector(s) and support rope. Remove driver air bag module.

Installation

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

To install, reverse removal procedure. Tighten driver air bag module bolts or nuts to specification. See

TORQUE SPECIFICATIONS table. Activate air bag system. See AIR BAG DISABLING &

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

OPERATION CHECK .

STEERING WHEEL

Removal

Set front wheels in straight-ahead position. Disconnect negative battery cable. Disable air bag system. See AIR

BAG DISABLING & ACTIVATING . Remove driver air bag module. See DRIVER AIR BAG MODULE .

Mark steering wheel and shaft for reassembly reference. Remove steering wheel nut. Using appropriate puller, remove steering wheel.

Installation

Ensure front wheels are in straight-ahead position. Install steering wheel, ensuring reference marks are aligned.

Tighten steering wheel nut to specification. See TORQUE SPECIFICATIONS table. To install remaining components, reverse removal procedure.

COMBINATION SWITCH

Removal

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

2. Remove driver air bag module. See DRIVER AIR BAG MODULE . Remove steering wheel. See

STEERING WHEEL . Remove upper and lower steering column covers. Disconnect combination switch electrical connectors. Remove combination switch screws.

3. Remove clockspring and combination switch as an assembly. Separate clockspring from combination switch.

Installation

1. To install, reverse removal procedure. Ensure front wheels are in straight-ahead position. Before installing steering wheel, center clockspring. See CLOCKSPRING CENTERING under

ADJUSTMENTS. Tighten steering wheel nut to specification. See TORQUE SPECIFICATIONS table.

2. After installation, activate air bag system. See AIR BAG DISABLING & ACTIVATING . Check AIR

BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

IGNITION SWITCH/STEERING LOCK ASSEMBLY

Removal & Installation

1. Remove driver air bag module, steering wheel and combination switch. See the following:



DRIVER AIR BAG MODULE .

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns



STEERING WHEEL .



COMBINATION SWITCH .

Disconnect ignition switch connectors. Remove key interlock cable from ignition switch/steering lock assembly (if equipped).

2. Using a hammer and chisel, make a groove in ignition switch/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 heads break off.

STEERING COLUMN

CAUTION: Excessive pressure or impact to steering shaft assembly during service may cause column to collapse.

Removal & Installation

1. Remove driver air bag module, steering wheel and combination switch. See the following:



DRIVER AIR BAG MODULE .



STEERING WHEEL .

COMBINATION SWITCH .

See Fig. 5 -11 . Remove ignition switch/steering lock assembly. See IGNITION SWITCH/STEERING

LOCK ASSEMBLY under REMOVAL & INSTALLATION.

2. Remove lower panel. Remove air duct (if equipped). Remove "U" joint dust cover (if equipped). Remove steering shaft assembly-to-intermediate shaft "U" joint bolt. Mark steering shaft assembly-to-intermediate shaft for installation reference. On MPV, disconnect shift lever mechanism.

3. On all models, remove steering column lower mounting bolts. Separate steering shaft from intermediate shaft. Remove steering column upper bracket bolts. Remove steering column.

4. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE

SPECIFICATIONS table.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 5: Exploded View Of Steering Column (Miata)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 6: Exploded View Of Steering Column (Millenia)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 7: Exploded View Of Steering Column (MPV)

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Courtesy of MAZDA MOTORS CORP.

Fig. 8: Exploded View Of Steering Column (MX-3 & Protege)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 9: Exploded View Of Steering Column (MX-6 & 626)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 10: Exploded View Of Steering Column (RX7)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 11: Exploded View Of Steering Column (929)

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

STEERING COLUMN

Disassembly

1. Remove driver air bag module, steering wheel and combination switch. See Fig. 5 -11 . See the following:



DRIVER AIR BAG MODULE .

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns



STEERING WHEEL .



COMBINATION SWITCH .

2. Remove ignition switch/steering lock assembly. See IGNITION SWITCH/STEERING LOCK

ASSEMBLY under REMOVAL & INSTALLATION. Remove steering column. See STEERING

COLUMN under REMOVAL & INSTALLATION. Turn steering shaft to remove.

Inspection

Inspect all components for damage and wear. Check steering shaft for bends, damage or sheared plastic pins.

Check bearings for excessive play. Replace components as necessary. Measure length of steering shaft. See

STEERING SHAFT DIMENSIONS table. See Fig. 12 -18 .

Reassembly

To reassemble, reverse disassembly procedure. Grease steering shaft, bushings and bearings. Use NEW shear screws.

STEERING SHAFT DIMENSIONS

(1)

Application Length - In. (mm)

Miata

Millenia

MPV

22.75-22.83 (577.8-579.8)

21.95 (557.5)

24.09-24.21 (612.0-615.0)

MX-3

MX-6 & 626

Protege

RX7

929

22.46-22.54 (570.6-572.6)

22.35-22.42 (567.6-569.6)

21.24-21.31 (539.3-541.3)

30.69-30.76 (779.5-781.5)

24.49-24.57 (622.0-624.0)

(1) For measuring points, see Fig. 12 Fig. 18 .

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 12: Measuring Steering Shaft Dimensions (Miata)

Courtesy of MAZDA MOTORS CORP.

Fig. 13: Measuring Steering Shaft Dimensions (Millenia)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 14: Measuring Steering Shaft Dimensions (MPV)

Courtesy of MAZDA MOTORS CORP.

Fig. 15: Measuring Steering Shaft Dimensions (MX-3, Protege & 323)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 16: Measuring Steering Shaft Dimensions (MX-6, 626)

Courtesy of MAZDA MOTORS CORP.

Fig. 17: Measuring Steering Shaft Dimensions (RX7)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Fig. 18: Measuring Steering Shaft Dimensions (929)

Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

Application

Steering Column Upper Mounting Bolts

Miata, Millenia, MPV, MX-6, RX7, 626 & 929

Steering Column Lower Mounting Bolts

Miata, RX7 & 929

Millenia, MX-6 & 626

Steering Shaft "U" Joint Bolts

Steering Wheel Lock Nut

Column Lower Bracket Mounting Bolts

MX-3

Protege

Driver Air Bag Module Bolts/Nuts

Millenia

MPV, MX-6, Protege & 626

Miata

Key Interlock Cable Bolt

Steering Column Lower Mounting Nuts

MPV

MX-3 & Protege

Microsoft

Sunday, July 05, 2009 1:40:02 PM

Ft. Lbs. (N.m)

12-16 (16-22)

13-19 (18-26)

12-17 (16-23)

13-19 (18-26)

29-36 (39-49)

INCH Lbs. (N.m)

80-124 (9-14)

53-80 (6-9)

80-115 (9-13)

71-106 (8-12)

35-53 (4-6)

Page 20

62-89 (7-10)

18-53 (2-6)

1997 Mazda MX-5 Miata

STEERING COLUMN 1995-97 STEERING Mazda Motors Corp. - Steering Columns

Steering Column Upper Mounting Bolts

MX-3 & Protege 80-124 (9-14)

Microsoft

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

1997-98 APPLICATIONS & IDENTIFICATION

Oil Pan Gasket Identification

AUTOMATIC TRANSMISSIONS

Fig. 1: Aisin-Warner 03-72LE Pan Gasket

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 2: Aisin-Warner 50-42LE Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 3: Audi 01V Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 4: Ford 4R44E & 5R55E Pan Gasket (Mazda)

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 5: Honda M4VA Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 6: Hydra-Matic 4L30-E Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 7: Hydra-Matic 4L60-E Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 8: Hyundai A4AF2 & A4BF1 Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 9: Hyundai KM175 Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 10: Mazda FB4A-EL Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 11: Mazda GF4A-EL Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 12: Mazda LA4A-EL Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 13: Mazda LJ4A-EL Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 14: Mazda NC4A-EL Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 15: Mazda RA4A-EL/RA4AX-EL Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 16: Mitsubishi F4AC1 Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 17: Mitsubishi F4A23 Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 18: Mitsubishi F4A33 & W4A33 Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 19: Mitsubishi F4A41, F4A42 & F4A51 Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 20: Mitsubishi R4AW3 & V4AW3 Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 21: Nissan RE4F04A/V Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 22: Nissan RE4R01A, RE4R03A & RL4R01A Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 23: Nissan RL4F03A & RE4F03A/V Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 24: Suzuki ECC 3-Speed Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 25: Toyota A-43D Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 26: Toyota A-131L, A-132L & A-140E Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 27: Toyota A-241E, A-242L & A-244E Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 28: Toyota A-245E, A-246E & A-247E Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 29: Toyota A-340E, A-340F, A-343F, A-350E & A-650E Pan Gasket

Microsoft

1997 Mazda MX-5 Miata

1997-98 APPLICATIONS & IDENTIFICATION Oil Pan Gasket Identification

Fig. 30: Toyota A-540E, A-540H & A-541E Pan Gasket

Microsoft

AIR CONDITIONING

1997 System Wiring Diagrams Mazda - Miata

1997 System Wiring Diagrams

Mazda - Miata

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 1: A/C Circuit

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 2: Heater Circuit

ANTI-LOCK BRAKES

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 3: Anti-lock Brake Circuits

COMPUTER DATA LINES

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 4: Computer Data Lines

COOLING FAN

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 5: Cooling Fan Circuit

CRUISE CONTROL

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 6: Cruise Control Circuit

DEFOGGERS

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 7: Defogger Circuit

ENGINE PERFORMANCE

1.8L

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 8: 1.8L, Engine Performance Circuits (1 of 2)

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 9: 1.8L, Engine Performance Circuits (2 of 2)

EXTERIOR LIGHTS

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 10: Back-up Lamps Circuit

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 11: Exterior Lamps Circuit, W/ DRL

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 12: Exterior Lamps Circuit, W/O DRL

GROUND DISTRIBUTION

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 13: Ground Distribution Circuit

HEADLIGHTS

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 14: Headlight Circuit, W/ DRL

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 15: Headlight Circuit, W/O DRL

HORN

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 16: Horn Circuit

INSTRUMENT CLUSTER

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 17: Instrument Cluster Circuit

INTERIOR LIGHTS

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 18: Interior Light Circuit

POWER ANTENNA

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 19: Power Antenna Circuit

POWER DISTRIBUTION

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 20: Power Distribution Circuit

POWER MIRRORS

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 21: Power Mirror Circuit

POWER WINDOWS

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 22: Power Window Circuit

RADIO

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 23: Base Radio

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 24: Premium Sound Radio Circuit

SHIFT INTERLOCKS

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 25: Shift Interlock Circuit

STARTING/CHARGING

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 26: Charging Circuit

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 27: Starting Circuit, A/T

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 28: Starting Circuit, M/T

SUPPLEMENTAL RESTRAINTS

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Fig. 29: Supplemental Restraint Circuit

TRANSMISSION

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 30: A/T Circuit

WARNING SYSTEMS

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 31: Warning System Circuits

WIPER/WASHER

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

Fig. 32: Wiper/Washer Circuit

1997 Mazda MX-5 Miata

1997 System Wiring Diagrams Mazda - Miata

Microsoft

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

AIR BAG RESTRAINT SYSTEM

1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

DESCRIPTION & OPERATION

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

The Supplemental Restraint System (SRS), when used in conjunction with seat belt, provides increased protection for driver and front passenger in a frontal collision. The air bag restraint system consists of AIR BAG warning light, driver-side air bag module, passenger-side air bag module, clockspring, SAS unit, and wiring harness. See Fig. 1 .

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 1: Air Bag System Component Identification

Courtesy of MAZDA MOTORS CORP.

Air bag deploys when ignition is on, crash sensor senses adequate deceleration, and SAS unit logic circuits determine that the impact is sufficient to warrant deployment.

The SAS unit monitors the air bag system for failures. If a failure occurs, the SAS unit turns the AIR BAG warning light on. If AIR BAG warning light is burned out, SAS unit will sound a buzzer to alert driver of a system malfunction.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

SYSTEM OPERATION CHECK

Turn ignition on. AIR BAG warning light in instrument cluster should glow for 6 seconds and then turn off. If

AIR BAG warning light does not function as described, a failure has occurred in Supplemental Restraint

System (SRS). Repair malfunctioning SRS. See DIAGNOSIS . Also, see SERVICE PRECAUTIONS .

SERVICE PRECAUTIONS

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



Disable air bag before servicing any air bag system/steering column component. See DISABLING &

ACTIVATING AIR BAG SYSTEM .



Because of critical system operating requirements, DO NOT service any air bag system component or wiring harness. 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 injury in event of accidental 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.



SAS unit must always be installed with arrow facing the front of the vehicle.

DO NOT disconnect SAS unit until unit is firmly mounted in vehicle.



Disconnecting or removing SAS unit with ignition switch in ON position can cause accidental deployment and serious personal injury. Before disconnecting or removing SAS unit connector or removing SAS unit, turn ignition to LOCK position.

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

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



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

ADJUSTMENTS

CLOCKSPRING CENTERING

Turn clockspring clockwise until it stops, then turn clockspring counterclockwise 2.75 turns. Align marks on clockspring with marks on outer housing. See Fig. 2 .

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 2: Locating Clockspring Alignment Marks

Courtesy of MAZDA MOTORS CORP.

DISABLING & ACTIVATING AIR BAG SYSTEM

WARNING: After disabling the air bag system, wait at least one minute before servicing. Air bag system voltage is maintained for more than minute after system is disabled. Failure to wait at least minute may cause accidental air bag deployment and possible personal injury.

DISABLING SYSTEM

Disconnect and shield negative battery cable. Wait at least one minute for back-up power supply to be depleted.

Remove cover panel below left side of instrument panel. Disconnect clockspring connectors for driver-side air bag. See Fig. 3 . Remove glove compartment. Disconnect passenger-side air bag module connectors. See Fig.

4 .

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 3: Locating Driver-Side Air Bag Clockspring Connectors

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 4: Locating Passenger-Side Air Bag Connectors

Courtesy of MAZDA MOTORS CORP.

ACTIVATING SYSTEM

Ensure negative battery cable is disconnected. Connect Orange and Blue passenger-side air bag module connectors. See Fig. 4 . Install glove compartment. Connect driver-side air bag Orange and Blue clockspring connectors. See Fig. 3 . Install lower cover panel. Connect negative battery cable. See SYSTEM

OPERATION CHECK .

DISPOSAL PROCEDURES

DEPLOYED AIR BAG

Wrap deployed air bag module in a plastic bag and dispose of as you would any other part. Wear gloves and safety glasses when handling air bag module.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

SCRAPPED VEHICLE

NOTE: When scrapping vehicles with an undeployed air bag(s), air bag(s) must be deployed inside vehicle.

INSPECTING DEPLOYMENT TOOL

NOTE: Deployment tool should always be inspected for proper operation before deploying air bag.

1. Connect Red deployment tool clip to battery positive terminal. Connect Black deployment tool clip to battery negative terminal. Observe deployment tool lights. Green light should be on with Red light off.

2. Connect deployment tool connector "A" to connector "B". See Fig. 5 . Green light should be off with Red light on. Press deployment tool activation switch. Green light should be on with Red light off.

3. If deployment tool lights function as described, it is safe to use deployment tool to activate air bag. If deployment tool lights do not function as described, DO NOT use deployment tool. Replace deployment tool with another unit and repeat procedure.

Driver-Side Air Bag

1. Before deploying air bag, inspect operating condition of Deployment Tool (49 H066 002). See

INSPECTING DEPLOYMENT TOOL under DISPOSAL PROCEDURES. Ensure vehicle is in an open space and away from other vehicles and people. Open doors. Open convertible top (if equipped).

Disconnect negative battery cable.

2. Remove lower center panel. Disconnect clockspring connectors from driver-side air bag. See Fig. 3 .

3. Connect deployment tool (49 H066 002) to clockspring connector. See Fig. 5 . Connect Red deployment tool clip to battery positive terminal. Connect Black deployment tool clip to battery negative terminal.

Verify deployment tool Red light is on.

4. Ensure all persons are at least 20 feet from vehicle. Press deployment tool activation switch to deploy air bag. Because of heat generated from air bag deployment, wait at least 15 minutes before handling deployed air bag module.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 5: Air Bag Deployment Tool Connector Identification

Courtesy of MAZDA MOTORS CORP.

Passenger-Side Air Bag

1. Before deploying air bag, inspect operating condition of Deployment Tool (49 H066 002). See

INSPECTING DEPLOYMENT TOOL under DISPOSAL PROCEDURES. Ensure vehicle is in an open space and away from other vehicles and people. Open doors. Open convertible top (if equipped).

Disconnect negative battery cable.

2. Remove glove compartment. Disconnect passenger-side air bag module connectors. See Fig. 4 . Connect deployment tool connector to passenger-side air bag connector. See Fig. 5 . Connect Red deployment tool clip to battery positive terminal. Connect Black deployment tool clip to battery negative terminal. Verify deployment tool Red light is on.

3. Ensure all persons are at least 20 feet from vehicle. Press deployment tool activation switch to deploy air bag. Because of heat generated from air bag deployment, wait at least 15 minutes before handling deployed air bag module.

POST-COLLISION INSPECTION

POST-COLLISION AIR BAG SAFETY INSPECTION

Action

Replace After Deployment

Components

Air Bag Module(s), Air Bag Sensor Unit

Inspect & If Damaged, Replace Component (Even Clockspring, Impact Sensors & Sensor Mountings,

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

If Air Bag Did Not Deploy)

Comments

Steering Column, Steering Wheel, Wiring Harness

DO NOT attempt wiring harness repairs. Replace entire harness. Impact sensors must always be installed with arrow on sensor facing front of vehicle.

REMOVAL & INSTALLATION

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

WARNING: DO NOT install driver-side air bag module unless DTC 6 is set. This can cause accidental deployment of the air bag. Verify DTC 6 is indicated before installing driver-side air bag module.

NOTE: After replacing components, check system to ensure proper operation. See

SERVICE PRECAUTIONS .

