Mazda MX-5 2005 Workshop Manual

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2005 RESTRAINTS Air Bag System - MX-5 Miata

2005 RESTRAINTS

Air Bag System - MX-5 Miata

AIR BAG SYSTEM LOCATION INDEX

Fig. 1: Identifying Air Bag System Components

Courtesy of MAZDA MOTORS CORP.

2005 Mazda MX-5 Miata

2005 RESTRAINTS Air Bag System - MX-5 Miata

AIR BAG SYSTEM SERVICE WARNINGS

COMPONENT DISASSEMBLY



Disassembling and reassembling the components of the air bag system can render the system inoperative, which may result in serious injury or death in the event of an accident. Do not disassemble any air bag system component.

Fig. 2: Warning Against Disassembling Air Bag System Components

Courtesy of MAZDA MOTORS CORP.

WIRING HARNESS REPAIR

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2005 RESTRAINTS Air Bag System - MX-5 Miata



Incorrectly repairing an air bag system wiring harness can accidentally deploy the air bag module or pre-tensioner seat belt, which can cause serious injury. If a problem is found in the system wiring, replace the wiring harness. Do not try to repair it.

Fig. 3: Identifying Incorrect Wiring Harness Repair

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE INSPECTION



Inspecting an air bag module using an ohmmeter can deploy the air bag module, which may cause serious injury. Do not use an ohmmeter to inspect an air bag module. Always use the on-board diagnostic function to diagnose the air bag module for malfunctions. (See FOREWORD .)

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2005 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 4: Inspecting Air Bag Module Incorrectly

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE HANDLING



A live (undeployed) air bag module may accidentally deploy when it is handled and cause serious injury. When carrying a live (undeployed) air bag module, point the front surface away from your body to lessen the chance of injury in case it deploys.

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2005 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 5: Identifying Proper Air Bad Module Carrying Method

Courtesy of MAZDA MOTORS CORP.



A live (undeployed) air bag module placed face down on a surface is dangerous. If the air bag module deploys, the motion of the module can cause serious injury. Always face the front surface up to reduce the motion of the module in case it accidentally deploys.

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2005 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 6: Identifying Proper Air Bag Module Facing

Courtesy of MAZDA MOTORS CORP.

SAS CONTROL MODULE HANDLING



Disconnecting the SAS control module connector or removing the SAS control module with the ignition switch at ON position can cause the air bag modules and pre-tensioner seat belts to deploy, which may seriously injure you. Before disconnecting the SAS control module connector or removing the SAS control module, turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the

SAS control module to deplete its stored power.

Connecting the SAS control module connector without firmly installing the SAS control module to the vehicle is dangerous. The crash sensor inside the control module may send an electrical signal to the air bag modules and pre-tensioner seat belts. This will deploy the air bag modules and pretensioner seat belts, which may result in serious injury. Therefore, before connecting the connector, firmly mount the control module to the vehicle.



For vehicles with a single point sensor, once an air bag module is deployed due to an accident or other causes, the SAS control module must be replaced with a new one even if the used one does not have any external signs of damage. The used SAS control module may have been damaged internally which may cause improper operation, resulting in major injuries or even death. The used single point SAS control module cannot be bench-checked or self-educated.

CRUSH ZONE SENSOR HANDLING



Disconnecting the crush zone sensor connector or removing the crush zone sensor with the ignition

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2005 RESTRAINTS Air Bag System - MX-5 Miata switch at ON position can cause the air bag modules and pre-tensioner seat belts to deploy, which may seriously injure you. Before disconnecting the crush zone sensor connector or removing the crush zone sensor, turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS control module to deplete its stored power.



If the crush zone sensor is subjected to shock or the sensor is disassembled, the air bag modules and pre-tensioner seat belts may operate (deploy) suddenly and cause injury, or it may fail to operate normally and cause a serious accident. Do not subject the crush zone sensor to shock or disassemble the sensor.

PRE-TENSIONER SEAT BELT INSPECTION



Inspecting a pre-tensioner seat belt using an ohmmeter can deploy the pre-tensioner seat belt, which can cause serious injury. Do not use an ohmmeter to inspect the pre-tensioner seat belt.

Always use the on-board diagnostic to diagnose the pre-tensioner seat belt for malfunctions.

Fig. 7: Identifying Improper Method For Inspecting Pre-Tensioner Seat Belt

Courtesy of MAZDA MOTORS CORP.

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2005 RESTRAINTS Air Bag System - MX-5 Miata

COMPONENT HANDLING



Oil, grease, water, etc. on components may cause the air bag modules and pre-tensioner seat belts to fail to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., on components.

Inserting a screwdriver, etc. into the connector of an air bag modules may damage the connector and cause the air bag module or the pre-tensioner seat belt to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connector.

Fig. 8: Warning Against Screwdriver Insertion

Courtesy of MAZDA MOTORS CORP.

COMPONENT REUSE



Once an air bag module is deployed due to an accident or other causes, even if it does not have any external signs of damage, the air bag module may have been damaged internally which may cause improper operation. Improper operation may cause serious injury. Always self-check the undamaged air bag module or pre-tensioner seat belt to determine whether it can be reused. (See

FOREWORD .)

DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION

WARNING:



Handling the air bag module improperly can accidentally deploy the

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2005 RESTRAINTS Air Bag System - MX-5 Miata air bag module and pre-tensioner seat belts, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the air bag module. (See AIR BAG SYSTEM SERVICE

WARNINGS.)

1. Turn the ignition switch to LOCK position.

2. Disconnect the negative battery cable and wait for more than 1 minute.

3. Remove in the order indicated in the table.

Fig. 9: Removing Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

5. Turn the ignition switch to ON position.

6. Verify that the air bag system warning light illuminates for approximately 6 seconds and then goes off.



If the air bag system warning light remains on, off, or repeats flashing after servicing, there are malfunctions in the system. Carry out the inspection again. (See FOREWORD .)

CONNECTOR INSTALLATION NOTE

1. Install the connector as shown in Fig. 10 .

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2005 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 10: Installing Connector

Courtesy of MAZDA MOTORS CORP.

BOLT INSTALLATION NOTE

1. Tighten the bolts in the order shown in Fig. 11 .

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Fig. 11: Tightening Bolts

Courtesy of MAZDA MOTORS CORP.

PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION

WARNING:



Handling the air bag module improperly can accidentally deploy the air bag module and pre-tensioner seat belts, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the air bag module. (See AIR BAG SYSTEM SERVICE

WARNINGS.)

1. Turn the ignition switch to LOCK position.

2. Disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS control module to deplete its stored power.

3. Remove the glove compartment.

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4. Remove in the order indicated in the table.

Fig. 12: Removing Glove Compartment

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

6. Turn the ignition switch to ON position.

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2005 RESTRAINTS Air Bag System - MX-5 Miata

7. Verify that the air bag system warning light illuminates for approximately 6 seconds and then goes off.



If the air bag system warning light remains on, off, or repeats flashing after servicing, there are malfunctions in the system. Carry out the inspection again. (See DTC TABLE .)

CONNECTOR INSTALLATION NOTE

1. Connect the connector, then install it as shown in Fig. 13 .

Fig. 13: Installing Connector

Courtesy of MAZDA MOTORS CORP.

CLOCK SPRING ADJUSTMENT

NOTE:



The adjustment procedure is also specified on the caution label of the clock spring.

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1. Set the front wheels straight ahead.

CAUTION:



The clock spring will break if over-wound. Do not forcibly turn the clock spring when turning it.

2. Turn the clock spring clockwise until it stops.

Fig. 14: Turning Clock Spring Clockwise Until Stops

Courtesy of MAZDA MOTORS CORP.

3. Turn the clock spring counterclockwise 2 3/4 turns.

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Fig. 15: Turning Clock Spring Counterclockwise

Courtesy of MAZDA MOTORS CORP.

4. Align the mark on the clock spring with the mark on the outer housing.

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Fig. 16: Aligning Mark On Clock Spring With Mark On Outer Housing

Courtesy of MAZDA MOTORS CORP.

CLOCK SPRING REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the column cover.

3. Remove the driver-side air bag module. (See DRIVER-SIDE AIR BAG MODULE

REMOVAL/INSTALLATION .)

4. Remove the steering wheel. (See STEERING WHEEL AND COLUMN

REMOVAL/INSTALLATION .)

5. Remove in the order indicated in the table.

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Fig. 17: Removing Clock Spring - With Torque Specification

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

CLOCK SPRING INSPECTION

1. Remove the clock spring. (See CLOCK SPRING REMOVAL/INSTALLATION .)

2. Inspect for continuity between the clock spring terminals using an ohmmeter.



If not as specified, replace the clock spring.

NOTE:



When terminals 3A and 3B are disconnected from the vehicle's main harness, they are shorted to prevent unexpected air bag deployment.

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Fig. 18: Clock Spring Terminal Continuity Table

Courtesy of MAZDA MOTORS CORP.

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Fig. 19: Identifying Clock Spring Terminal Connectors

Courtesy of MAZDA MOTORS CORP.

PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH

REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the center panel. (See CENTER PANEL REMOVAL/INSTALLATION .)

3. Push the tabs of PAD switch and pull the switch out.

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Fig. 20: Removing PAD Switch

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH INSPECTION

1. Disconnect the negative battery cable.

2. Remove the center panel. (See CENTER PANEL REMOVAL/INSTALLATION .)

3. Confirm that the PAD switch warning light bulb and the PAD switch illumination bulb are okay.



If the bulbs go out, replace them with new ones.

4. Inspect for continuity between PAD switch terminals using an ohmmeter.



If not as specified, replace the PAD switch.

Fig. 21: Passenger Air Bag Deactivation Terminal Continuity Table

Courtesy of MAZDA MOTORS CORP.

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Fig. 22: Identifying Passenger Air Bag Terminal Connectors

Courtesy of MAZDA MOTORS CORP.

PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH WARNING LIGHT

BULB AND PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH

ILLUMINATION BULB REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the center panel. (See CENTER PANEL REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

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Fig. 23: Removing PAD Switch Warning Light Bulb And PAD Switch Illumination Bulb

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

SAS CONTROL MODULE REMOVAL/INSTALLATION

WARNING:



Handling the SAS control module improperly can accidentally deploy the air bag modules and pre-tensioner seat belts, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the SAS control module. (See AIR BAG SYSTEM

SERVICE WARNINGS.)

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for more than 1 minute.

3. Remove the dashboard. (See CENTER PANEL REMOVAL/INSTALLATION .)

4. Remove in the order indicated in the table.

Fig. 24: Removing SAS Control Module - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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5. Install in the reverse order of removal.

6. Turn the ignition switch to ON position.

7. Verify that the air bag system warning light illuminates for approximately 6 seconds and then goes off.



If the air bag system warning light remains on, off, or repeats flashing after servicing, there are malfunctions in the system. Carry out the inspection again. (See FOREWORD .)

NUT INSTALLATION NOTE

1. Tighten the nuts in the order shown in Fig. 25 .

Fig. 25: Tightening SAS Control Module Nuts In Order

Courtesy of MAZDA MOTORS CORP.

CRUSH ZONE SENSOR REMOVAL/INSTALLATION

WARNING:



Handling the crush zone sensor improperly can accidentally deploy the air bag modules and pre-tensioner seat belts, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the crush zone sensor. (See AIR BAG SYSTEM

SERVICE WARNINGS.)

1. Turn the ignition switch to LOCK position.

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2005 RESTRAINTS Air Bag System - MX-5 Miata

2. Disconnect the negative battery cable and wait for more than 1 minute.

3. Remove in the order indicated in the table.

Fig. 26: Removing Crush Zone Sensor - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

5. Turn the ignition switch to ON position.

6. Verify that the air bag system warning light illuminates for approximately 6 seconds and then goes off.



If the air bag system warning light does not operate in the manner described above, there are malfunctions in the system. Inspect the system using the on-board diagnostic function. (Refer to

FOREWORD .)

Bolt Installation Note

1. Tighten the bolts in the order shown in Fig. 27 .

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Fig. 27: Tightening Crush Zone Sensor Bolts In Order

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT

AUTHORIZATION PROCEDURES

1. After installing a new SAS control module, verify that the air bag system warning light flashes continuously approximately 6 seconds after the ignition switch is turned to ON position.



If a diagnostic trouble code is indicated, perform the appropriate AIR BAG SYSTEM ON-BOARD

DIAGNOSTIC. (See FOREWORD .)

2. Turn the ignition switch to LOCK position then back to ON position while the air bag system warning light is flashing continuously.

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

If the procedures have been performed correctly, the air bag system warning light illuminates, then goes off after approximately 6 seconds.



If it does not go off, perform the deployment authorization procedure again.

AIR BAG MODULE DEPLOYMENT PROCEDURE

WARNING:



A live (undeployed) air bag module and pre-tensioner seat belt may accidentally deploy when it is disposed of and cause serious injury.

Do not dispose of a live (undeployed) air bag module and pretensioner seat belt. If the SSTs (Deployment Tool and Adapter

Harness) are not available, consult the nearest Mazda representative for assistance.

NOTE:



When disposing of a deployed air bag module and pre-tensioner seat belt, refer to Air Bag Module and Pre-tensioner Seat Belt Disposal Procedure.

(See AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL

PROCEDURES.)

DEPLOYMENT PROCEDURES FOR INSIDE OF VEHICLE

1. Inspect the SST (Deployment Tool). (See INSPECTION OF SST (DEPLOYMENT TOOL) .)

2. Move the vehicle to an open space, away from strong winds, and close all of the vehicle's doors and windows.

3. Turn the ignition switch to LOCK position.

4. Disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS control module to deplete its stored power.

Driver-side air bag module

1. Remove the column cover.

2. Disconnect the clock spring connector.

3. Connect the SST (Adapter Harness) to the clock spring as shown in Fig. 28 .

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Fig. 28: Connecting Adapter Harness To Clock Spring

Courtesy of MAZDA MOTORS CORP.

4. Connect the SST (Deployment Tool) to the SST (Adapter Harness).

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Fig. 29: Connecting Deployment Tool To Adapter Harness

Courtesy of MAZDA MOTORS CORP.

5. Connect the red clip of the SST (Deployment Tool) to the positive battery terminal and the black clip to the negative battery terminal.

6. Verify that the red light on the SST (Deployment Tool) is illuminated.

7. Make sure all persons are standing at least 6 m {20 ft} away from the vehicle.

8. Press the activation switch on the SST (Deployment Tool) to deploy the driver-side air bag module.

Passenger-side air bag module

1. Remove the glove compartment.

2. Disconnect the passenger-side air bag module connector.

3. Connect the SST (Adapter Harness) to the passenger-side air bag module as shown in Fig. 30 .

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Fig. 30: Connecting Adapter Harness To Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

4. Connect the SST (Deployment Tool) to the SST (Adapter Harness).

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Fig. 31: Connecting Deployment Tool To Adapter Harness

Courtesy of MAZDA MOTORS CORP.

5. Connect the red clip of the SST (Deployment Tool) to the positive battery terminal and the black clip to the negative battery terminal.

6. Verify that the red light on the SST (Deployment Tool) is illuminated.

7. Make sure all persons are standing at least 6 m {20 ft} away from the vehicle.

8. Press the activation switch on the SST (Deployment Tool) to deploy the passenger-side air bag module.

Pre-tensioner seat belt

1. Remove the quarter trim.

2. Remove the pre-tensioner seat belt and connect the SST (Adapter Harness) to it as shown in Fig. 32 .

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Fig. 32: Connecting Adapter Harness To Pre-Tensioner Seat Belt

Courtesy of MAZDA MOTORS CORP.

3. Install the pre-tensioner seat belt.

4. Connect the SST (Deployment Tool) to the SST (Adapter Harness).

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Fig. 33: Connecting Deployment Tool To Adapter Harness

Courtesy of MAZDA MOTORS CORP.

5. Connect the red clip of the SST (Deployment Tool) to the positive battery terminal and the black clip to the negative battery terminal.

6. Verify that the red light on the SST (Deployment Tool) is illuminated.

7. Make sure all persons are standing at least 6 m {20 ft} away from the vehicle.

8. Press the activation switch on the SST (Deployment Tool) to deploy the pre-tensioner seat belt.

DEPLOYMENT PROCEDURES FOR OUTSIDE OF VEHICLE

1. Inspect the SST (Deployment Tool). (See INSPECTION OF SST (DEPLOYMENT TOOL) .)

2. Turn the ignition switch to LOCK position.

3. Disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS control module to deplete its stored power.

Driver-side air bag module

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1. Remove the driver-side air bag module. (See DRIVER-SIDE AIR BAG MODULE

REMOVAL/INSTALLATION .)

2. Place the driver-side air bag module on the center of the wheel with the module facing up. See Fig. 34 .



To secure the air bag module to the tire wheel, wrap the wire harness through the wheel and the bolt installation hole at least 4 times.

WARNING:



If the air bag module is not properly installed to the wheel, serious injury may occur when the module is deployed. When installing the air bag module to the wheel, make sure the module is facing up.

Fig. 34: Placing Driver-Side Air Bag Module On Center Of Wheel With Module Facing Up

Courtesy of MAZDA MOTORS CORP.

3. Connect the SST (Adapter Harness) to the driver-side air bag module as shown in Fig. 35 .

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Fig. 35: Connecting Adapter Harness To Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

4. Stack three tires on top of the tire with the air bag module. Stack another tire that has a wheel on top of the four tires.

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Fig. 36: Stacking Tires - For Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

5. Tie all tires together with wire.

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Fig. 37: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

6. Connect the SST (Deployment Tool) to the SST (Adapter Harness).

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Fig. 38: Connecting Deployment Tool To Adapter Harness

Courtesy of MAZDA MOTORS CORP.

7. Connect the red clip of the SST (Deployment Tool) to the positive battery terminal and the black clip to the negative battery terminal.

8. Verify that the red light on the SST (Deployment Tool) is illuminated.

9. Make sure all persons are standing at least 6 m {20 ft} away from the tires.

10. Press the activation switch on the SST (Deployment Tool) to deploy the driver-side air bag module.

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Fig. 39: Identifying Deployment Tool

Courtesy of MAZDA MOTORS CORP.

Passenger-side air bag module

1. Remove the passenger-side air bag module. (See PASSENGER-SIDE AIR BAG MODULE

REMOVAL/INSTALLATION .)

2. Install the bolts or nuts to the passenger-side air bag module.

WARNING:



If the air bag module is not properly installed to the tire, serious injury may occur when the module is deployed. When installing the air bag module to the tire, make sure the module is facing the center of the tire.

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Fig. 40: Installing Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

3. Tie the passenger-side air bag module to a tire with the module facing the center of the tire. Wrap the wire harness through the tire and around the bolts or nut at least 4 times.

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Fig. 41: Tying Passenger-Side Air Bag Module To Tire

Courtesy of MAZDA MOTORS CORP.

4. Connect the SST (Adapter Harness) to the passenger-side air bag module as shown in Fig. 42 .

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Fig. 42: Connecting Adapter Harness To Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

5. Stack the tire with the passenger-side air bag module on top of two tires. Stack a tire on top of the three tires. Stack another tire that has a wheel on top of the four tires.

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Fig. 43: Stacking Tires - For Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

6. Tie all tires together with wire.

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Fig. 44: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

7. Connect the SST (Deployment Tool) to the SST (Adapter Harness).

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Fig. 45: Connecting Deployment Tool To Adapter Harness

Courtesy of MAZDA MOTORS CORP.

8. Connect the red clip of the SST (Deployment Tool) to the positive battery terminal and the black clip to the negative battery terminal.

9. Verify that the red light on the SST (Deployment Tool) is illuminated.

10. Make sure all persons are standing at least 6 m {20 ft} away from the tires.

11. Press the activation switch on the SST (Deployment Tool) to deploy the passenger-side air bag module.

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Fig. 46: Identifying Deployment Tool

Courtesy of MAZDA MOTORS CORP.

Pre-tensioner seat belt

1. Remove the pre-tensioner seat belt and connect the SST (Adapter Harness) to it as shown in Fig. 47 .

WARNING:



If the pre-tensioner seat belt is not properly installed to the tire, serious injury may occur when the pre-tensioner seat belt is deployed. When installing the pre-tensioner seat belt to the tire, make sure the module is facing the center of the tire.

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Fig. 47: Connecting Adapter Harness To Pre-Tensioner Seat Belt

Courtesy of MAZDA MOTORS CORP.

2. Tie the pre-tensioner seat belt to a tire with the module facing the center of the tire. Wrap the wire harness through the tire and around the bolts or nut at least 4 times.

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Fig. 48: Tying Pre-Tensioner Seat Belt To Tire

Courtesy of MAZDA MOTORS CORP.

3. Stack the tire with the pre-tensioner seat belt on top of two tires. Stack a tire on top of the three tires.

Stack another tire that has a wheel on top of the four tires.

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Fig. 49: Stacking Tires - For Pre-Tensioner Seat Belt

Courtesy of MAZDA MOTORS CORP.

4. Tie all tires together with wire.

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Fig. 50: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

5. Connect the SST (Deployment Tool) to the SST (Adapter Harness).

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Fig. 51: Connecting Deployment Tool To Adapter Harness

Courtesy of MAZDA MOTORS CORP.

6. Connect the red clip of the SST (Deployment Tool) to the positive battery terminal and the black clip to the negative battery terminal.

7. Verify that the red light on the SST (Deployment Tool) is illuminated.

8. Make sure all persons are standing at least 6 m {20 ft} away from the tires.

9. Press the activation switch on the SST (Deployment Tool) to deploy the pre-tensioner seat belt.

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2005 Mazda MX-5 Miata

2005 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 52: Identifying Deployment Tool

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL

PROCEDURES

WARNING:



Before scrapping a vehicle with a live (undeployed) air bag module and pre-tensioner seat belt, deploy the air bag module and pretensioner seat belt. Never dispose of a live (undeployed) air bag module and pre-tensioner seat belt.

The air bag module and the tube of the pre-tensioner seat belt is very hot immediately after it is deployed. You can get burned. Do not touch the air bag module and pre-tensioner seat belt for at least 15 minutes after deployment.

Pouring water on the deployed air bag module and pre-tensioner seat belt is dangerous. The water will mix with the residual gases to form a gas that can make breathing difficult. Do not pour water on the deployed air bag module and pre-tensioner seat belt.

The deployed air bag module and pre-tensioner seat belt may contain deposits of sodium hydroxide, a caustic by product of the gas-generated combustion. If this substance gets into your eyes or on your hands, it can cause irritation and itching. When handling the deployed air bag module and pre-tensioner seat belt, wear gloves

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2005 Mazda MX-5 Miata

2005 RESTRAINTS Air Bag System - MX-5 Miata and safety glasses.

1. Put on gloves and safety glasses.

2. Put the deployed air bag module or pre-tensioner seat belt in a plastic bag, seal it, and then dispose of it.

Fig. 53: Putting Deployed Air Bag Module In Plastic Bag

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 RESTRAINTS Air Bag System - MX-5 Miata

3. Wash your hands after removing your gloves.

INSPECTION OF SST (DEPLOYMENT TOOL)

1. Use the SST (Deployment Tool) to deploy a live air bag module before disposing of it.

2. Before connecting the SST (Deployment Tool) to the clock spring or passenger-side air bag module, inspect the operation of the SST (Deployment Tool).

Fig. 54: Identifying Deployment Tool Components

Courtesy of MAZDA MOTORS CORP.

INSPECTION PROCEDURE

1. Follow the steps below to verify that the SST (Deployment Tool) is operating correctly.



If not as specified, do not use the SST (Deployment Tool) because it may cause the air bag module to unexpectedly deploy upon connection to the air bag module.

INSPECTION PROCEDURE

Step Inspection procedure

Light condition

Green Red

On Off 1

Connect red clip to positive battery terminal and black clip to negative battery terminal.

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2005 Mazda MX-5 Miata

2005 RESTRAINTS Air Bag System - MX-5 Miata

2 Connect connectors A and B of SST (Deployment Tool).

3 Press activation switch.

Off

Fig. 55: Inspecting Deployment Tool

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 BRAKES Antilock Brake System - MX-5 Miata

2005 BRAKES

Antilock Brake System - MX-5 Miata

ANTILOCK BRAKE SYSTEM LOCATION INDEX

Fig. 1: Identifying Antilock Brake System Components Location

Courtesy of MAZDA MOTORS CORP.

ABS SYSTEM DIAGRAM

2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

Fig. 2: ABS System Diagram

Courtesy of MAZDA MOTORS CORP.

ABS HU/CM SYSTEM INSPECTION

SYSTEM INSPECTION

Preparation

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

1. Verify that the battery is fully charged. With the ignition switch on, verify that the ABS and BRAKE system warning lights goes out after 3 seconds .

2. If the lights stays on after 3 seconds , the ABS HU/CM detects a failure. Follow the troubleshooting procedures.

3. Turn the ignition switch off.

4. On level ground, jack up the vehicle and support it evenly on safety stands. Shift the transaxle to N position.

5. Release the parking brake.

6. Rotate the wheels by hand, and inspect for brake drag.

USING THE SSTS

1. Perform the " PREPARATION ".

2. Connect the SSTs (WDS or equivalent) to the data link connector-2 (DLC-2).

3. Set up an active command mode inspection according to the combination of commands below. (See ABS

ON-BOARD DIAGNOSIS .)

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2005 Mazda MX-5 Miata

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Fig. 3: Locating Connector-2 (DLC-2)

Courtesy of MAZDA MOTORS CORP.

OPERATION

Pressure retention

Pressure reduction

PMP_MOTOR

COMMAND NAME

RF_OUTLET

OFF

RF_INLET

OFF

COMMAND

TYPE

Manual

The chart above shows an example of a right wheel inspection.

NOTE:



When working with two people, one should press on the brake pedal, the other should attempt to rotate the wheel being inspected.

4. Send the command while pressing on the brake pedal and attempting to rotate the wheel being inspected.

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

5. When pressure is being maintained, and click sound indicating the solenoid is operating comes from the

ABS HU/CM, confirm that the wheel does not rotate. When pressure is being reduced, and click sound indicating the solenoid is operating comes from the ABS HU/CM, confirm that the wheel rotates, even though the brake pedal is being depressed.

NOTE:



To protect the ABS HU/CM, the solenoid valve used for simulations and the ABS motor stay on for 10 seconds each time they are switched on.

Performing the inspections above determines the following.



The ABS HU/CM brake lines are normal.

The ABS HU/CM hydraulic system is not significantly abnormal.



The ABS HU/CM wiring is normal.

However, the following items cannot be checked.



ABS HU/CM input system harness and parts

Extremely small leaks in the ABS HU/CM internal hydraulic system

Unusual intermittent occurrences in the above items

WITHOUT USING THE SSTS

1. Perform the PREPARATION .

CAUTION:



Connecting to the wrong data link connector (DLC) terminal may cause a malfunction. Carefully connect only to the specified terminal.

2. Use a jumper wire to short terminal TBS of the DLC to body GND.

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2005 Mazda MX-5 Miata

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Fig. 4: Using Jumper Wire To Short Terminal TBS Of DLC To Body GND

Courtesy of MAZDA MOTORS CORP.

3. Depress the brake pedal, and have an assistant verify that the right front wheel does not turn.

4. With the brake pedal still depressed, turn the ignition switch on and verify that the brake is released momentarily ( approx.0.5 seconds ) and that the wheel turns when pressure-reduction operates.

5. Inspect the operation of the remaining wheels in order: right front, left front, rear.



Replace the ABS HU/CM if wheels do not rotate.

 Inspect brake piping to ABS HU/CM if operation of the remaining wheel order is not within specified.

NOTE:



If Steps 4 and 5 show correct operation, the following systems are okay:



Brake piping to ABS HU/CM



Braking system, including ABS HU/CM



Electrical system in ABS HU/CM (solenoid, ABS motor, etc.)

The following are not inspected with above steps:



Input system and harness of ABS HU/CM



Intermittent failure

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata



Fluid leakage from brake including the ABS HU/CM and master cylinder

Fig. 5: Antilock Brake System Inspecting Pattern

Courtesy of MAZDA MOTORS CORP.

6. Turn the ignition switch off and remove the jumper wire.

ABS HU/CM REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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Fig. 6: Exploded View Of ABS HU/CM & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CONNECTOR REMOVAL NOTE

1. Pull the lock lever to disconnect the connector.

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2005 BRAKES Antilock Brake System - MX-5 Miata

Fig. 7: Disconnecting Connector

Courtesy of MAZDA MOTORS CORP.

BRAKE PIPE REMOVAL NOTE

1. Mark the brake pipe connecting positions before removal for reference during installation.

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

Fig. 8: Identifying Brake Pipe Connecting Positions Mark

Courtesy of MAZDA MOTORS CORP.

ABS HU/CM REMOVAL/INSTALLATION NOTE

1. When removing/installing the ABS HU/CM from/to the vehicle, attach a strip of protective tape on the

ABS HU/CM connector to prevent brake fluid from entering.

BRAKE PIPE INSTALLATION NOTE

1. When installing the brake pipe, align the marks made before removal with the ABS HU/CM as shown in

Fig. 9 .

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

Fig. 9: Identifying Brake Pipe Connecting Positions

Courtesy of MAZDA MOTORS CORP.

CONNECTOR INSTALLATION NOTE

1. Verify that the lock lever is completely pushed in.

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

Fig. 10: Pushing In Lock Lever Is Completely

Courtesy of MAZDA MOTORS CORP.

ABS HARNESS AND INPUT SIGNAL INSPECTION

1. Disconnect the ABS HU/CM connector with the ignition switch at OFF.

CAUTION:



Be careful not to damage the terminals during inspection.

2. Insert a thin isolation plate to the short bar of the connector (asterisk shown in Fig. 11 ) and open circuit between terminal D and E, D and F.

3. Attach a wire to the tester lead to avoid damaging the terminals then inspect voltage, resistance or continuity, referring to the table below.

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2005 Mazda MX-5 Miata

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Fig. 11: Identifying ABS CM Connector Terminals And Reference Table (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

Fig. 12: Identifying ABS CM Connector Terminals And Reference Table (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

INSPECTION USING AN OSCILLOSCOPE (REFERENCE) WHEEL SPEED

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

Fig. 13: Wheel Speed Wave Form Pattern

Courtesy of MAZDA MOTORS CORP.



ABS HU/CM terminal:

RF:P (+)-O (-)

RR:N (+)-L (-)

I_F:R (+)-Q (-)

LR:T (+)-S (-)



Oscilloscope setting:0.2 V/DIV (Y), 4 ms/DIV (X), AC range

Vehicle condition: When turned 1 revolution per second

NOTE:



As vehicle speed increase, period of wave shorten.

If malfunctioning in the sensor rotor, wave profile warp.

FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

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Fig. 14: Exploded View Of Front ABS Wheel-Speed Sensor & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

FRONT ABS WHEEL-SPEED SENSOR INSPECTION

CLEARANCE INSPECTION

1. Remove the wheel and tire, and inspect the sensor for looseness and damage. Replace the sensor as necessary.

2. Verify the clearance between the ABS wheel-speed sensor and the sensor rotor.

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

Fig. 15: Identifying Clearance Between ABS Wheel-Speed Sensor And Sensor Rotor

Courtesy of MAZDA MOTORS CORP.



If not as specified, replace the ABS wheel-speed sensor or sensor rotor as necessary.

Clearance

0.3-1.1 mm {0.012-0.043 in}

RESISTANCE INSPECTION

1. Disconnect the ABS wheel-speed sensor connector.

2. Inspect for resistance at the ABS wheel-speed sensor.

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2005 Mazda MX-5 Miata

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Fig. 16: Inspecting Resistance At ABS Wheel-Speed Sensor

Courtesy of MAZDA MOTORS CORP.

Resistance

1.0-2.0 kilohm

VOLTAGE INSPECTION

1. On level ground, jack up the vehicle and support it evenly on safety stands.

2. Disconnect the ABS wheel-speed sensor connector.

3. Inspect each wheel by rotating it at one revolution per second.



If not as specified, replace the ABS wheel-speed sensor or sensor rotor as necessary.

Voltage

0.25-2.0 V (AC)

REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION

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2005 Mazda MX-5 Miata

2005 BRAKES Antilock Brake System - MX-5 Miata

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

Fig. 17: Exploded View Of Rear ABS Wheel-Speed Sensor & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

REAR ABS WHEEL-SPEED SENSOR INSPECTION

1. Inspect the rear ABS wheel-speed sensor in the same procedure as the front ABS wheel-speed sensor.

(See FRONT ABS WHEEL-SPEED SENSOR INSPECTION .)

Microsoft

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

2005 TRANSMISSION

Automatic Transmission - MX-5 Miata

AUTOMATIC TRANSMISSION LOCATION INDEX

2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 1: Identifying Automatic Transmission Components

Courtesy of MAZDA MOTORS CORP.

AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

See TRANSMISSION .

MECHANICAL SYSTEM TEST

MECHANICAL SYSTEM TEST PREPARATION

1. Apply the parking brake and use wheel chocks at the front and rear of the wheels.

2. Inspect the engine coolant. (See ENGINE COOLANT LEVEL INSPECTION .)

3. Inspect the engine oil. (See ENGINE OIL LEVEL INSPECTION .)

4. Inspect the ATF levels. (See ATF LEVEL INSPECTION .)

5. Inspect the ignition timing. (See ENGINE TUNE-UP .)

6. Inspect the idle speed. (See ENGINE TUNE-UP .)

LINE PRESSURE TEST

1. Perform mechanical system test preparation. (See MECHANICAL SYSTEM TEST PREPARATION .)

WARNING:



Removing the plug when the ATF is hot can be dangerous. Hot

ATF can come out of the opening and cause severe burns.

Before removing the plug, allow the ATF to cool.

2. Connect the SSTs to the line pressure inspection port.

3. Shift the selector lever to D range and read the line pressure at idle.

4. Connect the SST to the line pressure inspection port.

CAUTION:



If the accelerator pedal (AP) is pressed for longer than 5 seconds while the brake pedal is pressed, the transmission could be damaged. Therefore, perform both Steps 5 and 6 within 5 seconds.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 2: Connecting SSTs To Line Pressure Inspection Port

Courtesy of MAZDA MOTORS CORP.

5. Firmly depress the brake pedal with the left foot, and gently depress the AP to the floor with the right.

6. When the engine speed no longer increases, quickly read the line pressure and release the AP.

7. Shift the selector lever to the N position and let the engine idle for 1 minute or more to cool the ATF.

8. Read the line pressure at idle and at the engine stall speed for the 2, 1 ranges, and R position in the same manner.

SPECIFIED LINE PRESSURE

Position/Range

D, 2, 1

Line pressure kPa {kgf/cm2, psi}

Idle Stall

370-420 {3.7- 4.2, 53-59} 960-1,110 {9.8- 11.4, 140-162}

R 520-580 {5.3- 5.9, 76-83} 1,270-1,520 {13.0-15.4, 185- 218}

WARNING:



Removing the SST when the ATF is hot can be dangerous. Hot

ATF can come out of the opening and cause severe burns.

Before removing the SST, allow the ATF to cool.

9. Remove the SSTs.

10. Apply ATF to a new O-ring.

11. Install the O-ring to the plug.

12. Install a plug in the inspection port.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Tightening torque

5.9-8.8 N.m {60-90 kgf.cm, 53-78 in.lbf}

EVALUATION OF LINE PRESSURE TEST

Line pressure

Low pressure in all ranges

Low pressure in D range

Low pressure in R position

Possible cause

Primary regulator valve sticking

Throttle valve sticking

Throttle cable misadjustment

Worn oil pump

Oil is leaking from hydraulic circuit of D range

Oil is leaking from hydraulic circuit of R position

High pressure in all ranges

Primary regulator valve sticking

Throttle valve sticking

Throttle cable misadjustment

STALL TEST

1. Perform mechanical system test preparation. (See MECHANICAL SYSTEM TEST PREPARATION .)

2. Shift the selector lever to the R position.

CAUTION:



If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is pressed, the transmission could be damaged. Therefore, perform both Steps 3 and 4 within 5 seconds.

3. Firmly depress the brake pedal with the left foot, and gently depress the accelerator pedal (AP) to the floor with the right.

4. When the engine speed no longer increases, quickly read the speed and release the AP.

5. Shift the selector lever to the N position and let the engine idle for 1 minute or more to cool the ATF.

6. Perform a stall test of D, 2, and 1 ranges in the same manner.

Engine stall speed

2,370-2,740 rpm

EVALUATION OF STALL TEST

Condition

In D range

Microsoft

Saturday, July 04, 2009 10:21:41 AM

Possible cause

Insufficient line pressure



Forward clutch slipping



One-way clutch No.2 slipping

Insufficient line pressure

2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Above specification



Direct clutch slipping

In R position

In all range and R position



Reverse brake slipping

Insufficient line pressure

Below specification



4GR clutch or one-way clutch No.O slipping

Engine out of tune

One-way clutch slipping in torque converter

TIME LAG TEST

1. Perform mechanical system test preparation. (See MECHANICAL SYSTEM TEST PREPARATION .)

2. Shift the selector lever from the N position to D range. (O/D OFF switch OFF)

3. Use a stopwatch to measure the time it takes from shifting until engagement is felt. Make three measurements for each test and take the average from the results.

4. Perform the test for the following shifts in the same manner. a. N position --> D range (O/D OFF SW ON) b. N position --> R position

Time lag

N position --> D range: 0.7 sec.

N position --> R position: 1.2 sec.

EVALUATION OF TIME LAG TEST

Condition Possible cause

Insufficient line pressure

N --> D select Forward clutch slipping

One-way clutch NO.2 slipping

N --> R select

Insufficient line pressure

Direct clutch slipping

Reverse brake slipping

ROAD TEST

ROAD TEST PREPARATION

1. Inspect the engine coolant. (See ENGINE COOLANT LEVEL INSPECTION .)

2. Inspect the engine oil. (See ENGINE OIL LEVEL INSPECTION .)

3. Inspect the ATF levels. (See AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION .)

4. Inspect the idle speed and ignition timing. (See ENGINE TUNE-UP .)

5. Bring up the engine and transmission to normal operating temperature.

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2005 TRANSMISSION Automatic Transmission - MX-5 Miata

TYPICAL SHIFT DIAGRAM

Fig. 3: Typical Shift Diagram

Courtesy of MAZDA MOTORS CORP.

SHIFT SCHEDULE TEST

1. Drive the vehicle with wide open throttle, half throttle, closed throttle position and kickdown, and verify that following shifts are obtained. The shift points must be as shown in the table below.



GR-->2GR, 2GRh ->3GR, and 3GR-->4GR upshifts and downshifts are obtained in D range (O/D

OFF switch OFF).



1GR-->2GR and 2GR-->3GR upshifts and downshifts are obtained in D range (O/D OFF switch

ON).

2GR is held in 2 range.



1GR is held in 1 range.

2. Decelerate the vehicle and verify that engine braking effect is felt in 4GR.

3. Drive the vehicle and verify that TCC operation is obtained in 3GR and 4GR in D range.

NOTE:



The shift solenoid electrical ON-OFF pattern is this chart describes the stabilized condition before and after shift control. The pattern may oscillate between ON and OFF momentarily while shifting-up or down. This is normal.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

VEHICLE SPEED AT SHIFT POINT

Range/Mode

D range (O/D OFF switch OFF)

Throttle condition

Wide open throttle

Half throttle

Shift

Vehicle speed

(km/h {mph})

1GR-->2GR 58-64 {36-40}

Shift solenoid A

2GR-->3GR 102-110 (63-68} ON-->OFF

3GRh-->4GR 157-167 (97-103} OFF

1GR-->2GR 33-42 {20-26}

2GR-->3GR 59-76 {37-47}

ON-->OFF

3GR TCC operation

94-106 (58-65}

3GR-->4GR 85-112 (52-69}

4GR TCC operation

81-109 (50-67}

OFF

D range (O/D OFF switch ON)

Closed throttle position

Kickdown (wide open throttle)

Wide open throttle

Half throttle

Shift solenoid B

OFF-->ON

ON-->OFF

OFF-->ON

ON-->OFF

OFF

4GR-->3GR 17-23 (11-14}

3GR-->1GR 5-11 {3-6}

4GR-->3GR 145-155 (90-96}

OFF OFF-->ON

OFF-->ON ON-->OFF

OFF OFF-->ON

3GR-->2GR 95-103 (59-63} OFF-->ON

2GR-->1GR 42-48 {26-29} ON

1GR-->2GR 58-64 {36-40} ON

ON-->OFF

OFF-->ON

2GR-->3GR

1GR-->2GR

2GR-->3GR

3GR TCC operation

102-110 (63-68}

33-42 {20-26}

59-76 {37-47}

94-106 (58-65}

ON-->OFF

OFF

OFF-->ON

Closed throttle position

3GR-->1GR 5-11 {3-6} OFF-->ON ON-->OFF

Kickdown (wide open throttle)

3GR-->2GR 95-103 (59-63} OFF-->ON

2GR-->1GR 42-48 {26-29} ON

3GR-->2GR 101-107 (63-66} OFF-->ON

2GR-->1GR 35-41 {22-25} ON

ON-->OFF

NOISE AND VIBRATION TEST

1. Drive the vehicle and listen closely for any noise or vibration. The torque converter, drive shaft, and differential can be sources of noise and vibration if they are not functioning properly. Inspect these when searching for sources of noise and vibration.

P POSITION TEST

1. Shift into P position on a gentle slope. Release the brake, and verify that the vehicle does not roll.



If the vehicle rolls, inspect the AT. (See AUTOMATIC TRANSMISSION SYMPTOM

TROUBLESHOOTING .)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION

ATF CONDITION INSPECTION

1. One way of determining whether the transmission should be disassembled is by noting:



If the ATF is muddy or varnished.



If the ATF smells strange or unusual.

If ATF condition is poor, repair as follows. i. Dark color condition



Overhaul transmission and repair or replace parts if necessary. ii. Light pink and/or reddish-brown condition.



Replace ATF.

ATF condition

ATF CONDITION POSSIBLE CAUSE

Condition

Clear red Normal -

Light red (pink)

Reddish brown

Has burnt smell

Contaminated with water and metal pieces

Deteriorated are found

Has no burnt smell

ATF

Normal

Possible cause



Broken oil cooler inside of radiator

Poor breather hose installation:

By water contamination, problem could be occurring to parts inside of transmission. It is necessary to overhaul transmission and detect defective parts.



If necessary, repair or replace transmission.

Defective powertrain components inside of transmission:

Specks cause wide range of problems by plugging up in oil pipe, control valve body, and oil cooler in radiator.



When large amount of specks are found. Overhaul transmission and detect defective parts.



If necessary, repair or replace transmission.

Implement flushing operation as there is a possibility of having specks plugged up oil pipe and/or oil cooler inside of radiator.



Discoloration by oxidation.

ATF LEVEL INSPECTION

CAUTION:



The ATF amount varies according to ATF temperature. Therefore,

Microsoft

2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata when checking the ATF level or replacing the ATF, use a thermometer to measure the temperature then adjust the ATF amount to the specified level according to the specified temperature.

1. Park the vehicle on level ground.

2. Apply the parking brake and position wheel chocks securely to prevent the vehicle from rolling.

3. Adjust the length of thermistor probe measure to the measure same as the dipstick and hold the probe with a paper holder.

Fig. 4: Adjusting Length Of Thermistor Probe Measure To Measure Same As Dipstick

Courtesy of MAZDA MOTORS CORP.

4. Insert into the filler tube and measure the temperature.

5. Inspect the ATF level before warming up the engine. In this case, use the cool range (15- 25°C {59-77°

F}).

6. Warm up the engine until the ATF reaches 60- 70°C{140-158°F}.

7. While depressing the brake pedal, shift the selector lever to each range (P-1), pausing momentarily in each range.

8. Shift back to the P position.

9. While the engine is idling, verify that the ATF level is in the HOT 65°C {149°F} range.



Adjust ATF level to the specification, if necessary.

ATF type

M-III or equivalent (e.g.Dexron(R)III)

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2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 5: Identifying Hot And Cool Range

Courtesy of MAZDA MOTORS CORP.

AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT

WARNING:



Hot transmissions and ATF can cause severe burns. Turn off the engine and wait until the transmission and ATF are cool before replacing the ATF.

1. Remove the dipstick.

2. Remove the drain plug and washer.

3. Drain the ATF into a container.

4. Install a new washer and the drain plug.

Tightening torque

18-22 N.m {1.8-2.3 kgf.m, 14-16 in.lbf}

5. Add the specified amount and type of ATF through the oil filler tube.

ATF type

M-III or equivalent (e.g.Dexron°III)

Fill amount (approx.quantity)

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2005 TRANSMISSION Automatic Transmission - MX-5 Miata

6.7 L {7.1 US qt, 5.9 Imp qt}

6. Install the dipstick.

7. Verify that the ATF level is in the HOT 65°C {149°F} range.



Add ATF to the specified level if necessary.

THROTTLE CABLE INSPECTION

1. Verify that the throttle cable is adjusted within dimension A as show in the figure below when the throttle cable is in closed throttle position.



If it is not within specification, adjust the throttle cable. (See THROTTLE CABLE

ADJUSTMENT .)

Dimension A

0.8-1.5 mm {0.03-0.05 in}

Fig. 6: Adjusting Throttle Cable

Courtesy of MAZDA MOTORS CORP.

THROTTLE CABLE ADJUSTMENT

Microsoft

1. Loosen nuts A and B.

2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 7: Tightening Throttle Cable

Courtesy of MAZDA MOTORS CORP.

2. Put nut B in the direction of the arrow as shown in the figure, with the throttle lever in closed throttle position. Then tighten the nut by hand.

NOTE:



Tighten nut A by pushing it down so that the throttle cable will not come off from the bracket.

3. Tighten nut A with the throttle lever totally closed.

Tightening torque

12-16 N.m {1.2-1.7 kgf.m, 8.7-12.2 ft.lbf}

Microsoft

2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 8: Identifying Closed Throttle Position

Courtesy of MAZDA MOTORS CORP.

4. Verify that the throttle cable moves smoothly.

5. Verify that there is no deflection, and that the throttle cable is adjusted within dimension A as shown in

Fig. 9 below when the throttle cable is in closed throttle position.

Dimension A

0.8-1.5 mm {0.03-0.05 in}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 9: Adjusting Throttle Cable Within Dimension A

Courtesy of MAZDA MOTORS CORP.

THROTTLE CABLE REMOVAL/INSTALLATION

ON-VEHICLE REMOVAL

1. Disconnect the negative battery cable.

2. Clean the transmission exterior thoroughly with a steam cleaner or cleaning solvents.

3. Drain the ATF into separate suitable containers. (See AUTOMATIC TRANSMISSION FLUID (ATF)

REPLACEMENT .)

4. Remove the throttle cable from the throttle lever.

5. Remove the oil pan and gasket.

CAUTION:



To prevent deformation of the tube, remove the tube by pulling both ends up.

6. Remove the tube.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 10: Removing Tube

Courtesy of MAZDA MOTORS CORP.

7. Disconnect the shift solenoids A, B, and torque converter clutch solenoid valve connectors.

8. Remove the oil strainer.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 11: Removing Oil Strainer

Courtesy of MAZDA MOTORS CORP.

9. Remove the control valve body installation bolts.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 12: Removing Control Valve Body Bolts

Courtesy of MAZDA MOTORS CORP.

10. Remove the nipple of the throttle cable from the throttle cam.

11. Remove the control valve body.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 13: Removing Control Valve Body

Courtesy of MAZDA MOTORS CORP.

12. Remove the accumulator spring.

13. Remove the throttle cable from the transmission case using a 10 mm {0.4 in} socket wrench.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 14: Removing Throttle Cable From Transmission Case Using Socket Wrench

Courtesy of MAZDA MOTORS CORP.

14. Remove the throttle cable.

15. Remove the O-ring from the throttle cable.

ON-VEHICLE INSTALLATION

1. Apply ATF to a new O-ring.

2. Install the O-ring to the throttle cable.

3. Install the throttle cable.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 15: Installing Throttle Cable

Courtesy of MAZDA MOTORS CORP.

4. Install the nipple of the throttle cable to the throttle cam.

5. Verify that the manual valve and manual shaft are assembled correctly.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 16: Identifying Manual Valve And Manual Shaft Assembly

Courtesy of MAZDA MOTORS CORP.

6. Install the control valve body.

Tightening torque

7.9-11.7 N.{80-120 kgf.cm, 70-104 in.lbf}

NOTE:



Step 7 is for the throttle cable replacement only.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 17: Installing Control Valve Body

Courtesy of MAZDA MOTORS CORP.

7. With throttle cable installed to the throttle cam, bend near the center of the throttle cable to a radius of

200 mm {7.87 in} . Then, pull the throttle cable until there is no play or just before the throttle cam starts to move, and stake the adjustment mark at the position shown in the figure.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 18: Bending Throttle Cable

Courtesy of MAZDA MOTORS CORP.

8. Install the oil strainer.

Tightening torque

5.0-5.8 N.m {50-60 kgf.cm, 44-52 in.lbf}

9. Connect the shift solenoids A, B, and torque converter clutch solenoid valve connectors.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 19: Connecting Shift Solenoids And Torque Converter Clutch Solenoid Valve Connectors

Courtesy of MAZDA MOTORS CORP.

10. Install the tube.

11. Install the new gasket and oil pan.

Tightening torque

4.0-4.9 N.m {40-50 kgf.cm, 35-43 in.lbf}

12. Install the throttle cable to the throttle lever.

13. Adjust the throttle cable. (See THROTTLE CABLE ADJUSTMENT .)

14. Add ATF to the specified level. (See AUTOMATIC TRANSMISSION FLUID (ATF)

REPLACEMENT .)

15. Carry out mechanical test. (See MECHANICAL SYSTEM TEST .)

16. Carry out road test. (See ROAD TEST .)

O/D OFF SWITCH INSPECTION

INSPECTION OF OPERATION

1. Turn the ignition switch from OFF to ON.

2. Verify that the O/D OFF indicator light is not illuminated. Depress the O/D OFF switch and verify that the O/D OFF indicator light illuminates.



If not as specified, inspect the terminal voltage of the O/D OFF switch.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

INSPECTION OF VOLTAGE

1. Remove the rear console.

2. Turn the ignition switch to the ON position.

3. Measure the voltage at the O/D OFF switch connector.



If not as specified, inspect for continuity at the O/D OFF switch.

Position

Normal

Depressed

Connector terminal (V)

B+

4. Install the rear console.

Fig. 20: Identifying O/D Off Switch Connector Terminals

Courtesy of MAZDA MOTORS CORP.

INSPECTION OF CONTINUITY

1. Disconnect the negative battery cable.

2. Remove the rear console.

3. Disconnect the O/D OFF switch connector.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

4. Inspect for continuity at the O/D OFF switch.



If not as specified, replace the selector lever knob component.

If the switch is okay, inspect the wiring harness. (O/D OFF switch - transmission control module,

O/D OFF switch - Body ground.)

Fig. 21: Identifying Harness Side Connector (View From Terminal Side)

Courtesy of MAZDA MOTORS CORP.

Fig. 22: Inspecting O/D Off Switch Continuity

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

5. Install the rear console.

6. Connect the negative battery cable.

O/D OFF SWITCH REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the rear console.

3. Disconnect the connector and remove the O/D OFF switch terminals. (See SELECTOR LEVER

DISASSEMBLY/ASSEMBLY .)

4. Remove the selector lever knob component.

5. Install a selector lever knob component.

Tightening torque

2.0-2.9 N.m {20-30 kgf.cm, 18-26 in.lbf}

6. Install the O/D OFF switch terminals and connect the connector. (See SELECTOR LEVER

DISASSEMBLY/ASSEMBLY .)

7. Install the rear console.

8. Connect the negative battery cable.

TRANSMISSION RANGE (TR) SWITCH INSPECTION

INSPECTION OF OPERATION

1. Verify that the starter operates only with the ignition switch at the START position and selector lever in the P/N position.

2. Verify that the back-up lights illuminate when shifted to the R position with the ignition switch at the ON position.



If not as specified, inspect the continuity of the TR switch.

INSPECTION OF CONTINUITY

1. Inspect the OBD trouble code. (See DTC TABLE .)

2. Remove the TR switch. (See TRANSMISSION RANGE (TR) SWITCH

REMOVAL/INSTALLATION .)

3. Inspect for continuity at the TR switch.



If not as specified, replace the TR switch.

Range/position Terminals Continuity

D-C

Yes

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

I-B

Other

I-F

Other

D-C

I-J

Other

I-H

Other

I-E

Other

I-G

Other

Yes

Fig. 23: Identifying TR Switch Connector (View From Terminal Side)

Courtesy of MAZDA MOTORS CORP.

4. Install the TR switch. (See TRANSMISSION RANGE (TR) SWITCH

REMOVAL/INSTALLATION .)

TRANSMISSION RANGE (TR) SWITCH REMOVAL/INSTALLATION

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

1. Disconnect the negative battery cable.

2. Disconnect the TR switch connector.

3. Remove the selector rod from the manual shaft lever.

4. Remove the manual shaft lever.

5. Remove the staking of the lock washer using a screwdriver.

6. Remove the nut, lock washer, and packing.

7. Remove the TR switch.

8. Rotate the manual shaft to the N position.

9. Hand-tighten the TR switch bolt.

10. Install a new packing.

11. Install a new lock washer.

12. Tighten the nut.

Tightening torque

3.0-4.9 N.m {30-50 kgf.cm, 27-43 in.lbf}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 24: Installing Nut

Courtesy of MAZDA MOTORS CORP.

13. Bend claws of the lock washer.

14. Adjust the TR switch. (See TRANSMISSION RANGE (TR) SWITCH ADJUSTMENT .)

15. Tighten the TR switch mounting bolt.

Tightening torque

4.0-6.8 N.m {40-70 kgf.cm, 35-60 in.lbf}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 25: Tightening TR Switch Mounting Bolt

Courtesy of MAZDA MOTORS CORP.

16. Rotate the manual shaft to the P position.

17. Install the manual shaft lever.

18. Install the selector rod to the manual shaft lever.

TRANSMISSION RANGE (TR) SWITCH ADJUSTMENT

1. Disconnect the negative battery cable.

2. Remove the selector rod from the manual shaft lever.

3. Rotate the manual shaft to the N position.

4. Loosen the TR switch mounting bolt.

5. Align the cut groove in the switch with the neutral reference line.

6. Tighten the TR switch mounting bolt.

Tightening torque

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

4.0-6.8 N.m {40-70 kgf.cm, 35-60 in.lbf}

7. Install the selector rod to the manual shaft lever.

8. Connect the negative battery cable.

9. Inspect the operation of the TR switch. (See TRANSMISSION RANGE (TR) SWITCH

INSPECTION .)

Fig. 26: Adjusting Transmission Range (TR) Switch

Courtesy of MAZDA MOTORS CORP.

INPUT/TURBINE SPEED SENSOR INSPECTION

1. Remove the bracket and front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

2. Disconnect the input/turbine speed sensor connector.

NOTE:



Resistance value of the input/turbine speed sensor varies with temperature. Normal resistance value occurs when the temperature is 20°C {68°F} , but it may be abnormal at high temperatures.

Therefore, do not determine the resistance value only at 20°C {68°F}.

3. Measure the resistance between the terminals of the input/turbine speed sensor.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata



If not correct, replace the input/turbine speed sensor.

Resistance

560-680 ohms (20°C {68° F})

4. Connect the input/turbine speed sensor connector.

5. Install the front pipe and bracket. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

6. Connect the negative battery cable.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 27: Input/Turbine Speed Sensor Part Side Connector Graph

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the bracket and front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

3. Disconnect the input/turbine speed sensor connector.

4. Remove the input/turbine speed sensor.

5. Remove the O-ring from the input/turbine speed sensor.

6. Apply ATF to a new O-ring.

7. Install the O-ring to the input/turbine speed sensor.

8. Install the input/turbine speed sensor.

Tightening torque

5.8-8.8 N.m {59-90 kgf.cm, 52-78 in.lbf}

9. Connect the input/turbine speed sensor connector.

10. Install the front pipe and bracket. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

11. Connect the negative battery cable.

OUTPUT SPEED SENSOR INSPECTION

1. Disconnect the output speed sensor connector.

2. Remove the output speed sensor.

NOTE:



Resistance value of the output speed sensor varies with temperature.

Normal resistance value occurs when the temperature is 20°C {68°F} , but it may be abnormal at high temperatures. Therefore, do not determine the resistance value only at 20°C {68°F}.

3. Measure the resistance between the terminals of the output speed sensor.



If not correct, replace the output speed sensor.

Resistance

387-473 ohms (20°C {68°F})

4. Install the output speed sensor.

Tightening torque

5.0-6.8 N.m {50-70 kgf.cm, 44-60 in.lbf}

5. Connect the output speed sensor connector.

6. Connect the negative battery cable.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 28: Output Speed Sensor Part Side Connector Graph

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

OUTPUT SPEED SENSOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Disconnect the output speed sensor connector.

3. Remove the output speed sensor from the transmission

4. Apply ATF to a new O-ring.

5. Install the O-ring to the output speed sensor.

6. Install the output speed sensor to the transmission.

Tightening torque

5.0-6.8 N.m {50-70 kgf.cm, 44-60 in.lbf}

7. Connect the output speed sensor connector.

8. Connect the negative battery cable.

SOLENOID VALVES INSPECTION

INSPECTION OF SOLENOID VALVES

1. Inspect the OBD trouble code. (See DTC TABLE .)

2. Remove the solenoid valves. (See SOLENOID VALVES REMOVAL/INSTALLATION .)

NOTE:



Resistance value of the solenoid valve varies with temperature.

Normal resistance value occurs when the temperature is 20°C {68°F} , but it may be abnormal at high temperatures. Therefore, do not determine the resistance value only at 20°C {68°F}.

3. Measure the resistance between solenoid valve terminals.



If not correct, replace the solenoid valves.

Solenoid

Shift solenoid B

Shift solenoid A

Torque converter clutch solenoid valve

Resistance (ohm)

11-15

4. Install the solenoid valves. (See SOLENOID VALVES REMOVAL/INSTALLATION .)

5. Connect the solenoid valve connector.

6. Connect the negative battery cable.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 29: Solenoid Valve Part Side Connector Graph

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

OPERATING INSPECTION

1. Disconnect the negative battery cable.

2. Remove the solenoid valves. (See SOLENOID VALVES REMOVAL/INSTALLATION .)

3. Apply the voltage at terminal and listen for a ' "click" sound at all solenoid valves.



If a "click" is not heard, replace the solenoid valve.

4. Install the solenoid valves. (See SOLENOID VALVES REMOVAL/INSTALLATION .)

5. Connect the solenoid valve connector.

6. Connect the negative battery cable.

Fig. 30: Inspecting Solenoid Valve Operation

Courtesy of MAZDA MOTORS CORP.

FAIL-SAFE FUNCTION

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

FAIL-SAFE FUNCTION

Gear/solenoid condition

Required gear position

Shift solenoid A malfunction

Shift solenoid B malfunction

Shift solenoids A and B both malfunction

D range 2 range 1 range

1GR 2GR 3GR 4GR 2GR 1GR

3GR 3GR 3GR 4GR 3GR

1GR 4GR 4GR 4GR 3GR

4GR 4GR 4GR 4GR 3GR

1GR

SOLENOID VALVES REMOVAL/INSTALLATION

1. Clean the transmission exterior thoroughly with a steam cleaner or cleaning solvents.

2. Disconnect the negative battery cable.

3. Drain the ATF. (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT .)

4. Remove the oil pan and gasket.

CAUTION:



To prevent deformation of the tube, remove the tube by pulling both ends up.

5. Remove the tubes.

Fig. 31: Removing Tubes

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

6. Disconnect the shift solenoids A, B and torque converter clutch solenoid valve connectors.

Fig. 32: Disconnecting Shift Solenoids & Torque Converter Clutch Solenoid Valve Connectors

Courtesy of MAZDA MOTORS CORP.

7. Remove the solenoid valve.

8. Apply ATF to a new O-ring.

9. Install the O-ring to the torque converter clutch solenoid valve.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 33: Identifying Torque Converter Clutch Solenoid Valve

Courtesy of MAZDA MOTORS CORP.

10. Install a new gasket and solenoid valve to the control valve body.

Tightening torque

A: 7.9-11.7 N.m {80-120 kgf.cm, 70-104 in.lbf}

B: 5.0-5.8 N.m {50-60 kgf.cm, 44-52 in.lbf}

11. Connect shift solenoids A, B, and torque converter clutch solenoid valve connectors.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 34: Connecting Shift Solenoids And Torque Converter Clutch Solenoid Valve Connectors

Courtesy of MAZDA MOTORS CORP.

12. Install the tubes.

13. Install the new gasket and oil pan.

Tightening torque

4.0-4.9 N.m {40-50 kgf.cm, 35-43 in.lbf}

14. Add ATF to the specified level. (See AUTOMATIC TRANSMISSION FLUID (ATF)

REPLACEMENT .)

15. Carry out mechanical test. (See MECHANICAL SYSTEM TEST .)

16. Carry out road test. (See ROAD TEST .)

TRANSMISSION CONTROL MODULE (TCM) INSPECTION

1. Turn the ignition switch to the ON position, and inspect the TCM terminal voltage, referring to the

Terminal Voltage Chart.



If any TCM terminal voltage is incorrect, inspect the related input of output devices and wiring.

If no problem is found, replace the TCM.

NOTE:



Use the ground of terminal AP of the TCM when measuring terminal

Microsoft

2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata voltage as an error may occur when the negative (-) lead of the circuit tester is connected to ground.

TERMINAL VOLTAGE TABLE (REFERENCE DATA)

Fig. 35: Transmission Control Module (TCM) Terminal Voltage Reference Table (1 Of 4)

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 36: Transmission Control Module (TCM) Terminal Voltage Reference Table (2 Of 4)

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 37: Transmission Control Module (TCM) Terminal Voltage Reference Table (3 Of 4)

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 38: Transmission Control Module (TCM) Terminal Voltage Reference Table (4 Of 4)

Courtesy of MAZDA MOTORS CORP.

INPUT/OUTPUT PULSE (REFERENCE)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Input/turbine speed sensor



Connecting terminal: W (+)-AP (-)



Measuring device setting: 1V/DIV (Y) 5 ms/DIV (X)

 Measuring condition: Idle

Fig. 39: Turbine Speed Sensor Graph

Courtesy of MAZDA MOTORS CORP.

Vehicle speed signal



Connecting terminal: AC (+)-AP (-)

Measuring device setting: 1V/DIV (Y) 5ms/DIV (X)



Measuring condition: Vehicle speed at 30 km/h {18.6 mph}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 40: Vehicle Speed Signal Graph

Courtesy of MAZDA MOTORS CORP.

Output speed sensor



Connecting terminal: AF (+)-AP (-)



Measuring device setting: 1V/DIV (Y) 5ms/DIV (X)

Measuring condition: Vehicle speed at 30 km/h {18.6 mph}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 41: Output Speed Sensor Graph

Courtesy of MAZDA MOTORS CORP.

Engine speed signal



Connecting terminal: AG (+)-AP (-)



Measuring device setting: 2V/DIV (Y) 5 ms/DIV (X)

Measuring condition: Idle

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 42: Engine Speed Signal Graph

Courtesy of MAZDA MOTORS CORP.

TRANSMISSION CONTROL MODULE (TCM) REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Disconnect the TCM connector.

3. Remove the TCM.

4. Install the TCM.

Tightening torque

36 N.m {3.7 kgf.m, 27 ft.lbf}

5. Connect the TCM connector.

6. Connect the negative battery cable.

AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Drain the ATF. (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT .)

3. Remove the cross member bracket. (16-inch wheel model) (See CROSSMEMBER BRACKET

REMOVAL/INSTALLATION .)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

4. Remove the rear crossbar. (16-inch wheel model) (See REAR CROSSMEMBER

REMOVAL/INSTALLATION .)

5. Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

6. Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)

WARNING:



Improperly jacking a transmission is dangerous. It can slip off the jack and cause serious injury.

7. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 43: Removing Automatic Transmission - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

9. Add ATF to the specified level. (See AUTOMATIC TRANSMISSION FLUID (ATF)

REPLACEMENT .)

10. Connect the negative battery cable.

11. Inspect the operation of the transmission range switch. (See INSPECTION OF OPERATION .)

12. Inspect the operation of the selector lever. (See SELECTOR LEVER INSPECTION .)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

13. Carry out the mechanical system test. (See MECHANICAL SYSTEM TEST .)

14. Carry out the road test. (See ROAD TEST .)

POWER PLANT FRAME (PPF) REMOVAL NOTE

1. Disconnect the wire harness from the power plant frame.

2. Support the transmission on a jack.

Fig. 44: Supporting Transmission On Jack

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

3. Remove the front bolts.

Fig. 45: Removing Font Bolt

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

4. Remove the differential side bolts, and pry out the bolt spacer.

Fig. 46: Removing Bolt Spacer

Courtesy of MAZDA MOTORS CORP.

5. Remove the differential mounting spacer.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 47: Removing Differential Mounting Spacer

Courtesy of MAZDA MOTORS CORP.

6. Remove the transmission side bolts, and remove the PPF. Do not remove the spacers from the PPF.



If the spacers are removed, replace the PPF as a component.

NOTE:



If the sleeve cannot be removed easily, tap the side of the sleeve with a plastic hammer.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 48: Warning Against Removing Spacers From PPF

Courtesy of MAZDA MOTORS CORP.

7. Remove the sleeve.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 49: Removing Sleeve

Courtesy of MAZDA MOTORS CORP.

TRANSMISSION REMOVAL NOTE

1. Set the transmission onto the transmission jack, paying special attention not to damage the oil pipes.

Make sure that the torque converter side of the transmission is tilted slightly upward during removal.

Carefully lower the transmission from the vehicle.

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2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 50: Removing Transmission

Courtesy of MAZDA MOTORS CORP.

TRANSMISSION INSTALLATION NOTE

1. Set the transmission onto the transmission jack, paying special attention not to damage the oil pipes.

Make sure that the torque converter side of the transmission is tilted slightly upward.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 51: Installing Transmission

Courtesy of MAZDA MOTORS CORP.

TORQUE CONVERTER BOLTS INSTALLATION NOTE

1. Align the holes while turning the torque converter.

2. Lock the drive plate using a screwdriver.

3. Hand-tighten the torque converter mounting bolts in a crisscross pattern.

4. Modify the torque converter mounting bolts tightening torque to allow for a torque wrench SST

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata combination.

(See TORQUE FORMULAS .)

5. Tighten the torque converter mounting bolts using the SST.

Tightening torque

35-49 N.m {3.5-5.0 kgf.m, 26-36 ft.lbf}

Fig. 52: Tightening Torque Converter Mounting Bolts Using SST

Courtesy of MAZDA MOTORS CORP.

POWER PLANT FRAME (PPF) INSTALLATION NOTE

1. Install the differential mounting spacer.

2. Support the transmission on a jack so that it is level.

3. Position the PPF and install the sleeve.

4. Install the spacer and bolts, and tighten the reamer bolt firmly. The reamer bolt should be installed in the forward hole.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 53: Installing Differential Mounting Spacer

Courtesy of MAZDA MOTORS CORP.

5. Tighten the outer bolts snugly.

Tightening torque

104-123 N.m {10.6-12.6 kgf.m, 77-91 ft.lbf}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 54: Tightening Outer Bolts

Courtesy of MAZDA MOTORS CORP.

6. Tighten the bolts to the specified torque in the order shown.

Tightening torque

104-123 N.m {10.6-12.6 kgf.m, 77-91 ft.lbf}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 55: Tightening Bolts In Sequence

Courtesy of MAZDA MOTORS CORP.

7. Remove the jack.

8. Measure distance A using a straightedge and vernier calipers.



If the distance is not within the specification, reposition the power plant frame at the transmission.

Distance A

50.5-62.5 mm {1.99-2.46 in}

Fig. 56: Measuring Distance A

Courtesy of MAZDA MOTORS CORP.

EXTENSION HOUSING REMOVAL/INSTALLATION

1. Clean the transmission exterior thoroughly using a steam cleaner or cleaning solvent.

2. Disconnect the negative battery cable.

3. Drain the ATF. (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT .)

4. Disconnect the output speed sensor connector.

5. Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

6. Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

7. Support the transmission on a jack.

Fig. 57: Supporting Transmission On Jack

Courtesy of MAZDA MOTORS CORP.

8. Remove the power plant frame.

9. Remove the extension housing and gasket.

10. Install a new gasket and extension housing on the transmission case.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Tightening torque

24-41 N.m {2.4-4.2 kgf.m, 18-30 ft.lbf}

11. Install the power plant frame.

12. Install the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)

13. Install the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

14. Connect the speed sensor connector.

15. Add ATF to the specified level. (See ATF LEVEL INSPECTION .)

16. Carry out the line pressure test. (See LINE PRESSURE TEST .)

17. Carry out the road test. (See ROAD TEST .)

Fig. 58: Removing Extension Housing And Gasket

Courtesy of MAZDA MOTORS CORP.

OIL SEAL (TRANSMISSION) REPLACEMENT

1. Clean the transmission exterior thoroughly using a steam cleaner or cleaning solvent.

2. Drain the ATF. (See ATF LEVEL INSPECTION .)

3. Remove the exhaust pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

4. Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

5. Remove the oil seal using the SST.

6. Apply ATF to a new oil seal lip.

Fig. 59: Removing Oil Seal Using SST

Courtesy of MAZDA MOTORS CORP.

7. Install the oil seal to the position shown in the figure within dimension A as follows using the convex part of the SST.

Dimension A

6.2-6.8 mm {0.25-0.26 in}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 60: Installing Oil Seal Using SST

Courtesy of MAZDA MOTORS CORP.

8. Install the retainer to dimension B position using the concave part of the SST.

Dimension B

0.7-1.3 mm {0.03-0.05 in}

9. Install the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)

10. Install the exhaust pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .)

11. Add ATF to the specified level. (See ATF LEVEL INSPECTION .)

12. Carry out the line pressure test. (See LINE PRESSURE TEST .)

13. Carry out the road test. (See ROAD TEST .)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 61: Installing Retainer Using SST

Courtesy of MAZDA MOTORS CORP.

CONTROL VALVE BODY REMOVAL/INSTALLATION

ON-VEHICLE REMOVAL

1. Clean the transmission exterior thoroughly with a steam cleaner or cleaning solvents.

2. Disconnect the negative battery cable.

3. Drain the ATF. (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT .)

4. Remove the oil pan and gasket.

CAUTION:



To prevent deformation of the tube, remove the tube by pulling both ends up.

5. Remove the tubes.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 62: Removing Tube

Courtesy of MAZDA MOTORS CORP.

6. Disconnect shift solenoids A, B, and torque converter clutch solenoid valve connectors.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 63: Disconnecting Shift Solenoids And Torque Converter Clutch Solenoid Valve Connectors

Courtesy of MAZDA MOTORS CORP.

