Mazda MX-5 2007 Workshop Manual

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2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

2006-08 ENGINE

Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

ENGINE IDENTIFICATION

Engine can be identified by engine model and number

ENGINE IDENTIFICATION CODE

Engine

2.0L 4-Cylinder

2.3L 4-Cylinder

Code

MECHANICAL

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

1. Install the SSTs (arms) to the cylinder block holes as shown, and hand-tighten the bolts (part No.:

9YA20-1003) or M10 x 1.5T length 90 mm {3.55 in}.

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 1: Installing SST (Arms) To Cylinder Block Holes

Courtesy of MAZDA MOTORS CORP.

2. Assemble the SSTs (bolts, nuts and plate) to the specified positions.

3. Adjust the SSTs (bolts) so that less than 20 mm {0.79 in} of thread is exposed.

4. Make the SSTs (arms and plate) parallel by adjusting the SSTs (bolts and nuts).

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 2: Assembling SSTs (Bolts, Nuts And Plate) To Positions

Courtesy of MAZDA MOTORS CORP.

5. Tighten the SSTs (bolts and nuts) to affix the SSTs firmly.

Fig. 3: Identifying SST Bolts, Nuts & Parallel Plates

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

WARNING:



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 rotating handle firmly when turning the engine.

6. Mount the engine on the SST (engine stand).

7. Drain the engine oil into a container.

8. Install the oil pan drain plug.



With washer

1. Install the oil pan drain plug with a new washer.

Tightening torque

30-41 N.m {3.1-4.1 kgf.m, 23-30 ft.lbf}

 Without washer

1. Inspect the seal rubber of the oil pan drain plug and make sure there are no cracks or damage.

- If necessary, replace the oil pan drain plug.

2. Clean the flange surface (seal rubber) on the oil pan drain plug, then install the oil pan drain plug.

Tightening torque

22-30 N.m {2.2-3.1 kgf.m, 16-22 ft.lbf}

DISMOUNTING



Dismount in the reverse order of mounting.

TIMING CHAIN DISASSEMBLY

1. Disassemble in the order indicated in the table.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 4: Exploded View Of Timing Chain Components

Courtesy of MAZDA MOTORS CORP.

Crankshaft Pulley Lock Bolt Disassembly Note

1. Install the SST to the ring gear to lock the crankshaft against rotation.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 5: Installing SST Ring Gear To Lock Crankshaft Against Rotation

Courtesy of MAZDA MOTORS CORP.

Front Oil Seal Disassembly Note

1. Remove the oil seal using a screwdriver.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 6: Removing Oil Seal

Courtesy of MAZDA MOTORS CORP.

Chain Tensioner Disassembly Note

1. Unlock the chain tensioner ratchet using a suitable screw driver or equivalent tool.

2. Slowly press the tensioner piston.

3. Hold the chain tensioner piston with a 1.5 mm {0.06 in} wire or paper clip.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 7: Disassembling Chain Tensioner

Courtesy of MAZDA MOTORS CORP.

Oil Pump Sprocket Disassembly Note

1. Hold the oil pump sprocket using the SST .

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 8: Holding Oil Pump Sprocket Using SST

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD (I) DISASSEMBLY

1. Disassemble in the order indicated in the table.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 9: Exploded View Of Cylinder Head (I) Disassembly

Courtesy of MAZDA MOTORS CORP.

Camshaft Sprocket Lock Bolt, Variable Valve Timing Actuator Lock Bolt Disassembly Note

1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft sprocket

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata installation bolt or variable valve timing actuator installation bolt (With variable valve timing mechanism).

Without variable valve timing mechanism

Fig. 10: Using Wrench On Cast Hexagon

Courtesy of MAZDA MOTORS CORP.

With variable valve timing mechanism

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 11: Using Wrench On Cast Hexagon

Courtesy of MAZDA MOTORS CORP.

Camshaft Cap Disassembly Note

1. Before removing the camshaft caps, inspect the following:



Camshaft end play and camshaft journal oil clearance (See CAMSHAFT INSPECTION ).

NOTE:



The camshaft caps are numbered to make sure they are assembled in their original positions. When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.

2. Loosen the camshaft caps bolts in 2--3 steps in the order shown in the figure.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 12: Identifying Loosening Sequence Of Camshaft Cap Bolts

Courtesy of MAZDA MOTORS CORP.

Tappet Disassembly Note

NOTE:



The tappets are numbered to make sure they are assembled in their original positions. When removed, keep the tappets with the cylinder head they were removed from. Do not mix the tappets.