DRIVER-SIDE AIR BAG MODULE

Removal

Before proceeding, see SERVICE PRECAUTIONS . Disable air bag system. See DISABLING &

ACTIVATING AIR BAG SYSTEM . Remove driver-side air bag module nuts. Disconnect driver-side air bag module connector. Disconnect support rope. See Fig. 6 . Remove driver-side air bag module.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 6: Removing Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

Installation

1. Connect negative battery cable. Turn ignition switch on. Verify that Air Bag warning light comes on for 6 seconds and then goes off. Verify that DTC 6 is set. If another diagnostic trouble code is set, perform appropriate diagnosis and testing. See DIAGNOSIS .

2. If DTC 6 is set, turn ignition switch to LOCK position. Disconnect negative battery cable and wait for one minute. Connect driver-side air bag connector. Install support rope and driver-side air bag module.

Tighten air bag module retaining nuts to specification. See TORQUE SPECIFICATIONS .

3. Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

PASSENGER-SIDE AIR BAG MODULE

WARNING: DO NOT install passenger-side air bag module unless DTC 7 is set. This can cause accidental deployment of the air bag. Verify DTC 7 is indicated before installing passenger-side air bag module.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Removal

Before proceeding, see SERVICE PRECAUTIONS . Disable air bag system. See DISABLING &

ACTIVATING AIR BAG SYSTEM . Remove passenger-side air bag module retaining bolts. See Fig. 7 .

Remove passenger-side air bag module.

Fig. 7: Removing Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 8: Connecting SST (490839285) To Clockspring Connector

Courtesy of MAZDA MOTORS CORP.

Installation

1. Connect leads of SST (490839285) to terminals B and C of clockspring connector. Set resistance of SST

(490839285) to 2 ohms. Connect negative battery cable. Turn ignition switch on. Verify that air bag warning light comes on for 6 seconds and then goes Off. See Fig. 8 .

2. Verify that DTC 7 is set. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait for one minute. Install passenger-side air bag module and retaining bolts. Activate air bag system.

See TORQUE SPECIFICATIONS .

3. Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

SAS UNIT

Removal

1. Before proceeding, see SERVICE PRECAUTIONS . Disable air bag system. See DISABLING &

ACTIVATING AIR BAG SYSTEM .

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

2. Drain cooling system. Remove dashboard. Remove heater unit. SAS unit connectors. Remove 4 SAS unit mounting bracket nuts. Remove 2 SAS unit retaining screws. Remove SAS unit. See Fig. 9 .

Installation

To install, reverse removal procedure. Position SAS unit and bracket with arrow toward front of vehicle.

Tighten fasteners to specification. See TORQUE SPECIFICATIONS . After SAS unit is installed, activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

CLOCKSPRING

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

Removal

1. Set front wheels in straight-ahead position. Before proceeding, see SERVICE PRECAUTIONS .

Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

2. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove steering wheel nut. Using a puller, remove steering wheel. Remove steering column covers. Remove clockspring screws.

Remove clockspring and combination switch as an assembly.

Installation

1. To install, reverse removal procedure. Tighten steering wheel nut to specification. See TORQUE

SPECIFICATIONS .

2. After installation, activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .

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

CHECK .

SAS UNIT

Removal

1. Before proceeding, see SERVICE PRECAUTIONS . Disable air bag system. See DISABLING &

ACTIVATING AIR BAG SYSTEM .

2. SAS unit is located under center of dashboard. See Fig. 1 . Remove dashboard. Remove heater assembly.

Disconnect SAS unit connectors. Remove 4 SAS unit mounting bracket nuts. Remove 2 SAS unit retaining screws. Remove SAS unit. See Fig. 9 .

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 9: Removing/Installing SAS Unit

Courtesy of MAZDA MOTORS CORP.

Installation

To install, reverse removal procedure. Position SAS unit and bracket with arrow toward front of vehicle.

AIR BAG SYSTEM DEPLOYMENT AUTHORIZATION NOTE

New SAS units are not input with a deployment approval signal to prevent accidental deployment during installation and will not operate properly until the signal is input.

1. Install new SAS unit and verify air bag warning light continuously flashes approximately 6 seconds after ignition is turned on. Turn ignition to LOCK position and then back to ON position while warning light is flashing.

2. Air bag warning light should illuminate and then go out after approximately 6 seconds. If warning light does not go out, repeat procedure.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

DIAGNOSIS

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

SELF-DIAGNOSTIC SYSTEM

NOTE: If AIR BAG warning light does not come on and buzzer sounds when ignition is turned on, check and repair warning light circuit first.

SAS unit will only display one code at a time. SAS unit will always display highest priority code first. After repairing system, perform SYSTEM OPERATION CHECK . If AIR BAG warning light is still flashing during SYSTEM OPERATION CHECK, record code displayed. Repair system as necessary.

Retrieving & Clearing Codes

If codes are stored, AIR BAG warning light will flash or remain on when ignition is turned on. Codes are automatically cleared when fault is corrected.

AIR BAG Warning Light Flashes

AIR BAG warning light indicates fault codes by flashing. Count the number of flashes between pauses to determine code. See AIR BAG CODES table. Codes are prioritized. If 2 or more faults are present, SAS unit will display highest priority code first. After identifying code, go to appropriate code test.

AIR BAG Warning Light Remains On

Illumination of AIR BAG warning light continuously when ignition is turned on indicates a Code 0 (zero). See

AIR BAG CODES table.

AIR BAG Warning Light Does Not Come On

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

AIR BAG CODES

Code

(1)

(1) AIR BAG warning light remains on, indicating a Code 0.

Possible Cause

SAS unit

Power Source Circuit

Driver-Side Air Bag Module Circuit

Passenger-Side Air Bag Module Circuit

WARNING LIGHT DOES NOT COME ON

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove meter hood. Ensure instrument cluster 12 pin connector is securely connected and that terminal No. 1 E is not damaged. Check continuity between terminal No. 1E of 12 pin cluster connector and terminal No. 2K of print plate of instrument cluster. If there is continuity, go to next step. If there is no continuity, replace print plate and then go to next step.

2. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check if terminal

No. Q of 21 pin SAS unit connector is securely connected and is not damaged. If ok, go to next step. If terminal Q is not securely connected or is damaged, replace air bag harness, then go to next step.

3. Disconnect 21 pin SAS unit connector and 12 pin instrument cluster connector. Check continuity between terminal No. Q of SAS unit connector and terminal No. 1 E of instrument cluster connector. If there is continuity, replace SAS unit and then go to next step. See SAS UNIT under REMOVAL &

INSTALLATION. If there is no continuity, go to next step.

4. Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check AIR BAG warning light for proper system function. See SYSTEM OPERATION CHECK .

WARNING LIGHT DOES NOT COME ON

NOTE: For connector terminal identification, see WIRING DIAGRAM .

Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove meter hood.

Ensure instrument cluster 12 pin connector is securely connected and that terminal No. 1 E is not damaged.

Check continuity between terminal No. 1E of 12 pin cluster connector and terminal No. 2K of print plate of instrument cluster. If there is continuity, go to next step. If there is no continuity, replace print plate and then go to next step.

WARNING LIGHT REMAINS ON

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Measure battery voltage. If voltage is more than 9 volts, go to next step. If voltage is not more than 9 volts, check charging system.

2. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove dashboard.

Remove heater unit. Check if SAS unit connector is securely connected. Check short bar between SAS unit terminal No. Q and terminal No. S. If short bar is bent, replace wiring harness and then go to next step. If short bar is OK, go to next step.

3. Check short bar hook on SAS unit. If hook is OK, go to next step. If hook is damaged, replace SAS unit.

See SAS UNIT under REMOVAL & INSTALLATION.

4. Disconnect SAS unit 21 pin connector and instrument panel 12 pin connector. Carefully insert an insulation material between terminal No. Q and terminal No. S of SAS unit so short bar cannot move.

NOTE: Use care not to damage short bar when inserting insulation material.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

5. Check continuity between terminal No. Q and ground. If continuity exists, replace or repair wiring harness between instrument cluster and SAS unit. If no continuity exists, replace SAS unit. See SAS

UNIT under REMOVAL & INSTALLATION.

6. Activate air bag system and perform SYSTEM OPERATION CHECK . Check that AIR BAG warning light is operating properly. If not, reconfirm malfunction symptoms.

DTC 0 - SAS UNIT

NOTE: When air bag warning light remains on, it can indicate a DTC 0 caused by no continuity between terminal No. V and terminal No. Y of SAS unit This can be due to a damaged SAS unit, an open or short circuit in wiring harness or poor connections.

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove dashboard.

Remove heater unit. Check if SAS unit connector is securely connected. If not, reconnect connector and go next step. If ok, go to next step.

2. Disconnect SAS unit connector and check for continuity between terminal No. V and terminal No. Y of

SAS unit connector. If there is continuity, replace SAS unit. If there is no continuity, replace wiring harness. Perform SYSTEM OPERATION CHECK .

DTC 3 - BATTERY

NOTE: When voltage supplied to SAS unit is less than 1 volt due to weak battery, open or short in wiring harness, poor connection of connector or damaged SAS unit,

DTC 3 will set

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Check that battery voltage is at least 8 volts. If not, check battery and/or charging system. Turn ignition on and check voltage at joint connector terminals A or E (X-33).

2. If voltage is over 8 volts, replace SAS unit. See SAS UNIT under REMOVAL & INSTALLATION. If voltage is not over 8 volts, replace wiring harness from battery to fuse box. Perform SYSTEM

OPERATION CHECK .

DTC 6 - DRIVER-SIDE AIR BAG MODULE

NOTE: When resistance Is detected between terminals M-O of SAS unit is NOT 2 ohms,

DTC 6 will set.

NOTE: For connector terminal identification, see WIRING DIAGRAM .

1. Disable air bag system. See procedures under DISABLING & ACTIVATING AIR BAG SYSTEM .

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL &

INSTALLATION.

2. Inspect clockspring connectors for damage. If connectors are okay, go to next step. If connectors are damaged, replace clockspring. Perform SYSTEM OPERATION CHECK .

3. Connect Special Service Tool (49 0839 285) to terminal No. 3B and terminal No. 3C of clockspring. Set

SST resistance to 2 ohms. Connect clockspring connector. Connect negative battery cable. Turn ignition switch to ON position and cheek for codes. If CODE 6 is displayed, go to next step. If CODE 6 is not present, replace driver-side air bag module. Perform SYSTEM OPERATION CHECK .

4. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait for 1 minute.

Disconnect clockspring connector and inspect. If pins are ok go next step. If pins are damaged, replace wiring harness from clockspring to SAS unit.

5. Connect Special Service Tool (49 0839 285) to terminal No. A and terminal No. B of clockspring connector. Set SST resistance to 2 ohms. Connect clockspring connector and connect negative battery cable. Turn ignition switch to ON position and cheek for codes. If CODE 6 is displayed, go to next step.

If CODE 6 is not present, replace clockspring. See CLOCKSPRING under REMOVAL &

INSTALLATION. Perform SYSTEM OPERATION CHECK .

6. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait for 1 minute. Remove dashboard and heater unit. Disconnect SAS unit connector.

7. Check wiring harness between terminal No. O of SAS unit connector and between terminal No. A of clockspring connector. Also check between terminal No. M of SAS unit connector and terminal No. B of clockspring connector. Check for short to ground, short to power or open circuit. If wiring is OK, replace

SAS unit. See SAS UNIT under REMOVAL & INSTALLATION.If wiring is not OK, replace wiring harness from clockspring to SAS unit. Perform SYSTEM OPERATION CHECK .

DTC 7 - PASSENGER-SIDE AIR BAG MODULE

NOTE: For connector terminal identification, see WIRING DIAGRAM .

NOTE: When resistance is detected between terminals l-K of SAS unit is NOT 2 ohms and/or there is no continuity between terminal No. E of SAS unit and ground,

DTC 7 will set

1. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Inspect passengerside air bag module connectors for damage. If connectors are okay, go to next step. If connectors are damaged, replace wiring harness from passenger-side air bag module to SAS unit. Perform SYSTEM

OPERATION CHECK .

2. Connect Special Service Tool (49 0839 285) to terminal No A and terminal No. B of passenger-side air bag module connector. Set Special Service Tool resistance to 2 ohms. Connect clockspring connector.

Connect negative battery cable. Turn ignition switch to ON position and check for codes. If DTC 7 is displayed, go to next step. If CODE 7 is not present replace passenger-side air bag module. See

PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. Perform SYSTEM

OPERATION CHECK .

3. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait 1 minute. Disconnect clockspring connector. Remove dashboard and heater unit.

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

4. Disconnect SAS unit connector. Check wiring between terminal K of SAS unit connector and terminal C of passenger-side air bag module connector for short to ground, short to power or open circuit. If wiring is OK, replace SAS unit. See SAS UNIT under REMOVAL & INSTALLATION. If wiring is not OK, replace wiring harness between passenger-side air bag module and SAS unit. Perform SYSTEM

OPERATION CHECK .

WIRE REPAIR

DO NOT repair air bag system wiring. If a problem is found with air bag system wiring, replace faulty wiring.

TORQUE SPECIFICATIONS

Application

Passenger-Side Air Bag Module Retaining Bolts

Steering Wheel Nut

Driver-Side Air Bag Module Retaining Nuts

SAS Unit Retaining Nuts

Ft. Lbs. (N.m)

13-20 (18-27)

29-36 (39-49)

INCH Lbs. (N.m)

35-52 (4.0-5.8)

61-86 (6.7-9.8)

WIRING DIAGRAM

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Microsoft

1997 Mazda MX-5 Miata

AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System

Fig. 10: SRS Wiring Diagram

Microsoft

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

ANTI-LOCK BRAKE SYSTEM

1997 BRAKES Mazda - Anti-Lock

DESCRIPTION

CAUTION: See ANTI-LOCK BRAKE SAFETY PRECAUTIONS article in GENERAL

INFORMATION.

The Anti-Lock Brake System (ABS) control module 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 module. An ABS warning light is located on the instrument cluster.

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

OPERATION

Under normal driving conditions, Anti-Lock Brake System (ABS) functions like a standard brake system. When vehicle speed reaches 3.8 MPH, ABS will diagnose pump motor by briefly operating motor. Pump motor operation may be heard inside vehicle.

ABS control module controls ABS by detecting speed sensor signals and activating solenoid valve in hydraulic unit. Control module also controls pump motor and self-diagnostic function. If a problem is detected in ABS,

ABS will function like a conventional brake system. ABS 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.

COMPONENT LOCATIONS

Application

ABS Control Module

Data Link Connector

Front Sensor Rotor

Hydraulic Unit

Motor & Valve Relays

Pump Motor

Rear Sensor Rotor

Wheel Speed Sensor

Location

Under Carpet, Behind Passenger Seat

Left Side Of Engine Compartment

On Front Wheel Hub

Right Rear Of Engine Compartment

On Hydraulic Unit

On Rear Drive Axle

On Knuckle

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

BLEEDING BRAKE SYSTEM

CAUTION: DO NOT allow reservoir to run dry during brake bleeding procedure. If brake fluid is spilled, clean surface immediately with alcohol, as brake fluid will damage painted surfaces. Use only DOT 3 brake fluid and DO

NOT mix with any other types.

1. Raise and support vehicle. Ensure brake fluid reservoir remains at least half full during bleeding procedure. When bleeding brake system, start with longest brakeline first. Remove bleed screw cap.

Connect one end of transparent vinyl tube to bleed screw. Submerge other end of tube in a container half filled with clean brake fluid.

2. Have an assistant depress brake pedal several times and hold in depressed position. Loosen bleed screw and drain fluid into container. Tighten bleed screw.

NOTE: Ensure brake pedal remains depressed until bleed screw is tightened.

3. Refill brake fluid reservoir if necessary. Repeat step 2) until air is no longer discharged. Tighten bleed screw to 52-78 INCH lbs. (5.9-8.8 N.m). Ensure fluid leakage is not present. Add fluid to reservoir.

Repeat procedure for remaining wheels.

TROUBLE SHOOTING

Before attempting to diagnose vehicle, ensure ABS warning light is functioning properly. ABS warning light will not illuminate and ABS will not operate if battery voltage is insufficient. Perform trouble shooting procedures on ABS warning light to eliminate unnecessary repairs and/or component replacement.

ABS WARNING LIGHT DOES NOT ILLUMINATE WHEN IGNITION IS TURNED ON

1. Turn ignition on. Check if other warning lights illuminate. If other warning lights do not illuminate, check

METER fuse. Replace as necessary. If other warning lights illuminate, check for possible malfunction and repair as necessary. Go to next step.

2. Turn ignition off. Disconnect ABS Control Module (ABS CM) connector. See COMPONENT

LOCATIONS . Turn ignition on. Check if ABS warning light illuminates. If ABS warning light illuminates, go to next step. If ABS warning light does not illuminate, go to step 5).

3. Reconnect ABS CM connector. Turn ignition on. Check if ABS warning light illuminates. If ABS warning light does not illuminate, go to next step. If ABS warning light illuminates, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

4. Check if terminal AD of ABS CM harness connector is damaged or deformed. See Fig. 3 . If terminal AD is damaged or deformed, replace wiring harness connector. If terminal AD is okay, replace ABS CM.

5. With ABS CM connector disconnected, use a jumper wire and ground terminal AD of ABS CM harness connector. Check if ABS warning light illuminates. If ABS warning light illuminates, go to next step. If

ABS warning light does not illuminate, go to step 7).

6. With ABS CM disconnected, check continuity between terminal AB of ABS CM harness connector and ground. Also, check continuity between terminal AC of ABS CM harness connector and ground, and

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock between terminal AM of ABS CM harness connector and ground. If continuity exists, replace wiring harness connector. If continuity does not exist, repair wiring harness.