7. Remove the oil strainer.

8. Remove the control valve body installation bolts.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 64: Removing Control Valve Body Bolts

Courtesy of MAZDA MOTORS CORP.

9. Remove the nipple of the throttle cable from the throttle cam.

10. Remove the control valve body.

11. Remove the accumulator spring.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 65: Removing Control Valve Body

Courtesy of MAZDA MOTORS CORP.

ON-VEHICLE INSTALLATION

1. Set the accumulator springs into the control valve body as shown.

2. Install the nipple of the throttle cable to the throttle cam.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 66: Installing Control Valve Body

Courtesy of MAZDA MOTORS CORP.

3. Verify that the manual valve and manual shaft are assembled correctly.

4. Install the control valve body.

Tightening torque

7.9-11.7 N.m {80-120 kgf.cm, 70-104 in.lbf}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 67: Installing Control Valve Body

Courtesy of MAZDA MOTORS CORP.

5. Install the oil strainer.

Tightening torque

5.0-5.8 N.m {50-60 kgf.cm, 44-52 in.lbf}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 68: Installing Oil Strainer

Courtesy of MAZDA MOTORS CORP.

6. Connect shift solenoids A, B, and torque converter clutch solenoid valve connectors.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 69: Connecting Shift Solenoids And Torque Converter Clutch Solenoid Valve Connectors

Courtesy of MAZDA MOTORS CORP.

7. Install the tubes.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 70: Installing Tubes

Courtesy of MAZDA MOTORS CORP.

8. Install the new gasket and oil pan.

Tightening torque

4.0-4.9 N.m {40-50 kgf.cm, 35-43 in.lbf}

9. Add ATF to the specified level. (See AUTOMATIC TRANSMISSION FLUID (ATF)

REPLACEMENT .)

10. Carry out the mechanical test. (See MECHANICAL SYSTEM TEST .)

11. Carry out the road test. (See ROAD TEST .)

TORQUE CONVERTER REMOVAL/INSTALLATION

1. Remove the transmission. (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION .)

CAUTION:



The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the splines contact the oil seal.

2. Remove the torque converter, and immediately turn it so that the hole faces upward. This will help to keep any remaining fluid from spilling.

3. Drain any ATF remaining in the torque converter.

4. Pour in solvent (approx.0.50 L {0.53 Us qt, 0.44 Imp qt}).

5. Shake the torque converter to clean the inside. Pour out the solvent.

6. Install the torque converter in the converter housing while rotating it to align the splines.

7. To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing.

Distance A

22.7 mm {0.894 in}

8. Install the transmission. (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION .)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 71: Installing Torque Converter In Converter Housing

Courtesy of MAZDA MOTORS CORP.

OIL COOLER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Drain the ATF. (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT .)

3. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 72: Removing Oil Cooler - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

5. Add ATF to the specified level. (See AUTOMATIC TRANSMISSION FLUID (ATF)

REPLACEMENT .)

6. Connect the negative battery cable.

7. Inspect for oil leakage from the oil pipes and oil hoses.

8. Inspect the ATF level and condition. (See ATF LEVEL INSPECTION .)

9. Carry out the mechanical system test. (See MECHANICAL SYSTEM TEST .)

10. Carry out the road test. (See ROAD TEST .)

ELBOW INSTALLATION NOTE

1. Apply ATF to the O-ring, then install it to the elbow.

2. Install the elbows in the angle shown in Fig. 73 , then tighten the nut.

Tightening torque

Microsoft

2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

34 N.m {3.5 kgf.m, 25 ft.lbf}

Fig. 73: Installing Elbow

Courtesy of MAZDA MOTORS CORP.

RADIATOR (IN TANK OIL COOLER) INSTALLATION NOTE

1. The automatic transmission oil cooler flushing must be performed whenever a transmission is removed for service to remove existing fluid which may be contaminated to prevent contamination of new fluid.

The flushing must be performed after installation of the overhauled or replaced transmission.

2. Follow the instruction in the manufacturers publication for flushing operation.

OIL HOSE INSTALLATION NOTE

CAUTION:



In order to prevent ATF leakage, replace the hose when any damage is found inside or outside of the hose, especially on areas contacting with pipes.

1. Apply compressed air to cooler-side opening, and blow any remaining dust and foreign material from the cooler pipes. Compressed air should be applied for no less than one minute.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 74: Applying Compressed Air To Cooler-Side

Courtesy of MAZDA MOTORS CORP.

2. Align the marks, and slide the oil cooler hose onto the oil cooler pipe until it is fully seated as shown.

Fig. 75: Aligning Marks

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

3. Install the hose clamp onto the hose.

 If reusing the hose, install a new hose clamp exactly onto the mark left by the previous hose clamp.

4. Verify that the hose clamp does not interfere with any other parts.

Fig. 76: Installing Hose Clamp

Courtesy of MAZDA MOTORS CORP.

DRIVE PLATE REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

Fig. 77: Removing Drive Plate - With Torque Specifications

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

2. Install in the reverse order of removal.

DRIVE PLATE MOUNTING BOLTS REMOVAL NOTE

1. Set the SST against the drive plate.

2. Remove the bolts and the drive plate.

Fig. 78: Identifying Drive Plate

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

DRIVE PLATE MOUNTING BOLTS INSTALLATION NOTE

1. Set the SST against the drive plate.

2. Tighten the drive plate mounting bolts gradually in the order shown.

Tightening torque

97-102 N.m {9.8-10.5 kgf.m, 71-75 ft.lbf}

Microsoft

2005 Mazda MX-5 Miata

2005 TRANSMISSION Automatic Transmission - MX-5 Miata

Fig. 79: Tightening Drive Plate Mounting Bolts In Sequence

Courtesy of MAZDA MOTORS CORP.

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2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

2005 ACCESSORIES & EQUIPMENT

Body Panels - MX-5 Miata

FUEL-FILLER LID REMOVAL/INSTALLATION

1. Remove the bolts, then remove the fuel-filler lid.

Fig. 1: Removing Fuel-Filler Lid

Courtesy of MAZDA MOTORS CORP.

2. Install in the reverse order of removal.

3. Adjust the fuel-filler lid. (See FUEL-FILLER LID ADJUSTMENT .)

FUEL-FILLER LID ADJUSTMENT

1. Measure the gap and height between the fuel-filler lid and the body panel.



If not as specified, loosen the fuel-filler lid installation bolts and reposition the fuel-filler lid.

Clearance

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata a:2.5-4.5 mm {0.10-0.17 in} b:-1.0-1.0 mm {-0.03-0.03 in}

2. Tighten the bolts.

Fig. 2: Adjusting Fuel Filler Lid

Courtesy of MAZDA MOTORS CORP.

HOOD REMOVAL/INSTALLATION

WARNING:



The hood may fall and injure you. Always perform these procedures together with at least another person.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

1. To remove the hood hinge, remove the front fender panel. (See FRONT FENDER PANEL

REMOVAL/INSTALLATION .)

2. Remove in the order indicated in the table.

Fig. 3: Removing Hood - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

4. Adjust the hood. (See HOOD ADJUSTMENT .)

HOOD ADJUSTMENT

1. Measure the gap and height between the hood and the body.



If not as specified, adjust the gap and height.

Clearance a:4.1-7.1 mm {0.16-0.28 in} b:-1.8-1.2 mm {-0.07-0.47 in} c:3.3-5.7 mm {0.13-0.23 in}

2. Adjust the hood lock after the hood has been aligned.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 4: Adjusting Hood

Courtesy of MAZDA MOTORS CORP.

GAP ADJUSTMENT

1. Loosen the hood installation nuts and reposition the hood.

2. Tighten the nuts.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 5: Adjusting Hood Gap

Courtesy of MAZDA MOTORS CORP.

HEIGHT ADJUSTMENT

1. Turn the stop rubber to adjust the height of the hood.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 6: Adjusting Hood Height

Courtesy of MAZDA MOTORS CORP.

TRUNK LID REMOVAL/INSTALLATION

WARNING:



Removing the balance spring without supporting the trunk lid can be dangerous. The trunk lid may fall and injure you. Open the trunk lid fully and support it before removing the balance spring. Perform these procedures together with another person.

1. Disconnect the negative battery cable.

2. Remove the rear package trim. (See REAR PACKAGE TRIM REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 7: Removing Trunk Lid

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

5. Adjust the trunk lid. (See TRUNK LID ADJUSTMENT .)

BALANCE SPRING REMOVAL NOTE

NOTE:



The balance springs are under high tension.

1. Carefully lift the balance spring using a tape-wrapped screwdriver.

2. Remove the balance spring.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 8: Removing Balance Spring

Courtesy of MAZDA MOTORS CORP.

TRUNK LID ADJUSTMENT

CLEARANCE

1. Measure the gap between the trunk lid and the body panel.



If not as specified, loosen the trunk lid installation nuts and reposition the trunk lid.

Clearance a:3.5-6.5 mm {0.14-0.25 in} b:3.8-6.2 mm {0.15-0.24 in}

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 9: Adjusting Trunk Lid

Courtesy of MAZDA MOTORS CORP.

2. Tighten the trunk lid installation nuts.

Tightening torque

7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf}

3. Adjust the trunk lid striker after the trunk lid has been aligned.

TENSION

1. Slide the balance spring to the desired position as described below using a tape-wrapped screwdriver.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 10: Adjusting Tension

Courtesy of MAZDA MOTORS CORP.

NOTE:



The trunk lid should rise 50-300 mm {2.0-11.8 in} when the trunk lid is unlocked.

SET POSITIONS TENSION REFERENCE

Set position

Standard

Tension

Increase

Decrease

Hook bracket

Right side

Left side

Right side

Left side

Right side

Left side a

(1)

(1) b

(1)

(1) Position

FRONT BUMPER REMOVAL/INSTALLATION

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

1. Disconnect the negative battery cable.

2. Disconnect the front fog light connector. (With front fog light)

3. Remove in the order indicated in the table.

Fig. 11: Removing Front Bumper - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

REAR BUMPER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the license plate.

3. Remove the rear combination light. (See REAR COMBINATION LIGHT

REMOVAL/INSTALLATION .)

4. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 12: Removing Rear Bumper - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

FRONT FENDER PANEL REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION .)

3. Remove the front side maker light.

4. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Body Panels - MX-5 Miata

Fig. 13: Removing Front Fender Panel

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

Microsoft

2005 BRAKES Conventional Brake System - MX-5 Miata

2005 BRAKES

Conventional Brake System - MX-5 Miata

CONVENTIONAL BRAKE SYSTEM LOCATION INDEX

2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 1: Identifying Conventional Brake System Components Location

Courtesy of MAZDA MOTORS CORP.

AIR BLEEDING

NOTE:



The brakes should be bled whenever a brake line is disconnected. If a hydraulic line is disconnected at the master cylinder, start at the brake caliper or wheel cylinder farthest from the brake master cylinder, and move to the next farthest brake caliper or wheel cylinder until all cylinders four cylinders have been bled. If the disconnection point is anywhere except the master cylinder, start at the point closest to the disconnection, and move to the next closest brake caliper or wheel cylinder until all four have been bled.

1. On level ground, jack up the vehicle and support it evenly on safety stands.

2. Remove the bleeder cap and attach a vinyl tube to the bleeder screw.

3. Place the other end of the vinyl tube in a clear, fluid-filled container.

4. The first person depresses the brake pedal a few times, and then holds it in the depressed position.

5. The second person loosens the bleeder screw, drains out the fluid and closes the screw using the SST .

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 2: Bleeding Air From Brake System

Courtesy of MAZDA MOTORS CORP.

6. Repeat step 4 and 5 until no air bubbles are seen. The reservoir should be kept about 3/4 full during bleeding to prevent air from reentering the lines.

Tightening torque

5.9-8.8 N.m {60-90 kgf.cm, 53-78 in.lbf}

7. Inspect for correct brake operation.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

8. Verify that there is no fluid leakage. Wipe off any spilled fluid immediately.

9. After bleeding the brakes, add brake fluid to the maximum level.

VACUUM LINE INSPECTION

1. Remove the clamps and vacuum hose.

2. Apply both suction and pressure to the engine-side hose, and verify that air blows only toward that side.



If air flows in both directions or not at all, replace the vacuum hose.

Fig. 3: Inspecting Vacuum Line

Courtesy of MAZDA MOTORS CORP.

BRAKE PEDAL INSPECTION

BRAKE PEDAL HEIGHT INSPECTION

1. Verify that the distance from the center of the upper surface of the pedal pad to the carpet is as specified.

Pedal height (reference value)

171-181 mm {6.74-7.12 in} (With carpet)

BRAKE PEDAL PLAY INSPECTION

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

1. Depress the pedal a few times to eliminate the vacuum in the system.

2. Gently depress the pedal by hand until resistance is felt, and inspect for the free play.

Free play

4.0-12.0 mm {0.16-0.47 in}

PEDAL-TO-FLOOR CLEARANCE INSPECTION

1. Verify that the distance from the floor panel to the center of the upper surface of the pedal pad is as specified when the pedal is depressed with a force of 588 N {60 kgf, 132 lbf} .

 If the distance is less than specified, inspect for air in the brake system.

Pedal-to-floor clearance

95 mm {3.7 in} min. (Without carpet)

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 4: Inspecting Pedal-To-Floor Clearance

Courtesy of MAZDA MOTORS CORP.

BRAKE PEDAL ADJUSTMENT

BRAKE PEDAL HEIGHT ADJUSTMENT

1. Disconnect the brake switch connector.

2. Loosen locknut B and turn switch A until it does not contact the pedal.

3. Loosen locknut D and turn rod C to adjust the height.

4. Tighten the bolt with locknut B so that clearance between the bolt for brake switch A and pedal stopper is within the specification.

Specification

0.1-1.0 mm {0.004-0.039 in}

Tightening torque

13.8-17.6 N.m {140-180 kgf.cm, 122-156 in.lbf}

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 5: Identifying Clearance Between Bolt For Brake Switch And Pedal Stopper

Courtesy of MAZDA MOTORS CORP.

5. Connect the brake switch connector.

6. After adjustment, inspect the pedal play and the brake light operation.

PEDAL PLAY ADJUSTMENT

1. Remove the spring pin and the clevis pin. (See BRAKE PEDAL REMOVAL/INSTALLATION .)

2. Loosen locknut D and turn rod C to align the holes in the fork and in the pedal.

3. Install the clevis pin and the spring pin.

4. Verify the pedal height and the brake light operation.

Tightening torque

Microsoft

2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

24-34 N.m {2.4-3.5 kgf.m, 18-25 ft.lbf}

Fig. 6: Identifying Locknut And Turn Rod

Courtesy of MAZDA MOTORS CORP.

BRAKE PEDAL REMOVAL/INSTALLATION

1. Disconnect the brake switch connector.

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

4. After installation, verify and adjust the pedal height and free play as necessary.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 7: Exploded View Of Brake Pedal & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

BRAKE SWITCH INSPECTION

1. Disconnect the brake switch connector.

2. Inspect for continuity between the terminals of the brake switch connector using the circuit tester.



If not as specified, replace the brake switch.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 8: Brake Switch Connector Continuity Condition Table

Courtesy of MAZDA MOTORS CORP.

Fig. 9: Identifying Brake Switch Connectors

Courtesy of MAZDA MOTORS CORP.

MASTER CYLINDER REMOVAL/INSTALLATION

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

1. Remove the cruise actuator.

(See CRUISE ACTUATOR REMOVAL/INSTALLATION .)

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

Fig. 10: Exploded View Of Master Cylinder & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

MASTER CYLINDER INSTALLATION NOTE

1. Turn the nut of the SST clockwise to fully retract the SST gauge rod. Attach the SST to the power brake unit.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Tightening torque

9.8-16 N.m {1.0-1.6 kgf.m, 7.3-11 ft.lbf}

2. Apply a 66.7 kPa {500 mmHg, 19.7 inHg} vacuum by using a vacuum pump.

Fig. 11: Attaching SST To Power Brake Unit

Courtesy of MAZDA MOTORS CORP.

3. Turn the adjusting nut of the SST counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and SST body.

4. Remove the SST from the power brake unit without disturbing the adjusting nut. Set the SST onto the master cylinder as shown in Fig. 12 .

CAUTION:



When pushing the SST gauge rod into the master cylinder piston, only use enough pressure to push the rod to the bottom of the piston. If too much pressure is applied, a false reading will occur.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 12: Identifying Adjusting Nut Of SST

Courtesy of MAZDA MOTORS CORP.

5. Push lightly on the end of the SST gauge rod to be sure it has contacted the bottom of the master cylinder piston, but do not push so hard that the piston moves. Note any clearance between the SST body and the adjusting nut (clearance B) or between the body and the master cylinder (clearance C).

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 13: Push Rod Measurement

Courtesy of MAZDA MOTORS CORP.

Measurement Push rod

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Clearance at (B) Too short

Clearance at (C)

No clearance at (B) or (C)

Too long

ADJUSTING THE PUSH ROD CLEARANCE AT B

NOTE:



The threads of the push rod are specially designed so that the bolt becomes harder to turn past a certain point. This is to prevent the bolt from coming loose. Turn the bolt only within this range when adjusting.

1. Push lightly on the end of the SST gauge rod, and measure the clearance between the adjusting nut and the SST body.

Fig. 14: Adjusting Push Rod Clearance At B

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

2. Using the SST , turn the nut to lengthen the power booster push rod an amount equal to the sum subtracting 0.1-0.4 mm {0.004-0.016 in} from the clearance measured at B.

Fig. 15: Turning Nut To Lengthen Power Booster Push Rod Using SST

Courtesy of MAZDA MOTORS CORP.

ADJUSTING THE PUSH ROD CLEARANCE AT C OR NO CLEARANCE AT B OR C

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

NOTE:



1. Measure and record height D1 of the gauge rod.

2. Turn the adjusting nut until the SST body sets squarely on the master cylinder. (Turn only enough for the body to touch.)

Fig. 16: Measuring Height D1 Of Gauge Rod

Courtesy of MAZDA MOTORS CORP.

3. Measure and record height D2 of the gauge rod.

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 17: Measuring Height D2 Of Gauge Rod

Courtesy of MAZDA MOTORS CORP.

4. Subtract D1 from D2 and add 0.1-0.4 mm {0.004-0.016 in} . Using the SST , turn the nut to shorten the power booster push rod an amount equal to the sum.

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 18: Turning Nut To Shorten Power Booster Push Rod Using SST

Courtesy of MAZDA MOTORS CORP.

FLUID LEVEL SENSOR INSPECTION

1. Disconnect the sensor connector.

2. Connect an ohmmeter to the connector.

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 19: Connecting Ohmmeter To Connector

Courtesy of MAZDA MOTORS CORP.

3. Starting with the fluid level above MIN, verify that there is no continuity.

4. Remove the brake fluid and verify that there is continuity when the level is below MIN.



If not as specified, replace the sensor.

MASTER CYLINDER DISASSEMBLY/ASSEMBLY

1. After removing the brake fluid, disassemble in the order indicated in the table,

2. Assemble in the reverse order of disassembly.

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Fig. 20: Exploded View Of Master Cylinder & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

STOP SCREW AND O-RING (WITHOUT ABS) ASSEMBLY NOTE

1. Push the primary piston component in fully.

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Fig. 21: Pushing Primary Piston Component In Fully

Courtesy of MAZDA MOTORS CORP.

2. Install and tighten a new O-ring and the stop screw.

3. Push and release the piston to verify that it is held by the stop screw.

STOP PIN AND O-RING (WITH ABS) ASSEMBLY NOTE

1. Install the secondary piston component with the piston hole facing the stop pin.

2. Install and tighten a new O-ring and the stop pin.

3. Push and release the piston to verify that it is held by the stop pin.

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Fig. 22: Installing New O-Ring And Stop Pin

Courtesy of MAZDA MOTORS CORP.

POWER BRAKE UNIT INSPECTION

POWER BRAKE UNIT FUNCTION INSPECTION (SIMPLE METHOD)

Step 1

1. With the engine stopped, depress the pedal a few times.

2. With the pedal depressed, start the engine.



If the pedal moves down slightly immediately after the engine starts, the unit is operating.

Step 2

1. Start the engine.

2. Stop the engine after it has run for 1 or 2 minutes .

3. Depress the pedal with the usual force.

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2005 Mazda MX-5 Miata

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

If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating.



If a problem is found, inspect for damage or improper connection of the check valve or vacuum hose. Repair if necessary and inspect it once again.

Step 3

1. Start the engine.

2. Depress the pedal with the usual force.

3. Stop the engine with the pedal held depressed.

4. Hold the pedal down for about 30 seconds .



If the pedal height does not change, the unit is operating.



If there is a problem, inspect for damage or improper connection of the check valve or vacuum hose. Repair if necessary and inspect it once again.

If the nature of the problem is still not clear after following the 3 steps above, follow the more detailed inspect described in INSPECTION USING GAUGES .

POWER BRAKE UNIT FUNCTION INSPECTION (INSPECTION USING GAUGES)

1. Connect the SST gauges, a vacuum gauge, and a pedal depression gauge as shown in Fig. 23 . Bleed the air from the SST gauges before performing the following tests.

Fig. 23: Connecting SST Gauges, Vacuum Gauge And Pedal Depression Gauge

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2005 BRAKES Conventional Brake System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Checking for vacuum loss (unloaded condition)

1. Start the engine.

2. Stop the engine when the vacuum gauge indicates 66.7 kPa {500 mmHg, 19.7 inHg} .

3. Observe the vacuum gauge for 15 seconds .



If the gauge indicates 63.4-66.6 kPa {475-500 mmHg, 18.8-19.6 inHg} , the unit is operating.

Checking for vacuum loss (loaded condition)

1. Start the engine.

2. Depress the brake pedal with a force of 196 N {20 kgf, 44 lbf} .

3. With the brake pedal held depressed, stop the engine when the vacuum gauge indicates 66.7 kPa {500 mmHg, 19.7 inHg} .

4. Observe the vacuum gauge for 15 seconds .



If the gauge indicates 63.4-66.6 kPa {475-500 mmHg, 18.8-19.6 inHg} , the unit is operating.

Checking for hydraulic pressure

1. With the engine is stopped (vacuum 0 kPa {0 mmHg, 0 inHg} ) and the fluid pressure is within the specification, the unit is operating.

Pedal force Fluid pressure

196 N {20 kgf, 44 lbf} 740 kPa {7.55 kgf/cm2,107 psi}

2. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa {500 mmHg, 19.7 inHg} .



If the fluid pressure is within specification, the unit is operating.

Pedal force

196 N {20 kgf, 44 lbf}

Fluid pressure

With ABS (BP with TC (vehicle equipped with 17 inch wheel)):4,700 kPa {48 kgf/cm2, 683 psi}

With ABS (vehicle equipped with 15 and 16 inch wheel):7,200 kPa {73 kgf/cm2,

1,038 psi}

Without ABS (vehicle equipped with 16 inch wheel):4,700 kPa {48 kgf/cm2, 683 psi}

Without ABS (vehicle equipped with 15 inch wheel):7,200 kPa {73 kgf/cm2, 1,038 psi}

POWER BRAKE UNIT REMOVAL/INSTALLATION

1. Remove the master cylinder and the proportioning bypass valve (without ABS) and brake pipe joint (with

ABS).

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2005 BRAKES Conventional Brake System - MX-5 Miata

(See MASTER CYLINDER REMOVAL/INSTALLATION .)

2. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 24: Removing Power Brake Unit & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

VACUUM HOSE INSTALLATION NOTE

1. Install the vacuum hose to the power brake unit and intake manifold as shown in Fig. 25 .

Fig. 25: Installing Vacuum Hose To Power Brake Unit And Intake Manifold

Courtesy of MAZDA MOTORS CORP.

PROPORTIONING BYPASS VALVE INSPECTION [WITHOUT ABS]

1. Connect the SSTs and the adapters to the brake pipes as shown in Fig. 26 .

2. Bleed the air from the brake system.

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 26: Connecting SSTs And Adapters To Brake Pipes

Courtesy of MAZDA MOTORS CORP.

3. Measure the fluid pressure from the master cylinder and to the rear brakes.



If not as specified, replace the valve component.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 27: Master Cylinder And To Rear Brakes Fluid Pressure Specifications

Courtesy of MAZDA MOTORS CORP.

Master Cylinder Pressure - Rear Brake Pressure Graph

Fluid pressure kPa {kgf/cm2, psi}

A A'

3,923 {40, 569} 3,923 {40, 569} +/-294

{3, 43}

B B'

5,884 {60, 853} 4,844 {49.4, 702} +/-392 {4, 57}

PROPORTIONING BYPASS VALVE (WITHOUT ABS) OR BRAKE PIPE JOINT

(WITH ABS) REPLACEMENT

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 28: Removing Brake Pipe Joint (With ABS) Or Proportioning Bypass Valve (Without ABS) &

Torque Specifications

Courtesy of MAZDA MOTORS CORP.

FRONT BRAKE (DISC) INSPECTION

BRAKE JUDDER REPAIR HINT

Description

1. Brake judder concern has the following 3 characteristics:

Steering wheel vibration

1. Steering wheel vibrates in the direction of its rotation. This characteristic is most noticeable when applying brakes at a vehicle speed of 100-140 km/h {62.1-86.8 mph} .

Floor vibration

1. When applying brakes, the vehicle body shakes back and forth. The seriousness of shake is not influenced by vehicle speed.

Brake pedal vibration

1. When applying brakes, a pulsating force tries to push the brake pad back occurs. The pulsation is transmitted to the brake pedal.

2. The following are the main possible causes of brake judder:

Due to an excessive runout (side-to-side wobble) of disc plate, the thickness of disc plate is uneven.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

1. If the runout is more than 0.05 mm {0.002 in} at the position 10 mm {0.39 in} from the disc plate edge, an uneven wear occurs on the disc plate because the pad contacts the plate unevenly.

2. If the runout is less than 0.05 mm {0.002 in} , uneven wear does not occur.

The disc plate is deformed by heat.

1. Repeated panic braking may raise the temperature in some portions of disc plate by approximately 1,000

°C {1,832 °F} . This results in deformed disc plate.

Due to corrosion, the thickness and friction coefficient of disc plate change.

1. If a vehicle is parked under damp conditions for a long time, corrosion occurs on the friction surface of disc plate.

2. The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the friction coefficient and causes a reaction force.

Inspection and repair procedure

Fig. 29: Inspection And Repair Procedure Flow Chart

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2005 BRAKES Conventional Brake System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Lateral runout inspection

1. To secure the disc plate and the hub, tighten the hub nuts upside down or insert a washer (thickness 10 mm {0.39 in} , inner diameter more than 12 mm {0,47 in} ) between the hub bolt and the hub nut.

NOTE:



The component parts of the SST (49 B017 001 or 49 G019 003) can be used as a suitable washer.

2. After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of disc plate

10 mm {0.39 in} from the disc plate edge.

3. Rotate the disc plate one time and measure the runout.

Runout limit

0.05 mm {0.002 in}

Thickness variation inspection

1. Clean the disc plate-to-pad friction surface using a brake cleaner.

2. Measure the points indicated in Fig. 30 using a caliper (micrometer).

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 30: Identifying Measuring Points

Courtesy of MAZDA MOTORS CORP.

3. Subtract the minimum value from the maximum, and if the result is not within specification, machine the disc plate using a lathe.

Thickness variation limit

0.015 mm {0.00059 in}

WARNING:

Microsoft

2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata



Do not exceed minimum disc plate thickness.

DISC PLATE THICKNESS INSPECTION

CAUTION:



Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine the disc plate while installed on the vehicle.

1. Measure the thickness of the disc plate.



If the thickness is not within the specification, replace the disc plate.

DISC PLATE MINIMUM THICKNESS SPECIFICATION

Disk plate outer diameter 255 mm {10.0 in}

Disk plate outer diameter 270 mm {10.6 in}

18.0 mm {0.71 in}

20.0 mm {0.79 in}

MINIMUM THICKNESS AFTER MACHINING

Disk plate outer diameter 255 mm {10.0 in}

Disk plate outer diameter 270 mm {10.6 in}

18.8 mm {0.74 in}

20.8 mm {0.82 in}

DISC PAD THICKNESS INSPECTION

1. Jack up the front of the vehicle and support it with safety stands.

2. Remove the wheels.

3. Verify the remaining thickness of the pads.

Thickness

2.0 mm {0.08 in} min.

4. Replace the pads as a set: right and left wheels, if either one is at or less than the minimum thickness.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 31: Inspecting Disc Pad Thickness

Courtesy of MAZDA MOTORS CORP.

FRONT BRAKE (DISC) REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 32: Exploded View Of Front Brake (Disc) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

DISC PLATE REMOVAL NOTE

1. Mark the wheel hub bolt and disc plate before removal for reference during installation.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 33: Identifying Mark On Wheel Hub Bolt And Disc Plate

Courtesy of MAZDA MOTORS CORP.

DISC PLATE INSTALLATION NOTE

1. Remove any rust or grime on the contact face of the disc plate and wheel hub.

2. Install the disc plate and align the marks made before removal.

DISC PAD INSTALLATION NOTE

1. Push the piston inward using the SST .

2. Install the new pads in the mounting support.

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 34: Pushing Piston Inward Using SST

Courtesy of MAZDA MOTORS CORP.

DISC PAD (FRONT) REPLACEMENT

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 35: Exploded View Of Disc Pad (Front) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CALIPER (FRONT) DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 36: Exploded View Of Caliper (Front) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

PISTON DISASSEMBLY NOTE

1. Place a piece of wood in the caliper.

2. Gently blow compressed air through the hole to force the piston out of the caliper.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 37: Placing Piece Of Wood In Caliper

Courtesy of MAZDA MOTORS CORP.

PISTON SEAL DISASSEMBLY NOTE

1. Remove the piston seal using the SST .

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 38: Removing Piston Seal Using SST

Courtesy of MAZDA MOTORS CORP.

REAR BRAKE (DISC) INSPECTION

BRAKE JUDDER REPAIR HINT

(See BRAKE JUDDER REPAIR HINT .)

DISC PAD THICKNESS INSPECTION

1. On level ground, jack up the rear of the vehicle and support it with safety stands.

2. Remove the wheels.

3. Look through the caliper inspection hole and verify the remaining thickness of the pad.

Thickness

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

2.0 mm {0.08 in} min.

DISC PLATE THICKNESS INSPECTION

1. Measure the thickness of the disc plate.



If the thickness is not within the specification, replace the disc plate.

CAUTION:



When it is necessary to machine the disc plate, if the disc plate is removed from the vehicle then machined, excessive runout may result. Machine the disc plate with it installed on the vehicle.

Minimum thickness:

8.0 mm {0.31 in}

Minimum thickness after machining by using a brake lathe on-vehicle:

8.4 mm {0.33 in}

DISC PLATE RUNOUT INSPECTION

1. Tighten the disc plate to the wheel hub using two wheel nuts. When measuring runout, measure at the outer edge of the disc plate surface.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 39: Measuring Disc Plate Runout

Courtesy of MAZDA MOTORS CORP.

Runout limit

0.05 mm {0.002 in} max.

REAR BRAKE (DISC) REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 40: Exploded View Of Rear Brake (Disc) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

DISC PAD INSTALLATION NOTE

1. Turn the manual adjustment gear counterclockwise using an Allen wrench to pull the brake caliper piston back.

2. Install the disc pads.

3. Turn the manual adjustment gear clockwise until the brake pads just touch the disc plate.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 41: Identifying Retracting Piston

Courtesy of MAZDA MOTORS CORP.

4. Return the manual adjustment gear counterclockwise 1/3 turn.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 42: Identifying Adjusting Brake Pads

Courtesy of MAZDA MOTORS CORP.

DISC PAD (REAR) REPLACEMENT

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 43: Exploded View Of Disc Pad (Rear) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CALIPER (REAR) DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

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2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 44: Exploded View Of Caliper (Rear) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

PISTON DISASSEMBLY NOTE

1. Turn the manual adjustment gear clockwise using an Allen wrench. (Turn the manual adjustment gear until it turns easily.)

2. Remove the piston.

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 45: Turning Manual Adjustment Gear Clockwise Using An Allen Wrench

Courtesy of MAZDA MOTORS CORP.

PISTON ASSEMBLY NOTE

1. Insert the piston into the caliper and turn the adjustment gear counterclockwise using an Allen wrench to pull the piston in fully. (Turn the adjustment gear until it stops.)

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2005 Mazda MX-5 Miata

2005 BRAKES Conventional Brake System - MX-5 Miata

Fig. 46: Turning Adjustment Gear Counterclockwise Using An Allen Wrench

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 ELECTRICAL Charging System - MX-5 Miata

2005 ELECTRICAL

Charging System - MX-5 Miata

CHARGING SYSTEM LOCATION INDEX

Fig. 1: Locating Components Of Charging System

Courtesy of MAZDA MOTORS CORP.

BATTERY REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

2005 Mazda MX-5 Miata

2005 ELECTRICAL Charging System - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 ELECTRICAL Charging System - MX-5 Miata

Fig. 2: Identifying Components Of Battery & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

2. Install in the reverse order of removal.

BATTERY INSPECTION

WARNING:



Since battery acid is toxic, be careful when handling the battery.

Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.

In case battery acid contacts skin, eyes, or clothing, flush it immediately with running water. Especially if the acid gets in the eyes, flush with water for more than 15 min and get prompt medical attention.

ELECTROLYTE GRAVITY

1. Measure the electrolyte gravity using a hydrometer.



If it is less than the specification, recharge the battery. (See BATTERY RECHARGING .)

Standard electrolyte gravity

1.22-1.29 [20°C {68°F}]

BATTERY VOLTAGE

1. Inspect the battery as follows:

BATTERY VOLTAGE INSPECTION

Step Inspection

1 Measure open circuit voltage of battery.

Result Action

12.4 V or more Go to step 3.

less than 12.4 V Go to the next step.

12.4 V or more Go to the next step.

Quick charge for 30 min and reinspect voltage.

Apply test load (see test load chart) to battery using a battery load tester and record battery voltage after 15 s. Is voltage more than specification?

less than 12.4 V Replace battery.

Yes

Battery is okay.

Replace battery.

LOAD TEST CHART

Battery Load (A)

S46A24L (S) 105

BATTERY POSITIVE VOLTAGE WITH LOAD

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2005 Mazda MX-5 Miata

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Approximate battery temp. Minimum voltage (V)

21 °C {70°F} 9.6

15 °C {59°F}

10 °C {50°F}

4 °C {39°F}

9.5

9.4

9.3

-1 °C {30°F}

-7 °C {19°F}

-12 °C {10°F}

-18 °C {0°F}

9.1

8.9

8.7

8.5

BACK-UP CURRENT

1. Verify that the ignition switch is turned off and that the key has been removed.

2. Disconnect the negative battery cable.

CAUTION:



Operating electrical loads while measuring the back-up current can damage the circuit tester.

3. Measure the back-up current between the negative battery terminal and the negative battery cable.

1. If the current exceeds the maximum, remove the fuse in the main fuse block and the fuse block one by one while measuring the back-up current.

2. Inspect and repair harnesses and connectors of the fuse at which the current reduces.

Back-up current

20 mA max.

BATTERY RECHARGING

WARNING:



Hydrogen gas is produced during normal battery operation. A battery-related explosion can cause serious injury. Keep all flames

(including cigarettes), heat, and sparks away from the top and surrounding area of open battery cells.

CAUTION:



When disconnecting the battery, remove the negative cable first and install it last to prevent damage to electrical components or the battery.

To prevent damage to electrical components or the battery, turn all accessories off and stop the engine before performing maintenance or recharging the battery.

Do not quick charge for over 30 min as it will damage the battery.

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2005 Mazda MX-5 Miata

2005 ELECTRICAL Charging System - MX-5 Miata

1. Place a battery in a pan of water to prevent it from overheating. The water level should come up about halfway on the battery. Keep water off the top of the battery.

2. Connect a battery charger to the battery and adjust the charging current as follows.

STANDARD SPECIFICATION

Battery type (5-h rate) Slow charge (A) Quick charge (A)/(30 min)

S46A24L (S) (32) 3.0-4.0

3. After the battery is recharged, verify that the voltage is within the specification and remains at the same value for 1 h or more after the recharging was completed.



If not within the specification, replace the battery.

Standard voltage

12.4 V or more

Fig. 3: Connecting A Battery Charger To Battery

Courtesy of MAZDA MOTORS CORP.

GENERATOR REMOVAL/INSTALLATION

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2005 Mazda MX-5 Miata

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WARNING:



When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components.

Always disconnect the battery before performing the following operation.

1. Disconnect the negative battery cable.

2. Remove the under cover.

3. Remove the air pipe No.5, No.6, and air hose No.8 (with TC). (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION [BP WITH TC] .)

4. Remove the intake manifold bracket.

5. Remove in the order indicated in the table.

Fig. 4: Removing Intake Manifold Bracket & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ELECTRICAL Charging System - MX-5 Miata

6. Install in the reverse order of removal.

7. Inspect the drive belt deflection/tension. (See DRIVE BELT INSPECTION .)

GENERATOR REMOVAL NOTE

1. Remove the generator from the underside of the engine compartment.

GENERATOR INSPECTION

GENERATOR WARNING LIGHT

1. Verify that the battery is fully charged.



Charge if necessary.

2. Verify that the drive belt deflection/tension is within the specification. (See DRIVE BELT

INSPECTION .)



Adjust if necessary.

3. Turn the ignition switch on and verify that the generator warning light comes on.



If the warning light does not illuminate, inspect the harness from ignition switch to generator warning light and from generator warning light to 3U terminal of PCM. If the generator warning light and harnesses are normal, replace the PCM.

4. Confirm that the generator warning light goes off after starting the engine.



If the generator warning light does not go off, inspect the on-board diagnostic system service code.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [BP, BP WITH TC] .)

GENERATOR

Voltage

1. Verify that the battery is fully charged.



Charge if necessary.

2. Verify that the drive belt deflection/tension is within the specification. (See DRIVE BELT

INSPECTION .)



Adjust if necessary.

3. Turn off all electrical loads.

4. Turn the ignition switch to START and verify that the generator turns smoothly without any noise while the engine is running.

5. Measure the voltage at the terminals shown in the table.



If not as specified, disassemble and inspect the generator.

Terminal

Ignition switch ON (V)

B+

Below 1

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Idle (V) [20 °C {68°F}]

13-15

Approx.3-8

2005 Mazda MX-5 Miata

2005 ELECTRICAL Charging System - MX-5 Miata

D Approx.0

()

() Turn the following electrical loads on and verify that the voltage reading increases.



Headlights



Blower motor

Rear window defroster

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2005 Mazda MX-5 Miata

2005 ELECTRICAL Charging System - MX-5 Miata

Fig. 5: Identifying Connector Terminal

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ELECTRICAL Charging System - MX-5 Miata

Current

1. Verify that the battery is fully charged.

 Charge if necessary.

2. Verify that the drive belt deflection/tension is within the specification. (See DRIVE BELT

INSPECTION .)



Adjust if necessary.

3. Disconnect the negative battery cable.

4. Connect a circuit tester, capable of reading 120 A or more, between generator terminal B and the wiring harness.

5. Connect the negative battery cable.

6. Turn off all electrical loads.

7. Start the engine and increase the engine speed to 2,000-2,500 RPM.

8. Turn the following electrical loads on and verify that the current reading increases.

1. Headlights

2. Blower motor

3. Rear window defroster



If generator terminal B current will not increase, disassemble and inspect the generator.

NOTE:



Current required for generating power varies with electrical loads applied.

Standard current (Reference)

Measuring conditions

Room temperature:20 °C {68°F}

Voltage:13.5 V

Engine hot

Engine speed (RPM) Terminal B current (A)

1,000 0

()

--65

2,000 0

()

--77

() Lower limit of current must be more than 0 A.

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2005 TRANSMISSION Clutch - MX-5 Miata

2005 TRANSMISSION

Clutch - MX-5 Miata

CLUTCH COMPONENT LOCATION INDEX

Fig. 1: Identifying Clutch Components

Courtesy of MAZDA MOTORS CORP.

2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

GENERAL PROCEDURES (CLUTCH)

PRECAUTION

Clutch pipe



If any clutch pipe has been disconnected anytime during the procedure, add brake fluid, bleed the air, and inspect for leakage after the procedure has been completed.



If removing the clutch pipe, remove it using the SST (49 0259 770B).

If installing the clutch pipe, change the clutch pipe tightening torque to allow use of a torque wrenchSST

(49 0259 770B) combination, and then tighten the clutch pipe using the SST (49 0259 770B). (See

TORQUE FORMULAS .)

CLUTCH FLUID INSPECTION

1. Check the fluid level is between MIN and MAX of the reservoir.



If the fluid level is not between MIN and MAX, fill up or drain the fluid.

CLUTCH FLUID REPLACEMENT

CAUTION:



Clutch fluid will damage painted surfaces.

If clutch fluid does get on a painted surface, wipe it off immediately.

NOTE:



Do not mix different brands of fluid.

Do not reuse the clutch fluid that was drained.

1. Drain the fluid from the reservoir using a suction pump.

2. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder screw.

3. Insert the other end of the vinyl hose into a clear container.

4. Loosen the bleeder screw using the SST.

5. Have an assistant slowly pump the clutch pedal and drain the fluid from the clutch system.

6. Repeat Step 5 until all the fluid is drained.

7. Calculate the bleeder screw tightening torque to allow use of a torque wrenchSST combination.

(See TORQUE FORMULAS .)

8. Tighten the bleeder screw using the SST.

Tightening torque

5.9-8.8 N.m {60-90 kgf.cm, 53-78 in.lbf}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 2: Tightening Bleeder Screw Using SST

Courtesy of MAZDA MOTORS CORP.

9. Fill the reservoir to MAX with new fluid of the specified type.

10. Bleed the air from the clutch. (See CLUTCH FLUID AIR BLEEDING .)

11. Verify correct clutch operation.

12. Verify that there is no fluid leakage.

CLUTCH FLUID AIR BLEEDING

CAUTION:



Clutch fluid will damage painted surfaces.

If clutch fluid does get on a painted surface, wipe it off immediately.

NOTE:



Do not mix different brands of fluid.

Do not reuse the clutch fluid that was drained.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

1. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug.

2. Place the other end of the vinyl hose in a clear container.

3. Slowly pump the clutch pedal several times.

4. With the clutch pedal depressed, loosen the bleeder screw using the SST to let the fluid escape. Close the bleeder screw using the SST.

5. Repeat Steps 3 and 4 until only clean fluid is seen.

6. Calculate the bleeder screw tightening torque to allow use of a torque wrenchSST combination.

(See TORQUE FORMULAS .)

7. Tighten the bleeder screw using the SST.

Tightening torque

5.9-8.8 N.m {60-90 kgf.cm, 53-78 in.lbf}

Fig. 3: Tightening Bleeder Screw Using SST

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

8. Add fluid to the MAX mark.

CLUTCH PEDAL INSPECTION

CLUTCH PEDAL HEIGHT INSPECTION

1. Measure the distance from the upper surface of the pedal pad to the cabin carpet.

Pedal height

175-180 mm {6.89-7.08 in} (With carpet)

2. Adjust the height if necessary.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 4: Inspecting Clutch Pedal Height & Free Play

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

CLUTCH PEDAL FREE PLAY INSPECTION

1. Depress the clutch pedal by hand until clutch resistance is felt.

Free play

0.6-3.1 mm {0.03-0.12 in}

Total free play

5-13 mm {0.20-0.51 in}

2. Adjust the free play if necessary. (See CLUTCH PEDAL FREE PLAY ADJUSTMENT .)

CLUTCH PEDAL ADJUSTMENT

CLUTCH PEDAL HEIGHT ADJUSTMENT

1. Disconnect the clutch switch connector.

2. Loosen locknut A and turn clutch switch B until the height is correct.

3. Tighten locknut A.

Tightening torque

13.8-17.6 N.m {140-180 kgf.cm, 122-156 in.lbf}

4. After adjustment, inspect the free play.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 5: Adjusting Clutch Pedal Height

Courtesy of MAZDA MOTORS CORP.

CLUTCH PEDAL FREE PLAY ADJUSTMENT

1. Loosen locknut C and turn push rod D until the free play is correct.

2. Verify that the disengagement height as measured from the upper surface of the pedal pad to the carpet is correct when the pedal is fully depressed.

Minimum disengagement height

68 mm {2.68 in} (With carpet)

3. Tighten locknut C.

Tightening torque

11.8-16.6 N.m {120-170 kgf.cm, 105-147 in.lbf}

4. After adjustment, inspect the height.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 6: Adjusting Clutch Pedal Free Play

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

CLUTCH PEDAL REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

Fig. 7: Removing Clutch Pedal

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

3. Install in the reverse order of removal.

SPRING REMOVAL NOTE

1. Place the clutch pedal component in a vise.

2. Pry the spring off the clutch pedal as shown in Fig. 8 .

Fig. 8: Prying Spring Off Clutch Pedal

Courtesy of MAZDA MOTORS CORP.

SPRING INSTALLATION NOTE

1. Place the clutch pedal component in a vise.

2. Install the spring onto the clutch pedal as shown in Fig. 9 .

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 9: Installing Spring Onto Clutch Pedal

Courtesy of MAZDA MOTORS CORP.

3. Adjust the clutch pedal height and free play after installation.

CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION

CAUTION:



Clutch fluid will damage painted surfaces.

If clutch fluid does get on a painted surface, wipe it off immediately.

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

3. Inspect and adjust the clutch pedal height and free play. (See CLUTCH PEDAL ADJUSTMENT .)

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 10: Installing Clutch Master Cylinder (BP) - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

BP WITH TC

Fig. 11: Installing Clutch Master Cylinder (BP With TC) - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

GASKET INSTALLATION NOTE

1. Install the gasket as shown.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 12: Identifying Gasket

Courtesy of MAZDA MOTORS CORP.

CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

WARNING:



Applying compressed air to the cylinder component can make the contents suddenly pop out, possibly causing injury. Hold a rag over the cylinder opening when using compressed air.

2. Wipe all parts, and use compressed air to clean all ports, passages, and inner parts.

3. Assemble in the reverse order of disassembly.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 13: Disassembling Clutch Master Cylinder (BP)

Courtesy of MAZDA MOTORS CORP.

BP WITH TC

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 14: Disassembling Clutch Master Cylinder (BP With TC)

Courtesy of MAZDA MOTORS CORP.

SNAP RING DISASSEMBLY/ASSEMBLY NOTE

1. While holding the piston down with a cloth-wrapped Phillips screwdriver, remove the snap ring.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 15: Removing Snap Ring Using Screwdriver

Courtesy of MAZDA MOTORS CORP.

CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION

CAUTION:



Clutch fluid will damage painted surfaces.

If clutch fluid does get on a painted surface, wipe it off immediately.

1. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 16: Removing Clutch Release Cylinder

Courtesy of MAZDA MOTORS CORP.

2. Install in the reverse order of removal.

CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

WARNING:



Applying compressed air to the cylinder component can make the contents suddenly pop out, possibly causing injury. Hold a rag over the cylinder opening when using compressed air.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 17: Disassembling Clutch Release Cylinder - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

2. Wipe all parts, and use compressed air to clean all ports, passages, and inner parts.

3. Assemble in the reverse order of disassembly.

CLUTCH UNIT REMOVAL/INSTALLATION

NOTE:



The clutch release cylinder can be removed from the transmission with the clutch pipe connected.

1. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 18: Removing Clutch Unit

Courtesy of MAZDA MOTORS CORP.

2. Install in the reverse order of removal.

CLUTCH COVER, CLUTCH DISC REMOVAL NOTE

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

1. Install the SST (49 SE01 310A).

2. Hold the flywheel using the SST (49 E011 1A0).

3. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.

Then remove the clutch cover and disc.

Fig. 19: Loosening Bolts

Courtesy of MAZDA MOTORS CORP.

PILOT BEARING REMOVAL NOTE

NOTE:



The pilot bearing does not need to be removed unless you are replacing it.

1. Remove the pilot bearing using the SST.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 20: Removing Pilot Bearing Using SST

Courtesy of MAZDA MOTORS CORP.

FLYWHEEL REMOVAL NOTE

1. Hold the flywheel using the SST.

2. Remove the flywheel.

3. Inspect for oil leakage from the crankshaft rear oil seal.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata



If there is any leakage or if the oil seal is damaged, replace the crankshaft oil seal.

(See REAR OIL SEAL REPLACEMENT .)

Fig. 21: Removing Flywheel

Courtesy of MAZDA MOTORS CORP.

FLYWHEEL INSTALLATION NOTE

1. Wipe the bolts clean, then apply sealant to the bolt threads.

2. Install the flywheel, and secure it using the SST.

3. Tighten the bolts in the pattern shown.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Tightening torque

97-102 N.m {9.8-10.5 kgf.m, 71-75 ft.lbf}

Fig. 22: Securing Flywheel Using SST

Courtesy of MAZDA MOTORS CORP.

PILOT BEARING INSTALLATION NOTE

1. Install a new pilot bearing using a suitable pipe.

Depth

0-0.4 mm {0-0.016 in}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 23: Installing Pilot Bearing Using Suitable Pipe

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

CLUTCH DISC INSTALLATION NOTE

1. Clean the clutch disc splines and main drive gear splines, and apply Mori White TA No.2 or equivalent organic molybdenum grease.

2. Hold the clutch disc in position using the SST.

Fig. 24: Holding Clutch Disc Position Using SST

Courtesy of MAZDA MOTORS CORP.

CLUTCH COVER INSTALLATION NOTE

1. Hold the flywheel using the SST.

2. Align the dowel holes with the flywheel dowels.

3. Tighten the bolts evenly and gradually in the pattern shown.

Tightening torque

Microsoft

2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

18-26 N.m {1.8-2.7 kgf.m, 14-19 ft.lbf}

Fig. 25: Installing Clutch Cover

Courtesy of MAZDA MOTORS CORP.

CLUTCH COVER INSPECTION

1. Inspect the contact surface for scoring, cracks, and burning. Repair or replace if necessary.

2. Remove minor scoring or burning using emery paper. Repair if scoring or burning is major. Replace if cracked.

3. Inspect the tips of the diaphragm spring for wear and cracks.



If there is wear or cracks, replace the clutch cover.

CLUTCH DISC INSPECTION

1. Inspect the lining surface for burning and oil contamination. Repair using sandpaper if the trouble is minor. Replace the clutch disc if it is badly burned or oil soaked.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

2. Inspect for loose facing rivets or torsion dampers. Replace the clutch disc if any are loose.

3. Measure the thickness of the lining at a rivet head on both sides using vernier calipers. Replace the clutch disc if less than minimum.

Minimum thickness

0.3 mm {0.012 in}

Fig. 26: Measuring Thickness Of Lining At Rivet Head On Both Sides Using Vernier Calipers

Courtesy of MAZDA MOTORS CORP.

4. Measure the clutch disc runout using a dial indicator. Replace the clutch disc if runout is excessive.

Maximum runout

0.7 mm {0.028 in}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 27: Measuring Clutch Disc Runout Using A Dial Indicator

Courtesy of MAZDA MOTORS CORP.

CLUTCH RELEASE COLLAR INSPECTION

CAUTION:



Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing.

1. Turn the collar while applying force in the axial direction.



If the collar sticks or has excessive resistance, replace it.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 28: Turning Collar While Applying Force

Courtesy of MAZDA MOTORS CORP.

PILOT BEARING INSPECTION

1. Turn the bearing while applying force in the axial direction.



If the bearing sticks or has excessive resistance, replace it.

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 29: Turning Bearing While Applying Force

Courtesy of MAZDA MOTORS CORP.

FLYWHEEL INSPECTION

1. Inspect the contact surface for scoring, cracks, and burning.

2. Remove minor scoring or burning using emery paper. Repair if scoring or burning is major. Replace if cracked.

3. Inspect the ring gear teeth for wear or damage.

4. Measure the flywheel runout using a dial indicator. Replace the flywheel if runout is excessive.

Maximum runout

0.2 mm {0.008 in}

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 TRANSMISSION Clutch - MX-5 Miata

Fig. 30: Measuring Flywheel Runout Using Dial Indicator

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 ENGINE Cooling System - MX-5 Miata

2005 ENGINE

Cooling System - MX-5 Miata

COOLING SYSTEM LOCATION INDEX

Fig. 1: Identifying Cooling System Location Index

Courtesy of MAZDA MOTORS CORP.

COOLING SYSTEM SERVICE WARNINGS

2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

WARNING:



Never remove the radiator cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot.

Scalding coolant and steam may shoot out and cause serious injury.

It may also damage the engine and cooling system.

Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

Hot engines and the engine coolant can cause severe burns. Turn off the engine and wait until it and the engine coolant have cooled before draining the engine coolant.

ENGINE COOLANT LEVEL INSPECTION

1. Remove the radiator cap. (See COOLING SYSTEM SERVICE WARNINGS .)

2. Verify that the coolant level is near the radiator filler neck.

3. Verify that the coolant level on the coolant reserve tank is between the FULL and LOW marks.



If the engine coolant level is below LOW, remove the radiator cap and add coolant. (See

COOLING SYSTEM SERVICE WARNINGS .)

ENGINE COOLANT REPLACEMENT

1. Drain the coolant in the coolant reserve tank.

2. Remove the radiator cap and the radiator drain plug. (See COOLING SYSTEM SERVICE

WARNINGS .)

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Fig. 2: Removing Radiator Cap And Radiator Drain Plug

Courtesy of MAZDA MOTORS CORP.

3. Drain the coolant into a container.

4. Flush the cooling system with water until all traces of color are gone.

5. Let the system drain completely.

6. Tighten the radiator drain plug.

Tightening torque

0.7-1.1 N.m {7-12 kgf.cm, 7-10 in.lbf}

CAUTION:



Microsoft

Saturday, July 04, 2009 11:10:30 AM

The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant.

Use only soft (demineralized) water in the coolant mixture.

Water that contains minerals will cut down the coolant effectiveness.

Engine coolant will damage paint. If engine coolant does get on

2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata a painted surface, rinse it off quickly.

7. Referring to the following chart, select proper gravity of the coolant.

ANTIFREEZE SOLUTION MIXTURE PERCENTAGE

Coolant protection

Volume percentage

Gravity at 20 °C {68 °F}

Water Coolant

Above -16 °C {3 °F} 65

Above -26 °C {-15 °F} 55

1.057

1.072

Above -40 °C {-40 °F} 45 55 1.086

8. Slowly pour the coolant into the radiator up to the coolant filler port.

Filling pace

1.0 L {1.1 US qt, 0.9 lmp qt}/min [max]

9. Fill the coolant into the coolant reserve tank up to the FULL mark on the coolant reservoir.

10. Fully install the radiator cap.

11. Start the engine and warm it up.

CAUTION:



If the coolant temperature becomes too high, stop the engine to prevent it from overheating.

12. After engine warms up, perform the following steps.

1. Run the engine at 2,500 RPM for 5 min.

2. Run the engine at 3,000 RPM for 5 min.

3. Repeat steps (1) and (2) several times.

13. Stop the engine and wait until it is cool.

14. Inspect the coolant level.



If it is low, repeat Steps 7-12.

15. Verify there is no coolant leakage.

ENGINE COOLANT LEAKAGE INSPECTION

1. Inspect the coolant level. (See ENGINE COOLANT LEVEL INSPECTION .)

2. Remove the radiator cap.

3. Connect a radiator cap tester and the SST to the radiator filler neck.

CAUTION:



Applying more than 123 kPa {1.25 kgf/cm2, 17.8 psi} can damage the hoses, fittings, and other components, and cause leakage.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Fig. 3: Connecting Radiator Cap Tester And SST To Radiator Filler Neck

Courtesy of MAZDA MOTORS CORP.

4. Apply pressure to the radiator.

Pressure

123 kPa {1.25 kgf/cm2, 17.8 psi}

5. Verify that the pressure is held.



If not, inspect the system for coolant leakage.

ENGINE COOLANT PROTECTION INSPECTION

1. Measure the coolant temperature and specific gravity with a thermometer and a hydrometer.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

CAUTION:



The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant.

Use only soft (demineralized) water in the coolant mixture.

Water that contains minerals will reduce the coolant's effectiveness.

2. Determine the coolant protection by referring to the graph shown.



If the coolant protection is not proper, add water or coolant.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Fig. 4: Engine Coolant Protection Graph

Courtesy of MAZDA MOTORS CORP.

RADIATOR CAP INSPECTION

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

WARNING:



Never remove the radiator cap while the engine is running, or when the engine and radiator are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.

1. Attach the radiator cap to a radiator cap tester with the SST . Apply pressure gradually.

Fig. 5: Attaching Radiator Cap To Radiator Cap Tester With SST

Courtesy of MAZDA MOTORS CORP.

2. Verify that the pressure becomes stable within the specification.



If the pressure is held for 10 s , the radiator cap is normal.

Pressure

94-122 kPa {0.95-1.25 kgf/cm2, 13.5-17.7 psi}

RADIATOR REMOVAL/INSTALLATION [BP]

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

WARNING:



Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

3. Remove the air hose.

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

Fig. 6: Exploded View Of Radiator & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

6. Add engine coolant. (See ENGINE COOLANT REPLACEMENT .)

7. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION .)

RADIATOR REMOVAL/INSTALLATION [BP WITH TC]

WARNING:



Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

3. Remove the air hose No.1 and No.2. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION

[BP WITH TC] .)

4. Set the air pipe No.3 out of the way.

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

Fig. 7: Exploded View Of Radiator With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

7. Add engine coolant. (See ENGINE COOLANT REPLACEMENT .)

8. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION .)

THERMOSTAT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the air hose (without TC).

3. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

4. Remove in the order indicated in the table.

Fig. 8: Identifying Thermostat And Cover With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

THERMOSTAT INSTALLATION NOTE

1. Install the thermostat into the cylinder head with the jiggle pin at the top.

Fig. 9: Installing Thermostat Into Cylinder Head With Jiggle Pin At Top

Courtesy of MAZDA MOTORS CORP.

THERMOSTAT COVER GASKET INSTALLATION NOTE

1. Install a new gasket with the seal print side facing the cylinder head.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Fig. 10: Installing Gasket With Seal Print Side Facing Cylinder Head

Courtesy of MAZDA MOTORS CORP.

THERMOSTAT INSPECTION

1. Visually check that the thermostat valve is closed.

2. Place the thermostat and a thermometer in water.

WARNING:



During inspection, the thermostat and water are extremely hot and they can cause burns. Do not touch the thermostat and water directly.

3. Heat the water and check the following.



If not as specified, replace the thermostat.

HEAT WATER SPECIFICATION

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Condition Specification

Initial-opening temperature °C {°F} 83.5-86.5 {183-187}

Full-open temperature

Full-open lift

°C {°F} mm {in}

100 {212}

8.5 {0.33}

Fig. 11: Identifying Full-Open Lift

Courtesy of MAZDA MOTORS CORP.

WATER PUMP REMOVAL/INSTALLATION

1. Remove the air cleaner.

2. Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION .)

3. Remove the exhaust manifold insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION

[BP] .) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

4. Set the A/C compressor out of the way.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

5. Remove in the order indicated in the table.

Fig. 12: Installing Water Pump & Torque Specifications

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

P/S OIL PUMP REMOVAL NOTE

1. Remove the P/S oil pump with the oil hose still connected.

2. Position the P/S oil pump so that it is out of the way.

WATER PUMP INSTALLATION NOTE

1. Install the new rubber seal with the bonding agent.

Fig. 13: Installing Rubber Seal With Bonding Agent

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

COOLING FAN MOTOR INSPECTION [BP]

1. Verify that the battery is fully charged. (See BATTERY INSPECTION .)

2. Disconnect the cooling fan motor connector.

3. Connect battery positive voltage and an ammeter to the cooling fan motor connector.

Fig. 14: Connecting Battery Positive Voltage And An Ammeter To Cooling Fan Motor Connector

Courtesy of MAZDA MOTORS CORP.

4. Verify that the cooling fan motor operates smoothly at the standard current draw.



If not as specified, replace the cooling fan motor.

Standard current

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

5.9 (A) [12V]

COOLING FAN MOTOR INSPECTION [BP WITH TC]

1. Verify that the battery is fully charged. (See BATTERY INSPECTION .)

2. Disconnect the fan motor connector.

3. Connect battery positive voltage and an ammeter to the fan motor connector.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Fig. 15: Connecting Battery Positive Voltage And An Ammeter To Fan Motor Connector

Courtesy of MAZDA MOTORS CORP.

4. Verify that the fan motor operates smoothly at the standard current draw.



If not within the specification, replace the fan motor.

Standard current

10 (A) [12 V]

COOLING FAN MOTOR REMOVAL/INSTALLATION [BP]

1. Remove the cooling fan. (See RADIATOR REMOVAL/INSTALLATION [BP] .)

2. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Fig. 16: Removing Cooling Fan & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

COOLING FAN MOTOR REMOVAL/INSTALLATION [BP WITH TC]

1. Remove the cooling fan component. (See RADIATOR REMOVAL/INSTALLATION [BP WITH

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

TC] .)

2. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE Cooling System - MX-5 Miata

Fig. 17: Removing Cooling Fan Component & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

Microsoft

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

2005 ACCESSORIES & EQUIPMENT

Cruise Control System - MX-5 Miata

CRUISE CONTROL SYSTEM LOCATION INDEX

Fig. 1: Identifying Components Of Cruise Control & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CRUISE CONTROL MODULE REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

2. Remove the lower panel.

3. Remove the key interlock unit. (See KEY INTERLOCK UNIT REMOVAL/INSTALLATION .)

4. Remove in the order indicated in the table.

Fig. 2: Removing Key Interlock Unit

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

CRUISE CONTROL MODULE INSPECTION

1. Remove the lower panel.

2. Remove the key interlock unit. (See KEY INTERLOCK UNIT REMOVAL/INSTALLATION .)

3. Remove the cruise control module with the connector connected.

4. Measure the voltage at the cruise control module terminals as indicated below.

5. Disconnect the cruise control module connector before inspecting for continuity at terminal T.



If not as specified, inspect the parts listed under "Action."

If the parts and wiring harnesses are okay but the system still does not work properly, replace the

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata cruise control module.

TERMINAL VOLTAGE TABLE (REFERENCE)

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 3: Identifying Terminal Voltage Table (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

Fig. 4: Identifying Terminal Voltage Table (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

CRUISE ACTUATOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 5: Exploded View Of Cruise Actuator

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

CRUISE ACTUATOR INSPECTION

1. Disconnect the cruise actuator connector.

2. Disconnect the actuator cable from the cruise actuator.

3. Start the engine and run it idle.

4. Confirm that the diaphragm is drawn into the cruise actuator when battery positive voltage is connected to terminal C and terminals A, B and D are connected to the ground.

Fig. 6: Identifying Battery Positive Voltage Is Connected To Cruise Actuator Terminal C And

Terminals A, B And D Are Connected To The Ground

Courtesy of MAZDA MOTORS CORP.

5. With the diaphragm being drawn into the cruise actuator, confirm that the diaphragm returns to its original position when terminals B and D are disconnected from the ground.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 7: Identifying Cruise Actuator Terminals B And D Disconnected From Ground

Courtesy of MAZDA MOTORS CORP.

6. With the diaphragm returning to its original position, confirm that the diaphragm stops moving when terminal D is reconnected to the ground.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 8: Identifying Cruise Actuator Terminal D Disconnected From Ground

Courtesy of MAZDA MOTORS CORP.

7. With the movement of the diaphragm stopped, confirm that the diaphragm returns completely to its original position when all terminals connected to the ground are disconnected.



If not as specified, replace the cruise actuator.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 9: Identifying All Cruise Actuator Terminals Disconnected From Ground

Courtesy of MAZDA MOTORS CORP.

ACTUATOR CABLE REMOVAL

1. Loosen the nut, and remove the actuator cable.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 10: Removing Actuator Cable

Courtesy of MAZDA MOTORS CORP.

2. Press the tabs of the bush, and remove it from the accelerator pedal.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 11: Removing Accelerator Pedal

Courtesy of MAZDA MOTORS CORP.

3. Press the tabs of the grommet, and remove it from the dash lower panel.

4. Push the actuator cable through the dash lower panel to remove it.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 12: Pushing Actuator Cable

Courtesy of MAZDA MOTORS CORP.

ACTUATOR CABLE INSTALLATION

1. Install the grommet to the dash lower panel.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 13: Installing Grommet To Dash Lower Panel

Courtesy of MAZDA MOTORS CORP.

2. Install the actuator cable to the accelerator pedal.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 14: Installing Actuator Cable To Accelerator Pedal

Courtesy of MAZDA MOTORS CORP.

3. Slide the lock lever in the direction shown by the arrow in Fig. 15 to unlock the adjuster.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 15: Sliding Lock Lever

Courtesy of MAZDA MOTORS CORP.

4. Turn the ratchet ring to release lock in the direction shown by the arrow in Fig. 16 .

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 16: Turning Ratchet Ring

Courtesy of MAZDA MOTORS CORP.

5. Insert the grommet into the actuator bracket.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 17: Inserting Grommet Into Actuator Bracket

Courtesy of MAZDA MOTORS CORP.

6. To adjust the free play, push or pull the actuator cable directly behind the spring two times.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 18: Pushing Actuator Cable

Courtesy of MAZDA MOTORS CORP.

7. Turn the ratchet ring in the direction shown by the arrow in Fig. 19 to lock it.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 19: Turning Ratchet Ring

Courtesy of MAZDA MOTORS CORP.

8. Slide the lock lever in the direction shown by the arrow in Fig. 20 to lock the adjuster.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 20: Sliding Lock Lever

Courtesy of MAZDA MOTORS CORP.

CRUISE CONTROL MAIN SWITCH REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the fuse block cover.

3. Remove the panel light control switch. (See PANEL LIGHT CONTROL SWITCH

REMOVAL/INSTALLATION .)

4. Push the tabs of the cruise control main switch and pull the switch out from inside of the dashboard.

5. Disconnect the cruise control main switch connector to remove the cruise control main switch.

6. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 21: Identifying Cruise Control Main Switch

Courtesy of MAZDA MOTORS CORP.

CRUISE CONTROL MAIN SWITCH INSPECTION

1. Remove the cruise control main switch. (See CRUISE CONTROL MAIN SWITCH

REMOVAL/INSTALLATION .)

2. Inspect for continuity between the cruise control main switch terminals using an ohmmeter.



If not as specified, replace the cruise control main switch.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 22: Identifying Terminal

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 23: Inspecting For Continuity Between Cruise Control Main Switch Terminals Using An

Ohmmeter

Courtesy of MAZDA MOTORS CORP.

CRUISE CONTROL SWITCH REMOVAL/INSTALLATION

NOTE:



The cruise control switch is together with the wiper lever.

1. Disconnect the negative battery cable.

2. Remove the wiper lever from the combination switch. (See COMBINATION SWITCH

DISASSEMBLY/ASSEMBLY .)

3. Install in the reverse order of removal.

CRUISE CONTROL SWITCH INSPECTION

1. Remove the combination switch. (See COMBINATION SWITCH REMOVAL/INSTALLATION .)

2. Measure the resistance between the cruise control switch terminals using an ohmmeter.



If not as specified, replace the wiper lever.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 24: Cruise Control Switch Position Chart

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

Fig. 25: Measuring Resistance Between Cruise Control Switch Terminals Using An

Ohmmeter

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 DRIVELINE/AXLE Differential - MX-5 Miata

2005 DRIVELINE/AXLE

Differential - MX-5 Miata

DIFFERENTIAL LOCATION INDEX

Fig. 1: Identifying Differential Location

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL OIL INSPECTION

1. Remove the filler plug.

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 2: Removing Filler Plug

Courtesy of MAZDA MOTORS CORP.

2. Verify that the oil is at the brim of the filler plug hole.



If it is low, add the specified oil.

3. Install the filler plug.

Tightening torque

40-53 N.m {4.0-5.5 kgf.m, 29-39 ft.lbf}

DIFFERENTIAL OIL REPLACEMENT

1. Remove the filler and drain plugs.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 3: Removing Filler And Drain Plugs

Courtesy of MAZDA MOTORS CORP.

2. Drain the differential oil into a container.

3. Wipe the plugs clean.

4. Install the drain plug and a new washer.

Tightening torque

39.2-53.9 N.m {4.00-5.49 kgf.m, 29.0-39.7 ft.lbf}

5. Add the specified oil from the filler plug until the level reaches the brim of the plug hole.

Specified oil

Type:API service GL-5 SAE 90

Capacity (Approximate quantity)

BP with TC:0.7-0.9 L {0.8-0.9 US qt, 0.62-0.79 imp qt}

BP:1.0L {1.1 US qt, 0.9 Imp qt}

6. Install the filler plug.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Tightening torque

39.2-53.9 N.m {4.00-5.49 kgf.m, 29.0-39.7 ft.lbf}

OIL SEAL REPLACEMENT

1. On level ground, jack up the vehicle and support it on safety stands.

2. Drain the differential oil.

NOTE:



For easier installation, do not depress the brake pedal after removing the brake caliper component.

3. Remove the brake caliper component, then suspend the brake caliper component using a rope.

4. Remove the lower arm installation bolt and nut.

5. Pull the rear hub support from the drive shaft.

NOTE:



If the drive shaft will not come out of the rear hub support easily, install a discarded nut onto the drive shaft so that the nut is flush with the end of the drive shaft. Tap the nut with a copper hammer to loosen the drive shaft from the wheel hub.

6. Remove the drive shaft from the differential. (See DRIVE SHAFT REMOVAL NOTE .)

7. Remove the oil seal.

8. Apply lithium-based grease to the new oil seal lip and install it using the SST.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 4: Applying Lithium-Based Grease To New Oil Seal Lip

Courtesy of MAZDA MOTORS CORP.

9. Install a new clip onto the drive shaft. (See DRIVE SHAFT REMOVAL NOTE .)

10. Install the lower arm installation bolt and nut.

Tightening torque

54-76 N.m {5.5-7.8 Kgf.m, 40-56 ft.lbf}

11. Install the brake caliper component.

Tightening torque

50-68 N.m {5.0-7.0 kgf.m, 37-50 ft.lbf}

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

12. Add the specified oil. (See DIFFERENTIAL OIL REPLACEMENT .)

13. Adjust the rear wheel alignment.

DIFFERENTIAL REMOVAL/INSTALLATION

1. Drain the differentia oil.

2. Remove the crossmember bracket. (See CROSSMEMBER BRACKET

REMOVAL/INSTALLATION .)

3. Remove the main silencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .) (See

EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

6. Add the specified oil to the specified level. (See DIFFERENTIAL OIL REPLACEMENT .)

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 5: Exploded View Of Differential & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

POWER PLANT FRAME (PPF), DIFFERENTIAL MOUNTING SPACER REMOVAL NOTE

1. Disconnect the wire harness from the PPF.

2. Support the transmission with a jack.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 6: Disconnecting Harness From PPF

Courtesy of MAZDA MOTORS CORP.