7. Check ABS warning light bulb. Replace bulb as necessary. If bulb is okay, go to next step.

8. Check continuity between terminal AD of ABS CM harness connector and terminal 1K of instrument cluster connector. See WIRING DIAGRAMS . If continuity exists, check ABS warning light. See ABS

WARNING LIGHT under COMPONENT TESTING . If continuity does not exist, repair wiring harness.

ABS WARNING LIGHT REMAINS ILLUMINATED

1. Ensure battery is fully charged. Charge or replace as necessary. If battery is fully charged, go to next step.

2. Check ABS Control Module (ABS CM) connector for poor connection. Turn ignition on. Check if ABS warning light goes out. If ABS warning light does not go out, go to next step. If ABS warning light goes out, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

NOTE: ABS warning light will illuminate if voltage between terminal "A" (voltage supply) of ABS CM harness connector and ground is less than about 10 volts.

3. Turn ignition off. Disconnect ABS CM connector. See COMPONENT LOCATIONS . Measure voltage between terminals "A" and AB of ABS CM harness connector. See Fig. 3 . Also, measure voltage between terminals "A" and AC of ABS CM harness connector, and between terminals "A" and AM of

ABS CM harness connector. If battery voltage is present, go to next step. If battery voltage is not present, repair wiring harness.

4. Connect ABS CM connector. Check for ABS DTCs. See RETRIEVING DIAGNOSTIC TROUBLE

CODES under DIAGNOSIS & TESTING. If no DTCs are present, go to next step.

5. Turn ignition off. Disconnect ABS CM connector. Connect Harness Adapter (49-F066-022). Turn ignition on. Check if ABS warning light goes out. If ABS warning light does not go out, repair short in

ABS warning light drive harness or instrument cluster. If ABS warning light goes out, replace ABS CM.

ABS WARNING LIGHT FLASHES WITH VEHICLE STOPPED

1. Ensure battery is fully charged. Charge or replace as necessary. If battery is fully charged, go to next step.

2. Check if a jumper wire is installed between terminals TBS and GND of Data Link Connector (DLC). See

Fig. 1 . If jumper wire is installed, remove jumper wire from DLC. If jumper wire is not installed, go to next step.

3. Turn ignition off. Disconnect ABS Control Module (ABS CM) connector. See COMPONENT

LOCATIONS . Check continuity between terminal "P" of ABS CM harness connector and ground. See

Fig. 3 . If continuity exists, repair short to ground in DLC wiring harness. If continuity does not exist, replace ABS CM.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 1: Identifying Data Link Connector (DLC) Terminals

Courtesy of MAZDA MOTORS CORP.

ABS WARNING LIGHT REMAINS ILLUMINATED DURING DRIVING UNTIL IGNITION IS

TURNED OFF

1. Check for ABS DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES under DIAGNOSIS &

TESTING. If no DTCs are present, go to next step.

2. Check ABS Control Module (ABS CM) connector for poor connection. Drive vehicle and recheck ABS warning light. If ABS warning light remains illuminated during driving and goes out when ignition is turned off, replace ABS CM. If ABS warning light does not remain illuminated during driving, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

ABS WARNING LIGHT ILLUMINATES/GOES OUT WITH VEHICLE STOPPED AND DURING

DRIVING

1. Check for ABS DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES under DIAGNOSIS &

TESTING. If no DTCs are present, go to next step.

2. Turn ignition off. Disconnect ABC Control Module (ABS CM) connector. See COMPONENT

LOCATIONS . Turn ignition on. Check if ABS warning light illuminates. If ABS warning light illuminates, go to next step. If ABS warning light does not illuminate, repair ABS warning light wiring harness or instrument cluster.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

3. Turn ignition off. Disconnect ABS CM connector. Measure voltage between terminals "A" and AB of

ABS CM harness connector. See Fig. 3 . Also, measure voltage between terminals "A" and AC of ABS

CM ha rness connector, and between terminals "A" and AM of ABS CM harness connector. If battery voltage is present, go to next step. If battery voltage is not present, repair wiring harness.

4. Turn ignition off. Reconnect ABS CM connector. Drive vehicle and recheck ABS warning light. If ABS warning light illuminates/goes out with vehicle stopped and during driving, replace ABS CM. If ABS warning light does not illuminate/go out with vehicle stopped and during driving, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

ABS WARNING LIGHT INDICATES NORMAL, BUT ABS DOES NOT OPERATE PROPERLY

Check for ABS DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES under DIAGNOSIS &

TESTING. If no DTCs are present, inspect mechanical system.

PRE-DIAGNOSIS INSPECTION

Visually inspect ABS components for possible cause of anti-lock problem. Visual inspection may help identify cause of a simple malfunction. Ensure ABS warning light is functioning properly. See TROUBLE

SHOOTING .

ABS warning light illuminates under the following conditions:



Vehicle operated on snow or ice with parking brake activated, or a dragging brake at one wheel.



Different size tires being used.



Tires with different traction characteristics are used on same axle.

Vehicle is jacked up and drive wheels spin for 20 seconds or more with ignition on.



Low battery voltage.

If ABS warning light illuminates because of these conditions, turn ignition off, then back on. ABS warning light will go out and no DTCs for described conditions will be stored in ABS control module memory.

DIAGNOSIS & TESTING

Diagnose ABS using New Generation Star (NGS) Tool (49-T088-0A0) and Adapter Harness (49-F066-002).

See RETRIEVING DIAGNOSTIC TROUBLE CODES . On all models, test ABS control module using

DVOM and adapter harness. See ABS CONTROL MODULE under COMPONENT TESTING .

If ABS test equipment is unavailable, test each component of ABS. See COMPONENT TESTING . If all

ABS components test okay, replace ABS control module with a known-good module and retest system.

RETRIEVING DIAGNOSTIC TROUBLE CODES

Using New Generation Star (NGS) Tool

1. Turn ignition off. Connect New Generation Star (NGS) Tool (49-T088-0A0) to Data Link Connector

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

(DLC). Set NGS Adapter (49-T088-003) to ABS. Select VEHICLE & ENGINE SELECTION, then select vehicle model, engine type and model year. Select DIAGNOSTIC DATA LINK. Select ABS-ANTI

LOCK BRAKE MODULE.

2. Select DIAGNOSTIC TEST MODE and note any codes displayed. See DIAGNOSTIC TROUBLE

CODE DESCRIPTION table. Perform appropriate test. See DIAGNOSTIC TROUBLE CODE (DTC)

TESTING . Clear codes after servicing. See CLEARING CODES .

DIAGNOSTIC TROUBLE CODE DESCRIPTION

DTC

(1) Pressure retention valve.

(2) Pressure reduction valve.

Probable Cause

Stoplight Switch Wiring Harness

Right Front Wheel Speed Sensor/Sensor Rotor

Left Front Wheel Speed Sensor/Sensor Rotor

Right Rear Wheel Speed Sensor/Sensor Rotor

Left Rear Wheel Speed Sensor/Sensor Rotor

Wheel Speed Sensor/Sensor Rotor

(1)

Right Front Solenoid Valve (AV)

(2)

Right Front Solenoid Valve (EV)

(1)

Left Front Solenoid Valve (AV)

(2)

Left Front Solenoid Valve (EV)

(1)

Rear Solenoid Valve (AV)

(2)

Rear Solenoid Valve (EV)

Valve Relay

Motor Relay/Pump Motor

ABS Control Module

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 2: Reading Diagnostic Trouble Code Output

Courtesy of MAZDA MOTORS CORP.

CLEARING CODES

NOTE: Disconnecting battery does not clear Diagnostic Trouble Codes (DTCs). If DTCs will not clear, ensure stoplight switch is functioning properly.

1. Turn ignition off. Connect a jumper wire between TBS terminal and GND terminal of Data Link

Connector (DLC). See Fig. 1 . Turn ignition on. Output all diagnostic trouble codes stored in ABS control module memory. When first code is repeated, depress brake pedal 10 times at intervals of less than one second.

2. When codes are cleared, ABS warning light will illuminate for 3 seconds, then go out. ABS operation should return to normal control. If ABS warning light does not operate as described and ABS does not return to normal operation, repeat procedure ensuring brake pedal interval does not exceed one second.

DIAGNOSTIC TROUBLE CODE (DTC) TESTING

* PLEASE READ FIRST *

NOTE: See PRE-DIAGNOSIS INSPECTION and DIAGNOSIS & TESTING before proceeding with DIAGNOSTIC TROUBLE CODE (DTC) TESTING. After repairs are complete, clear DTCs from ABS control module memory. See CLEARING

CODES under DIAGNOSIS & TESTING.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

DTC 05: STOPLIGHT SWITCH WIRING HARNESS

1. Check stoplight switch wiring harness for open or short to ground between stoplight switch and ABS control module. See WIRING DIAGRAMS . Repair as necessary. If wiring harness is okay, go to next step.

2. Clear DTCs. See CLEARING CODES under DIAGNOSIS & TESTING. Recheck for DTCs. If DTC 05 is displayed, replace ABS control module. If DTC 05 is not displayed, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

DTCS 11, 12, 13 & 14: WHEEL SPEED SENSOR, SENSOR ROTOR, HYDRAULIC UNIT OR

WIRING HARNESS

1. Check ABS control module connector for poor connection. See COMPONENT LOCATIONS . Repair as necessary. If connector is okay, go to next step.

2. Check wiring harness for open or short to ground between suspect wheel speed sensor and ABS control module. See WIRING DIAGRAMS . Repair as necessary. If wiring harness is okay, go to next step.

3. Check suspect wheel speed sensor. See WHEEL SPEED SENSORS under COMPONENT TESTING .

Replace as necessary. If wheel speed sensor is okay, go to next step.

4. Inspect wheel speed sensor rotor for damage or missing teeth. If sensor rotor is damaged or has missing teeth, replace sensor rotor. If sensor rotor is okay, go to next step.

5. Inspect brakeline for damage. If brakeline is damaged, replace brakeline. If brakeline is okay, go to next step.

6. Check hydraulic unit. See HYDRAULIC UNIT under COMPONENT TESTING . Replace as necessary. If hydraulic unit is okay, go to next step.

7. Clear DTCs. See CLEARING CODES under DIAGNOSIS & TESTING. Recheck for DTCs after driving vehicle from a stop to faster than 6.2 MPH. If DTC 11, 12, 13 or 14 is displayed, replace ABS control module. If DTC 11, 12, 13 or 14 is not displayed, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

DTC 15: WHEEL SPEED SENSOR, SENSOR ROTOR, HYDRAULIC UNIT OR WIRING HARNESS

If DTC 15 is displayed, perform DTCS 11 , 12, 13 & 14: WHEEL SPEED SENSOR, SENSOR ROTOR,

HYDRAULIC UNIT OR WIRING HARNESS test.

DTCS 22, 23, 24, 25, 26 & 27: SOLENOID VALVE OR WIRING HARNESS

1. Check ABS control module connector for poor connection. See COMPONENT LOCATIONS . Repair as necessary. If connection is okay, go to next step.

2. Check suspect solenoid valve with valve relay installed. See SOLENOID VALVES under

COMPONENT TESTING. Replace as necessary. If solenoid valve with valve relay installed is okay, go to next step.

3. Check suspect solenoid valve with valve relay removed. See SOLENOID VALVES under

COMPONENT TESTING. Replace solenoid valve as necessary. If solenoid valve with valve relay removed is okay, go to next step.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

4. Check wiring harness for open or short to ground between hydraulic unit and ABS control module. See

WIRING DIAGRAMS . Repair as necessary. If wiring harness is okay, go to next step.

5. Clear DTCs. See CLEARING CODES under DIAGNOSIS & TESTING. Recheck for DTCs. If DTC

22, 23, 24, 25, 26 or 27 is displayed, replace ABS control module. If DTC 22, 23, 24, 25, 26 or 27 is not displayed, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

DTC 51: VALVE RELAY OR WIRING HARNESS

1. Check BTN fuse. Replace as necessary. If BTN or ABS fuse is okay, go to next step.

2. Check valve relay. See VALVE RELAY under COMPONENT TESTING. Replace as necessary. If valve relay is okay, check wiring harness for open or short to ground between valve relay and ABS control module. See WIRING DIAGRAMS . Repair as necessary. If wiring harness is okay, go to next step.

3. Clear DTCs. See CLEARING CODES under DIAGNOSIS & TESTING. Recheck for DTCs. If DTC 51 is displayed, replace ABS control module. If DTC 51 is not displayed, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

DTC 53: PUMP MOTOR, MOTOR RELAY OR WIRING HARNESS

1. Turn ignition off and check if pump motor continues to operate. If pump motor continues operating after ignition is off, replace motor relay. If pump motor does not continue to operate after ignition is off, go to next step.

2. Check ABS fuse. Replace as necessary. If ABS fuse is okay, go to next step.

3. Check motor relay. See MOTOR RELAY under COMPONENT TESTING. Replace as necessary. If motor relay is okay, check wiring harness for open or short to ground between motor relay and ABS control module. See WIRING DIAGRAMS . Repair as necessary. If wiring harness is okay, go to next step.

4. Check pump motor. See PUMP MOTOR under COMPONENT TESTING. Replace as necessary. If pump motor is okay, check wiring harness for open or short to ground between hydraulic unit and ABS control module. Repair as necessary. If wiring harness is okay, go to next step.

5. Clear DTCs. See CLEARING CODES under DIAGNOSIS & TESTING. Recheck for DTCs. If DTC 53 is displayed, replace ABS control module. If DTC 53 is not displayed, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

DTC 61: ABS CONTROL MODULE

1. Check ABS control module connector for poor connection. See COMPONENT LOCATIONS . Repair as necessary. If connector is okay, go to next step.

2. Clear DTCs. See CLEARING CODES under DIAGNOSIS & TESTING. Recheck for DTCs. If DTC 61 is displayed, replace ABS control module. If DTC 61 is not displayed, a temporary poor contact in wiring may have occurred and ABS is now functioning properly.

COMPONENT TESTING

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

GENERAL NOTE

NOTE: Before testing ABS components, ensure battery and charging system are functioning properly.

ABS CONTROL MODULE

Turn ignition off. Test ABS Control Module (ABS CM) using DVOM and Adapter Harness (49-F066-002) connected to ABS CM connector. See Fig. 3 . Measure resistance, continuity or voltage as specified. See Fig. 3

-7. If checking voltage, measure between applicable terminal and GND terminal (AB, AC or AM) of ABS CM connector. If voltage, continuity or resistance is not as specified, replace ABS CM.

Fig. 3: Identifying ABS Control Module Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Fig. 4: Testing ABS Control Module (1 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 5: Testing ABS Control Module (2 Of 3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 6: Testing ABS Control Module (3 Of 3)

Courtesy of MAZDA MOTORS CORP.

HYDRAULIC UNIT

On-Vehicle Inspection

1. Ensure all diagnostic trouble codes have been cleared and battery is fully charged. See CLEARING

CODES under DIAGNOSIS & TESTING. Turn ignition on and check if ABS warning light goes out after 2-4 seconds. If ABS warning light remains illuminated, ABS control module has detected a failure and will not activate hydraulic unit. See DIAGNOSIS & TESTING .

2. Turn ignition off. Ensure vehicle is on level surface. Raise and support vehicle. Place transmission in

Neutral. Release parking brake. Rotate wheels by hand and check for brake drag. Connect a jumper wire between TBS terminal and GND terminal of data link connector. See Fig. 1 . Depress brake pedal and have an assistant attempt to rotate right front wheel. Wheel should not rotate.

3. With brake pedal still depressed, turn ignition on. Brake should be momentarily released (about .5 second) and wheel should turn when pressure reduction operates. Check operation of remaining wheels using same procedure beginning with left front, right rear, then left rear wheels.

4. If all wheels operate as specified, the following systems are operating properly.



Brake piping to hydraulic unit.



Braking system, including hydraulic unit.

Hydraulic unit electrical system (solenoid, pump motor, etc.)

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock



ABS control module output system (solenoid, relay, etc.) and harness.

5. If all wheels do not operate as specified, check ABS control module input system and wiring harness for intermittent failure. Check for fluid leakage. Repair as necessary. If input system, wiring harness, intermittent failure or fluid leakage are not present, replace hydraulic unit.

PUMP MOTOR

1. Turn ignition off. Disconnect ABS Control Module (ABS CM) connector. See COMPONENT

LOCATIONS . Connect Adapter Harness (49-F066-002) to ABS CM connector. Using ohmmeter, measure resistance between terminal "X" of ABS CM connector and ground. See Fig. 3 . Resistance should not be more than one ohm. If the resistance is not as specified, check wiring harness between ABS

CM and pump motor. Refer to WIRING DIAGRAMS . If wiring harness is okay, go to next step.

2. Turn ignition off. Disconnect pump motor/hydraulic unit 2-pin connector. Using ohmmeter, measure resistance between terminal "B" of pump motor/hydraulic unit connector and ground. See Fig. 7 .

Resistance should not be more than one ohm. Apply 12 volts across pump motor/hydraulic unit 2-pin connector terminals. Pump motor should operate. If resistance is not as specified or pump motor does not operate, check wiring harness. If wiring harness is okay, replace hydraulic unit.

Fig. 7: Identifying Pump Motor/Hydraulic Unit Connector Terminals

Courtesy of MAZDA MOTORS CORP.

SOLENOID VALVES

With Valve Relay Installed

Turn ignition off. Disconnect hydraulic unit 12-pin connector. See COMPONENT LOCATIONS . Apply 12

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock volts to terminal "A" and ground terminal "D" of hydraulic unit 12-pin connector. See Fig. 8 . Using ohmmeter, measure resistance between terminal "B" and specified terminals of hydraulic unit connector. See

HYDRAULIC UNIT CONNECTOR TERMINAL RESISTANCE table. If resistance is not as specified, check solenoid valves with vale relay removed. See WITH VALVE RELAY REMOVED. Also check valve relay. See VALVE RELAY.

HYDRAULIC UNIT CONNECTOR TERMINAL RESISTANCE

Terminal

"H"

"I"

"J"

"M"

"N"

"O"

Ohms

4.7

With Valve Relay Removed

Turn ignition off. Remove hydraulic unit. See HYDRAULIC UNIT under REMOVAL & INSTALLATION .

Remove valve relay from hydraulic unit. Using ohmmeter, measure resistance between terminal "X" of hydraulic unit valve relay connector and specified terminals of hydraulic unit connector. See Fig. 8 and Fig. 9 .

See HYDRAULIC UNIT CONNECTOR TERMINAL RESISTANCE table. If resistance is not as specified, check wiring harness. If wiring harness is okay, replace hydraulic unit.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 8: Identifying Hydraulic Unit Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 9: Locating Hydraulic Unit Valve Relay Connector Terminals

Courtesy of MAZDA MOTORS CORP.

ABS WARNING LIGHT

Operational Test

1. Start engine and observe ABS warning light. Light should illuminate for a few seconds. If light does not illuminate as described, turn ignition off. Disconnect ABS control module connector. Using a jumper wire, connect terminal AD of ABS control module connector to ground. See Fig. 3 . Turn ignition on.

2. If ABS warning light illuminates, check ABS control module. See ABS CONTROL MODULE. If light does not illuminate, remove instrument cluster. Remove and check ABS warning light bulb. Replace bulb as necessary. If bulb is okay, check METER fuse and wiring harness. Repair or replace as necessary. If

METER fuse and wiring harness are okay, go to next step.

3. Using ohmmeter, connect positive lead to terminal 2K (Black/Yellow wire) of instrument cluster and negative lead to terminal 1K (Blue/Yellow wire) of instrument cluster. See Fig. 10 . If continuity is not present, replace instrument cluster. If continuity is present, repair wiring harness between instrument cluster and ABS control module.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 10: Identifying Instrument Cluster Connector Terminals

Courtesy of MAZDA MOTORS CORP.

STOPLIGHT SWITCH

Disconnect stoplight switch connector. Using ohmmeter, check continuity between stoplight switch terminals.

With brake pedal depressed, continuity should exist. With brake pedal released, continuity should not exist. If continuity is not as specified, replace stoplight switch.

MOTOR RELAY

1. Turn ignition off. Disconnect ABS Control Module (ABS CM) connector. See COMPONENT

LOCATIONS . Connect Adapter Harness (49-F066-002) to ABS CM connector. Turn ignition on. Using voltmeter, measure voltage between terminals "X" and AB of ABS CM connector. See Fig. 3 . Voltage should be zero volts. Apply 12 volts to terminal "B" an d ground terminal "G" of ABS CM connector.

Using voltmeter, measure voltage between terminals "X" and AB of ABS CM connector. Voltage should be 12 volts. If voltage is not as specified, check wiring harness. If wiring harness is okay, go to next step.

2. Remove motor relay from hydraulic unit. See Fig. 14 . Using ohmmeter, check continuity between terminals "B" and "C" of motor relay. See Fig. 11 . Continuity should exist. Apply 12 volts to terminal

"C" and ground terminal "B". Using ohmmeter, check continuity between terminals "A" and "D" of motor relay. Continuity should exist. If continuity is not as specified, replace motor relay.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 11: Identifying Motor Relay Terminals

Courtesy of MAZDA MOTORS CORP.

VALVE RELAY

1. Turn ignition off. Disconnect ABS Control Module (ABS CM) connector. See COMPONENT

LOCATIONS . Connect Adapter Harness (49-F066-002) to ABS CM connector. Turn ignition on. Using voltmeter, measure voltage between terminal AB and terminals "E", "Z", "Y", AG, BA and BB of ABS

CM connector. See Fig. 3 . Voltage on all terminals should be zero volts. If voltage is as specified, go to next step. If voltage is not as specified, check wiring harness and repair as necessary. If wiring harness is okay, go to step 3).

2. Apply 12 volts to terminal "B" and ground terminal AK of ABS CM connector. Using voltmeter, measure voltage between terminal AB and terminals "E", "Z", "Y", AG, BA and BB of ABS CM connector. See

Fig. 3 . Voltage on all terminals should be 12 volts. If voltage is not as specified, check wiring harness. If wiring harness is okay, go to next step.

3. Remove valve relay from hydraulic unit. See Fig. 14 . Using ohmmeter, check continuity between terminals "B" and "C" of valve relay. See Fig. 12 . Continuity should exist. Apply 12 volts to terminal

"B" and ground terminal "C". Using ohmmeter, check continuity between terminals "A" and "D" of valve relay. Continuity should exist. If continuity is not as specified, replace valve relay.

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 12: Identifying Valve Relay Terminals

Courtesy of MAZDA MOTORS CORP.

WHEEL SPEED SENSORS

On-Vehicle Inspection

Remove wheel. Inspect wheel speed sensor for looseness and damage. Replace as necessary. Measure clearance between wheel speed sensor and sensor rotor. See Fig. 13 . Clearance should be .012-.043" (.3-1.1 mm). If clearance is not as specified, replace wheel speed sensor or sensor rotor.

Resistance Test

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

Voltage Test

Ensure vehicle is on level surface. Raise and support vehicle on safety stands. Disconnect wheel speed sensor connector. Using voltmeter, while rotating wheel one revolution per second, measure voltage between wheel speed sensor terminals. Voltage should be .25-1.2 volts (AC). If voltage is not as specified, replace wheel speed

Microsoft

sensor or sensor rotor.

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 13: Measuring Wheel Speed Sensor Clearance

Courtesy of MAZDA MOTORS CORP.

WHEEL SPEED SENSOR ROTORS

Inspection

Perform a comprehensive visual inspection of wheel speed sensor rotor. If any teeth are damaged or missing, or any other damage is noted, replace wheel speed sensor rotor.

REMOVAL & INSTALLATION

ABS CONTROL MODULE

Removal & Installation

1. Disconnect negative battery cable. Roll back carpet from passenger-side footwell. Remove ABS control module protector panel (if equipped).

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

2. Disconnect ABS control module electrical connector. Remove ABS control module mounting bolts/nuts.

Remove ABS control module. To install, reverse removal procedure. Tighten ABS control module mounting bolts/nuts to 61-87 INCH lbs. (6.9-9.8 N.m).

HYDRAULIC UNIT

Removal & Installation

1. Disconnect negative battery cable. Disconnect hydraulic unit electrical connector. Using Flare Nut

Wrench (49-0259-770B), disconnect brakelines from hydraulic unit. Note location of brakelines for installation reference. Disconnect electrical connectors. Remove hydraulic unit mounting bolts and nuts.

2. Remove hydraulic unit. To install, reverse removal procedure. Tighten mounting bolts and nuts to specification. See TORQUE SPECIFICATIONS . Add fluid and bleed air from system. See

BLEEDING BRAKE SYSTEM .

FRONT WHEEL SPEED SENSOR ROTOR

Removal

Raise and support vehicle. Remove front wheel assemblies. Remove brake caliper and wire aside. Remove rotor. Remove grease cap and wheel bearing lock nut. Remove wheel hub. Using Puller (49-0839-425C) and

Attachment (49-F027-007), remove wheel speed sensor rotor from hub.

Installation

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

SPECIFICATIONS .

REAR WHEEL SPEED SENSOR ROTOR

Removal

Raise and support vehicle. Remove rear wheel assemblies. Remove brake caliper and wire aside. Remove wheel bearing lock nut. Remove lower control arm-to-rear steering knuckle bolt and nut. Remove drive axle. DO NOT disassemble drive axle assembly to remove sensor rotor. Replace drive axle assembly.

Installation

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

SPECIFICATIONS .

WHEEL SPEED SENSOR

Removal & Installation

Raise and support vehicle. Remove wheel assemblies. Disconnect wheel speed sensor electrical connector.

Remove wheel speed sensor mounting bolt. Remove wheel speed sensor from vehicle. To install, reverse

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock removal procedure. Tighten mounting bolt to specification. See TORQUE SPECIFICATIONS .

VALVE & MOTOR RELAYS

Removal & Installation

Disconnect negative battery cable. Remove relay cover from hydraulic unit. Remove valve and motor relays.

See Fig. 14 . To install, reverse removal procedure.

Fig. 14: Locating Valve Relay & Motor Relay

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENTS

MASTER CYLINDER PUSH ROD

1. Before installing master cylinder, measure clearance between master cylinder piston and power brake unit push rod. Turn adjusting nut on Adjustment Gauge (49-B043-001) clockwise to fully retract gauge rod.

Place adjustment gauge onto power brake unit and tighten mounting nuts to 88-138 INCH lbs. (9.9-15.6

N.m).

2. Using a hand-held vacuum pump, apply 19.7 in. Hg to power brake unit. Turn adjusting gauge nut counterclockwise until gauge rod just contacts push rod end of power brake unit. Perform STEP 1. See

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 15 .

3. Lightly push on end of adjusting gauge rod to ensure it is properly seated. Verify no gap exists between adjusting nut and adjusting gauge body. Remove adjusting gauge from power brake unit without disturbing adjusting nut. Place adjusting gauge on master cylinder.

NOTE: When lightly pushing on end of adjusting gauge rod in step 4), only use enough pressure to bottom rod in piston. Too much pressure may cause a false reading.

4. Lightly push on end of adjusting gauge rod to ensure gauge rod is bottomed in master cylinder piston.

Ensure no clearance exists between adjusting gauge body and adjusting nut (clearance "B") or between body and master cylinder (clearance "C"). Perform STEP 2. See Fig. 15 .

5. If clearance "B" exists, push rod is too short. If clearance "C" exists, push rod is too long. To adjust clearance "B", go to next step. To adjust clearance "C", go to step 8).

NOTE: Push rod threads are specially designed so bolt becomes harder to turn past a certain point to prevent loosening of bolt. Turn bolt only within this range.

6. To adjust clearance "B", lightly push on end of adjusting gauge rod. Using a feeler gauge, measure clearance between adjusting nut and adjusting gauge. Perform STEP 3. See Fig. 15 .

7. Using Push Rod Adjuster (49-B043-004) and Adapter (49-B043-003), turn push rod nut to lengthen power brake booster push rod an amount equal to amount measured at clearance "B" in step 6). Perform

STEP 4. See Fig. 15 .

8. To adjust clearance "C", measure and record adjusting gauge rod height D1. Perfrom STEP 5. See Fig.

15 . Turn adjusting nut until adjusting gauge body sits squarely on master cylinder.

9. Turn adjusting nut only enough for body to touch adjusting gauge. Measure and record adjusting gauge height D2 of adjusting gauge rod. Perform STEP 6. See Fig. 15 . Subtract D1 from D2 measurement.

10. Using push rod adjuster and adapter, turn push rod nut to shorten power brake booster push rod an amount equal to difference between height D1 and D2. Perform STEP 4. See Fig. 15 .

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 15: Adjusting Master Cylinder Push Rod

Courtesy of MAZDA MOTORS CORP.

BRAKE 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 electrical connector. Loosen lock nut on stoplight switch. Rotate switch away from pedal. Loosen push rod lock nut. Rotate push rod until correct pedal height is as specified. See

BRAKE PEDAL HEIGHT SPECIFICATIONS table.

2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY under ADJUSTMENTS. Tighten push rod lock nut. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).

3. Rotate stoplight switch until it contacts pedal, then rotate an additional 1/2 turn. Tighten stoplight switch lock nut to 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.

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

Start engine. Depress brake pedal with a pressure of 132 lbs. (60 kg).

5. Measure applied pedal height. See BRAKE PEDAL HEIGHT SPECIFICATIONS table. If distance is not as specified, check for air in system or worn pads. Repair as necessary.

BRAKE PEDAL HEIGHT SPECIFICATIONS

Application

Pedal Released

Pedal Applied

(1)

(1) Minimum height.

In. (mm)

6.8-7.1 (171-181)

3.7 (95)

BRAKE PEDAL FREE PLAY

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS table. Adjust play by loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34

N.m).

BRAKE PEDAL FREE PLAY SPECIFICATIONS

Application

Miata

In. (mm)

.16-.28 (4-7)

PARKING/EMERGENCY BRAKE

1. Depress brake pedal several times. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 7-9 notches, parking brake is properly adjusted. If stroke is not 7-9 notches, raise and support rear of vehicle.

Release parking brake lever.

2. Rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

TORQUE SPECIFICATIONS

Application

Brake Caliper Mounting Bolts

Brakeline Nuts

Hydraulic Unit Brakeline Union Bolts

Hydraulic Unit Mounting Bolts/Nuts

I-Arm-To-Rear Steering Knuckle Bolt (RX7)

Lower Control Arm-To-Rear Steering Knuckle Nut

Push Rod Lock Nut

Stoplight Switch Lock Nut

Wheel Bearing Lock Nut

Front

Rear

Wheel Lug Nuts

Wheel Speed Sensor Mounting Bolt

ABS Control Unit Mounting Bolts/Nuts

Ft. Lbs. (N.m)

37-50 (50-68)

10-16 (14-22)

18-26 (24-35)

14-18 (19-24)

44-54 (59-73)

47-54 (64-73)

18-25 (24-34)

10-13 (14-18)

123-159 (167-216)

159-217 (216-294)

66-86 (89-117)

12-16 (16-22)

INCH Lbs. (N.m)

61-87 (6.9-9.8)

WIRING DIAGRAMS

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Microsoft

1997 Mazda MX-5 Miata

ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock

Fig. 16: Anti-Lock Brake System (ABS) Wiring Diagram (1997 Miata)

Microsoft

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

1997 AUTOMATIC TRANSMISSIONS

NC4A-EL Electronic Controls

APPLICATION

TRANSMISSION APPLICATION

Vehicle

Miata

Transmission Model

NC4A-EL

CAUTION: Vehicle is equipped with Supplemental Restraint System (SRS). When servicing vehicle, use care to avoid accidental air bag deployment. SRSrelated components are located in steering column, center console and instrument panel. DO NOT use electrical test equipment on these circuits.

If necessary, deactivate SRS before servicing components. See AIR BAG

DEACTIVATION PROCEDURES article in GENERAL INFORMATION.

CAUTION: Disconnecting battery on models equipped with anti-theft radio require canceling of anti-theft operation. See appropriate AUTOMATIC

TRANSMISSION SERVICING article in TRANSMISSION SERVICING. Refer to vehicle owner's manual to identify radio type.

DESCRIPTION

The NC4A-EL series is a 4-speed electronically controlled automatic transmission. Five solenoids attached to valve body control shift changes. Solenoids are controlled by the Transmission Control Module (TCM).

NOTE: Torque Converter Clutch (TCC) solenoid is also known as lock-up solenoid,

TCC lock-up or 4th gear solenoid.

The TCM receives information from various input devices. The TCM uses this information to control following solenoids:



Shift solenoids for transmission shifting.



Torque Converter Clutch (TCC) solenoid for torque converter clutch lock-up.

3-2 control solenoid for downshift timing control.

A HOLD switch is mounted on the shift lever. HOLD function may be activated in "D", "S" or "L" gears by pressing HOLD button. In "L" and "S" positions, vehicle is held in selected gear and no upshift or downshift takes place. This function is used for driving up steep inclines or for engine braking assistance when descending steep grades. If activated in "D" position a 1-2 and 2-3 upshift is permitted when starting from a stop, but after the 2-3 upshift the vehicle is locked in "D" until it comes to a complete stop. The 1-2 and 2-3 upshift pattern is changed to a "short shift" specification. This function is used for starting off or driving on slippery surfaces.

Pushing HOLD button again deactivates system.

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

OPERATION

TCM

TCM receives information from various input devices and uses this information to control solenoids on transmission valve body for transmission shifting and torque converter clutch engagement.

TCM automatically switches from NORMAL mode to POWER mode corresponding to driving condition in

"D" range. Upshifts and downshifts are performed at a higher speed in POWER mode than in NORMAL mode.

TCM contains a self-diagnostic system, which will store Diagnostic Trouble Codes (DTC) if a failure or problem exists in electronic control system. DTC can be retrieved to determine problem area. See SELF-

DIAGNOSTIC SYSTEM . TCM is located under left side of instrument panel, above fuse block.

TCM INPUT DEVICES & SIGNALS

4th Gear Inhibit Signal

Signal is input to TCM when cruise control is on. Signal detects when difference between target speed and actual speed exceeds specification.

HOLD Switch

HOLD switch delivers input to TCM to indicate gears preferred by operator. Switch is located on shift lever handle. HOLD switch is canceled when ignition switch is turned off.

Input/Turbine Speed Sensor

Sensor is a magnetic pick-up type pulse generator that monitors input shaft speed. AC waveform is input to

TCM by output speed sensor. Sensor is located on front of transmission, back of converter housing.

Throttle Position (TP) Sensor

TP sensor delivers an input signal to TCM indicating throttle valve position (opening). TP sensor is located on side of throttle body.

Transmission Range Switch

Transmission range switch delivers an input signal to TCM indicating shift lever position. Switch is located on side of transmission.

Transmission Fluid Temperature (TFT) Sensor

TFT sensor is threaded into cooler line banjo mounting on side of transmission case. Sensor sends signal to

TCM indicating fluid temperature.

Vehicle Speed Sensor

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Sensor is a cable driven pulse generator that is part of speedometer. Pulse signals are sent to TCM.

TCM OUTPUT DEVICES

HOLD Indicator Light

Receives signal from TCM to indicate switch position.

Inhibitor Signal

When shift selector lever is moved from Park or Neutral to another gear, signal is sent from TCM to ECM to regulate fuel injection volume for shift shock prevention.