3. Remove the PPF bracket.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 7: Removing PPF Bracket

Courtesy of MAZDA MOTORS CORP.

4. Remove the differential-side bolts, and pry out the spacer.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 8: Removing Differential-Side Bolts

Courtesy of MAZDA MOTORS CORP.

5. Remove the differential mounting spacer.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 9: Removing Differential Mounting Spacer (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 10: Removing Differential Mounting Spacer (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

CAUTION:



Removing the PPF spacers will reduce the performance of the

PPF. Do not remove the PPF spacers.

If the spacers are removed, replace the PPF as a component.

6. Remove the transmission-side bolts, and remove the PPF.

NOTE:



If the sleeve cannot be removed easily, tap the side of sleeve with a plastic hammer.

7. Remove the sleeve.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 11: Removing Sleeve

Courtesy of MAZDA MOTORS CORP.

8. To prevent damaging the fire wall and engine mount, support the transmission as follows.

1. Prepare a steel plate (as shown in Fig. 12 ), a wooden block, bolts (M8x1.25), and washers.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 12: Preparing A Steel Plate Wooden Block Bolts

Courtesy of MAZDA MOTORS CORP.

2. Install a wooden block as shown in Fig. 13 .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 13: Installing A Wooden Block

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL REMOVAL NOTE

1. Support the differential using a jack.

2. Lower the differential and move it forward.

POWER PLANT FRAME (PPF), DIFFERENTIAL MOUNTING SPACER INSTALLATION NOTE

1. Install the differential mounting spacer.

Tightening torque

38-51 N.m {3.8-5.3 kgf.m, 28-38 ft.m}

2. Support the transmission horizontally with a jack.

3. Install the PPF, and tighten the transmission side bolt slightly.

4. Align the PPF of the differential side, and install the sleeve.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 14: Installing Sleeve

Courtesy of MAZDA MOTORS CORP.

5. Install the spacer and bolt to the front side installation hole of the differential side.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 15: Installing Spacer And Bolt To Front Side

Courtesy of MAZDA MOTORS CORP.

6. Install the PPF installation bolt in the order as shown.

Tightening torque

104-123 N.m

{10.6-12.6 kgf.m, 76.7-91.1 ft.m}

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 16: Installing PPF Bolt

Courtesy of MAZDA MOTORS CORP.

7. Install the PPF bracket.(MT only)

Fig. 17: Installing PPF Bracket

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Tightening torque

A:104-123 N.m

{10.6-12.6 kgf.m, 76.7-91.1 ft.m}

B:37-53 N.m

{3.7-5.5 kgf.m, 27-39 ft.m}

8. Remove the jack, and install the wiring harness.

9. Measure the length A as shown.

Standard length

MT:60.0-72.0 mm {2.36-2.38 in}

AT:50.5-62.5 mm {1.99-2.46 in}

10. If not as specified, adjust the position of the PPF.

Fig. 18: Measuring Length

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 19: Differential Disassembled View & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 20: Differential Disassembled View Description

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL CASE DISASSEMBLY NOTE

CAUTION:



The differential case is made of aluminum, and is therefore easily dented and scratched by metal tools. When separating the differential carrier from the case, use only a plastic hammer at the point shown in Fig. 21.

1. Strike the differential carrier with a plastic hammer to separate it from the case.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 21: Striking Differential Carrier With A Plastic Hammer To Separate It From Case

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL GEAR COMPONENT DISASSEMBLY NOTE

1. Mount the differential gear component on the SSTs .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 22: Mounting Differential Gear Component On SSTs

Courtesy of MAZDA MOTORS CORP.

BEARING CAPS DISASSEMBLY NOTE

1. Mark one bearing cap and the carrier.

ADJUSTING NUTS DISASSEMBLY NOTE

1. Mark one adjusting nut and the carrier.

KNOCK PIN (STANDARD) DISASSEMBLY NOTE

1. Secure the gear case in a vise and tap out the knock pin toward the ring gear side.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 23: Knocking Pin Toward Ring Gear Side

Courtesy of MAZDA MOTORS CORP.

BEARING INNER RACES (SIDE BEARING) DISASSEMBLY NOTE

NOTE:



Mark the bearings so that they can later be reinstalled in the same position.

1. Remove the bearing inner races (side bearing) from the gear case using the SST .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 24: Removing Bearing Inner Races (Side Bearing) From Gear Case Using SST

Courtesy of MAZDA MOTORS CORP.

LOCKNUT (COMPANION FLANGE) DISASSEMBLY NOTE

1. Hold the companion flange using the SST and remove the locknut.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 25: Holding Companion Flange

Courtesy of MAZDA MOTORS CORP.

COMPANION FLANGE DISASSEMBLY NOTE

1. Pull the companion flange off using the SST .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 26: Pulling Companion Flange Off

Courtesy of MAZDA MOTORS CORP.

DRIVE PINION DISASSEMBLY NOTE

1. Push out the drive pinion by attaching a miscellaneous locknut to the drive pinion, and tapping it with a copper hammer.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 27: Pushing Out Drive Pinion

Courtesy of MAZDA MOTORS CORP.

BEARING OUTER RACES (FRONT AND REAR BEARING) DISASSEMBLY NOTE

1. Remove the bearing outer races using the 2 grooves in the carrier and alternately tapping the sides of the races.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 28: Removing Bearing Outer Races Using Grooves In Carrier And Alternately Tapping Sides

Of Races

Courtesy of MAZDA MOTORS CORP.

BEARING INNER RACE (REAR BEARING) DISASSEMBLY NOTE

1. While supporting the drive pinion to keep it from falling, remove the bearing inner race (rear bearing) using the SST .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 29: Disassembled View Of Bearing Inner Race

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL MOUNT DISASSEMBLY NOTE

1. Drill holes around the differential mount.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 30: Drilling Holes Around Differential Mount

Courtesy of MAZDA MOTORS CORP.

2. Hit the edge of the differential mount to remove it.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 31: Hitting Edge Of Differential Mount

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL MOUNT ASSEMBLY NOTE

1. Install the new differential mount with the voids facing front and rear.

2. Press in the differential mount using the SST .

Press force

19,610 N {2,000 kgf, 4,400 lbf} max.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 32: Installing New Differential Mount With Voids Facing Front And Rear

Courtesy of MAZDA MOTORS CORP.

OIL SEAL ASSEMBLY NOTE

1. Apply differential gear oil to the new oil seal lip and install it using the SST .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 33: Applying Differential Gear Oil To New Oil Seal Lip

Courtesy of MAZDA MOTORS CORP.

BEARING OUTER RACE (FRONT BEARING) ASSEMBLY NOTE

1. Install the bearing outer race (front bearing) using the SSTs .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 34: Installing Bearing Outer Race (Front Bearing) Using SSTs

Courtesy of MAZDA MOTORS CORP.

BEARING OUTER RACE (REAR BEARING) ASSEMBLY NOTE

1. Install the bearing outer race (rear bearing) using the SSTs .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 35: Installing Bearing Outer Race (Rear Bearing) Using SSTs

Courtesy of MAZDA MOTORS CORP.

BEARING INNER RACE (REAR BEARING), BEARING INNER RACE (FRONT BEARING)

ASSEMBLY NOTE

1. Adjust the drive pinion height as follows, using the SSTs .

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2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 36: Adjusting Drive Pinion Height As Follows, Using SSTs

Courtesy of MAZDA MOTORS CORP.

1. Install the previously-removed spacer onto the SST so that the beveled side of the spacer faces the drive pinion. Then install the rear bearing and O-ring onto the SST /spacer as shown in Fig. 37 .

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 37: Installing Previously-Removed Spacer Onto SST

Courtesy of MAZDA MOTORS CORP.

2. Assemble the spacer, bearing inner race (rear bearing), and SSTs .

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2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 38: Installing Bearing Inner Race

Courtesy of MAZDA MOTORS CORP.

3. Secure the SST with the O-ring. Install this assembly in the carrier.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

4. Install the bearing inner race (front bearing), the SST , companion flange, washer, and nut.

5. Tighten the nut just enough so that the companion flange can still be turned by hand.

6. Place the SST on the surface plate and set the dial indicator to "Zero".

Fig. 39: Placing SST On Surface Plate And Set Dial

Courtesy of MAZDA MOTORS CORP.

7. Place the SST atop the drive pinion model. Set the gauge body atop the gauge block.

8. Place the feeler of the dial indicator so that it contacts where the bearing inner race (side bearing) is installed in the carrier. Measure the lowest position on the left and right sides of the carrier.

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Fig. 40: Placing SST Atop Drive Pinion Model Set Gauge Body Atop Gauge Block

Courtesy of MAZDA MOTORS CORP.

NOTE:



The number is inscribed on the end of the drive pinion.

9. Add the 2 (left and right) values obtained by the measurements taken in step (8), and then divide the total by 2.From this result, subtract the result obtained by dividing the number inscribed on the end surface of the drive pinion by 100.(If there is no figure inscribed, use 0.) This is the pinion height adjustment value.

Mark Thickness Mark Thickness

08 3.08 mm {0.1213 in} 29 3.29 mm {0.1295 in}

11 3.11 mm {0.1224 in} 32 3.32 mm {0.1307 in}

14 3.14 mm {0.1234 in} 35 3.35 mm {0.1319 in}

17 3.17 mm {0.1248 in} 38 3.38 mm {0.1331 in}

20 3.20 mm {0.1260 in} 41 3.41 mm {0.1343 in}

23 3.23 mm {0.1271 in} 44 3.44 mm {0.1354 in}

26 3.26 mm {0.1283 in} 47 3.47 mm {0.1366 in}

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Differential - MX-5 Miata

NOTE:



The identification number is indicated on the outer side of the washer.

2. Install the spacer, selected in the procedure above, with the beveled side facing the drive pinion.

3. Using the SSTs , press the bearing inner race (rear bearing) onto the drive pinion until the force required starts to increase sharply.

Fig. 41: Installing Spacer

Courtesy of MAZDA MOTORS CORP.

4. Without installing the oil seal, install the drive pinion, spacer, new collapsible spacer, front bearing, washer, and companion flange to the carrier, and temporarily tighten the locknut using the SST .

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Fig. 42: Installing Drive Pinion, Spacer, New Collapsible Spacer, Front Bearing, Washer, And

Companion Flange

Courtesy of MAZDA MOTORS CORP.

Tightening torque

128-284 N.m {13-29 kgf.m, 95-209 ft.lbf}

5. Turn the companion flange several turns by hand to seat the bearing.

6. Measure the drive pinion preload. Adjust the preload by tightening the locknut, and record the tightening torque.

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Fig. 43: Measuring Drive Pinion Preload

Courtesy of MAZDA MOTORS CORP.

Preload

0.9-1.3 N.m {9-14 kgf.cm, 7.9-12.1 in.lbf}

Tightening torque

128-284 N.m {13-29 kgf.m, 95-209 ft.lbf}

7. Remove the locknut, washer, and companion flange.

8. Tap a new oil seal into the differential carrier with the SST .

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2005 DRIVELINE/AXLE Differential - MX-5 Miata

Fig. 44: Taping A New Oil Seal Into Differential Carrier With SST

Courtesy of MAZDA MOTORS CORP.

9. Install the companion flange and washer while holding the flange with the SST , and tighten a new locknut to the tightening torque recorded in step 6.

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Fig. 45: Installing Companion Flange And Washer While Holding Flange With SST

Courtesy of MAZDA MOTORS CORP.

THRUST WASHERS (STANDARD) ASSEMBLY NOTE

1. Adjust the backlash of the side gears and pinion gear as follows.

1. Set a dial gauge against the pinion gear as shown.

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Fig. 46: Securing One Of Side Gears

Courtesy of MAZDA MOTORS CORP.

2. Move the pinion gear, and measure the backlash at the end of it.

3. Secure one of the side gears.

Standard backlash

0-0.1 mm {0-0.004 in}

4. If the backlash exceeds the standard, use the selectable thrust washers for adjustment.

Thrust washer thickness

THRUST WASHER THICKNESS

Identification mark Thickness

0 2.00 mm {0.0787 in}

0.5

1.5

2.05 mm {0.0807 in}

2.10 mm {0.0827 in}

2.15 mm {0.0846 in}

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2005 DRIVELINE/AXLE Differential - MX-5 Miata

2 2.20 mm {0.0866 in}

2. Install the new knock pin to secure the pinion shaft. Stake the pin with a punch to prevent it from coming out of the case.

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Fig. 47: Installing New Knock Pin To Secure Pinion Shaft

Courtesy of MAZDA MOTORS CORP.

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2005 DRIVELINE/AXLE Differential - MX-5 Miata

3. Apply thread-locking compound to bolt threads A and points B of the gear back face. Apply approximately 0.04 cm3 {0.04 cc, 0.0024 cu in} of thread-locking compound at each point and bolt thread.

Fig. 48: Applying Thread-Locking Compound Bolt Threads A And Points B Of Gear Back Face

Courtesy of MAZDA MOTORS CORP.

4. Install the ring gear onto the gear case.

Tightening torque

69-83 N.m {7.0-8.5 kgf.m, 51-61 ft.lbf}

5. Press the bearing inner races (side bearing) on using the SST .

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Fig. 49: Pressing Bearing Inner Races Using SST

Courtesy of MAZDA MOTORS CORP.

6. Install the differential gear component in the carrier.

7. Note the identification marks on the adjusting nuts, and install them on their respective sides.

8. Install the differential bearing caps, making sure that the identification mark on the cap corresponds with the one on the carrier, using the SST . Then temporarily tighten the bolts.

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Fig. 50: Installing Differential Bearing Caps Using SST

Courtesy of MAZDA MOTORS CORP.

1. Mark the ring gear at four points at approx.90° intervals. Mount a dial indicator to the carrier so that the feeler comes in contact at a right angle with 1 of the ring gear teeth.

2. Turn both bearing adjusters equally using the SST until the backlash is 0.09-0.11 mm {0.0035-

0.0043 in} .

3. Inspect for the backlash at the 3 other marked points, and make sure the maximum backlash is less than 0.07 mm {0.0028 in} .

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Fig. 51: Mounting A Dial Indicator To Carrier

Courtesy of MAZDA MOTORS CORP.

9. Tighten or loosen the adjusting nuts equally until the distance between the pilot sections on the bearing caps is 185.428-185.500 mm {7.3003-7.3031 in}.

10. Reinspect for the backlash.

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Fig. 52: Inspecting Backlash

Courtesy of MAZDA MOTORS CORP.

11. Inspect the teeth contact as follows,

1. Coat both surfaces of 6-8 teeth of the ring gear with a thin coat of red lead.

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Fig. 53: Coating Both Surfaces Of Teeth Of Ring Gear With A Thin Coat Of Red Lead

Courtesy of MAZDA MOTORS CORP.

2. While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact.

3. If the tooth contact is good, wipe off the red lead.

4. If it is not good, adjust the pinion height, and then adjust the backlash.

1. Inspect the toe and flank contact by replacing the spacer with a thinner one to move the drive pinion outward.

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Fig. 54: Inspecting Toe And Flank Contact

Courtesy of MAZDA MOTORS CORP.

2. Inspect the heel and face contact by replacing the spacer with a thicker one to bring the drive pinion in.

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Fig. 55: Inspecting Heel And Face Contact By Replacing Spacer With A Thicker One

To Bring Drive Pinion

Courtesy of MAZDA MOTORS CORP.

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2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

2005 ACCESSORIES & EQUIPMENT

Security & Locks - MX-5 Miata

POWER DOOR LOCK SYSTEM LOCATION INDEX

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

Fig. 1: Identifying Power Door Lock System Components

Courtesy of MAZDA MOTORS CORP.

POWER DOOR LOCK SYSTEM WIRING DIAGRAM

See POWER DOOR LOCKS .

KEYLESS ENTRY SYSTEM WIRING DIAGRAM

See POWER DOOR LOCKS .

DOOR LOCK AND OPENER REMOVAL/INSTALLATION

1. Close the door glass completely.

2. Disconnect the negative battery cable.

3. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

4. To remove the door lock, remove the rear glass guide. (See DOOR DISASSEMBLY/ASSEMBLY .)

5. Remove in the order indicated in the table.

Fig. 2: Removing Door Lock And Opener - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

DOOR LOCK ACTUATOR INSPECTION

1. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

2. Remove the door screen.

3. Disconnect the door lock actuator connector.

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4. Apply battery positive voltage to the door lock actuator terminals and inspect the operation of the door lock actuator.



If not as specified, replace the passenger's side door lock.

Fig. 3: Inspecting Door Lock Actuator Connector Terminals

Courtesy of MAZDA MOTORS CORP.

ACTUATOR OPERATION REFERENCE

Connection

Actuator operation

B+ GND

A B Lock

B A Unlock

DOOR LOCK STRIKER REMOVAL/INSTALLATION

1. Remove the screws.

2. Remove the door lock striker.

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Fig. 4: Removing Door Lock Striker - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

4. Adjust the door. (See DOOR ADJUSTMENT .)

DOOR KEY CYLINDER SWITCH REMOVAL/INSTALLATION

1. Close the door glass completely.

2. Disconnect the negative battery cable.

3. Remove the door trim.

4. Remove the door screen.

5. Release the outer handle and the door key cylinder installation rods.

6. Disconnect the door key cylinder switch connector.

7. Remove the door key cylinder switch.

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Fig. 5: Removing Door Key Cylinder Switch

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

DOOR KEY CYLINDER SWITCH INSPECTION

1. Raise the door glass completely.

2. Disconnect the negative battery cable.

3. Remove door trim.

4. Remove the door screen.

5. Disconnect the door key cylinder switch connector.

6. Inspect for continuity between the door key cylinder switch terminals using an ohmmeter.



If not as specified, replace the door key cylinder switch.

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Fig. 6: Door Key Cylinder Switch Continuity And Resistance Table

Courtesy of MAZDA MOTORS CORP.

Fig. 7: Inspecting Door Key Cylinder Switch Connector Terminals

Courtesy of MAZDA MOTORS CORP.

DOOR LOCK SWITCH REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

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2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

2. Remove the door lock switch using a flathead screwdriver wrapped with protective tape.

Fig. 8: Removing Door Lock Switch

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

DOOR LOCK SWITCH INSPECTION

1. Remove the door lock switch. (See DOOR LOCK SWITCH REMOVAL/INSTALLATION .)

2. Inspect for continuity between the door lock switch terminals using an ohmmeter.

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2005 Mazda MX-5 Miata

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

If not as specified, replace the door lock switch.

Fig. 9: Door Lock Switch Resistance And Continuity Table

Courtesy of MAZDA MOTORS CORP.

Fig. 10: Inspecting Door Lock Switch Connector Terminals

Courtesy of MAZDA MOTORS CORP.

DOOR LOCK CONTROL MODULE REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the lower panel.

3. Remove in the order indicated in the table.

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Fig. 11: Removing Door Lock Control Module

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

DOOR LOCK CONTROL MODULE INSPECTION

1. Remove the lower panel.

2. Measure the voltage at the door lock control module terminals as indicated below.

3. Disconnect the door lock control module connector before inspecting for continuity at terminals M and N.



If not as specified, inspect the parts listed under "Action".



If the parts and wiring harnesses are okay but the system still does not work properly, replace the door lock control module.

TERMINAL VOLTAGE LIST (REFERENCE)

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Fig. 12: Door Lock Control Module Connector Terminal Voltage Reference Chart

Courtesy of MAZDA MOTORS CORP.

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KEYLESS CONTROL MODULE REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the glove compartment. (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)

3. Disconnect the keyless control module connector.

4. Remove the nut to remove the keyless control module and the bracket as a module.

Fig. 13: Removing Keyless Control Module

Courtesy of MAZDA MOTORS CORP.

5. Remove the screw.

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Fig. 14: Removing Screw

Courtesy of MAZDA MOTORS CORP.

6. Remove the bracket.

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Fig. 15: Removing Bracket

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

KEYLESS CONTROL MODULE INSPECTION

1. Pull out the keyless control module with the connector connected.

2. Measure the voltage at the keyless control module terminals (other than terminal L) as indicated below.



If not as specified, inspect the parts listed under "Action."

3. Disconnect the negative battery cable.

4. Disconnect the keyless control module connector and inspect for continuity between terminal L and bracket.

5. Inspect for continuity at terminal L as indicated below.

6. If the parts and wiring harnesses are okay but the system still does not work properly, replace the keyless

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2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata control module.

TERMINAL VOLTAGE TABLE (REFERENCE)

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Fig. 16: Keyless Terminal Control Module Connector Terminal Voltage Reference Table

Courtesy of MAZDA MOTORS CORP.

KEYLESS CONTROL MODULE ID CODE CHANGE



When programming the ID code into a transmitter, verify that other transmitters are not being operated in the vicinity.



Program the ID code as indicated in the procedure below.

Fig. 17: Keyless Control Module ID Code Change Procedure

Courtesy of MAZDA MOTORS CORP.

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TRANSMITTER BATTERY REPLACEMENT

RETRACTABLE KEY TYPE

1. Insert a small screwdriver into the slot and push the tab to remove the key from the transmitter.

Fig. 18: Removing Key From Transmitter

Courtesy of MAZDA MOTORS CORP.

2. Insert a small screwdriver into the slot and gently pry open the transmitter.

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Fig. 19: Opening Transmitter

Courtesy of MAZDA MOTORS CORP.

3. Remove the battery.

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Fig. 20: Removing Battery

Courtesy of MAZDA MOTORS CORP.

4. Put in the new battery (CR1620) with the positive pole (+) facing down.

5. Align the front and back covers and snap the transmitter shut.

Battery specification

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Lithium CR1620 x 1

Fig. 21: Putting In New Battery With Positive Pole (+) Facing Down

Courtesy of MAZDA MOTORS CORP.

NOTE:



The batteries will last about 2 years when used 10 times a day.

6. Install the key to the transmitter.

FUEL-FILLER LID OPENER REMOVAL/INSTALLATION

1. Remove the rear console. (See CONSOLE REMOVAL/INSTALLATION .)

2. Remove the rear package trim. (See REAR PACKAGE TRIM REMOVAL/INSTALLATION .)

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3. Remove the rear end mat.

4. Remove the driver's side trunk side trim.

5. Remove in the order indicated in the table.

Fig. 22: Removing Fuel-Filler Lid Opener

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

HOOD LOCK AND OPENER REMOVAL/INSTALLATION

1. Remove the upper shroud panel.

2. Remove in the order indicated in the table.

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Fig. 23: Removing Hood Lock And Opener - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

4. Adjust the hood. (See HOOD ADJUSTMENT .)

TRUNK LID LOCK AND OPENER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

3. Remove the rear package trim. (See REAR PACKAGE TRIM REMOVAL/INSTALLATION .)

4. Remove the rear end mat.

5. Remove the driver's side trunk side trim.

6. Remove the trunk end trim.

7. Remove the rear bumper. (See REAR BUMPER REMOVAL/INSTALLATION .)

8. Remove in the order indicated in the table.

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Fig. 24: Removing Trunk Lid Lock And Opener

Courtesy of MAZDA MOTORS CORP.

9. Install in the reverse order of removal.

10. Adjust the trunk lid. (See TRUNK LID ADJUSTMENT .)

INTERNAL TRUNK LID RELEASE HANDLE INSTALLATION NOTE

CAUTION:



Always keep the handle firmly attached to the holder and in the recessed position. Not securing the handle this way could allow it to snag luggage in the compartment and open the trunk lid.

1. After installation of the internal trunk lid release handle, pull the handle forward to verify the handle and rod are securely installed.

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2. Attach the handle to the holder on the cover and in the recessed position.

Fig. 25: Installing Internal Trunk Lid Release Handle

Courtesy of MAZDA MOTORS CORP.

TRUNK LID LOCK ACTUATOR INSPECTION

1. Disconnect the negative battery cable.

2. Disconnect trunk lid lock actuator.

3. Apply battery positive voltage to the trunk lid lock actuator terminals and inspect the operation of the trunk lid lock actuator.



If not as specified, replace the trunk lid lock.

ACTUATOR OPERATION REFERENCE

Connection

Actuator operation

A B

GND B+ Unlock

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Fig. 26: Inspecting Trunk Lid Lock Actuator Connector Terminals

Courtesy of MAZDA MOTORS CORP.

TRUNK LID OPENER RELAY REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the trunk end trim panel.

3. Remove the clip of the trunk lid opener relay using a flathead screwdriver to remove the trunk lid opener

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Fig. 27: Removing Trunk Lid Opener Relay

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

TRUNK LID STRIKER REMOVAL/INSTALLATION

1. Remove the bolts.

2. Remove the trunk lid striker.

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Fig. 28: Removing Trunk Lid Striker - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

4. Adjust the trunk lid. (See TRUNK LID ADJUSTMENT .)

IMMOBILIZER SYSTEM LOCATION INDEX

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Fig. 29: Identifying Immobilizer System Components

Courtesy of MAZDA MOTORS CORP.

IMMOBILIZER SYSTEM SERVICE CAUTION

CAUTION:



When an immobilizer system component (such as the PCM, immobilizer unit, coil or the key) has failed, it must be accurately determined according to the troubleshooting procedures or by the display of the DTCs prior to carrying out the service procedures.

If a normal component is mistakenly replaced and the ID number and/or code word are input into the new component, then neither

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 component can be reused on other vehicles.

When a new key registration or immobilizer unit and/or PCM replacement is performed on vehicles equipped with an immobilizer system, the new ID number should be registered using the procedure that includes engine cranking through idling. When the engine starts to reprogram the immobilizer system, if the input voltage to the immobilizer unit becomes lower than the operation voltage of the immobilizer system, the ID number cannot be input momentarily.

This is not a unit failure, so do not misunderstand during the problem diagnosis (when the terminal voltage goes back to the operation voltage, then the unit also begins to operate normally).

Charge or replace the battery.

IMMOBILIZER UNIT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

Fig. 30: Removing Immobilizer Unit

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

CAUTION:



After replacing the immobilizer unit with a new one, the engine cannot be started without reprogramming the ID number of the keys and the code word of the new immobilizer unit. Input the ID number and code word. (See IMMOBILIZER SYSTEM

REPROGRAM PROCEDURE.)

IMMOBILIZER UNIT INSPECTION

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1. Measure the voltage at the immobilizer unit terminals as indicated below.

2. Disconnect the immobilizer unit connector before inspecting for continuity at terminal C.



If not as specified, inspect the parts listed under "Action".



If the parts and wiring harnesses are okay but the system still does not work properly, replace the immobilizer unit.

TERMINAL VOLTAGE TABLE (REFERENCE)

Fig. 31: Immobilizer Unit Terminal Voltage Reference Table

Courtesy of MAZDA MOTORS CORP.

COIL REMOVAL/INSTALLATION

NOTE:



Do not remove the coil unless you are replacing it.

When only the coil is replaced, the immobilizer system reprogram procedure is not necessary.

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1. Disconnect the negative battery cable.

2. Remove the column cover.

3. Remove in the order indicated in table.

Fig. 32: Removing Coil

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

COIL INSTALLATION NOTE

1. Install the hook 1 to the steering lock.

2. Install the hook 2 to the steering lock.

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Fig. 33: Installing Hook 1 And 2

Courtesy of MAZDA MOTORS CORP.

IMMOBILIZER SYSTEM REPROGRAM PROCEDURE

NOTE:



When an error occurs during the reprogram procedures, except when both the immobilizer unit and PCM are replaced, repeat the procedure from Step

1. If you still cannot reprogram, confirm how many keys can start the engine. Then, perform the key replacement or addition reprogram procedure according to the valid key number.

To make a copy of the key or replace the immobilizer system component parts (the key(s), steering lock, immobilizer unit and/or PCM), the customer should bring all keys to the dealer. This is because the previously programmed key IDs are erased when reprogramming the key

IDs into the immobilizer unit and PCM.

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

If the customer has only one valid key when replacing the immobilizer system component parts, the dealer should contact a distributor to obtain the code word.

To replace the immobilizer unit or PCM, there should be at least one valid key. Otherwise, both the immobilizer unit and PCM should be replaced.

The immobilizer unit and PCM cannot be changed from one car to another.

If an immobilizer unit or PCM is replaced with one from another car, the engine will not start. Reprogramming of the IDs and code word of an immobilizer unit that has already been programmed as set is not possible.

The immobilizer unit and PCM should not be newly replaced as a trial during troubleshooting. If this is done, the ID and code word will be programmed into the new unit and it cannot be used for other cars even if you find that the old unit was normal.

The immobilizer system cannot be deactivated.

Confirm that all keys registered can start the engine after the reprogram procedure. When confirming, wait for more than 5 seconds before inserting the next key.

When the customer does not need to register more than two keys, the following procedures can be stopped after registering two keys.

KEY REPLACEMENT OR ADDITION

When customer has brought two or more valid keys

Fig. 34: Identifying Key Replacement Or Addition - Two Or More Valid Keys

Courtesy of MAZDA MOTORS CORP.

NOTE:



If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Cut new transponder equipped key (s).

2. Using key 1, turn ignition switch to ON position then back to LOCK position five times . The key should not remain at ON position or LOCK position for more than 1 second .

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

1. Turn key 1 back to ON position. Observe illumination of security light in instrument cluster.

2. Turn key 1 to LOCK position and remove key 1 from steering lock. Observe security light goes out.

3. Using key 2, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 2 to LOCK position and remove from steering lock.

4. Repeat Step 3 with key 1.

5. Repeat Step 3 with key 3.

6. If there are 4-8 keys (valid and/or new keys), repeat Step 3.

7. Wait for 30 seconds to quit reprogram mode.

When customer has brought only one or no valid key (code word is required)

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

Fig. 35: Identifying Key Replacement Or Addition - One Or No Valid Key

Courtesy of MAZDA MOTORS CORP.

NOTE:



If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Cut new transponder equipped key(s).

2. Using key 1, turn ignition switch to ON position then back to LOCK position five times . The key should not remain at ON position or LOCK position for more than 1 second .

1. Turn key 1 back to ON position. Observe flashing of security light ( 300 ms ON300 ms OFF) in instrument cluster.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

2. Turn key 1 to LOCK position and wait for 5 minutes until security light decreases in flashing frequency to 1.2 seconds.

3. Input code word. (See CODE WORD INPUT PROCEDURE .)

4. Observe security light stops flashing and illuminates.

5. Start engine with key 1.Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

6. Turn key 1 to LOCK position and remove from steering lock.

3. Using key 2, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 2 to LOCK position and remove from steering lock.

4. Repeat Step 3 with key 3.

5. If there are 4-8 keys (valid and/or new keys), repeat Step 3.

6. Wait for 30 seconds to quit reprogram mode.

STEERING LOCK REPLACEMENT

When customer has brought two or more valid keys for old steering lock

Fig. 36: Steering Lock Replacement - Two Or More Valid Keys

Courtesy of MAZDA MOTORS CORP.

NOTE:



When replacing the steering lock, the coil and keys should be replaced as a set.

If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Remove old steering lock.

2. Connect new steering lock to ignition switch connector.

3. Connect old steering lock to coil connector as shown in figure.

4. Insert key 1 into old steering lock.

5. Insert key 3 into new steering lock and turn to ON position then back to LOCK position five times.

The

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata key should not remain at ON position or LOCK position for more than 1 second.

1. Turn key 3 back to ON position. Observe illumination of security light in instrument cluster.

2. Turn key 3 to LOCK position. Observe security light goes out.

NOTE:



Operate next two steps within 30 seconds of Step 5-2.

6. Remove key 1 from old steering lock and insert key 2 into old steering lock.

7. Using key 3 of new steering lock, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 3 to LOCK position.

NOTE:



Operate next two steps within 30 seconds of Step 7-1.

8. Disconnect coil connector from old steering lock, and reconnect coil connector to new steering lock.

9. Using key 3 of new steering lock, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 3 to LOCK position and remove from steering lock.

10. Repeat Step 9 with key 4.

11. Repeat Step 9 with key 5.

12. Wait for 30 seconds to quit reprogram mode.

13. Install new steering lock.

When customer has brought only one or no valid key (code word is required)

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

Fig. 37: Steering Lock Replacement - One Or No Valid Key

Courtesy of MAZDA MOTORS CORP.

NOTE:



When replacing the steering lock, the coil and keys should be replaced as a set.

If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Replace steering lock.

2. Using key 1, turn ignition switch to ON position then back to LOCK position five times . Key should not remain at ON position or LOCK position for more than 1 second.

1. Turn key 1 back to ON position. Observe flashing of security light ( 300 ms ON -300 ms OFF) in instrument cluster.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

2. Turn key 1 to LOCK position and wait for 5 minutes until security light decreases in flashing frequency to 1.2 seconds .

3. Input code word. (See CODE WORD INPUT PROCEDURE .)

4. Observe the security light stops flashing and illuminates.

5. Start engine with key 1.Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

6. Turn key 1 to LOCK position and remove from steering lock.

3. Using key 2, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 2 to LOCK position and remove from steering lock.

4. Repeat Step 3 with key 3.

5. Wait for 30 seconds to quit reprogram mode.

IMMOBILIZER UNIT REPLACEMENT

When customer does not have valid key



PCM needs to be replaced with immobilizer unit. Perform BOTH IMMOBILIZER UNIT AND PCM

REPLACEMENT of the IMMOBILIZER SYSTEM REPROGRAM PROCEDURE. (See BOTH

IMMOBILIZER UNIT AND PCM REPLACEMENT .)

When customer has brought at least one valid key (code word is required)

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

Fig. 38: Immobilizer Unit Replacement - One Valid Key

Courtesy of MAZDA MOTORS CORP.

NOTE:



If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Cut new transponder equipped key(s) if necessary.

2. Replace immobilizer unit. (See IMMOBILIZER UNIT REMOVAL/INSTALLATION .)

3. Using key 1, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 1 to LOCK position and remove from steering lock.

4. Using key 2, turn ignition switch to ON position then back to LOCK position five times.

The key should not remain at ON position or LOCK position for more than 1 second.

1. Turn key 2 back to ON position. Observe flashing of security light ( 300 ms ON300 ms OFF) in

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata instrument cluster.

2. Turn key 2 to LOCK position and wait for 5 minutes until security light decreases in flashing frequency to 1.2 seconds.

3. Input code word. (See CODE WORD INPUT PROCEDURE .)

4. Observe the security light stops flashing and illuminates.

5. Start engine with key 2.Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

6. Turn key 2 to LOCK position and remove from steering lock.

5. Using key 1, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 1 to LOCK position and remove from steering lock.

6. Repeat Step 5 with key 3.

7. If there are 4-8 keys (valid and/or new keys), repeat Step 5.

8. Wait for 30 seconds to quit reprogram mode.

PCM REPLACEMENT

When customer does not have valid key

 Immobilizer unit needs to be replaced with PCM. Perform BOTH IMMOBILIZER UNIT AND PCM

REPLACEMENT of the IMMOBILIZER SYSTEM REPROGRAM PROCEDURE. (See BOTH

IMMOBILIZER UNIT AND PCM REPLACEMENT .)

When customer has brought two or more valid keys

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

Fig. 39: PCM Replacement - Two Or More Valid Keys

Courtesy of MAZDA MOTORS CORP.

NOTE:



If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Cut new transponder equipped key(s) if necessary.

2. Replace PCM. (See PCM REMOVAL/INSTALLATION [BP, BP WITH TC] .)

3. Using key 1, turn ignition switch to ON position, and observe that security light illuminates (for 1-2 seconds ) in instrument cluster.

1. Turn key 1 to LOCK position.

2. Turn key 1 to ON position then back to LOCK position six times.

The key should not remain at

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

ON position or LOCK position for more than 1 second.

It is particularly important to ensure that the 6th turn is done within 1 second.

3. Remove key 1.

4. Using key 2, turn ignition switch to ON position. Observe that security light illuminates (for 1-2 seconds ).(1) Turn key 2 to LOCK position and remove from steering lock.

5. Using key 1, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 1 to LOCK position and remove from steering lock.

6. Repeat Step 5 with key 3.

7. If there are 4-8 keys (valid and/or new keys), repeat Step 5.

8. Wait for 30 seconds to quit reprogram mode.

9. After reprogramming, clear DTCs of PCM with WDS or equivalent.

When customer has brought only one valid key (code word is required)

Fig. 40: PCM Replacement - Only One Valid Key

Courtesy of MAZDA MOTORS CORP.

NOTE:



If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Cut new transponder equipped key(s) if necessary.

2. Replace PCM. (See PCM REMOVAL/INSTALLATION [BP, BP WITH TC] .)

3. Using key 1, turn ignition switch to ON position. Observe that security light illuminates (for 1-2 seconds ) in instrument cluster.

1. Turn key 1 to LOCK position and remove from steering lock.

4. Using key 2, turn ignition switch to ON position then back to LOCK position six times.

The key should not remain at ON position or LOCK position for more than 1 second.

It is particularly important to ensure that the 6th turn is done within 1 second.

1. Observe flashing of security light ( 300 ms ON300 ms OFF) in instrument cluster.

2. Wait for 5 minutes until security light decreases in flashing frequency to 1.2 seconds.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

3. Input code word. (See CODE WORD INPUT PROCEDURE .)

4. Observe the security light stops flashing and illuminates.

5. Turn key 2 to ON position. Observe that security light illuminates (for 1-2 seconds ).

6. Turn key 2 to LOCK position and remove from steering lock.

5. Using key 3, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

1. Turn key 3 to LOCK position and remove from steering lock.

6. Repeat Step 5 with key 1.

7. If there are 4-8 keys (valid and/or new keys), repeat Step 5.

8. Wait for 30 seconds to quit reprogram mode.

9. After reprogramming, clear DTC of PCM with WDS or equivalent.

BOTH IMMOBILIZER UNIT AND PCM REPLACEMENT

When customer has brought two or more valid keys

NOTE:



Keys may be valid or new keys.

When an error occurs in Steps 1 to 4, repeat the procedure from Step 1.

When an error occurs in Step 5, perform the REPROGRAM ERROR

RECOVERY PROCEDURE FOR BOTH IMMOBILIZER UNIT AND PCM

REPLACEMENT.

If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Cut new transponder equipped key(s) if necessary.

2. Replace immobilizer unit and PCM. (See IMMOBILIZER UNIT REMOVAL/INSTALLATION .)

(See PCM REMOVAL/INSTALLATION [BP, BP WITH TC] .)

3. Using key 1, turn ignition switch to ON position. Observe security light illuminates and then goes out in instrument cluster.

1. Turn key 1 to LOCK position. Observe security light blinks once repeatedly.

4. Using key 2, turn ignition switch to ON position. Observe security light illuminates and then goes out.

1. Turn key 2 to LOCK position. Observe security light blinks twice repeatedly.

5. Using key 3, turn ignition switch to ON position. Observe security light illuminates and then goes out.

1. Turn key 3 to LOCK position. Observe security light blinks three times repeatedly.

6. If there are 4-8 keys (valid and/or new keys), repeat Step 4.

7. Wait for 30 seconds to quit reprogram mode.

8. After reprogramming, clear DTCs of PCM with WDS or equivalent.

Reprogram error recovery procedure for both immobilizer unit and PCM replacement

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

NOTE:



If no specific time interval is given, each step should be performed within

30 seconds of the previous step.

1. Using key 1, start engine. After security light illuminates for 1-2 seconds , turn key 1 to LOCK position.

2. Using key 1, turn ignition switch to ON position then back to LOCK position five times.

Key should not remain at ON position or LOCK position for more than 1 second.

3. Using key 1, turn ignition switch to ON position (security light illuminates).

4. Turn key 1 to LOCK position and remove from steering lock (security light goes out).

5. Using key 2, start engine. Observe that security light illuminates (for 1-2 seconds ) and engine continues to run.

6. Turn key 2 to LOCK position and remove from steering lock.

7. Repeat Steps 5 and 6 with key 1.

8. Repeat Steps 5 and 6 with key 3.

9. If there are 4-8 keys (valid and/or new keys), repeat Steps 5 and 6.

10. Wait for 30 seconds to quit reprogram mode.

11. After reprogramming, clear DTCs of PCM with WDS or equivalent.

CODE WORD INPUT PROCEDURE

NOTE:



A code word is composed of eight digits from 1-9 and is part of the immobilizer unit from the manufacturer. Each unit has its own code word.

To obtain the code word, you need to have the immobilizer serial number, then ask the distributor.

To input the code word into the PCM, turn the ignition key and count the number of flashes of the security light. The calculation of the number of flashes of the security light comes with the timing of the turning of the key.

1. Wait for 5 minutes until security light flashes slowly. ( 300 ms ON300 ms OFF --> 1.2 s ON1.2 s OFF)

2. Input the code word as shown in the example below.

Fig. 41: Inputting Code Word

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

1. Turn ignition switch to ON position while security light is off and count three illumination cycles.

As the light goes out after the third illumination, turn key to LOCK position.

2. Wait at least one illumination cycle and within 30 seconds of going to LOCK position, turn ignition switch to ON position while security light is off and count one illumination cycle. As the light goes out after the first illumination, turn key to LOCK position.

3. Repeat Step (2) for rest of six digits.

3. When code word is registered correctly in the PCM, the security light stops flashing and illuminates.

4. As soon as the security light stops flashing and illuminates, the following immobilizer system reprogram procedure should be started.

NOTE:



If the code word is not input correctly, the security light goes out after all eight digits are input. In this case, perform the CODE WORD

INPUT ERROR RECOVERY PROCEDURE.

EXAMPLES OF INCORRECT INPUT OF CODE WORD

NOTE:



The security light must flash one or more times between the digits of the code word.

If the code word is input incorrectly, the security light goes out. Turn the ignition switch to ON position then back to LOCK position five times

(except PCM replacement) or six times (PCM replacement) and repeat the procedure to input all eight figures for the code word.

When an error occurs during the reprogram procedures except when both the immobilizer unit and PCM are replaced, repeat the procedure from Step

1. If you still cannot reprogram, confirm how many keys can start the engine. Then, perform the key replacement or addition reprogram procedure according to the valid key number.



The security light flashes ten or more times while the ignition switch is at ON position.

Fig. 42: Security Light Flashing Pattern While Ignition Switch Is At On Position

Courtesy of MAZDA MOTORS CORP.



The ignition switch is turned to ON position and LOCK position while the security light is off.

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2005 ACCESSORIES & EQUIPMENT Security & Locks - MX-5 Miata

Fig. 43: Examples Of Incorrect Input Of Code Word (1 Of 3)

Courtesy of MAZDA MOTORS CORP.

 The ignition switch is turned to LOCK position and ON position while the security light is on.

Fig. 44: Examples Of Incorrect Input Of Code Word (2 Of 3)

Courtesy of MAZDA MOTORS CORP.



The ignition switch is turned to LOCK position and ON position while the security light is off.

Fig. 45: Examples Of Incorrect Input Of Code Word (3 Of 3)

Courtesy of MAZDA MOTORS CORP.



A non-corresponding code word is input to the immobilizer unit.

CODE WORD INPUT ERROR RECOVERY PROCEDURE

1. Turn ignition switch to ON position then back to LOCK position five times (except PCM replacement) or six times (PCM replacement). The key should not remain at ON position or LOCK position for more than 1 second.

2. Repeat the "CODE WORD INPUT PROCEDURE".

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2005 ACCESSORIES & EQUIPMENT Doors And Liftgate - MX-5 Miata

2005 ACCESSORIES & EQUIPMENT

Doors And Liftgate - MX-5 Miata

DOOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the front fender panel. (See FRONT FENDER PANEL REMOVAL/INSTALLATION .)

3. Remove the door speaker. (See DOOR SPEAKER REMOVAL/INSTALLATION .)

4. Remove in the order indicated in the table.

Fig. 1: Removing Door - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

6. Adjust the door. (See DOOR ADJUSTMENT .)

CONNECTOR REMOVAL NOTE

1. Pull the pin out.

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Doors And Liftgate - MX-5 Miata

Fig. 2: Removing Connector

Courtesy of MAZDA MOTORS CORP.

CONNECTOR INSTALLATION NOTE

1. Push the pin until it stops.

2. Connect the connector.

3. Repush the pin until it stops and locks the connector.

DOOR DISASSEMBLY/ASSEMBLY

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2005 ACCESSORIES & EQUIPMENT Doors And Liftgate - MX-5 Miata

1. Lower or raise the front door glass so that the distance from the top of the front door glass at the molding is 225 mm {8.86 in} .

2. Disconnect the negative battery cable.

3. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

4. Disassemble in the order indicated in the table.

Fig. 3: Disassembling Door - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

5. Assemble in the reverse order of disassembly.

6. Adjust the door glass. (See DOOR GLASS ADJUSTMENT .)

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Doors And Liftgate - MX-5 Miata

DOOR ADJUSTMENT

1. Measure the clearance between the door and body.



If not as specified, loosen the door hinge installation bolts or the door lock striker installation screws, and reposition the door.

Clearance a:4.0-6.0 mm {0.16-0.23 in} b:-1.0-1.0 mm {-0.03-0.03 in}

2. Tighten the bolts or screws.

Fig. 4: Adjusting Door

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

2005 DRIVELINE/AXLE

Drive Shaft - MX-5 Miata

DRIVE SHAFT LOCATION INDEX

Fig. 1: Identifying Drive Shaft Location

Courtesy of MAZDA MOTORS CORP.

DRIVE SHAFT PRE-INSPECTION

1. Inspect the dust boot on the drive shaft for cracks, damage, leaking grease, and looseness in boot band.

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 2: Inspecting Dust Boot On Drive Shaft

Courtesy of MAZDA MOTORS CORP.

2. Inspect the drive shaft for bending, cracks, and wear of the joint and splines.

 Repair or replace the drive shaft as necessary.

DRIVE SHAFT REMOVAL/INSTALLATION

CAUTION:



Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 3: Exploded View Of Drive Shaft & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

DRIVE SHAFT REMOVAL NOTE

NOTE:



1. Pull the rear hub support from the drive shaft.

2. Remove the drive shaft from the differential using a pry bar.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 4: Removing Drive Shaft From Differential

Courtesy of MAZDA MOTORS CORP.

DRIVE SHAFT INSTALLATION NOTE

1. Install a new clip onto the drive shaft.

2. Measure the outer diameter of the clip after installing.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 5: Measuring Outer Diameter Of Clip After Installing

Courtesy of MAZDA MOTORS CORP.



Replace the clip.



If it exceeds the specification.

CAUTION:



The sharp edges of the drive shaft snap ring can slice or puncture the oil seal. Be careful when installing the drive shaft to the transmission.

3. With the ends of the clip facing upward, push the drive shaft into the differential.

4. After installation, pull outward on the double offset joint outer ring and verify that the drive shaft is securely held by the clip.

DRIVE SHAFT DISASSEMBLY/ASSEMBLY (BP)

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

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2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 6: Disassembled View Of Drive Shaft

Courtesy of MAZDA MOTORS CORP.

BOOT BANDS DISASSEMBLY NOTE

1. Pry up the locking clips using a screwdriver.

2. Pull back the end of the band.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 7: Disassembling Boot Bands

Courtesy of MAZDA MOTORS CORP.

CLIP DISASSEMBLY NOTE

1. Mark the drive shaft and outer ring.

2. Remove the clip.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 8: Removing Clip

Courtesy of MAZDA MOTORS CORP.

SNAP RING DISASSEMBLY NOTE

1. Mark the drive shaft end and inner ring.

2. Remove the snap ring using snap-ring pliers.

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2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 9: Removing Snap Ring Using Snap-Ring Pliers

Courtesy of MAZDA MOTORS CORP.

BALLS, INNER RING, CAGE DISASSEMBLY NOTE

1. Insert a screwdriver between the inner ring and cage to remove the balls.

2. Mark the inner ring and cage.

3. Turn the cage approx.30° , then pull it away from the inner ring.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 10: Turning Cage Approx. 30 Degrees

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

BOOTS DISASSEMBLY NOTE

1. Wrap the shaft splines with tape.

Fig. 11: Wrapping Shaft Splines With Tape

Courtesy of MAZDA MOTORS CORP.

2. Remove the boot.

ABS SENSOR ROTOR (WITH ABS) DISASSEMBLY NOTE

NOTE:



The sensor rotor does not need to be removed unless it is being replaced.

1. Tap the ABS sensor rotor off the bell joint outer race using a chisel.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 12: Taping ABS Sensor Rotor Off Bell Joint Outer Race

Courtesy of MAZDA MOTORS CORP.

ABS SENSOR ROTOR (WITH ABS) ASSEMBLY NOTE

1. Press in the ABS sensor rotor using the SST .

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2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 13: Pressing ABS Sensor Rotor

Courtesy of MAZDA MOTORS CORP.

BOOTS ASSEMBLY NOTE

1. Before putting the boot onto the shaft, wrap the shaft splines with tape.

NOTE:



The initials DOJ and BJ are stamped on the wheel side and differential side boots respectively.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 14: Wrapping The Shaft Splines With Tape

Courtesy of MAZDA MOTORS CORP.

2. Install the wheel side and differential side boots, noting the shape and size of each one in the figure.

Outer diameter of large boot end

Differential side:87.4 mm {3.44 in}

Wheel side:90.8 mm {3.57 in}

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 15: Installing Wheel Side And Differential Side Boots

Courtesy of MAZDA MOTORS CORP.

CAGE, INNER RING, BALLS ASSEMBLY NOTE

1. Align the marks and install the balls to the inner ring.

2. Install the cage, inner ring, and ball component to the drive shaft in the direction shown in Fig. 16 . The larger diameter of the cage should be facing the snap ring groove.

3. Install a new snap ring in the drive shaft snap ring groove.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 16: Installing New Snap Ring In Drive Shaft Snap Ring Groove

Courtesy of MAZDA MOTORS CORP.

4. Apply the specified grease (supplied in the boot kit) to the joints and boots.

CAUTION:



Do not touch grease with your hand. Apply from the tube to prevent foreign matter entering the boot.

Total quantity

Differential side:85-105 g {3.01-3.70 oz}

Wheel side:55-75 g {1.95-2.64 oz}

5. Align the marks, then install a new clip.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 17: Installing A New Clip

Courtesy of MAZDA MOTORS CORP.

BOOT BANDS ASSEMBLY NOTE

1. Verify that the boots are not dented or twisted.

2. Set the drive shaft to the standard length.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 18: Setting Drive Shaft To Standard Length

Courtesy of MAZDA MOTORS CORP.

Standard length

772.6-782.6 mm {30.42-30.81 in}

3. Release any trapped air from the boots by carefully lifting up the small end of each boot with a clothwrapped screwdriver.

CAUTION:



Be careful not to allow the grease to leak.

Do not damage the boot.

4. Verify that the drive shaft length is within the standard.



If the drive shaft length is not within the standard, return to step 1.

5. Fold the new band back by pulling on the end of it with pliers. The band should be folded in the direction opposite the forward revolving direction of the drive shaft.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 19: Folding New Band Back By Pulling On End Of With Pliers

Courtesy of MAZDA MOTORS CORP.

6. Lock the end of the band by bending the locking clips.

CAUTION:



Verify that the boot band is installed in the boot groove securely.

DRIVE SHAFT DISASSEMBLY/ASSEMBLY (BP WITH TC)

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 20: View Of Drive Shaft

Courtesy of MAZDA MOTORS CORP.

BOOT BAND (AXLE SIDE) DISASSEMBLY NOTE

NOTE:



Remove the boot band only if there is an abnormality.

1. Remove the boot band using end clamp pliers.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 21: Removing Boot Band Using End Clamp Pliers

Courtesy of MAZDA MOTORS CORP.

BOOT BAND (DIFFERENTIAL SIDE) DISASSEMBLY NOTE

1. Remove the crimp of the clip using a flathead screwdriver.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 22: Removing Crimp Of Clip Using A Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

OUTER RING DISASSEMBLY NOTE

1. Place an alignment mark on the drive shaft and the outer ring.

2. Remove the outer ring.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 23: Placing An Alignment Mark On Drive Shaft And Outer Ring

Courtesy of MAZDA MOTORS CORP.

SNAP RING, TRIPOD JOINT DISASSEMBLY NOTE

1. Place an alignment mark on the shaft and tripod joint.

2. Remove the snap ring using a snap ring plier.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 24: Removing Tripod Joint From Shaft

Courtesy of MAZDA MOTORS CORP.

3. Remove the tripod joint from the shaft.

CAUTION:



To prevent damage to the component, do not use a hammer when removing it.

BOOT DISASSEMBLY NOTE

NOTE:



Remove the axle side boot only if there is an abnormality.

1. Wrap the shaft spline with vinyl tape.

Microsoft

2. Remove the boot.

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 25: Wrapping Shaft Spline With Vinyl Tape

Courtesy of MAZDA MOTORS CORP.

ABS SENSOR ROTOR DISASSEMBLY NOTE

CAUTION:



Do not remove the sensor rotor unless it is necessary.

Do not reuse the sensor rotor if removed.

1. Tap the ABS sensor rotor off the drive shaft using a chisel.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 26: Taping ABS Sensor Rotor Off Drive Shaft Using A Chisel

Courtesy of MAZDA MOTORS CORP.

ABS SENSOR ROTOR ASSEMBLY NOTE

1. Set a new ABS sensor rotor on the drive shaft and press it on using the SSTs .

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 27: Installing New ABS Sensor Rotor On Drive Shaft

Courtesy of MAZDA MOTORS CORP.

BOOT ASSEMBLY NOTE

NOTE:



The boot shapes on the axle side and the differential side are different so do not misinstall them.

1. Fill the inside of the new dust boot (wheel side) with grease.

NOTE:



Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

Grease amount

70-90 g {2.47-3.17 oz}

2. Install the boot with the drive shaft spline still wrapped with vinyl tape.

3. Remove the vinyl tape.

TRIPOD JOINT, SNAP RING ASSEMBLY NOTE

1. Align the tripod joint with the shaft mark and insert it using a brass bar.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 28: Aligning Tripod Joint With Shaft Mark And Insert It Using A Brass Bar

Courtesy of MAZDA MOTORS CORP.

CAUTION:



To prevent damage to the component, do not tap the roller part when installing.

2. Install the new snap ring to the shaft installation slot securely using a snap ring pliers.

OUTER RING ASSEMBLY NOTE

1. Fill the outer ring and boot (differential side) with the repair kit grease.

NOTE:



Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.

Grease amount

135-155 g {4.77-5.46 oz}

2. Assemble the outer ring.

3. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 29: Releasing Any Trapped Air From Boots

Courtesy of MAZDA MOTORS CORP.

CAUTION:



Do not let the grease leak.

Do not damage the boot.

4. Set the drive shaft length to the specification when the inside of the boots is at ambient pressure.

Standard

771.5-781.5 mm {30.38-30.76 in}

5. After installation, verify that there is no boot damage or grease leakage.

BOOT BAND (DIFFERENTIAL SIDE) ASSEMBLY NOTE

1. Using pliers, pull the boot band around the boot slot in opposite direction of drive shaft forward rotation direction and tighten.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 30: Pulling Boot Band Around Boot Slot In Opposite Direction Of Drive Shaft Forward

Rotation Direction And Tighten

Courtesy of MAZDA MOTORS CORP.

2. Insert the end of the boot band between the boot band clip and fold back the clip tabs using a flathead screwdriver to secure the boot band.

3. Verify that the boot band is installed to the boot slot securely.

BOOT BAND (AXLE SIDE) ASSEMBLY NOTE

1. Turn the adjusting bolt of the SST and adjust the opening size to the specification A.

Specification A

2.9 mm {0.11 in}

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 31: Adjusting Bolt Of SST

Courtesy of MAZDA MOTORS CORP.

2. Crimp the boot band (small-size) using the SST .

3. Verify that the crimp value B is within the specification.



If the crimp value B exceeds the specification, reduce opening length A of the SST and recrimp the boot band.

If the crimp value B is less than the specification, increase opening length A of the SST and crimp the new boot band.

Specification B

2.4-2.8 mm {0.095-0.110 in}

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata

Fig. 32: Crimping Boot Band

Courtesy of MAZDA MOTORS CORP.

4. Verify that the boot band does not protrude from the boot band installation area.



If the boot band protrudes from the installation area, replace it with a new band and repeat Step 2 --

5. Fill the boot with the repair kit grease.

6. Adjust opening length A of the SST to the specification.

Specification A

3.2 mm {0.13 in}

7. Crimp the boot band (large-size) using the SST .

8. Verify that the boot band crimp value B is within the specification.

Microsoft

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Drive Shaft - MX-5 Miata



If crimp value B exceeds the specification, reduce opening length A of the SST and recrimp the boot band.



If the crimp value B is less than the specification, replace the boot band, increase opening length A of the SST , and then recrimp the new boot band.

Specification B

2.4-2.8 mm {0.095-0.110 in}

9. Verify that the boot band does not protrude from the boot band installation area.



If the boot band protrudes from the installation area, replace it with a new band and repeat Step 7--

Microsoft

2005 MAZDA MX-5 Miata

2005 MAZDA

MX-5 Miata

BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION

Component

A/C Relay

Audio Relay

Blower Relay

Condenser Fan Relay

Cooling Fan Relay

Front Fog Light Relay

Fuel Pump Relay

Headlight Relay

Horn Relay

Main Relay

Rear Window Defroster Relay

TNS Relay

Trunk Lid Opener Relay

Location

At left front of engine compartment. See Fig. 21 .

Behind left side of dash. See Fig. 12 .

Behind left side of dash. See Fig. 21 .

At left front of engine compartment. See Fig. 21 .

At right rear of engine compartment. See Fig. 32 .

Behind left side of dash. See Fig. 26 .

Behind left side of dash. See Fig. 33 .

At right rear of engine compartment. See Fig. 28 .

In main fuse block. See Fig. 22 .

In main fuse block. See Fig. 40 .

Behind left side of dash. See Fig. 17 .

At right rear of engine compartment. See Fig. 28 .

Lower rear center of vehicle. See Fig. 2 .

CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION

Component

Fuse Block

Fusible Link

Main Fuse

Main Fuse Block

Thermal Protector

Location

Behind left side of dash. See

At right rear of engine compartment, behind main fuse block. See

Fig. 4

Fig. 7

At right rear of engine compartment.

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

At left front of engine compartment.

CONTROL UNITS

CONTROL UNITS LOCATION

Component

ABS Hydraulic Unit/Control Module

Cruise Control Module

Door Lock Control Module

DRL Control Module

Flasher Control Module

Location

At right rear of engine compartment. See Fig. 7 .

Behind left side of dash. See Fig. 6 .

Behind left side of dash. See Fig. 9 .

Behind left side of dash. See Fig. 25 .

Behind left side of dash. See Fig. 24 .

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Immobilizer Unit

Key Interlock Unit

Keyless Control Module

PCM

SAS Control Module

Transmission Control Module

MOTORS

MOTORS LOCATION

Component

ABS Hydraulic Unit/Control Module

Blower Motor

Condenser Fan

Cooling Fan Motor

EVAP System Leak Detection Pump

Fuel Pump Unit

Power Antenna

Power Window Regulator (Left)

Power Window Regulator (Right)

Starter

Trunk Lid Lock Actuator

Windshield Washer Motor

Windshield Wiper Motor

Behind lower left side of dash. See Fig. 3 .

Behind left end of dash. See Fig. 18 .

Behind right side of dash. See Fig. 15 .

Behind left side of dash. See Fig. 34 .

Behind upper center of dash. See Fig. 4 .

At left kick panel. See Fig. 20 .

Location

At right rear of engine compartment. See Fig. 7 .

Integral to blower unit, behind right side of dash. See Fig. 21 .

Front of engine compartment. See Fig. 21 .

Behind radiator. See Fig. 32 .

Under rear center of vehicle. See Fig. 38 .

Under rear center of vehicle. See Fig. 33 .

Left rear of vehicle. See Fig. 11 .

In left door. See Fig. 10 .

In right door. See Fig. 10 .

Left side of engine. See Fig. 39 .

At lower rear center of vehicle. See Fig. 2 .

On washer fluid reservoir. See Fig. 29 .

On right side of firewall. See Fig. 29 .

SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION

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

Crash Zone Sensor

EGR Boost Sensor

Engine Coolant Temperature Sensor

Fuel Gauge Sender Unit

Heated Oxygen Sensor (Front)

Location

At left front wheel. See Fig. 7 .

At left rear wheel. See Fig. 7 .

At right front wheel. See Fig. 7 .

At right rear wheel. See Fig. 7 .

In brake fluid reservoir. See Fig. 31 .

On right rear of engine. See Fig. 35 .

On front of engine. See Fig. 35 .

At front center of engine compartment. See Fig. 5 .

At right side of engine compartment. See Fig. 36 .

On top rear of engine. See Fig. 30 .

In fuel tank. See Fig. 30 .

On exhaust system, on left side of engine. See Fig. 38 .

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Heated Oxygen Sensor (Rear)

Input/Turbine Speed Sensor

Intake Air Temperature Sensor

Knock Sensor

Mass Air Flow Sensor

Output Speed Sensor

Throttle Position Sensor

Vehicle Speedometer Sensor (M/T)

On exhaust system, near rear of engine. See Fig. 38 .

On transmission. See Fig. 20 .

At left front of engine compartment. See Fig. 36 .

On right front of engine. See Fig. 37 .

Near left front corner of engine. See Fig. 35 .

On transmission. See Fig. 20 .

On right front of engine. See Fig. 36 .

On transmission. See Fig. 30 .

SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION

Component

Cruise Actuator

Door Lock Actuator (Left)

Door Lock Actuator (Right)

EC-A/T Solenoid Valve

EGR Boost Sensor Solenoid Valve

Location

At left side of engine compartment. See Fig. 6 .

In left door. See Fig. 9 .

In right door. See Fig. 9 .

On transmission. See Fig. 20 .

At right rear of engine compartment. See Fig. 38 .

EGR Valve

Fuel Injector No. 1

Fuel Injector No. 2

Fuel Injector No. 3

Fuel Injector No. 4

Idle Air Control Valve

Near right front of engine. See

On top of engine. See

Fig. 35

Fig. 34

On top of engine. See Fig. 34 .

On right front of engine. See Fig. 35 .

Key Interlock Solenoid

Magnetic Clutch

Oil Control Valve (OCV)

Purge Solenoid Valve

Shift Lock Actuator

VTCS Solenoid Valve

Behind left side of dash. See Fig. 18 .

Left front of engine, on A/C compressor. See Fig. 21 .

On right front of engine. See Fig. 37 .

At right side of engine compartment. See Fig. 38 .

Near base of gear selector lever. See Fig. 19 .

At right rear of engine compartment. See Fig. 35 .

SWITCHES

SWITCHES LOCATION

Component

Back-Up Light Switch (M/T)

Brake Switch

Buckle Switch

Clutch Switch

Door Key Cylinder Switch (Left)

Door Key Cylinder Switch (Right)

Microsoft

Saturday, July 04, 2009 11:13:26 AM Page 3

Location

On transmission. See Fig. 23 .

Behind left side of dash. See Fig. 6 .

On driver's seat belt buckle. See Fig. 31 .

Behind left side of dash. See Fig. 37 .

In left door. See Fig. 9 .

In right door. See Fig. 9 .

Door Switch (Left)

Door Switch (Right)

Key Reminder Switch

Neutral Switch

Oil Pressure Switch

Parking Brake Switch

Power Steering Pressure Switch

Refrigerant Pressure Switch

Seat Belt Switch

Starter Interlock Switch (M/T)

Thermoswitch

Transmission Range Switch (A/T)

Trunk Compartment Light Switch

VTCS Vacuum Switch

MISCELLANEOUS

MISCELLANEOUS LOCATION

Component

Aeroboard Speaker Amplifier (Left)

Aeroboard Speaker Amplifier (Right)

Coil (Immobilizer)

Condenser (Ignition)

Condenser (Rear Window Defogger)

Data Link Connector

Data Link Connector No. 2

Detachable Hardtop Filament

Driver Side Seat Belt Pretensioner

Front Audio Amplifier

Generator

Horn (Left & Right)

Ignition Coil No. 1

Ignition Coil No. 2

Passenger Side Seat Belt Pretensioner

Resistor (Shift Interlock)

CONNECTORS

CONNECTORS LOCATION

Component

X-04 (54 Pin)

Microsoft

Saturday, July 04, 2009 11:13:26 AM

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

On left "B" pillar. See Fig. 16 .

On right "B" pillar. See Fig. 16 .

On steering column. See Fig. 30 .

On transmission. See Fig. 37 .

On left side of engine. See Fig. 31 .

At base of parking brake lever. See Fig. 31 .

Near left front of engine. See Fig. 37 .

At right front of engine compartment. See Fig. 21 .

Inside driver's seat belt buckle.

Behind left side of dash. See Fig. 39 .

Behind right center of dash. See Fig. 21 .

On transmission. See Fig. 20 .

Left rear of trunk. See Fig. 27 .

At right side of engine compartment. See Fig. 37 .

Location

Left rear of vehicle. See Fig. 14 .

Right rear of vehicle. See Fig. 14 .

Inside of steering column. See Fig. 3 .

At rear of engine. See Fig. 34 .

Near lower rear of driver's door opening. See Fig. 17 .

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

At lower left side of dash. See Fig. 1 .

At rear of hardtop. See Fig. 17 .

Near base of left "B" pillar. See Fig. 5 .

Behind lower center of dash. See Fig. 13 .

Left front of engine. See Fig. 39 .

Behind front bumper. See Fig. 22 .

On top of engine. See Fig. 34 .

Near base of right "B" pillar. See Fig. 5 .

Behind left side of dash. See Fig. 18 .

Page 4

Location

Below left side of dash. See Fig. 1 .

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

X-05 (34 Pin)

X-06 (18 Pin)

X-07 (34 Pin)

X-08 (21 Pin)

X-09 (15 Pin)

X-10 (18 Pin)

X-11 (18 Pin)

X-12 (2 Pin)

X-14 (Black, 8 Pin)

X-15 (Gray, 4 Pin)

X-17 (4 Pin)

GROUNDS

GROUNDS LOCATION

Component

Below left side of dash. See Fig. 1 .

At right side of dash. See Fig. 4 .

Left rear of vehicle. See Fig. 2 .

Below main fuse block. See Fig. 1 .

At right rear of engine compartment. See Fig. 20 .

Near left "A" pillar. See Fig. 8 .

Near right "A" pillar. See Fig. 8 .

At left kick panel. See Fig. 16 .

On front of engine. See Fig. 30 .

On front of engine. See Fig. 34 .

At right rear quarterpanel. See Fig. 23 .

Location

Behind right headlight. See Fig. 9 .

Behind left side of dash. See Fig. 3 .

Behind left headlight. See Fig. 1 .

At right kick panel. See Fig. 7 .

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

Below center of dash. See Fig. 14 .

Behind left side of dash. See Fig. 1 .

At right sail panel. See Fig. 2 .

At rear of engine. See Fig. 34 .

COMPONENT LOCATION GRAPHICS

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

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 1: Data Link Connector

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 2: Trunk Lid Opener

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 3: Immobilizer System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 4: Air Bag System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 5: Air Bag System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 6: Cruise Control

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 7: Anti-Lock Brake System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 8: Power Mirrors

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 9: Door Locks

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 10: Power Windows

Courtesy of MAZDA MOTORS CORP.

Microsoft

Fig. 11: Power Antenna

Courtesy of MAZDA MOTORS CORP.

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 12: Audio (W/Bose)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 13: Audio (W/Bose)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 14: Audio (W/Bose)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 15: Keyless Entry

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 16: Interior Lights

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 17: Cigarette Lighter/Rear Defroster

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 18: Key Interlock

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 19: Shift-Lock

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 20: EC-AT Control

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 21: HVAC

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 22: Brake Lights & Horn

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 23: Back-Up Lights

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 24: Turn Signal & Hazard Lights

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 25: DRL

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 26: Fog Lights

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 27: Front Side Marker, License, Trunk & Parking Lights

Courtesy of MAZDA MOTORS CORP.

Microsoft

Fig. 28: Headlights (W/DRL)

Courtesy of MAZDA MOTORS CORP.

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 29: Wiper/Washer

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 30: Instrument Cluster

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 31: Instrument Cluster

Courtesy of MAZDA MOTORS CORP.

Microsoft

Fig. 32: Cooling Fan

Courtesy of MAZDA MOTORS CORP.

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 33: Fuel System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 34: Engine Control System

Courtesy of MAZDA MOTORS CORP.

Microsoft

Fig. 35: Engine Control System

Courtesy of MAZDA MOTORS CORP.

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 36: Engine Control System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

C:\Users\steve\AppData\Local\Temp\mric_tmp\~od246.jpg (2080 x 1505) @ 564.48px

Fig. 37: Engine Control System

Courtesy of MAZDA MOTORS CORP.

C:\Users\steve\AppData\Local\Temp\mric_tmp\~od247.jpg (2080 x 1410) @ 564.48px

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 38: Engine Control System

Courtesy of MAZDA MOTORS CORP.

C:\Users\steve\AppData\Local\Temp\mric_tmp\~od248.jpg (2067 x 1446) @ 564.48px

Fig. 39: Starting & Charging

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 MAZDA MX-5 Miata

Fig. 40: Relay & Main Fuse Block

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

2005 ENGINE PERFORMANCE

Emission System - MX-5 Miata

EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM LOCATION INDEX

(BP, BP WITH TC)

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 1: Locating Emission System Components

Courtesy of MAZDA MOTORS CORP.

EMISSION SYSTEM LOCATION INDEX (BP, BP WITH TC)

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 2: Locating Emission System Components

Courtesy of MAZDA MOTORS CORP.

FUEL-FILLER CAP INSPECTION (BP, BP WITH TC)

LEAKAGE INSPECTION

1. Perform the following SST (Evaporative Emission System Tester 134-01049) self-test:

NOTE:



If the tester does not work correctly during the self-test, refer to the tester operators manual for more detailed procedures.

1. Verify that the gas cylinder valve is closed and the control valve located on the tester is in the

TEST position.

2. All tester displays should be off at this time.

3. Connect the long hose (part of SST ) to the tester.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

4. Connect the manifold assembly (part of SST ) to the long hose as shown in Fig. 3 .

Fig. 3: Connecting Manifold Assembly

Courtesy of MAZDA MOTORS CORP.

5. Open the gas cylinder valve and verify that the left gauge of the gas cylinder regulator reads 10 to

12 psi (preset at factory).



If not, refer to the tester operators manual to contact the tester manufacturer.

6. Press the ON/OFF switch to turn on the SST and make sure the left display reads 0.0.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

7. Turn the control valve on the tester to the FILL position.

8. Verify that the display reading on the left is within 13.9 to 14.0 in of water.



If not, adjust the pressure using the regulator knob located on the right side of the tester.

9. Turn the control valve to the TEST position and press the START switch.

10. After the 2-min countdown (left display) is completed, the right display shows the total pressure loss for that period.

0.5 in of water loss is acceptable on the self-test.



If the loss is more than 0.5 in of water, perform one or more self-tests.

 If the test position fails repeatedly, check for leakage using the ultrasonic leak detector (part of SST ).