Shift Solenoids & 3-2 Control Solenoid

The TCM controls transmission shifting by delivering an output signal to operate proper solenoid. 3-2 control solenoid affects downshift timing. See SOLENOID OPERATION table. Hydraulic pressure is retained when solenoid is off and drained when solenoid is on. Solenoids are located on transmission valve body. See Fig. 1 .

SOLENOID OPERATION

1-2 Shift Solenoid 2-3 Shift Solenoid

3-4 Shift

Solenoid Shift Lever Position

"D" (Drive)

1st Gear

2nd Gear

3rd Gear

4th Gear

"2" (Second)

1st Gear

2nd Gear

"L" (Low)

1st Gear

"R" (Reverse)

"N" or "P"

Off

TCC Solenoid Valve

Solenoid valve is ON/OFF type controlled by TCM. Solenoid regulates pilot pressure to applied to lock-up control plug. Hydraulic pressure is retained when solenoid is on and drained when solenoid is off. Solenoid is located on side of case. See Fig. 1 .

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Fig. 1: Locating Solenoid Valves

Courtesy of MAZDA MOTORS CORP.

SELF-DIAGNOSTIC SYSTEM

SYSTEM DIAGNOSIS

NOTE: Before testing transmission, ensure fluid level is correct. Ensure engine starts with shift lever in Park and Neutral to ensure proper adjustment of transmission range switch. Transmission Control Module (TCM) must first be checked for stored codes. See RETRIEVING TROUBLE CODES .

TCM monitors transmission operation and contains a self-diagnostic system which stores a Diagnostic Trouble

Code (DTC) if an electronic control system failure or component malfunction exists. If a problem exists in any of the solenoids or speed sensors and DTC is set, TCM will deliver a signal to blink the HOLD indicator light on instrument panel to warn the driver. DTC may be set if a failure exists and can be retrieved for transmission diagnosis.

RETRIEVING TROUBLE CODES

NOTE: Before retrieving DTC, ensure proper battery voltage exists for self-diagnostic system operation. If any DTC are present other than those listed below, see

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls appropriate SELF-DIAGNOSTIC SYSTEM article in ENGINE PERFORMANCE.

Using Scan Tool

Ensure ignition is in OFF position. Connect scan tool to Data Link Connector (DLC) located under left side of instrument panel, near center console. Turn ignition switch to ON position. Check for stored DTC. See

DIAGNOSTIC TROUBLE CODE IDENTIFICATION table. For trouble shooting of codes, see

DIAGNOSTIC TESTS .

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Fig. 2: Locating Data Link Connector (DLC) Location

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC TROUBLE CODE IDENTIFICATION

DTC No.

P0705

Microsoft

Sunday, July 05, 2009 1:35:03 PM Page 6

(1)

Probable Cause

Transmission Range Sensor Malfunction

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

P0706

P0710

P0711

P0715

P0725

P0731

P0732

P0733

P0734

P0740

P0750

P0755

P0760

P1720

P1743

P1765

P1790

P1795

Transmission Range Sensor Range/Performance

(2)

TFT Sensor Malfunction

(2)

TFT Sensor Range/Performance

Input/Turbine Speed Sensor

Engine Speed Input Circuit Malfunction

Incorrect 1st Gear Ratio

Incorrect 2nd Gear Ratio

Incorrect 3rd Gear Ratio

Incorrect 4th Gear Ratio

TCC System Malfunction

1-2 Shift Solenoid

2-3 Shift Solenoid

3-4 Shift Solenoid

Vehicle Speed Sensor

Lock-Up Solenoid Valve

3-2 Timing Control Solenoid Valve

Throttle Position Sensor

Idle Switch

(1) Check listed component for probable cause. Check wiring and connection of specified component.

(2) Transmission Fluid Temperature.

CLEARING CODES

To clear DTC stored in TCM, use scan tool. See scan tool instruction manual. Road test vehicle.

COMPONENT LOCATION

Description

Engine Control Module

Input/Turbine Speed Sensor

Shift Solenoids

TCC Lock-Up Solenoid

Transmission Control Unit

3-2 Control Valve

TFT Sensor

Vehicle Speed Sensor

Location

Behind Passenger Seat

Mounted To 4th Gear Case

See Fig. 1

Above Fuse Box

See Fig. 1

Mounted In-Line To Cooler Line

Mounted In Speedometer

COMPONENT CONNECTOR IDENTIFICATION

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

COMPONENT CONNECTOR IDENTIFICATION

(1)

Component

Engine Control Module (ECM)

Hold Switch

Instrument Cluster

Transmission Control Module (TCM)

Valve Body Solenoids

(1) For connector location see Fig. 3 .

(2) See HOLD SWITCH under COMPONENT TESTING.

(3) See VEHICLE SPEED SENSOR (VSS) under COMPONENT TESTING.

(4) See SOLENOID VALVES under COMPONENT TESTING.

See Fig.

Fig. 5

(2)

(3)

Fig. 4

(4)

Fig. 3: Locating Transmission Component Connectors

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Courtesy of MAZDA MOTORS CORP.

Fig. 4: Identifying TCM Component Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Fig. 5: Identifying ECM Component Connector Terminals

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC TESTS

NOTE: For connector terminal identification, see COMPONENT CONNECTOR

IDENTIFICATION table under SELF-DIAGNOSTIC SYSTEM. For circuit or wire color identification, see appropriate wiring diagram in WIRING DIAGRAMS .

DTC P0705: TRANSMISSION RANGE SWITCH CIRCUIT MALFUNCTION & DTC P0706:

TRANSMISSION RANGE SWITCH CIRCUIT RANGE/PERFORMANCE

Condition

No signal is received from range switch or more than 2 signals are received at one time. Possible causes for either condition are:



Transmission range switch malfunction.

Damaged wiring or connectors between transmission range switch and TCM.



TCM malfunction.

Diagnosis & Repair Procedure

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Using voltmeter, backprobe TCM connector (as applicable). Measure voltage between ground and specified terminal. See

DTC P0705 VOLTAGE TEST table. If all voltages are within specification, go to step 5 . If any voltage is not within specification, go to next step.

DTC P0705 VOLTAGE TEST

TCM Terminal

No.

Measured

Voltage

10-14

Range Switch Position

"P" Or "N"

"R", "D", "S" Or "L"

"D"

All Except "D"

"S"

All Except "S"

"L"

All Except "L"

2. Check continuity of circuits between transmission range switch and TCM. See appropriate wiring diagram in WIRING DIAGRAMS . Repair as needed. If all circuits are okay, go to next step.

3. Disconnect negative battery cable. Disconnect transmission range switch harness connector. Inspect continuity of transmission range switch internal circuits. See TRANSMISSION RANGE SWITCH under COMPONENT TESTING. Replace as needed. If switch is okay, go to next step.

4. Reconnect negative battery cable. Turn ignition on. Measure voltage at terminal "I" (Black/Blue wire) on transmission range switch harness connector. If battery voltage does not exist, repair Black/Blue wire between switch and ignition switch. If battery voltage exists, go to next step.

5. Road test vehicle. Retrieve DTC. If code P0705 is still present, replace TCM. If code is no longer present, system is okay.

DTC P0710: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT MALFUNCTION

& DTC P0711: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT

RANGE/PERFORMANCE

Condition

Voltage input to TCM is less than .1 volt or greater than 5.0 volts. Possible causes for condition are:



Transmission fluid temperature sensor malfunction.

Damaged wiring or connectors between transmission fluid temperature sensor and TCM.



TCM malfunction.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Access TCM connectors.

Using voltmeter, backprobe harness connectors. DO NOT disconnect connectors. Go to next step.

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

2. Measure voltage between terminal No. 1G (Green wire) and No. 2P (Black/Light Blue wire) on TCM connector. Voltage should be about 3.3 volts at 77°F (25°C). If voltage is within specifications, go to step

6 . If voltage is not within specifications, go to next step.

3. Turn ignition off. Disconnect TCM harness connector. Measure resistance between terminals No. 1G and

No. 2P. See TFT SENSOR SPECIFICATIONS table. If resistance is within specification, go to step 6 .

If resistance is not within specification, go to next step.

4. Inspect TFT sensor. Disconnect TFT sensor harness connector. Measure resistance between connector terminals. See TFT SENSOR SPECIFICATIONS table. If resistance is within specification, go to step

6 . If resistance is not within specification, replace TFT sensor.

5. Check continuity of circuits between TFT sensor and TCM. See appropriate wiring diagram in WIRING

DIAGRAMS . Repair as needed. If circuit is okay, go to next step.

6. Reconnect all harness connectors. Road test vehicle. Retrieve DTC. If code P0710 or P0711 is still present, replace TCM. If code is no longer present, system is okay.

TFT SENSOR SPECIFICATIONS

Fluid Temperature

68°F (20°C)

140°F (60°C)

176°F (80°C) k/ohms

2.5

.35

DTC P0715: INPUT/TURBINE SPEED SENSOR

Condition

Input/Turbine speed sensor signal is not input to TCM when vehicle is moving. Possible causes for condition are:



Input/Turbine speed sensor malfunction.

Damaged wiring or connectors between turbine speed sensor and TCM.



TCM malfunction.

Diagnosis & Repair Procedure

1. Turn ignition on. Using voltmeter, backprobe TCM harness connector. DO NOT disconnect connector.

Measure AC voltage between terminals No. 2J (positive) and No. 2L (negative). Voltage should be 0-.1 volts when idling and zero with engine stopped. If voltage is within specification, go to step 5 . If voltage is not within specification, go to next step.

2. Turn ignition off. Disconnect TCM harness connector. Check for continuity between terminals No. 2J

(Yellow/Green wire) and No. 2L (Yellow/Blue wire). If continuity is present, go to step 5 . If continuity is not present, go to next step.

3. Inspect sensor. See INPUT/TURBINE SPEED SENSOR under COMPONENT TESTING. Repair as needed. If sensor is okay, go to next step.

4. Check continuity of circuits between input/turbine speed sensor and TCM. See appropriate wiring diagram in WIRING DIAGRAMS . Repair as needed. If circuits are okay, go to next step.

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

5. Reconnect all harness connectors. Road test vehicle. Retrieve DTC. If code P0715 is still present, replace

PCM. If code is no longer present, system is okay.

DTC P0725: ENGINE SPEED INPUT CIRCUIT MALFUNCTION

NOTE: If DTC P0335 is also present, repair it first and then proceed with this test. Go to appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE and perform test.

Condition

Engine speed input signal is not input to TCM. Possible causes are:



Crankshaft position sensor malfunction.



Damaged wiring or connectors between ECM and TCM.



ECM malfunction.

TCM malfunction.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Using voltmeter, backprobe TCM harness connector. DO NOT disconnect connector.

2. Measure voltage between ground and terminal No. 1N (White wire) on TCM harness connector. Voltage should be zero or 4.5-5.5 volts with engine stopped or 2-3 volts with engine idling. If voltage is within specifications, go to step 7 . If voltage is not within specifications, go to next step.

3. Ignition off. Measure continuity between terminal No. 1N (White wire) on TCM harness connector and terminal No. 4F (White wire) on ECM harness connector. If continuity is not present, repair wiring then go to step 7 .

4. Using voltmeter, backprobe ECM harness connector. Measure voltage between ground and terminal No.

4H (Yellow/White wire). Voltage should be less than one volt with engine stopped or greater than one volt with engine idling. If voltage is within specifications, go to step 7 . If voltage is not within specifications, go to next step.

5. Inspect crankshaft position sensor. See appropriate SYSTEM & COMPONENT TESTS article in

ENGINE PERFORMANCE. Replace as needed. If sensor is okay, go to next step.

6. Turn ignition off. Using ohmmeter, backprobe TCM harness connector. DO NOT disconnect connector.

Measure resistance between terminals 1N (White wire) and 2P (Black/Light Green wire). If resistance is

7.2-8.0 ohms, go to next step. If resistance is not 7.2-8.0 ohms, replace TCM.

7. Reconnect all harness connectors. Road test vehicle. Retrieve DTC. If code P0725 is still present, replace

TCM. If code is no longer present, problem is intermittent.

DTC P0731: INCORRECT 1ST GEAR RATIO

NOTE: If any following DTC is also present, repair it first and then proceed with this test: DTC P0750 , P0755 , P0760 .

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Condition

TCM outputs solenoid pattern of 1st gear when gear ratio is other than 1st gear. Possible causes are:



Low ATF level.

Low line pressure.



Control valve stuck.

Solenoid valve malfunction.



TCM malfunction.

Diagnosis & Repair Procedure

1. Ensure ATF level and condition is okay. Check line pressure and stall speed. See LINE PRESSURE

TEST and STALL SPEED under TESTING in MAZDA NC4A-EL OVERHAUL article. Repair any components as necessary. If malfunction is not present, go to next step.

2. Inspect 1-2, 2-3 and 3-4 shift solenoid valves. See SOLENOID VALVES under COMPONENT

TESTING. Repair as needed. If solenoid valves are okay, go to next step.

3. Inspect valve body. Ensure all valves operate smoothly. Repair as needed. If valve body is okay, go to next step.

4. Clear DTC and retest. See CLEARING CODES . If code P0731 is still present, replace TCM. If code is no longer present and symptom still exists, problem may be caused by intermittent clutch slippage.

Further investigation may be required. See MAZDA NC4A-EL OVERHAUL article.

DTC P0732: INCORRECT 2ND GEAR RATIO

NOTE: If any following DTC is also present, repair it first and then proceed with this test: DTC P0750 , P0755 , P0760 .

Condition

TCM outputs solenoid pattern of 2nd gear when gear ratio is other than 2nd gear. Possible causes are:



Low ATF level.

Direct clutch slippage.



One-way clutch slippage.

Faulty band servo.



Low line pressure.

Control valve stuck.



Solenoid valve malfunction.

 TCM malfunction.

Diagnosis & Repair Procedure

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

1. Ensure ATF level and condition is okay. Check line pressure and stall speed. See LINE PRESSURE

TEST and STALL SPEED under TESTING in MAZDA NC4A-EL OVERHAUL article. Repair any components as necessary. If malfunction is not present, go to next step.

2. Inspect 1-2, 2-3 and 3-4 shift solenoid valves. See SOLENOID VALVES under COMPONENT

TESTING. Repair as needed. If solenoid valves are okay, go to next step.

3. Inspect valve body. Ensure all valves operate smoothly. Repair as needed. If valve body is okay, go to next step.

4. Clear DTC and retest. See CLEARING CODES . If code P0732 is still present, replace PCM. If code is no longer present and symptom still exists, problem may be caused by intermittent clutch slippage.

Further investigation may be required. See MAZDA NC4A-EL OVERHAUL article.

DTC P0733: INCORRECT 3RD GEAR RATIO

NOTE: If any following DTC is also present, repair it first and then proceed with this test: DTC P0750 , P0755 , P0760 .

Condition

TCM outputs solenoid pattern of 3rd gear when gear ratio is other than 3rd gear. Possible causes are:



Low ATF level.

Direct clutch slippage.



One-way clutch slippage.

Front clutch slippage.



Low line pressure.



Control valve stuck.

Solenoid valve malfunction.



TCM malfunction.

Diagnosis & Repair Procedure

1. Ensure ATF level and condition is okay. Check line pressure and stall speed. See LINE PRESSURE

TEST and STALL SPEED under TESTING in MAZDA NC4A-EL OVERHAUL article. Repair any components as necessary. If malfunction is not present, go to next step.

2. Inspect 1-2, 2-3 and 3-4 shift solenoid valves. See SOLENOID VALVES under COMPONENT

TESTING. Repair as needed. If solenoid valves are okay, go to next step.

3. Inspect valve body. Ensure all valves operate smoothly. Repair as needed. If valve body is okay, go to next step.

4. Clear DTC and retest. See CLEARING CODES . If DTC P0733 is still present, replace PCM. If code is no longer present and symptom still exists, problem may be caused by intermittent clutch slippage.

Further investigation may be required. See MAZDA NC4A-EL OVERHAUL article.

DTC P0734: INCORRECT 4TH GEAR RATIO

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

NOTE: If any following DTC is also present, repair it first and then proceed with this test: DTC P0750 , P0755 , P0760 .

Condition

TCM outputs solenoid pattern of 3rd gear when gear ratio is other than 3rd gear. Possible causes are:



Low ATF level.



Band servo slippage.

Front clutch slippage.



Low line pressure.

Control valve stuck.



Solenoid valve malfunction.

 TCM malfunction.

Diagnosis & Repair Procedure

1. Ensure ATF level and condition is okay. Check line pressure and stall speed. See LINE PRESSURE

TEST and STALL SPEED under TESTING in MAZDA NC4A-EL OVERHAUL article. Repair any components as necessary. If malfunction is not present, go to next step.

2. Inspect 1-2, 2-3 and 3-4 shift solenoid valves. See SOLENOID VALVES under COMPONENT

TESTING. Repair as needed. If solenoid valves are okay, go to next step.

3. Inspect valve body. Ensure all valves operate smoothly. Repair as needed. If valve body is okay, go to next step.

4. Clear DTC and retest. See CLEARING CODES . If DTC P0734 is still present, replace PCM. If code is no longer present and symptom still exists, problem may be caused by intermittent clutch slippage.

Further investigation may be required. See MAZDA NC4A-EL OVERHAUL article.

DTC P0740: TORQUE CONVERTER CLUTCH MALFUNCTION

Condition

TCM outputs TCC signal, but TCC does not operate. Possible causes are:



Low ATF level.

Low line pressure.



Torque converter slippage.

Control valve stuck.



Lock-up solenoid valve malfunction.

 TCM malfunction.

Diagnosis & Repair Procedure

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

1. Inspect ATF level and condition. Correct as needed. If fluid level and condition is okay, check line pressure. See LINE PRESSURE TEST under TESTING in MAZDA NC4A-EL OVERHAUL article.

Follow repair recommendations if line pressure is not within specifications. If line pressure is okay, go to next step.

2. Inspect lock-up solenoid. See SOLENOID VALVES under COMPONENT TESTING. Repair as needed. If solenoid valve is okay, go to next step.

3. Inspect lock-up control valve in valve body. If valve is okay, go to next step.

4. Using an EC-AT tester connected to TCM, ensure that engine speed and turbine speed during TCC lockup in 4th gear are the same. If speeds are different, replace torque converter. If speeds are the same, go to next step.

5. Clear DTC. See CLEARING CODES . Retrieve DTC. If DTC P0740 is still present, replace TCM. If code is no longer present and symptom still exists, problem may be caused by intermittent TCC slippage.

Further investigation may be required. See MAZDA NC4A-EL OVERHAUL article.

DTC P0750: 1-2 SHIFT SOLENOID MALFUNCTION

Possible Causes:



Short or open circuit between TCM and solenoid.



TCM malfunction.

 Shift solenoid malfunction.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Access TCM connectors.

Using voltmeter, backprobe harness connectors. DO NOT disconnect connectors. Go to next step.

2. Measure voltage between ground and terminal No. 2E (Blue/Yellow wire) on TCM connector. During test drive, voltage should be less than one volt when solenoid is off and battery voltage when solenoid is on. See SOLENOID OPERATION table under TCM OUTPUT DEVICES. If voltage is within specification, go to step 5 . If voltage is not within specification, go to next step.

3. Turn ignition off. Disconnect TCM harness connector. Measure resistance between ground and terminal

No. 2E. If resistance is 13-27 ohms at 68°F (20°C), go to step 5 . If resistance is not 13-27 ohms at 68°F

(20°C), go to next step.

4. Inspect 1-2 shift solenoid and related circuits. See SOLENOID VALVES under COMPONENT

TESTING. Repair as needed. If solenoid valve and related circuits are okay, go to next step.

5. Clear DTC and road test vehicle. Retrieve DTC. If DTC P0750 is still present, replace TCM. If code is no longer present, system is okay.

DTC P0755: 2-3 SHIFT SOLENOID MALFUNCTION

Possible Causes:



Short or open circuit between TCM and solenoid.

 TCM malfunction.

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls



Shift solenoid malfunction.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Access TCM connectors.

Using voltmeter, backprobe harness connectors. DO NOT disconnect connectors. Go to next step.

2. Measure voltage between ground and terminal No. 2G (Orange wire) on TCM connector. During test drive, voltage should be less than one volt when solenoid is off and battery voltage when solenoid is on.

See SOLENOID OPERATION table under TCM OUTPUT DEVICES. If voltage is within specification, go to step 5 . If voltage is not within specification, go to next step.

3. Turn ignition off. Disconnect TCM harness connector. Measure resistance between ground and terminal

No. 2G. If resistance is 13-27 ohms at 68°F (20°C), go to step 5 . If resistance is not 13-27 ohms at 68°F

(20°C), go to next step.

4. Inspect 2-3 shift solenoid and related circuits. See SOLENOID VALVES under COMPONENT

TESTING. Repair as needed. If solenoid valve and related circuits are okay, go to next step.

5. Clear trouble codes and road test vehicle. Retrieve DTC. If DTC P0755 is still present, replace TCM. If code is no longer present, system is okay.

DTC P0760: 3-4 SHIFT SOLENOID MALFUNCTION

Possible Causes:



Short or open circuit between TCM and solenoid.

TCM malfunction.



Shift solenoid malfunction.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Access TCM connectors.

Using voltmeter, backprobe harness connectors. DO NOT disconnect connectors. Go to next step.

2. Measure voltage between ground and terminal No. 2I (Blue wire) on TCM connector. During test drive, voltage should be less than one volt when solenoid is off and battery voltage when solenoid is on. See

SOLENOID OPERATION table under TCM OUTPUT DEVICES. If voltage is within specification, go to step 5 . If voltage is not within specification, go to next step.

3. Turn ignition off. Disconnect TCM harness connector. Measure resistance between ground and terminal

No. 2E. If resistance is 13-27 ohms at 68°F (20°C), go to step 5 . If resistance is not 13-27 ohms at 68°F

(20°C), go to next step.

4. Inspect 3-4 shift solenoid and related circuits. See SOLENOID VALVES under COMPONENT

TESTING. Repair as needed. If solenoid valve and related circuits are okay, go to next step.

5. Clear codes and road test vehicle. Retrieve DTC. If DTC P0760 is still present, replace TCM. If code is no longer present, problem is intermittent. Further investigation may be necessary.

DTC P1720: VEHICLE SPEED SENSOR SIGNAL MISSING

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Condition

Vehicle speed sensor signal is not input to TCM. Possible causes are:



Vehicle speed sensor malfunction.

Vehicle speedometer sensor malfunction.



Damaged circuits or connectors between sensors and TCM.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Using voltmeter, backprobe TCM harness connector. DO NOT disconnect connector. Test drive vehicle.

2. Measure voltage between ground and terminal No. 1P (Green/Red wire) on TCM harness connector.

During test drive voltage should be about 4 volts. When parked, voltage should be less than 1.5 or 7-9 volts. If voltage is within specifications, go to step 5 . If voltage is not within specifications, go to next step.

3. Turn ignition off. Disconnect negative battery cable. Remove instrument cluster. Disconnect TCM harness connectors. Ensure continuity exists on Green/Red wire between terminal No. 1P on TCM connector and terminal No. 2F on instrument cluster harness left connector. Repair as needed. If continuity exists, go to next step.

4. With combination meter removed, measure voltage between terminals No. 2F and 2D on combination meter connector using analog voltmeter. Raise and support vehicle. Rotate rear wheels. If voltage pulse is present, go to next step. If voltage pulse is not present, inspect speedometer cable. Replace as needed. If cable is okay, replace combination meter or circuit board (as applicable).

5. Clear codes and road test vehicle. Retrieve DTC. If DTC 1720 is still present, replace TCM. If code is no longer present, problem may be caused by poor connection. Repair as needed.

DTC P1743: TORQUE CONVERTER CLUTCH (TCC) SOLENOID MALFUNCTION

Possible Causes:



Short or open circuit between TCM and solenoid.



TCM malfunction.

Lock-up solenoid malfunction.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Access TCM connectors.

Using voltmeter, backprobe harness connectors. DO NOT disconnect connectors. Go to next step.

2. Measure voltage between ground and terminal No. 2K (Yellow/Black wire). Battery voltage should be present with solenoid on and zero volts with solenoid off. If voltage is within specifications, go to step 5 .

If voltage is not within specifications, go to next step.

3. Turn ignition off. Disconnect TCM harness connector. Measure resistance between ground and terminal

No. 2K. If resistance is 13-25 ohms at 68°F (20°C), go to step 5 . If resistance is not 13-25 ohms at 68°F

(20°C), go to next step.

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

4. Inspect lock-up solenoid and related circuits. See SOLENOID VALVES under COMPONENT

TESTING. Repair as needed. If solenoid valve and related circuits are okay, go to next step.

5. Clear codes and road test vehicle. Retrieve DTC. If DTC P1743 is still present, replace TCM. If code is no longer present, problem may be caused by poor connection. Repair as needed.

DTC P1765: 3-2 CONTROL SOLENOID VALVE MALFUNCTION

Possible Causes:



Short or open circuit between TCM and solenoid.



TCM malfunction.

3-2 control solenoid malfunction.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Access TCM connectors.

Using voltmeter, backprobe harness connectors. DO NOT disconnect connectors. Go to next step.

2. Drive vehicle and measure voltage between ground and terminal No. 2M (Blue/Orange wire). Battery voltage should be present with solenoid on during 3-2 or 4-3 downshift, and zero volts with solenoid off.

If voltage is within specifications, go to step 5 . If voltage is not within specifications, go to next step.

3. Turn ignition off. Disconnect TCM harness connector. Measure resistance between ground and terminal

No. 2M. If resistance is 13-27 ohms at 68°F (20°C), go to step 5 . If resistance is not 13-27 ohms at 68°F

(20°C), go to next step.

4. Inspect 3-2 control clutch solenoid and related circuits. See SOLENOID VALVES under

COMPONENT TESTING. Repair as needed. If solenoid valve and related circuits are okay, go to next step.

5. Clear codes and road test vehicle. Retrieve DTC. If DTC P1765 is still present, replace TCM. If code is no longer present, problem may be caused by poor connection. Repair as needed.

DTC P1790: THROTTLE POSITION (TP) SENSOR MALFUNCTION

NOTE: If DTC P0725 is also present, repair it first and then proceed with this test.

Condition

TP sensor voltage is less than one volt or more than 4.9 volts. Possible causes are:



Poor harness connection at TP sensor.



Circuit fault between TP sensor and ECM or TCM.

TP sensor malfunction.



ECM or TCM malfunction.

Diagnosis & Repair Procedure

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

1. Ensure all connections are clean and tight. Repair as needed. Ensure that TP sensor is adjusted correctly.

See appropriate ON-VEHICLE ADJUSTMENTS article in ENGINE PERFORMANCE. Turn ignition on. Access TCM connectors. Using voltmeter, backprobe harness connectors. DO NOT disconnect connectors. Go to next step.

2. Measure voltage between ground and terminal No. 2T (Red/Black wire) on TCM harness connector. With throttle closed, voltage should be .1-1.1 volts. With wide open throttle, voltage should be 3.1-4.4 volts. If voltage is within specification, go to step 5 . If voltage is not within specification, go to next step.

3. Measure voltage between ground and terminal No. 2A (Light Green/White wire) on TCM harness connector. With ignition on, voltage should be 4.5-5.5 volts. With ignition off, voltage should be zero volts. If voltage is within specification, go to step 5 . If voltage is not within specification, go to next step.

4. Inspect circuits between TP sensor and TCM. See appropriate wiring diagram under WIRING

DIAGRAMS . Repair as needed. If circuits are okay between sensor and TCM, go to next step.

5. Clear codes, and road test vehicle. Retrieve DTC. If DTC P1790 is still present, replace TCM. If code is no longer present, system is okay.

DTC P1795: IDLE SWITCH OPEN OR SHORT

Condition

Closed throttle position switch is ON and TP sensor position is closed. Possible causes are:



Damaged wiring or connectors between closed throttle position switch and TCM.

Closed throttle position switch malfunction.



TCM malfunction.

Diagnosis & Repair Procedure

1. Ensure all connections are clean and tight. Repair as needed. Turn ignition on. Access TCM connectors.

Using voltmeter, backprobe harness connectors. DO NOT disconnect connectors. Go to next step.

2. Measure voltage between ground and terminal No. 1O (Red wire) on TCM harness connector. With throttle closed, battery voltage should be present. With wide open throttle, voltage should be zero volts. If voltage is within specification, go to step 5 . If voltage is not within specification, go to next step.

3. Inspect circuits between closed throttle position switch and TCM. See appropriate wiring diagram under

WIRING DIAGRAMS . Repair as needed. If circuits are okay between sensor and TCM, go to next step.

4. Disconnect battery negative cable. Disconnect closed throttle position switch connector. Check for continuity between closed throttle position switch terminals. If continuity exists, go to next step. If continuity does not exist, replace or adjust throttle position sensor.

5. Clear codes, and road test vehicle. Retrieve DTC. If DTC P1795 is still present, replace TCM. If code is no longer present, problem is intermittent. Further investigation is required.

COMPONENT TESTING

NOTE:

Microsoft

For connector terminal identification, see COMPONENT CONNECTOR

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

IDENTIFICATION table under SELF-DIAGNOSTIC SYSTEM. For circuit or wire color identification, see appropriate wiring diagram in WIRING DIAGRAMS .

HOLD SWITCH

1. Turn ignition on. Ensure HOLD indicator illuminates with switch depressed. Ensure indicator light is not illuminated when switch is released. If switch is not working as described, go to next step.

2. Access switch connector under center console. Disconnect connector. Check continuity between terminals "A" and "B". See Fig. 6 . Continuity should exist when switch is depressed. When switch is released, continuity should not exist. Replace as needed. If HOLD switch system does not function correctly, inspect circuits between switch and TCM. See appropriate wiring diagram in WIRING

DIAGRAMS .

Fig. 6: Testing HOLD Switch

Courtesy of MAZDA MOTORS CORP.

INPUT/TURBINE SPEED SENSOR

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Disconnect output speed sensor connector. See Fig. 3 . Measure resistance between terminals. Resistance should be 245 ohms. Replace as needed.

SOLENOID VALVES (EXCEPT TCC SOLENOID)

Disconnect negative battery cable. Disconnect transmission solenoid harness connector. See Fig. 3 . Note that solenoids ground through transmission case. Check resistance between connector terminals and ground. See

Fig. 7 . Resistance should be 13-27 ohms. Replace solenoids as necessary. See SOLENOID VALVE

IDENTIFICATION table. Ensure transmission case is grounded.

Fig. 7: Identifying Solenoid Valve Terminals

Courtesy of MAZDA MOTORS CORP.

SOLENOID VALVE IDENTIFICATION

Solenoid Valve

1-2 Shift Solenoid

2-3 Shift Solenoid

3-4 Shift Solenoid

3-2 Control

(1) See Fig. 7 for terminal identification.

(1)

Terminal No.

TCC SOLENOID

Disconnect negative battery cable. Disconnect TCC solenoid harness connector. See Fig. 3 . Check resistance

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls between connector terminals and ground. Resistance should be 13-25 ohms. Replace solenoids as necessary.

Ensure transmission case is grounded.

VEHICLE SPEED SENSOR (VSS)

NOTE: Vehicle speed sensor signal is input to TCM from combination meter driven by speedometer cable.

Disconnect negative battery cable. Remove combination meter. Disconnect harness connectors and speedometer cable. Connect analog voltmeter leads to meter terminals "A" and "B". See Fig. 8 . Using appropriate screwdriver, rotate speedometer cable shaft. If voltmeter needle does not fluctuate, replace sensor.

Fig. 8: Testing Vehicle Speed Sensor

Courtesy of MAZDA MOTORS CORP.

TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR

Disconnect TFT sensor harness connector. Sensor is threaded into cooler line banjo mounting on side of transmission case. Measure resistance between connector terminals. See TFT SENSOR SPECIFICATIONS table.

TFT SENSOR SPECIFICATIONS

Fluid Temperature

68°F (20°C)

140°F (60°C)

Microsoft

Sunday, July 05, 2009 1:35:04 PM Page 23 k/ohms

2.5

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

176°F (80°C) .35

TRANSMISSION RANGE SWITCH

1. Check for starter operation with ignition switch in START position and selector lever in "P" and "N" position only. Ensure back-up lights illuminate with ignition in ON position and selector lever in "R" position. If any problems are found, go to next step.

2. Disconnect transmission range switch connector. See Fig. 3 . Check continuity between specified terminals. See Fig. 9 . If continuity is not as specified, replace switch.

Fig. 9: Checking Transmission Range Switch

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

TCM TERMINAL VOLTAGE TESTS

Turn ignition switch to ON position. Access TCM. TCM is mounted under left corner of dash, above fuse box.

DO NOT disconnect harness connector. Using DVOM, measure voltage. See Fig. 4 for terminal identification.

See Fig. 10 and Fig. 11 . After verifying that appropriate condition has been met, check voltage. If voltage is not within specification, inspect component or appropriate circuit. If voltage is within specification, replace

TCM.

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Fig. 10: TCM Pin Voltage Table (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Fig. 11: TCM Pin Voltage Table (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

ELECTRICAL SPECIFICATIONS

SOLENOID RESISTANCE SPECIFICATIONS

Component

Solenoids

Shift Solenoids

TCC Solenoid

Sensor

TSS

Microsoft

Sunday, July 05, 2009 1:35:04 PM Page 27

Resistance Ohms

13-27

13-25

245

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

WIRING DIAGRAMS

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Microsoft

1997 Mazda MX-5 Miata

1997 AUTOMATIC TRANSMISSIONS NC4A-EL Electronic Controls

Fig. 12: Transmission Wiring Diagram (1997 Miata)

Microsoft

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

1997-2001 DRIVE AXLES

Axle Shafts - MX-5 Miata

TROUBLE SHOOTING

NOTE: See DRIVE AXLE NOISE DIAGNOSIS article in GENERAL INFORMATION.

Inspect CV joint boot on axle shaft for cracks, damage, leaking, grease, and looseness in boot band. Inspect axle shaft for bending, cracks, and wear of joint splines. Repair or replace as necessary.

REMOVAL & INSTALLATION

CAUTION: If vehicle is equipped with ABS, before performing following procedure, remove ABS wheel speed sensor (axle side) and fix it to an appropriate place where sensor will not be pulled by mistake while servicing vehicle.

AXLE SHAFTS

NOTE: If axle shaft will not come out of rear hub support easily, install a discarded nut onto axle shaft so that nut is flush with end of axle shaft. Tap nut with a copper hammer to loosen axle shaft from wheel hub.

Removal

1. Raise vehicle and support with safety stands. Remove wheel and tire assembly. Remove axle shaft lock nut. See Fig. 1 .

2. Remove brake caliper assembly. Remove lower control arm bolt at knuckle, and pull knuckle/hub assembly outward. Using pry bar between differential housing and inner CV joint, remove inner CV joint from differential. See Fig. 2 . Remove axle shaft from knuckle/hub assembly.

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 1: Removing Axle Shaft

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 2: Prying Out Axle Shaft

Courtesy of MAZDA MOTORS CORP.

Installation

CAUTION: Sharp edges of axle shaft snap ring can slice or puncture oil seal. Be careful when installing axle shaft to differential.

To install, reverse removal procedure. Install NEW clip. Measure outer diameter of clip after installing. See Fig.

3 . Replace clip if it exceeds specification. With the ends of clip facing upward, push axle shaft into deferential.