2. Press the RESET switch to set the left display reading to 0.0.

3. Connect the fuel cap receiver assembly (part of SST ) to the manifold assembly and the fuel-filler cap from the vehicle.

Fig. 4: Connecting Fuel Cap Receiver Assembly

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.



If the fuel-filler cap is not a genuine part, replace it.

4. Turn the control valve to the FILL position.

5. Wait ( max.20 s ) until the left display reads 13.9 to 14.0 in of water.



If the reading is slightly below, adjust it using the regulator knob.

If the reading is far below, the fuel-filler cap has leakage. Replace it.

6. Turn the control valve to the TEST position and press the START switch.

7. After the 2-min countdown (left display) is completed, check the test result (the failed/passed light on the tester).



If the green light illuminates, the fuel-filler cap is okay.

If the red light illuminates, the fuel-filler cap has leakage. Replace it.

8. Close the gas cylinder valve.

9. Turn the control valve to the FILL position.

10. Press the ON/OFF switch to turn off the tester.

FUEL SHUT-OFF VALVE/ROLLOVER VALVE INSPECTION (BP, BP WITH

TC)

CAUTION:



Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1. Disconnect the plastic fuel hose and the FP unit connector. (See FUEL PUMP (FP)

REMOVAL/INSTALLATION (BP, BP WITH TC) .)

2. Remove the fuel tank with the FP unit. (See FUEL TANK REMOVAL/INSTALLATION (BP, BP

WITH TC) .)

3. Plug the fuel main pipe and fuel return pipe of the FP unit.

4. Plug port A.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 5: Plugging Fuel Main Pipe And Fuel Return Pipe Of The FP Unit

Courtesy of MAZDA MOTORS CORP.

5. Level the fuel tank.

6. Blow through port B and verify that there is airflow from port C.



If there is no airflow, replace the fuel tank.

If there is airflow, plug port C and proceed to Step 7.

7. Blow through port B and verify that there is airflow from port A.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 6: Blowing Through Port B And Verify That There Is Airflow From Port A

Courtesy of MAZDA MOTORS CORP.



If there is no airflow, replace the fuel tank.



If there is airflow, turn the fuel tank upside-down, and proceed to Step 8.

8. Blow through port B and verify that there is no airflow from port A.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 7: Blowing Through Port B And Verify That There Is No Airflow From Port A

Courtesy of MAZDA MOTORS CORP.



If there is airflow, replace the fuel tank.

AIR FILTER INSPECTION (BP, BP WITH TC)

1. Remove the air filter.

2. Blow from port A and verify that there is airflow from port B.



If not as specified, replace the air filter.

3. Blow from port B and verify that there is airflow from port A.



If not as specified, replace the air filter.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 8: Identifying Air Filter

Courtesy of MAZDA MOTORS CORP.

CHARCOAL CANISTER INSPECTION (BP, BP WITH TC)

1. Remove the charcoal canister. (See FUEL TANK REMOVAL/INSTALLATION (BP, BP WITH

TC) .)

2. Plug ports A and B.

CAUTION:



Do not apply more than 20 kPa {150 mmHg, 16 inHg} of pressure to the charcoal canister. Doing so may break the charcoal canister.

3. Verify that there is no air leakage when pressure of 20 kPa {150 mmHg, 16 inHg} is applied to port C.



If not as specified, replace the charcoal canister.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 9: Identifying Charcoal Canister

Courtesy of MAZDA MOTORS CORP.

EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP

REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Disconnect the negative battery cable.

2. Raise the rear of the vehicle and support it with safety stands.

3. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 10: Exploded View Of Evaporative Emission (EVAP) System Leak Detection Pump & Torque

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Specifications

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

EVAPORATIVE HOSE INSTALLATION NOTE

1. Completely insert the evaporative hose into the EVAP system leak detection pump.

EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP

INSPECTION (BP, BP WITH TC)

AIRFLOW INSPECTION

NOTE:



Perform the following test only when directed.

1. Disconnect the negative battery cable.

2. Remove the EVAP system leak detection pump. (See EVAPORATIVE EMISSION (EVAP) SYSTEM

LEAK DETECTION PUMP REMOVAL/INSTALLATION (BP, BP WITH TC) .)

3. Blow air into port A and verify that there is airflow from port B.



If not as specified, replace the EVAP system leak detection pump.

4. Blow air into port B and verify that there is airflow from port A.



If not as specified, replace the EVAP system leak detection pump.



If as specified, perform the following " RESISTANCE INSPECTION ".

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 11: Identifying EVAP System Leak Detection Pump

Courtesy of MAZDA MOTORS CORP.

RESISTANCE INSPECTION

NOTE:



Perform the following test only when directed.

1. Disconnect the negative battery cable.

2. Inspect resistance of the EVAP system leak detection pump.



If not as specified, replace the EVAP system leak detection pump.



If as specified, carry out the "Circuit Open/Short Inspection".

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 12: Inspecting Resistance Of EVAP System Leak Detection Pump

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 13: Identifying Terminal

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



EVAP system leak detection pump terminal C (harness-side) and PCM terminal 4AH



EVAP system leak detection pump terminal D (harness-side) and PCM terminal 3K



EVAP system leak detection pump terminal A (harness-side) and main relay terminal D (harnessside)

 EVAP system leak detection pump terminal B (harness-side) and the body GND

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 14: Identifying Main Relay

Courtesy of MAZDA MOTORS CORP.

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



EVAP system leak detection pump terminal C (harness-side) and power supply



EVAP system leak detection pump terminal D (harness-side) and power supply

 EVAP system leak detection pump terminal A (harness-side) and the body GND



EVAP system leak detection pump terminal B (harness-side) and power supply

CATCH TANK INSPECTION (BP, BP WITH TC)

1. Remove the catch tank.

2. Plug the purge solenoid valve side port of the catch tank.

3. Blow from the charcoal canister side port and verify that there is no air leakage.



If not as specified, replace the catch tank.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 15: Identifying Catch Tank

Courtesy of MAZDA MOTORS CORP.

PURGE SOLENOID VALVE REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 16: Identifying Purge Solenoid Valve Components & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

VACUUM HOSE, EVAPORATIVE HOSE INSTALLATION NOTE

1. Install the vacuum hose and evaporative hose until it contacts the stopper.

PURGE SOLENOID VALVE INSPECTION (BP, BP WITH TC)

AIRFLOW INSPECTION

NOTE:



Perform the following test only when directed.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

1. Remove the purge solenoid valve. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION

(BP, BP WITH TC) .)

2. Inspect airflow between the ports under the following conditions:



If as specified, inspect the vacuum hoses for improper routing, kinks or leakage, and carry out

"Circuit Open/Short Inspection".



If not as specified, replace the purge solenoid valve.

Fig. 17: Identifying Terminal Airflow

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 18: Identifying Connector Terminal

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



GND circuit (Purge solenoid valve connector terminal B and PCM connector terminal 3C through common connector)



Power circuit (Purge solenoid valve connector terminal A and main relay connector terminal D through common connector)

Short circuit



Purge solenoid valve connector terminal B and PCM connector terminal 3C to GND

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 19: Identifying Main Relay

Courtesy of MAZDA MOTORS CORP.

EVAPORATIVE CHAMBER INSPECTION (BP, BP WITH TC)

1. Remove the evaporative chamber.

2. Blow from port A and verify that there is airflow from port B.



If not as specified, replace the evaporative chamber.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 20: Identifying Evaporative Chamber

Courtesy of MAZDA MOTORS CORP.

EGR VALVE REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 21: Removing EGR Valve & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

4. Connect the negative battery cable.

EGR VALVE INSPECTION (BP, BP WITH TC)

RESISTANCE INSPECTION

NOTE:



Perform the following test only when directed.

1. Disconnect the negative battery cable.

2. Inspect resistance of the EGR valve coils.



If as specified, inspect the vacuum hoses for improper routing, kinks or leakage, and carry out

"Circuit Open/Short Inspection".

 If not as specified, replace the EGR valve.

3. Remove the EGR valve, and inspect for any damage or clogging. If not as specified, replace the EGR valve.

4. Connect the negative battery cable.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 22: Inspecting Resistance Of EGR Valve Coils

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata



GND circuit (EGR valve connector terminal E and PCM connector terminal 2E)



GND circuit (EGR valve connector terminal A and PCM connector terminal 2F)

GND circuit (EGR valve connector terminal B and PCM connector terminal 2H)



GND circuit (EGR valve connector terminal F and PCM connector terminal 2l)

Power circuit (EGR valve connector terminal C or D and main relay connector terminal D through common connector)

Fig. 23: Identifying Main Relay

Courtesy of MAZDA MOTORS CORP.

Short circuit



EGR valve connector terminal E and PCM connector terminal 2E to GND

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata



EGR valve connector terminal A and PCM connector terminal 2F to GND



EGR valve connector terminal B and PCM connector terminal 2H to GND

EGR valve connector terminal F and PCM connector terminal 2l to GND

EGR BOOST SENSOR SOLENOID VALVE INSPECTION (BP, BP WITH TC)

AIRFLOW INSPECTION

NOTE:



Perform the following test only when directed.

1. Disconnect the negative battery cable.

2. Remove the EGR boost sensor solenoid valve.

3. Inspect airflow between each port under the following conditions:

Fig. 24: Identifying EGR Boost Sensor Solenoid Valve Connector Terminal

Courtesy of MAZDA MOTORS CORP.



If as specified, inspect the vacuum hoses for improper routing, kinks or leakage, and carry out

"Circuit Open/Short Inspection".



If not as specified, replace the EGR boost sensor solenoid valve.

4. Connect the negative battery cable.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 25: Identifying EGR Boost Sensor Solenoid Valve Terminal

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



GND circuit (EGR boost sensor solenoid valve connector terminal B and PCM connector terminal 3D)



Power circuit (EGR boost sensor solenoid valve connector terminal A and main relay connector terminal

D through common connector)

Short circuit



EGR boost sensor solenoid valve connector terminal B and PCM connector terminal 3D to GND

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 26: Identifying Main Relay

Courtesy of MAZDA MOTORS CORP.

PCV VALVE INSPECTION (BP, BP WITH TC)

1. Remove the PCV valve.

2. Blow through the valve and verify that air flows as specified.



If not as specified, replace the PCV valve.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 27: Identifying PCV Valve Port

Courtesy of MAZDA MOTORS CORP.

EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM CHECK VALVE

(ONE-WAY) INSPECTION (BP WITH TC)

1. Remove the EVAP control system check valve (one-way). (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION (BP WITH TC) .)

2. Blow through A and verify that the air flows from B.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 28: Identifying EVAP Control System Check Valve

Courtesy of MAZDA MOTORS CORP.



If not as specified, replace the EVAP control system check valve (one-way).

3. Blow through B and verify that the air does not flow from A.



If not as specified, replace the EVAP control system check valve (one-way).

THREE-WAY CATALYTIC CONVERTER (TWC) INSPECTION (BP, BP WITH

TC)

NOTE:



Make sure that no HO2S DTC has been detected. If detected, this inspection cannot be used for TWC inspection.

1. Connect the WDS or equivalent and monitor PIDs as follows:



Monitor TWC using O2S11 PID for upstream HO2S and O2S12 PID for downstream HO2S.

2. Begin monitoring the appropriate PIDs.

3. Drive the vehicle for 10 min at 65-96 km/h {40-60 mph} to ensure the front catalytic converter reaches operating temperature.

4. Stop the vehicle and leave in a safe place.

5. Idle the engine.

6. Record PIDs for 1 min .

7. Select the appropriate PIDs and read the graph.

8. Count the number of times (inversions) that the upstream HO2S graph line actually crosses the 0.5 V line.

9. Count the number of times (inversions) that the downstream HO2S graph line actually crosses the 0.5 V

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata line.

NOTE:



Do not count the number of peaks. Refer to Fig. 29.

10. Using the following equation, calculate the value of ratio.

Equation

RATIO = Upstream HO2S inversion DIVISION downstream HO2S inversion

Fig. 29: Identifying Upstream HO2S Graph Line

Courtesy of MAZDA MOTORS CORP.



If the ratio is 2 or more or no downstream HO2S inversion, the TWC is functioning properly.



If the ratio is less than 2 , the TWC is not functioning properly. Replace the TWC.

Upstream HO2S graph line example

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 30: Identifying Upstream HO2S Graph Line

Courtesy of MAZDA MOTORS CORP.

Downstream HO2S graph line example 1

Fig. 31: Identifying Good Catalytic Converter (7 Inversions) Graph

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Equation

RATIO = 26 inversions (upstream HO2S inversions) DIVISION 7 inversions (downstream HO2S inversions) = 3.7 (good converter)

Downstream HO2S graph line example 2

Fig. 32: Identifying Good Catalytic Converter (No Inversions) Graph

Courtesy of MAZDA MOTORS CORP.

Downstream HO2S graph line example 3

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 33: Identifying Bad Catalytic Converter (19 Inversions) Graph

Courtesy of MAZDA MOTORS CORP.

Equation

RATIO = 26 inversions (upstream HO2S inversions) DIVISION 19 inversions (downstream HO2S inversions) = 1.4 (bad converter)

Microsoft

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

2005 ENGINE PERFORMANCE

Control System - MX-5 Miata

CONTROL SYSTEM LOCATION INDEX (BP, BP WITH TC)

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 1: Locating Components Of Control System (BP, BP With TC)

Courtesy of MAZDA MOTORS CORP.

CONTROL SYSTEM DIAGRAM (BP)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 2: Identifying Control System Diagram (BP)

Courtesy of MAZDA MOTORS CORP.

CONTROL SYSTEM DIAGRAM (BP WITH TC)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 3: Identifying Control System Diagram (BP With TC)

Courtesy of MAZDA MOTORS CORP.

CONTROL SYSTEM WIRING DIAGRAM (BP)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 4: Identifying Control System Wiring Diagram (BP) (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 5: Identifying Control System Wiring Diagram (BP) (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

CONTROL SYSTEM WIRING DIAGRAM (BP WITH TC)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 6: Identifying Control System Wiring Diagram (BP With TC) (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

Fig. 7: Identifying Control System Wiring Diagram (BP With TC) (2 Of 2)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

PCM REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Disconnect the negative battery cable.

2. Disconnect the connector from the PCM installed on the upper part of the brake pedal.

3. Remove the bolt and nut holding the PCM.

Fig. 8: Locating PCM Installation Bolt

Courtesy of MAZDA MOTORS CORP.

1. Push the harness (PCM harness) installed to the brake pedal bracket in the opposite direction of the brake pedal bracket.

2. While pushing the harness, push the stay until it comes apart from the stud with the PCM installation nut.

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2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 9: Removing PCM Wiring Harness

Courtesy of MAZDA MOTORS CORP.

3. Remove the PCM installation nut.

4. Install in the reverse order of removal.

Tightening torque

Bolt, nut: 7.9-10.7 N.m {80-110 kgf.cm, 70-95.4 in.lbf}

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 10: Tightening PCM Installation Nut

Courtesy of MAZDA MOTORS CORP.

PCM INSPECTION (BP, BP WITH TC)

USING SST (WDS OR EQUIVALENT)

Procedure

NOTE:



PIDs for the following parts are not available on this model. Go to the appropriate part inspection page.

ECT sensor (Water temperature sender unit). (See ENGINE COOLANT

TEMPERATURE (ECT) SENSOR INSPECTION (BP, BP WITH TC).)

Camshaft position sensor. (See CAMSHAFT POSITION (CMP) SENSOR

INSPECTION (BP, BP WITH TC).)

Main relay. (See RELAY INSPECTION .)

1. Connect the WDS or equivalent to the DLC-2.

2. Turn the ignition switch to the ON position.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

3. Measure the value.



If value is not within the specification, follow the instructions in ACTION column.

PCM TERMINALS REFERENCE (BP)

Monitor item

(Definition) Unit/Condition

ACCS (A/C relay)

Condition/Specification

ON/OFF A/C operating: ON

Ignition switch ON:

OFF

(Reference) ACTION



Inspect following PIDs: RPM,

TP, ECT, ACSW.



Inspect A/C relay

PCM terminal

ACSW

(Refrigerant pressure switch)

ALTF

(Generator field coil control duty value)

ON/OFF Refrigerant pressure switch and fan switch

ON: ON

Refrigerant pressure switch OFF: OFF

Ignition switch ON: 0%

Idle: 0-100%

Generator operating -->

E/L ON:

Duty value rise



(See RELAY INSPECTION )

Inspect refrigerant pressure switch

(See REFRIGERANT

PRESSURE SWITCH

INSPECTION )

Inspect following PIDs: IAT,

RPM, ALTT V.

Inspect generator

ALTT V

(Generator output voltage)

V Ignition switch ON: 1.0

V or less

Idle: Approx.14V



(See GENERATOR

INSPECTION )

Inspect following PIDs: IAT,

RPM, ALTF.

Inspect generator

ARPMDES

(Target engine speed)

RPM Idle (after warm up and no load): 750-850 rpm

(See GENERATOR

INSPECTION )



Perform "ON-BOARD

DIAGNOSTIC TEST" (See ON-

BOARD DIAGNOSTIC TEST

(BP, BP WITH TC) )



Inspect EGR boost sensor

BARO

(Barometric pressure) kPa Hg Below 400 m {0.25 mile} above sea level:

99-103 kPa {29-30 inHg}

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4AE

Page 12

(See EGR BOOST SENSOR

(BP), BAROMETRIC

PRESSURE

(BARO)/MANIFOLD

ABSOLUTE PRESSURE

(MAP) SENSOR (BP WITH

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

V Below 400 m {0.25 mile} above sea level:

4.1-4.3 V

With pressure gauge:



Vacuum reading -

26.6 kPa {-200 mmHg, -7.85 inHg}: 3.0-3.4 V



TC) INSPECTION (BP, BP

WITH TC) )

Inspect EGR boost sensor

(See EGR BOOST SENSOR

(BP), BAROMETRIC

PRESSURE

(BARO)/MANIFOLD

ABSOLUTE PRESSURE

(MAP) SENSOR (BP WITH

TC) INSPECTION (BP, BP

WITH TC) )



Inspect brake switch

4AE

BOO (Brake switch)

CDCV

(EVAP leak detection pump)

ON/OFF Brake pedal depressed:

ON/OFF

Brake pedal released:

OFF

Ignition switch ON:

OFF

Idle: OFF



(See BRAKE SWITCH

INSPECTION )

Inspect EVAP leak detection pump.

4AH

(See EVAPORATIVE

EMISSION (EVAP) SYSTEM

LEAK DETECTION PUMP

INSPECTION (BP, BP WITH

TC) )



Inspect generator warning light

CHRGLP

(Generator warning light)

ON/OFF Ignition switch ON: ON

Idle: OFF

CPP (Clutch switch)

ON/OFF Clutch pedal depressed:

Clutch pedal released:

OFF



(See WARNING AND

INDICATOR LIGHT BULB

REMOVAL/INSTALLATION )

Inspect clutch pedal position switch

(See CLUTCH PEDAL

POSITION SWITCH

INSPECTION (BP, BP WITH

TC) )



Inspect neutral switch

CPP/PNP

(MT) (Neutral switch)

Neutral/Drive Shift position at neutral:

Neutral

Others: Drive

ECT (Engine coolant temperature)

°C °F ECT 20°C {68°F}: 20°C

{68°F}

ECT 60°C {140°F}: 60°

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Saturday, July 04, 2009 10:52:35 AM Page 13

(See NEUTRAL SWITCH

INSPECTION (BP, BP WITH

TC) .)



Inspect ECT sensor

(See ENGINE COOLANT

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

EGRCHK

(EGR boost sensor solenoid valve)

EVAPCP

(Purge solenoid valve duty value)

FAN2

(Condenser fan control)

FAN3

(Cooling fan control)

FP (Fuel pump relay)

ON/OFF

C {140°F}

ECT 20°C {68°F}: 3.0-

3.1 V

After warm up: Below

1.0 V

Ignition switch ON:

OFF

Idle: OFF

Ignition switch ON: 0%

ON/OFF Condenser fan operating

(ECT above 108°C

{226°F}) or terminal

TEN grounded and throttle valve open or

A/C relay ON: ON

Others: OFF

ON/OFF Cooling fan operating

(ECT above 97°C {207°

F}) or terminal TEN grounded and throttle valve open or A/C relay

ON: ON

Others: OFF

ON/OFF Idle: ON

Cranking: ON

TEMPERATURE (ECT)

SENSOR INSPECTION (BP,

BP WITH TC) )



Inspect ECT sensor

(See ENGINE COOLANT

TEMPERATURE (ECT)

SENSOR INSPECTION (BP,

BP WITH TC) )



Inspect EGR boost sensor solenoid valve

(See EGR BOOST SENSOR

SOLENOID VALVE

INSPECTION (BP, BP WITH

TC) )



Inspect following PIDs: IAT,

RPM, ECT, MAR TP, BARO,

O2S11.

Inspect purge solenoid valve

(See PURGE SOLENOID

VALVE INSPECTION (BP, BP

WITH TC) )



Inspect following PIDs: RPM,

TP, ECT, ACSW, TEST.



Inspect condenser fan relay

(See RELAY INSPECTION )

 Inspect following PIDs: RPM,

TP, ECT, ACSW.



Inspect cooling fan relay

(See RELAY INSPECTION )



Inspect following PID: RPM.



Inspect FP relay

(See RELAY INSPECTION )



Inspect fuel gauge sender unit

4AD FTL V (Fuel tank level

V Idle condition

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata signal voltage)

FUELPW1

(Fuel injection duration)

HTR11

(Heated oxygen sensor heater

(Front))

HTR12

(Heated oxygen sensor heater (Rear))

IAC (Idle air control valve) ms

ON/OFF



Fuel tank full: 0.2-

0.5 V

Fuel tank empty:

3.4-4.4 V



Fuel tank half:

1.8-2.8 V

NOTE:

 The voltages above will be measured when the battery voltage is between 12 V and 14 V.

Ignition switch ON: 0 ms

Idle: 1.5-4.0 ms

Always: ON

ECT above 70°C {158°

F}: ON

ECT below 70°C {158°

F}: OFF

Idle: Approx.30%

(See FUEL GAUGE SENDER

UNIT INSPECTION )

 Inspect following PIDs: MAF,

IAT, RPM, TP, ECT, PNP, CPP,

O2S11, PSP, BOO, ACSW, CMP sensor

2A, 2D,

2G, 2J

(See CAMSHAFT POSITION

(CMP) SENSOR INSPECTION

(BP, BP WITH TC) )



Inspect following PIDs: ECT,

MAF.



Inspect HO2S heater

(See HEATED OXYGEN

SENSOR (HO2S)

INSPECTION (BP, BP WITH

TC) )



Inspect following PIDs: ECT,

MAF.

 Inspect HO2S heater



(See HEATED OXYGEN

SENSOR (HO2S)

INSPECTION (BP, BP WITH

TC) )

Inspect following PIDs: IAT,

RPM, ECT, MAF, TP, PNP, CPP,

PSP, ACSW, TEST.

2P, 2Q



Inspect IAC valve

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

IAT (Intake air temperature)

IMRC (VTCS solenoid valve)

°C

°F

ON/OFF

IAT 20°C {68°F}: 20°C

{68°F}

IAT 20°C {68°F}: 2.3-

2.4 V

IAT 30°C {86°F}: 1.9 V

ECT below 60°C {140°

F} while idling: ON

(See IDLE AIR CONTROL

(IAC) VALVE INSPECTION

(BP, BP WITH TC) )



Inspect IAT sensor

(See INTAKE AIR

TEMPERATURE (IAT)

SENSOR INSPECTION (BP,

BP WITH TC) )



Inspect IAT sensor

(See INTAKE AIR

TEMPERATURE (IAT)

SENSOR INSPECTION (BP,

BP WITH TC) )



Inspect following PIDs: RPM,

TP, ECT,

Inspect VTCS solenoid valve.

(See VARIABLE TUMBLE

CONTROL SYSTEM (VTCS)

SOLENOID VALVE

INSPECTION (BP, BP WITH

TC) )



Inspect the vacuum hose for improper routing, kinks or leaks



Inspect following PIDs: RPM,

TP, ECT.

Inspect VTCS vacuum switch.

IMRCM

(VTCS vacuum switch)

ON/OFF ECT below 60°C {140°

F} while idling: ON

(See VARIABLE TUMBLE

CONTROL SYSTEM (VTCS)

VACUUM SWITCH

INSPECTION (BP, BP WITH

TC) )

KNOCKR

(Knocking retard)

° Ignition switch ON: 0°

Idle: 0°

Microsoft

Saturday, July 04, 2009 10:52:35 AM



Inspect the vacuum hose for improper routing, kinks or leaks

 Inspect KS

Page 16

(See KNOCK SENSOR (KS)

INSPECTION (BP, BP WITH

TC) )

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

LOAD

(Calculated engine load)

LONGFT1

(Current long term fuel trim adjustment)

MAF (Intake

MAF)

Idle: 15.0-23.0% (MT),

14.0-23.0 (AT) Indicator engine load

Idle: -20-20% g/s lb/min Idle: 2.6-3.3 g/s {0.3-0.4 lb/min} (MT), 2.4-3.4 g/s {0.3-0.4 lb/min}

(AT)

V Ignition switch ON: 0.9-

2.0 V

Idle: 1.7-2.4 V



Perform "ON-BOARD

DIAGNOSTIC TEST" (See ON-

BOARD DIAGNOSTIC TEST

(BP, BP WITH TC) )



Perform "ON-BOARD

DIAGNOSTIC TEST" (See ON-

BOARD DIAGNOSTIC TEST

(BP, BP WITH TC) )



Inspect MAF sensor (See MASS

AIR FLOW (MAF) SENSOR

INSPECTION (BP, BP WITH

TC) )

Inspect MAF sensor

(See MASS AIR FLOW (MAF)

SENSOR INSPECTION (BP,

BP WITH TC) )



Inspect MIL

MIL

(Malfunction indicator lamp)

ON/OFF Ignition switch ON: ON

DTC output: ON

No DTC output: OFF

(See WARNING AND

INDICATOR LIGHT BULB

REMOVAL/INSTALLATION )

MTSW

(MA/AT discrimination signal)

O2S11

(Heated oxygen sensor

(Front))

1/0

MT: 1

AT: 0

Ignition switch ON: 0-

1.0 V

After warm up: 0-1.0 V

Acceleration: 0.5-1.0 V

Deceleration: 0-0.5 V

O2S12

(Heated oxygen sensor

(Rear))

PSP (PSP switch)

V Ignition switch ON: 0-

1.0 V

Idle (After warm up): 0-

1.0 V

Idle (Engine cold): 0-0.5

Accelerate: 0.5-1.0 V

Decelerate: 0-0.5 V

High/Low Steering wheel is at straight ahead position:

Low

Steering wheel is fully

Microsoft

Saturday, July 04, 2009 10:52:35 AM Page 17



Inspect HO2S (Front)

(See HEATED OXYGEN

SENSOR (HO2S)

INSPECTION (BP, BP WITH

TC) )



Inspect HO2S (Rear)

(See

SENSOR (HO2S)

INSPECTION (BP, BP WITH

TC) )

HEATED OXYGEN



Inspect PSP switch

(See POWER STEERING

PRESSURE (PSP) SWITCH

4AA

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

RFCFLAG

(Fuel learning correction set flag)

RPM (Engine speed)

SEGRP (EGR valve

(stepping motor) position)

SHRTFT1

(Short term trim) turned: High INSPECTION (BP, BP WITH

TC) )

ON/OFF Adaptive memory exists: --

No adaptive memory:

OFF

RPM Idle (After warm up and no load): 750-850 rpm



Inspect CKP sensor step Ignition switch ON: 0 step

Idle: 0 step

Cranking: 0-60 steps



(See CRANKSHAFT

POSITION (CKP) SENSOR

INSPECTION (BP, BP WITH

TC) )

Inspect following PIDs: ECT, TP.

2E, 2F,

2H, 2I

Inspect EGR valve

% Idle: -25-25%

(See EGR VALVE

INSPECTION (BP, BP WITH

TC) )



Perform "ON-BOARD

DIAGNOSTIC TEST" (See ON-

BOARD DIAGNOSTIC TEST

(BP, BP WITH TC) )

MIN ---SORK TIME

(Engine sork time)

SPARKADV

(Ignition timing)

° Idle: BTDC 6-18°

Idle (Terminal TEN

GND): BTDC

9-11°

Cranking: Approx.6°



Inspect following PIDs: MAF,

IAT, RPM, TP, ECT, PSP, PNP,

CPP, ACSW, TEST, CMP sensor.

Perform engine tune-up

(See ENGINE TUNE-UP )

Test (TEN terminal

(DLC))

TP (Throttle position sensor signal voltage)

ON/OFF Open terminal TEN:

OFF

Shorted terminal TEN:

V Closed TP: 0.1-1.1 V

WOT: 3.0-4.6 V



Inspect the DLC TEN terminal and PCM connector terminal 4E

Inspect TP sensor

(See THROTTLE POSITION

(TP) SENSOR INSPECTION

(BP, BP WITH TC) )

VPWR

(Battery positive voltage)

Microsoft

V Ignition switch ON: B+

Saturday, July 04, 2009 10:52:35 AM Page 18



Inspect main relay

(See RELAY INSPECTION )

4AF

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

VSS (Vehicle speed)

VT ACT

(Actual valve timing)

VT TGT

(Target valve timing)

KPH MPH Vehicle speed 20 km/h

{12.5 mph}: 20 km/h

{12.5 mph}

Vehicle speed 40 km/h

{25 mph}: 40 km/h {25 mph}

° 4,500-5,000 rpm: 20° -

15°

° 4,500-5,000 rpm: 20° -

15°



Inspect battery

(See BATTERY

INSPECTION )



Inspect VSS.

(See VEHICLE

SPEEDOMETER SENSOR

INSPECTION (M15M-D) )



Inspect CMP sensor.

(See CAMSHAFT POSITION

(CMP) SENSOR INSPECTION

(BP, BP WITH TC) )

4D, 4R



Inspect oil control valve (OCV).

(See OIL CONTROL VALVE

(OCV) INSPECTION (BP) )

 Inspect CMP sensor.

(See CAMSHAFT POSITION

(CMP) SENSOR INSPECTION

(BP, BP WITH TC) )



Inspect oil control valve (OCV).

(See OIL CONTROL VALVE

(OCV) INSPECTION (BP) )

BP WITH TC

PCM TERMINALS REFERENCE (BP WITH TC)

Monitor item

(Definition) Unit/Condition

ACCS (A/C relay)

Condition/Specification

(Reference)

ON/OFF A/C operating: ON

Ignition switch ON:

OFF

ACTION



Inspect following PIDs: RPM,

TP, ECT, ACSW.

 Inspect A/C relay

PCM terminal

ACSW

(Refrigerant

ON/OFF Refrigerant pressure switch and fan switch

Microsoft

Saturday, July 04, 2009 10:52:35 AM Page 19

(See RELAY INSPECTION )



Inspect refrigerant pressure switch

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata pressure switch)

ON: ON

Refrigerant pressure switch OFF: OFF

(See REFRIGERANT

PRESSURE SWITCH

INSPECTION )

ALTF

(Generator field coil control duty value)

% Ignition switch ON: 0%

Idle: 0-100%

Generator operating -->

E/L ON:

Duty value rise



Inspect following PIDs: IAT,

RPM, ALTT V.

Inspect generator

ALTT V

(Generator output voltage)

V Ignition switch ON: 1.0

V or less

Idle: Approx.14 V



(See GENERATOR

INSPECTION )

Inspect following PIDs: IAT,

RPM, ALTF.

Inspect generator

ARPMDES

(Target engine speed)

BOO (Brake switch)

RPM Indicate the target engine speed

(See GENERATOR

INSPECTION )



Perform "ON-BOARD

DIAGNOSTIC TEST" (See ON-

BOARD DIAGNOSTIC TEST

(BP, BP WITH TC) )



Inspect brake switch

CDCV

(EVAP leak detection pump)

ON/OFF Brake pedal depressed:

ON/OFF

Brake pedal released:

OFF

Ignition switch ON:

OFF

Idle: OFF



(See BRAKE SWITCH

INSPECTION )

Inspect EVAP leak detection pump.

4AH

(See EVAPORATIVE

EMISSION (EVAP) SYSTEM

LEAK DETECTION PUMP

INSPECTION (BP, BP WITH

TC) )



Inspect generator warning light

CHRGLP

(Generator warning light)

CPP (Clutch switch)

ON/OFF Ignition switch ON: ON

Idle: OFF

ON/OFF Clutch pedal depressed:

Clutch pedal released:

OFF

Microsoft

Saturday, July 04, 2009 10:52:35 AM



(See WARNING AND

INDICATOR LIGHT BULB

REMOVAL/INSTALLATION )

Inspect clutch pedal position switch

Page 20

(See CLUTCH PEDAL

POSITION SWITCH

INSPECTION (BP, BP WITH

TC) )

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

CPP/PNP

(Neutral switch)

ECT (Engine coolant temperature)

EGRCHK

(EGR boost sensor solenoid valve)

EVAPCP

(Purge solenoid valve duty value)

Neutral/Drive Shift position at neutral:

Neutral

Others: Drive

°C

°F Ignition switch is turned to the ON position:

Indicate the engine coolant temperature

ECT 20°C {68°F}:

Approx.3.0 V

ECT 80°C {176°F}:

Approx.0.9 V

ON/OFF Ignition switch ON:

OFF

Idle: ON

% Ignition switch ON: 0%



Inspect neutral switch

(See NEUTRAL SWITCH

INSPECTION (BP, BP WITH

TC) )



Inspect ECT sensor



(See ENGINE COOLANT

TEMPERATURE (ECT)

SENSOR INSPECTION (BP,

BP WITH TC)

O2S11.

)



Inspect EGR boost sensor solenoid valve

(See EGR BOOST SENSOR

SOLENOID VALVE

INSPECTION (BP, BP WITH

TC) )

Inspect following PIDs: IAT,

RPM, ECT, MAF, TP, MAP,

Inspect purge solenoid valve

FAN2 (Fan control)

ON/OFF Terminal TEN grounded and throttle valve open:

Others: OFF

(See PURGE SOLENOID

VALVE

REMOVAL/INSTALLATION

(BP, BP WITH TC) )



Inspect following PIDs: RPM,

TP, ECT, ACSW, TEST.

Inspect fan relay No.2

Inspect fan relay No.3

FAN3 (Fan control)

FP (Fuel pump relay)

ON/OFF Terminal TEN grounded and throttle valve open:

Others: OFF

ON/OFF Idle: ON

Cranking: ON

Microsoft

Saturday, July 04, 2009 10:52:35 AM



(See RELAY INSPECTION )

Inspect following PIDs: RPM,

TP, ECT, ACSW.

Inspect fan relay No.1

Page 21

(See RELAY INSPECTION )



Inspect following PID: RPM.



Inspect FP relay

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

FTL V (Fuel tank level signal voltage)

V Idle condition



Fuel tank full: 0.2-

0.5 V

Fuel tank empty:

3.4-4.4 V

 Fuel tank half:

1.8-2.8 V



(See RELAY INSPECTION )

Inspect fuel gauge sender unit

(See FUEL GAUGE SENDER

UNIT INSPECTION )

4AD

NOTE:

 The voltages above will be measured when the battery voltage is between 12 V and 14 V.

Idle: Approx.1.7 ms FUELPW1

(Fuel injection duration) ms



Inspect following PIDs: MAF,

IAT, RPM, TP, ECT, PNP, CPP,

O2S11, PSP, BOO, ACSW, CMP sensor

2A, 2D,

2GN, 2J

HTR11

(Heated oxygen sensor heater

(Front))

HTR12

(Heated oxygen sensor heater

(Rear))

ON/OFF

Always: ON

ECT above 70°C {158°

F}: ON

ECT below 70°C {158°

F}: OFF

IAC (Idle air control

% Idle: Approx.18%

Microsoft

Saturday, July 04, 2009 10:52:35 AM Page 22

(See CAMSHAFT POSITION

(CMP) SENSOR INSPECTION

(BP, BP WITH TC) )



Inspect following PIDs: ECT,

MAF.



Inspect HO2S heater

(See HEATED OXYGEN

SENSOR (HO2S)

INSPECTION (BP, BP WITH

TC) )



Inspect following PIDs: ECT,

MAF.

 Inspect HO2S heater

(See HEATED OXYGEN

SENSOR (HO2S)

INSPECTION (BP, BP WITH

TC) )



Inspect following PIDs: IAT,

2P, 2Q

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata valve)

IAT (Intake air temperature)

IAT2 (Intake air temperature)

IMRC

(VTCS solenoid valve)

°C

°F Indicate the intake air temperature

IAT 20°C {68°F}: 2.3-

2.4 V

IAT 30°C {86°F}:

Approx.1.9 V

°C

°F Indicate the intake air temperature

IAT 25°C {77°F}:

Approx.2.7 V

IAT 85°C {185°F}:

Approx.0.6 V

ON/OFF ECT below 65°C{149°

F} while idling: ON

RPM, ECT, MAF, TP, PNP, CPP,

PSP, ACSW, TEST.

 Inspect IAC valve

(See IDLE AIR CONTROL

(IAC) VALVE INSPECTION

(BP, BP WITH TC) )



Inspect IAT sensor No.1

(See INTAKE AIR

TEMPERATURE (IAT)

SENSOR INSPECTION (BP,

BP WITH TC) )



Inspect IAT sensor No.2

(See INTAKE AIR

TEMPERATURE (IAT)

SENSOR NO.2 INSPECTION

(BP WITH TC) )



Inspect following PIDs: RPM,

TP, ECT,

Inspect VTCS solenoid valve.

IMRCM

(VTCS vacuum switch)

ON/OFF ECT below 65°C {149°

F} while idling: ON

(See VARIABLE TUMBLE

CONTROL SYSTEM (VTCS)

SOLENOID VALVE

INSPECTION (BP, BP WITH

TC) )



Inspect the vacuum hose for improper routing, kinks or leaks



Inspect following PIDs: RPM,

TP, ECT.

Inspect VTCS vacuum switch.

(See VARIABLE TUMBLE

CONTROL SYSTEM (VTCS)

VACUUM SWITCH

INSPECTION (BP, BP WITH

TC) )

KNOCKR ° Ignition switch ON: 0°

Microsoft

Saturday, July 04, 2009 10:52:35 AM Page 23

 Inspect the vacuum hose for improper routing, kinks or leaks



Inspect KS

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

(Knocking retard)

Idle: 0° (See KNOCK SENSOR (KS)

INSPECTION (BP, BP WITH

TC) )

LOAD

(Calculated engine load)

LONGFT1

(Current long term fuel trim adjustment)

MAF (Intake

MAF)

Idle: Approx.20%

Idle: Approx.10%



Perform "ON-BOARD

DIAGNOSTIC TEST" (See ON-

BOARD DIAGNOSTIC TEST

(BP, BP WITH TC) )



Perform "ON-BOARD

DIAGNOSTIC TEST" (See ON-

BOARD DIAGNOSTIC TEST

(BP, BP WITH TC) )

MAP (Boost pressure) g/s lb/min

V kPa

Bar psi

Idle: 2.6-3.3 g/s {0.3-0.4 lb/min}

Idle: Approx.2.0 V

Indicate the boost pressure

Ignition switch is turned to the ON position:

Approx.2.6 V

(1)



Inspect MAF sensor (See MASS

AIR FLOW (MAF) SENSOR

INSPECTION (BP, BP WITH

TC) )



Inspect BARO/MAP sensor (See

EGR BOOST SENSOR (BP),

BAROMETRIC PRESSURE

(BARO)/MANIFOLD

ABSOLUTE PRESSURE

(MAP) SENSOR (BP WITH

TC) INSPECTION (BP, BP

WITH TC) )



Inspect MIL

4AE

MIL

(Malfunction indicator lamp)

ON/OFF Ignition switch ON: ON

DTC output: ON

No DTC output: OFF

(See WARNING AND

INDICATOR LIGHT BULB

REMOVAL/INSTALLATION )



Inspect HO2S (Front)

O2S11

(Heated oxygen sensor

(Front))

V Ignition switch ON: 0-

1.0 V

After warm up: 0-1.0 V

Acceleration: 0.5-1.0 V

Deceleration: 0-0.5 V

O2S12

(Heated oxygen sensor

(Rear))

PSP (PSP

V Ignition switch ON: 0-

1.0 V

Idle (After warm up): 0-

1.0 V

Idle (Engine cold): 0-0.5

Accelerate: 0.5-1.0 V

Decelerate: 0-0.5 V

High/Low Steering wheel is at

Microsoft

Saturday, July 04, 2009 10:52:35 AM Page 24

(See HEATED OXYGEN

SENSOR (HO2S)

INSPECTION (BP, BP WITH

TC) )

 Inspect HO2S (Rear)

(See

TC) )

HEATED OXYGEN

SENSOR (HO2S)

INSPECTION (BP, BP WITH

4AA

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata switch) straight ahead position:

Low

Steering wheel is fully turned: High

ON/OFF Adaptive memory exists: --

No adaptive memory:

OFF



Inspect PSP switch

(See POWER STEERING

PRESSURE (PSP) SWITCH

INSPECTION (BP, BP WITH

TC) )

RFCFLAG

(Fuel learning correction set flag)

RPM

(Engine speed)

SEGRP

(EGR valve

(stepping motor) position)

SHRTFT1

(Short term trim)

RPM step

Indicate the engine speed



Inspect CKP sensor

Ignition switch ON: 0 step

Idle: 0 step

Cranking: 0-60 steps

Idle: -25-25%



(See CRANKSHAFT

POSITION (CKP) SENSOR

INSPECTION (BP, BP WITH

TC) )

Inspect following PIDs: ECT, TP.

2E, 2F,

2H, 2I

Inspect EGR valve

(See EGR VALVE

INSPECTION (BP, BP WITH

TC) )



Perform "ON-BOARD

DIAGNOSTIC TEST" (See ON-

BOARD DIAGNOSTIC TEST

(BP, BP WITH TC) )

-SORK TIME

(Engine sork time)

SPARKADV

(Ignition timing)

MIN

° Indicate the ignition timing

 Inspect following PIDs: MAF,

IAT, RPM, TP, ECT, PSP, PNP,

CPP, ACSW, TEST, CMP sensor.



Perform engine tune-up

Test (TEN terminal

(DLC))

TP (Throttle position sensor signal voltage)

ON/OFF Open terminal TEN:

OFF

Shorted terminal TEN:

V Closed TP: 0.1-1.1 V

WOT: 3.0-4.6 V

Microsoft

Saturday, July 04, 2009 10:52:35 AM Page 25

(See ENGINE TUNE-UP )



Inspect the DLC TEN terminal and PCM connector terminal 4AC



Inspect TP sensor

(See THROTTLE POSITION

4AC

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

VPWR

(Battery positive voltage)

V Ignition switch ON: B+



(TP) SENSOR INSPECTION

(BP, BP WITH TC) )

Inspect main relay

(See RELAY INSPECTION

 Inspect battery

(See BATTERY

INSPECTION )

VSS

(Vehicle speed)

KPH MPH Indicate the vehicle speed



Inspect VSS.

(See VEHICLE

SPEEDOMETER SENSOR

INSPECTION (M15M-D) )

(1) The voltage may vary excessively depending on the weather conditions.

)

4AF,

4AG

BARO PID inspection procedure

1. Confirm the ignition switch is turned to ON.

2. Confirm that the following PIDs are within the specifications:

BARO

101.3 kPa {760 mmHg, 29.9 inHg} (Absolute pressure)

IAT

10-50°C {50-122°F}

3. Disconnect the EGR boost sensor connector and measure the voltage at EGR boost sensor connector terminal C.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 11: Identifying EGR Boost Sensor Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

Voltage

4.5-5.5 V

4. Reconnect the connector.

5. Disconnect the vacuum hose from the EGR boost sensor.

6. Connect the vacuum pump to the EGR boost sensor.

7. Select BARO PID on the WDS or equivalent.

8. Apply the vacuum and verify that the BARO PID is as specified on the table.

VREF terminal circuit inspection

1. Turn the ignition switch to the ON position.

2. Measure the voltage between the TP sensor connector (vehicle side) terminal A and body GND using a voltmeter.

1. Measurement voltage is 0 V.

1. Turn the ignition switch to the LOCK position.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

2. Disconnect the TP sensor connector, EGR boost sensor (BP), and BARO/MAP sensor (BP

WITH TC) connector (to which VREF is applied).

3. Verify there is no continuity between the TP sensor connector (vehicle side) terminal A and body GND using an ohmmeter.



If there is continuity, repair the related harness for short to circuit.

Fig. 12: Identifying TP Sensor Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

4. Inspect for continuity between the PCM connector (vehicle side) terminal 4L and each sensor connector (vehicle side) terminals to which VREF is applied using an ohmmeter.



If there is continuity, repair the related harnesses.

PCM terminal Connector (vehicle side)

TP sensor

4L EGR boost sensor (BP)

BARO/MAP sensor (BP WITH TC)

Terminal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 13: Identifying EGR Boost Sensor And TP Sensor Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

2. Measurement voltage is B+.

1. Turn the ignition switch to the LOCK position.

2. Disconnect the battery positive harness and battery negative harness.

3. Verify there is no continuity between the TP sensor connector (vehicle side) terminal A and battery positive harness using an ohmmeter.



If there is continuity, repair the related harnesses for short to B+ circuit.

3. Measurement voltage is approx.5 V.



VREF terminal of PCM is okay.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 14: Identifying TP Sensor Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

GND circuit inspection

1. Turn the ignition switch to the LOCK position.

2. Disconnect the PCM connectors.

3. Inspect for continuity between the PCM GND terminals and body GND using an ohmmeter.



If not as specified, repair the related harnesses for open circuit.

PCM GND terminal

Power supply circuit inspection

1. Turn the ignition switch to the LOCK position.

2. Disconnect the PCM connectors.

3. Measure the voltage between the PCM battery power terminal and body GND using a voltmeter.

Microsoft



If not as specified, repair the related harnesses and fuses.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Power supply terminal

4AG

4AF (Ignition switch: ON)

Power supply terminal voltage

B+

Serial communication terminal inspection

1. Turn the ignition switch to the LOCK position.

2. Disconnect PCM connectors.

3. Verify there is continuity between PCM connector terminal 3Q and DLC-2 KLN terminal.

Fig. 15: Identifying DLC-2 KLN Terminal

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



If not as specified, repair the related harnesses.

PCM TERMINAL VOLTAGE TABLE (REFERENCE)

Fig. 16: Identifying PCM Terminal

Courtesy of MAZDA MOTORS CORP.

PCM TERMINAL VOLTAGE REFERENCE (BP)

Terminal Signal

2A Fuel injector control

Connected to

Fuel injector

No.1

Test condition

Voltage

(V)

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE)

(1)

)

2B Cooling fan control

Cooling fan Idle relay

2C Condenser fan control

Condenser fan relay

Idle

ECT above

97°C {207°

F}. A/C operating.

Throttle valve fully open with terminal

TEN (DLC) shorted to

GND

Others

ECT above

108°C {226°

F}, A/C operating,

Throttle valve fully open with

Below

1.0

B+

Below

1.0

Microsoft

Saturday, July 04, 2009 10:52:36 AM Page 32



Action



Inspect fuel injector. (See FUE

INJECTOR INSPECTION

BP WITH TC) )



Inspect related harness.



Inspect cooling fan relay. (See

RELAY INSPECTION )

Inspect related harness.

Inspect condenser fan relay. (S

RELAY INSPECTION )

Inspect related harness.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fuel injector control

EGR valve #1 coil control

EGR valve #2 coil control

Fuel injector control

EGR valve #3 coil control

EGR valve #4 coil control

Fuel injector control

A/C control

FP control

EGR valve

(terminal E)

EGR valve

(terminal

EGR valve

(terminal B)

EGR valve

(terminal F)

Microsoft

Saturday, July 04, 2009 10:52:36 AM

Others

Ignition switch on

Idle

Ignition switch on

Idle

Ignition switch on

Idle

Ignition switch on

Idle terminal

TEN (DLC) shorted to ground

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

B+

Fuel injector

No.2

Fuel injector No.

Fuel injector

No.4

A/C relay

FP relay

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Inspect using the wave profile.

(See

Idle

Cranking

Idle

INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Below

1.0

B+

Below

1.0



Inspect fuel injector, (See FUE

INJECTOR INSPECTION

BP WITH TC) )

 Inspect related harness.



Inspect EGR valve. (See EGR

VALVE INSPECTION (BP,

WITH TC) )



Inspect related harness.



Inspect EGR valve. (See EGR

VALVE INSPECTION (BP,

WITH TC) )

Inspect related harness.



Inspect fuel injector (See FUE

INJECTOR INSPECTION

BP WITH TC) )



Inspect related harness.



Inspect EGR valve. (See EGR

VALVE INSPECTION (BP,

WITH TC) )

Inspect related harness.



Inspect EGR valve. (See EGR

VALVE INSPECTION (BP,

WITH TC) )

 Inspect related harness.



Inspect fuel injector. (See FUE

INJECTOR INSPECTION

BP WITH TC) )



Inspect related harness.



Inspect A/C relay. (See RELA

INSPECTION )

Inspect related harness.

A/C and fan switches are on.

Others

Page 33

Below

1.0

B+

Below

1.0



Inspect FP relay. (See RELAY

INSPECTION )

Inspect related harness.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

VTCS control

VTCS solenoid valve

IAC (negative) IAC valve

3G -

Microsoft

Saturday, July 04, 2009 10:52:36 AM

ECT above 60°C {140°F} while idling

ECT below 60°C {140°F} and engine speed at 3,500 rpm

2P IAC (positive) IAC valve Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Below

1.0

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

B+



Inspect VTCS solenoid valve.

(See VARIABLE TUMBLE

CONTROL SYSTEM (VTC

SOLENOID VALVE

INSPECTION (BP, BP WIT

TC) )



Inspect related harness.



Inspect IAC valve inspection.

(See IDLE AIR CONTROL

(IAC) VALVE INSPECTIO

(BP, BP WITH TC) )

 Inspect related harness.

 Inspect IAC valve inspection.

(See IDLE AIR CONTROL

(IAC) VALVE INSPECTIO

(BP, BP WITH TC) )



Inspect related harness.



Inspect MIL.

Inspect related harness.

2R MIL control MIL (in instrument cluster)

GND 3A Fuel injector

GND

3B PCM GND GND

Purge control

EGR boost sensor switching control

3F IGT control

(No. 1, No.4 cylinders)

Purge solenoid valve

EGR boost sensor solenoid valve

Ignition switch on

Idle (MIL OFF)

Below

1.0

B+

Under any condition

Below

1.0

Below

1.0

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Ignition switch on

Idle

OSCILLOSCOPE

(REFERENCE) )

Page 34

B+

Ignition coil Inspect using the wave profile.

(See INSPECTION USING AN



Inspect related harness.



Inspect purge solenoid valve.

PURGE SOLENOID VALV

INSPECTION (BP, BP WIT

TC) )

Inspect related harness.



Inspect EGR boost sensor solenoid valve. (See EGR

BOOST SENSOR SOLENO

VALVE INSPECTION (BP,

WITH TC) )



Inspect related harness.



Inspect ignition coil. (See

IGNITION COIL

INSPECTION )

Inspect related harness.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Main relay control

IGT control

(No.2, No.3 cylinders)

HO2S heater

(Front) control

EVAP system leak detection pump (pump)

Main relay Ignition switch off

Ignition switch on

EVAP system leak

Ignition switch on detection pump

Idle

B+

Below

1.0

Ignition coil Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

HO2S

(Front)

Ignition switch on

Idle

Below

1.0

B+



Inspect main relay. (See REL

INSPECTION )

Inspect related harness.



Inspect ignition coil. (See

IGNITION COIL

INSPECTION )

 Inspect related harness.



Inspect HO2S heater (Front).

HEATED OXYGEN SENSO

(HO2S) INSPECTION (BP,

WITH TC) )



Inspect related harness.



Inspect EVAP system leak detection pump. (See

EVAPORATIVE EMISSIO

(EVAP) SYSTEM LEAK

DETECTION PUMP

INSPECTION (BP, BP WIT

TC) )



Inspect related harness.



Inspect generator. (See

GENERATOR INSPECTIO



Inspect related harness.

3L -

3M Generator field coil control

Generator

(terminal

3N -

3O Engine speed DLC terminal

IG-TCM

(AT), tachometer

3P HO2S heater

(Rear) control

HO2S

(Rear)

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Verify that voltage is raised when electrical load (headlight, A/C) is turned on at idle.

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Ignition switch on B+

Idle (Heater operating) Below

1.0



Inspect related harness.



Inspect HO2S heater (Rear). (

HEATED OXYGEN SENSO

(HO2S) INSPECTION (BP,

WITH TC) )

Inspect related harness.



Inspect related harness.

3Q K-LINE (Serial DLC communication) terminal

KLN DLC

Carry out inspection according to DTC

DTC output is a part of serial communication

Microsoft

Saturday, July 04, 2009 10:52:36 AM Page 35

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

3R -

3S Immobilizer communication

Judgement by terminal voltage is not possible

Immobilizer Because of this terminal for serial unit communication, good/no good judgment by terminal voltage is not possible. Carry out inspection according to diagnostic trouble codes.

3T Vehicle speed VSS Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

3U Generator

4C warning light control

SGC

3Y NE

Brake

PSP

Device GND

Generator warning light (in instrument cluster)

Ignition switch on ldle (DTC P0111, P0112,

P1631, P1633 or P1634 is not stored.)

Below

1.0

B+

CMP sensor Inspect using the wave profile.

CKP sensor Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

GND

Brake switch

Microsoft

Saturday, July 04, 2009 10:52:36 AM

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Under any condition

Brake pedal released

Brake pedal depressed

PSP switch Idle Steering wheel

Page 36



Inspect Immobilizer unit. (See

IMMOBILIZER UNIT

INSPECTION )



Inspect related harness.



Inspect vehicle speedometer sensor. (See VEHICLE

SPEEDOMETER SENSOR

INSPECTION (M15M-D) )



Inspect related harness.

 Inspect generator warning ligh inspection. (See WARNING

AND INDICATOR LIGHT

BULB

REMOVAL/INSTALLATIO



Inspect related harness.



Inspect CMP sensor. (See

CAMSHAFT POSITION

(CMP) SENSOR

REMOVAL/INSTALLATIO

(BP, BP WITH TC) )

Inspect related harness.



Inspect CKP sensor. (See

CRANKSHAFT POSITION

(CKP) SENSOR INSPECTI

(BP, BP WITH TC) )

Inspect related harness.



Inspect related harness.

Below

1.0

Below

1.0

B+



Inspect brake switch. (See

BRAKE SWITCH

INSPECTION )

Inspect related harness.



Inspect PSP switch. (See

POWER STEERING

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Oil control valve

(OCV) straight ahead position

Steering wheel fully turned

Below

1.0

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )



PRESSURE (PSP) SWITCH

INSPECTION (BP, BP WIT

TC) )

Inspect related harness.

4D Oil control valve (OCV) control

(positive)



Inspect oil control valve (OCV

(See OIL CONTROL VALV

(OCV) INSPECTION (BP) )

Inspect related harness.

4E DTM switching DLC terminal

TEN

Ignition switch on

Open

Terminal

TEN

Short to

GND terminal

TEN

A/C and fan switches are on.

B+

Below



Inspect related harness.

4F A/C Refrigerant pressure switch

Ignition switch on

Others

Below

1.0

B+



Inspect refrigerant pressure switch. (See REFRIGERAN

PRESSURE SWITCH

INSPECTION )

Inspect related harness.

Load/no load distinction

Neutral switch

(MT)

Ignition switch on

Others

Transmission in neutral position

Below

1.0

B+



Inspect neutral switch. (See

NEUTRAL SWITCH

INSPECTION (BP, BP WIT

TC) )



Inspect related harness.

4I Load/no load distinction

Clutch switch

(MT)

Ignition switch on

Clutch pedal depressed

Clutch pedal released

B+

Below

1.0



Inspect clutch pedal position switch. (See CLUTCH PEDA

POSITION SWITCH

INSPECTION (BP, BP WIT

TC) )



Inspect related harness.

4J VTCS vacuum switch

4K -

4L Constant

VTCS vacuum switch

Microsoft

Saturday, July 04, 2009 10:52:36 AM

Ignition switch on

ECT Above 60°C {140°

F} while idling

ECT below 60°C {140°F} and engine speed at 3,500 rpm

TP sensor, Ignition switch on

Page 37

B+

Below

1.0



Inspect VTCS vacuum switch

(See VARIABLE TUMBLE

CONTROL SYSTEM (VTC

VACUUM SWITCH

INSPECTION (BP, BP WIT

TC) )

Inspect related harness.

Approx.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata voltage (VREF) EGR boost sensor

4M Knocking KS

4N IAT

5.0

Ignition switch on (Using digital type voltmeter, because measurement voltage is less than true voltage when using analog type voltmeter.)

Approx.

2.4

IAT sensor Ignition switch on

IAT 20°C

{68°F}

2.3-2.4



Inspect related harness.

Inspect KS. (See KNOCK

SENSOR (KS) INSPECTIO

(BP, BP WITH TC) )

Inspect related harness.

IAT 30°C

{86°F}

1.9



Inspect IAT sensor. (See

INTAKE AIR

TEMPERATURE (IAT)

SENSOR INSPECTION (BP

BP WITH TC) )

Inspect related harness.



Inspect related harness.

4O Analogue sensor GND

GND, EGR boost sensor, TP sensor, ECT

Under any condition sensor, IAT sensor,

HO2S

(Front),

HO2S

(Rear)

ECT sensor Ignition switch on

ECT 20°C

{68°F}

Below

1.0

4P ECT

4Q -

4R Oil control valve (OCV) control

(negative)

4V TP

ECT 80°C

{176°F}

Approx.

3.0

Approx.

0.9

Oil control valve

(OCV)

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

4S Ignition switch

(IG1)

Ignition switch

4T Generator output voltage

Ignition switch off

Generator

(terminal P)

Ignition switch on

TP sensor Ignition Closed TP 0.1-1.1

Microsoft

Saturday, July 04, 2009 10:52:36 AM

Idle (No electrical load)

Page 38

Below

1.0

B+

Below

1.0

3-8



Inspect ECT sensor. (See

ENGINE COOLANT

TEMPERATURE (ECT)

SENSOR INSPECTION (BP

BP WITH TC) )

Inspect related harness.



Inspect oil control valve (OCV

(See OIL CONTROL VALV

(OCV) INSPECTION (BP) )

Inspect related harness.

Inspect ignition switch.

Inspect related harness.



Inspect generator. (See

GENERATOR INSPECTIO

Inspect related harness.



Inspect TP sensor. (See

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata switch on (AP released)

WOT (AP fully depressed)

3.0-4.6

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )



THROTTLE POSITION (T

SENSOR INSPECTION (BP

BP WITH TC) )

Inspect related harness.

HO2S (Front)

MAF

HO2S

(Front)

MAF sensor

Ignition switch on

Idle (After warm up)

0.9-2.0

1.7-2.4

4Y -

4Z PCM-TCM communication

(From PCM to

TCM) (AT)

TCM

(terminal

Because this terminal is for serial communication, good/no good judgement by terminal voltage is not possible. Carry out inspection according to DTC.

4AA HO2S (Rear) HO2S

(Rear)

4AB -

4AC PCM- TCM communication

(From TCM to

PCM) (AT)

TCM

(terminal

AL)

NOTE:

 If PCM/TCM communication is not correct, DTC P1601 is stored.

Ignition switch on

Idle Engine cold

0-1.0

0-0.5

0-1.0

After warm

Acceleration up

Deceleration

0.5-1.0

0-0.5

Because this terminal is for serial communication, good/no good judgement by terminal voltage is not possible. Carry out inspection according to DTC.

Microsoft

Saturday, July 04, 2009 10:52:36 AM



Inspect HO2S (Front). (See

HEATED OXYGEN SENSO

(HO2S) INSPECTION (BP,

WITH TC) )

Inspect related harness.



Inspect MAP sensor. (See MA

AIR FLOW (MAF) SENSOR

INSPECTION (BP, BP WIT

TC) )



Inspect related harness.



Inspect related harness.



Inspect HO2S heater (Rear). (

HEATED OXYGEN SENSO

(HO2S) INSPECTION (BP,

WITH TC)

Inspect related harness.

NOTE:

 If PCM/TCM communication is not correct, DTC P1601 is stored.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

4AD Fuel tank level Fuel gauge sender unit

Ignition switch on

Fuel tank full 0.2-0.5

(1)

Fuel tank empty

3.4-4.4

(1)

Fuel tank half

1.8-2.8

(1)

4AE BARO/EGR boost

EGR boost sensor

Ignition switch on,

Idle

Below 400 m 4.1-4.3

{0.25 mile} above sea level

With pressure gauge:

Vacuum reading -26.6 kPa {-200 mmHg, -7.85 inHg}

3.0-3.4

4AF Power supply Main relay Ignition switch on B+

Ignition switch off Below

1.0

4AG Back-up power supply

Battery

4AH EVAP system leak detection pump

(solenoid)

Under any condition

EVAP system leak

Ignition switch on detection pump solenoid valve

Idle

B+

(1) The voltages above will be measured when the battery voltage is 12-14V.



Inspect fuel gauge sender unit

(See FUEL GAUGE SENDE

UNIT INSPECTION )

Inspect related harness.

Inspect EGR boost sensor. (Se

EGR BOOST SENSOR (BP

BAROMETRIC PRESSURE

(BARO)/MANIFOLD

ABSOLUTE PRESSURE

(MAP) SENSOR (BP WITH

TC) INSPECTION (BP, BP

WITH TC) )

Inspect related harness.



Inspect main relay. (See REL

INSPECTION )



Inspect related harness.



Inspect related harness.



Inspect EVAP system leak detection pump. (See

EVAPORATIVE EMISSIO

(EVAP) SYSTEM LEAK

DETECTION PUMP

INSPECTION (BP, BP WIT

TC) )

Inspect related harness.

BP WITH TC

PCM TERMINAL VOLTAGE REFERENCE (BP WITH TC)

Terminal

Signal

Fuel injector control

Connected to

Test condition

Voltage

(V)

Fuel injector

No.1

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Action



Inspect fuel injector. (See FU

INJECTOR INSPECTION

BP WITH TC) )

Inspect related harness.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fan control

Fuel injector control

EGR valve #1 coil control

EGR valve #2 coil control

Fuel injector control

EGR valve #3 coil control

EGR valve #4 coil control

Fan relay

No.1

Fan relay

No.2 and

No.3

Idle

Throttle valve fully open with terminal

TEN (DLC) shorted to

GND

Others

Throttle valve fully open with terminal

TEN (DLC) shorted to ground

Others

Below

B+

1.0

Below

B+

1.0

Fuel injector

No.2

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

EGR valve

(terminal E)

EGR valve

(terminal A)

Fuel injector

No.3

EGR valve

(terminal B)

EGR valve

(terminal F)

Ignition switch on

Idle

Ignition switch on

Idle

OSCILLOSCOPE

(REFERENCE) )

Ignition switch on

Idle

Ignition switch on

Idle

Below

1.0

B+

Inspect using the wave profile.

(See INSPECTION USING AN

B+

Below

1.0



Inspect cooling fan relay. (Se

RELAY INSPECTION )

Inspect related harness.

Inspect condenser fan relay.

RELAY INSPECTION )

Inspect related harness.



Inspect fuel injector. (See FU

INJECTOR INSPECTION

BP WITH TC) )



Inspect related harness.



Inspect EGR valve. (See EG

VALVE INSPECTION (BP

WITH TC) )



Inspect related harness.



Inspect EGR valve. (See EG

VALVE INSPECTION (BP

WITH TC) )

Inspect related harness.



Inspect fuel injector (See FU

INJECTOR INSPECTION

BP WITH TC) )



Inspect related harness.



Inspect EGR valve. (See EG

VALVE INSPECTION (BP

WITH TC) )

Inspect related harness.



Inspect EGR valve. (See EG

VALVE INSPECTION (BP

WITH TC) )



Inspect related harness.

Fuel injector Fuel injector

Inspect using the wave profile.

(See INSPECTION USING AN

Microsoft

Saturday, July 04, 2009 10:52:36 AM Page 41



Inspect fuel injector. (See FU

INJECTOR INSPECTION

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

2M control

A/C control

FP control

2N VTCS control

No.4

OSCILLOSCOPE

(REFERENCE) )

A/C relay

FP relay

Idle

A/C and fan switches are on.

Others

Below

B+

1.0

Cranking

Idle

Turn the ignition switch to

ON position without do it immediately.

Below

1.0

B+

ECT above 65°C {149°F} while idling

B+

VTCS solenoid valve

ECT below 65°C {149°F} and engine speed below

3,250 rpm

Below

1.0

IAC (positive)

IAC valve

IAC (negative) IAC valve

MIL control

Fuel injector.GND

3B PCM GND

Purge control

MIL (in instrument cluster)

GND

Purge solenoid valve

Microsoft

Saturday, July 04, 2009 10:52:36 AM

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Ignition switch on

Idle (MIL OFF)

Under any condition

Below

1.0

B+

Below

1.0

Below

1.0

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Page 42



BP WITH TC) )

Inspect related harness.



Inspect A/C relay. (See REL

INSPECTION )

Inspect related harness.

Inspect FP relay. (See RELA

INSPECTION )

Inspect related harness.



Inspect VTCS solenoid valve

(See VARIABLE TUMBLE

CONTROL SYSTEM (VT

SOLENOID VALVE

INSPECTION (BP, BP WI

TC) )

Inspect related harness.



Inspect IAC valve inspection

(See IDLE AIR CONTROL

(IAC) VALVE INSPECTIO

(BP, BP WITH TC) )

Inspect related harness.



Inspect IAC valve inspection

(See IDLE AIR CONTROL

(IAC) VALVE INSPECTIO

(BP, BP WITH TC) )

Inspect related harness.



Inspect MIL.

Inspect related harness.



Inspect related harness.



Inspect purge solenoid valve

PURGE SOLENOID VAL

INSPECTION (BP, BP WI

TC) )



Inspect related harness.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

BARO/MAP sensor switching control

IGT control

(No.1, No.4 cylinders)

Main relay control

IGT control

(No.2, No.3 cylinders)

HO2S heater

(Front) control

EVAP system leak detection pump (pump)

EGR boost sensor solenoid valve

HO2S

(Front)

Ignition coil

Main relay

Ignition coil

EVAP system leak detection pump

Ignition switch on

Idle

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Ignition switch off

Ignition switch on

B+

Below

1.0

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Ignition switch on

Idle

Ignition switch on

Idle

B+

1.0 or less

Below

B+

1.0

B+



Inspect EGR boost sensor solenoid valve. (See EGR

BOOST SENSOR SOLENO

VALVE INSPECTION (B



Inspect related harness.



Inspect ignition coil. (See

IGNITION COIL

INSPECTION )



Inspect related harness.



Inspect main relay. (See REL

INSPECTION )

 Inspect related harness.



Inspect ignition coil. (See

IGNITION COIL

INSPECTION )



Inspect related harness.



Inspect HO2S heater (Front)

HEATED OXYGEN SENS

(HO2S) INSPECTION (BP

WITH TC) )

Inspect related harness.



Inspect EVAP system leak detection pump. (See

EVAPORATIVE EMISSIO

(EVAP) SYSTEM LEAK

DETECTION PUMP

INSPECTION (BP, BP WI

TC) )

Inspect related harness.

3N -

Generator field coil control

Generator

(terminal D)

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Verify that voltage is raised when electrical load (headlight, A/C) is turned on at idle.

Microsoft

Saturday, July 04, 2009 10:52:36 AM



Inspect generator. (See

GENERATOR INSPECTI

Inspect related harness.

Inspect using the wave profile.

(See INSPECTION USING AN

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

3O Engine speed Tachometer

OSCILLOSCOPE

(REFERENCE) )



Inspect related harness.

HO2S heater

(Rear) control

HO2S (Rear)

Ignition switch on

Idle (Heater operating)

Below

1.0

B+ 



Inspect HO2S heater (Rear).

HEATED OXYGEN SENS

(HO2S) INSPECTION (BP

WITH TC) )

Inspect related harness.

K-LINE (Serial communication)

DLC terminal

KLN DLC 2

Immobilizer communication

Immobilizer unit

Carry out inspection according to DTC output is a part of serial communication

Judgement by terminal voltage is not possible

Because of this terminal for serial communication, good/no good judgment by terminal voltage is not possible. Carry out inspection according to diagnostic trouble codes.

Vehicle speed

Instrument cluster

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Generator warning light control

SGC

Generator warning light

Ignition switch on

(in instrument cluster)

CMP sensor

CKP sensor

Microsoft

Saturday, July 04, 2009 10:52:36 AM ldle (DTC P0111, P0112,

P1631, P1633 or P1634 is not stored.)

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Inspect using the wave profile.

(See

Below

B+

1.0

INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )

Page 44



Inspect related harness.

Inspect Immobilizer unit. (Se

IMMOBILIZER UNIT

INSPECTION )

Inspect related harness.



Inspect instrument cluster. (S

INSTRUMENT CLUSTER

INSPECTION )



Inspect related harness.



Inspect generator warning lig inspection. (See WARNING

AND INDICATOR LIGHT

BULB

REMOVAL/INSTALLATI

Inspect related harness.



Inspect CMP sensor. (See

CAMSHAFT POSITION

(CMP) SENSOR

REMOVAL/INSTALLATI

(BP, BP WITH TC) )



Inspect related harness.



Inspect CKP sensor. (See

CRANKSHAFT POSITIO

(CKP) SENSOR INSPECT

(BP, BP WITH TC) )

 Inspect related harness.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Device GND GND

Under any condition

Below

1.0



Inspect related harness.

Brake

PSP

Turbocharger wastegate control

Turbocharger wastegate control monitor

A/C request

PNP

Brake switch

Turbocharger wastegate Turbocharger wastegate regulating valve regulating valve on

Turbocharger wastegate regulating valve OFF

Turbocharger wastegate regulating valve

Refrigerant pressure switch

Neutral switch

Clutch

Microsoft

Saturday, July 04, 2009 10:52:36 AM

Brake pedal released

PSP switch

Brake pedal depressed B+

Idle

Steering wheel straight ahead position

Steering wheel fully turned

B+

Below

1.0

Idle

Turbocharger wastegate regulating valve on

Turbocharger wastegate regulating valve off

Ignition switch on

Ignition

A/C and fan switches are on.

Others

Transmission in neutral position

Others

Below

B+

1.0

Below

1.0

Below

1.0

Below

B+

1.0

Below

1.0



Inspect brake switch. (See

BRAKE SWITCH

INSPECTION )



Inspect related harness.



Inspect PSP switch. (See

POWER STEERING

PRESSURE (PSP) SWITC

INSPECTION (BP, BP WI

TC) )

Inspect related harness.