After installation, pull outward on double offset joint outer ring and verify that axle shaft is securely held by clip. Install NEW locknut and stake it as shown. See Fig. 4 . Tighten all bolts and nuts to specification. See

TORQUE SPECIFICATIONS .

Microsoft

NOTE:

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

For rear axle shaft length, see REAR AXLE SHAFT LENGTH table.

Fig. 3: Measuring Clip Outer Diameter

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 4: Installing Axle Shaft Locknut

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

AXLE SHAFTS

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 .

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

3. Insert a screwdriver between inner ring and cage to remove balls. See Fig. 8 . Mark inner ring and cage with paint. Turn cage approximately 30 degrees and pull it away from inner ring. See Fig. 9 . Wrap shaft splines with tape and remove boot. See Fig. 10 .

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 5: Removing Boot Band

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 6: Marking Axle Shaft & Outer Ring

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 7: Removing Snap Ring

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 8: Removing Balls From Inner Ring

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 9: Separating Inner Ring From Cage

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 10: Removing CV Joint Boot

Courtesy of MAZDA MOTORS CORP.

Fig. 11: Exploded View Of Axle Shaft Assembly

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Reassembly

NOTE: Inner and outer CV joint boots differ in design and/or diameter. CV joint boots are stamped DOJ (wheel side) and BJ (differential side). Ensure correct boot is installed at proper end when reassembling axle shaft. See REAR AXLE SHAFT

BOOT IDENTIFICATION table. See Fig. 13 .

1. To reassemble, reverse disassembly procedure. Wrap tape around drive axle shaft ends before sliding CV joint boots onto drive axle shaft. See Fig. 12 .

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.

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. Align marks and install NEW clip.

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. Ensure that axle shaft length is within standard. If drive shaft length is not within standard, repeat this step.

5. Fold NEW band back by pulling on end with pliers. See Fig. 15 . Band should be folded in direction opposite forward revolving direction of axle shaft. Lock end of band by bending locking clips.

Fig. 12: Installing CV Joint Boot

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 13: Measuring Axle Shaft & Identifying Boots

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 14: Installing Balls In To Inner Ring

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Fig. 15: Installing Boot Band

Courtesy of MAZDA MOTORS CORP.

AXLE SHAFT BOOT IDENTIFICATION

Application

Miata

Wheel Side Diameter - In. (mm)

3.58 (90.8)

LUBRICATION SPECIFICATION

Application

Differential Side CV Joint Boot

Wheel Side CV Joint Boot

AXLE SHAFT LENGTH

Application

1997

1999-2001

TORQUE SPECIFICATIONS

Microsoft

Sunday, July 05, 2009 1:51:38 PM

Differential Side Diameter - In.

(mm)

3.44 (87.4)

Quantify

3-3.71 oz. (85-105 g)

1.94-2.65 oz. (55-75 g)

In. (mm)

30.21-30.60 (767.3-777.3)

30.42-30.81 (772.6-782.6)

TORQUE SPECIFICATIONS

Application

Axle Shaft Lock Nut

1997

1999-2001

Brake Caliper Mounting Bolt

Lower Control Arm Bolt/Nut

Wheel Lug Nuts

1997 Mazda MX-5 Miata

1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata

Ft. Lbs. (N.m)

160-216 (216-294)

174-235 (236-318)

37-50 (50-68)

47-54 (64-73)

66-86 (89-117)

Microsoft

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

BRAKE SYSTEM

1995-97 BRAKES Mazda - Disc & Drum

DESCRIPTION & OPERATION

NOTE: For information on anti-lock brake systems, see appropriate ANTI-LOCK article in BRAKES.

All models use hydraulic-operated brake system with a tandem master cylinder, proportioning valve and a power brake unit. All models are equipped with front disc brakes and either rear disc or rear drum brakes.

Rear Anti-lock System (RABS) is standard on B2300, B3000, B4000 and MPV models.

BLEEDING BRAKE SYSTEM

NOTE: If vehicle is equipped with anti-lock brakes, see appropriate ANTI-LOCK article for brake bleeding procedure.

BRAKE LINE BLEEDING SEQUENCE

Application

B2300, B3000 & B4000

All Other Models

Sequence

(1)

RR, LR, RF, LF

Longest Line First

(1) Bleed master cylinder and RABS hydraulic unit before bleeding wheel cylinders and calipers.

ADJUSTMENTS

MASTER CYLINDER PUSH ROD

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.

Miata Without ABS, MPV, MX-6 M/T Without ABS & 626 M/T Without ABS

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 gauge on power brake unit. Adjust push rod on power brake unit until there is no clearance between push rod and adjuster gauge screw.

B2300, B3000 & B4000

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

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

With engine running and vacuum line connected to booster, 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.

Fig. 1: Adjusting Brake Booster Push Rod (B2300, B3000 & B4000)

Courtesy of FORD MOTOR CO.

REAR BRAKE SHOES ADJUSTMENT

NOTE: Rear brakes are self-adjusting and require manual adjustment only if brake shoes have been replaced.

B2300, B3000 & B4000

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

1. Raise and support rear of vehicle. Remove rear wheel assemblies. 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. Using a brake shoe adjustment gauge, measure 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 engagement while rotating adjusting screw to prevent burring screw slots. Ensure adjusting screw rotates freely.

MX-3, MX-6, Protege & 626

Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake. Remove brake drum.

Insert screwdriver between adjusting plate and quadrant. Twist screwdriver to disengage teeth. See Fig. 2 . Push quadrant adjusting lever toward backing plate. Install brake drum. Operate parking brake a few times to reset adjuster. Adjust parking brake.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 2: Moving Quadrant On Rear Drum Brake Adjuster (MX-6 & 626 Shown; MX-3 & Protege Are

Similar)

Courtesy of MAZDA MOTORS CORP.

PARKING BRAKE SHOES ADJUSTMENT

Millenia, MPV & 929

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove service plug from rotor. Insert a screwdriver into service plug hole and turn adjuster in direction of arrow marked on rotor until rotor will not turn.

2. On Millenia and MPV, rotate adjuster 3-5 notches in opposite direction. On 929, rotate adjuster 6-8 notches in opposite direction. On all models, ensure rotor rotates freely. Install service plug.

PARKING/EMERGENCY BRAKE

NOTE: B2300, B3000 & B4000 are equipped with self-adjusting parking brake system.

Manual adjustment is not required.

Miata, MX-3, MX-6, Protege & 626

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

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 Miata, pull parking brake lever with a force of 44 lbs. (20 kg). On all other models, pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 7-9 notches on Miata or 5-7 notches on all others, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle. Release parking brake lever.

3. Rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

Millenia

1. Depress brake pedal several times. Pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 3-5 notches, parking brake is properly adjusted. If stroke is not 3-5 notches, raise and support rear of vehicle.

Release parking brake lever.

2. Remove parking brake lever cover. Rotate cable adjusting nut at lever end of cable until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

MPV (1995-96)

1. Depress brake pedal several times. Pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 3-6 notches, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle.

Release parking brake lever.

2. Remove adjusting nut clip and rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake lever is pulled one notch.

MPV (1997)

1. Depress brake pedal several times. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 6-9 notches, parking brake is properly adjusted. If stroke is not as specified, raise and support rear of vehicle.

Release parking brake lever.

RX7

1. Depress brake pedal several times. Pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 7-

10 notches, parking brake is properly adjusted. If stroke is not 7-10 notches, raise and support rear of vehicle. Release parking brake lever.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

929

1. Depress brake pedal several times. Depress parking brake pedal several times with a force of 44 lbs. (20 kg). If stroke is 5-7 notches, parking brake is properly adjusted. If stroke is not 5-7 notches, rotate adjusting nut, located under parking brake pedal, until stroke is within specification.

2. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake pedal is depressed one notch.

BRAKE PEDAL FREE PLAY

NOTE: On B2300, B3000 & B4000, brake pedal free play is built into pedal linkage and is not adjustable.

With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS . Adjust play by loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).

BRAKE PEDAL FREE PLAY SPECIFICATIONS

Application

Miata, MPV & MX-3

Millenia, MX-6, Protege & 626

RX7

929

In. (mm)

.16-.28 (4-7)

.16-.47 (4-12)

.12-.31 (3-8)

.12-.47 (8-12)

BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH

NOTE: B2300, B3000 & B4000 are equipped with dual brake master cylinder and vacuum booster. System is designed to permit full stroke of master cylinder when brake pedal is fully depressed. Brake pedal height adjustment is not required.

Miata, MPV, MX-3, MX-6, RX7, 626 & 929

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

BRAKE PEDAL HEIGHT SPECIFICATIONS .

2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY . Tighten push rod lock nut to 18-25 ft. lbs.

(24-34 N.m).

3. Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight switch lock nut 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.

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

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

5. Measure applied pedal height. See BRAKE PEDAL HEIGHT SPECIFICATIONS . If distance is not

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum as specified, check for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.

BRAKE PEDAL HEIGHT SPECIFICATIONS

Application

Pedal Released

Miata

MPV

MX-3

MX-6 & 626

RX7

929

Pedal Applied

(1)

Miata

MPV, MX-6 & 626

MX-3

RX7

929

(1) Minimum height.

In. (mm)

6.8-7.1 (171-181)

7.5-7.9 (191-201)

7.6-7.7 (193-196)

7.5-7.7 (191-196)

6.5-6.9 (165-176)

7.4-7.7 (188-195)

3.7 (95)

3.3 (85)

2.8 (70)

3.9 (100)

1.6 (40)

Millenia & Protege

1. Released pedal height is measured between brake pedal and stoplight switch mounting bracket. See Fig.

3 . Disconnect stoplight switch electrical connector and remove switch. Measure length "L" between stoplight switch mounting bracket and brake pedal. See Fig. 3 . On Millenia, length should be .79-

.90" (20-23 mm). On Protege, length should be .71-.86" (18-22 mm).

2. On all models, if clearance is as specified, install stoplight switch. No adjustment is necessary. If clearance is not as specified, loosen lock nut "B" and rotate self-locking nut "A" counterclockwise until it does not contact brake pedal.

3. Loosen push rod lock nut and rotate push rod until correct clearance between brake pedal and stoplight switch mounting bracket is obtained. Tighten push rod lock nut. Rotate self-locking nut "A" clockwise until clearance between brake pedal and end of self-locking nut "A" is .004-.039 (.1-1.0 mm). See Fig. 3 .

Tighten lock nut "B".

NOTE: When adjusting brake pedal height, a NEW stoplight switch must be used.

Stoplight switch can only be adjusted one time.

4. Install NEW stoplight switch. Stoplight switch is automatically adjusted by pulling back on brake pedal until stoplight switch click noise is heard. Reconnect stoplight switch electrical connector. Check stoplight operation. Adjust pedal free play. See BRAKE PEDAL FREE PLAY . Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).

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

Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure. On Millenia, distance should be 2.7" (70 mm). On Protege, distance should be 3.8" (95 mm). On all models, if distance is not as specified, check

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.

Fig. 3: Adjusting Brake Pedal Height (Millenia Shown; Protege Is Similar)

Courtesy of MAZDA MOTORS CORP.

TESTING

PROPORTIONING VALVE

NOTE: B2300, B3000 and B4000 are not equipped with a proportioning valve.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

1. Connect 2 pressure gauges and adapters to proportioning valve. One to input port and other to output port.

Bleed brake system. See BLEEDING BRAKE SYSTEM . Depress brake pedal until pressure gauge reads as specified and check output pressure. See PROPORTIONING VALVE PRESSURE

SPECIFICATIONS .

2. Depress brake pedal again, applying additional pressure. Recheck output pressure. See

PROPORTIONING VALVE PRESSURE SPECIFICATIONS . If output pressure is not as specified, replace proportioning valve.

PROPORTIONING VALVE PRESSURE SPECIFICATIONS

Inlet Pressure psi (kg/cm

)

Outlet Pressure psi

(kg/cm

) Application

Miata

With ABS 569 (40) 850 (60)

Without ABS

Millenia

427 (30) 850 (60)

430 (31) 850 (60)

526-612 (37-43) 626-740

(44-52)

384-470 (27-33) 540-654

(38-46)

400-460 (28-32) 520-600

(37-42)

MPV

1995 512 (36) 1422 (100)

1996-97 427 (30) 853 (61)

484-540 (34-38) 854-995

(60-70)

370-484 (26-34) 583-697

(41-49)

MX-3

With ABS 356 (25) 853 (61)

Without ABS 427 (30) 853 (61)

328-384 (23-27) 512-598

(36-42)

399-455 (28-32) 512-598

(36-42)

MX-6 & 626

With ABS 500 (35) 850 (60)

Without ABS 500 (35) 850 (60)

470-530 (33-37) 597-683

(42-48)

470-530 (33-37) 557-643

(39-45)

Protege

With ABS

RX7

929

Without ABS 1.5L

Without ABS 1.8L

Microsoft

Sunday, July 05, 2009 1:51:03 PM

356 (25) 853 (61)

570 (40) 850 (60)

427 (30) 853 (61)

Page 9

328-384 (23-27) 568-654

(40-46)

328-384 (23-27) 483-569

(34-40)

328-384 (23-27) 654-740

(46-52)

530-610 (37-43) 626-739

(44-52)

399-455 (28-32) 541-654

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

(38-46)

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, 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, check valve and vacuum hose between vacuum source and power brake unit. Repair as necessary.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal & Installation (B2300, B3000 & B4000)

1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake fluid from master cylinder reservoir. Raise and support vehicle. Remove front wheel assemblies. Place a large "C" clamp on caliper.

2. Tighten clamp to bottom piston in cylinder bore. Remove clamp. Remove 2 caliper pin bolts. Remove caliper from rotor and wire aside. Slide brake pads off caliper anchor plate. Remove anchor plate (if necessary). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING

SPECIFICATIONS (FRONT) .

3. To install, reverse removal procedure. Use "C" clamp and old pad to push caliper piston into piston bore until piston bottoms out. Bleed air from brake system (if necessary).

Removal & Installation (Miata, Millenia, MPV, MX-6, 626 & 929)

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt.

See Fig. 4 , Fig. 5 or Fig. 6 . Pivot caliper upward and support using rope.

2. Remove pads, shims, guide plates or pad guides and "V" springs (if equipped). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) .

3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 4: Exploded View Of Front Disc Brake Assembly (Miata Shown; MPV Is Similar)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 5: Exploded View Of Front Brake Disc Assembly (MX-6 & 626)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 6: Exploded View Of Front Disc Brake Assembly (929 Shown; Millenia Is Similar)

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (MX-3 & Protege)

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove "M" spring. See Fig. 7 .

Remove "W" spring. 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) .

2. To install, reverse removal procedure. Use Disc Brake Expand Tool (49-0221-600C) and an old pad to push piston fully inward to install disc pads.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 7: Exploded View Of Front Disc Brake Assembly (MX-3 & Protege)

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (RX7)

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove "M" clip. See Fig. 8 .

Remove pad pins. Remove "M" spring. Remove pads and shims. Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) .

2. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. Ensure shims are installed with arrows facing direction of forward rotor rotation.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

MINIMUM PAD LINING SPECIFICATIONS (FRONT)

Application

B2300, B3000 & B4000

Miata, MX-6, Protege, RX7, 626 & 929

Millenia, MPV & MX-3

Thickness In. (mm)

.12 (3.0)

.04 (1.0)

.08 (2.0)

Fig. 8: Exploded View Of Front Disc Brake Assembly (RX7)

Courtesy of MAZDA MOTORS CORP.

FRONT DISC BRAKE CALIPER

NOTE: For removal and installation of front disc brake caliper for B2300, B3000 &

B4000, see FRONT DISC BRAKE PADS .

Removal & Installation (Except B2300, B3000 & B4000)

Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS . Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system.

FRONT BRAKE ROTOR

Removal & Installation (B2300, B3000 & B4000 2WD)

1. Raise and support vehicle. Remove front wheel assemblies and brake caliper. See FRONT DISC

BRAKE PADS . Remove grease cap, cotter pin, retainer, adjusting 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 17-25 ft. lbs. (23-34 N.m) to seat bearings. Back off adjusting nut 1/2 turn. Tighten adjusting nut to

18-20 INCH lbs. (2.0-2.3 N.m). Install bearing retainer and NEW cotter pin. DO NOT turn adjusting nut to align cotter pin.

Removal (B2300, B3000 & B4000 4WD With Automatic Locking Hubs)

1. Raise and support vehicle. Remove front wheel assemblies and caliper. See FRONT DISC BRAKE

PADS . Remove retainer washers from lug nut studs. Remove automatic locking hub assembly from spindle.

2. Remove snap ring from end of spindle shaft. Remove axle spacers. See Fig. 9 . Carefully pull cam assembly off wheel bearing adjusting nut. If necessary, rotate adjusting nut slightly to relieve pressure on locking key.

3. Using a magnet, remove locking key. Using 2 3/8" Hex Lock Nut Wrench (49-UN01-037), remove wheel bearing adjusting nut. Remove outer wheel bearing and 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. 7 . After assembly is complete, wheel to spindle end play should be .000-.003" (.00-.08 mm).

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

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 9: Removing Front Rotor (B2300, B3000 & B4000 With Automatic Locking Hubs)

Courtesy of FORD MOTOR CO.

Removal (B2300, B3000 & B4000 4WD With Manual Locking Hubs)

1. Raise and support vehicle. Remove front wheel assemblies and caliper. See FRONT DISC BRAKE

PADS . Remove retainer washers from lug nut studs. Remove manual locking hub assembly from spindle.

2. Remove snap ring from end of spindle shaft. Remove axle spacers. See Fig. 10 . Using Lock Nut Wrench

(49-UN01-042), remove outer wheel bearing lock nut. Remove lock washer. Using lock nut wrench, remove inner wheel bearing lock nut. Remove outer wheel bearing, cup and rotor.