Turbocharger wastegate regulating valve (See

TURBOCHARGER

WASTEGATE REGULAT

VALVE INSPECTION (BP

WITH TC) )

Related wiring harness



Turbocharger wastegate regulating valve (See

TURBOCHARGER

WASTEGATE REGULAT

VALVE INSPECTION (BP

WITH TC) )

Related wiring harness



Inspect refrigerant pressure switch. (See REFRIGERAN

PRESSURE SWITCH

INSPECTION )



Inspect related harness.



Inspect neutral switch. (See

NEUTRAL SWITCH

INSPECTION (BP, BP WI

TC) )

Inspect related harness.

Clutch pedal released

Page 45

B+



Inspect clutch pedal position switch. (See CLUTCH PED

POSITION SWITCH

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

CPP

VTCS vacuum switch switch

VTCS vacuum switch switch on

Clutch pedal depressed

Ignition switch on

ECT above 6O°C {140°

F} while idling

ECT above 6O°C {140°

F} and engine speed at

3,500 rpm

Below

1.0

B+

Below

1.0

INSPECTION (BP, BP WI

TC) )

 Inspect related harness.



Inspect VTCS vacuum switc

(See VARIABLE TUMBLE

CONTROL SYSTEM (VT

VACUUM SWITCH

INSPECTION (BP, BP WI

TC) )



Inspect related harness.

Constant voltage (VREF)

TP sensor,

EGR boost sensor

Ignition switch on

Approx.

5.0



Inspect related harness.

4M Knocking KS

Ignition switch on (Using digital type voltmeter, because measurement voltage is less than true voltage when using analog type voltmeter.)

Approx.

2.4



Inspect KS. (See KNOCK

SENSOR (KS) INSPECTIO

(BP, BP WITH TC) )

Inspect related harness.

4N IAT

I AT sensor

No.1

Ignition switch on

IAT 20°C

{68°F}

IAT 30°C

{86°F}

2.3-2.4

Approx.

1.9



Inspect IAT sensor No.1. (Se

INTAKE AIR

TEMPERATURE (IAT)

SENSOR INSPECTION (B

BP WITH TC) )

Inspect related harness.

Analogue sensor GND

ECT

GND,

BARO/MAP sensor, TP sensor, ECT sensor, IAT sensor No.1,

IAT sensor

No.2, HO2S

(Front),

HO2S (Rear)

Under any condition

ECT sensor

Microsoft

Saturday, July 04, 2009 10:52:36 AM

Below

1.0



Inspect related harness.

Ignition switch on

ECT 20°C

{68°F}

ECT 80°C

{176°F}

Page 46

Approx.

0.9

3.0



Inspect ECT sensor. (See

ENGINE COOLANT

TEMPERATURE (ECT)

SENSOR INSPECTION (B

BP WITH TC) )

 Inspect related harness.



Inspect IAT sensor No.2. (Se

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

4R IAT

IAT sensor

No.2

Ignition switch on

IAT 25°C

{77°F}

IAT 85°C

{185°F}

Approx.

0.6

2.7



INTAKE AIR

TEMPERATURE (IAT)

SENSOR NO.2 INSPECTI

(BP WITH TC) )

Inspect related harness.

Ignition switch

(IG1)

Generator output voltage

Ignition switch

Generator

(terminal P)

TP sensor

Ignition switch off

Ignition switch on

Below

1.0

B+

Below

1.0

Idle (No electrical load) 3-8

Ignition switch on

Closed TP

(AP released)

WOT (AP fully depressed)

0.1-1.1

3.0-4.6



Inspect ignition switch.

Inspect related harness.

Inspect generator. (See

GENERATOR INSPECTI

Inspect related harness.

Inspect TP sensor. (See

THROTTLE POSITION (T

SENSOR INSPECTION (B

BP WITH TC) )

Inspect related harness.

4W HO2S (Front)

HO2S

(Front)

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) )



Inspect HO2S (Front). (See

HEATED OXYGEN SENS

(HO2S) INSPECTION (BP

WITH TC) )

Inspect related harness.

4X MAP MAF sensor Idle (After warm up)

Approx.

2.0

Ignition switch on

0-1.0

Engine cold 0-0.5

4AA HO2S (Rear) HO2S (Rear)

Idle

Acceleration

After warm up

Deceleration

0-1.0

0.5-1.0

0-0.5

4AB -

4AC Test mode

DLC terminal

TEN

Ignition switch on

Open terminal

TEN

Short to

GND terminal

B+

Below

Microsoft

Saturday, July 04, 2009 10:52:36 AM Page 47



Inspect MAF sensor. (See M

AIR FLOW (MAF) SENSO

INSPECTION (BP, BP WI

TC) )

Inspect related harness.



Inspect HO2S heater (Rear).

HEATED OXYGEN SENS

(HO2S) INSPECTION (BP

WITH TC) )

Inspect related harness.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

4AD Fuel tank level

Fuel gauge sender unit

Ignition switch on

TEN

Fuel tank full

0.2-0.5

(1)

Fuel tank empty

Fuel tank half

3.4-4.4

(1)

1.8-2.8

(1)



Inspect fuel gauge sender un

(See FUEL GAUGE SEND

UNIT INSPECTION )

Inspect related harness.

4AE

BARO/EGR boost

BARO/MAP sensor

4AF Power supply Main relay

4AG

4AH

Back-up power supply

Battery

EVAP system leak detection pump

(solenoid)

Ignition switch on

Ignition switch off

Under any condition

EVAP system leak detection pump solenoid valve

Ignition switch on

Idle

Approx.

2.6

(2)

B+

Below

1.0

B+



Inspect BARO/MAP sensor.

EGR BOOST SENSOR (B

BAROMETRIC PRESSUR

(BARO)/MANIFOLD

ABSOLUTE PRESSURE

(MAP) SENSOR (BP WITH

TC) INSPECTION (BP, BP

WITH TC) )

 Inspect related harness.



Inspect main relay. (See REL

INSPECTION )



Inspect related harness.



Inspect related harness.



Inspect EVAP system leak detection pump. (See

EVAPORATIVE EMISSIO

(EVAP) SYSTEM LEAK

DETECTION PUMP

INSPECTION (BP, BP WI

TC) )

Inspect related harness.

(1) The voltages above will be measured when the battery voltage is 12-14V.

(2) The voltage may vary excessively depending on the weather conditions.

INSPECTION USING AN OSCILLOSCOPE (REFERENCE)

Fuel injection control signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 17: Fuel Injection Control Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal

 No.1: 2A (+) <--> 3A (-)



No.2: 2D (+) <--> 3A (-)



No.3: 2G (+) <--> 3A (-)



No.4: 2J (+) <--> 3A (-)



Oscilloscope setting: 2.0 V/DIV (Y), 20 ms/DIV (X), DC range

Vehicle condition: Idling after warm-up

IAC control signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 18: IAC Control Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 2P(+) <--> 2Q(-)



Oscilloscope setting: 2.0 V/DIV (Y), 25 ms/DIV (X), DC range

Vehicle condition: Idling after warm-up (no electrical load)

Purge control signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 19: Purge Control Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 3C(+) <--> 4A(-)



Oscilloscope setting: 2.0 V/DIV (Y), 10 ms/DIV (X), DC range

Vehicle condition:



ECT: above 80°C {176°F}



D range and 7.5 km/h {5 mph} or below

IGT control signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 20: IGT Control Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal:





3F (+) <--> 4A (-)



3I (+) <--> 4A (-)

Oscilloscope setting: 1.0 V/DIV (Y), 50 ms/DIV (X), DC range



Vehicle condition: Idling after warm-up

Generator field coil signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 21: Generator Field Coil Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 3M(+) <--> 4A(-)



Oscilloscope setting: 0.5 V/DIV (Y), 2.5 ms/DIV (X), DC range

Vehicle condition: Idling after warm-up (no electrical load)

Engine speed signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 22: Engine Speed Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 3O(+) <--> 4A(-)



Oscilloscope setting: 2.0 V/DIV (Y), 20 ms/DIV (X), DC range

Vehicle condition: Idling

Vehicle speed signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 23: Vehicle Speed Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 3T(+) <--> 4A(-)



Oscilloscope setting: 1.0 V/DIV (Y), 10 ms/DIV (X), DC range

Vehicle condition: Driving 50 km/h (31 mph)

SGC signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 24: SGC Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 3V(+) <--> 4A(-)



Oscilloscope setting: 2.0 V/DIV (Y), 20 ms/DIV (X), DC range



Vehicle condition: Idling

NE signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 25: NE Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 3Y(+) <--> 4A(-)

Oscilloscope setting: 1,0 V/DIV (Y), 5.0 ms/DIV (X), DC range



Vehicle condition: Idling

Oil control valve (OCV) signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 26: Oil Control Valve Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 4D(+) <--> 4A(-)



Oscilloscope setting: 2.0 V/DIV (Y), 0.5 ms/DIV (X), DC range

 Vehicle condition: Idling after warm-up (no electrical load)

HO2S (front) signal

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 27: HO2S (Front) Signal - Oscilloscope Graph

Courtesy of MAZDA MOTORS CORP.



PCM terminal: 4W(+) <--> 4A(-)

Oscilloscope setting: 0.2 V/DIV (Y), 2.0 ms/DIV (X), DC range



Vehicle condition: Idling after warm-up

INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION (BP, BP WITH TC)

INSPECTION OF RESISTANCE

NOTE:



Perform the following test only when directed.

1. Disconnect the IAT sensor connector.

2. Remove the IAT sensor.

3. Place the IAT sensor in water with a thermometer, and heat the water gradually.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 28: Measuring Resistance Of IAT Sensor

Courtesy of MAZDA MOTORS CORP.

4. Measure the resistance of the IAT sensor using an ohmmeter.



If IAT sensor is okay, but PID value is out of specification, perform the CIRCUIT

OPEN/SHORT INSPECTION .



If not as specified, replace the IAT sensor.

Specification

Water temperature (°C {°F}) Resistance (kilohm)

20 {68} 2.21-2.69

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

80 (176}

5. Reconnect the IAT sensor connector.

0.29-0.354

Fig. 29: IAT Sensor Signal Graph

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



Reference voltage circuit (IAT sensor connector terminal B and PCM connector terminal 4N.)



GND circuit (IAT sensor connector terminal A and PCM connector terminal 4O.)

Fig. 30: Identifying IAT Sensor Connector Terminal

Courtesy of MAZDA MOTORS CORP.

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



IAT sensor connector terminal B and PCM connector terminal 4N to GND.

INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 INSPECTION (BP WITH

TC)

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart.

RESISTANCE INSPECTION

1. Disconnect the IAT sensor No.2 connector.

2. Verify that the resistance between terminals A and B is within the specification.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



If not within the specification, replace the IAT sensor No.2. (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION (BP WITH TC) .)



If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the CIRCUIT OPEN/SHORT INSPECTION .

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 31: Identifying IAT Sensor No.2 Connector Terminal

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

IAT SENSOR RESISTANCE SPECIFICATION

Ambient temperature (°C {°F})

25 {77}

85 (185}

Resistance (kilohm)

Approx.33

Approx.3.5

Fig. 32: IAT Sensor Characteristics Graph

Courtesy of MAZDA MOTORS CORP.

IAT SENSOR CHARACTERISTICS REFERENCE

Ambient temperature (°C {°F})

Resistance (kilohm)

-20 {-4} 0 (32} 20 {68} 40 {104} 60 {140}

Approx.357 Approx.112

Approx.41

Approx.17

Approx.8

Voltage (V) Approx.4.6

Approx.4.0

Approx.3.0 Approx.2.0 Approx.1.2

CIRCUIT OPEN/SHORT INSPECTION

1. Remove the PCM connector cover.

2. Disconnect the PCM connector.

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

3. Inspect the following wiring harness for open or short circuit (continuity check).

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 33: Identifying PCM Connector Terminal

Courtesy of MAZDA MOTORS CORP.

Open circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.



IAT sensor No.2 terminal A and PCM terminal 4O



IAT sensor No.2 terminal B and PCM terminal 4R

Short circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.

 IAT sensor No.2 terminal A and power supply



IAT sensor No.2 terminal B and power supply



IAT sensor No.2 terminal B and body GND

MASS AIR FLOW (MAF) SENSOR INSPECTION (BP, BP WITH TC)

NOTE:



Perform the following test only when directed.

1. Visually check for the following on the MAF sensor.



Damage

Cracks



Terminal bends



Terminal rust



If any of the above are found, replace the MAF sensor.



If the above are found okay, but PID value is out of specification, perform the CIRCUIT

OPEN/SHORT INSPECTION .

2. Reconnect the MAF sensor connector.

NOTE:



The scan tool shows the MAF rate and load value.

Specification

Intake MAF (g/s)

MT AT

Idle

()

Engine speed 2,500 rpm

()

2.6-3.3

7.1-9.3

2.4-3.4

8.3-9.6

() 750-850 rpm

() No load, neutral or P position

Microsoft

Saturday, July 04, 2009 10:52:37 AM Page 68

Engine load calculated value (%)

16.0-23.0

15.0-23.0

16.0-21.0

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



MAF circuit (MAF sensor connector terminal B and PCM connector terminal 4X.)



Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector.)



GND circuit (MAF sensor connector terminal A and PCM connector terminal 4A through common connector.)

Fig. 34: Identifying Main Relay And MAF Sensor Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



MAF sensor connector terminal B and PCM connector terminal 4X to GND.



MAF sensor connector terminal C and main relay terminal D through common connector to GND.

THROTTLE POSITION (TP) SENSOR INSPECTION (BP, BP WITH TC)

NOTE:



The TP sensor on this type of vehicle is maintenance-free.

Perform the following test only when directed.

1. Measure the PID value.

Microsoft



If PID value is not as specified, inspect as follows:

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



Verify that the throttle valve is fully closed.



Accelerator cable free play (See ACCELERATOR CABLE

INSPECTION/ADJUSTMENT (BP, BP WITH TC) )

Throttle cable free play (See ACCELERATOR CABLE INSPECTION/ADJUSTMENT

(BP, BP WITH TC) )



If the above are okay, but PID value is out of specification, perform the CIRCUIT OPEN/SHORT

INSPECTION .

2. Reconnect the TP sensor connector.



If the above open or short circuit are correct, replace TP sensor.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 4L.)



TP circuit (TP sensor connector terminal C and PCM connector terminal 4V.)



GND circuit (TP sensor connector terminal B and PCM connector terminal 4O.)

Fig. 35: Identifying TP Sensor Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



TP sensor connector terminal A and PCM connector terminal 4L to GND.

 TP sensor connector terminal C and PCM connector terminal 4V to GND.

THROTTLE POSITION (TP) SENSOR REPLACEMENT (BP, BP WITH TC)

1. Disconnect the TP sensor connector.

2. Remove the attaching screws.

3. Remove the TP sensor.

4. Verify that the throttle valve is fully closed.

5. Catch the tang of the TB on the TP sensor plastic rotor.

6. Position the TP sensor on the TB so that the mounting holes align.

7. Install the attaching screws.

Tightening torque

1.6-2.3 N.m {16-24 kgf.cm, 14-20 in.lbf}

8. Release the throttle.

9. Verify the TP sensor PID value. (See PCM INSPECTION (BP, BP WITH TC) .)



If the PID value is not as specified, inspect the TP sensor. (See THROTTLE POSITION (TP)

SENSOR INSPECTION (BP, BP WITH TC) )



If the PID (TP) condition is not as specified, replace the TB.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION (BP, BP

WITH TC)

INSPECTION OF RESISTANCE

NOTE:



Perform the following test only when directed.

1. Drain the engine coolant. (See COOLING SYSTEM SERVICE WARNINGS .) (See ENGINE

COOLANT REPLACEMENT .)

2. Disconnect the ECT sensor connector.

3. Remove the ECT sensor.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 36: Identifying ECT Sensor Connector

Courtesy of MAZDA MOTORS CORP.

4. Place the sensor in water with a thermometer, and heat the water gradually.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 37: Identifying ECT Sensor Connector Terminals

Courtesy of MAZDA MOTORS CORP.

5. Measure the resistance between the ECT sensor terminals using an ohmmeter.



If not as specified, replace the ECT sensor.

If ECT sensor is okay, but PID value is out of specification, perform the CIRCUIT

OPEN/SHORT INSPECTION .

Temperature (°C {°F}) Resistance (kilohm)

20 {68} 2.27-2.74

80 (176} 0.29-0.34

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

6. Reconnect the ECT sensor connector.

Fig. 38: Identifying ECT Sensor Signal Reference Graph

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



Reference voltage circuit (ECT sensor connector terminal A and PCM connector terminal 4P through common connector.)

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



GND circuit (ECT sensor connector terminal B and PCM connector terminal 4O through common connector.)

Fig. 39: Identifying ECT Sensor Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



ECT sensor connector terminal A and PCM connector terminal 4P through common connector to

GND.

WATER TEMPERATURE SENDER UNIT INSPECTION

1. Drain the engine coolant. (See COOLING SYSTEM SERVICE WARNINGS .) (See ENGINE

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

COOLANT REPLACEMENT .)

2. Remove the ECT sensor.

3. Place the sensor in water with a thermometer, and heat the water gradually.

4. Measure the resistance between ECT sensor terminal C and body GND using an ohmmeter.



If not as specified, replace the ECT sensor.

Specification

Water temperature (°C {°F}) Resistance (ohm)

50 {122} 160-230

Fig. 40: Identifying ETC Sensor Connector

Courtesy of MAZDA MOTORS CORP.

CRANKSHAFT POSITION (CKP) SENSOR INSPECTION (BP, BP WITH TC)

INSPECTION OF AIR GAP

NOTE:



Perform the following test only when directed.

1. Measure the air gap between each four projections of the plate behind the crankshaft pulley and the CKP sensor using a feeler gauge.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



If not as specified, adjust the CKP sensor air gap and inspect as follows:



Is any of the four projections of the plate behind the crankshaft pulley twisted or bent.



If not adjusted, replace the plate behind the crankshaft pulley (See PLATE

REMOVAL/INSTALLATION (BP, BP WITH TC) .) or CKP sensor. (See

CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION (BP,

BP WITH TC) )



If CKP sensor PID value is out of specification, perform the " CIRCUIT OPEN/SHORT

INSPECTION ".

Fig. 41: Measuring Air Gap Between Projections Of Plate Behind Crankshaft Pulley And CKP

Sensor

Courtesy of MAZDA MOTORS CORP.

Specification

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

0.5-1.5 mm {0.020-0.059 in}

2. Reconnect the CKP sensor connector.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



CKP circuit (CKP sensor connector terminal B and PCM connector terminal 3Y.)



Power circuit (CKP sensor connector terminal A and main relay terminal D through common connector.)



GND circuit (CKP sensor connector terminal C and PCM connector terminal 4A through common connector.)

Fig. 42: Identifying Main Relay

Courtesy of MAZDA MOTORS CORP.

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



CKP sensor connector terminal B and PCM connector terminal 3Y circuit through common connector to GND.



CKP sensor connector terminal A and main relay terminal D through common connector to GND.

CRANKSHAFT POSITION (CKP) SENSOR ADJUSTMENT (BP, BP WITH TC)

1. Loosen the CKP sensor installation bolt.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

2. While moving the CKP sensor, adjust the air gap between the CKP sensor and the four projections on the plate using a feeler gauge.

Specification

0.5-1.5 mm {0.020-0.059 in}

3. Tighten the CKP sensor installation bolt.



If not adjusted, replace the plate behind the crankshaft pulley or the CKP sensor. (See PLATE

REMOVAL/INSTALLATION (BP, BP WITH TC) .) (See CRANKSHAFT POSITION (CKP)

SENSOR REMOVAL/INSTALLATION (BP, BP WITH TC) .)

Fig. 43: Adjusting Air Gap Between CKP Sensor And Four Projections On Plate

Courtesy of MAZDA MOTORS CORP.

Tightening torque

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf}

CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION (BP,

BP WITH TC)

1. Disconnect the CKP sensor connector.

2. Remove the undercover.

3. Remove the CKP sensor installation bolt.

4. Install in the reverse order of removal.

Tightening torque

7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf}

5. Reconnect the CKP sensor connector.

NOTE:

6. Adjust the air gap. (See CRANKSHAFT POSITION (CKP) SENSOR ADJUSTMENT (BP, BP

WITH TC) .)

PLATE REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Remove the drive belt.

2. Remove the crankshaft pulley.

3. Remove the plate.

4. Install in the reverse order of removal.

NOTE:



Do not forcefully pull the wiring harness of the CKP sensor.



Adjust the drive belt when installing the drive belt. (See DRIVE BELT

ADJUSTMENT .)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 44: Removing Crankshaft Pulley & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION (BP, BP

WITH TC)

1. Disconnect the negative battery cable.

2. Disconnect the CMP sensor connector.

3. Remove the CMP sensor installation bolt.

4. Remove the CMP sensor.

5. Make sure that the CMP sensor is free of any metallic shavings or particles.



If metallic shavings or particles are found on the sensor, clean them off.

6. Install the CMP sensor in the reverse order of removal.

Tightening torque

7.9-10.7 N.m {80-110 kgf cm, 69.5-95.4 in.lbf}

CAMSHAFT POSITION (CMP) SENSOR INSPECTION (BP, BP WITH TC)

VISUAL INSPECTION

1. Remove the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

REMOVAL/INSTALLATION (BP, BP WITH TC) .)

2. Make sure that the CMP sensor is free of any metallic shavings or particles.



If metallic shavings or particles are found on the sensor, clean them off.

3. Install the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR

REMOVAL/INSTALLATION (BP, BP WITH TC) .)

WAVE PROFILE INSPECTION

1. Remove the PCM. (See PCM REMOVAL/INSTALLATION (BP, BP WITH TC) .)

2. Connect WDS or equivalent to DLC-2 connector.

3. Connect oscilloscope test leads to the following PCM connector terminals.



(+) lead: PCM terminal 3V

(-) lead: PCM terminal 4A

4. Start the engine.

5. Monitor RPM PID.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 45: Identifying PCM Connector Terminal

Courtesy of MAZDA MOTORS CORP.

6. Inspect wave profile when idling engine.



If wave profile or voltage are out of specifications, carry out the "Circuit Open/Short Inspection".



PCM terminal: 3V(+) <--> 4A(-)



Oscilloscope setting: 2.0V/DIV(Y), 20ms/DIV(X), DC range

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



Vehicle condition: Idling

Fig. 46: Identifying Waveform Graph

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

1. Remove the PCM. (See PCM REMOVAL/INSTALLATION (BP, BP WITH TC) .)

2. Inspect the following wiring harnesses for an open or short circuit by probing the applicable sensor and

PCM terminals with ohmmeter leads.



If there is an open or short circuit, repair or replace wiring harnesses.



If there is no open or short circuit, replace the CMP sensor.

Open circuit



CMP signal circuit (CMP sensor connector terminal B and PCM connector terminal 3V)



Power circuit (CMP sensor connector terminal A and main relay terminal D through common connector)

GND circuit (CMP sensor connector terminal C and PCM connector terminal 4A)

Short circuit

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



CMP signal circuit (CMP sensor connector terminal B and PCM connector terminal 3V to GND)



Power circuit (CMP sensor connector terminal A and main relay terminal D through common connector to GND)

3. Reconnect the CMP sensor connector.

4. Inspect the protrusion of camshaft (intake side) for damage and cracks.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 47: Identifying CMP Sensor Connector Terminal

Courtesy of MAZDA MOTORS CORP.

KNOCK SENSOR (KS) REMOVAL/INSTALLATION (BP, BP WITH TC)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

1. Disconnect the negative battery cable.

2. Remove the intake manifold bracket.

3. Remove the KS using the SST (49 H018 001).

4. Install in the reverse order of removal.

Tightening torque

19.6-34.3 N.m {2.0-3.5 kgf.m, 14.5-25.3 ft.lbf}

Fig. 48: Identifying Knock Sensor Location

Courtesy of MAZDA MOTORS CORP.

KNOCK SENSOR (KS) INSPECTION (BP, BP WITH TC)

INSPECTION OF RESISTANCE

NOTE:



Perform the following test only when directed.

1. Verify that the ignition switch is at LOCK.

2. Disconnect KS connector.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

3. Measure the resistance between KS terminal A and the KS body using an ohmmeter.



If not as specified, replace the KS.

If knock sensor is okay, but PID value is out of specification, perform the CIRCUIT

OPEN/SHORT INSPECTION . (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION

(BP, BP WITH TC) .)

Fig. 49: Identifying Knock Sensor Harness Side Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Specification

Approx.560 kilohms (20°C {68°F})

4. Reconnect the KS connector.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



KS circuit (KS connector terminal A and PCM connector terminal 4M through common connector.)

Short circuit

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



If there is continuity, the circuit is shorted. Repair or replace the harness.



KS connector terminal A and PCM connector terminal 4M through common connector to GND.

HEATED OXYGEN SENSOR (HO2S) INSPECTION (BP, BP WITH TC)

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart.

HO2S VOLTAGE INSPECTION

1. Warm up the engine to normal operating temperature.

2. Using the WDS or equivalent, monitor the following:



Vehicle speed (PID: VSS)



Engine speed (PID: RPM)



Front/rear HO2S voltage (PID: O2S11/O2S12)

3. Drive the vehicle and decelerate the engine speed by releasing the accelerator pedal fully when the engine speed is 3,000 rpm or more.

4. Verify that the front/rear HO2S outputs a voltage of 0.6 V or more , one time or more, then verify that the front/rear HO2S voltage (PID: O2S11/O2S12) is 0.3 V or less while decelerating as shown in Fig. 50 .

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 50: HO2S Voltage Graph

Courtesy of MAZDA MOTORS CORP.



If not within the specification, inspect the HO2S for an open or short circuit. (See HO2S Voltage inspection .) Then if there is no malfunction in the wiring harness, replace the HO2S.

HO2S CIRCUIT OPEN/SHORT INSPECTION (SENSOR)

Open circuit

 If there is no continuity, the circuit is open. Repair or replace the harness.



Heated oxygen circuit (HO2S connector terminal A and PCM connector terminal 4W (Front).)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



GND circuit (HO2S connector terminal B and PCM connector terminal 4O through common connector (Front).)



Heated oxygen circuit (HO2S connector terminal A and PCM connector terminal 4AA (Rear).)



GND circuit (HO2S connector terminal B and PCM connector terminal 4O through common connector (Rear).)

Fig. 51: Identifying HO2S Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

Short circuit

 If there is continuity, the circuit is shorted. Repair or replace the harness.



HO2S connector terminal A and PCM connector terminal 4W to GND (Front).



HO2S connector terminal A and PCM connector terminal 4AA to GND (Rear).

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

HO2S HEATER RESISTANCE INSPECTION

NOTE:



Perform the following test only when directed.

1. Disconnect the HO2S connector.

2. Measure the resistance between HO2S terminals C and D using an ohmmeter.



If not as specified, replace the HO2S.

If HO2S heater is okay, but PID value is out of specification, perform the CIRCUIT

OPEN/SHORT INSPECTION .

Fig. 52: Identifying HO2S Part Side Connector

Courtesy of MAZDA MOTORS CORP.

HO2S heater resistance

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Front: 2-20 ohms

Rear: 2-50 ohms

3. Reconnect the HO2S connector.

HO2S CIRCUIT OPEN/SHORT INSPECTION (HEATER)

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



GND circuit (HO2S connector D and PCM connector terminal 3J through common connector

(Front).)



Power circuit (HO2S connector terminal C and ignition switch (IG1) circuit through common connector (Front).)



GND circuit (HO2S connector terminal D and PCM connector terminal 3P (Rear).)



Power circuit (HO2S connector terminal C and ignition switch (IG1) circuit through common connector (Rear).)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 53: Identifying HO2S Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



HO2S connector terminal C and ignition switch (IG1) through common connector to GND (Front).



HO2S connector terminal D and PCM connector terminal 3J through common connector to GND,

(Front).



HO2S connector terminal D and PCM connector terminal 3P to GND (Rear).

EGR BOOST SENSOR (BP), BAROMETRIC PRESSURE (BARO)/MANIFOLD

ABSOLUTE PRESSURE (MAP) SENSOR (BP WITH TC) INSPECTION (BP,

BP WITH TC)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

NOTE:



Perform the following test only when directed.

1. Inspect the EGR boost sensor (BP), BARO/MAP sensor (BP WITH TC) for damage and cracks.

2. Inspect the vacuum hose for improper routing, kinks or leaks.



If the above are okay, perform the CIRCUIT OPEN/SHORT INSPECTION .

3. Reconnect the EGR boost sensor (BP), BARO/MAP sensor (BP WITH TC) connector.



If the above open or short circuit are correct, replace EGR boost sensor (BP), BARO/MAP sensor

(BP WITH TC).

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



EGR boost circuit (EGR boost sensor (BP), BARO/MAP sensor (BP WITH TC) connector terminal

B and PCM connector terminal 4AE.)



Reference voltage circuit (EGR boost sensor (BP), BARO/MAP sensor (BP WITH TC) connector terminal C and PCM connector terminal 4L)



GND circuit (EGR boost sensor (BP), BARO/MAP sensor (BP WITH TC) connector terminal A and PCM connector terminal 4O through common connector.)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 54: Identifying EGR Boost Sensor Harness Side Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



EGR boost sensor (BP), BARO/MAP sensor (BP WITH TC) connector terminal C and PCM connector terminal 4L through common connector to GND.



EGR boost sensor (BP), BARO/MAP sensor (BP WITH TC) connector terminal B and PCM connector 4AE through common connector to GND.

CLUTCH PEDAL POSITION SWITCH INSPECTION (BP, BP WITH TC)

INSPECTION OF CONTINUITY

NOTE:



Perform the following test only when directed.

1. Verify that the clutch pedal position switch is installed properly. (See CLUTCH PEDAL

REMOVAL/INSTALLATION .)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

2. Disconnect the negative battery cable.

3. Remove the clutch pedal position switch. (See CLUTCH PEDAL REMOVAL/INSTALLATION .)

4. Inspect continuity between the clutch pedal position switch terminals using an ohmmeter.



If not as specified, replace the clutch pedal position switch.

If clutch pedal position switch is okay, but PID value is out of specification, perform the CIRCUIT

OPEN/SHORT INSPECTION .

Specification

Fig. 55: Identifying Clutch Pedal Position Switch Terminal Continuity

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 56: Identifying Clutch Pedal Position Switch Part Side Connector

Courtesy of MAZDA MOTORS CORP.

5. Reconnect the clutch pedal position switch connector.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



Power circuit (Clutch switch connector terminal A and PCM connector terminal 4I through common connector.)



GND circuit (Clutch switch connector terminal B and GND.)

Short circuit

 If there is continuity, the circuit is shorted. Repair or replace the harness.



Clutch switch connector terminal A and PCM connector terminal 4I through common connector to

GND.

NEUTRAL SWITCH INSPECTION (BP, BP WITH TC)

INSPECTION OF CONTINUITY

NOTE:



Perform the following test only when directed.

1. Disconnect the negative battery cable.

2. Remove the neutral switch.

3. Inspect for continuity between the neutral switch terminals using an ohmmeter.



If not as specified, replace the neutral switch.

If neutral switch is okay but PID value is out of specification, perform the CIRCUIT

OPEN/SHORT INSPECTION .

Specification

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 57: Identifying Neutral Switch Terminal Continuity

Courtesy of MAZDA MOTORS CORP.

Fig. 58: Identifying Neutral Switch Part Side Connector

Courtesy of MAZDA MOTORS CORP.

4. Reconnect the neutral switch connector.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit

 If there is no continuity, the circuit is open. Repair or replace the harness.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata



Power circuit (Neutral switch connector terminal A and PCM connector terminal 4H through common connector.)



GND circuit (Neutral switch connector terminal B and GND through common connector.)

Short circuit



If there is continuity, the circuit is shorted. Repair or replace the harness.



Neutral switch connector terminal A and PCM connector terminal 4H through common connector to GND.

POWER STEERING PRESSURE (PSP) SWITCH INSPECTION (BP, BP WITH

TC)

INSPECTION OF CONTINUITY

NOTE:



Perform the following test only when directed.

1. Inspect as follows if power steering is inoperative:



POWER STEERING FLUID INSPECTION (See POWER STEERING FLUID INSPECTION )

2. Disconnect the PSP switch connector.

3. Start the engine.

4. Inspect for continuity between PSP switch terminal and GND using an ohmmeter.



If not as specified, replace the PSP switch.



If PSP switch is okay but PID value is out of specification, perform the CIRCUIT OPEN/SHORT

INSPECTION .

Specification

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Control System - MX-5 Miata

Fig. 59: Identifying PSP Switch Terminal Continuity

Courtesy of MAZDA MOTORS CORP.

5. Reconnect the PSP switch connector.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



Power circuit (PSP switch connector terminal and PCM connector terminal 4C through common connector.)



GND circuit (PSP switch GND circuit.)

Short circuit

 If there is continuity, the circuit is shorted. Repair or replace the harness.



PSP switch connector terminal and PCM connector terminal 4C through common connector to

GND.

Microsoft

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

2003-05 ENGINE

Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

ENGINE OVERHAUL SERVICE WARNING

WARNING:



Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.

ENGINE MOUNTING/DISMOUNTING

MOUNTING

1. Use the holes shown in the figure.

Fig. 1: Identifying SST Mounting Holes

Courtesy of MAZDA MOTORS CORP.

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

2. Install the SST (arms) to the cylinder block holes as shown, and hand-tighten the SST (bolts).

Fig. 2: Installing SST Arms To Cylinder Block

Courtesy of MAZDA MOTORS CORP.

3. Assemble the SST (bolts, nuts, and plate) in the specified positions.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 3: Identifying SST Mounting Positions

Courtesy of MAZDA MOTORS CORP.

4. Install the SST assembled in step 3 to the respective arms.

5. Adjust the SST (bolts) so that less than 20 mm {0.79 in} of thread is exposed.

6. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts).

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 4: Adjusting SST Plate & Arms

Courtesy of MAZDA MOTORS CORP.

7. Tighten the SST (bolts and nuts) to affix the SST firmly.

WARNING:



The self-locking brake system of the engine stand may not be effective when the engine is held in an unbalanced position.

This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury. Never keep the engine in an unbalanced position, and always hold the rotation handle firmly turning the engine.

8. Mount the engine on the SST (engine stand).

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 5: Mounting Engine To Engine Stand

Courtesy of MAZDA MOTORS CORP.

9. Drain the engine oil.

10. Install the oil drain plug.

Tightening Torque

30-41 N.m {3.0-4.2 kgf.m, 22-30 ft.lbf}

DISMOUNTING



Dismount in the reverse order of mounting.

ENGINE DISASSEMBLY/ASSEMBLY

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

TIMING BELT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the figure.

Fig. 6: Disassembling/Assembling Timing Belt

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

Crankshaft Pulley Disassembly Note



Hold the crankshaft using the SST .

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 7: Holding Crankshaft

Courtesy of MAZDA MOTORS CORP.

Pulley Boss Disassembly Note

1. Turn the crankshaft clockwise and align the timing marks of the pulleys.

NOTE:



For the crankshaft side, face the locating pin on the pulley boss straight up.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 8: Aligning Timing Marks

Courtesy of MAZDA MOTORS CORP.

2. Hold the crankshaft using the SST .

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 9: Holding Crankshaft

Courtesy of MAZDA MOTORS CORP.

Timing Belt Disassembly Note

CAUTION:



The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, or allowing oil or grease on it.

1. Mark the timing belt rotation on the belt for proper reinstallation.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 10: Marking Timing Belt & Identifying Faulty Belts

Courtesy of MAZDA MOTORS CORP.

2. Loosen the tensioner lock bolt.

3. Push the tensioner in the direction of the arrow and hand-tighten the lock bolt.

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 11: Identifying Tensioner & Lock Bolt

Courtesy of MAZDA MOTORS CORP.

4. Remove the timing belt.

Timing Belt Pulley And Key Assembly Note



Insert the key into the timing belt pulley, facing the tapered side downward. Push the key until it stops.

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Fig. 12: Installing Timing Belt Pulley Key

Courtesy of MAZDA MOTORS CORP.

Tensioner And Tensioner Spring Assembly Note

1. Install the tensioner spring so that the chamfer of dumping rubber faces the right side as shown.

2. Push the tensioner in the direction of the arrow and hand-tighten the lock bolt.

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Fig. 13: Pushing Tensioner Outward

Courtesy of MAZDA MOTORS CORP.

Timing Belt Assembly Note



Verify that all timing marks are correctly aligned.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 14: Aligning Timing Marks

Courtesy of MAZDA MOTORS CORP.

Pulley Boss Assembly Note

1. Install the pulley boss and pulley lock bolt. Turn the crankshaft clockwise 1 and 5/6 times, and verify that the timing mark and the tension set mark A are aligned.

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 15: Aligning Timing Mark & Tension Set Mark

Courtesy of MAZDA MOTORS CORP.

2. Loosen the tensioner lock bolt to apply tension to the timing belt. Do not apply tension other than that of the tensioner spring.

3. Tighten the tensioner lock bolt.

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 16: Identifying Tensioner Lock Bolt

Courtesy of MAZDA MOTORS CORP.

NOTE:



For the crankshaft side, face the locating pin on the pulley boss straight up.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 17: Aligning Timing Marks

Courtesy of MAZDA MOTORS CORP.

4. Turn the crankshaft clockwise 2 and 1/6 times, and verify that all timing marks are correctly aligned.

5. Inspect for the belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf, 22 lbf}.

Timing Belt Deflection

8.5-11.5 mm {0.34-0.45 in}

6. If the timing belt deflection is not as specified, remove the timing belt and repeat from TIMING BELT

ASSEMBLY NOTE .

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Fig. 18: Checking Timing Belt Deflection

Courtesy of MAZDA MOTORS CORP.

7. Hold the crankshaft by using the SST .

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Fig. 19: Holding Crankshaft

Courtesy of MAZDA MOTORS CORP.

Crankshaft Pulley Assembly Note



Hold the crankshaft by using the SST .

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 20: Holding Crankshaft

Courtesy of MAZDA MOTORS CORP.

Cylinder Head Cover Assembly Note

1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material.

2. Install the cylinder head cover gasket into the cylinder head cover.

3. Apply silicone sealant to the cylinder head as shown.

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Fig. 21: Applying Silicone Sealant

Courtesy of MAZDA MOTORS CORP.

4. Hand-tighten the cylinder head cover bolt as shown.

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 22: Identifying Cylinder Head Cover Bolt

Courtesy of MAZDA MOTORS CORP.

5. Tighten the cylinder head cover bolts in two or three step in the order shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 23: Identifying Cylinder Head Cover Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD DISASSEMBLY/ASSEMBLY (I)

1. Disassemble in the order indicated in the figure.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 24: Disassembling/Assembling Cylinder Head

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

Camshaft Pulley Disassembly Note



Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft pulley lock bolt.

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 25: Holding Camshaft

Courtesy of MAZDA MOTORS CORP.

Camshaft Cap Disassembly Note



Loosen the camshaft cap bolts in two or three steps in the order shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 26: Camshaft Cap Bolt Loosening Sequence

Courtesy of MAZDA MOTORS CORP.

Camshaft Disassembly Note

 Inspect the camshaft end play. (Refer to ENGINE INSPECTION/REPAIR , CAMSHAFT END

PLAY INSPECTION .)

Cylinder Head Disassembly Note



Loosen the cylinder head bolts in two or three steps in the order shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 27: Cylinder Head Bolt Loosening Sequence

Courtesy of MAZDA MOTORS CORP.

Cylinder Head Assembly Note



Install the bolts and tighten them in two or three steps in the order shown.

Fig. 28: Cylinder Head Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Camshaft Assembly Note

CAUTION:



Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust receiving area of the cylinder head journal. To avoid this, the following

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata procedure must be observed.



Assemble the camshaft onto the cylinder head, facing the cam noses at No.1 and No.3 cylinders as shown.

Fig. 29: Installing Camshaft

Courtesy of MAZDA MOTORS CORP.

Camshaft Cap Assembly Note

1. Apply silicone sealant to the shaded areas shown in the figure.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 30: Applying Silicone Sealant

Courtesy of MAZDA MOTORS CORP.

2. Install the camshaft caps to the positions from which they were removed.

3. Tighten the camshaft cap bolts in two or three steps in the order shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 31: Camshaft Cap Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

4. Apply clean engine oil to the lip of the new camshaft oil seal.

5. Push the oil seal slightly in by hand.

6. Press the oil seal in evenly by using the SST .

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Fig. 32: Installing Oil Seal

Courtesy of MAZDA MOTORS CORP.

Camshaft Pulley

1. Install the camshaft pulleys with the "I" mark (intake side) or the "E" mark (exhaust side) straight up.

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Fig. 33: Identifying Camshaft Pulley Marks

Courtesy of MAZDA MOTORS CORP.

2. Hold the camshaft by using a wrench on the cast hexagon, and tighten the camshaft pulley lock bolt.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 34: Holding Camshaft

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD DISASSEMBLY/ASSEMBLY (II)

1. Disassemble in the order indicated in the figure.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 35: Disassembling/Assembling Cylinder Head

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

Valve Keeper Disassembly Note



Remove the valve keeper using the SST.

Fig. 36: Removing Valve Keeper

Courtesy of MAZDA MOTORS CORP.

Valve Seal Disassembly Note



Remove the valve seal using the SST.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 37: Removing Valve Seal

Courtesy of MAZDA MOTORS CORP.

Valve Seal Assembly Note

NOTE:



The intake and exhaust valve seals are different as shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 38: Identifying Intake & Exhaust Valve Seals

Courtesy of MAZDA MOTORS CORP.

1. Assemble the SST so that depth L is as specified.

Depth L

19.9 mm {0.783 in}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 39: Adjusting SST For Depth L

Courtesy of MAZDA MOTORS CORP.

2. Press the valve seal onto the valve guide by hand.

3. Tap the SST by using a plastic hammer until its lower end touches the cylinder head.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 40: Installing Valve Seal

Courtesy of MAZDA MOTORS CORP.

Valve Spring Assembly Note

1. Install the valve spring with the closer pitch toward the cylinder head.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 41: Identifying Valve Spring Pitch

Courtesy of MAZDA MOTORS CORP.

Valve Keeper Assembly Note

1. Install the valve keeper by using the SST .

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 42: Installing Valve Keeper

Courtesy of MAZDA MOTORS CORP.

CYLINDER BLOCK DISASSEMBLY/ASSEMBLY (I)

1. Disassemble in the order indicated in the figure.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 43: Disassembling/Assembling Cylinder Block

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Flywheel (MT), Drive Plate (AT) Disassembly Note



Hold the crankshaft by using the SST .

Fig. 44: Holding Crankshaft

Courtesy of MAZDA MOTORS CORP.

Oil Pan Disassembly Note

1. Remove the oil pan mounting bolts.

CAUTION:



Pry tools can easily scratch the cylinder block and oil pan contact surfaces.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 45: Identifying Screwdriver Insertion Points

Courtesy of MAZDA MOTORS CORP.

2. Insert a screwdriver only at the points shown.

Oil Baffle Disassembly Note

1. Insert a screwdriver between the cylinder block and the oil baffle to separate them.

2. Remove the oil baffle.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 46: Removing Oil Baffle

Courtesy of MAZDA MOTORS CORP.

Oil Pump Disassembly Note



Remove the oil seal by using a screwdriver protected with a rag.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 47: Removing Oil Pump Oil Seal

Courtesy of MAZDA MOTORS CORP.

Rear Cover Disassembly Note

 Remove the oil seal by using a screwdriver protected with a rag.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 48: Removing Rear Cover Oil Seal

Courtesy of MAZDA MOTORS CORP.

Rear Cover Assembly Note

1. Apply clean engine oil to the new oil seal.

2. Push the oil seal slightly in by hand.

3. Press the oil seal in evenly by using the SST .

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 49: Installing Rear Cover Oil Seal

Courtesy of MAZDA MOTORS CORP.

4. Apply silicone sealant to the rear cover as shown.

Thickness

2 mm {0.079 in}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 50: Applying Silicone Sealant To Rear Cover

Courtesy of MAZDA MOTORS CORP.

5. Install the rear cover.

6. Cut away the portion of the silicone sealant that projects from the rear cover toward the oil pan side.

Oil Pump Assembly Note

1. Apply clean engine oil to a new oil seal.

2. Push the oil seal slightly in by hand.

3. Press the oil seal in evenly using the SST .

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 51: Installing Oil Pump Seal

Courtesy of MAZDA MOTORS CORP.

4. Install the new O-ring.

5. Apply silicone sealant to the oil pump as shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 52: Applying Silicone Sealant To Oil Pump

Courtesy of MAZDA MOTORS CORP.

Thickness

1-2 mm {0.040-0.078 in}

6. Install the oil pump.

7. Cut away the portion of the silicone sealant that projects from the body toward the oil pan side.

Oil Baffle Assembly Note (BP)

1. Remove all foreign material from the contact surfaces.

2. Apply silicone sealant to the oil baffle along the inside of the bolt holes, and install within five minutes.

Thickness

2.5-3.5 mm {0.099-0.137 in}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 53: Applying Silicone Sealant To Oil Baffle

Courtesy of MAZDA MOTORS CORP.

MBSP Assembly Note (BP With TC)

1. Apply silicone sealant to the MBSP along the inside of the bolt holes, and install within five minutes.

Thickness

2.5-3.5 mm {0.099-0.137 in}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 54: Applying Silicone Sealant To MBSP

Courtesy of MAZDA MOTORS CORP.

2. Tighten the MBSP bolts in two or three steps in the order shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 55: MBSP Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Oil Strainer Assembly Note (BP With TC)

1. Install a new oil strainer gasket onto the oil pump body.

2. Tighten the oil strainer bolts in the order shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 56: Oil Strainer Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Oil Pan Assembly Note (BP)

1. Apply silicone sealant to the oil pan as shown.

Thickness

2.5-3.5 mm {0.099-0.137 in}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 57: Applying Silicone Sealant To Oil Pan

Courtesy of MAZDA MOTORS CORP.

Oil Pan Assembly Note (BP With TC)

CAUTION:



If the bolts are reused, remove the old sealant from the bolt threads.

Tightening a bolt that has old sealant on it can cause bolt hole damage

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 58: Identifying Old Sealant & Possible Damage

Courtesy of MAZDA MOTORS CORP.

1. Apply silicone sealant to oil pan gasket as shown.

Thickness

2.0 mm {0.079 in}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 59: Applying Silicone Sealant To Oil Pan Gaskets

Courtesy of MAZDA MOTORS CORP.

2. Install oil pan gaskets onto the oil pump body and the rear cover with the projections in the notches as shown.

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2005 Mazda MX-5 Miata

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Fig. 60: Identifying Oil Pump/Rear Cover Body Notches

Courtesy of MAZDA MOTORS CORP.

3. Apply silicone sealant onto the area of oil pan gasket indicated by A and B.

Thickness

2.0 mm {0.079 in}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 61: Applying Silicone Sealant To Oil Pan Gasket

Courtesy of MAZDA MOTORS CORP.

4. Apply silicone sealant to the shaded areas shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 62: Applying Silicone Sealant To Shaded Areas

Courtesy of MAZDA MOTORS CORP.

5. Apply silicone sealant to the oil pan along the inside of the bolt holes, and install within five minutes.

Thickness

2.5-3.5 mm {0.099-0.137 in}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 63: Applying Silicone Sealant To Oil Pan

Courtesy of MAZDA MOTORS CORP.

Flywheel (MT), Drive Plate (AT) Assembly Note

CAUTION:



If all of the old thread locking sealant cannot be removed from the bolt, it will not torque properly. Replace the bolt.

NOTE:



If a new bolt is used, do not apply thread locking sealant. New bolts have sealant on them.

1. Remove the sealant from the bolt holes in the crankshaft and from the bolts.

2. Set the flywheel or drive plate onto the crankshaft.

3. Apply sealant to the flywheel bolts and install them.

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Fig. 64: Applying Sealant To Flywheel Bolts

Courtesy of MAZDA MOTORS CORP.

4. Hold the flywheel or drive plate using the SST .

5. Tighten the bolts in two or three steps in the order shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 65: Flywheel Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Water Pump Assembly Note

1. Verify that the rubber seal is securely fixed onto the water pump.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 66: Installing Rubber Seal To Water Pump

Courtesy of MAZDA MOTORS CORP.

2. If not as specified, remove the rubber seal and reinstall it with the bonding agent.

CYLINDER BLOCK DISASSEMBLY/ASSEMBLY (II)

1. Disassemble in the order indicated in the figure.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 67: Disassembling/Assembling Cylinder Block

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

Piston And Connecting Rod Disassembly Note

1. Inspect the connecting rod side clearance. (Refer to ENGINE INSPECTION/REPAIR ,

CONNECTING ROD SIDE CLEARANCE INSPECTION .)

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

2. Use the handle of a hammer to remove the piston and connecting rod through the top of the cylinder block.

Fig. 68: Removing Piston & Connecting Rod

Courtesy of MAZDA MOTORS CORP.

3. Inspect the piston and connecting rod. (Refer to ENGINE INSPECTION/REPAIR , PISTON AND

CONNECTING ROD INSPECTION .)

4. Remove the piston rings by using a piston ring expander.

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Fig. 69: Removing Piston Rings

Courtesy of MAZDA MOTORS CORP.

5. Remove the piston pin by using the SST .

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 70: Removing Piston Pins

Courtesy of MAZDA MOTORS CORP.

Main Bearing Cap Disassembly Note

1. Inspect the crankshaft end play. (Refer to ENGINE INSPECTION/REPAIR , CRANKSHAFT END

PLAY INSPECTION .)

2. Loosen the main bearing cap bolts in two or three steps in the order shown.

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Fig. 71: Main Bearing Cap Bolt Loosening Sequence

Courtesy of MAZDA MOTORS CORP.

3. Remove the main bearing caps.

Main Bearing Cap Assembly Note

1. Install the crankshaft and the main bearing caps according to the cap number and "<=" mark which indicates front side.

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Fig. 72: Installing Crankshaft & Main Bearing Caps

Courtesy of MAZDA MOTORS CORP.

2. Tighten the main bearing cap bolts in two or three steps in the order shown.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 73: Main Bearing Cap Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Piston And Connecting Rod Assembly Note

1. Install one piston pin clip into the clip groove in the piston.

2. Assemble the piston and the connecting rod.

3. Apply clean engine oil to the piston pin.

4. Install the piston pin from the side opposite the clip.

5. Tap the piston pin in with the SST until the pin contacts the clip. If the pin cannot be installed easily, replace the connecting rod.

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 74: Installing Piston Pin

Courtesy of MAZDA MOTORS CORP.

6. Install the second clip into the clip groove in the piston.

NOTE:



The upper and lower rails are the same. They can be installed with either face upward.

7. Install the three-piece oil rings on the pistons.

1. Apply clean engine oil to the oil ring spacer and rails.

2. Install the oil ring spacer with the ends upward.

3. Install the upper and lower rails.

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Fig. 75: Installing Three-Piece Oil Rings

Courtesy of MAZDA MOTORS CORP.

8. Verify that the spacer tang separates the rails, and that the rails turn smoothly in both directions.

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Fig. 76: Checking Oil Ring Installation

Courtesy of MAZDA MOTORS CORP.

9. Using a piston ring expander, install the second ring with the scraper face downward.

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Fig. 77: Installing Second Ring

Courtesy of MAZDA MOTORS CORP.

10. Using a piston ring expander, install the top ring with the chamfer facing upward.

11. Apply clean engine oil to the top and second piston rings.

12. Position the end gaps of the rings as shown.

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Fig. 78: Positioning Piston Ring End Gaps

Courtesy of MAZDA MOTORS CORP.

13. Protect the connecting rod bolts with rubber sleeves.

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Fig. 79: Installing Rubber Sleeves On Connecting Rod Bolts

Courtesy of MAZDA MOTORS CORP.

14. Apply clean engine oil to the cylinder walls, pistons, and piston rings.

15. Inspect the piston rings for correct end gap alignment.

16. Insert each piston into the cylinder block with the F mark facing the front of the engine. Use a piston ring compressor.

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Fig. 80: Installing Piston & Connecting Rod

Courtesy of MAZDA MOTORS CORP.

Connecting Rod Cap Assembly Note

1. Align the matching marks on the cap and the connecting rod and install the connecting rod cap.

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Fig. 81: Aligning Connecting Rod Cap Matching Marks

Courtesy of MAZDA MOTORS CORP.

ENGINE INSPECTION/REPAIR

CYLINDER HEAD INSPECTION/REPAIR

1. Carry out cooling flaw detection on the cylinder head surface. Replace the cylinder head as necessary.

2. Inspect for the following and repair or replace as necessary.

1. Sunken valve seats.

2. Excessive camshaft oil clearance and end play.

3. Measure the cylinder head for distortion in the six directions as shown.

Distortion

0.10 mm {0.004 in} max.

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Fig. 82: Cylinder Head Distortion Measurement Directions

Courtesy of MAZDA MOTORS CORP.

4. If the cylinder head distortion exceeds the maximum, repair by grinding height or replace the cylinder head. If the cylinder head height is not as specified, replace it.

Standard Height

133.8-134.0 mm {5.268-5.275 in}

Grinding

0.10 mm {0.004 in} max.

5. Measure the manifold contact surface distortion as shown.

Distortion

0.15 mm {0.006 in} max.

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Fig. 83: Manifold Contact Surface Distortion Measurements

Courtesy of MAZDA MOTORS CORP.

6. If the distortion exceeds the specification, grind the surface or replace the cylinder head.

Grinding

0.20 mm {0.008 in} max.

VALVE INSPECTION

1. Measure the valve head margin thickness of each valve. Replace the valve as necessary.

Margin Thickness

IN: 0.9 mm {0.035 in} min.

EX: 1.0 mm {0.039 in} min.

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Fig. 84: Measuring Margin Thickness

Courtesy of MAZDA MOTORS CORP.

2. Measure the length of each valve. Replace the valve as necessary.

Standard Length

IN: 101.71-102.31 mm {4.0044-4.0279 in}

EX: 101.71-102.31 mm {4.0044-4.0279 in}

Minimum Length

IN: 101.61 mm {4.0004 in}

EX: 101.61 mm {4.0004 in}

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3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) shown.

Replace the valves as necessary.

Standard Diameter

IN: 5.970-5.985 mm {0.2351-0.2356 in}

EX: 5.965-5.980 mm {0.2349-0.2354 in}

Fig. 85: Measuring Valve Stem Diameter

Courtesy of MAZDA MOTORS CORP.

Minimum Diameter

IN: 5.920 mm {0.2331 in}

EX: 5.915 mm {0.2329 in}

VALVE GUIDE INSPECTION

1. Measure the inner diameter of each valve guide in X and Y directions at the three points (A, B, and C) shown. Replace the valve guide as necessary.

Standard Inner Diameter

6.02-6.04 mm {0.2371-0.2377 in}

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Fig. 86: Measuring Valve Guide Inner Diameter

Courtesy of MAZDA MOTORS CORP.

2. Measure the protrusion height (dimension A) of each valve guide without the lower valve spring seat.

Replace the valve guide as necessary.

Standard Height

18.3-18.9 mm {0.721-0.744 in}

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Fig. 87: Measuring Valve Guide Protrusion Height

Courtesy of MAZDA MOTORS CORP.

VALVE GUIDE REPLACEMENT

NOTE:



Intake and exhaust valve guides are different.

Valve Guide Removal



Remove the valve guide from the combustion chamber side by using the SST .

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Fig. 88: Removing Valve Guide

Courtesy of MAZDA MOTORS CORP.

Valve Guide Installation

1. Assemble the SSTs so that depth L is as specified.

Depth L

18.3-18.9 mm {0.721-0.744 in}

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Fig. 89: Assembling SST To Depth L

Courtesy of MAZDA MOTORS CORP.

2. Tap the valve guide in from the side opposite the combustion chamber until the SST contacts the cylinder head.

3. Verify that the valve guide projection height (dimension) is as specified.

Standard Height

18.3-18.9 mm {0.721-0.744 in}

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Fig. 90: Measuring Valve Guide Projection Height

Courtesy of MAZDA MOTORS CORP.

VALVE SEAT INSPECTION/REPAIR

1. Measure the seat contact width. As necessary, resurface the valve seat using a 45 ° valve seat cutter and/or resurface the valve face.

Standard Width

0.8-1.4 mm {0.032-0.055 in}

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Fig. 91: Measuring Seat Contact Width

Courtesy of MAZDA MOTORS CORP.

2. Verify that the valve seating position is at the center of the valve face.

1. If the seating position is too high, correct the valve seat using a 70 ° cutter, and a 45 ° cutter.

2. If the seating position is too low, correct the valve seat using a 45° cutter.

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Fig. 92: Centering Valve Seating Position

Courtesy of MAZDA MOTORS CORP.

3. Inspect the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem.

Replace the cylinder head as necessary.

Standard Dimension L

IN: 45.0 mm {1.772 in}

EX: 45.0 mm {1.772 in}

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Fig. 93: Measuring Protruding Length

Courtesy of MAZDA MOTORS CORP.

Maximum Dimension L

IN: 45.6 mm {1.795 in}

EX: 45.6 mm {1.795 in}

VALVE SPRING INSPECTION

1. Apply pressing force to the pressure spring and measure the spring height. Replace the valve spring as necessary.

Pressing Force

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IN: 172.60-195.15 N

{17.6-19.9 kgf, 38.72-43.78 lbf}

EX: 172.60-195.15 N

{17.6-19.9 kgf, 38.72-43.78 lbf}

Standard Height

IN: 39.5 mm {1.56 in}

EX: 39.5 mm {1.56 in}

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Fig. 94: Measuring Spring Height Under Pressing Force

Courtesy of MAZDA MOTORS CORP.

2. Measure the out-of-square of the valve spring. Replace the valve spring as necessary.

Fig. 95: Measuring Valve Spring Out-Of-Square

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VALVE SPRING OUT-OF-SQUARE SPECIFICATIONS

Valve Spring BP - mm {in}

1.63 {0.064} max.

BP with TC - mm {in}

1.58 {0.062} max.

CAMSHAFT INSPECTION

1. Set the No.1 and No.5 journals on V-blocks. Measure the camshaft runout. Replace the camshaft as necessary.

Runout

0.03 mm {0.0012 in} max.

Fig. 96: Measuring Camshaft Runout

Courtesy of MAZDA MOTORS CORP.

2. Measure the cam lobe height at the two points as shown. Replace the camshaft as necessary.

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CAM LOBE STANDARD HEIGHT SPECIFICATIONS

Camshaft BP - mm {in} BP with TC - mm {in}

IN 44.3 {1.744} 44.8 {1.764}

EX 44.9 {1.768}

CAM LOBE MINIMUM HEIGHT SPECIFICATIONS

Camshaft

BP - mm {in}

44.1 {1.736}

BP with TC - mm {in}

44.7 {1.760}

44.6 {1.756}

Fig. 97: Measuring Camshaft Lobe Height

Courtesy of MAZDA MOTORS CORP.

3. Measure the journal diameters in X and Y directions at the two points (A and B) as shown. Replace the camshaft as necessary.

Standard Diameter

25.940-25.965 mm {1.0213-1.0222 in}

Minimum Diameter

25.910 mm {1.0201 in}

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Fig. 98: Measuring Journal Diameter

Courtesy of MAZDA MOTORS CORP.

CAMSHAFT OIL CLEARANCE INSPECTION

1. Position a plastigage on the top of the journals in the axial direction.

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Fig. 99: Positioning Plastigage On Camshaft Journal

Courtesy of MAZDA MOTORS CORP.

2. Install the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER HEAD

DISASSEMBLY/ASSEMBLY (II) , CAMSHAFT DISASSEMBLY NOTE .)

3. Remove the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER HEAD

DISASSEMBLY/ASSEMBLY (II) , CAMSHAFT DISASSEMBLY NOTE .)

4. Measure the oil clearance. Replace the cylinder head as necessary.

Standard Clearance

0.035-0.081 mm {0.0014-0.0031 in}

Maximum Clearance

0.15 mm {0.006 in}

CAMSHAFT END PLAY INSPECTION

1. Install the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER HEAD

DISASSEMBLY/ASSEMBLY (II) , CAMSHAFT DISASSEMBLY NOTE .)

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2. Measure the camshaft end play. Replace the cylinder head or camshaft as necessary.

Standard End Play

0.057-0.127 mm {0.0023-0.0049 in}

Maximum End Play

0.20 mm {0.008 in}

Fig. 100: Measuring Camshaft End Play

Courtesy of MAZDA MOTORS CORP.

3. Remove the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER HEAD

DISASSEMBLY/ASSEMBLY (II) , CAMSHAFT DISASSEMBLY NOTE .)

TAPPET INSPECTION

1. Measure the diameter of each tappet bore.

Standard Diameter

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30.000-30.025 mm {1.1811-1.1820 in}

Fig. 101: Measuring Tappet Bore Diameter

Courtesy of MAZDA MOTORS CORP.

2. Measure the diameter of each tappet.

Standard Diameter

29.959-29.975 mm {1.1795-1.1801 in}

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Fig. 102: Measuring Tappet Diameter

Courtesy of MAZDA MOTORS CORP.

3. Calculate the clearance between the tappet and the related tappet bore. Replace the tappet or cylinder head as necessary.

Standard Clearance

0.025-0.066 mm {0.00099-0.00259 in}

Maximum Clearance

0.180 mm {0.0071 in}

CYLINDER BLOCK INSPECTION/REPAIR

1. Measure the distortion of the cylinder block top surface in the six directions as shown. Repair by grinding or replace as necessary.

Cylinder Block Distortion

0.15 mm {0.006 in} max.

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Fig. 103: Cylinder Block Top Surface Distortion Measurement Directions

Courtesy of MAZDA MOTORS CORP.

Cylinder Block Height

221.5 mm {8.720 in}

Grinding

0.20 mm {0.008 in} max.

2. Measure the cylinder bores in X and Y directions at 35 mm {1.38 in} below the top surface.

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Fig. 104: Measuring Cylinder Bores

Courtesy of MAZDA MOTORS CORP.

NOTE:



Base the boring diameter on the diameter of an oversize piston. All cylinders must be the same diameter.

3. If the cylinder bore exceeds the wear limit, replace the cylinder block or rebore the cylinder and install

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata the oversize pistons so that the specified piston-to-cylinder clearance is obtained.

CYLINDER BORE

CYLINDER BORE SPECIFICATIONS

Size - mm {in}

Standard

0.25 {0.01} oversize

0.50 {0.02} oversize

Diameter - mm {in}

83.000-83.019 {3.2678-3.2684}

83.250-83.269 {3.2776-3.2783}

83.500-83.519 {3.2874-3.2881}

Wear Limit

0.15 mm {0.006 in}

OIL JET INSPECTION

1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B. If not, replace the oil jet valve.

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Fig. 105: Identifying Oil Jet Valve Ports

Courtesy of MAZDA MOTORS CORP.

Air Pressure

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167-225 kPa {1.7-2.3 kgf/cm

, 25-32 psi}

2. Inspect the oil jet nozzle for clogs. Replace the nozzle as necessary.

PISTON INSPECTION



Measure the outer diameter of each piston at right angle ( 90 °) to the piston pin, 16.5 mm {0.650 in} below the oil ring groove lower edge.

Piston Diameter

PISTON DIAMETER SPECIFICATIONS

Size - mm {in}

Standard

0.25 {0.01} oversize

0.50 {0.02} oversize

Diameter - mm {in}

82.953-82.975 {3.2659-3.2667}

83.203-83.225 {3.2758-3.2765}

83.453-83.475 {3.2856-3.2864}

Fig. 106: Measuring Piston Diameter

Courtesy of MAZDA MOTORS CORP.

PISTON CLEARANCE INSPECTION/REPAIR

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1. Calculate the piston-to-cylinder clearance.

Replace the piston or rebore the cylinders to fit oversize piston as necessary.

Standard Clearance

0.025-0.066 mm {0.0010-0.0025 in}

Maximum Clearance

0.15 mm {0.006 in}

2. If the piston is replaced, the piston rings must also be replaced.

PISTON RING CLEARANCE INSPECTION

1. Measure the piston ring-to-ring land clearance around the entire circumference. Replace the piston and piston ring as necessary.

Standard Clearance

Top : 0.030-0.065 mm {0.0012-0.0025 in}

Second : 0.030-0.070 mm {0.0012-0.0027 in}

Oil : 0.07-0.16 mm {0.003-0.006 in}

Maximum Clearance

Top, Second : 0.15 mm {0.006 in}

Oil : 0.20 mm {0.008 in}

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Fig. 107: Measuring Piston Ring-To-Ring Land Clearance

Courtesy of MAZDA MOTORS CORP.

2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.

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Fig. 108: Pushing Ring To Bottom Of Ring Travel

Courtesy of MAZDA MOTORS CORP.

3. Measure each piston ring end gap by using a feeler gauge. Replace the piston ring as necessary.

Standard End Gap

Top : 0.15-0.30 mm {0.006-0.011 in}

Second : 0.30-0.45 mm {0.012-0.017 in}

Oil rail : 0.20-0.70 mm {0.008-0.027 in}

Maximum End Gap

1.0 mm {0.039 in}

PISTON PIN CLEARANCE INSPECTION

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

1. Measure each piston pin hole diameter in X and Y directions at the four points (A, B, C, and D) as shown.

Standard Diameter

19.988-20.000 mm {0.7870-0.7874 in}

Fig. 109: Measuring Piston Pin Hole Diameter

Courtesy of MAZDA MOTORS CORP.

2. Measure each connecting rod small end inner diameter in X and Y directions as shown.

Standard Diameter

20.003-20.014 mm {0.7876-0.7879 in}

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Fig. 110: Measuring Connecting Rod Small End Inner Diameter

Courtesy of MAZDA MOTORS CORP.

3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown.

Standard Diameter

19.987-19.993 mm {0.7869-0.7871 in}

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Fig. 111: Measuring Piston Pin Diameter

Courtesy of MAZDA MOTORS CORP.

4. Calculate the piston pin-to-piston pin bore clearance. Replace the piston and/or piston pin as necessary.

Standard Clearance

-0.005-0.013 mm {-0.0002-0.0005 in}

5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin.

Standard Clearance

0.010-0.027 mm {0.004-0.0010 in}

CRANKSHAFT INSPECTION

1. Measure the crankshaft runout. Replace the crankshaft as necessary.

Runout

0.04 mm {0.0016 in} max.

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown. Replace the crankshaft or grind the journal and install the undersize bearing as necessary.

Main Journal

Fig. 112: Measuring Crankshaft Runout

Courtesy of MAZDA MOTORS CORP.

MAIN JOURNAL BEARING SPECIFICATIONS

Bearing Size - mm {in}

Standard

0.25 {0.01} Undersize

0.50 {0.02} Undersize

0.75 {0.03} Undersize

Diameter - mm {in}

49.938-49.956 {1.9661-1.9667}

49.688-49.706 {1.9563-1.9569}

49.438-49.456 {1.9464-1.9470}

49.188-49.206 {1.9366-1.9372}

Out-of-Round

0.05 mm {0.002 in} max.

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Crank Pin

CRANK PIN BEARING SPECIFICATIONS

Bearing Size - mm {in}

Standard

0.25 {0.01} Undersize

0.50 {0.02} Undersize

0.75 {0.03} Undersize

Out-of-Round

0.05 mm {0.002 in} max.

Diameter - mm {in}

44.940-44.956 {1.7693-1.7699}

44.690-44.706 {1.7595-1.7600}

44.440-44.456 {1.7497-1.7502}

44.190-44.206 {1.7398-1.7403}

Fig. 113: Measuring Journal Out Of Round

Courtesy of MAZDA MOTORS CORP.

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CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR

1. Position plastigage on the top of the journals in the axial direction.

2. Install the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER HEAD

DISASSEMBLY/ASSEMBLY (II) , CAMSHAFT DISASSEMBLY NOTE .)

3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER

HEAD DISASSEMBLY/ASSEMBLY (II) , CAMSHAFT DISASSEMBLY NOTE .)

4. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained.

Standard Clearance

0.018-0.036 mm {0.0008-0.0014 in}

Maximum Clearance

0.10 mm {0.0039 in}

MAIN JOURNAL BEARING SPECIFICATION

Bearing Size - mm {in} Bearing Thickness - mm {in}

Standard

0.25 {0.01} Undersize

2.007-2.025 {0.0791-0.0797}

2.133-2.137 {0.0840-0.0841}

0.50 {0.02} Undersize

0.75 {0.03} Undersize

2.258-2.262 {0.0889-0.0890}

2.383-2.387 {0.0938-0.0940}

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Fig. 114: Measuring Main Journal Oil Clearance

Courtesy of MAZDA MOTORS CORP.

CRANKSHAFT END PLAY INSPECTION/REPAIR

1. Install the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER

BLOCK DISASSEMBLY/ASSEMBLY (II) , MAIN BEARING CAP ASSEMBLY NOTE .)

2. Measure the crankshaft end play. If the end play exceeds the maximum, replace the thrust bearing or grind the crankshaft and install an undersize bearing so that the specified end play is obtained.

Standard End Play

0.080-0.282 mm {0.0032-0.0111 in}

Maximum End Play

0.30 mm {0.012 in}

THRUST BEARING SPECIFICATION

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2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Bearing Size - mm {in}

Standard

0.25 {0.01} Undersize

0.50 {0.02} Undersize

0.75 {0.03} Undersize

Bearing Thickness - mm {in}

2.500-2.550 {0.0985-0.1003}

2.625-2.675 {0.1034-0.1053}

2.750-2.800 {0.1083-0.1102}

2.875-2.925 {0.1132-0.1151}

Fig. 115: Measuring Crankshaft End Play

Courtesy of MAZDA MOTORS CORP.

3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER

BLOCK DISASSEMBLY/ASSEMBLY (II) , MAIN BEARING CAP DISASSEMBLY NOTE .)

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CONNECTING ROD INSPECTION



Measure each connecting rod for bending and distortion. Replace the connecting rod as necessary.

Bending

0.05 mm {0.0020 in} max. /50 mm {1.97 in}

Distortion

0.07 mm {0.0028 in} max. /50 mm {1.97 in}

Center-to-Center Distance

132.85-132.95 mm {5.2304-5.2342 in}

Fig. 116: Measuring Connecting Rod For Bending & Distortion

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR

1. Position a plastigage on the top of the journals in the axial direction.

2. Install the connecting rod cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER

BLOCK DISASSEMBLY/ASSEMBLY (II) , PISTON AND CONNECTING ROD ASSEMBLY

NOTE .)

3. Remove the connecting rod cap.

4. Measure the crankpin oil clearance. If the clearance exceeds the maximum, replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained.

Standard Clearance

0.028-0.048 mm {0.0012-0.0018 in}

Maximum Clearance

0.10 mm {0.0039 in}

CONNECTING ROD BEARING SPECIFICATIONS

Bearing Size - mm {in} Bearing Thickness - mm {in}

Standard

0.25 {0.01} Undersize

1.504-1.520 {0.05922-0.05984}

1.631-1.635 {0.06422-0.06436}

0.50 {0.02} Undersize

0.75 {0.03} Undersize

1.756-1.760 {0.06914-0.06929}

1.881-1.885 {0.07406-0.07421}

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 117: Measuring Crank Pin Rod Oil Clearance

Courtesy of MAZDA MOTORS CORP.

CONNECTING ROD SIDE CLEARANCE INSPECTION

1. Install the connecting rod cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY , CYLINDER

BLOCK DISASSEMBLY/ASSEMBLY (II) , PISTON AND CONNECTING ROD ASSEMBLY

NOTE .)

2. Measure the connecting rod large end side clearance. Replace the connecting rod and cap as necessary.

Standard Clearance

0.110-0.262 mm {0.005-0.010 in}

Maximum Clearance

0.30 mm {0.012 in}

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 118: Measuring Connecting Rod Clearance

Courtesy of MAZDA MOTORS CORP.

3. Remove the connecting rod cap.

PISTON AND CONNECTING ROD INSPECTION



Inspect the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 119: Inspecting Oscillation Torque

Courtesy of MAZDA MOTORS CORP.

TENSIONER SPRING INSPECTION



Measure the free length of the tensioner spring. Replace the tensioner spring as necessary.

Free Length

59.2 mm {2.331 in}

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 120: Measuring Tensioner Spring Free Length

Courtesy of MAZDA MOTORS CORP.

VALVE CLEARANCE INSPECTION

1. Remove the cylinder head cover.

2. Verify that the engine is in cold condition.

3. Measure the valve clearance.

1. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.

2. Measure the valve clearance at A in the figure.

Standard Valve Clearance [Engine Cold]

IN: 0.18-0.24 mm {0.0071-0.0094 in}

(0.21 +/- 0.03 mm {0.0083 +/- 0.0012 in}

EX: 0.28-0.34 mm {0.0111-0.0133 in}

(0.31 +/- 0.03 mm {0.0122 +/- 0.0012 in}

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 121: Identifying Measurement Points

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 122: Measuring Valve Clearance

Courtesy of MAZDA MOTORS CORP.

3. If the valve clearance exceeds the standard, replace the adjustment shim. (Refer to VALVE

CLEARANCE ADJUSTMENT .)

4. Turn the crankshaft 360° clockwise so that the No.4 piston is at TDC of the compression stroke.

5. Measure the valve clearance at B in the figure.

Standard Valve Clearance [Engine Cold]

IN: 0.18-0.24 mm {0.0071-0.0094 in}

(0.21 +/- 0.03 mm {0.0083 +/- 0.0012 in}

EX: 0.28-0.34 mm {0.0111-0.0133 in}

(0.31 +/- 0.03 mm {0.0122 +/- 0.0012 in}

6. If the valve clearance exceeds the standard, replace the adjustment shim. (Refer to VALVE

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

CLEARANCE ADJUSTMENT .)

4. Install the cylinder head cover.

VALVE CLEARANCE ADJUSTMENT

Perform this same procedure for all camshafts requiring valve clearance adjustment.

1. Turn the crankshaft clockwise so that the cams on the camshafts requiring valve clearance adjustment are positioned straight up.

2. Remove the camshaft cap bolts as necessary.

Remove only one pair of cap bolts at a time.

Reinstall the cap bolts before removing the next pair.

A: For EX side No. 1, 2, 3 cylinder adjustment shim removal.

B: For IN side No. 1, 2, 3 cylinder adjustment shim removal.

C: For EX side No. 2, 3, 4 cylinder adjustment shim removal.

C: For IN side No. 2, 3, 4 cylinder adjustment shim removal.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 123: Valve Adjustment Identification

Courtesy of MAZDA MOTORS CORP.

NOTE:



For EX side No.2, 3 cylinder adjustment shim removal, remove bolts either A or C.

For IN side No.2, 3 cylinder adjustment shim removal, remove bolts either B or D.

3. Install the SSTs on the camshaft using the camshaft cap bolt holes.

Tightening Torque

11.3-14.2 N.m {115-145 kgf.cm, 100-125 in.lbf}

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 124: Installing Camshaft SSTs

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 125: Installing Camshaft SSTs

Courtesy of MAZDA MOTORS CORP.

4. Align the marks on the SSTs (shaft and shaft clamp).

5. Tighten bolts A to secure the SST (shaft).

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 126: Identifying SST Bolt A

Courtesy of MAZDA MOTORS CORP.

6. Face the SST (body) outside of the cylinder head, and mount it on the SST (shaft) at the point of the adjustment shim to be replaced.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 127: Mounting SST

Courtesy of MAZDA MOTORS CORP.

7. Face the notch of the tappet so that a fine screwdriver can be installed.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 128: Identifying Tappet Notch

Courtesy of MAZDA MOTORS CORP.

8. Set the SST on the tappet by its notch.

9. Tighten bolt B to secure the SST (body).

CAUTION:



Cylinder head can be damaged when the tappet is pressed down.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 129: Identifying SST Bolts

Courtesy of MAZDA MOTORS CORP.

10. Tighten bolt C, and press down the tappet.

11. Using a fine screwdriver, pry up the adjustment shim through the notch on the tappet. Remove the shim by using a magnet.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 130: Prying Up Adjustment Shim

Courtesy of MAZDA MOTORS CORP.

12. Select proper adjustment shim.

New Adjustment Shim

= Removed Shim Thickness + Measured Valve Clearance - Standard Valve Clearance (IN:

0.21 mm {0.0111 in}, EX: 0.31 mm {0.0122 in})

13. Push the selected shim into the tappet.

14. Loosen bolt C to allow the tappet to move up.

15. Loosen bolt B and remove the SST (body).

16. Remove the SSTs and tighten the camshaft cap bolts.

Tightening Torque

11.3-14.2 N.m {115-145 kgf.cm, 100-125 in.lbf}

17. Inspect for the valve clearance. (Refer to VALVE CLEARANCE ADJUSTMENT , VALVE

CLEARANCE INSPECTION .)

TORQUE SPECIFICATIONS

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

TORQUE SPECIFICATIONS

Application

Camshaft Pulley Bolt

Without Variable Valve Timing Actuator

With Variable Valve Timing Actuator

Connecting Rod Nuts

Crankshaft Pulley Bolts

Crankshaft Pulley Boss Bolt

Cylinder Head Bolts

(1) (2)

Drive Plate/Flywheel Bolts

Intake Manifold Nuts

Lower Oil Control Valve Pipe Bolts

(3)

Bolt 1

Bolt 2

Bolt 3

Main Bearing Cap Bolts

(1) (5)

MBSP Bolts

Oil Jet Bolt

Oil Pressure Switch

Oil Pump Bolts

Pulley Boss Bolt

Spark Plug

Thermostat Housing Bolts

Timing Belt Pulley Bolt

Timing Belt Tensioner Bolt

Water Pump Bolts

Camshaft Cap Bolts

(6)

Cylinder Head Cover Bolts

(7)

End Plate Bolts

Dipstick Tube Bolt

Oil Control Valve Adapter Bolt

Oil Control Valve Case Bolts

(8)

Oil Pan Bolts

Oil Pump Cover Bolts

Oil Strainer Bolts/Nut

Rear Cover Bolt

Seal Plate Bolts

(9)

Timing Case Cover Bolts

(10)

Microsoft

Saturday, July 04, 2009 10:58:12 AM

Ft. Lbs. (N.m)

37-44 (50-60)

47-61 (63-83)

35-37 (48-50)

9.1-12.6 (12.3-17.1)

116-122 (157-166)

56-60 (76-81)

72-75 (97-102)

14-18 (19-25)

12-17 (16-23)

26-35 (35-47)

(4)

40-43 (54-58)

12-15 (16-21)

8.7-12.9 (11.8-17.6)

9-13 (11.8-17.6)

14-18 (19-25)

116-122 (157-166)

11-16 (15-22)

14-18 (19-25)

28-38 (38-51)

14-18 (19-25)

INCH Lbs. (N.m)

100-125 (11.3-14.2)

44-78 (5-8.8)

69.5-95.4 (7.9-10.7)

71-97 (8-11)

70.8-97.3 (8-11)

71-97 (8-11)

52.2-77.8 (5.9-8.8)

69.5-95.4 (7.9-10.7)

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Upper Oil Control Valve Pipe Bolts

(11)

Variable Tumble Control System Shutter Valve Bolt

Variable Valve Timing Actuator Cover Bolts

Water Pump Pulley Bolts

(1) Tighten to specification in 2 or 3 steps.

(2) Tighten cylinder head bolts in sequence. See Fig. 131 .

(3) Tighten lower oil control valve pipe bolts in sequence. See Fig. 132 .

(4) Tighten to 71-97 INCH Lbs. (8-11 N.m).

(5) Tighten main bearing bolts in sequence. See Fig. 133 .

(6) Tighten camshaft cap bolts in sequence. See Fig. 134 .

(7) Tighten cylinder head cover bolts in sequence. See Fig. 135 .

(8) Tighten oil control valve case assembly bolts in sequence. See Fig. 136 .

(9) Tighten seal plate bolts in sequence. See Fig. 137 .

(10) Tighten timing case cover bolts in sequence. See Fig. 138 .

(11) Tighten upper oil control valve pipe bolts in sequence. See Fig. 139 .

69.5-95.4 (7.9-10.7)

35-53 (4-6)

69.5-94.7 (7.9-10.7)

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 131: Cylinder Head Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 132: Lower Oil Control Valve Pipe Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 133: Main Bearing Cap Bolt Tightening Sequence

Courtesy of MAZDA MOTOR CORP.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 134: Camshaft Cap Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 135: Cylinder Head Cover Bolt Tightening Sequence

Courtesy of MAZDA MOTOR CORP.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 136: Oil Control Valve Case Assembly Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 137: Seal Plate Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 138: Timing Case Cover Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 Mazda MX-5 Miata

2003-05 ENGINE Overhaul - 1.8L (BP) 4-Cylinder - MX-5 Miata

Fig. 139: Upper Oil Control Valve Pipe Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

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2005 ENGINE Mechanical - MX-5 Miata

2005 ENGINE

Mechanical - MX-5 Miata

MECHANICAL LOCATION INDEX

2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

Fig. 1: Locating Mechanical Component

Courtesy of MAZDA MOTORS CORP.

DRIVE BELT INSPECTION

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

DRIVE BELT DEFLECTION CHECK

1. Verify the drive belt deflection when the engine is cold, or at least 30 min after the engine has stopped.

Apply moderate pressure 98 N {10 kgf, 22 lbf} midway between the specified pulleys.



If the deflection is not within the specification, adjust it. (See DRIVE BELT ADJUSTMENT .)

Fig. 2: Identifying Generator, P/S, P/S+A/C Pulley

Courtesy of MAZDA MOTORS CORP.

DRIVE BELT DEFLECTION SPECIFICATION

Deflection

Drive belt (1)

New

Generator

P/S, P/S+A/C

5.5-7.0 {0.22-0.27}

7.0-8.0 {0.28-0.31}

Used

6.0-7.5 {0.24-0.29}

9.0-10.0 {0.36-0.39}

(1) A belt that has been on a running engine for less than 5 min mm {in}

Limit

8.0 {0.31}

11.5 {0.45}

DRIVE BELT TENSION CHECK

1. Belt tension can be verified in place of belt deflection.

2. Verify the drive belt tension when the engine is cold, or at least 30 min after the engine has stopped.

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2005 ENGINE Mechanical - MX-5 Miata

3. Using the SST , verify the belt tension between any two pulleys.



If the tension is not within the specification, adjust it. (See DRIVE BELT ADJUSTMENT .)

Fig. 3: Verifying Drive Belt Tension

Courtesy of MAZDA MOTORS CORP.

DRIVE BELT TENSION SPECIFICATION

Tension

Drive belt

(1)

New

Generator

P/S, P/S+A/C

491-745

{50-76, 111-167}

588-686

{59-70, 130-154}

Used

491-706

{50-72, 111-158}

422-490

{43-50, 95-110}

(1) A belt that has been on a running engine for less than 5 min

N {kgf, lbf}

Limit

343 {35, 77}

245 {25, 55}

DRIVE BELT ADJUSTMENT

1. Loosen mounting bolts A, B and nut C.

2. Adjust the belt deflection or tension by turning the adjusting bolt D. (See DRIVE BELT

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

INSPECTION .)

3. Tighten mounting bolts A, B and nut C.

GENERATOR

Tightening torque

A:38-52 N.m {3.8-5.3 kgf.m, 28-38 ft.lbf}

B:19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}

Fig. 4: Tightening Generator Mounting Bolts And Nut

Courtesy of MAZDA MOTORS CORP.

P/S, P/S+A/C

Tightening torque

A:38-51 N.m {3.8-5.3 kgf.m, 28-38 ft.lbf}

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

B:37-53 N.m {3.7-5.5 kgf.m, 27-39 ft.lbf}

C:19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}

4. Verify the belt deflection or tension. (See DRIVE BELT INSPECTION .)

Fig. 5: Verifying Belt Deflection Or Tension

Courtesy of MAZDA MOTORS CORP.

VALVE CLEARANCE INSPECTION

1. Remove the cylinder head cover.

2. Verify that the engine is in cold condition.

3. Measure the valve clearance.

1. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.

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2005 ENGINE Mechanical - MX-5 Miata

Fig. 6: Measuring Valve Clearance

Courtesy of MAZDA MOTORS CORP.

2. Measure the valve clearance at A in the figure.



If the valve clearance exceeds the standard, replace the adjustment shim. (See VALVE

CLEARANCE ADJUSTMENT .)

Standard [Engine cold]

IN:0.18-0.24 mm {0.007-0.009 in} (0.21+/-0.03 mm {0.008+/-0.0.0012 in})

EX:0.28-0.34 mm {0.011-0.013 in} (0.31+/-0.03 mm {0.012+/-0.0012 in})

3. Turn the crankshaft 360° clockwise so that the No.4 piston is at TDC of the compression stroke.

4. Measure the valve clearance at B in the figure.

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata



If the valve clearance exceeds the standard, replace the adjustment shim. (See VALVE

CLEARANCE ADJUSTMENT .)

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

Fig. 7: Measuring Valve Clearance With Feeler Gauge

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Standard [Engine cold]

IN:0.18-0.24 mm {0.007-0.009 in} (0.21+/-0.03 mm {0.008+/-0.0012 in})

EX:0.28-0.34 mm {0.011-0.013 in} (0.31+/-0.03 mm {0.012+/-0.0012 in})

4. Install the cylinder head cover. (See CYLINDER HEAD COVER INSTALLATION NOTE .)

VALVE CLEARANCE ADJUSTMENT

NOTE:



Perform this same procedure for all camshafts requiring valve clearance adjustment.

1. Turn the crankshaft clockwise so that the cams on the camshaft requiring valve clearance adjustment are positioned straight up.

2. Remove the camshaft cap bolts if necessary.

Remove only one pair of cap bolts at a time.

Install the cap bolts before removing the next pair.

A. For EX side No.1, 2, 3 cylinder adjustment shim removal

B. For IN side No.1, 2, 3 cylinder adjustment shim removal

C. For EX side No.2, 3, 4 cylinder adjustment shim removal

D. For IN side No.2, 3, 4 cylinder adjustment shim removal

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

Fig. 8: Identifying Cylinder Adjustment Shim

Courtesy of MAZDA MOTORS CORP.

NOTE:



For EX side No.2, 3 cylinder adjustment shim removal, remove bolts either A or C.

For IN side No.2, 3 cylinder adjustment shim removal, remove bolts either B or D.

3. Install the SSTs on the camshaft using the camshaft cap bolt holes.

Tightening torque

11.3-14.2 N.m {115-145 kgf.cm, 100-125 in.lbf}

4. Align the marks on the SSTs (shaft and shaft clamp).

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

Fig. 9: Installing SSTs On Camshaft Using Camshaft Cap Bolt Holes

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

5. Tighten bolts A to secure the SST (shaft).

Fig. 10: Tightening Bolts To Securing SST

Courtesy of MAZDA MOTORS CORP.

6. Face the SST (body) outside of the cylinder head, and mount it on the SST (shaft) at the point of the adjustment shim to be replaced.

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

Fig. 11: Mounting SST At Point Of Adjustment Shim

Courtesy of MAZDA MOTORS CORP.

7. Face the notch of the tappet so that a small screwdriver can be inserted.

8. Set the SST on the tappet by its notch.

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

Fig. 12: Setting SST On Tappet By Notch

Courtesy of MAZDA MOTORS CORP.

9. Tighten bolt B to secure the SST (body).

CAUTION:



Cylinder head can be damaged when the tappet is pressed down.

10. Tighten bolt C, and press down the tappet.

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2005 ENGINE Mechanical - MX-5 Miata

Fig. 13: Tightening Bolt And Pressing Down Tappet

Courtesy of MAZDA MOTORS CORP.

11. Using a fine screwdriver, pry up the adjustment shim through the notch on the tappet.

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

Fig. 14: Prying Up Adjustment Shim Using Screwdriver

Courtesy of MAZDA MOTORS CORP.

12. Remove the shim using a magnet.

13. Select a proper adjustment shim.

New adjustment shim

= Removed shim thickness + Measured valve clearance - Standard valve clearance (IN:0.21 mm {0.008 in}, EX:0.31 mm {0.012 in})

14. Push the selected shim into the tappet.

15. Loosen bolt C to allow the tappet to move up.

16. Loosen bolt B and remove the SST (body).

17. Remove the SSTs and tighten the camshaft cap bolts.

Tightening torque

11.3-14.2 N.m {115-145 kgf.cm, 100-125 in.lbf}

18. Verify the valve clearance. (See VALVE CLEARANCE INSPECTION .)

COMPRESSION INSPECTION

WARNING:



Hot engines and engine oil can cause severe burns. Be careful not

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata



 to burn yourself during removal/installation of each component.

Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line

Safety Procedure". (See BEFORE SERVICE PRECAUTION [BP, BP

WITH TC] .)

1. Verify that the battery is fully charged.

2. Charge it again if necessary. (See BATTERY INSPECTION .)

3. Warm up the engine to the normal operating temperature.

4. Stop the engine and allow it to cool off for about 10 min.

5. Perform "Fuel Line Safety Procedure". (See BEFORE SERVICE PRECAUTION [BP, BP WITH

TC] .)

6. Leave the fuel pump relay removed.

7. Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION .)

8. Disconnect the ignition coil connector.

9. Connect a compression gauge into the No.1 spark plug hole.

10. Fully depress the accelerator pedal and crank the engine.

11. Record the maximum gauge reading.

12. Inspect each cylinder as above.



If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and inspect the compression again.



If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required.

 If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.



If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head is distorted and overhaul is required.

ENGINE COMPRESSION SPECIFICATIONS

Compression

Standard

Minimum

Item

Maximum difference between cylinders kPa {kgf/cm2, psi} [RPM]

Engine

BP BP with TC

1363 {13.9, 198} [300] 1442 {14.7, 209} [300]

1009 {10.29, 146} [300]

196 kPa {2.0 kgf/cm2, 28 psi}

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata

13. Disconnect the compression gauge.

14. Connect the ignition coil connector.

15. Install the fuel pump relay.

16. Install the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION .)

OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [BP]

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

Fig. 15: Identifying OCV And Connector With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

OIL CONTROL VALVE (OCV) INSPECTION [BP]

COIL RESISTANCE

1. Disconnect the OCV connector.

2. Verify that the resistance between terminals A and B is within the specification.

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2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata



If not as specified, replace the OCV.

Specification (20°C {68°F})

6.9-7.9 ohms

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2005 ENGINE Mechanical - MX-5 Miata

Fig. 16: Identifying OCV Connector Terminals

Courtesy of MAZDA MOTORS CORP.

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SPOOL VALVE OPERATION

1. Remove the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [BP] .)

2. Verify that the spool valve in the OCV is the maximum valve timing retard position.



If not as specified, replace the OCV.

3. Verify that the battery is fully charged.

Fig. 17: Verifying Spool Valve In OCV Is Maximum Valve Timing Retard Position

Courtesy of MAZDA MOTORS CORP.

4. Apply battery positive voltage between the OCV terminals and verify that the spool valve operates and moves to the maximum valve timing advance position.

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Fig. 18: Verifying Spool Valve Operates

Courtesy of MAZDA MOTORS CORP.



If not as specified, replace the OCV.

NOTE:



When applying battery positive voltage between the OCV terminals, the connection can be either of the following:



Positive battery cable to terminal A, negative battery cable to terminal B.

Positive battery cable to terminal B, negative battery cable to terminal A.

5. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing retard position.



If not as specified, replace the OCV.

VARIABLE VALVE TIMING ACTUATOR INSPECTION [BP]

STOPPER PIN

1. Disconnect the negative battery cable.

2. Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION .)

3. Hold a hexagonal part of the intake camshaft with an adjustable wrench to prevent the camshaft from

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE Mechanical - MX-5 Miata rotating. Attempt to rotate the variable timing actuator by hand and verify that it does not move.

Fig. 19: Holding Hexagonal Part Of Intake Camshaft With Adjustable Wrench

Courtesy of MAZDA MOTORS CORP.



If the variable valve timing actuator moves, the stopper pin in the variable valve timing actuator is not operating. Replace the variable valve timing actuator.

4. Install in the timing belt. (See TIMING BELT REMOVAL/INSTALLATION .)

EXTREME SPARK RETARD POSITION

1. Disconnect the negative battery cable.

2. Remove the variable valve timing actuator.

CAUTION:



If engine oil gets on parts, they may not function properly.

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When removing the variable valve timing actuator, be sure to cover the other parts with a cloth to protect them from the oil.

3. Verify that the camshaft dowel pin hole on the variable valve timing actuator is aligned with the top of the third tooth, by counting back 3 teeth to the sprocket gap which is aligned with the alignment mark.

Fig. 20: Identifying Camshaft Dowel Pin Hole Alignment Mark

Courtesy of MAZDA MOTORS CORP.



If not as specified, the stopper pin in the variable valve timing actuator is not engaged at the position of maximum valve timing retard. Replace the variable valve timing actuator.

4. Install the variable valve timing actuator.

TIMING BELT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

3. Remove the front strut bar. (See FRONT STRUT BAR REMOVAL/INSTALLATION [BP] .) (See

FRONT STRUT BAR REMOVAL/INSTALLATION [BP WITH TC] .)

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4. Remove the air hose No.2, air hose No.1, air cleaner cover, and air pipe No.1 installation bolt. (BP with

TC) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

5. Remove the air pipe. (BP) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP] .)

6. Remove the drive belt. (See DRIVE BELT ADJUSTMENT .)

7. Remove the CMP sensor. (BP with TC)

8. Remove the CKP sensor.

9. Remove the high-tension lead and ignition coil. (See IGNITION COIL

REMOVAL/INSTALLATION .)

10. Remove the spark plug. (See SPARK PLUG REMOVAL/INSTALLATION .)

11. Remove in the order indicated in the table.

12. Install in the reverse order of removal.

13. Inspect the air gap between the crankshaft position sensor.

14. Inspect the engine oil level.

15. Start the engine, and inspect the following and adjust if necessary:



Pulley and belt for runout or contact

Engine oil and engine coolant for leakage



Ignition timing



Operation of auxiliary parts

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Fig. 21: Identifying Mechanical Component & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

OIL PIPE REMOVAL NOTE (BP)

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CAUTION:



If the engine oil get spilled on other components, it may cause malfunction of the components. Cover with a rag to prevent engine oil from spilling whenever removing the oil pipe.

NOTE:



Keep the oil pipe of engine side with the bolt removed.

PULLEY LOCK BOLT REMOVAL/INSTALLATION NOTE

1. Install SST on the pulley boss to prevent the crankshaft from rotating.

Fig. 22: Installing SST On Pulley Boss To Prevent Crankshaft From Rotating

Courtesy of MAZDA MOTORS CORP.

TIMING BELT REMOVAL NOTE

1. Install the pulley boss on the crankshaft to temporarily tighten with pulley lock bolt.

2. Rotate the crankshaft in the appropriate direction to meet the timing mark.

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Fig. 23: Rotating Crankshaft Of Appropriate Direction Timing Mark

Courtesy of MAZDA MOTORS CORP.

NOTE:



It is preferable that the positioning pins of the pulley boss are just above the timing marks.

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Fig. 24: Positioning Pins Of Pulley Boss

Courtesy of MAZDA MOTORS CORP.

3. Loosen the tensioner lock bolt and temporarily tighten the tensioner lock bolt while pulling the tensioner to the left.

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Fig. 25: Loosening Tensioner Lock Bolt

Courtesy of MAZDA MOTORS CORP.

CAUTION:



The following will damage the belt and shorten its life; forcefully t it, turning it inside out, or allowing oil or grease on it.

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Fig. 26: Locating Timing Belt Mark Direction

Courtesy of MAZDA MOTORS CORP.

NOTE:



Mark the timing belt rotation on the belt for proper reinstallation.

TENSIONER AND TENSIONER SPRING INSTALLATION NOTE

1. Measure the tensioner spring free length.



If not within the specification, replace the tensioner spring.

Free length

59.2 mm {2.33 in}

2. Install the tensioner.

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Fig. 27: Measuring Tensioner Spring Free Length

Courtesy of MAZDA MOTORS CORP.

3. Install the tensioner spring with the damper rubber closing face on the right side.

4. Temporarily secure the tensioner with the spring fully extended.

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Fig. 28: Installing Tensioner Spring With Damper Rubber

Courtesy of MAZDA MOTORS CORP.

TIMING BELT INSTALLATION NOTE

1. Verify that the timing belt pulley mark and camshaft pulley marks are aligned with the timing marks as shown.

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Fig. 29: Aligning With Timing Marks

Courtesy of MAZDA MOTORS CORP.

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Fig. 30: Identifying Timing Marks

Courtesy of MAZDA MOTORS CORP.

2. Install the timing belt so that there is no looseness at the idler side and between the camshaft pulleys.

3. Install the pulley boss and pulley lock bolt.

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Fig. 31: Installing Timing Belt No Looseness At Idler Side

Courtesy of MAZDA MOTORS CORP.

4. Turn the crankshaft clockwise 1 and 5/6 times , and align the timing belt pulley mark with the tensioner set mark for proper timing belt tension adjustment.

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Fig. 32: Aligning Timing Belt Pulley Mark With Tensioner Set Mark

Courtesy of MAZDA MOTORS CORP.

5. Hold the crankshaft using the SST , and remove the pulley lock bolt and the pulley boss.

6. Verify that the timing belt pulley mark is aligned with the tensioner set mark.

7. Loosen the tensioner lock bolt to apply tension to the timing belt.

8. Tighten the tensioner lock bolt.

CAUTION:



Avoid the tensioner from moving with the tensioner lock bolt as it is turned.

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Fig. 33: Removing Pulley Lock Bolt And Pulley Boss

Courtesy of MAZDA MOTORS CORP.

9. Install the pulley boss and the pulley lock bolt.

10. Turn the crankshaft 2 and 1/6 times , and face the pin on the pulley boss straight up.

11. Verify that the camshaft pulley marks are aligned with the timing marks as shown.



If not, repeat from "Timing Belt Removal Note". (See TIMING BELT REMOVAL NOTE .)

NOTE:



It is preferable that the positioning pins of the pulley boss are just above the timing marks.

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Fig. 34: Verifying Camshaft Pulley Marks And Aligning With Timing Marks

Courtesy of MAZDA MOTORS CORP.

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Fig. 35: Identifying Pulley Boss

Courtesy of MAZDA MOTORS CORP.

12. Measure the belt deflection at the point shown in Fig. 36 .



If not as specified, repeat from Step 4.

Timing belt deflection

8.5-11.5 mm {0.34-0.45 in}

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Fig. 36: Measuring Belt Deflection Point

Courtesy of MAZDA MOTORS CORP.

TIMING BELT COVER INSTALLATION NOTE

1. Tighten the timing belt cover bolts in the numerical order shown in Fig. 37 .

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Fig. 37: Tightening Timing Belt Cover Bolts

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD COVER INSTALLATION NOTE

1. Apply liquid gasket to the portions shown in Fig. 38 .

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Fig. 38: Applying Liquid Gasket

Courtesy of MAZDA MOTORS CORP.

2. Temporarily tighten the cylinder head cover bolt on the portion A shown in Fig. 39 .

CAUTION:



Do not damage the O-ring while installing the OCV case. If the

O-ring of the OCV adapter on camshaft cap is damaged, it may cause hydraulic leakage.

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Fig. 39: Tightening Cylinder Head Cover Bolt On Portion Of Cylinder Head

Courtesy of MAZDA MOTORS CORP.

3. Tighten the cylinder head cover bolts for several times in the numerical order shown in Fig. 40 .

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Fig. 40: Tightening Sequence Of Cylinder Head Cover Bolts

Courtesy of MAZDA MOTORS CORP.

OIL CONTROL VALVE (OCV) CASE INSTALLATION NOTE (BP)

1. Tighten the OCV case bolts for several times in the numerical order shown in Fig. 41 .

CAUTION:



Do not damage the O-ring while installing the OCV case. If the

O-ring of the OCV adapter on camshaft cap is damaged, it may cause hydraulic leakage.

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Fig. 41: Tightening OCV Case Bolts

Courtesy of MAZDA MOTORS CORP.

OIL PIPE INSTALLATION NOTE (BP)

CAUTION:



Perform the following procedures so that there is no load applied on each connection part while installing the oil pipe as it may cause oil leakage.

1. Hold the frame of the OCV filter and install the OCV so as to align with the projected part on flange end

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2005 ENGINE Mechanical - MX-5 Miata of the oil pipe.

2. Apply engine oil to the new washer.

3. Temporarily install the upper and side oil pipe and position the oil pipe.

Fig. 42: Installing Upper And Side Oil Pipe

Courtesy of MAZDA MOTORS CORP.

4. Tighten the oil pipe bolts for several times in the numerical order shown in Fig. 43 .

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Fig. 43: Tightening Oil Pipe Bolts

Courtesy of MAZDA MOTORS CORP.

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5. Tighten the oil pipe bolts for several times on the portion A shown in Fig. 44 .

Tightening torque

7.8-10.8 N.m {80-110 kgf.cm, 70-95 in.lbf}

Fig. 44: Tightening Oil Pipe Bolts

Courtesy of MAZDA MOTORS CORP.

6. Temporarily tighten the oil pipe bolt on the portion B shown in Fig. 45 .

Tightening torque

2.9-6.9 N.m {26-61 kgf.cm, 26-61 in.lbf}

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Fig. 45: Tightening Oil Pipe Bolt

Courtesy of MAZDA MOTORS CORP.

7. Temporarily tighten the oil pipe bolt on the portion C shown in Fig. 46 .

Tightening torque

11.8-17.6 N.m {1.2-1.8 kgf.m, 8.7-13 ft.lbf}

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Fig. 46: Tightening Oil Pipe Bolt

Courtesy of MAZDA MOTORS CORP.

8. Tighten the oil pipe bolts for several times in the numerical order shown in Fig. 47 .

Tightening torque

No.1, 2, 3, 4, 7:7.8-10.8 N.m

{80-110 kgf.cm, 70-95 in.lbf}

No.5:15.7-23.5 N.m

{1.6-2.3 kgf.m, 11.6-17.3 ft.lbf}

No.6:34.4-47.0 N.m

{3.5-4.7 kgf.m, 25.4-34.6 ft.lbf}

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Fig. 47: Tightening Sequence Of Oil Pipe Bolt

Courtesy of MAZDA MOTORS CORP.

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CYLINDER HEAD GASKET REPLACEMENT

WARNING:



Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line

Safety Procedure". (See BEFORE SERVICE PRECAUTION [BP, BP

WITH TC] .)

1. Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION .)

2. Remove the front pipe and exhaust manifold insulator. (See EXHAUST SYSTEM

REMOVAL/INSTALLATION [BP] .) (See EXHAUST SYSTEM REMOVAL/INSTALLATION

[BP WITH TC] .)

3. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP] .) (See

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

4. Remove the turbocharger, exhaust manifold, engine coolant pipe (out side), joint pipe. (BP with TC) (See

EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

5. Remove the air pipe No.6 and air hose No.8 as a single unit. (BP with TC) (See INTAKE-AIR

SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

6. Disconnect the vacuum hose and engine harness connectors.

7. Disconnect the fuel hose. (See BEFORE SERVICE PRECAUTION [BP, BP WITH TC] .) (See

AFTER SERVICE PRECAUTION [BP, BP WITH TC] .)

8. Remove the intake manifold bracket.

9. Remove in the order indicated in the table.

10. Install in the reverse order of removal.

11. Verify the engine oil level. (See ENGINE OIL LEVEL INSPECTION .)

12. Inspect for the engine oil, engine coolant, and fuel leakage.

13. Verify the compression. (See COMPRESSION INSPECTION .)

14. Start the engine and verify the idle speed. (See IDLE SPEED ADJUSTMENT .)

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Fig. 48: Replacing Cylinder Head Gasket

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD REMOVAL NOTE

1. Loosen the cylinder head bolts in two or three steps in the order shown.

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Fig. 49: Loosening Cylinder Head Bolts

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD INSTALLATION NOTE

1. Tighten the cylinder head bolts in two or three steps in the order shown.

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Fig. 50: Tightening Cylinder Head Bolts

Courtesy of MAZDA MOTORS CORP.

TAPPET AND ADJUSTMENT SHIM REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Inspect the air gap between the crankshaft position sensor.

6. Inspect the engine oil level.

7. Start the engine, and inspect the following and adjust if necessary:



Pulley and belt for runout or contact



Engine oil and engine coolant for leakage

Ignition timing



Operation of auxiliary parts

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Fig. 51: Exploded View Of Tappet And Adjustment Shim

Courtesy of MAZDA MOTORS CORP.

VARIABLE VALVE TIMING ACTUATOR (BP) AND CAMSHAFT PULLEY REMOVAL NOTE

CAUTION:



If the engine oil get spilled on other components, it may cause malfunction of the components. Cover with a rag to prevent engine oil from spilling whenever removing the blind cap and variable valve timing actuator.

1. Hold the hexagonal part of the camshaft with an adjustable wrench or the like to prevent the camshaft from rotating, and loosen the lock bolt.

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Fig. 52: Holding Hexagonal Part Of Camshaft With Adjustable Wrench

Courtesy of MAZDA MOTORS CORP.

CAMSHAFT REMOVAL NOTE

1. Loosen the camshaft cap bolts in two or three steps in the order shown.

2. Remove the camshaft caps.

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Fig. 53: Removing Camshaft Caps

Courtesy of MAZDA MOTORS CORP.

CAMSHAFT INSTALLATION NOTE

1. Apply engine oil to the camshaft and journal receiving part of cylinder head.

2. Install the camshaft so that the cam projections of cylinder No.1 and 3 face the direction as shown in Fig.

54 .

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Fig. 54: Identifying Cam Projections Of Cylinder No.1 And 3 Face

Courtesy of MAZDA MOTORS CORP.

3. Apply liquid gasket to the sliding surface of cylinder head shown in the figure so as not to be projected out.

4. Install the camshaft cap to its original position.

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Fig. 55: Applying Liquid Gasket To Sliding Surface Of Cylinder Head

Courtesy of MAZDA MOTORS CORP.

5. Tighten the camshaft cap bolts for several times in the numerical order shown in the figure.

CAUTION:



Install the camshaft while keeping horizontally as the camshaft thrust clearance is small. Otherwise, excessive force may be applied on the thrust part and cause burrs to the thrust part of cylinder head. Therefore, confirm that the camshaft lowers horizontally in accordance with tightening the 2 camshaft cap bolts on the No.3 journal part while tightening the camshaft cap bolts.

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Fig. 56: Tightening Camshaft Cap Bolts

Courtesy of MAZDA MOTORS CORP.

6. Apply engine oil to the camshaft oil seal.

7. Slightly insert the camshaft oil seal by hand.

8. Tap the camshaft oil seal with the SST.

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Fig. 57: Applying Engine Oil To Camshaft Oil Seal

Courtesy of MAZDA MOTORS CORP.

VARIABLE VALVE TIMING ACTUATOR (BP) AND CAMSHAFT PULLEY INSTALLATION

NOTE

1. Rotate the camshaft and face the knock pin to the just above position.

2. Install the camshaft so that the alignment mark of camshaft pulley faces to the just above position.

3. Install the camshaft so that the knock pin of camshaft is connected with the camshaft knock pin hole of variable valve timing actuator.

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Fig. 58: Installing Camshaft And Alignment Mark Of Camshaft Pulley

Courtesy of MAZDA MOTORS CORP.

4. Hold the hexagonal part of the camshaft with an adjustable wrench or the like to prevent the camshaft from rotating, and tighten the lock bolt.

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Fig. 59: Holding Hexagonal Part Of Camshaft With An Adjustable Wrench

Courtesy of MAZDA MOTORS CORP.

FRONT OIL SEAL REPLACEMENT

1. Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION .)

2. Remove in the order indicated in the table.

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Fig. 60: Removing Timing Belt

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

FRONT OIL SEAL REMOVAL NOTE

1. Cut the oil seal lip using a razor.

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2. Remove the oil seal using a screwdriver protected with a rag.

Fig. 61: Removing Oil Seal Using Screwdriver Protected With Rag

Courtesy of MAZDA MOTORS CORP.

FRONT OIL SEAL INSTALLATION NOTE

1. Apply clean engine oil to the oil seal lip.

2. Push the oil seal slightly in hand.

3. Tap the oil seal in evenly using the SST and a hammer.

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Fig. 62: Installing Front Oil Seal

Courtesy of MAZDA MOTORS CORP.

REAR OIL SEAL REPLACEMENT

1. Remove the flywheel. (MT) (See CLUTCH UNIT REMOVAL/INSTALLATION .)

2. Remove the drive plate. (AT) (See DRIVE PLATE REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

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Fig. 63: Identifying Rear Oil Seal

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

REAR OIL SEAL REMOVAL NOTE

1. Cut the oil seal lip using a razor.

2. Remove the oil seal using a screwdriver protected with a rag.

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Fig. 64: Removing Oil Seal Using Screwdriver Protected With Rag

Courtesy of MAZDA MOTORS CORP.

REAR OIL SEAL INSTALLATION NOTE

1. Apply clean engine oil to the new oil seal lip.

2. Push the oil seal slightly in hand.

3. Tap the oil seal in evenly using the SST and a hammer.

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Fig. 65: Taping Oil Seal Using SST

Courtesy of MAZDA MOTORS CORP.

ENGINE REMOVAL/INSTALLATION [BP]

WARNING:



Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line

Safety Procedure". (See BEFORE SERVICE PRECAUTION [BP, BP

WITH TC] .)

1. Disconnect the negative battery cable.

2. Remove the radiator. (See RADIATOR REMOVAL/INSTALLATION [BP] .) (See RADIATOR

REMOVAL/INSTALLATION [BP WITH TC] .)

3. Remove the air cleaner.

4. Disconnect the accelerator cable and bracket.

5. Disconnect the fuel hose. (See BEFORE SERVICE PRECAUTION [BP, BP WITH TC] .) (See

AFTER SERVICE PRECAUTION [BP, BP WITH TC] .)

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6. Disconnect the vacuum hose and engine harness connectors.

7. Disconnect the heater hose.

8. Remove the drive belt. (See DRIVE BELT ADJUSTMENT .)

9. Remove the P/S oil pump with the oil hose still connected.

10. Position the P/S oil pump so that it is out of the way. (Vehicles with P/S oil pump)

11. Remove the P/S oil pump with the oil hose still connected.

12. Position the A/C compressor so that it is out of the way. (Vehicles with A/C compressor)

13. Remove the transmission. (See MANUAL TRANSMISSION REMOVAL/INSTALLATION [M15M-

D] .) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION .)

14. Remove in the order indicated in the table.

15. Install in the reverse order of removal.

16. Start the engine and

1. Inspect for the engine oil, engine coolant, transmission oil and fuel leakage.

2. Verify the ignition timing. (See IGNITION TIMING INSPECTION .)

3. Verify the idle speed. (See IDLE SPEED ADJUSTMENT .)

4. Verify the idle mixture. (See IDLE MIXTURE INSPECTION .)

17. If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no abnormality.

Fig. 66: Identifying Engine (BP) Torque Specification

Courtesy of MAZDA MOTORS CORP.

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ENGINE REMOVAL/INSTALLATION [BP WITH TC]

WARNING:



Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line

Safety Procedure". (See BEFORE SERVICE PRECAUTION [BP, BP

WITH TC] .)

1. Disconnect the negative battery cable.

2. Remove the under cover.

3. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

4. Remove the front strut bar. (See FRONT STRUT BAR REMOVAL/INSTALLATION [BP WITH

TC] .)

5. Remove the washer tank with the hose still connected.

6. Remove the washer tank bracket.

7. Remove the air hose No.2, air cleaner, and air pipe No.1. (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION [BP WITH TC] .)

8. Remove the air pipe No.3 and air pipe No.5, air pipe No.6 and air hose No.8, air pipe No.5 and air hose

No.7. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

9. Disconnect the upper radiator hose.

10. Remove the cooling fan assembly. (See RADIATOR REMOVAL/INSTALLATION [BP WITH

TC] .)

11. Disconnect the lower radiator hose.

12. Remove the radiator. (See RADIATOR REMOVAL/INSTALLATION [BP WITH TC] .)

13. Remove the drive belt. (See DRIVE BELT ADJUSTMENT .)

14. Remove the P/S oil pump with the oil hose still connected.

15. Position the P/S oil pump so that it is out of the way.

16. Remove the A/C compressor with the pipe still connected.

17. Position the A/C compressor so that it is out of the way.

18. Disconnect the fuel hose.

19. Disconnect the vacuum hose and engine harness connectors.

20. Disconnect the heater hose.

21. Remove the transmission. (See MANUAL TRANSMISSION REMOVAL/INSTALLATION [M15M-

D] .) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION .)

22. Remove in the order indicated in the table.

23. Install in the reverse order of removal.

24. Start the engine and

1. Inspect for the engine oil, engine coolant, transmission oil and fuel leakage.

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2. Verify the ignition timing. (See IGNITION TIMING INSPECTION .)

3. Verify the idle speed. (See IDLE SPEED ADJUSTMENT .)

4. Verify the idle mixture. (See IDLE MIXTURE INSPECTION .)

25. If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no abnormality.

Fig. 67: Identifying Engine (BP With TC) & Torque Specification

Courtesy of MAZDA MOTORS CORP.

ENGINE REMOVAL NOTE

1. Install the SST to the position shown in Fig. 68 using the suitable washer and air pipe No.1 installation bolt.

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Fig. 68: Installing Bolt Using Suitable Washer And Air Pipe & Torque Specification

Courtesy of MAZDA MOTORS CORP.

ENGINE DISASSEMBLY/ASSEMBLY

1. Remove the oil pressure switch. (See OIL PRESSURE INSPECTION .)

2. Remove the OCV. (BP) (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [BP] .)

3. Remove the oil pipe. (BP) (See TIMING BELT REMOVAL/INSTALLATION .)

4. Remove the camshaft position sensor.

5. Remove the crankshaft position sensor.

6. Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP] .)

(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

7. Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [BP] .) (See

EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC] .)

8. Remove the generator.

9. Remove the oil filter. (See OIL FILTER REPLACEMENT .)

10. Remove the oil cooler.

11. Remove the thermostat. (See THERMOSTAT REMOVAL/INSTALLATION .)

12. Disassemble in the order indicated in the table.

13. Assemble in the reverse order of disassembly.

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Fig. 69: Dissembling Engine Assembly & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

WATER OUTLET PIPE INSTALLATION NOTE

1. Install the water outlet pipe gasket so that the print area faces the cylinder head.

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Fig. 70: Identifying Print Area Faces Cylinder Head

Courtesy of MAZDA MOTORS CORP.

ENGINE TUNE-UP

ENGINE TUNE-UP PREPARATION

1. Warm up the engine to normal operating temperature.

2. Shift transmission into Neutral (MT) or P position (AT).

3. Turn off all electrical loads.



Headlight

Blower



Rear window defroster

4. Verify that the battery is fully charged. (See BATTERY INSPECTION .)

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5. Wait until the electrical fan stops.

6. Connect the SST (WDS or equivalent) to the DLC-2.

7. Access RPM PID.

8. Short the DLC terminal TEN to body GND using a jumper wire.

9. Select "START" to begin.

Fig. 71: Shorting DLC Terminal Ten To Body Gnd Using Jumper Wire

Courtesy of MAZDA MOTORS CORP.

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IGNITION TIMING INSPECTION

1. Perform ENGINE TUNE-UP PREPARATION .

2. Verify that the idle speed is within the specification.



If not as specified, adjust the idle speed. (See IDLE SPEED ADJUSTMENT .)

Specification

750-850 (800 +/- 50) RPM

3. Connect a timing light to the high-tension lead of the No.1 cylinder.

4. Verify that the timing mark (white) on the crankshaft pulley and the T mark on the timing belt cover are aligned.

Ignition timing

BTDC 9°--11° (10° +/- 1°) (TIMING MARK [YELLOW])

5. Disconnect the jumper wire.

6. Press "CANCEL".

7. Verify that the timing mark (yellow) is within the specification.

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Fig. 72: Verifying Timing Mark Within Specification

Courtesy of MAZDA MOTORS CORP.



If not as specified, inspect the following.



CMP sensor

CKP sensor



TP sensor

ECT sensor



Neutral switch (MT)



Clutch switch (MT)

TR switch (AT)



If the devices are normal, replace the PCM.

Specification

BTDC 6°--18°

IDLE SPEED ADJUSTMENT

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1. Perform ENGINE TUNE-UP PREPARATION .

2. Verify that the idle speed is within the specification.



If not within the specification, adjust the idle speed by turning the AAS.

CAUTION:



The TAS is set at the factory and must not be adjusted. Any adjustment will negatively affect the engine performance.

Fig. 73: Adjusting Idle Speed By Turning AAS

Courtesy of MAZDA MOTORS CORP.

Specification

750-850 (800 +/- 50) RPM

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3. Disconnect the jumper wire.

4. Press "CLEAR" to clear previously selected items.

5. Disconnect the SST (WDS or equivalent).

IDLE-UP SPEED INSPECTION

1. Perform ENGINE TUNE-UP PREPARATION , and IDLE SPEED ADJUSTMENT .

2. Verify "RPM" PID is selected.

3. Press "START".

4. Verify that the idle speed is normal.

5. Verify that the idle-up speed is within the specification.



If not as specified under all load conditions, inspect the IAC valve.

If not as specified under some load conditions, inspect related input switches, harnesses and connectors.

IDLE-UP SPEED SPECIFICATION

Load condition

Idle-up speed (RPM)

(1)

N, P position D range

BP WITH TC

E/L ON

P/S ON

A/C ON

(2)

(3)

(4)

750-850 (800 +/-

50)

950-1050 (1000 +/-

50)

750-850 (800 +/-

50)

700-800 (750 +/-

50)

800-900 (850 +/-

50)

750-850 (800 +/-

50)

950-1050 (1000 +/-

(1) Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on.

50)

(2) Headlight is on, fan switch (above 1st), cooling fan are operating, rear window defroster is on.

(3) Steering wheel is fully turned.

(4) A/C switch and fan switch are on.

IDLE MIXTURE INSPECTION

1. Perform ENGINE TUNE-UP PREPARATION .

2. Verify that the idle speed and ignition timing are within the specification.

3. Insert an exhaust gas analyzer to the tailpipe.

4. Verify that the CO and HC concentrations are within the regulation.



If not, inspect the following.



OBD system

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

HO2S



Intake manifold vacuum

Fuel line pressure





Ignition timing control

If the systems are normal, replace the TWC.

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2005 ENGINE Technical Data - MX-5 Miata

2005 ENGINE

Technical Data - MX-5 Miata

ENGINE TECHNICAL DATA

Fig. 1: Engine Technical Data Chart (1 Of 3)

Courtesy of MAZDA MOTORS CORP.

2005 Mazda MX-5 Miata

2005 ENGINE Technical Data - MX-5 Miata

Fig. 2: Engine Technical Data Chart (2 Of 3)

Courtesy of MAZDA MOTORS CORP.

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Fig. 3: Engine Technical Data Chart (3 Of 3)

Courtesy of MAZDA MOTORS CORP.

ENGINE OIL SPECIFICATION

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Fig. 4: Engine Oil Specification

Courtesy of MAZDA MOTORS CORP.

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2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

2005 ACCESSORIES & EQUIPMENT

Entertainment - MX-5 Miata

ENTERTAINMENT LOCATION INDEX

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Fig. 1: Identifying Entertainment Components

Courtesy of MAZDA MOTORS CORP.

DOOR SPEAKER REMOVAL/INSTALLATION

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CAUTION:



When removing or installing a door speaker, touching the radio cone paper could cause poor sound quality. When removing or installing a door speaker, hold the speaker's bracket and handle with care.

1. Disconnect the negative battery cable.

2. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

3. Remove the screws.

4. Disconnect the door speaker connector and remove the door speaker.

Fig. 2: Removing Door Speaker

Courtesy of MAZDA MOTORS CORP.

5. Position the door speaker so that the terminals face downward and install in the reverse order of removal.

DOOR SPEAKER INSPECTION

1. Remove the door speaker. (See DOOR SPEAKER REMOVAL/INSTALLATION .)

2. Inspect for resistance between the door speaker terminals using an ohmmeter.



If not as specified, replace the door speaker.

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Fig. 3: Door Speaker Connector Terminal Continuity Chart

Courtesy of MAZDA MOTORS CORP.

Fig. 4: Inspecting For Resistance Between Door Speaker Terminals Using An Ohmmeter

Courtesy of MAZDA MOTORS CORP.

AEROBOARD SPEAKER REMOVAL/INSTALLATION

CAUTION:



When removing or installing an aeroboard speaker, touching the

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata radio cone paper could cause poor sound quality. When removing or installing an aeroboard speaker, hold the speaker bracket and handle with care.

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

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Fig. 5: Removing Aeroboard Speaker

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

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COVER REMOVAL NOTE

1. Insert a tape-wrapped flathead screwdriver into the service hole.

2. Pry with the screwdriver in the direction shown by ' the arrow to remove the cover.

Fig. 6: Inserting A Tape-Wrapped Flathead Screwdriver Into Service Hole

Courtesy of MAZDA MOTORS CORP.

SPEAKER COVER REMOVAL NOTE

1. Pull the speaker cover outward, detach clips A and B from the aeroboard, and then remove the speaker cover.

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Fig. 7: Detaching Clips A And B From Aeroboard

Courtesy of MAZDA MOTORS CORP.

AEROBOARD SPEAKER INSPECTION

1. Remove the aeroboard speaker. (See AEROBOARD SPEAKER REMOVAL/INSTALLATION .)

2. Inspect for resistance between the aeroboard speaker terminals using an ohmmeter.



If not as specified, replace the aeroboard speaker.

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Fig. 8: Aeroboard Speaker Terminal Connector Continuity

Courtesy of MAZDA MOTORS CORP.

Fig. 9: Inspecting For Resistance Between Aeroboard Speaker Terminals

Courtesy of MAZDA MOTORS CORP.

TWEETER REMOVAL/INSTALLATION

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CAUTION:



When removing or installing a tweeter, touching the radio cone paper could cause poor sound quality. When removing or installing a tweeter speaker, hold the speaker's bracket and handle with care.

1. Disconnect the negative battery cable.

2. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

3. Remove the screws, then remove the tweeter.

Fig. 10: Removing Tweeter

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

TWEETER INSPECTION

1. Remove the tweeter speaker. (See TWEETER REMOVAL/INSTALLATION .)

2. Inspect for resistance between the tweeter speaker terminals using an ohmmeter.



If not as specified, replace the tweeter speaker.

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Fig. 11: Tweeter Terminal Connector Continuity

Courtesy of MAZDA MOTORS CORP.

Fig. 12: Inspecting For Resistance Between Tweeter Speaker Terminals

Courtesy of MAZDA MOTORS CORP.

POWER ANTENNA REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

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2. Remove the trunk side trim (LH). (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .

3. Remove in the order indicated in the table.

Fig. 13: Removing Power Antenna - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

MOUNTING NUT REMOVAL NOTE

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1. Use snap-ring pliers to remove the mounting nut.

Fig. 14: Removing Mounting Nut

Courtesy of MAZDA MOTORS CORP.

POWER ANTENNA DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

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Fig. 15: Disassembling Power Antenna

Courtesy of MAZDA MOTORS CORP.

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2. Assemble in the reverse order of disassembly.

POWER ANTENNA INSPECTION

1. Remove the trunk side trim (LH). (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

2. Disconnect the power antenna connector.

3. Connect ground to terminal H of the power antenna.

4. Connect B+ to the following terminals of the power antenna. Verify that the power antenna operated as indicated below.



If not as specified, replace the necessary part.

Terminal

Power antenna operation

B D

B+ -

B+ B+

Down

Fig. 16: Inspecting Power Antenna Connector Terminals

Courtesy of MAZDA MOTORS CORP.

ANTENNA MAST REMOVAL

CAUTION:



Always remove the antenna mast with the power antenna installed in the vehicle. Removing the antenna mast from the removed power antenna may damage the power antenna or the antenna mast.

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1. Use snap-ring pliers to remove the mounting nut.

Fig. 17: Removing Mounting Mast

Courtesy of MAZDA MOTORS CORP.

2. Turn the ignition switch to the ON position or the ACC position.

3. Audio power switch is the ON position.

4. Press AM/FM button and turn on the radio.

5. Pull out the antenna mast after it fully extends.

ANTENNA MAST INSTALLATION

1. Turn the ignition switch to the ON position or the ACC position.

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2. Straighten the warp of rack end.

3. Audio power switch is the ON position.

4. Press AM/FM button and turn on the radio.

5. Turn audio power switch off, then immediately insert the rack into the power antenna.

6. After the antenna mast is fully retracted, tighten the mounting nut to the specification.

Tightening torque

1.5-2.9 N.m {15-30 kgf.cm, 14-26 in.lbf}

7. Verify that the power antenna operates smoothly when the audio unit radio is on.

Fig. 18: Installing Antenna Mast

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Courtesy of MAZDA MOTORS CORP.

FRONT ANTENNA FEEDER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the audio unit. (See AUDIO UNIT INSTALLATION .)

3. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

4. Disconnect the connection between the front antenna feeder and the rear antenna feeder.

5. Remove in the order indicated in the table.

Fig. 19: Removing Front Antenna Feeder

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

FRONT ANTENNA FEEDER INSPECTION

1. Disconnect the negative battery cable.

2. Remove the audio unit. (See AUDIO UNIT REMOVAL .)

3. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

4. Disconnect the connection between front antenna feeder and the rear antenna feeder.

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5. Verify that there is no continuity between front antenna feeder terminals A and B using an ohmmeter.

Fig. 20: Identifying Front Antenna Feeder

Courtesy of MAZDA MOTORS CORP.

6. Inspect for continuity between the front antenna feeder terminals using an ohmmeter.



If not as specified, replace the front antenna feeder.

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Fig. 21: Front Antenna Terminal Connector Continuity

Courtesy of MAZDA MOTORS CORP.

REAR ANTENNA FEEDER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the trunk side trim (LH). (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

3. Disconnect the connection between the rear antenna feeder and the power antenna. (With manual antenna)

4. Remove the rear package trim. (See REAR PACKAGE TRIM REMOVAL/INSTALLATION .)

5. Turn over the floor covering from the right side. (See FLOOR COVERING

REMOVAL/INSTALLATION .)

6. Disconnect the connection between the front-antenna feeder and the rear antenna feeder.

7. Remove in the order indicated in the table.

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Fig. 22: Removing Rear Antenna Feeder

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

REAR ANTENNA FEEDER INSPECTION

1. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

2. Disconnect the connection between the front antenna feeder and the rear antenna feeder.

3. Remove the trunk side trim (LH). (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

4. Disconnect the connection between the rear antenna feeder and the power antenna. (With manual antenna)

5. Verify that there is no continuity between rear antenna feeder terminals A and B using an ohmmeter.

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Fig. 23: Identifying Rear Antenna Feeder

Courtesy of MAZDA MOTORS CORP.

6. Inspect for continuity between the rear antenna feeder terminals using an ohmmeter.



If not as specified, replace the rear antenna feeder.

Fig. 24: Rear Antenna Feeder Terminal Connector Continuity

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Courtesy of MAZDA MOTORS CORP.

ANTI-THEFT SYSTEM

ALARM CONDITIONS



If the anti-theft system protection has been activated, any one of the following conditions will trigger the system:



Disconnected battery cable



Discharged battery



Disconnected audio unit connectors



If the system is triggered, the audio unit will then be inoperative when it is reconnected to a power source, and "code" will flash on the display until the preselected code number is input. If the anti-theft system is triggered, follow the procedures in "Canceling Anti-theft Operation" to reset the unit.

Operation

Input code number to activate anti-theft system

Delete previous code number and set new number

Reference

Setting the Code Number

Canceling the Code Number

Resume audio unit operation after anti-theft system is triggered Canceling Anti-theft Operation

SETTING THE CODE NUMBER

Complete each step (Steps 1-3) within 10 seconds or the setting procedure will be canceled.

1. Turn the ignition switch to ACC position and then turn off the audio unit.

2. First press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds until "CODE" appears on the display.

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Fig. 25: Pressing AUTO-M Button and Channel Button 6 Until "CODE" Appears On Display

Courtesy of MAZDA MOTORS CORP.

3. Press the AUTO-M button again, then simultaneously press channel button 6 until dashes appear on the display.

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Fig. 26: Pressing AUTO-M Button and Channel Button 6 Until Dashes Appear On Display

Courtesy of MAZDA MOTORS CORP.

4. Select a personal code number and record it before inputting it. If the number is input and then forgotten, it cannot be canceled, and if the unit is disconnected again, the audio unit will be inoperative.

5. Use channel buttons 1-4 to input the selected code number. Press button 1 for the first digit, 2 for the second, 3 for the third, and 4 for the last digit. Input the number within 10 seconds.

If the display is deleted, repeat the procedure from Step 1.

NOTE:



Perform Step 6 within 10 seconds after Step 5.

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Fig. 27: Inputting Code Number

Courtesy of MAZDA MOTORS CORP.

6. With the code number displayed, press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds.

"CODE" will be displayed for approximately 5 seconds.

After it disappears, the code number is set.

7. If "Err" (error) appears on the display, repeat the procedure from Step 1. If input error is repeated three times, turn the ignition switch to LOCK position and repeat the procedure from Step 1.

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Fig. 28: Pressing AUTO-M Button and Channel Button 6 Until "CODE" Appears On Display

Courtesy of MAZDA MOTORS CORP.

CANCELING THE CODE NUMBER

Complete each step (Steps 1-3) within 10 seconds or the canceling procedure will be canceled.

1. Turn the ignition switch to ACC position and then turn off the audio unit.

2. First press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds until "CODE" appears on the display.

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Fig. 29: Pressing AUTO-M Button and Channel Button 6 Until "CODE" Appears On Display

Courtesy of MAZDA MOTORS CORP.

3. Press the AUTO-M button again, then simultaneously press channel button 6 until dashes appear on the display.

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Fig. 30: Pressing AUTO-M Button and Channel Button 6 Until Dashes Appear On Display

Courtesy of MAZDA MOTORS CORP.

4. Use channel buttons 1-4 to input the current code number. Press button 1 for the first digit, 2 for the second, 3 for the third, and 4 for the last digit. Input the number within 10 seconds.

If the display is deleted, repeat the procedure from Step 1.

NOTE:



Perform Step 5 within 10 seconds after Step 4.

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Fig. 31: Inputting Code Number

Courtesy of MAZDA MOTORS CORP.

5. With the code number displayed, press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds.

"CODE" will be displayed for approximately 5 seconds.

After it disappears, the code number is canceled.

6. If "Err" (error) appears on the display, repeat the procedure from Step 4.

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Fig. 32: Pressing AUTO-M Button and Channel Button 6 Until "CODE" Appears On Display

Courtesy of MAZDA MOTORS CORP.

CANCELING ANTI-THEFT OPERATION

Properly input the selected code number to deactivate the anti-theft system and resume normal audio operation.

1. Turn the ignition switch to ACC position. ("CODE" will flash on the display.)

2. First press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds until dashes appears on the display.

NOTE:



Perform Step 3 within 10 seconds after Step 2.

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Fig. 33: Pressing AUTO-M Button and Channel Button 6 Until Dashes Appear On Display

Courtesy of MAZDA MOTORS CORP.

3. Use channel buttons 1-4 to input the selected code number. Press button 1 for the first digit, 2 for the second, 3 for the third, and 4 for the last digit. Input the number within 10 seconds.

If the display is deleted, repeat the procedure from Step 1.

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Fig. 34: Inputting Code Number

Courtesy of MAZDA MOTORS CORP.

CAUTION:



Three consecutive errors, including turning the ignition switch to LOCK position and disconnecting the audio unit, will activate the anti-theft system and render the audio unit completely inoperative.

4. With the code number displayed, press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds.

"CODE" will flash for approximately 5 seconds.

5. If "Err" (error) appears on the display, repeat the procedure from Step 1.

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Fig. 35: Pressing AUTO-M Button and Channel Button 6 Until "CODE" Appears On Display

Courtesy of MAZDA MOTORS CORP.

AUDIO UNIT REMOVAL

1. Cancel the anti-theft operation. (For vehicles equipped with anti-theft system)

2. Disconnect the negative battery cable.

3. Remove the service hole covers by inserting a small tape-wrapped flathead screwdriver into the slot and carefully pry them off without scratching the center panel. Pry up and pull off the service hole covers carefully to prevent the posts from breaking off.

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Fig. 36: Removing Service Hole Covers

Courtesy of MAZDA MOTORS CORP.

NOTE:



Two sets of the SSTs (Removing tool) are necessary to remove the audio unit.

4. With the beveled parts of the SST (Removing tool) facing inward, insert them into the audio unit.

5. Pull the SST (Removing tool) outward and rearward to slide out the audio unit.

6. Disconnect the audio unit connectors and antenna jacks.

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Fig. 37: Removing Audio Unit

Courtesy of MAZDA MOTORS CORP.

AUDIO UNIT INSTALLATION

CAUTION:



Make certain that the wiring harness and antenna feeder are not caught between the unit and dashboard. If the harness or the antenna feeder is caught between the unit and dashboard, it may become the cause of trouble or malfunctions.

1. Install the audio unit service hole covers.

2. Connect the audio unit connectors and antenna jacks.

3. Insert the audio unit until each clip clicks.

4. Connect the negative battery cable.

5. Operate the anti-theft system by setting the code number. (For vehicles equipped with anti-theft system)

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Fig. 38: Installing Audio Unit Service Hole Covers

Courtesy of MAZDA MOTORS CORP.

UPPER MODULE REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the audio unit. (See AUDIO UNIT REMOVAL .)

3. Remove in the order indicated in the table.

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Fig. 39: Removing Upper Module

Courtesy of MAZDA MOTORS CORP.

4. Install in the order of removal.

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UPPER MODULE REMOVAL NOTE

1. Insert a screwdriver into the hole stamped mark.

2. To remove upper module, lift it by pushing down the screwdriver's handle.

Fig. 40: Removing Upper Module

Courtesy of MAZDA MOTORS CORP.

COVER REMOVAL NOTE

1. Insert a tape-wrapped screwdriver between the cover and the base unit, then unhook the hook A.

2. To unhook the hook B, pull the cover upward.

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Fig. 41: Removing Cover

Courtesy of MAZDA MOTORS CORP.

SCREW INSTALLATION NOTE

CAUTION:



If an undesignated screw is used, the inside of the upper module could be damaged. When installing the module, be sure to use a designated screw (red).

LOWER MODULE REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the audio unit. (See AUDIO UNIT REMOVAL .)

3. Remove in the order indicated in the table.

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Fig. 42: Removing Lower Module

Courtesy of MAZDA MOTORS CORP.

4. Install in the order of removal.

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COVER REMOVAL NOTE

1. Insert the SST into the service holes on the bottom surface of the lower module.

2. To remove the cover, push the SST in the direction shown by the arrow.

Fig. 43: Removing Cover

Courtesy of MAZDA MOTORS CORP.

SCREW INSTALLATION NOTE

CAUTION:



If an undesignated screw is used, the inside of the upper module could be damaged. When installing the module, be sure to use a designated screw (red).

STARTING PROCEDURE FOR ON-BOARD DIAGNOSTIC TEST MODE

NOTE:



All DTCs displayed in the on-board diagnostic test mode should be

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata entered in the Audio Exchange Order Form.

1. Turn the ignition switch to the ACC or ON position.

2. First press the POWER button and hold it, then press the SAT button and CLOCK button for 2 seconds or more.

Fig. 44: Identifying Audio Buttons

Courtesy of MAZDA MOTORS CORP.

NOTE:



If several DTCs are in the memory, they can be displayed using the

SEEK button.

3. To stop the on-board diagnostic test mode, turn the ignition switch to the LOCK position.

SUPPLIER IDENTIFICATION PROCEDURE

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NOTE:



When asking the supplier (service center) for repair or replace, verify which supplier the module belongs to and enter in the Audio Exchange

Order Form. Use the table and illustration below to determine the audio supplier.

IDENTIFICATION WITH PRINTED NUMBERS/LABEL BASE UNIT

1. To get the supplier name, compare the leftmost number of the ID code (4 digits), printed on the upper right corner of the LCD, with the table below.

Fig. 45: Identifying Audio ID Number

Courtesy of MAZDA MOTORS CORP.

Upper/lower module

1. Remove the audio unit.

2. Verify the supplier name written in the label attached on each module.

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IDENTIFICATION WITH ON-BOARD DIAGNOSTIC TEST MODE

1. Start the on-board diagnostic test mode.

2. Verify the device code and supplier code displayed in the LCD.

NOTE:



When no DTCs are in the memory, device code and supplier codes will not be displayed.

Fig. 46: Displaying Device Code And Supplier Codes

Courtesy of MAZDA MOTORS CORP.

DEVICE CODE

Device code

Cassette deck (lower module)

CD player (upper module)

CD changer (external type)

CD changer (upper module)

MD player (lower module)

Base unit

Parts name

CD player system MP3 operation

SUPPLIER CODE

Supplier code

FMS Audio

Panasonic

Clarion

Supplier name

DTC CLEARING PROCEDURE

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1. Start the on-board diagnostic test mode.

2. First press the POWER button and hold it, then press AUDIO CONT button for 2 seconds or more.

Fig. 47: Identifying POWER Button & AUDIO CONT Button

Courtesy of MAZDA MOTORS CORP.

CAUTION:



Before clearing the DTCs, be sure to enter all of them displayed in the onboard diagnostic test mode in the Audio Exchange

Order Form.

3. To stop the on-board diagnostic test mode, turn the ignition switch to the LOCK position.

DTC TABLE

DTC TABLE

Screen display

DTC

DTC 09:ER22

DTC 09:ER20

DTC 00:ER10

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Saturday, July 04, 2009 12:12:07 PM

Output signal

Page 46

Malfunction location

Base unit (peripheral circuit)

Power supply circuit of base unit

Cassette deck-base unit

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

DTC 03:ER10

DTC 05:ER10

DTC 06:ER10

DTC 07:ER10 -

communication line

CD player-base unit communication line

CD changer (external type)-base unit communication line

CD changer (upper module)-base unit communication line

MD player-base unit communication line

CD player

DTC 03:ER01

DTC 03:ER02

DTC 03:ER07

DTC 00:ER01

DTC 00:ER03

DTC 00:ER04

DTC 05:ER01

DTC 05:ER07

DTC 06:ER01

DTC 06:ER02

DTC 06:ER07

DTC 07:ER01

DTC 07:ER02

DTC 10:ER01

DTC 10:ER02

CHECK

(1)

(2)

CHECK

(1)

(2)

CHECK

(1)

TAPE

(2)

CHECK

(1)

(2)

CHECK

(1)

(2)

CHECK

(1)

(2)

CHECK

(1)

(2)

CHECK

(1)

(2)

CHECK

(1)

(2)

CD player

Cassette deck

Cassette tape

CD changer (external type)

CD changer (upper module)

MD player

CD player system MP3 operation

CD player system MP3 operation no Err No stored DTCs

(1) When an error occurs, the error messages are displayed three times in the order of *1 and *2, respectively.

(2) When an error occurs, the error messages are displayed three times in the order of *1 and *2, respectively.

DTC 09:ER22

Fig. 48: DTC 09:ER22 - Detection Condition & Possible Cause

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Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 09:ER22 - DIAGNOSTIC PROCEDURE

INSPECTION

INSPECT BASE UNIT



Clear DTC.



Turn on radio and operate it for 3 seconds or more.

Start on-board diagnostic test mode.



Is DTC 09:Er22 displayed?

DTC 09:ER20

ACTION

Yes Replace base unit.

No Troubleshooting completed.

Fig. 49: DTC 09:ER20 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 09:ER20 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

Yes Go to next step.

ACTION

INSPECT BATTERY



Measure battery voltage.

Microsoft

Saturday, July 04, 2009 12:12:07 PM Page 48

No Battery is weak or the system is overcharging.

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata



Inspect charge/discharge system.

Yes Go to next step.



Measure voltage at fuse block terminals I and

AE.



Is voltage 8.5 V-16 V ?

INSPECT WIRING HARNESS BETWEEN

FUSE BLOCK AND BASE UNIT

Repair wiring harness between battery and fuse block.

Yes Go to next step.



Is voltage 8.5 V-16 V ?

INSPECT WIRING HARNESS BETWEEN

BATTERY AND FUSE BLOCK



Measure voltage at base unit connector terminals 1B and 1R.



Is voltage 8.5 V-16 V ?

INSPECT BASE UNIT

Repair wiring harness between fuse block and base unit.



Clear DTC.



Turn ignition switch to ACC or ON position and hold for 30 seconds or more.

Start on-board diagnostic test mode.



Is DTC 09:Er20 displayed?

Yes Replace base unit.

No Troubleshooting completed.

DTC 00:ER10

Fig. 50: DTC 00:ER10 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 00:ER10 - DIAGNOSTIC PROCEDURE

STEP INSPECTION ACTION

INSPECT CONNECTOR

Yes Go to next step.



Remove cassette deck (lower module) and inspect connector for the following.

 Deformation of pin



Poor connection of female terminal

Repair connector, then go to next

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2005 Mazda MX-5 Miata

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

Pinching of foreign material



Is connector okay?

VERIFY THAT CASSETTE DECK (LOWER

MODULE) IS INSTALLED WITH BASE UNIT

Yes Go to next step.

step.



Install cassette deck (lower module) and verify its installation condition.



Is cassette deck securely installed?

INSPECT CASSETTE DECK (LOWER MODULE)

Securely install cassette deck (lower module), then go to next step.



Clean DTC.

Turn ignition switch to ACC or ON position and hold for 3 seconds or more.



Start on-board diagnostic test mode.