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 install remaining components, reverse removal procedure. See Fig. 10 . After assembly is complete, wheel to spindle end play should be .000-.003" (.00-.08 mm).

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 10: Removing Front Rotor (B2300, B3000 & B4000 With Manual Locking Hubs)

Courtesy of FORD MOTOR CO.

Removal & Installation (Except B2300, B3000 & B4000)

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. See FRONT DISC BRAKE CALIPER . Wire caliper aside. Remove rotor-to-hub screws (if equipped). 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 . To install, reverse removal procedure.

REAR DISC BRAKE PADS

Removal & Installation (Miata & Protege)

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove manual adjustment gear concealment plug from caliper. See Fig. 11 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.

2. Remove lower guide bolt from caliper. Rotate caliper upward and wire side. 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. Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 11: Exploded View Of Rear Disc Brake Assembly (Miata & Protege Shown; MX-6 & 626 Are

Similar)

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (Millenia)

1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake fluid from master cylinder reservoir. Raise and support rear of vehicle.

2. Remove rear wheel assemblies. Remove lower guide bolt from caliper. See Fig. 12 . Rotate caliper upward and support using wire. Remove "V" spring. Remove pads, shims and guide plates. Replace pads if lining thickness is less than .08" (2.0 mm).

3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads.

Removal & Installation (MPV & 929)

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove upper guide bolt from caliper.

See Fig. 12 . Rotate caliper downward and support using wire. Remove "V" spring. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04" (1.0 mm).

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

2. To install, reverse removal procedure. Use Disc Brake Expander (49-022 1-600C) and an old pad to push piston fully inward to install disc pads.

Fig. 12: Exploded View Of Rear Disc Brake Assembly (MPV & 929)

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (MX-3)

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove upper caliper mounting bolt.

See Fig. 13 . Rotate caliper downward. Remove "V" spring, brake pads, shims and guide plates. Replace brake pads if pad lining thickness is less than .04" (1.0 mm).

2. To install, reverse removal procedure. Using Brake Piston Wrench (49 FA18 602), turn wrench clockwise until piston bottoms out in brake caliper.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 13: Exploded View Of Rear Disc Brake Assembly (MX-3)

Courtesy of MAZDA MOTORS CORP.

Removal & Installation (MX-6 & 626)

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. See

Fig. 11 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.

2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire. Remove "M" springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04" (1.0 mm).

3. To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Removal & Installation (RX7)

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove lower guide bolt from caliper.

Rotate caliper upward and support using wire. Remove "V" spring. Remove pads, shims and guide plates.

Replace pad if lining thickness is less than .04" (1.0 mm).

2. To install, reverse removal procedure. Use Disc Brake Piston Wrench (49-FA18-602) to rotate piston clockwise to install disc pads. Ensure grooves in piston are aligned. See Fig. 14 .

Fig. 14: Aligning Brake Caliper Piston (RX7)

Courtesy of MAZDA MOTORS CORP.

REAR BRAKE CALIPER

Removal & Installation (Miata, MPV, MX-6, Protege, RX7, 626 & 929)

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

2. On Miata, MX-6, Protege and 626, remove manual adjustment gear concealment plug from caliper. See

Fig. 11 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.

3. On all models, remove guide bolts from caliper. Remove brake caliper from caliper mount. To install, reverse removal procedure. Bleed air from system.

Removal & Installation (Millenia)

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Disconnect brake flexhose from

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum caliper. Remove rear brake pads. See REAR DISC BRAKE PADS . Remove remaining caliper guide bolt. Remove brake caliper from caliper mount. To install, reverse removal procedure. Bleed air from system.

Removal & Installation (MX-3)

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Disconnect brake flexhose from caliper. See Fig. 13 .

2. Remove upper caliper mounting bolt. Rotate caliper downward. Remove "V" spring, pads, shims and guide plates. Replace brake pads if pad lining thickness is less than .04" (1.0 mm).

3. Remove lower caliper mounting bolt. Pull caliper toward center of vehicle to slide it off of caliper mount.

To install, reverse removal procedure. Using Brake Piston Wrench (49 FA18 602), turn wrench clockwise until piston bottoms out in brake caliper. Bleed air from system.

REAR BRAKE ROTOR

Removal & Installation (Miata, Millenia, MPV, MX-3, MX-6, Protege, RX7, 626 & 929)

1. Raise and support vehicle. Remove rear wheel assemblies. Remove rear brake caliper with brake hose connected. See REAR BRAKE CALIPER . Support caliper using wire. Remove rotor-to-hub screws (if equipped). 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 .

3. To install, reverse removal procedure. Check end play at grease cap. On 929, if end play exceeds .004" (.10 mm), check lock nut torque or replace wheel bearings. On all other models, if end play exceeds .002" (.05 mm), check lock nut torque or replace wheel bearings.

REAR BRAKE SHOES & WHEEL CYLINDERS

Removal (B2300, B3000 & B4000)

1. Raise and support vehicle. Remove rear wheel assemblies. Remove brake drum. Machine or replace drum as necessary if inner diameter is not as specified. See DRUM BRAKE SPECIFICATIONS .

2. Place a wheel cylinder clamp over ends of wheel cylinder. Disengage adjusting lever from adjusting screw by pulling backwards on self adjuster cable. See Fig. 15 .

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

4. Remove adjusting lever spring and adjusting lever. Remove secondary shoe-to-retracting spring. Remove primary shoe-to-retracting spring. Unhook cable anchor and remove anchor pin plate.

5. Note color and position of shoe hold-down springs for reassembly. Remove cable guide, shoe hold-down springs, brake shoes, adjusting screw, pivot nut and socket. Remove parking brake link spring and link.

6. Disconnect parking brake cable from lever. Remove secondary shoe. Disassemble parking brake lever from shoe by removing retaining clip and spring washer. See Fig. 16 . Remove brake cylinder-to-shoe connecting links. Disconnect brake line from brake cylinder. Remove brake cylinder.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Installation

1. To install, reverse removal procedure. Clean and sand brake shoe contact points on backing plate. Apply a light coating of lithium base grease to brake shoe contact points on backing plate. Lubricate adjusting screw, pivot nut and socket.

2. Install primary and secondary shoes in original positions. Adjust brake shoes. See REAR BRAKE

SHOES ADJUSTMENT . Bleed air from system.

NOTE: Socket end of adjusting screw assembly and adjusting lever are marked with an

"R" or "L" for reassembly onto proper side of vehicle. Interchanging adjusting screw assembly and adjusting lever from one side of vehicle to other will cause brake shoes to retract when automatic adjuster is operated.

Fig. 15: Identifying Rear Brake Assembly Components (B2300, B3000 & B4000)

Courtesy of FORD MOTOR CO.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 16: Exploded View Of Rear Drum Brake Assembly (B2300, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.

Removal (MX-3, MX-6, Protege & 626)

1. Raise and support vehicle. Remove rear wheel assemblies. Remove brake drum. Machine or replace drum as necessary if inner diameter is not as specified. See DRUM BRAKE SPECIFICATIONS .

2. Remove return springs, hold pins and springs, and anti-rattle spring. See Fig. 17 . Note positions of primary and secondary shoes and remove brake shoes. Minimum brake shoe lining thickness is .04" (1.0 mm).

3. Remove stopper spring and clip (if equipped), and return spring. Release parking brake and disconnect parking brake cable. Remove operating lever assembly. Using Flare Nut Wrench (49-0259-770B), disconnect brake line from wheel cylinder. Remove wheel cylinder.

Installation

1. To install, reverse removal procedure. Apply lithium base grease to wheel cylinder and anchor sliding parts, adjuster threads and shoe contact points on backing plate.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

2. Install primary and secondary shoes in original positions (secondary shoe is longer). Adjust brake shoes.

See REAR BRAKE SHOES ADJUSTMENT . Bleed air from system.

Fig. 17: Exploded View Of Rear Drum Brake Assembly (MX-3 & Protege Shown; MX-6 & 626 Are

Similar)

Courtesy of MAZDA MOTORS CORP.

PARKING BRAKE SHOES

Removal (Millenia, MPV & 929)

Raise and support vehicle. Remove rear wheel assemblies. Remove service plug. See Fig. 18 . Remove brake caliper with brake hose connected. Support caliper using wire. Remove brake rotor. Remove return springs,

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum pull-off spring, and hold springs and pins. Remove parking brake shoes. Minimum parking brake shoe lining thickness is .04" (1.0 mm). Remove adjuster and operating lever.

Installation

To install, reverse removal procedure. Apply lithium base grease to anchor sliding plate, adjuster threads and shoe contact points on backing plate. Set marked side (with arrow) of operating lever to front side. Ensure threaded side of adjuster faces forward on left wheel and rearward on right wheel. Adjust parking brake shoes.

See PARKING BRAKE SHOES ADJUSTMENT . Bleed air from system.

Fig. 18: Exploded View Of Parking Brake Assembly (Millenia, MPV & 929)

Courtesy of MAZDA MOTORS CORP.

REAR AXLE BEARING & OIL SEAL

NOTE: For information on models with sealed wheel bearings, see appropriate article

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum in SUSPENSION.

MASTER CYLINDER

Removal & Installation

Disconnect fluid level sensor electrical connector at fluid reservoir. Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid. Remove nuts attaching master cylinder to power brake unit.

Remove master cylinder from vehicle. To install master cylinder, reverse removal procedure. Bleed air from system.

POWER BRAKE UNIT

Removal & Installation

Remove master cylinder from power brake unit. See MASTER CYLINDER . Disconnect vacuum line at power brake unit. See Fig. 19 . From inside vehicle, remove cotter pin and clevis pin. Separate push rod from brake pedal. Remove power brake unit-to-firewall nuts. Remove power brake unit. To install, reverse removal procedure. Bleed air from system.

Fig. 19: Removing Power Brake Unit (Typical)

Courtesy of MAZDA MOTORS CORP.

OVERHAUL

Microsoft

NOTE:

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Use appropriate illustrations for exploded view of rear caliper assembly and master cylinder. See Fig. 20 through Fig. 29 .

Fig. 20: Exploded View Of Rear Caliper Assembly (Miata & Protege Shown; MX-6 & 626 Are Similar)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 21: Exploded View Of Rear Caliper Assembly (Millenia)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 22: Exploded View Of Rear Caliper Assembly (MX-3)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 23: Exploded View Of Rear Caliper Assembly (RX7)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 24: Exploded View Of Rear Caliper Assembly (929)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 25: Exploded View Of Master Cylinder (B2300, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 26: Exploded View Of Master Cylinder (Miata Without ABS, MPV, MX-3 Without ABS, MX-6 M/T

Without ABS & 626 M/T Without ABS)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 27: Exploded View Of Master Cylinder (Miata With ABS, MX-3 With ABS, RX7 & 929)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 28: Exploded View Of Master Cylinder (Millenia)

Courtesy of MAZDA MOTORS CORP.

Microsoft

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Fig. 29: Exploded View Of Master Cylinder (MX-6 & 626; With ABS &/Or A/T)

Courtesy of MAZDA MOTORS CORP.

SPECIFICATIONS

TORQUE SPECIFICATIONS

Application

Backing Plate Bolts (Rear)

B2300, B3000 & B4000

MX-3 & Protege

MX-6 & 626

Microsoft

Sunday, July 05, 2009 1:51:03 PM Page 38

Ft. Lbs. (N.m)

25-35 (34-47)

33-43 (45-58)

37-50 (50-68)

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Caliper Guide Bolts (Front)

Miata

Millenia & 929

MPV

MX-6 & 626

Caliper Guide Bolts (Rear)

Miata

MPV

Millenia & MX-3

MX-6 & 626

Protege

RX7

929

Caliper Mount Bracket Bolts (Front)

Miata

Millenia

MPV

MX-6 & 626

929

Caliper Mount Bracket Bolts (Rear)

Miata

Millenia & MPV

MX-3 & Protege

MX-6 & 626

RX7

929

Front Caliper Mounting Bolt

B2300, B3000 & B4000

MX-3 & Protege

RX7

Power Brake Unit Nuts

B2300, B3000 & B4000

Except B2300, B3000 & B4000

Rear Axle Lock Nut

Miata

Millenia, MX-3, MX-6, Protege, RX7, 626 & 929

Wheel Lug Nut

B2300, B3000 & B4000

All Other Models

58-65 (78-88)

46-62 (63-84)

62-69 (84-93)

22-30 (30-40)

33-36 (45-49)

28-36 (38-49)

12-18 (16-24)

26-29 (35-39)

33-44 (45-60)

46-62 (63-84)

28-36 (38-49)

36-51 (49-69)

75-101 (102-137)

66-79 (89-107)

58-74 (79-100)

75-87 (102-118)

34-48 (46-66)

37-50 (50-68)

33-44 (45-60)

34-48 (46-66)

34-49 (46-67)

74-96 (100-130)

30-36 (40-49)

58-72 (79-98)

16-21 (22-28)

14-18 (19-25)

160-216 (216-294)

131-173 (177-235)

Wheel Cylinder Bleeder Screw

(1)

MX-3 & Protege

Microsoft

Sunday, July 05, 2009 1:51:03 PM Page 39

85-115 (115-155)

65-87 (88-118)

INCH Lbs. (N.m)

52-78 (5.9-8.8)

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Wheel Cylinder Mounting Bolt

(1)

(1) Information is not available at time of publication for B2300, B3000 & B4000.

DISC BRAKE SPECIFICATIONS

Application

B2300, B3000 & B4000 - Front

(1)

Original Thickness

Minimum Thickness

Miata

Front

(2)

Original Thickness

Minimum Thickness

(3)

Rear

(2)

Original Thickness

Minimum Thickness

(4)

Millenia

Front

(5)

Original Thickness

Minimum Thickness

(6)

Rear

(5)

Original Thickness

Minimum Thickness

(4)

MPV

Front

(2)

Original Thickness

Minimum Thickness

(6)

Rear

(2)

Original Thickness

MX-3

Minimum Thickness

(7)

Front

(2)

Original Thickness

Minimum Thickness

(8)

Rear

(2)

Original Thickness

Microsoft

Sunday, July 05, 2009 1:51:03 PM Page 40

88-108 (10-12)

In. (mm)

.94 (24)

.81 (21)

.79 (20)

.71 (18)

.35 (9)

.31 (8)

1.10 (28)

1.02 (26)

.37 (9.5)

.29 (7.5)

1.10 (28)

1.02 (26)

.71 (18)

.63 (16)

.87 (22)

.79 (20)

.35 (9)

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

Minimum Thickness

(4)

MX-6 & 626

Front

(2)

Original Thickness

Minimum Thickness

(9)

Rear

(2)

Original Thickness

Minimum Thickness

(10)

Protege

Front

(11)

Original Thickness

Minimum Thickness

(8)

Rear

(11)

Original Thickness

Minimum Thickness

(12)

RX7

Front

(2)

Original Thickness

Minimum Thickness

Rear

(2)

Original Thickness

Minimum Thickness

929

Front

(2)

Original Thickness

Minimum Thickness

Rear

(2)

Original Thickness

Minimum Thickness

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

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

(3) If using a brake lathe to machine rotor on vehicle, minimum thickness is .74" (18.8 mm).

(4) If using a brake lathe to machine rotor on vehicle, minimum thickness is .33" (8.4 mm).

(5) Maximum lateral runout is .002" (.05 mm).

(6) If using a brake lathe to machine rotor on vehicle, minimum thickness is 1.06" (26.8 mm).

(7) If using a brake lathe to machine rotor on vehicle, minimum thickness is .66" (16.8 mm).

Microsoft

Sunday, July 05, 2009 1:51:03 PM Page 41

.31 (8)

.94 (24)

.87 (22)

.39 (10)

.31 (8)

.87 (22)

.79 (20)

.35 (9)

.28 (7)

.87 (22)

.79 (20)

.71 (18)

.94 (24)

.87 (22)

.71 (18)

.63 (16)

1997 Mazda MX-5 Miata

BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

(8) If using a brake lathe to machine rotor on vehicle, minimum thickness is 82" (20.8 mm).

(9) If using a brake lathe to machine rotor on vehicle, minimum thickness is .90" (22.8 mm).

(10) If using a brake lathe to machine rotor on vehicle, minimum thickness is .35" (8.8 mm).

(11) Maximum lateral runout is .002" (.50 mm).

(12) If using a brake lathe to machine rotor on vehicle, minimum thickness is .31" (7.8 mm).

DRUM BRAKE SPECIFICATIONS

Application

B2300, B3000 & B4000 Drum Diameter

Original

10"

Maximum Refinish Diameter

10"

Millenia & MPV Parking Brake Drum Diameter

Original

Maximum Finish Diameter

MX-3 & Protege

Drum Diameter

Original

Maximum Finish Diameter

Wheel Cylinder Bore Diameter

MX-3

Protege

MX-6 & 626 Drum Diameter

Original

Maximum Finish Diameter

Wheel Cylinder Bore Diameter

929 Parking Brake Drum Diameter

Original

Maximum Refinish Diameter

In. (mm)

9.00 (228.6)

10.00 (254.0)

9.09 (230.8)

10.09 (256.3)

7.48 (190.0)

5.51 (191.0)

7.87 (200.0)

7.93 (201.5)

0.687 (17.46)

0.75 (19.0)

9.00 (228.6)

9.06 (230.1)

0.687 (17.46)

7.48 (190.0)

5.51 (191.0)

Microsoft

Hello! I am an AI chatbot specifically trained to assist you with the Mazda MX-5 1997 Workshop Manual. I have thoroughly reviewed the document and can help you locate the exact information you need or explain the content in clear and simple terms. Whether you’re looking for guidance on specific features, troubleshooting steps, or general usage, feel free to ask your questions. The more details you provide about your concerns or needs, the more accurately and effectively I can assist you!

Assistant typing

Assistant terminated