 Is DTC 00:Er10 displayed?

Yes

Replace base unit and cassette deck

(lower module).

No Troubleshooting completed.

DTC 03:ER10

Fig. 51: DTC 03:ER10 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 03:ER10 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

INSPECT CONNECTOR

ACTION

Yes Go to next step.



Remove CD player (upper module) and inspect connector for the following.



Deformation of pin



Poor connection of female terminal



Pinching of foreign material



Is connector okay?

Repair connector, then go to next step.

VERIFY THAT CD PLAYER (UPPER MODULE)

IS INSTALLED WITH BASE UNIT

Microsoft

Saturday, July 04, 2009 12:12:07 PM Page 50

Yes Go to next step.

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata



Install CD player (upper module) and verify its installation condition.



Is CD player securely installed?

INSPECT CD PLAYER (UPPER MODULE)

Securely install CD player (upper module), then go to next step.



Clear DTC.

Turn ignition switch to ACC or ON position and hold for 3 seconds or more.

Yes

Replace base unit and CD player

(upper module).



Start on-board diagnostic test mode.

Is DTC 03:Er10 displayed?

No Troubleshooting completed.

DTC 05: ER10

Fig. 52: DTC 05:ER10 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 05:ER10 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

INSPECT CONNECTOR

ACTION

Yes Go to next step.

1 

Inspect base unit and CD changer (external type) connectors for connection. No

Reconnected connector, then go to next step.



Are connectors securely connected?

INSPECT WIRING HARNESS BETWEEN CD

CHANGER (EXTERNAL TYPE) AND BASE UNIT

Yes Go to next step.



Inspect wiring harness between base unit and CD changer (external type).

Is wiring harness okay?

Securely install CD changer

(external type), then go to next step.

INSPECT CD CHANGER (EXTERNAL TYPE)



Clear DTC.

Turn ignition switch to ACC or ON position and hold for 3 seconds or more.

Microsoft

Saturday, July 04, 2009 12:12:07 PM Page 51

Yes

Replace base unit and CD changer

(external type).

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata



Start on-board diagnostic test mode.

Is DTC 05:Er10 displayed?

DTC 06: ER10

No Troubleshooting completed.

Fig. 53: DTC 06:ER10 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 06:ER10 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

INSPECT CONNECTOR

ACTION

Yes Go to next step.



Remove CD changer (upper module) and inspect connector for the following.



Deformation of pin



Poor connection of female terminal No

Repair connector, then go to next step.



Pinching of foreign material

 Is connector okay?

VERIFY THAT CD CHANGER (UPPER

MODULE) IS INSTALLED WITH BASE UNIT

Yes Go to next step.



Install CD changer (upper module) and verify its installation condition.



Is CD changer (upper module) securely installed?

INSPECT CD CHANGER (UPPER MODULE)

Securely install CD changer (upper module), then go to next step.



Clear DTC.

Turn ignition switch to ACC or ON position and hold for 3 seconds or more.

Start on-board diagnostic test mode.

Yes

Replace base unit and CD changer

(upper module).

No Troubleshooting completed.



Is DTC 06:Er10 displayed?

DTC 07: ER10

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Fig. 54: DTC 07:ER10 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 07:ER10 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

INSPECT CONNECTOR

ACTION

Yes Go to next step.



Remove MD player (lower module) and inspect connector for the following.



Deformation of pin



Poor connection of female terminal



Pinching of foreign material



Is connector okay?

VERIFY THAT MD PLAYER (LOWER

MODULE) IS INSTALLED WITH BASE UNIT

Repair connector, then go to next

Yes Go to next step.

step.



Install MD player (lower module) and verify its installation condition.



Is MD player (lower module) securely installed?

INSPECT MD PLAYER (LOWER MODULE)

Securely install MD player (lower module), then go to next step.



Clear DTC.

 Turn ignition switch to ACC or ON position and hold for 3 seconds or more.



Start on-board diagnostic test mode.



Is DTC 07:Er10 displayed?

Yes

Replace base unit and MD player

(lower module).

No Troubleshooting completed.

DTC 03: ER01

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

Fig. 55: DTC 03:ER01 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 03:ER01 - DIAGNOSTIC PROCEDURE

STEP INSPECTION



Is CD able to be ejected?

ACTION

Yes Go to next step.

No Replace CD player (upper module).

INSPECT CD



Inspect condition of CD where error

Yes Go to next step.

has occurred.

2 

Is CD okay?

NOTE:

Repair (remove foreign material) or replace CD, then go to next step.

 In some cases, not all CD-R/CD-

RW will play.

INSPECT CD PLAYER (UPPER

MODULE)

Yes Replace CD player (upper module).



Clear DTC.



Insert and eject CD with no defect.

Start on-board diagnostic test mode.

Is DTC 03:Er01 displayed?

Troubleshooting completed.

DTC 03: ER02

Fig. 56: DTC 03:ER02 - Detection Condition & Possible Cause

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Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 03:ER02 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

VERIFY WHETHER MALFUNCTION IS

IN CD PLAYER (UPPER MODULE) OR

Yes

ACTION

Go to Step 3.

Not able to change particular tracks.

Go to next step.

Change CD and perform tracks-change again.



Play CD and select other song (change

 tracks).

Does CD player change tracks?

Not able to change any tracks.



If CD player change tracks, then go to

Step 3.



If not, replace CD player (upper module).

INSPECT CD

Yes Go to next step.



Inspect condition of CD where error has occurred.

2 

Is CD okay?

NOTE:

Repair (remove foreign material) or replace

CD, then go to next step.

 In some cases, not all CD-R/CD-RW will play.

INSPECT CD PLAYER (UPPER

MODULE)

Yes



Clear DTC.

Play CD and select other song (change tracks).



Start on-board diagnostic test mode.



Is DTC 03:Er02 displayed?

Replace CD player (upper module).

Troubleshooting completed.

DTC 03: ER07

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2005 Mazda MX-5 Miata

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Fig. 57: DTC 03:ER07 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 03:ER07 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

INSPECT CD



Inspect condition of CD where error has occurred.

Yes Go to next step.

1 

Is CD okay?

NOTE:

ACTION

Repair (remove foreign material) or replace CD, then go to next step.

 In some cases, not all CD-R/CD-

RW will play.

INSPECT CD PLAYER (UPPER

MODULE)

Yes Replace CD player (upper module).



Clear DTC.



Insert and play CD with no defect.

Start on-board diagnostic test mode. No



Is DTC 03:Er07 displayed?

Troubleshooting completed.

DTC 00: ER01

Fig. 58: DTC 00:ER01 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

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2005 Mazda MX-5 Miata

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DTC 00:ER01 - DIAGNOSTIC PROCEDURE

STEP INSPECTION



Is cassette tape able to be ejected?

ACTION

Yes Go to next step.

No Replace cassette deck (lower module).

INSPECT CASSETTE TAPE

Yes Go to next step.



Inspect condition of cassette tape where error has occurred. No

Repair (remove foreign material) or replace cassette tape, then go to next step.



Is cassette tape okay?

INSPECT CASSETTE DECK (LOWER

MODULE)

Yes Replace cassette deck (lower module).



Clear DTC.



Insert and eject cassette tape with no defect.

Start on-board diagnostic test mode.



Is DTC 00:Er01 displayed?

Troubleshooting completed.

DTC 00: ER03

Fig. 59: DTC 00:ER03 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 00:ER03 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

INSPECT CASSETTE TAPE

Yes Go to next step.

ACTION

1 



Inspect condition of cassette tape where error has occurred. No

Is cassette tape okay?

INSPECT CASSETTE DECK

(LOWER MODULE)

Repair (remove tape slack or repair pinched tape) or replace cassette tape, then go to next step.

Yes Replace cassette deck (lower module).



Clear DTC.

Insert cassette tape with no

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata



 defect.

Play cassette tape for 20 seconds or more.

Start on-board diagnostic test mode.

 Is DTC 00:Er03 displayed?

DTC 00:ER04

Troubleshooting completed.

Fig. 60: DTC 00:ER04 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 00:ER04 - DIAGNOSTIC PROCEDURE

STEP

INSPECTION

INSPECT CASSETTE TAPE

ACTION

Yes Go to next step.



Inspect condition of cassette tape where error has occurred. No



Is cassette tape okay?

INSPECT CASSETTE DECK (LOWER MODULE)

Replace cassette tape, then go to next step.

Yes

Replace cassette deck (lower module).



Clear DTC.



Insert cassette tape with no defect.



Play cassette tape for 20 seconds or more.

Start on-board diagnostic test mode.



Is DTC 00:Er04 displayed?

No Troubleshooting completed.

DTC 05:ER01

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Fig. 61: DTC 05:ER01 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 05:ER01 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

VERIFY WHETHER MALFUNCTION IS IN

CD CHANGER OR OTHER PARTS



Operate changer function.



Is function okay?

INSPECT CD

Yes Go to Step 4.

ACTION

Not able to change particular CD.

Go to next step.

Not able to change any CD. Go to Step 3.

Yes Go to next step.



Inspect condition of CD where error has occurred.

Is CD okay?

NOTE:

 In some cases, not all CD-R/CD-RW will play.

INSPECT MAGAZINE

Repair (remove foreign material) or replace CD, then go to next step.

Yes Go to next step.



Inspect magazine.



Is magazine okay?

INSPECT CD CHANGER (EXTERNAL TYPE)

Repair or replace magazine, then go to next step.

Yes Replace CD changer (external type).



Clear DTC.



Operate changer function.

Start on-board diagnostic test mode. No Troubleshooting completed.



Is DTC 05:Er01 displayed?

DTC 05:ER07

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

Fig. 62: DTC 05:ER07 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 05:ER07 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

VERIFY WHETHER MALFUNCTION IS IN

CD CHANGER OR OTHER PARTS



Play all CD in magazine.



Is CD changer able to read them properly?

INSPECT CD

Yes Go to Step 3.

ACTION

Not able to change particular CD.

Go to next step.

Not able to change any CD. Go to Step 3.

Yes Go to next step.



Inspect condition of CD where error has occurred.

Is CD okay?

NOTE:

Repair (remove foreign material) or replace CD, then go to next step.

 In some cases, not all CD-R/CD-RW will play.

INSPECT CD CHANGER (EXTERNAL TYPE)

Yes Replace CD changer (external type).



Clear DTC.



Insert and play CD with no defect.

Start on-board diagnostic test mode.



Is DTC 05:Er07 displayed?

No Troubleshooting completed.

DTC 06:ER01

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2005 Mazda MX-5 Miata

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Fig. 63: DTC 06:ER01 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 06:ER01 - DIAGNOSTIC PROCEDURE

STEP INSPECTION



Is CD able to be ejected?

ACTION

Yes Go to next step.

No Replace CD changer (upper module).

INSPECT CD



Inspect condition of CD where error has occurred.

Yes Go to next step.

2 

Is CD okay?

NOTE:

Repair (remove foreign material) or replace CD, then go to next step.

 In some cases, not all CD-R/CD-

RW will play.

INSPECT CD CHANGER (UPPER

MODULE)

Yes Replace CD changer (upper module).



Clear DTC.

Insert and eject CD with no defect.

Start on-board diagnostic test mode. No



Is DTC 06:Er01 displayed?

Troubleshooting completed.

DTC 06:ER02

Fig. 64: DTC 06:ER02 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 06:ER02 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

Microsoft

Saturday, July 04, 2009 12:12:08 PM

ACTION

Yes Go to Step 3.

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

Not able to change particular tracks.

Go to next step.

VERIFY WHETHER MALFUNCTION IS

IN CD CHANGER (UPPER MODULE)

OR CD



Play all CDs in changer and select other

No song (change tracks).



Is CD changer able to change tracks?

Not able to change any tracks.

Change CD and perform tracks-change again.



If CD changer change tracks, then go to

Step 3.

If not, replace CD changer (upper module).

INSPECT CD



Inspect condition of CD where error has

Yes Go to next step.

occurred.



Is CD okay?

NOTE:

Repair (remove foreign material) or replace

CD, then go to next step.

 In some cases, not all CD-R/CD-RW will play.

INSPECT CD CHANGER (UPPER

MODULE)

Yes Replace CD changer (upper module).



Clear DTC.



Play CD and select other song (change tracks).



Start on-board diagnostic test mode.

Is DTC 06:Er02 displayed?

No Troubleshooting completed.

DTC 06:ER07

Fig. 65: DTC 06:ER07 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

DTC 06:ER07 - DIAGNOSTIC PROCEDURE

STEP

INSPECTION ACTION

VERIFY WHETHER MALFUNCTION IS IN CD Yes Go to Step 3.

CHANGER (UPPER MODULE) OR CD

Not able to read particular CD.

 Play all CDs in changer.



Is CD changer able to read them properly?

Go to next step.

Not able to read any CD. Go to Step 3.

INSPECT CD

Yes Go to next step.



Inspect condition of CD where error has occurred.



Is CD okay?

NOTE:

Repair (remove foreign material) or replace CD, then go to next step.

 In some cases, not all CD-R/CD-RW will play.

INSPECT CD CHANGER (UPPER MODULE)

Yes Replace CD changer (upper module).



Clear DTC.



Insert and play CD for 12 seconds or more.

Start on-board diagnostic test mode.



Is DTC 06:Er07 displayed?

No Troubleshooting completed.

DTC 07:ER01

Fig. 66: DTC 07:ER01 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 07:ER01 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

 Is MD able to be ejected?

ACTION

Yes Go to next step.

No Replace MD player (lower module).

Yes Go to next step.

INSPECT MD



Inspect condition of MD where error

Microsoft

Saturday, July 04, 2009 12:12:08 PM

Repair (remove foreign material) or replace MD,

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

3 has occurred.

 Is MD okay?

INSPECT MD PLAYER (LOWER

MODULE)

No then go to next step.

Yes Replace MD player (lower module).



Clear DTC.



Insert and eject MD with no defect.

Start on-board diagnostic test mode. No



Is DTC 07:Er01 displayed?

Troubleshooting completed.

DTC 07:ER02

Fig. 67: DTC 07:ER02 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 07:ER02 - DIAGNOSTIC PROCEDURE

STEP INSPECTION ACTION

VERIFY WHETHER MALFUNCTION IS

IN MD PLAYER (LOWER MODULE) OR

Yes Go to Step 3.

Not able to change

Go to next step.

particular tracks.

Change MD and perform tracks-change again.



Play MD and select other song (change tracks).

No  If MD player change tracks, then go to

Step 3.



Is MD player able to change tracks?

Not able to change any tracks.



If not, replace MD player (lower module).

INSPECT MD

Yes Go to next step.

2  Inspect condition of MD where error has occurred.



Is MD okay?

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Saturday, July 04, 2009 12:12:08 PM

Page 64

Repair (remove foreign material) or replace

MD, then go to next step.

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

INSPECT MD PLAYER (LOWER

MODULE)

Yes Replace MD player (lower module).



Clear DTC.



Play MD and select other song (change tracks).

Start on-board diagnostic test mode.



Is DTC 07:Er02 displayed?

Troubleshooting completed.

DTC 07:ER07

Fig. 68: DTC 07:ER07 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 07:ER07 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

INSPECT MD

Yes Go to next step.

ACTION



Inspect condition of MD where error has occurred. No



Is MD okay?

INSPECT MD PLAYER (LOWER

MODULE)

Repair (remove foreign material) or replace MD, then go to next step.

Yes Replace MD player (lower module).



Clear DTC.

Insert and play MD for 12 seconds or more.

Start on-board diagnostic test mode.

Is DTC 07:Er07 displayed?

Troubleshooting completed.

DTC 10:ER01

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2005 Mazda MX-5 Miata

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Fig. 69: DTC 10:ER01 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DIAGNOSTIC PROCEDURE

DTC 10:ER01 - DIAGNOSTIC PROCEDURE

STEP INSPECTION

ACTION

Verify the condition of the CD when Yes Go to the next step.

the error occurs.

Is the CD normal?

Repair (remove foreign material, clean) or replace the

CD, and go to the next step.

Clear the DTC and insert a normal

CD.

Play the CD.

Is DTC 10:Er01 displayed?

Yes Replace the CD player system MP3 operation.

No DTC troubleshooting completed.

DTC 10:ER02

Fig. 70: DTC 10:ER02 - Detection Condition & Possible Cause

Courtesy of MAZDA MOTORS CORP.

DTC 10:ER02 - INSPECTION & ACTION

STEP INSPECTION

Yes Go to Step 3.

ACTION

Cannot change to

Go to the next step.

specific tracks.

Play the CD and change tracks.

Can tracks be changed?

Cannot change to any track.

Replace the CD and try to change tracks

 again.

If the function is normal, go to Step 3.



If the function is not normal, replace

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

Verify the condition of the

CD when the error occurs.

Is the CD normal?

Clear the DTC.

Play the CD and change tracks.

Is DTC 10:Er02 displayed?

the CD player system MP3 operation.

Yes Go to the next step.

Repair (remove foreign material, clean) or replace the CD, and go to the next step.

Yes Replace the CD player system MP3 operation.

No DTC troubleshooting completed.

DIAGNOSTIC ASSIST FUNCTION

STRUCTURAL VIEW

Switch location

Fig. 71: Identifying Switch Location

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

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LCD INSPECTION

1. With audio on, first press the POWER button and hold it, then press the SEEK button (upper) for approximately 1 second.

2. Inspect the LCD according to the following table:

Fig. 72: LCD Inspection Chart

Courtesy of MAZDA MOTORS CORP.

3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function.

BUTTON INSPECTION

1. With audio on, first press the POWER button and hold it, then press the CLOCK button for approximately 1 second.

2. Inspect the button according to the following table:

NOTE:



The button inspection mode is designed for base unit button. The following lower module button cannot be inspected in this mode. (A buzz will not sound.)



Cassette deck: DOLBY button, EJECT button

MD player: DISP button, EJECT button

BUTTON INSPECTION

Inspection



Start button inspection mode.

Press the all buttons.

Display

Buzzer sound.

Action

Button is okay.

Buzzer dose not sound. Replace base unit.

3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function.

SPEAKER INSPECTION

1. With audio on, first press the POWER button and hold it, then press the AUTO-M button for approximately 1 second.

2. Inspect the speaker according to the following table:

SPEAKER INSPECTION

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2005 Mazda MX-5 Miata

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Inspection



Start speaker inspection mode.

 Does each speaker output sound in the following order?

1. Left front door speaker and tweeter

2. Right front door speaker and tweeter

Display Action

Yes

Speakers and wiring harness between base unit and speakers are okay.

Inspect the following parts.



Malfunctioning speaker

Wiring harness between base unit and malfunctioning speaker

3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function.

RADIO RECEPTION CONDITION INSPECTION

1. With audio on and at radio mode, first press the POWER button and hold it, then press the preset button

"2" for approximately 1 second.

2. Inspect the radio reception condition according to the following table:

Fig. 73: Radio Reception Condition Inspection Chart

Courtesy of MAZDA MOTORS CORP.

3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function.

POWER ANTENNA INSPECTION

1. With audio on and at radio mode, first press the POWER button and hold it, then press the SAT button for approximately 1 second.

2. Inspect the power antenna according to the following table:

POWER ANTENNA INSPECTION

Inspection

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Saturday, July 04, 2009 12:12:08 PM

Display

NORMAL

Page 69

Action

Speakers

System is okay.

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

Start power antenna inspection mode.

Ant - On

POWER ANTENNA OPERATING output sound.

Speakers do

SIGNAL IS OUTPUT not output sound.

MALFUNCTIONING

AMP - OF

AUDIO AMPLIFIER

OPERATING SIGNAL IS NOT

OUTPUT

Replace base unit.

Inspect power antenna and wiring harness between base unit and power antenna.

3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function.

AUDIO AMPLIFIER (EXTERNAL) INSPECTION

1. With audio on, first press the POWER button and hold it, then press the SCAN button for approximately

1 second.

2. Inspect the audio amplifier (external) according to the following table:

AUDIO AMPLIFIER INSPECTION

Start audio amplifier

(external) inspection mode.

Inspection Display Action

Speakers output sound.

System is okay.

Inspect following parts.

NORMAL

AMP - On

AUDIO AMPLIFIER

OPERATING SIGNAL IS

OUTPUT

Speakers do not output sound.

MALFUNCTIONING

AMP - OF

AUDIO AMPLIFIER

OPERATING SIGNAL IS NOT

OUTPUT

Replace base unit.



 audio amplifier

(external)

Speakers



Wiring harness (Base unit - audio amplifier

(external))

3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function.

AUDIO AMPLIFIER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the dashboard. (See DASHBOARD REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

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Fig. 74: Removing Audio Amplifier

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

AEROBOARD SPEAKER AMPLIFIER REMOVAL/INSTALLATION

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

1. Disconnect the negative battery cable.

2. Remove the aeroboard. (See AEROBOARD REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

Fig. 75: Removing Aeroboard Speaker Amplifier

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

AUDIO RELAY REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the center lower panel. (See CENTER PANEL REMOVAL/INSTALLATION .)

3. Disconnect the audio relay connector.

4. Remove the audio relay.

5. Install in the reverse order of removal.

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Fig. 76: Removing Audio Relay

Courtesy of MAZDA MOTORS CORP.

CIGARETTE LIGHTER REMOVAL/INSTALLATION

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Entertainment - MX-5 Miata

1. Disconnect the negative battery cable.

2. Remove the center panel. (See CENTER PANEL REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

Fig. 77: Removing Cigarette Lighter

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

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SOCKET REMOVAL NOTE

1. Pry up the stopper with the tape-wrapped flathead screwdriver.

2. Pull the socket while prying up the stopper.

Fig. 78: Removing Socket

Courtesy of MAZDA MOTORS CORP.

CIGARETTE LIGHTER INSPECTION

NOTE:



Verify that the cigarette lighter plug will move normally within 20-30 seconds , after pressing the plug into the socket.



If the fuse does not move, perform the following procedures.

1. Remove the socket. (See CIGARETTE LIGHTER REMOVAL/INSTALLATION .)

2. Verify the bimetals in the socket are not warped.

3. Inspect if the backs of the bimetals can be seen from the inside or outside.



If the back of the bimetal can be seen from the inside, replace the socket.



If the fuse has been burnt, replace the socket.

If the bimetal and the socket are normal, replace the cigarette lighter plug.

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Fig. 79: Inspecting Cigarette Lighter

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 ENGINE Exhaust System - MX-5 Miata

2005 ENGINE

Exhaust System - MX-5 Miata

EXHAUST SYSTEM INSPECTION [BP, BP WITH TC]

1. Start the engine and inspect each exhaust system component for exhaust gas leakage.



If leakage is found, repair or replace if necessary.

EXHAUST SYSTEM REMOVAL/INSTALLATION [BP]

WARNING:



Hot engines and the exhaust system can cause severe burns. Turn off the engine and wait until it and the exhaust system are cool before removing or installing the exhaust system.

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

2005 Mazda MX-5 Miata

2005 ENGINE Exhaust System - MX-5 Miata

Fig. 1: Identifying Components Of Exhaust System & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

EXHAUST MANIFOLD INSULATOR REMOVAL NOTE

1. Remove the windshield washer tank with the washer tank connector connected before removing the exhaust manifold insulator. (See WINDSHIELD WASHER TANK REMOVAL/INSTALLATION .)

EXHAUST MANIFOLD GASKET INSTALLATION NOTE

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2005 Mazda MX-5 Miata

2005 ENGINE Exhaust System - MX-5 Miata

1. To install the exhaust manifold gasket, make sure that the convex side of the gasket is facing the exhaust manifold side.

Fig. 2: Identifying Exhaust Manifold Side

Courtesy of MAZDA MOTORS CORP.

EXHAUST SYSTEM REMOVAL/INSTALLATION [BP WITH TC]

WARNING:



A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until all components they are cool before removing the exhaust system.

1. Disconnect the negative battery cable.

2. Remove the under cover.

3. Remove the air pipe No.2 and the air hose No.4. (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION [BP WITH TC] .)

4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

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STEP 1

2005 Mazda MX-5 Miata

2005 ENGINE Exhaust System - MX-5 Miata

Fig. 3: Identifying Components Of Exhaust System & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

STEP2

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2005 Mazda MX-5 Miata

2005 ENGINE Exhaust System - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 ENGINE Exhaust System - MX-5 Miata

Fig. 4: Identifying Components Of Exhaust System & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

HO2S (REAR) REMOVAL NOTE

1. Disconnect the HO2S (rear) connector.

2. Install the SST .

3. Remove the HO2S (rear)

Fig. 5: Disconnecting HO2S (Rear) Connector

Courtesy of MAZDA MOTORS CORP.

HO2S (FRONT) REMOVAL NOTE

1. Remove the dipstick and pipe. (See OIL PAN REMOVAL/INSTALLATION [BP WITH TC] .)

2. Disconnect the HO2S (front) connector.

3. Install the SST .

4. Remove the HO2S (front).

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2005 Mazda MX-5 Miata

2005 ENGINE Exhaust System - MX-5 Miata

Fig. 6: Disconnecting HO2S (Front) Connector

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

2005 ACCESSORIES & EQUIPMENT

Exterior Trim - MX-5 Miata

COWL GRILLE REMOVAL/INSTALLATION

1. Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE

REMOVAL/INSTALLATION .)

2. Remove in the order indicated in the table.

Fig. 1: Removing Cowl Grille

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

BELTLINE MOLDING REMOVAL/INSTALLATION

1. Remove the rear package trim.

2. Remove the set plate.

3. Remove the bolts.

4. Remove the beltline molding.

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 2: Removing Beltline Molding

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

FRONT BELTLINE MOLDING REMOVAL/INSTALLATION

1. Remove the screws.

2. Pull front beltline molding upward to disengage the clips from the body and remove it.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 3: Removing Front Beltline Molding

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

REAR WINDOW MOLDING REMOVAL

DETACHABLE HARDTOP

1. Pull the rear window molding to remove it.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 4: Removing Rear Window Molding

Courtesy of MAZDA MOTORS CORP.

REAR WINDOW MOLDING INSTALLATION

DETACHABLE HARDTOP

1. Apply protective tape along the edge of the body to protect it from damage.

2. Cut the sealant using a razor as shown.

WARNING:



Using a razor with bare hands can cause injury. Always wear gloves when using a razor.

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 5: Cutting Sealant Using Razor

Courtesy of MAZDA MOTORS CORP.

3. Insert the blade of the SST (Sealant Remover) into the sealant, and pull on the bar to cut the sealant near the body as shown.

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2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 6: Cutting Sealant Near Body

Courtesy of MAZDA MOTORS CORP.

4. Insert the blade of the SST (Sealant Remover) into the sealant, and pull on the bar to cut the sealant near the glass as shown.

5. Remove as much sealant as possible from between the body and the glass.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 7: Cutting Sealant Near Glass (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

6. Carefully clean around the edge of the glass and the adhesion surface of the body.

CAUTION:



Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body which may cause leaks to occur.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 8: Cutting Sealant Near Glass (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

7. Apply primer onto the bonding area of the new rear window molding using a brush. Allow the primer to dry for approximately 30 minutes .

8. Apply a 3.0 mm {0.12 in} bead of sealant between the glass and the body.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 9: Applying Primer Onto Bonding Area Of New Rear Window Molding

Courtesy of MAZDA MOTORS CORP.

9. Reshape the sealant as shown if necessary.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 10: Reshaping Sealant

Courtesy of MAZDA MOTORS CORP.

10. Install the rear window molding with the molding joint at the top.



If the molding is too long, cut the excess molding 10 mm {0.39 in} inside the molding joint edge.

Hardening time of sealant

SEALANT HARDENING TIME

Temperature Surface hardening time Time required until vehicle can be put into service

5°C {41°F}

20°C {68°F}

35°C {95°F}

Approx.1.5 h

Approx.1 h

Approx.10 min

Approx.12 h

Approx.4 h

Approx.2 h

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 11: Installing Rear Window Molding With Molding Joint At Top

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 12: Identifying Joint Molding Edge Specification

Courtesy of MAZDA MOTORS CORP.

11. Check for water leaks.



If a leak is found, wipe the water off well and repeat the installation.

WINDSHIELD MOLDING REMOVAL

1. Remove the windshield molding from the windshield.

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Fig. 13: Removing Windshield Molding From Windshield

Courtesy of MAZDA MOTORS CORP.

WINDSHIELD MOLDING INSTALLATION

1. Apply protective tape along the edge of the body to protect it from damage.

2. Cut the sealant using a razor as shown.

WARNING:



Using a razor with bare hands can cause injury. Always wear gloves when using a razor.

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 14: Cutting Sealant Using Razor

Courtesy of MAZDA MOTORS CORP.

3. Insert the blade of the SST (Sealant Remover) into the sealant, and pull on the bar to cut the sealant near the body as shown.

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Fig. 15: Cutting Sealant Near Body

Courtesy of MAZDA MOTORS CORP.

4. Insert the blade of the SST (Sealant Remover) into the sealant, and pull on the bar to cut the sealant near the glass as shown.

5. Remove as much sealant as possible from between the body and the glass.

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2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 16: Cutting Sealant Near Glass

Courtesy of MAZDA MOTORS CORP.

6. Carefully clean around the edge of the glass and the adhesion surface of the body.

7. Align the edge of the protector to the spot mark.

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Fig. 17: Cleaning Around Edge Of Glass

Courtesy of MAZDA MOTORS CORP.

8. Securely bond the protector to the body as shown.

CAUTION:



Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body which may cause leaks to occur.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 18: Bonding Protector To Body

Courtesy of MAZDA MOTORS CORP.

9. Apply primer onto the bonding area of the glass, body, and new windshield molding using a brush. Use only glass primer on the glass and body primer on the body and molding. Allow the primer to dry for approximately 30 minutes .

10. Apply a 3.0 mm {0.12 in} bead of sealant between the glass and the body.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 19: Apply Primer Onto Bonding Area Of Glass

Courtesy of MAZDA MOTORS CORP.

11. Reshape the sealant as shown if necessary.

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Fig. 20: Reshaping Sealant

Courtesy of MAZDA MOTORS CORP.

12. Install the windshield molding before the sealant has hardened.

13. Align the center mark in the molding with the glass mark (A).

14. Install the upper portions of the molding into the body (B).

15. Push the corners of the molding onto the body (C).

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Fig. 21: Installing Windshield Molding

Courtesy of MAZDA MOTORS CORP.

16. Push the sides of the molding onto the body, beginning from the bottom (D).

SEALANT HARDENING TIME

Temperature Surface hardening time Time required until vehicle can be put into service

5°C {41°F}

20°C {68°F}

35°C {95°F}

Approx.1.5 h

Approx.1 h

Approx.10 min

Approx.12 h

Approx.4 h

Approx.2 h

17. Check for water leaks.



If a leak is found, wipe the water off well and repeat the installation.

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Fig. 22: Identifying Molding

Courtesy of MAZDA MOTORS CORP.

CONVERTIBLE TOP REMOVAL/INSTALLATION

1. Cover both sides of the rear window glass with thick cloth to protect the window.

2. Remove the scuff plate.

3. Remove the quarter trim.

4. Remove the rear package trim.

5. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 23: Removing Convertible Top - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

CONVERTIBLE TOP REMOVAL NOTE

1. Unlock the top lock.

2. Lower the convertible top fully.

CONVERTIBLE TOP INSTALLATION NOTE

1. Insert the rain rail into the beltline molding lip, and install it over the studs.

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2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 24: Inserting Rain Rail Into Beltline Molding Lip

Courtesy of MAZDA MOTORS CORP.

2. Align and install the link bracket over the studs with no clearance between the studs and the bracket.

3. Tighten the installation bolts.

Tightening torque

19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}

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2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 25: Installing Link Bracket Over Studs

Courtesy of MAZDA MOTORS CORP.

CONVERTIBLE TOP DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

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Fig. 26: Disassembling Convertible Top - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

RETAINER DISASSEMBLY NOTE

1. Set the convertible top upside down on a workbench covered with clean, thick cloth.

2. Mark around the retainer installation screws with paint before removing them.

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Fig. 27: Disassembling Retainer

Courtesy of MAZDA MOTORS CORP.

END PLATE DISASSEMBLY NOTE

1. Remove the rivets from the link using a drill.

Drill size

4.0 mm diameter {0.16 in diameter}

2. Remove the screws and remove the end plates from the link.

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Fig. 28: Disassembling End Plate

Courtesy of MAZDA MOTORS CORP.

TOP FABRIC DISASSEMBLY NOTE

1. Fold the convertible top.

2. Remove the top fabric from the link.

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2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 29: Removing Top Fabric From Link

Courtesy of MAZDA MOTORS CORP.

CABLE DISASSEMBLY NOTE

1. Peel back the top fabric from the front header.

2. Remove the screws and disconnect the cables from the rear of the link.

3. Unfold the convertible top and set it upright.

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Fig. 30: Disconnecting Cables From Rear Of Link

Courtesy of MAZDA MOTORS CORP.

4. Remove the rivets from the link using a drill.

Drill size

4.0 mm diameter {0.16 in diameter}

5. Pry back the bow retainers using a tape-wrapped flathead screwdriver.

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Fig. 31: Removing Rivets From Link

Courtesy of MAZDA MOTORS CORP.

6. Remove the top fabric from the bow retainer.

Fig. 32: Removing Top Fabric From Bow Retainer

Courtesy of MAZDA MOTORS CORP.

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7. Remove the cables from the cable guide.

8. Remove the top fabric and cables from the link.

Fig. 33: Removing Top Fabric And Cables From Link

Courtesy of MAZDA MOTORS CORP.

9. Remove the cables from the top fabric.

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2005 Mazda MX-5 Miata

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Fig. 34: Removing Cables From Top Fabric

Courtesy of MAZDA MOTORS CORP.

CABLE ASSEMBLY NOTE

1. Thread the cable into the top fabric.

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Fig. 35: Threading Cable Into Top Fabric

Courtesy of MAZDA MOTORS CORP.

TOP FABRIC ASSEMBLY NOTE

1. Cover the workbench with thick cloth to prevent damaging the top fabric and rear window.

2. Place the link onto the top fabric.

3. Install the top fabric to the front bow.

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Fig. 36: Installing Top Fabric To Front Bow

Courtesy of MAZDA MOTORS CORP.

4. Roll the top fabric over the bow retainer.

5. Hang the end of the top fabric on the bow retainer.

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2005 Mazda MX-5 Miata

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Fig. 37: Assembling Top Fabric To Bow Retainer

Courtesy of MAZDA MOTORS CORP.

6. Clamp the top fabric to the bow using water pump pliers which have been wrapped in tape. Pull the top fabric by hand to verify that it is held securely.

7. Set the convertible top upright.

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Fig. 38: Clamping Top Fabric To Bow

Courtesy of MAZDA MOTORS CORP.

8. Rivet the cables to the front of the link.

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Fig. 39: Riveting Cables To Front Of Link

Courtesy of MAZDA MOTORS CORP.

SET PLATE ASSEMBLY NOTE

1. Turn the convertible top over and fold it.

2. Install the front of the top fabric to the front header.

3. Align the set plate and top fabric with the set plate installation holes.

4. Install the set plate to the link.

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Fig. 40: Installing Set Plate To Link

Courtesy of MAZDA MOTORS CORP.

END PLATE ASSEMBLY NOTE

1. Unfold the convertible top half-way.

2. Pass the cables through the cable guides.

3. Install the cables to the rear of the link.

4. Fold the convertible top.

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Fig. 41: Installing Cables To Rear Of Link

Courtesy of MAZDA MOTORS CORP.

5. Install the top fabric to the link.

6. Unfold the convertible top.

7. Install the end plates to the link.

Fig. 42: Installing Top Fabric To Link

Courtesy of MAZDA MOTORS CORP.

8. Rivet the top fabric to the link.

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2005 Mazda MX-5 Miata

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Fig. 43: Riveting Top Fabric To Link

Courtesy of MAZDA MOTORS CORP.

RETAINER ASSEMBLY NOTE

1. Install the retainers to the link, aligning the retainer marks with the retainer installation screws.

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Fig. 44: Installing Retainers To Link

Courtesy of MAZDA MOTORS CORP.

CONVERTIBLE TOP ADJUSTMENT

1. Lift the protector away from the top lock adjusting nut.

2. Turn the adjusting nut clockwise to decrease clearance A and height B; turn the nut counterclockwise to increase them.

Clearance

A: 3-7 mm {0.12-0.27 in}

B: -2-2 mm {-0.07-0.07 in}

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Fig. 45: Adjusting Convertible Top

Courtesy of MAZDA MOTORS CORP.

3. Secure the adjusting nut with the protector.

RETAINER ADJUSTMENT

1. Remove the weatherstrip.

2. Loosen the retainer installation screws and adjust the retainer as necessary.

3. Tighten the screws and reinstall the weatherstrip.

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Fig. 46: Adjusting Retainer

Courtesy of MAZDA MOTORS CORP.

TOP FABRIC REMOVAL/INSTALLATION

1. Cover over the rear deck area using a protective rag.

2. Remove the rear package trim.

3. Remove in the order indicated in the table.

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Fig. 47: Removing Top Fabric - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

WEATHERSTRIP REMOVAL NOTE

Vertical section

1. Lower the convertible top fully.

2. Remove the fastener as shown in Fig. 48 using a fastener remover.

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Fig. 48: Removing Fastener

Courtesy of MAZDA MOTORS CORP.

RETAINER REMOVAL NOTE

1. Mark around the retainer installation screws with paint before removing them.

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2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 49: Marking Around Retainer Installation Screws

Courtesy of MAZDA MOTORS CORP.

TOP FABRIC REMOVAL NOTE

1. Remove the rivets from the link with a drill.

Drill size

4.0 mm diameter{0.16 in diameter}

2. Peel the top fabric end.

3. Remove the rivets from the link using a drill.

Drill size

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

4.0 mm diameter{0.16 in diameter}

Fig. 50: Removing Rivets From Link Using Drill

Courtesy of MAZDA MOTORS CORP.

4. Lower the convertible top to release the cable spring tension, and unhook the spring.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 51: Removing Rivets From Link Using Drill

Courtesy of MAZDA MOTORS CORP.

5. Remove the cable from the top fabric.

6. Pry back the front bow retainer using a tape-wrapped flathead screwdriver.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 52: Identifying Cable Spring And Screw

Courtesy of MAZDA MOTORS CORP.

7. Remove the top fabric from the bow retainer.

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 53: Removing Top Fabric From Bow Retainer

Courtesy of MAZDA MOTORS CORP.

RAIN RAIL REMOVAL NOTE

1. Remove the rivets from the top fabric using a drill.

Drill size

4.0 mm diameter {0.16 in diameter}

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 54: Removing Rivets From Top Fabric Using Drill

Courtesy of MAZDA MOTORS CORP.

RAIN RAIL INSTALLATION NOTE

If the rivets will not be used

1. Degrease the rain rail using white gasoline.

2. Install the insulation tape to the rivet installation holes of the rain rail.

Insulation tape

Width:20 mm {0.79 in}

Height:15 mm {0.59 in}

Thickness:3 mm {0.12 in}

Fig. 55: Installing Insulation Tape To Rivet Installation Holes Of Rain Rail

Courtesy of MAZDA MOTORS CORP.

If the rivets will be used

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

1. Rivet the rain rail to the top fabric.

Fig. 56: Riveting Rain Rail To Top Fabric

Courtesy of MAZDA MOTORS CORP.

2. Flatten the stem using a hammer.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 57: Flattening Stem Using Hammer

Courtesy of MAZDA MOTORS CORP.

TOP FABRIC INSTALLATION NOTE

1. Place the top fabric onto the link.

2. Install the top fabric from the rear bow to the front bow.

3. Roll the top fabric over the bow retainer.

4. Hang the end of the top fabric on the bow retainer.

5. Clamp the top fabric to the bow using water pump pliers which have been wrapped in tape.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 58: Clamping Top Fabric To Bow

Courtesy of MAZDA MOTORS CORP.

6. Pull the top fabric by hand to verify that it is held securely.

7. Insert a metal rod into the fabric as shown, tie the cable around the rod, and pull the cable through the fabric.

8. Raise the convertible top as shown in the figure.

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Fig. 59: Inserting A Metal Rod Into Fabric

Courtesy of MAZDA MOTORS CORP.

9. Install the screw.

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2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 60: Installing Screw

Courtesy of MAZDA MOTORS CORP.

10. Rivet the top fabric upper side to the link.

11. Peel the top fabric end.

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Fig. 61: Riveting Top Fabric Upper Side To Link

Courtesy of MAZDA MOTORS CORP.

12. Rivet the top fabric lower side to the link.

NOTE:



If the lower side rivet is difficult to install to the link, install the top fabric using a Tinnerman clip and a screw.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 62: Riveting Top Fabric Lower Side To Link

Courtesy of MAZDA MOTORS CORP.

TOP FABRIC REPAIR

HOLES

1. Place the repair sheet (NC10 R1 211) over the damaged section. Cut both the top fabric and the repair sheet using a razor and a straightedge.

2. Cut another piece of repair sheet larger than the first for use as a back repair sheet.

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Fig. 63: Placing Repair Sheet Over Damaged Section

Courtesy of MAZDA MOTORS CORP.

3. Trim the top fabric and the repair sheets using scissors.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 64: Identifying Repair Sheets

Courtesy of MAZDA MOTORS CORP.

4. Degrease the repair sheets using ethyl alcohol.

5. Apply a generous amount of adhesive agent (K180 W0 313) or equivalent to the section being repaired, the repair sheet, and the back repair sheet. Let stand for a few minutes.

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Fig. 65: Degreasing Repair Sheets Using Ethyl Alcohol

Courtesy of MAZDA MOTORS CORP.

6. Insert the repair sheet squarely into the section of the top fabric being repaired. Then install the back repair sheet from the underside of the top.

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2005 Mazda MX-5 Miata

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Fig. 66: Inserting Repair Sheet Squarely Into Section Of Top Fabric Being Repaired

Courtesy of MAZDA MOTORS CORP.

7. Press the repair sheets firmly together.

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2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 67: Pressing Repair Sheets Together

Courtesy of MAZDA MOTORS CORP.

8. Let the top fabric stand until the adhesive agent is fully dry.

TEARS

1. Cut a piece of repair sheet (NC10 R1 211) larger than the damaged section for use as a back repair sheet.

2. Degrease the repair sheet using ethyl alcohol.

3. Apply a generous amount of adhesive agent (K180 W0 313) or equivalent to the section being repaired and the back repair sheet. Let stand for a few minutes.

4. Install the back repair sheet from the underside of the top.

5. Press the repair sections firmly together.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 68: Degreasing Repair Sheet Using Ethyl Alcohol

Courtesy of MAZDA MOTORS CORP.

6. Let the top fabric stand until the adhesive agent is fully dry.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 69: Identifying Back Repair Sheet

Courtesy of MAZDA MOTORS CORP.

DETACHABLE HARDTOP DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

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Fig. 70: Disassembling Detachable Hardtop

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

DETACHABLE HARDTOP ADJUSTMENT

TOP LOCK

1. Lift the protector away from the top lock adjusting nut.

2. Turn the adjusting nut clockwise to decrease clearance A and height B; turn the nut counterclockwise to increase them.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Clearance

A:3-7 mm {0.12-0.27 in}

B:-2-2 mm {-0.07-0.07 in}

3. Secure the adjusting nut with the protector.

Fig. 71: Adjusting Detachable Hardtop

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

SIDE LOCK

1. Lift the protector away from the side lock adjusting nut.

2. Turn the adjusting nut clockwise to tighten the striker and side lock engagement; turn the nut counterclockwise to loosen the engagement.

3. Secure the adjusting nut using the protector.

Fig. 72: Adjusting Side Lock

Courtesy of MAZDA MOTORS CORP.

REAR DECK LOCK

1. Remove the screw and open the lock cover.

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Fig. 73: Opening Lock Cover

Courtesy of MAZDA MOTORS CORP.

2. Loosen the plate installation bolts.

3. Install the detachable hardtop to the body.

4. Move the plate right, left, fore, or aft until it is tight.

5. Tighten the plate installation bolts.

Tightening torque

18-26 N.m {1.8-2.7 kgf.m, 14-19 ft.lbf}

6. Close the lock cover and install the screw.

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Fig. 74: Tightening Plate

Courtesy of MAZDA MOTORS CORP.

FRONT AIRDAM SKIRT REMOVAL (BP WITH TC)

1. Remove the screws and fasteners.

2. Remove the front airdam skirt while cutting away the double-sided adhesive tape using a flathead

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata screwdriver or cutter.

WARNING:



Using a cutter with bare hands can cause injury. Always wear gloves when using a cutter.

Fig. 75: Removing Front Airdam Skirt (BP With TC)

Courtesy of MAZDA MOTORS CORP.

FRONT AIRDAM SKIRT INSTALLATION (BP WITH TC)

WARNING:



Using a cutter with bare hands can cause injury. Always wear gloves when using a cutter.

NOTE:



If installing a new front airdam skirt, double-sided adhesive tape is already affixed to the skirt.

1. If installing a new front airdam skirt, perform the following procedure:

1. Using a cutter, remove any remaining double-sided tape from the front bumper.

2. Remove any grease or dirt from the front bumper affixing surface.

2. If reusing the front airdam skirt, perform the following procedure:

1. Using a cutter, remove any remaining double-sided tape from the front airdam skirt and body.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

2. Remove any grease or dirt from the front airdam skirt and front bumper affixing surfaces.

3. Affix double-sided adhesive tape to the front airdam skirt as shown in the figure.

3. Peel back the tape backing approx.3 cm from each end and fold towards the exposed surface of the front airdam skirt.

4. Install the front airdam skirt to the body.

Fig. 76: Affixing Double-Sided Adhesive Tape To Front Airdam Skirt

Courtesy of MAZDA MOTORS CORP.

5. Install fasteners A.

6. Install fasteners B and temporarily tighten the screws.

7. Completely remove the tape backing and press to adhere.

8. Tighten the screws.

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Fig. 77: Installing Front Airdam Skirt (BP With TC)

Courtesy of MAZDA MOTORS CORP.

REAR AIRDAM SKIRT REMOVAL (BP WITH TC)

1. Remove the fasteners, screws, and bolts.

2. Remove the rear airdam skirt while cutting away the double-sided adhesive tape using a flathead screwdriver or cutter.

WARNING:



Using a cutter with bare hands can cause injury. Always wear gloves when using a cutter.

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 78: Removing Rear Airdam Skirt (BP With TC)

Courtesy of MAZDA MOTORS CORP.

REAR AIRDAM SKIRT INSTALLATION (BP WITH TC)

WARNING:



Using a cutter with bare hands can cause injury. Always wear gloves when using a cutter.

NOTE:



If installing a new rear airdam skirt, double-sided adhesive tape is already affixed to the skirt.

1. If installing a new rear airdam skirt, perform the following procedure:

1. Using a cutter, remove any remaining double-sided tape from the rear bumper.

2. Remove any grease or dirt from the rear bumper affixing surface.

2. If reusing the rear airdam skirt, perform the following procedure:

1. Using a cutter, remove any remaining double-sided tape from the rear airdam skirt and rear bumper.

2. Remove any grease or dirt from the rear airdam skirt and rear bumper affixing surfaces.

3. Affix double-sided adhesive tape to the rear airdam skirt as shown in the figure.

3. Peel back the tape backing approx.3 cm from each end and fold towards the exposed surface of the rear airdam skirt.

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Fig. 79: Affixing Double-Sided Adhesive Tape To Rear Airdam Skirt

Courtesy of MAZDA MOTORS CORP.

4. Install the fasteners.

5. Install the rear airdam skirt to the rear bumper and temporarily install the screws.

6. Completely remove the tape backing and press to adhere.

7. Tighten the bolts.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 80: Installing Rear Airdam Skirt (BP With TC) - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

REAR SPOILER REMOVAL (BP WITH TC)

1. Remove the bolts and nut.

2. Remove the rear spoiler while cutting away the double-sided adhesive tape using a flathead screwdriver or cutter.

WARNING:



Using a cutter with bare hands can cause injury. Always wear gloves when using a cutter.

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Exterior Trim - MX-5 Miata

Fig. 81: Removing Rear Spoiler (BP With TC)

Courtesy of MAZDA MOTORS CORP.

REAR SPOILER INSTALLATION (BP WITH TC)

WARNING:



Using a cutter with bare hands can cause injury. Always wear gloves when using a cutter.

NOTE:



If installing a new rear spoiler, double-sided adhesive tape is already affixed to the spoiler.

1. If installing a new rear spoiler, perform the following procedure:

1. Using a cutter, remove any remaining double-sided tape from the trunk lid.

2. Remove any grease or dirt from the trunk lid affixing surface.

2. If reusing the rear spoiler, perform the following procedure:

1. Using a cutter, remove any remaining double-sided tape from the rear spoiler and trunk lid.

2. Remove any grease or dirt from the rear spoiler and trunk lid affixing surfaces.

3. Affix double-sided adhesive tape to the rear spoiler as shown in the figure.

3. Peel back the tape backing approx.3 cm from each end and fold towards the exposed surface of the rear spoiler.

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Fig. 82: Affixing Double-Sided Adhesive Tape To Rear Spoiler

Courtesy of MAZDA MOTORS CORP.

4. Install the rear spoiler to the trunk lid.

5. Completely remove the tape backing and press to adhere.

6. Tighten the bolts and nut.

Fig. 83: Installing Rear Spoiler (BP With TC)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

2005 DRIVELINE/AXLE

Front Axle - MX-5 Miata

FRONT AXLE LOCATION INDEX

Fig. 1: Identifying Front Axle

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB, STEERING KNUCKLE PRE-INSPECTION

WHEEL BEARING PLAY

1. Remove the brake caliper component and disc plate.

2. Position a dial indicator against the wheel hub.

3. Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play.

2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

4. If the bearing play exceeds the specification, inspect and tighten the locknut to the specified torque and retest.



Replace the wheel bearing as necessary.

Maximum wheel bearing play

0.05 mm {0.002 in}

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

Fig. 2: Measuring Wheel Bearing Play

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

WHEEL HUB BOLT REPLACEMENT

1. Remove the hub bolt using the SST.

2. Install the hub bolt into the wheel hub and install a washer and hub nut on the hub bolt using a brass bar.

Fig. 3: Installing Hub Bolt Into Wheel Hub

Courtesy of MAZDA MOTORS CORP.

3. Tighten the hub nut while holding the wheel hub using a brass bar.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

Fig. 4: Tightening Hub Nut While Holding Wheel Hub

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION

CAUTION:



1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

3. After installation, adjust the total toe-in. (See TOTAL TOE-IN ADJUSTMENT .)

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

Fig. 5: Adjusting Total Toe-In & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

ABS SENSOR ROTOR REMOVAL NOTE

1. Remove the sensor rotor using a chisel.

NOTE:



The sensor rotor does not need to be removed unless replacing it.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

Fig. 6: Removing Sensor Rotor Using A Chisel

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB BOLT REMOVAL NOTE

NOTE:



The hub bolts do not need to be removed unless they are being replaced.

1. Remove the hub bolts using a press.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

Fig. 7: Removing Hub Bolts Using A Press

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB BOLT INSTALLATION NOTE

1. Install the new hub bolts using a press.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

Fig. 8: Installing New Hub Bolts

Courtesy of MAZDA MOTORS CORP.

ABS SENSOR ROTOR INSTALLATION NOTE

1. Install a new sensor rotor using the SST and a press.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

Fig. 9: Installing A New Sensor Rotor Using SST

Courtesy of MAZDA MOTORS CORP.

LOCKNUT INSTALLATION NOTE

1. Install a new locknut and stake it as shown.

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2005 Mazda MX-5 Miata

2005 DRIVELINE/AXLE Front Axle - MX-5 Miata

Fig. 10: Installing A New Locknut And Stake

Courtesy of MAZDA MOTORS CORP.

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2005 SUSPENSION Front Suspension - MX-5 Miata

2005 SUSPENSION

Front Suspension - MX-5 Miata

FRONT SUSPENSION LOCATION INDEX

Fig. 1: Identifying Front Suspension Location

Courtesy of MAZDA MOTORS CORP.

FRONT STRUT BAR REMOVAL/INSTALLATION (BP)

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 2: View Of Front Strut Bar & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

FRONT STRUT BAR REMOVAL/INSTALLATION (BP WITH TC)

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 3: View Of Front Strut Bar & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION

CAUTION:



1. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

2. Install in the reverse order of removal.

3. Inspect the front wheel alignment.



If not as specified, adjust the front wheel alignment. (See FRONT WHEEL ALIGNMENT .)

Fig. 4: Inspecting Front Wheel Alignment & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL NOTE

1. Disconnect the lower arm ball joint. (See LOWER ARM BALL JOINT REMOVAL NOTE .)

2. Loosen the lower arm bolts.

3. Lower the lower arm to remove the shock absorber.

CAUTION:



Do not lower the arms excessively, doing so may damage the brake hose.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 5: Disconnecting Lower Arm Ball Joint

Courtesy of MAZDA MOTORS CORP.

PISTON ROD NUT REMOVAL NOTE

1. Loosen the piston rod nut several turns, but do not remove the nut.

2. Secure the shock absorber in the SSTs.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 6: Securing Shock Absorber

Courtesy of MAZDA MOTORS CORP.

3. Compress the coil spring using the SSTs and remove the nut.

WARNING:



Removing the piston rod nut is dangerous. The shock absorber and spring could fly off under tremendous pressure and cause serious injury or death. Secure the shock absorber in the SSTs before removing the coil spring nut.

BOUND STOPPER INSTALLATION NOTE

1. Install the bound stopper to the piston rod as shown.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 7: Installing Bound Stopper To Piston Rod.

Courtesy of MAZDA MOTORS CORP.

2. Verify that the lower end of the bound stopper does not contact the cylinder.

COIL SPRING INSTALLATION NOTE

1. Temporarily install the upper spring seat, upper spring seat rubber and coil spring on the shock absorber as shown.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 8: Identifying Coil Spring

Courtesy of MAZDA MOTORS CORP.

2. Mark the upper spring seat, shock absorber and coil spring for proper reassembly.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

3. Align the marks of the upper spring seat and coil spring. Protect the upper spring seat and the coil spring with a piece of cloth, then assemble the SSTs.

4. Compress the spring using the SSTs.

Fig. 9: Compressing Spring By SST

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

5. Install the shock absorber, making sure that the marks on the shock absorber and coil spring are aligned.

6. Tighten the nut several turns.

7. Remove the SSTs.

8. Secure the shock absorber in a vise.

CAUTION:



Using an air tool will damage the piston rod thread. Do not use an air tool.

9. Apply an antirust penetrating oil lubricant to the piston rod thread and tighten the lower piston rod nut so that the exposed thread of the piston rod is 15.7-17.7 mm {0.62-0.69 in} (BP with TC) or 18.7-20.7 mm

{0.74-0.81 in} (BP).

10. Tighten the upper nut to the specified torque.

Fig. 10: Tightening Upper Nut

Courtesy of MAZDA MOTORS CORP.

Tightening torque

16-23 N.m {1.6-2.4 kgf.m, 12-17 ft.lbf}

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

FRONT SHOCK ABSORBER AND COIL SPRING INSTALLATION NOTE

1. Install the front shock absorber and coil spring so that the ABS wheel-speed sensor bracket of the shock absorber faces the rear of the vehicle.

FRONT SHOCK ABSORBER INSPECTION

1. Inspect the following and replace as necessary.



Inspect for damage and oil leakage.



Inspect the rubber bushing for deterioration and wear.

Compress and extend the shock piston at least 3 times. Verify that the operational force does not change and that there is no unusual noise.



Compress the shock absorber piston and release it.

Verify that the piston extends fully at a normal speed.

FRONT SHOCK ABSORBER DISPOSAL

SHOWA SHOCK ABSORBER

1. Clamp a shock absorber flat or with the piston downwards.

2. Drill a 2-3 mm {0.08-0.11 in} hole at a point 20-30 mm {0.79-1.18 in} from the bottom of the tube, so that the gas can escape.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 11: Drilling Hole In Shock Absorber

Courtesy of MAZDA MOTORS CORP.

WARNING:



Whenever drilling into a shock absorber, wear protective eye wear. The gas in the shock absorber is pressurized, and could spray metal chips into the eyes and face when drilling.

3. Turn the hole downwards.

4. The oil can be collected by moving the piston rod several times up and down and cutting the tube at the end.

5. Dispose of the waste oil according to local waste disposal laws.

NOTE:



Shock absorber gas is nitrogen gas.

Shock absorber oil is mineral oil.

BILSTEIN SHOCK ABSORBER

WARNING:



Whenever drilling into a shock absorber, wear protective eye wear.

The gas in the shock absorber is pressurized, and could spray metal

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata chips into the eyes and face when drilling.

1. Clamp a shock absorber on a flat surface or with the piston pointing downwards.

2. Drill a 2-3 mm {0.08-0.11 in} hole at a point 10-20 mm {0.4-0.8 in} shown in Fig. 12 , so that the gas can escape.

Fig. 12: Drilling A Shock Absorber On A Flat Surface Or With Piston Pointing

Courtesy of MAZDA MOTORS CORP.

3. Drill two 2-3 mm {0.08-0.11 in} holes at points as shown in Fig. 13 , so that the oil can escape.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 13: Drilling Two Holes

Courtesy of MAZDA MOTORS CORP.

4. Turn the hole downwards.

5. The oil can be collected by moving the piston rod several times up and down and drain the oil through the hole.

6. Dispose of waste oil according to the waste disposal law.

NOTE:



Shock absorber gas is nitrogen gas.

Shock absorber oil is mineral oil.

FRONT LOWER ARM REMOVAL/INSTALLATION

CAUTION:



1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

3. Inspect the front wheel alignment.



If not as specified, adjust the front wheel alignment. (See FRONT WHEEL ALIGNMENT .)

Fig. 14: View Of Front Lower Arm & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

LOWER ARM BALL JOINT REMOVAL NOTE

1. Separate the ball joint from the knuckle using the SST.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 15: Separate Ball Joint From Knuckle Using SST

Courtesy of MAZDA MOTORS CORP.

DUST BOOT REMOVAL NOTE

1. Remove the dust boot using a chisel, being careful not to damage the ball joint and the arm.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 16: Removing Dust Boot Using A Chisel

Courtesy of MAZDA MOTORS CORP.

LOWER ARM BUSHING (FRONT AND REAR) REMOVAL NOTE

1. Press the lower arm bushing out using the SSTs and a socket as shown.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 17: Pressing Lower Arm Bushing Out Using SSTS And A Socket

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

LOWER ARM BUSHING (FRONT AND REAR) INSTALLATION NOTE

1. Apply soapy water to the lower arm bushing.

2. Press the bushing in using the SST and a socket in the direction of the arrow.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 18: Installing Lower Arm Bushing

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

DUST BOOT INSTALLATION NOTE

1. Wipe the grease off the ball joint.

2. Fill the inside of the new dust boot with grease.

3. Press the dust boot onto the ball joint using the SST.

Fig. 19: Pressing Dust Boot Onto Ball Joint

Courtesy of MAZDA MOTORS CORP.

4. Wipe away the excess grease.

FRONT LOWER ARM INSPECTION

1. Shake the ball joint stud 5 times.

2. Connect the SST to the ball stud, and measure the rotation torque using a pull scale.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 20: Connecting SST To Ball Stud

Courtesy of MAZDA MOTORS CORP.



Replace if it is not within the specification.

Rotation torque

0.4-1.9 N.m {3.5-19.5 kgf.cm, 3.1-16.9 in.lbf}

Pull scale reading

3.5-19.1 N {0.35-1.95 kgf, 0.78-4.29 lbf}

FRONT UPPER ARM REMOVAL/INSTALLATION

CAUTION:



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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

3. Inspect the front wheel alignment.



If not as specified, adjust the front wheel alignment. (See FRONT WHEEL ALIGNMENT .)

Fig. 21: View Of Front Upper Arm & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

UPPER ARM BALL JOINT REMOVAL NOTE

1. Separate the upper arm ball joint from the knuckle using the SST.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 22: Identifying Upper Arm Ball Joint From Knuckle

Courtesy of MAZDA MOTORS CORP.

DUST BOOT REMOVAL NOTE

1. Remove the dust boot using a chisel, being careful not to damage the ball joint and the arm.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 23: Removing Dust Boot Using A Chisel

Courtesy of MAZDA MOTORS CORP.

UPPER ARM BUSHING (FRONT AND REAR) REMOVAL NOTE

1. Press the upper arm bushing out using the SST and a socket as shown.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 24: Pressing Upper Arm Bushing Out Using SST And A Socket

Courtesy of MAZDA MOTORS CORP.

UPPER ARM BUSHING (FRONT AND REAR) INSTALLATION NOTE

1. Apply soapy water to the upper arm bushing.

2. Press the bushing in using the SST and a socket in the direction of the arrow.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 25: Installing Upper Arm Bushing

Courtesy of MAZDA MOTORS CORP.

DUST BOOT INSTALLATION NOTE

1. Fill the inside of the new dust boot with grease.

2. Press the dust boot on using a 30 mm {1.18 in} socket until the dust boot contacts the seat.

CAUTION:



Install the dust boot squarely and do not press excessively. The inner metal ring will be deformed if not done correctly.

3. Verify that the clearance between the boot and the seat is less than 1 mm {0.04 in}.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 26: Installing Dust Boot

Courtesy of MAZDA MOTORS CORP.

FRONT UPPER ARM INSPECTION

1. Shake the ball joint stud 5 times.

2. Connect the SST to the ball stud, and measure the rotation torque using a pull scale.



Replace if it is not within the specification.

Rotation torque

0.3-2.2 N.m {2.8-23.4 kgf.cm, 2.5-20.3 in.lbf}

Pull scale reading

3.0-22.5 N {0.3-2.3 kgf, 0.7-5.0 lbf}

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 27: Shaking Ball Joint Stud

Courtesy of MAZDA MOTORS CORP.

FRONT STABILIZER REMOVAL/INSTALLATION

CAUTION:



1. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

2. Install in the reverse order of removal.

Fig. 28: View Of Front Stabilizer & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

STABILIZER BUSHING INSTALLATION NOTE

1. Align the bushing with the positioning bushing on the stabilizer.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 29: Aligning Bushing With Positioning Bushing On Stabilizer

Courtesy of MAZDA MOTORS CORP.

STABILIZER CONTROL LINK INSPECTION

1. Remove the stabilizer control link from the vehicle.

2. Inspect for bending and damage.

3. Measure the ball joint starting torque.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 30: Measuring Ball Joint Starting Torque

Courtesy of MAZDA MOTORS CORP.

1. Rock the ball joint stud side to side 10 times.

2. Rotate the ball joint stud 10 times.

3. Measure the starting torque using a suitable Allen socket and a torque wrench.



Replace if it is not within the specification.

Starting torque

0.2-2.7 N.m {1.4-27 kgf.cm, 1.3-23.4 in.lbf}

FRONT CROSSMEMBER REMOVAL/INSTALLATION

CAUTION:



Performing the following procedures without first removing the ABS

Microsoft

2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Remove the air cleaner, MAF sensor, air hose No.2, air hose No.1, air pipe No.1, air bypass valve. (BP with TC) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WITH TC) .)

2. Install the SST to the position shown in Fig. 31 using the suitable washer and air pipe No.1 installation bolt. (BP with TC)

Fig. 31: Installing SST To Position

Courtesy of MAZDA MOTORS CORP.

3. Support the engine with a hoist or baby crane.

4. Remove the steering gear and linkage. (See STEERING GEAR AND LINKAGE

REMOVAL/INSTALLATION .)

5. Remove the steering knuckles. (See WHEEL HUB, STEERING KNUCKLE

REMOVAL/INSTALLATION .)

6. Remove the front stabilizer. (See FRONT STABILIZER REMOVAL/INSTALLATION .)

7. Remove the front lower arms. (See FRONT LOWER ARM REMOVAL/INSTALLATION .)

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

8. Remove the front upper arms. (See FRONT UPPER ARM REMOVAL/INSTALLATION .)

9. Remove in the order indicated in the table.

10. Install in the reverse order of removal.

11. Inspect the front wheel alignment.



If not as specified, adjust the front wheel alignment. (See FRONT WHEEL ALIGNMENT .)

Fig. 32: View Of Front Crossmember & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CROSSMEMBER COMPONENT REMOVAL/INSTALLATION

1. Remove the crossmember component.

2. Install the crossmember component.

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2005 Mazda MX-5 Miata

2005 SUSPENSION Front Suspension - MX-5 Miata

Fig. 33: Installing Crossmember Component & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

2005 ENGINE PERFORMANCE

Fuel System - MX-5 Miata

FUEL SYSTEM LOCATION INDEX (BP, BP WITH TC)

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 1: Locating Fuel System (BP, Bp With TC) Components

Courtesy of MAZDA MOTORS CORP.

BEFORE SERVICE PRECAUTION (BP, BP WITH TC)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

WARNING:



Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the FUEL LINE

SAFETY PROCEDURE.

FUEL LINE SAFETY PROCEDURE

NOTE:



Fuel in the fuel system is under high pressure also when the engine is not running.

1. Remove the fuel-filler cap and release the pressure in the fuel tank.

2. Disconnect the fuel pump relay (FP RLY) connector (6-pin type connector:4 terminal) located above the accelerator pedal (AP).

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 2: Disconnecting Fuel Pump Relay (FP RLY) Connector

Courtesy of MAZDA MOTORS CORP.

3. Start the engine.

4. After the engine stalls, crank the engine several times.

5. Turn the ignition switch to the LOCK position.

6. Connect the FP RLY connector.

AFTER SERVICE PRECAUTION (BP, BP WITH TC)

WARNING:



Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata hose, observe "Fuel Hose Installation" and "Fuel Leakage

Inspection" described below.

FUEL HOSE INSTALLATION

1. Replace damaged or deformed fuel hoses, fuel pipes, and hose clamps.

2. When installing the fuel hose onto the fuel pipe, fit the hose onto the pipe over 25 mm {1.00 in}.

When the pipe has a stopper, fit the hose until it contacts the stopper.

Fig. 3: Installing Fuel Hose Onto Fuel Pipe

Courtesy of MAZDA MOTORS CORP.

3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 4: Installing Hose Clamp Over Fuel Hose Within Clamp

Courtesy of MAZDA MOTORS CORP.

4. When installing two clamps, their tabs must be positioned more than 45° (desired 180°) apart.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 5: Installing Clamps

Courtesy of MAZDA MOTORS CORP.

FUEL LEAKAGE INSPECTION

WARNING:



Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

CAUTION:



Connecting to the wrong DLC terminals may cause a malfunction.

Carefully connect only to the specified terminals.

1. Short the DLC terminals F/P and body GND using a jumper wire.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 6: Shorting DLC Terminals F/P And Body Gnd Using Jumper Wire

Courtesy of MAZDA MOTORS CORP.

2. Turn the ignition switch to the ON position to operate the fuel pump.

3. Pressurize the system this way for at least 5 min to be sure of no leakage.



If there is fuel leakage, inspect for damaged fuel hoses, hose clamps, and fuel pipe sealing surface and replace if necessary.

4. After repair, assemble the system and repeat Steps 1 to 3.

FUEL LINE PRESSURE INSPECTION (BP, BP WITH TC)

WARNING:



Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Disconnect the fuel pipe on the pulsation damper No.1 outlet side. Set the SST between the pulsation damper No.1 and the fuel distributor as shown in the figure. (See FUEL INJECTOR

REMOVAL/INSTALLATION (BP, BP WITH TC) (+)

Fig. 7: Setting SST Between Pulsation Damper No.1 And Fuel Distributor

Courtesy of MAZDA MOTORS CORP.

NOTE:



Verify that a click is heard when the SST is pushed into pulsation damper No.1.

4. Pull the connector by hand and verify that it is installed securely. Visually inspect that the tabs of the retainer are securely fitted into the connector.

5. Connect the negative battery cable.

6. Verify that AT vehicles are in the N range, and MT vehicles are in the neutral position.

7. Start the engine and idle it. Measure the fuel line pressure.



If not as specified, inspect the following:

Zero or low

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata



FP circuit



Main fuel line (clogged)



Fuel leakage inside pressure regulator

High



Pressure regulator due to high pressure

Return fuel line (clogged)

Fuel line pressure

370-420 kPa {3.7-4.3 kgf/cm2, 53-61 psi}

8. Observe the fuel pressure gauge indicator during heavy acceleration.

9. Verify that the fuel pressure fluctuation is within the specification during the test.



If not as specified, inspect the following:



PCM



Fuel line for improper routing, kinks or leakage

Fuel pressure fluctuation

370-420 kPa {3.7-4.3 kgf/cm2, 53-61 psi}

10. Turn the ignition switch to the LOCK position.

11. Measure the fuel hold pressure after 5 min.



If not as specified, inspect the following:



FP hold pressure



Fuel injector for leakage

Fuel line for improper routing, kinks or leakage

Fuel hold pressure

More than 250 kPa {2.55 kgf/cm2, 36.3 psi}

12. Disconnect the SST and connect the fuel pipe to the pulsation damper No.1. (See FUEL INJECTOR

REMOVAL/INSTALLATION (BP, BP WITH TC) (+)

13. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) (+)

FUEL PRESSURE HOLD INSPECTION (BP, BP WITH TC)

WARNING:



Fuel line spills and leakage are dangerous. Fuel can ignite and

Microsoft

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Disconnect the fuel pipe on the pulsation damper No.1 outlet side. Set the SST between pulsation damper

No.1 and the fuel distributor as shown in the figure. (See FUEL INJECTOR

REMOVAL/INSTALLATION (BP, BP WITH TC) (+)

Fig. 8: Setting SST Between Pulsation Damper No.1 And Fuel Distributor

Courtesy of MAZDA MOTORS CORP.

NOTE:



Verify that a click is heard when the SST is pushed into pulsation damper No.1.

4. Pull the connector by hand and verify that it is installed securely. Visually inspect that the tabs of the retainer are securely fitted into the connector.

5. Connect the negative battery cable.

6. Verify that AT vehicles are in the N range and MT vehicles are in the neutral position, then start the engine.

7. Observe the fuel pressure gauge indicator during heavy acceleration.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

8. Verify that the fuel pressure holds steady within specification during the test.

Fuel hold pressure

370-420 kPa {3.7-4.3 kgf/cm2, 53-61 psi}

9. Disconnect the SST and connect the fuel pipe to pulsation damper No.1. (See FUEL INJECTOR

REMOVAL/INSTALLATION (BP, BP WITH TC) (+)



If not as specified, inspect fuel hold pressure. (See FUEL PRESSURE HOLD INSPECTION

(BP, BP WITH TC) (+)

FUEL TANK REMOVAL/INSTALLATION (BP, BP WITH TC)

WARNING:



Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury.

Always properly steam clean a fuel tank before repairing it.

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Siphon the fuel from the fuel tank. (See FUEL DRAWING NOTE (+)

4. Remove the middle pipe (BP) or the presilencer (BP WITH TC). (See EXHAUST SYSTEM

REMOVAL/INSTALLATION (BP) (+) (See EXHAUST SYSTEM REMOVAL/INSTALLATION

(BP WITH TC) (+)

5. Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION (+)

6. Remove the power plant frame. (See MANUAL TRANSMISSION REMOVAL/INSTALLATION

(M15M-D) (+) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION (+)

7. Remove in the order indicated in the table.

8. Install in the reverse order of removal.

9. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) (+)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 9: Installing Fuel Tank & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

FUEL DRAWING NOTE

1. Remove the fuel-filler cap and insert a hose into the fuel tank through the fuel-filler pipe.

2. Siphon the fuel into a container using a fuel drawing pump.

Fig. 10: Identifying Siphon Fuel Into A Container Using Fuel Drawing Pump

Courtesy of MAZDA MOTORS CORP.

NOTE:



For ease of work, prepare a hose of the following size.

Specification

Outer diameter:13 mm {0.51 in}

Length:2160 mm {85.0 in} or longer

REAR CROSSMEMBER COMPONENT REMOVAL NOTE

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

1. Support the rear crossmember component using a transmission jack.

2. Remove the rear crossmember mounting bolts and nuts.

3. Lower the rear crossmember component.

PLASTIC FUEL HOSE DISASSEMBLY NOTE

CAUTION:



The retainer must be replaced if removed from the fuel pipe without using the SST. Otherwise, effectiveness of the retainer will be reduced.

1. Verify that the quick release connector joint area is free of foreign material.

2. Clean if necessary.

3. Set the SST as shown and push it into the quick release connector to disconnect the plastic fuel hose.

Fig. 11: Identifying Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.

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2005 Mazda MX-5 Miata

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Fig. 12: Disconnecting Quick Release Connector And Fuel Pipe

Courtesy of MAZDA MOTORS CORP.

BREATHER HOSE, EVAPORATIVE HOSE INSTALLATION NOTE

1. Fit each hose onto the respective fittings within specification, and install clamps as shown.

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2005 Mazda MX-5 Miata

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Fig. 13: Fitting Hose Within Specification

Courtesy of MAZDA MOTORS CORP.

JOINT HOSE INSTALLATION NOTE

1. Fit the joint hose onto the respective fittings within specification, and install clamps as shown.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 14: Fitting Joint Hose Within Specification

Courtesy of MAZDA MOTORS CORP.

PLASTIC FUEL HOSE ASSEMBLY NOTE

1. Verify that the inside of the fuel pipe and the quick release connector is free of foreign material and damage.

2. Clean if necessary, taking care not to damage the sealing surfaces.

3. Push the quick release connector into the fuel pipe until a click is heard.

4. Pull the quick release connector by hand and verify that it is installed securely.

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 15: Pulling Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

NONRETURN VALVE INSPECTION (BP, BP WITH TC)

1. Remove the nonreturn valve. (See FUEL TANK REMOVAL/INSTALLATION (BP, BP WITH TC)

(+)

2. Verify that the nonreturn valve operates under its own weight.



If the valve does not operate, replace the nonreturn valve.

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2005 Mazda MX-5 Miata

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Fig. 16: Removing Nonreturn Valve

Courtesy of MAZDA MOTORS CORP.

FUEL PUMP (FP) REMOVAL/INSTALLATION (BP, BP WITH TC)

WARNING:



Fuel line spills and leakage are dangerous. Fuel can ignite and

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the FP unit when removing or installing.

CAUTION:



Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Uncover the rear package trim.

4. Remove the service hole cover.

5. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 17: Installing Fuel Pump (FP) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

7. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) (+)

FUEL PUMP (FP) DISASSEMBLY/ASSEMBLY (BP, BP WITH TC)

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

1. Disassemble in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 18: Disassembling Fuel Pump (FP) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

FP ASSEMBLY NOTE

1. After installing the FP to the bracket, pull the pump down so that it is flush against the bracket and there is no gap.

Fig. 19: Installing FP To Bracket

Courtesy of MAZDA MOTORS CORP.

FUEL HOSE ASSEMBLY NOTE

1. Do not apply excessive side force when pushing the fuel hose onto the FP nipple.

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 20: Assembling Fuel Hose Assembly

Courtesy of MAZDA MOTORS CORP.

2. Install the clamps as shown.

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 21: Installing Clamps

Courtesy of MAZDA MOTORS CORP.

FUEL PUMP (FP) INSPECTION (BP, BP WITH TC)

CONTINUITY INSPECTION

NOTE:



Perform the following test only when directed.

1. Disconnect the negative battery cable.

2. Remove the service hole cover.

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

3. Disconnect the FP connector.

4. Inspect for continuity between FP connector terminals B and D.



If there is no continuity, replace the FP body.



If as specified, carry out the "Circuit Open/Short Inspection".

Fig. 22: Inspecting Continuity Between FP Connector Terminals

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

1. Inspect the following wiring harness for an open or short circuit. (Continuity check).

Open circuit

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

If there is no continuity, the circuit is open.

Repair or replace the harness.



GND circuit (FP connector terminal D and body GND)



Power circuit (fuel pump relay (FP RLY) connector terminal C and FP connector terminal B through common connector)

Fig. 23: Identifying Fuel Pump Relay (FP RLY) Connector Terminal

Courtesy of MAZDA MOTORS CORP.

Short circuit



If there is no continuity, the circuit is shorted.

Repair or replace the harness.

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

FP RLY connector terminal C and FP connector terminal B through common connector to GND

FUEL PUMP (FP) PRESSURE INSPECTION

WARNING:



Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

CAUTION:



NOTE:



Perform the following test only when directed.

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Lift up the vehicle with safety stands.

4. Remove the fuel filter cover.

5. Verify that the quick release connector joint area is free of foreign material.

6. Clean if necessary.

7. Set the SST to the fuel filter outlet pipe and push it into the quick release connector, and disconnect the fuel pipe.



If removal of the retainer is required, remove it by squeezing the tabs of the retainer.

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Fig. 24: Disconnecting Fuel Pipe

Courtesy of MAZDA MOTORS CORP.

CAUTION:

8. Cover the disconnected quick release connector and fuel filter outlet pipe to prevent them from being scratched or contaminated with foreign material.

9. Turn the lever as shown in Fig. 25 to plug the SST outlet.

10. Push the SST into the fuel filter outlet pipe until a click is heard.

11. Connect a fuel hose and clamp to the SST outlet pipe.

12. Set the fuel hose into a container to avoid fuel spills.

13. Pull the quick release connector by hand and verify that it is installed securely.

14. Connect the negative battery cable.

CAUTION:



Removing the retainer from the disconnected fuel pipe will reduce the effectiveness of the retainer. The retainer must be replaced when any of the following applies:

1. Scratches or damage is observed on the retainer.

2. Fuel pipe has been replaced.

3. Fuel filter (high-pressure) has been replaced.



Connecting to the wrong DLC terminals may cause a malfunction. Carefully connect only to the specified terminals.

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15. Short the DLC terminals F/P and body GND using a jumper wire.

Fig. 25: Setting Fuel Hose Into A Container To Fuel Spills

Courtesy of MAZDA MOTORS CORP.

16. Turn the lever 90° against the hose of the SST.

17. Turn the ignition switch to the ON position to operate the FP.

18. Measure the FP maximum pressure.



If not as specified, inspect the following:

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

FP RLY

Fuel filter for clogging



Fuel line for clogging or leakage

FP maximum pressure

Less than 637 kPa {6.5 kgf/cm2, 92 psi}

Fig. 26: Shorting DLC Terminals F/P And Body Gnd

Courtesy of MAZDA MOTORS CORP.

19. Turn the ignition switch to the ON position for 10 s to operate the FP.

20. Turn the ignition switch to the LOCK position.

21. Measure the FP hold pressure after 5 min.

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

If not as specified, replace the FP.

FP hold pressure

More than 343 kPa {3.5 kgf/cm2, 50 psi}

22. Disconnect the jumper wire.

23. Disconnect the SST.

24. Inspect the fuel pipe for kinks.

25. Replace the fuel pipe if necessary.

26. Verify that the inside of the fuel filter outlet pipe and the quick release connector is free of foreign material and damage.

27. Clean if necessary, taking care not to damage the sealing surfaces.

28. Push the fuel pipe into the fuel filter outlet pipe until a click is heard.

29. Pull the quick release connector by hand and verify that it is installed securely.

30. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) (+)

FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION (BP, BP WITH

TC)

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Raise the rear of the vehicle and support it with safety stands.

4. Remove the fuel filter protector.

5. Remove in the order indicated in the table.

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Fig. 27: Identifying Fuel Filter (High-Pressure) (BP, BP With TC) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

7. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) (+)

PLASTIC FUEL HOSE DISASSEMBLY NOTE

1. Verify that the quick release connector joint area is free of foreign material.

2. Clean if necessary.

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

3. Squeeze the tabs of the retainer and disconnect the quick release connector.

CAUTION:



Removing the retainer from the disconnected fuel pipe will reduce the effectiveness of the retainer. The retainer must be replaced when any of the following applies:

1. Retainer has been removed.

2. Scratches or damage is observed on the retainer.

3. Plastic fuel hose has been replaced.

4. Fuel filter (high-pressure) has been replaced.

Fig. 28: Disconnecting Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign materials.

 If removal of the retainer is required, remove it in the following procedure:

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Fig. 29: Removing Retainer

Courtesy of MAZDA MOTORS CORP.

CAUTION:



Removing the retainer using a tool can damage the fuel pipe and cause fuel leakage. Remove the retainer by opening the tabs outward by hand.

1. Open the tabs of the retainer outward.

2. Remove and discard the retainer.

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Fig. 30: Discarding Retainer

Courtesy of MAZDA MOTORS CORP.

FUEL FILTER (HIGH-PRESSURE) REMOVAL NOTE

1. Before removing the fuel filter, paint mark the fuel filter and fuel filter bracket for correct reassembly.

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Fig. 31: Removing Fuel Filter (High-Pressure)

Courtesy of MAZDA MOTORS CORP.

FUEL FILTER (HIGH-PRESSURE) INSTALLATION NOTE

Replacing the fuel filter:

1. Paint mark the new fuel filter on the same spot as the removed fuel filter.

2. Align the paint marks and install the fuel filter.

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Fig. 32: Aligning Paint Marks

Courtesy of MAZDA MOTORS CORP.

REPLACING THE FUEL FILTER BRACKET:

1. Paint mark the new fuel filter bracket on the same spot as the removed fuel filter bracket.

2. Align the paint marks and install the fuel filter bracket.

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

Fig. 33: Installing Fuel Filter Bracket

Courtesy of MAZDA MOTORS CORP.

PLASTIC FUEL HOSE ASSEMBLY NOTE

1. When the retainer is not removed, observe the following procedure:

1. Inspect the plastic fuel hose for kinks.

2. Replace if necessary.

3. Verify that the inside of the fuel pipe and the quick release connector is free of foreign material and damage.

4. Clean if necessary, taking care not to damage the sealing surfaces.

5. Align the fuel pipe and quick release connector so that the tabs of the retainer are correctly fitted into the quick release connector.

6. Push the quick release connector into the retainer until a click is heard.

7. Pull the quick release connector by hand and verify that it is installed securely.

8. Visually inspect that the tabs of the retainer are securely fitted into the quick release connector.

2. When the retainer is removed, observe the following procedure:

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Fig. 34: Pushing Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

NOTE:



Use the designated genuine retainer only.

1. Install a new retainer onto the quick release connector.

2. Visually inspect that the tabs of the retainer are securely fitted into the quick release connector.

3. Verify that the inside of the fuel pipe and the quick release connector are free of foreign material and damage.

4. Clean if necessary, taking care not to damage the sealing surfaces.

5. Push the quick release connector into the fuel pipe until a click is heard.

6. Pull the quick release connector by hand and verify that it is installed securely.

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Fig. 35: Identifying New Retainer

Courtesy of MAZDA MOTORS CORP.

FUEL INJECTOR REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Remove the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP) (+)

(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WI (+)

4. Remove in the order indicated in the table.

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Fig. 36: Installing Fuel Injector (BP, BP With TC) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

6. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) (+)

FUEL INJECTOR INSTALLATION NOTE

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1. Use new fuel injector O-rings.

2. Apply a small amount of engine oil to the O-rings and install them into the fuel distributor.

3. Verify that the O-rings and the fuel injector sealing surfaces are free of foreign material.

4. Clean with gasoline if necessary.

5. Install the fuel injectors in the fuel distributor with a light twisting motion so that the O-rings will not be folded.

Fig. 37: Identifying Fuel Injector Insulator

Courtesy of MAZDA MOTORS CORP.

FUEL INJECTOR INSPECTION (BP, BP WITH TC)

ON-VEHICLE INSPECTION

1. Warm up the engine and idle it.

2. Listen for operation sound of each fuel injector with a screwdriver or a soundscope.



If no sound is heard, perform the "Fuel Injector Resistance Inspection".

NOTE:



The best way to judge the performance of a fuel injector is to

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata compare its sound with the sound of other fuel injectors.

RESISTANCE INSPECTION

NOTE:



Perform the following test only when directed.

1. Disconnect the fuel injector connectors.

2. Measure the resistance of the fuel injector using an ohmmeter.



If as specified but the On-vehicle Inspection failed, perform the " CIRCUIT OPEN/SHORT

INSPECTION ".



If not as specified, replace the fuel injector. (See FUEL INJECTOR

REMOVAL/INSTALLATION (BP, BP WITH TC) (+)

Resistance

12-13 ohms (20°C {68°F})

Fig. 38: Measuring Resistance Of Fuel Injector Using Ohmmeter

Courtesy of MAZDA MOTORS CORP.

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CIRCUIT OPEN/SHORT INSPECTION

Open circuit



GND circuit (No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2A)

GND circuit (No.2 cylinder fuel injector connector terminal B and PCM connector terminal 2D)



GND circuit (No.3 cylinder fuel injector connector terminal B and PCM connector terminal 2G)

Fig. 39: Identifying Main Relay Harness Side Connector

Courtesy of MAZDA MOTORS CORP.



GND circuit (No.4 cylinder fuel injector connector terminal B and PCM connector terminal 2J)

Power circuit (No.1 cylinder fuel injector connector terminal A and main relay connector terminal D

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2005 ENGINE PERFORMANCE Fuel System - MX-5 Miata

 through common connector)

Power circuit (No.2 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)



Power circuit (No.3 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)

Power circuit (No.4 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)

Short circuit



No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2A to GND



No.2 cylinder fuel injector connector terminal B and PCM connector terminal 2D to GND

No.3 cylinder fuel injector connector terminal B and PCM connector terminal 2G to GND



No.4 cylinder fuel injector connector terminal B and PCM connector terminal 2J to GND

FUEL LEAKAGE AND VOLUME TEST

WARNING:



Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Remove the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP) (+)

(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WITH TC) (+)

4. Remove the fuel injectors together with the fuel distributor. (See FUEL INJECTOR

REMOVAL/INSTALLATION (BP, BP WITH TC) (+)

5. Fasten the fuel injectors firmly to the fuel distributor with wire and connect the fuel pipe connector.

6. Connect the negative battery cable.

CAUTION:



Connecting to the wrong DLC terminals may cause a malfunction. Carefully connect only to the specified terminals.

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Fig. 40: Identifying Fuel Injectors

Courtesy of MAZDA MOTORS CORP.

7. Connect DLC terminal F/P and body GND using a jumper wire.

8. Turn the ignition switch to the ON position to operate the FP.

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Fig. 41: Connecting DLC Terminal F/P And Body Gnd Using Jumper Wire

Courtesy of MAZDA MOTORS CORP.

9. Tilt the fuel injectors approx.60 deg.

and verify that fuel leaking from the fuel injector nozzles is within the specification.



If not as specified, replace the fuel injector.

Fuel leakage

Less than 1 drop/2 min

10. Turn the ignition switch to the LOCK position.

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Fig. 42: Identifying Tilt Fuel Injectors

Courtesy of MAZDA MOTORS CORP.

11. Connect the SST as shown in Fig. 43 the figure.

12. Turn the ignition switch to the ON position to operate the FP.

13. Measure the injection volume of each fuel injector using a graduated container.



If not as specified, replace the fuel injector.

Injection volume

66-82 ml {66-82 cc, 2.3-2.7 fl oz}/15 s

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Fig. 43: Measuring Injection Volume Of Fuel Injector Using Graduated Container

Courtesy of MAZDA MOTORS CORP.

14. Turn the ignition switch to the LOCK position and disconnect the jumper wire.

15. Install the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP) (+)

(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WI (+)

16. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) (+)

Using a fuel injector tester

1. Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION (BP, BP WITH

TC) (+)

2. Connect the fuel injector to the fuel injector tester.

3. Measure the injection volume of each fuel injector.

 If not as specified, replace the fuel injector.

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Injection volume

66-82 ml {66-82 cc, 2.3-2.7 fl oz}/15 s.

4. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) (+)

PRESSURE REGULATOR REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Remove and install the pressure regulator. (See FUEL PUMP (FP) DISASSEMBLY/ASSEMBLY (BP,

BP WITH TC) (+)

PRESSURE REGULATOR INSPECTION (BP, BP WITH TC)

NOTE:



Due to the adoption of the mechanical returnless fuel system, the pressure regulator cannot be inspected separately.

1. Perform FUEL LINE PRESSURE INSPECTION (BP, BP WITH TC) .

PULSATION DAMPER NO.1 REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION (BP,

BP WITH TC) (+)

2. Disconnect the negative battery cable.

3. Remove in the order indicated in the table.

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Fig. 44: Removing Pulsation Damper (BP, BP With TC) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

5. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

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WITH TC) (+)

PULSATION DAMPER NO.2 REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Remove and install pulsation damper No.2.

(See FUEL INJECTOR REMOVAL/INSTALLATION (BP, BP WITH TC) (+)

PULSATION DAMPER NO.1, NO.2 INSPECTION (BP, BP WITH TC)

1. Visually inspect pulsation dampers No.1 and No.2 for damage and cracks. Also verify that there is no extreme rust which will cause fuel leakage.



If either is observed, replace the faulty pulsation damper.

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2005 HVAC Basic System - MX-5 Miata

2005 HVAC

Basic System - MX-5 Miata

BASIC SYSTEM LOCATION INDEX

Fig. 1: Identifying HVAC Basic System Components

Courtesy of MAZDA MOTORS CORP.

BLOWER UNIT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the glove compartment.

3. Remove the bracket.

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2005 HVAC Basic System - MX-5 Miata

Fig. 2: Removing Bracket

Courtesy of MAZDA MOTORS CORP.

4. Remove the seal plate.

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Fig. 3: Removing Seal Plate

Courtesy of MAZDA MOTORS CORP.

5. Remove in the order indicated in the table.

Fig. 4: Removing Blower Unit Bolts - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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6. Install in the reverse order of removal.

BLOWER UNIT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 5: Disassembling Blower Unit

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

COOLING UNIT REMOVAL/INSTALLATION

1. Discharge the refrigerant from the system. (See REFRIGERANT CHARGING .)

2. Disconnect the negative battery cable.

3. Remove the glove compartment.

4. Disconnect cooler pipe No.1 and No.2. (See REFRIGERANT LINES REMOVAL NOTE .) (See

REFRIGERANT LINES INSTALLATION NOTE .)

CAUTION:



If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur.

Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

5. Remove in the order indicated in the table. Do not allow compressor oil to spill.

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Fig. 6: Removing Cooling Unit - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

7. Perform refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE

TEST .)

COOLING UNIT INSTALLATION NOTE

1. When installing a new cooling unit, add DENSO OIL8 compressor oil into the refrigeration cycle.

Supplemental amount (approx.quantity)

40 ml {40 cc, 1.4 fl oz}

COOLING UNIT DISASSEMBLY/ASSEMBLY

CAUTION:



If moisture of foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

1. Disassemble in the order indicated in the table.

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Fig. 7: Disassembling Cooling Unit - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

EVAPORATOR ASSEMBLY NOTE

1. When installing a new evaporator, add DENSO OIL8 compressor oil into the refrigeration cycle.

Supplemental amount (approx.quantity)

40 ml {40 cc, 1.4 fl oz}

EXPANSION VALVE ASSEMBLY NOTE

1. Apply compressor oil to the O-rings and connect the joints.

2. Install the heat-sensing tube to its proper position.

THERMOSWITCH ASSEMBLY NOTE

1. Insert the thermoswitch probe in location as shown in Fig. 8 .

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Fig. 8: Identifying Thermoswitch Assembly

Courtesy of MAZDA MOTORS CORP.

EVAPORATOR INSPECTION

1. Inspect for cracks, damage, and oil leakage. If any are found, replace the evaporator.

2. Inspect for bent fins.



If any are bent, use a flathead screwdriver to straighten them.

HEATER UNIT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

3. Remove the dashboard. (See DASHBOARD REMOVAL/INSTALLATION .)

4. Remove the seal plate.

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

Fig. 9: Removing Seal Plate

Courtesy of MAZDA MOTORS CORP.

5. Remove in the order indicated in the table.

Fig. 10: Removing Heater Unit - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

6. Install in the reverse order of removal.

7. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

HEATER UNIT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 11: Disassembling Heater Unit

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

HEATER CORE INSPECTION

1. Inspect for cracks, damage, and coolant leakage.



If any are found, replace the heater core.

2. Inspect for bent fins.



If any are bent, use a flathead screwdriver to straighten them.

3. Verify that the heater core inlet and outlet are not distorted or damaged. Repair with pliers if necessary.

A/C COMPRESSOR REMOVAL/INSTALLATION

1. Discharge the refrigerant from the system. (See REFRIGERANT CHARGING .)

2. Disconnect the negative battery cable.

3. Remove the under cover.

4. Remove the drive belt (P/S+A/C).

CAUTION:



If moisture or foreign material enters the refrigeration cycle,

Microsoft

2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata cooling ability will be lowered and abnormal noise will occur.

Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

5. Remove in the order indicated in the table. Do not allow compressor oil to spill.

Fig. 12: Removing A/C Compressor - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

7. Adjust the drive belt (P/S+A/C). (See DRIVE BELT ADJUSTMENT .)

8. Perform refrigerant system performance test.

(See REFRIGERANT SYSTEM PERFORMANCE TEST .)

A/C COMPRESSOR INSTALLATION NOTE

CAUTION:



Due to the high moisture-absorption characteristics of the compressor oil, it may absorb moisture if left over a long period of time thereby negatively affecting A/C operation. Drain the compressor oil and refill within 10 min. of each other.

1. Rotate new A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a clean measuring device. Use this refrigerant oil to refill new compressor. Do not allow refrigerant oil to become contaminated.

2. Rotate old A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a separate, clean measuring device.

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

3. Compare those oil amounts. The amount of the oil drained from the new A/C compressor should be greater than the old one.

4. Pour the same amount oil of drained from the old A/C compressor back into the new A/C compressor.

A/C compressor oil type

DENSO OIL8

A/C compressor oil sealed volume (approx.quantity)

60 ml {60 cc, 2.03 fl oz}

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

Fig. 13: Exchanging A/C Compressor Oil

Courtesy of MAZDA MOTORS CORP.

CONDENSER REMOVAL/INSTALLATION

1. Discharge the refrigerant from the system. (See REFRIGERANT CHARGING .)

2. Disconnect the negative battery cable.

3. Remove the cooling fan. (See RADIATOR REMOVAL/INSTALLATION [BP] .) (See RADIATOR

REMOVAL/INSTALLATION [BP WITH TC] .)

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

4. Remove the condenser fan. (See CONDENSER FAN REMOVAL/INSTALLATION .)

5. Remove the radiator brackets.

Fig. 14: Removing Radiator Brackets

Courtesy of MAZDA MOTORS CORP.

6. Keep pushing the radiator fully backward to remove the condenser.

CAUTION:



If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur.

Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

Fig. 15: Identifying Radiator

Courtesy of MAZDA MOTORS CORP.

7. Remove the splash shield.

8. Remove the condenser. Do not allow compressor oil to spill. (See CONDENSER INSTALLATION

NOTE .)

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

Fig. 16: Removing Condenser - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

9. Install in the reverse order of removal.

10. Perform the refrigerant system performance test.

(See REFRIGERANT SYSTEM PERFORMANCE TEST .)

CONDENSER INSTALLATION NOTE

1. When installing a new condenser, add DENSO OIL8 compressor oil into the refrigeration cycle.

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

Supplemental amount (approx.quantity)

30 ml {30 cc, 1.0 fl 02}

CONDENSER INSPECTION

1. Inspect for cracks, damage, and oil leakage.



If any are found, replace the condenser.

2. Inspect for fins clogged by dust.



If any are clogged, remove the dust from the fins.

3. Inspect for bent fins.



If any are bent, use a flathead screwdriver to straighten them.

REFRIGERANT LINES REMOVAL/INSTALLATION

1. Discharge the refrigerant from the system. (See REFRIGERANT CHARGING .)

2. Disconnect the negative battery cable.

3. Remove the under cover.

CAUTION:



If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur.

Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

To prevent the pipe from breaking, loosen the joint using two open-end wrenches.

4. Remove in the order indicated in the table.

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2005 HVAC Basic System - MX-5 Miata

Fig. 17: Removing Refrigerant Lines - With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

6. Perform the refrigerant system performance test.

(See REFRIGERANT SYSTEM PERFORMANCE TEST .)

REFRIGERANT LINES REMOVAL NOTE

NOTE:



There are two types of SSTs:

49 N061 001 (high-pressure) and 49 N061 002 (low-pressure).

1. Set the SST into the clamp with the arrow mark on the clamp facing the SST .

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

Fig. 18: Setting SST Into Clamp

Courtesy of MAZDA MOTORS CORP.

2. Push the SST with your thumb until the clamp clicks.

CAUTION:



If the SST is pushed with excessive force, the clamp will deform. Be careful when pushing the SST into the clamp.

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata

Fig. 19: Pushing SST With Your Thumb

Courtesy of MAZDA MOTORS CORP.

3. Pull up the stopper, then pull the SST from the pipe.

4. Remove the SST from the clamp.

CAUTION:



Be careful not to bend the SST needles when performing a clamp removal. If the needles are bent, the clamp can not be

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2005 Mazda MX-5 Miata

2005 HVAC Basic System - MX-5 Miata unlocked.

Fig. 20: Removing SST

Courtesy of MAZDA MOTORS CORP.

REFRIGERANT LINES INSTALLATION NOTE

1. Apply compressor oil to the O-rings and connect the joints.

2. When installing a new cooler hose or pipe add DENSO OIL8 compressor oil into the refrigeration cycle.

Supplemental amount (approx.quantity)

10 ml {10 cc, 0.3 fl oz}

3. Tighten the joints.

1. Tighten the nut or bolt of the joint by hand.

2. Tighten the joint to the specified torque.



If it is a nut joint, tighten the nut using a spanner and torque wrench.

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2005 HVAC Refrigerant System - MX-5 Miata

2005 HVAC

Refrigerant System - MX-5 Miata

REFRIGERANT SYSTEM SERVICE WARNINGS

USING/HANDLING UNAPPROVED REFRIGERANT



Using a flammable refrigerant, such as OZ-12, in this vehicle is dangerous. In an accident, the refrigerant may catch fire, resulting in serious injury or death. When servicing this vehicle, use only R-134a.



Checking for system leakage on a vehicle that has been serviced with flammable refrigerant, such as OZ-12, is dangerous. Conventional leak detectors use an electronically generated arc which can ignite the refrigerant, causing serious injury or death. If a flammable refrigerant may have been used to service the system, or if you suspect a flammable refrigerant has been used, contact the local fire marshal or EPA office for information on handling the refrigerant.

HANDLING REFRIGERANT



Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. Also, due to environmental concerns, use service equipment certified to meet the requirements of SAE J2210 (R-134a recycling equipment) when draining R-134a from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service.

 Do not pressure test or leak test R-134a service equipment and/or vehicle air conditioning system with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.



Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any operation that can cause refrigerant leakage, extinguish or remove the abovementioned heat sources and maintain adequate ventilation.

Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite.

When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and consult a doctor.

STORING REFRIGERANT



The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at temperatures below 40 °C {104 °F}.

REFRIGERANT SYSTEM SERVICE CAUTIONS

 Use only DENSO OIL8 compressor oil for this vehicle. Using PAG oil other than DENSO OIL8

2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata

 compressor oil can damage the A/C compressor.

Do not spill DENSO OIL8 compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately.



PAG oil has a higher moisture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. Therefore, install caps immediately after using the compressor oil or removing refrigerant system parts to prevent moisture absorption.

Fig. 1: Refrigerant System Service Graph

Courtesy of MAZDA MOTORS CORP.

REFRIGERANT SYSTEM GENERAL PROCEDURES

MANIFOLD GAUGE SET INSTALLATION

1. Fully close the valves of the manifold gauge.

2. Connect the charging hoses to the high- and low-pressure side joints of the manifold gauge.

3. Connect the quick couplers to the ends of the charging hoses.

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2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata

4. Remove the caps from the high- and low-pressure side charging valves.

5. Connect the quick couplers to the charging valves.

Fig. 2: Installing Manifold Gauge Set

Courtesy of MAZDA MOTORS CORP.

REFRIGERANT SYSTEM PERFORMANCE TEST

NOTE:



After servicing the refrigerant system, test its performance.

1. Install the manifold gauge set. (See MANIFOLD GAUGE SET INSTALLATION .)

2. Open the hood.

3. Close all the doors and all the windows.

4. Warm up the engine and run it at a constant 1,500 RPM.

5. Turn the A/C switch on.

6. Set the fan switch at 4th.

7. Set the REC/FRESH lever to REC.

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2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata

8. Set the mode dial to VENT.

9. Set the temperature control dial to MAX COLD.

10. Measure the center ventilator temperature and record the temperature reading.

11. Measure the ambient temperature and record the temperature reading.

12. Verify that the temperature reading is in the shaded zone (maximum 6°C {43°F}) .



If the performance is not within the shaded zone, troubleshoot the refrigerant system. (See

FOREWORD .)

Fig. 3: Refrigerant System Performance Test Graph

Courtesy of MAZDA MOTORS CORP.

REFRIGERANT CHARGE CHECK

1. Install the manifold gauge set. (See MANIFOLD GAUGE SET INSTALLATION .)

2. Check the refrigerant pressure reading with the engine stopped.

3. Verify that the high- and low-pressure side readings of the manifold gauge are at 493-788 kPa {5.02-8.04 kgf/cm2, 72-114 psi}.



If the pressure readings are lower than specified, recharge the refrigerant amount. (See

REFRIGERANT CHARGING .)

Microsoft



If the pressure readings are within the specification but there is insufficient cooling, go to the next step.

If the pressure readings are within the specification and there are no leaks, the refrigerant amount is

OK.

2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata

4. Start the engine and run it at a constant 2,000 RPM.

5. Turn the A/C switch on and set the fan switch at 4th.

6. Set the REC/FRESH lever to REC.



If the A/C compressor is short-cycling, note the low-pressure side reading at which the magnetic clutch kicks out.

If the pressure is 167 kPa {1.7 kgf/cm2, 24 psi} or lower, evacuate then recharge the refrigerant system with the proper amount of refrigerant. (See REFRIGERANT CHARGING .)



If the pressure is 206 kPa {2.1 kgf/cm2, 30 psi} or higher, inspect the thermoswitch. (See

THERMOSWITCH INSPECTION .)

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2005 HVAC Refrigerant System - MX-5 Miata

Fig. 4: Identifying Gauge Reading

Courtesy of MAZDA MOTORS CORP.

REFRIGERANT PRESSURE CHECK

1. Install the manifold gauge set. (See MANIFOLD GAUGE SET INSTALLATION .)

2. Open the hood.

3. Close all the doors and all the windows.

4. Warm up the engine and run it at a constant 1,500 RPM.

5. Turn the A/C switch on.

6. Set the fan switch to 4th speed.

7. Set the REC/FRESH lever to REC.

8. Set the mode dial to VENT.

9. Set the temperature control dial to MAX COLD.

10. Measure the high- and low-pressure side readings of the manifold gauge.



If the high- and low-pressure side readings are in the shaded zones as shown in the figure, the refrigerant system is normal.

 If the high- and low-pressure side readings are not as specified, troubleshoot the refrigerant system.

(See FOREWORD .)

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2005 HVAC Refrigerant System - MX-5 Miata

Fig. 5: Refrigerant Pressure Check Chart

Courtesy of MAZDA MOTORS CORP.

REFRIGERANT RECOVERY

WARNING:



Avoid breathing air conditioning refrigerant or lubricant vapor.

Exposure may irritate eyes, nose and throat. Also, due to

Microsoft

2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata environmental concerns, use service equipment certified to meet the requirements of SAE J2210 (R-134a recycling equipment) when draining R-134a from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service.

1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's instructions.

REFRIGERANT CHARGING

1. Install the manifold gauge set. (See MANIFOLD GAUGE SET INSTALLATION .)

2. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge.

3. Connect the vacuum pump hose to the center joint of the manifold gauge.

4. Connect the vacuum pump hose to the vacuum pump.

5. Connect the charging hose to the refrigerant tank.

6. Place the refrigerant tank on the scale.

Refrigerant type

R-134a

Regular amount of refrigerant (approx.quantity)

400 g {14.1 oz}

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2005 HVAC Refrigerant System - MX-5 Miata

Fig. 6: Connecting Charging Hose To Refrigerant Tank

Courtesy of MAZDA MOTORS CORP.

7. Open all the valves of the manifold gauge.

8. Start the vacuum pump and let it operate for 15 min.

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2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata

Fig. 7: Starting Vacuum Pump

Courtesy of MAZDA MOTORS CORP.

9. Verify that the high- and low-pressure side readings of the manifold gauge are at 101 kPa {-760 mmHg,

-29.9 inHg}.

Close each valve of the manifold gauge.

10. Stop the vacuum pump and wait for about 5 min.

11. Inspect the low-pressure side reading of the manifold gauge.



If the reading has changed, check for leaks and then repeat from Step 7.



If the reading has not changed, go to next step.

12. Open the valve of the refrigerant tank.

13. Weigh the refrigerant tank.

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2005 HVAC Refrigerant System - MX-5 Miata

Fig. 8: Opening Valve Of Refrigerant Tank

Courtesy of MAZDA MOTORS CORP.

14. Open the low-pressure side valve of the manifold gauge.

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2005 HVAC Refrigerant System - MX-5 Miata

Fig. 9: Opening Low-Pressure Side Valve Of Manifold Gauge

Courtesy of MAZDA MOTORS CORP.

15. When the low-pressure side reading increases to 0.1 MPa {1 kgf/cm2,14 psi} , close the low-pressure side valve of the manifold gauge.

16. Inspect for leaks from the cooler pipe/hose connections using a gas leak tester.



If there are no leaks, go to next step.

If a leak is found at a loose joint, tighten the joint and check for leaks again.



If there is still a leak at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from Step 7.

If there are no leaks after tightening the joint, go to next step.

17. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of the refrigerant tank has decreased 200 g {7.0 oz} from the amount in Step 13.

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2005 HVAC Refrigerant System - MX-5 Miata

Fig. 10: Closing Low-Pressure Side Valve Of Manifold Gauge

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata

Fig. 11: Opening Low-Pressure Side Valve Of Manifold Gauge

Courtesy of MAZDA MOTORS CORP.

18. Close the low-pressure side valve of the manifold gauge.

WARNING:



Running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.

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2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata

Fig. 12: Closing Low-Pressure Side Valve Of Manifold Gauge

Courtesy of MAZDA MOTORS CORP.

19. Start the engine and actuate the A/C compressor.

20. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of the refrigerant tank has decreased 400 g {14.1 oz} from the amount in Step 13.

21. Close the low-pressure side valve of the manifold gauge.

22. Stop the engine and A/C compressor.

23. Inspect for leaks using a gas leak tester.



If there are no leaks, go to next step.



If a leak is found at a loose joint, tighten the joint and check for leaks again.

If there is still a leak at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from Step 7.



If there are no leaks after tightening the joint, go to next step.

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2005 HVAC Refrigerant System - MX-5 Miata

Fig. 13: Opening Low-Pressure Side Valve

Courtesy of MAZDA MOTORS CORP.

24. Disconnect the high- and low-pressure side quick couplers from the charging valves.

25. Install the caps to the charging valves.

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2005 Mazda MX-5 Miata

2005 HVAC Refrigerant System - MX-5 Miata

Fig. 14: Installing Caps To Charging Valves

Courtesy of MAZDA MOTORS CORP.

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2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

2005 ENGINE PERFORMANCE

Ignition System - MX-5 Miata

IGNITION SYSTEM LOCATION INDEX

Fig. 1: Locating Components Of Ignition System

Courtesy of MAZDA MOTORS CORP.

IGNITION COIL REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove in the order indicated in the table.

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Fig. 2: Identifying Ignition Coil & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

3. Install in the reverse order of removal.

IGNITION COIL INSPECTION

IGNITER

1. Perform spark test. (See SPARK TEST .)

IGNITION COIL OPERATION INSPECTION

1. Remove the ignition coils, high-tension leads, and spark plugs.

2. Connect the ignition coil, high-tension lead, spark plug, and the battery as shown in Fig. 3 .

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Fig. 3: Connecting Ignition Coil, High-Tension Lead, Spark Plug, And Battery

Courtesy of MAZDA MOTORS CORP.

CAUTION:



When connecting the ignition coil, be sure to attach as a female terminal to each terminal. Otherwise, coil terminals may come into contact and the ignition coil could be damaged.

NOTE:



Use the high-tension lead and spark plug that function properly.

3. Verify that the spark plug produces a strong, pale spark when changing the switch off to on.

WARNING:



Do not hold the spark plug, high-tension lead, or ignition coil while inspecting the ignition coil. You may be subjected to a strong shock.

NOTE:



No.1 and No.4 cylinders and No.2 and No.3 cylinders are ignited simultaneously.

SECONDARY COIL WINDING

1. Remove the ignition coil.

2. Measure the resistance from lead hole 1 to 4, and lead hole 2 to 3 using an ohmmeter.



If not within the specification, replace the ignition coil.

Specification

7-11 kilohms

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Fig. 4: Measuring Resistance From Lead Hole Using An Ohmmeter

Courtesy of MAZDA MOTORS CORP.

INSULATION RESISTANCE OF CASE

1. Disconnect the high-tension lead.

2. Disconnect the ignition coil connector.

3. Measure the insulation resistance from terminal 1A to ignition coil case, and terminal 2A to ignition coil case using an ohmmeter.



If not as specified, replace the ignition coil.

Specification

Above 10 megohms

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Fig. 5: Measuring Insulation Resistance From Terminal 1A To Ignition Coil Case

Courtesy of MAZDA MOTORS CORP.

SPARK PLUG REMOVAL/INSTALLATION

CAUTION:



To avoid breaking the spark plug, be sure to fit the socket squarely over it.

1. Disconnect the high-tension lead. (See IGNITION COIL REMOVAL/INSTALLATION .)

2. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION .)

3. Remove the spark plug.

4. Install in the reverse order of removal.

Tightening torque

15-22 N.m {1.5-2.3 kgf.m, 11-16 ft.lbf}

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Fig. 6: Identifying Spark Plug Socket

Courtesy of MAZDA MOTORS CORP.

SPARK PLUG INSPECTION [BP]

VISUAL INSPECTION

1. Inspect the following and replace the spark plugs if necessary.



Damaged insulation

Worn electrode



Carbon deposits



If cleaning is necessary, use a plug cleaner or a wire brush. Wipe the upper insulator.



Damaged gasket

Burnt condition



Plug gap

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Plug gap

1.0-1.1 mm {0.040-0.043 in}

Fig. 7: Identifying Spark Plugs Components

Courtesy of MAZDA MOTORS CORP.

RESISTANCE INSPECTION

1. Measure the resistance of the spark plug using a tester as shown in Fig. 8 .

 If not within the specification, replace the spark plug.

Resistance

3.0-7.5 kilohms [20 °C {68°F}]

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Fig. 8: Measuring Resistance Of Spark Plug Using A Tester

Courtesy of MAZDA MOTORS CORP.

SPARK PLUG INSPECTION [BP WITH TC]

SPECIFICATION

Spark plug type

SK16PR-F8

SK20PR-F8

*1: Standard plug

*2: Cold type plug

PLUG GAP INSPECTION

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

CAUTION:

1. Measure the spark plug gap using the wire type plug gap gauge.



If it exceeds the specification, replace the spark plug.

Standard plug gap

0.7-0.8 mm {0.028-0.031 in}

CLEANING

CAUTION:



To avoid possible damage to the tip, do not adjust the plug gap.

To prevent damaging the tip, use wire type plug gap gauge when inspecting the plug gap.



Carbon may adhere to the tip of the spark plug during vehicle delivery or repeated short distance driving during the winter time. If there is any malfunction such as rough idling or start difficulty due to carbon adhesion causing plug fouling, burn off the carbon by noload racing the engine.

When performing the no-load racing, apply the side brake and foot brake, move the shift lever to neutral (MT) to prevent serious injury.

To avoid possible damage to the spark plug tip, do not use a wire brush for cleaning.

NOTE:



To avoid possible damage to the tip, use gasoline to clean the spark plugs after removing dirt.

1. If there is carbon adhering to the spark plug, perform no-load racing at 3,000 rpm for 3 min.

VISUAL INSPECTION

1. Inspect the following items:



If there is any malfunction, replace the spark plug.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Fig. 9: Identifying Worn Electrode

Courtesy of MAZDA MOTORS CORP.



Insulator breakage

Worn electrode



Damaged gasket

Badly burned insulator (sparking side)

RESISTANCE INSPECTION

1. Measure the resistance of the spark plug using a tester as shown in Fig. 10 .

 If not within the specification, replace the spark plug.

Resistance

3.0-7.5 kilohms [20 °C {68°F}]

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Ignition System - MX-5 Miata

Fig. 10: Measuring Resistance Of Spark Plug Using A Tester

Courtesy of MAZDA MOTORS CORP.

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2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

2005 ACCESSORIES & EQUIPMENT

Instrumentation/Driver Info - MX-5 Miata

INSTRUMENT CLUSTER SYSTEM WIRING DIAGRAM

See INSTRUMENT CLUSTER .

INSTRUMENT CLUSTER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the meter hood. (See METER HOOD REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

Fig. 1: Removing Instrument Cluster

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

CAUTION:



If the instrument cluster is dropped or damaged, the system will not work properly and it may be the cause of trouble or malfunction.

1. Disassemble in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 2: Disassembling Instrument Cluster

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

INSTRUMENT CLUSTER INSPECTION

SPEEDOMETER

1. Remove the speedometer. (See INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY .)

2. Measure the resistance between the speedometer terminals using an ohmmeter.



If not as specified, replace the speedometer.

(See INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY .)

Fig. 3: Speedometer Terminal Connector Continuity

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 4: Identifying Speedometer Terminals

Courtesy of MAZDA MOTORS CORP.

TACHOMETER

1. Remove the tachometer. (See INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY .)

2. Measure the resistance between the tachometer terminals using an ohmmeter.



If not as specified, replace the tachometer.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

(See INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY .)

Fig. 5: Tachometer Terminal Connector Continuity

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 6: Identifying Tachometer Terminals

Courtesy of MAZDA MOTORS CORP.

FUEL GAUGE

1. Remove the fuel gauge. (See INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY .)

2. Measure the resistance between the fuel gauge terminals using an ohmmeter.



If not as specified, replace the fuel gauge.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

(See INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY .)

Fig. 7: Fuel Gauge Terminal Connector Continuity

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 8: Identifying Fuel Gauge Terminals

Courtesy of MAZDA MOTORS CORP.

WATER TEMPERATURE GAUGE

1. Remove the water temperature gauge. (See INSTRUMENT CLUSTER

DISASSEMBLY/ASSEMBLY .)

2. Measure the resistance between the water temperature gauge terminals using an ohmmeter.



If not as specified, replace the water temperature gauge. (See INSTRUMENT CLUSTER

DISASSEMBLY/ASSEMBLY .)

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 9: Water Temperature Gauge Terminal Connector Continuity

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 10: Identifying Water Temperature Gauge Terminals

Courtesy of MAZDA MOTORS CORP.

OIL PRESSURE GAUGE

1. Remove the oil pressure gauge. (See INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY .)

2. Measure the resistance between the oil pressure gauge terminals using an ohmmeter.



If not as specified, replace the oil pressure gauge. (See INSTRUMENT CLUSTER

DISASSEMBLY/ASSEMBLY .)

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 11: Oil Pressure Gauge Terminal Connector Continuity

Courtesy of MAZDA MOTORS CORP.

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2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 12: Identifying Oil Pressure Gauge Terminals

Courtesy of MAZDA MOTORS CORP.

INSTRUMENT CLUSTER INPUT/OUTPUT CHECK MODE

NOTE:



In this mode, it is possible to check the item in the following chart.

DIAGNOSTIC TROUBLE CODE

DTC

Seat belt switch

Door switch

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Saturday, July 04, 2009 12:03:16 PM

Checking item

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

TNS relay

Buzzer

Key reminder switch

NOTE:



The DTC switch are not listed may be indicated, but they cannot be inspected.

OPERATING ORDER

NOTE:



Wait 30 seconds or more have passed after disconnecting the negative battery cable and connect the cable then operate the input/output check mode again after terminating the input/output check mode.

1. Close the all doors.

2. Disconnect the negative battery cable.

3. Open the driver's side door.

4. Connect the negative battery cable.

5. Perform the following procedures within 30 seconds , after connecting the negative battery cable. a. Turn the ignition switch to the ON position. b. Push the door switch 3 times. c. Push the odometer/tripmeter switch 3 times.

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2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

Fig. 13: Identifying Odometer/Tripmeter Switch

Courtesy of MAZDA MOTORS CORP.

CHECKING ORDER

NOTE:



The DTC are displayed in numerical order. (While performing the inspection, if you want to inspect a DTC whose number is smaller than the code number you are currently inspecting, terminate the check mode then repeat the inspection from the beginning.)

If rotating the wheels, cancel the input/output check mode.

CHECK CODE 01-14

NOTE:



The DTC can be fast-forwarded by pushing and holding the odometer/tripmeter switch for 1 second or more.

1. Push the odometer/tripmeter switch and select the DTC.

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2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata

2. Inspect each DTC by following the related inspection procedures. (See INSPECTION OF

DIAGNOSTIC TROUBLE CODES (DTC) .)

CHECK CODE 31

1. Turn the ignition switch to the ACC position.

2. Push the odometer/tripmeter switch and select the DTC.

3. Inspect each DTC by following the related inspection procedures. (See INSPECTION OF

DIAGNOSTIC TROUBLE CODES (DTC) .)

CANCEL ORDER

1. Cancel the input/output check mode by turning the ignition switch to the LOCK position then back to the

ON position.

NOTE:



Cancel the input/output check mode by leaving the instrument cluster in check mode for approximately 45 minutes.

INSPECTION OF DIAGNOSTIC TROUBLE CODES (DTC)

DTC 01 - DIAGNOSTIC TROUBLE CODES INSPECTION CHART

DTC

Seat belt switch on/off signal

STEP

INSPECTION

Pull the driver's side seat belt.

INDICATION oFF on

ACTION

Check the seat belt switch. Check the wiring harness.

(Instrument cluster - seat belt switch)

Go to next step.

Release the driver's side seat belt.

oFF on Input signal to instrument cluster is okay.

Check the seat belt switch. Check the wiring harness.

(Instrument cluster - seat belt switch)

DTC 04 - DIAGNOSTIC TROUBLE CODES INSPECTION CHART

DTC

Door switch on/off signal

STEP INSPECTION INDICATION on

ACTION

Close the driver's side door, then go to next step.

Open the driver's side door.

oFF on

Check the door switch. Check the wiring harness.

(Instrument cluster - door switch)

Close the passenger's side door, then go to next step.

Open the passenger's side door.

oFF

Check the door switch. Check the wiring harness.

(Instrument cluster - door switch)

3 Close all doors.

Check the door switch. Check the wiring harness.

(Instrument cluster - door switch)

Microsoft

2005 Mazda MX-5 Miata

2005 ACCESSORIES & EQUIPMENT Instrumentation/Driver Info - MX-5 Miata oFF Input signal to instrument cluster is okay.

DTC 08 - DIAGNOSTIC TROUBLE CODES INSPECTION CHART

DTC

TNS relay on/off signal

STEP INSPECTION INDICATION ACTION on

Turn the headlight switch to

TNS position.

Turn the headlight switch to

OFF.

oFF oFF on

Go to next step.

Check the TNS relay. Check the wiring harness.

(Battery - TNS relay - instrument cluster)

Check the TNS relay. Check the wiring harness.

(Battery - TNS relay - instrument cluster)

Input signal to instrument cluster is okay.

DTC 14 - DIAGNOSTIC TROUBLE CODES INSPECTION CHART

DTC 14 Operation signal to buzzer

INSPECTION

Wait for 2 seconds selecting DTC 14.

after

INDICATION SITUATION

Buzzer continuously

(No indication) sounds.

Buzzer does not continuously sound.

ACTION

Buzzer is okay.

Replace the odometer/tripmeter.

DTC 31 - DIAGNOSTIC TROUBLE CODES INSPECTION CHART

DTC

Key reminder switch on/off, signal

STEP INSPECTION

Insert the key into steering lock.

Remove the key from steering lock.

INDICATION on Go to next step.

oFF on

ACTION

Check the key reminder switch. Check the wiring harness. (Battery - key reminder switch - instrument cluster)

Check the key reminder switch. Check the wiring harness. (Battery - key reminder switch - instrument cluster) oFF Input signal to instrument cluster is okay.

WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the instrument cluster. (See INSTRUMENT CLUSTER REMOVAL/INSTALLATION .)

3. Turn the socket counterclockwise to remove the bulb as shown in the figure.

4. Install in the reverse order of removal.

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Fig. 14: Removing Warning And Indicator Light Bulb

Courtesy of MAZDA MOTORS CORP.

FUEL GAUGE SENDER UNIT INSPECTION

1. Remove the fuel pump. (See FUEL PUMP (FP) REMOVAL/INSTALLATION [BP, BP WITH

TC] .)

2. Move the float to the topmost and bottommost positions, and verify that the resistance between terminals

A and B of the unit and the position of the float are as indicated in the figure.



If they are not as indicated, replace the fuel gauge sender unit. (See FUEL PUMP (FP)

REMOVAL/INSTALLATION [BP, BP WITH TC] .)

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Fig. 15: Inspecting Fuel Gauge Sender Unit

Courtesy of MAZDA MOTORS CORP.

OIL PRESSURE SWITCH INSPECTION

1. Verify that the oil pressure gauge needle moves to H when the engine is started.

2. Verify that the oil pressure gauge needle moves to L when the engine is stopped.



If the oil pressure gauge needle does not move, inspect the oil pressure gauge and related wiring harness.



If the oil pressure gauge and related wiring harness are normal, inspect the oil pressure. (See OIL

PRESSURE INSPECTION .)

If the oil pressure is normal, replace the oil pressure switch. (See OIL PRESSURE

INSPECTION .)

HORN REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the upper seal board.

3. Disconnect the horn connector.

4. Remove the bolt.

5. Remove the horn.

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Fig. 16: Removing Horn

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

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2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

2005 ENGINE PERFORMANCE

Intake - Air System - MX-5 Miata

INTAKE-AIR SYSTEM LOCATION INDEX (BP, BP WITH TC)

BP, BP WITH TC

Fig. 1: Identifying Intake-Air System Location Index (BP, BP With TC)

2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

BP WITH TC

Fig. 2: Identifying Intake-Air System Location Index (BP With TC)

Courtesy of MAZDA MOTORS CORP.

VACUUM HOSE ROUTING DIAGRAM (BP)

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Fig. 3: Identifying Vacuum Hose Routing Diagram (BP)

Courtesy of MAZDA MOTORS CORP.

VACUUM HOSE ROUTING DIAGRAM (BP WITH TC)

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Fig. 4: Identifying Vacuum Hose Routing Diagram (BP With TC)

Courtesy of MAZDA MOTORS CORP.

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP)

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2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

WARNING:



Hot engines and the intake-air system can cause severe burns. Turn off the engine and wait until it and the intake-air system are cool before removing the intake-air system.

1. Disconnect the negative battery cable.

2. Drain the engine coolant from the radiator. (See ENGINE COOLANT REPLACEMENT .)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Refill the radiator engine coolant. (See ENGINE COOLANT REPLACEMENT .)

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Fig. 5: Exploded View Of Intake-Air System (BP) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

INTAKE MANIFOLD GASKET INSTALLATION NOTE

1. Install the intake manifold gasket with the convex side of the gasket facing the intake manifold side.

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Fig. 6: Installing Intake Manifold Gasket With Convex Side Of Gasket Facing Intake Manifold

Side

Courtesy of MAZDA MOTORS CORP.

DYNAMIC CHAMBER GASKET INSTALLATION NOTE

1. Install the dynamic chamber gasket with the convex side of the gasket facing the intake manifold side.

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Fig. 7: Installing Dynamic Chamber Gasket With Convex Side Of Gasket Facing Intake Manifold

Side

Courtesy of MAZDA MOTORS CORP.

DYNAMIC CHAMBER BRACKET INSTALLATION NOTE

1. Tighten the bolts firmly, then tighten the dynamic chamber side bolt before tightening the fuel distributor side bolt.

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WITH TC)

WARNING:



A hot engine and intake air system can cause severe burns. Turn off the engine and wait until all components are cool before removing the intake air system.

Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE SERVICE

PRECAUTION (BP, BP WITH TC) .)

1. Disconnect the negative battery cable.

2. Drain the engine coolant from the radiator. (See ENGINE COOLANT REPLACEMENT .)

3. Remove the under cover.

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2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

6. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) .)

STEP1

Fig. 8: Exploded View Of Intake-Air System (BP With TC) (Step1) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

STEP2

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2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 9: Exploded View Of Intake-Air System (BP With TC) (Step2) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

STEP 3

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2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 10: Exploded View Of Intake-Air System (BP With TC) (Step3) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

AIR HOSE NO.3 REMOVAL NOTE

1. Position the windshield washer tank out of the way and remove the bracket. (See WINDSHIELD

WASHER TANK REMOVAL/INSTALLATION .)

INTAKE MANIFOLD REMOVAL NOTE

1. Remove the EGR pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP WITH TC) .)

INTAKE MANIFOLD GASKET INSTALLATION NOTE

1. Install the intake manifold gasket with the convex side of the gasket facing the intake manifold side.

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Fig. 11: Installing Intake Manifold Gasket With Convex Side Of Gasket Facing Intake Manifold

Side

Courtesy of MAZDA MOTORS CORP.

DYNAMIC CHAMBER GASKET INSTALLATION NOTE

1. Install the dynamic chamber gasket with the convex side of the gasket facing the intake manifold side.

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2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 12: Installing Dynamic Chamber Gasket With Convex Side Of Gasket Facing Intake Manifold

Side

Courtesy of MAZDA MOTORS CORP.

DYNAMIC CHAMBER BRACKET INSTALLATION NOTE

1. Tighten the bolts firmly, then tighten the dynamic chamber side bolt before tightening the fuel distributor side bolt.

TURBOCHARGER REMOVAL/INSTALLATION (BP WITH TC)

WARNING:



A hot engine and intake air system can cause severe burns. Turn off the engine and wait until all components are cool before removing the intake air system.

PRECAUTION (BP, BP WITH TC) .)

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)

3. Remove the under cover.

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4. Disconnect the MAF sensor connector.

5. Disconnect the IAT sensor No.1 connector.

6. Remove the air cleaner cover together with the MAF sensor and the IAT sensor No.1. (See INTAKE-

AIR SYSTEM REMOVAL/INSTALLATION (BP WITH TC) .)

7. Remove the air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP

WITH TC) .)

8. Remove the air hose No.3 and air pipe No.2. (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION (BP WITH TC) .)

9. Remove the air pipe No.1 together with the air bypass valve. (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION (BP WITH TC) .)

10. Remove the exhaust manifold insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION

(BP WITH TC) .)

11. Remove the turbocharger insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP

WITH TC) .)

12. Remove the joint pipe insulator No.1. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP

WITH TC) .)

13. Remove the dipstick. (See OIL PAN REMOVAL/INSTALLATION (BP WITH TC) .)

14. Remove the HO2S (front). (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP WITH

TC) .)

15. Remove the joint pipe insulator No.2. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP

WITH TC) .)

16. Remove the HO2S (rear). (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP WITH

TC) .)

17. Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP WITH TC) .)

18. Remove the joint pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP WITH TC) .)

19. Remove the oil pipe (oil in). (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP WITH

TC) .)

20. Remove the oil pipe (oil out) nuts. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP

WITH TC) .)

21. Remove the engine coolant pipe (engine coolant out). (See EXHAUST SYSTEM

REMOVAL/INSTALLATION (BP WITH TC) .)

22. Remove the EGR pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP WITH TC) .)

23. Remove the turbocharger bracket. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (BP

WITH TC) .)

24. Remove the turbocharger together with the exhaust manifold. (See EXHAUST SYSTEM

REMOVAL/INSTALLATION (BP WITH TC) .)

25. Install in the reverse of removal.

26. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION (BP, BP

WITH TC) .)

TURBOCHARGER INSPECTION (BP WITH TC)

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2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

COMPRESSOR WHEEL INSPECTION

1. Remove the air hose No.4.(engine compartment). (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION (BP WITH TC) .)

2. Visually inspect the compressor wheel from view A for the cracks, damage, or bending on all the compressor wheel blades.

Fig. 13: Inspecting Compressor Wheel From View Cracks, Damage, Or Bending On All

Compressor Wheel Blades

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata



If there are any cracks or damage, replace the turbocharger.

NOTE:



It is easier to inspect the compressor wheel by inserting a mirror at the position shown in Fig. 13 and illuminating the area using a pen light.

If there is contact between the compressor wheel and compressor housing, there may be cracks, damage, or bending on the blade end area.

If there are cracks, damage, or bending on the compressor wheel, verify the following after replacing the turbocharger.



Intake air/exhaust system related components



Oil pipe damage

TURBINE WHEEL INSPECTION

1. Remove the joint pipe. (See TURBOCHARGER REMOVAL/INSTALLATION (BP WITH TC) .)

2. Visually inspect the turbine wheel from view B for the cracks, damage, or bending on all the turbine wheel blades.

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Fig. 14: Inspecting Turbine Wheel From View Cracks, Damage, Or Bending On All Turbine Wheel

Blades

Courtesy of MAZDA MOTORS CORP.



If there are cracks, damage, or bending on the turbine wheel, replace the turbocharger.

NOTE:



It is easier to inspect the compressor wheel by inserting a mirror at the position shown in Fig. 14 and illuminating the area using a pen light.



If there is contact between the turbine wheel and turbine housing, there may be cracks, damage, or bending on the blade end area.

If there are cracks, damage, or bending on the turbine wheel, verify the following after replacing the turbocharger.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata



Intake air/exhaust system related components



Oil pipe damage

WASTEGATE ACTUATOR INSPECTION (BP WITH TC)

1. Remove the vacuum hose connected to the wastegate actuator port.

2. Connect the SST to the wastegate actuator.

Fig. 15: Connecting SST To Wastegate Actuator

Courtesy of MAZDA MOTORS CORP.

3. Check that the rod moves when supply compressed air.



If there is any malfunction, replace the turbocharger.



If there is no malfunction, verify that there is no malfunction such as incorrect connection or damage in the vacuum hose.

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2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Specification

65-70 kPa {0.67-0.71 kg/cm2, 9.5-10.1 psi}

CHARGE AIR COOLER REMOVAL/INSTALLATION (BP WITH TC)

WARNING:



A hot engine and intake air system can cause severe burns. Turn off the engine and wait until all components are cool before removing the intake air system.

1. Disconnect the negative battery cable.

2. Remove the under cover.

3. Remove the cover with the charge air cooler bottom for easier access.

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

Fig. 16: Exploded View Of Charge Air Cooler (BP With TC) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

TURBOCHARGER WASTEGATE REGULATING VALVE INSPECTION (BP

WITH TC)

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CONTINUITY INSPECTION

1. Remove the turbocharger wastegate regulating valve. (See VACUUM HOSE ROUTING DIAGRAM

(BP WITH TC) .)

Fig. 17: Removing Turbocharger Wastegate Regulating Valve

Courtesy of MAZDA MOTORS CORP.

2. Verify that the airflow is as indicated in the table.

Fig. 18: Verify That Airflow Is As Indicated

Courtesy of MAZDA MOTORS CORP.

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

If there is any malfunction, replace the turbocharger wastegate regulating valve.



If there is no malfunction, perform the CIRCUIT OPEN/SHORT INSPECTION .

CIRCUIT OPEN/SHORT INSPECTION

1. Remove the PCM connector cover.

2. Disconnect the PCM connector.

3. Inspect the following wiring harness for open or short circuit (continuity check).

Open circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.



Turbocharger wastegate regulating valve terminal A and PCM terminal 4D



Turbocharger wastegate regulating valve terminal B and body GND

Short circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.



Turbocharger wastegate regulating valve terminal A and body GND

AIR BYPASS VALVE INSPECTION (BP WITH TC)

1. Remove the air bypass valve. (See VACUUM HOSE ROUTING DIAGRAM (BP WITH TC) .)

2. Connect the vacuum pump to the vacuum ports of the air bypass valve.

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Fig. 19: Connecting Vacuum Pump To Vacuum Ports Of Air Bypass Valve

Courtesy of MAZDA MOTORS CORP.

3. Verify that the airflow is as indicated in the table.



If there is any malfunction, replace the air bypass valve.

Connecting Vacuum Pump To Vacuum Ports Of Air Bypass Valve

Vacuum (kPa {mmHg, inHg}) Valve operation condition Airflow between port A-B

Approx.-37 {-280, -11} Open Yes

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Less than -14 {-100, -4.0} Closed No

AIR CLEANER (ACL) ELEMENT INSPECTION (BP, BP WITH TC)

1. Remove the ACL element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP) .) (See

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WITH TC) .)

2. Verify that the ACL element surface is free of dirt.



If there is dirt present, use an air gun or similar tool to clean the element.



If the replacement time limit has passed, replace the element.

IDLE AIR CONTROL (IAC) VALVE REMOVAL/INSTALLATION (BP, BP WITH

TC)

1. Disconnect the negative battery cable.

2. Remove the air hose and the throttle body. (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION (BP) .) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION

(BP WITH TC) .)

Fig. 20: Removing Air Hose And Throttle Body & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

3. Disconnect the IAC valve connector.

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

IDLE AIR CONTROL (IAC) VALVE INSPECTION (BP, BP WITH TC)

NOTE:



Perform the following test only when directed.

SIMULATION TEST

1. Carry out the "Idle Air Control (IAC) Inspection". (See IDLE AIR CONTROL (IAC) INSPECTION .)



If not as specified, perform a further inspection of the IAC valve.

RESISTANCE INSPECTION

1. Disconnect the negative battery cable.

2. Disconnect the IAC valve connector.

3. Measure the resistance between the IAC valve terminals using an ohmmeter.

Fig. 21: Measuring Resistance Between IAC Valve Terminals Using An Ohmmeter

Courtesy of MAZDA MOTORS CORP.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata



If as specified but the Simulation Test is failed, carry out the CIRCUIT OPEN/SHORT

INSPECTION .



If not as specified, replace the IAC valve. (See IDLE AIR CONTROL (IAC) VALVE

REMOVAL/INSTALLATION (BP, BP WITH TC) .)

Resistance

8.7-10.5 ohms (24°C {75°F})

4. Remove the IAC valve, and inspect it for any damage or clogging.



If not as specified replace the IAC valve. (See IDLE AIR CONTROL (IAC) VALVE

REMOVAL/INSTALLATION (BP, BP WITH TC) .)

CIRCUIT OPEN/SHORT INSPECTION

Open circuit



Power circuit (IAC valve connector terminal A and PCM connector terminal 2P)

GND circuit (IAC valve connector terminal B and PCM connector terminal 2Q)

Short circuit

 IAC valve connector terminal A and PCM connector terminal 2P to GND

VARIABLE TUMBLE CONTROL SYSTEM (VTCS) CHECK VALVE (ONE-

WAY), DELAY VALVE REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Remove the VTCS check valve (one-way) or delay valve. (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION (BP) .) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION

(BP WITH TC) .)

VARIABLE TUMBLE CONTROL SYSTEM (VTCS) CHECK VALVE (ONE-

WAY), DELAY VALVE INSPECTION (BP, BP WITH TC)

1. Remove the VTCS check valve (one-way) or delay valve. (See VARIABLE TUMBLE CONTROL

SYSTEM (VTCS) CHECK VALVE (ONE-WAY), DELAY VALVE REMOVAL/INSTALLATION

(BP, BP WITH TC) .)

2. Blow through A and verify that the air flows from B.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 22: Verify That Air Flows Through A From B

Courtesy of MAZDA MOTORS CORP.

3. Blow through B and verify that the air does not flow from A.



If not as specified, replace the VTCS check valve (one-way) or delay valve.

VARIABLE TUMBLE CONTROL SYSTEM (VTCS) SHUTTER VALVE

ACTUATOR REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Remove the air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP) .) (See

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (BP WITH TC) .)

2. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 23: Removing Intake-Air System & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

VARIABLE TUMBLE CONTROL SYSTEM (VTCS) SHUTTER VALVE

ACTUATOR INSPECTION (BP, BP WITH TC)

NOTE:



Perform the following test only when directed.

1. Disconnect the vacuum hose from the VTCS shutter valve actuator.

2. Connect a vacuum pump to the VTCS shutter valve actuator.

3. Apply vacuum slowly and inspect the rod movement of the VTCS shutter valve actuator under the following conditions:



If not as specified, replace the VTCS shutter valve actuator. (See VARIABLE TUMBLE

CONTROL SYSTEM (VTCS) SHUTTER VALVE ACTUATOR

REMOVAL/INSTALLATION (BP, BP WITH TC) .)



If as specified but the Simulation Test failed, inspect for the following:



Vacuum hose improper routing, kinks or leakage.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 24: Connecting Vacuum Pump To VTCS Shutter Valve Actuator

Courtesy of MAZDA MOTORS CORP.

VARIABLE TUMBLE CONTROL SYSTEM (VTCS) SOLENOID VALVE

REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Disconnect the negative battery cable.

2. Disconnect the VTCS solenoid valve connector.

3. Disconnect the vacuum hose from the VTCS solenoid valve.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 25: Disconnecting Vacuum Hose From VTCS Solenoid Valve

Courtesy of MAZDA MOTORS CORP.

4. Remove in the order indicated in the table.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 26: Removing Variable Tumble Control System (VTCS) Solenoid Valve & Torque

Specifications

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

VARIABLE TUMBLE CONTROL SYSTEM (VTCS) SOLENOID VALVE

INSPECTION (BP, BP WITH TC)

AIRFLOW INSPECTION

NOTE:



Perform the following test only when directed.

1. Remove the VTCS solenoid valve.

2. Inspect for airflow between each port under the following conditions:



If as specified but the Simulation Test is failed, inspect for the following and perform the

CIRCUIT OPEN/SHORT INSPECTION :





Vacuum hose improper routing, kinks or leakage.

If not as specified, replace the VTCS solenoid valve. (See VARIABLE TUMBLE CONTROL

SYSTEM (VTCS) SOLENOID VALVE REMOVAL/INSTALLATION (BP, BP WITH TC) .)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 27: Part Side Connector Terminal Chart

Courtesy of MAZDA MOTORS CORP.

Fig. 28: Inspect For Airflow Between Each Port

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

Open circuit

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata



Power circuit (VTCS solenoid valve connector terminal A and main relay connector terminal D through common connector)



GND circuit (VTCS solenoid valve connector terminal B and PCM connector terminal 2N)

Short circuit



VTCS solenoid valve connector terminal A and main relay connector terminal D through common connector to GND

Fig. 29: Identifying Hardness Side Connector

Courtesy of MAZDA MOTORS CORP.

VARIABLE TUMBLE CONTROL SYSTEM (VTCS) VACUUM SWITCH

INSPECTION (BP, BP WITH TC)

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

OPERATION INSPECTION

1. Disconnect the negative battery cable.

2. Disconnect the vacuum hose from the VTCS vacuum switch.

3. Connect a vacuum pump to the VTCS vacuum switch.

4. Apply vacuum slowly and verify that continuity between the VTCS vacuum switch terminals changes as indicated in the table using an ohmmeter.



If not as specified, replace the VTCS vacuum switch.



If VTCS vacuum switch is okay but the PID value is out of specification, perform the CIRCUIT

OPEN/SHORT INSPECTION .

Fig. 30: VTCS Vacuum Switch PID Value Specification

Courtesy of MAZDA MOTORS CORP.

Connecting Vacuum Pump To VTCS Vacuum Switch

Vacuum (kPa {mmHg, inHg}) Continuity

-36.0- -27.8 {-270- -208,-10.6- -8.2} From no continuity to continuity

-33.9- -27.3 {-254- -204, -10.0- -8.0} From continuity to no continuity

CIRCUIT OPEN/SHORT INSPECTION

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Open circuit



If there is no continuity and the circuit is open, repair or replace the harness.



Power circuit (VTCS vacuum switch connector terminal A and PCM connector terminal 4J through common connector)

 GND circuit (VTCS vacuum switch connector terminal B and GND through common connector)

Short circuit



If there is no continuity and the circuit is shorted, repair or replace the harness.



VTCS vacuum switch connector terminal A and PCM connector terminal 4J through common connector to GND

ACCELERATOR PEDAL (AP) REMOVAL/INSTALLATION (BP, BP WITH TC)

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

Fig. 31: Exploded View Of Accelerator Pedal (AP) (BP, BP With TC) & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

ACCELERATOR CABLE INSTALLATION NOTE

1. Perform the " ACCELERATOR CABLE INSPECTION/ADJUSTMENT " procedure after installing the accelerator cable.

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2005 Mazda MX-5 Miata

2005 ENGINE PERFORMANCE Intake - Air System - MX-5 Miata

ACCELERATOR CABLE INSPECTION/ADJUSTMENT (BP, BP WITH TC)

1. Verify that the throttle valve is at the closed throttle position (TP).

2. Measure the free play of the accelerator cable.

Fig. 32: Measuring Free Play Of Accelerator Cable

Courtesy of MAZDA MOTORS CORP.



If not within the specification, adjust by turning locknuts A.

Free play

1-3 mm {0.04-0.11 in}

Tightening torque

9.9-14.0 N.m {1.0-1.5 kgf.m, 7.3-10.0 ft.lbf}

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2005 ACCESSORIES & EQUIPMENT Interior Trim - MX-5 Miata

2005 ACCESSORIES & EQUIPMENT

Interior Trim - MX-5 Miata

DASHBOARD REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Remove the driver-side air bag module. (See DRIVER-SIDE AIR BAG MODULE

REMOVAL/INSTALLATION .)

3. Remove the passeng