Cylinder Head Bolt Disassembly Note

1. Loosen the cylinder head bolts in 2-3 steps in the order shown in the figure.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 13: Loosening Cylinder Head Bolts

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD (II) DISASSEMBLY

1. Disassemble in the order indicated in the table.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 14: Exploded View Of Cylinder Head (II) Disassembly

Courtesy of MAZDA MOTORS CORP.

Valve Keeper Disassembly Note

1. Remove the valve keeper using the SSTs .

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 15: Removing Valve Keeper

Courtesy of MAZDA MOTORS CORP.

Valve Seal Disassembly Note

1. Remove the valve seal using the SST.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 16: Removing Valve Seal

Courtesy of MAZDA MOTORS CORP.

CYLINDER BLOCK (I) DISASSEMBLY

1. Disassemble in the order indicated in the table.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 17: Exploded View Of Cylinder Block (I) Disassembly

Courtesy of MAZDA MOTORS CORP.

Drive Plate (ATX), Flywheel (MTX) Disassembly Note

1. Hold the crankshaft using the SST.

2. Remove the bolts in several passes.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 18: Removal Sequence Of Drive Plate Or Flywheel Bolts

Courtesy of MAZDA MOTORS CORP.

CYLINDER BLOCK (II) DISASSEMBLY

1. Disassemble in the order indicated in the table.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 19: Exploded View Of Cylinder Block (II) Disassembly

Courtesy of MAZDA MOTORS CORP.

Connecting Rod Cap Disassembly Note

1. Before removing connecting rod inspect the connecting rod side clearance. (See CONNECTING ROD

INSPECTION ).

2. Remove the connecting rod bolt from the connecting rod cap by tapping the bolt with a plastic hammer.

NOTE:



The tappets are numbered to make sure they are assembled in their original positions. When removed, keep the tappets with the cylinder head they were removed from. Do not mix the tappets.

Main Bearing Cap Disassembly Note

1. Before removing main bearing cap inspect the crankshaft end play. (See CRANKSHAFT

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

INSPECTION ).

2. Loosen the main bearing cap bolts in two or three steps in the order shown in the figure.

Fig. 20: Loosening Main Bearing Cap Bolts

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD INSPECTION

1. Perform color contrast penetrate examination on the cylinder head surface.



Replace the cylinder head if necessary.

2. Inspect for the following and repair or replace if necessary.

1. Sunken valve seats

2. Excessive camshaft oil clearance and end play

3. Measure the cylinder head for distortion in six directions as shown in the figure.



If it exceeds the maximum specification, replace the cylinder head.

Cylinder head gasket contact surface distortion (Maximum)

0.10 mm {0.004 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 21: Measuring Cylinder Head For Distortion

Courtesy of MAZDA MOTORS CORP.

4. Measure the manifold contact surface distortion as shown in the figure.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 22: Measuring Manifold Contact Surface Distortion

Courtesy of MAZDA MOTORS CORP.



If it exceeds the maximum specification, grind the surface or replace the cylinder head.

Manifold contact surfaces distortion (Maximum)

0.10 mm {0.004 in}

Manifold contact surfaces distortion (Maximum grinding)

0.15 mm {0.006 in}

VALVE, VALVE GUIDE INSPECTION

1. Measure the valve head margin thickness of each valve.



If it is less than the specification, replace the valve.

Valve head margin thickness (Minimum)

IN: 1.62 mm {0.0637 in}

EX: 1.82 mm {0.0716 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 23: Measuring Valve Head Margin Thickness Of Each Valve

Courtesy of MAZDA MOTORS CORP.

2. Measure the length of each valve. Replace the valve if necessary.



If it is less than the specification, replace the valve.

Valve length (Standard)

IN: 102.99-103.79 mm {4.055-4.086 in}

EX: 104.25-105.05 mm {4.105-4.135 in}

Valve length (Minimum)

IN: 102.99 mm {4.055 in}

EX: 104.25 mm {4.104 in}

Fig. 24: Measuring Length Of Each Valve

Courtesy of MAZDA MOTORS CORP.

3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) as indicated in the figure.



If it exceeds the specification, replace the valve.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Valve stem diameter (Standard)

IN: 5.470-5.485 mm {0.2154-0.2159 in}

EX: 5.465-5.480 mm {0.2152-0.2157 in}

Valve stem diameter (Minimum)

IN: 5.440 mm {0.2142 in}

EX: 5.435 mm {0.2140 in}

Fig. 25: Measuring Stem Diameter

Courtesy of MAZDA MOTORS CORP.

4. Measure the inner diameter of each valve guide in X and Y directions at the three points (A, B, and C) as indicated in the figure.



If not as specified, replace the valve guide.

Valve guide inner diameter (Standard)

5.509-5.539 mm {0.2169-0.2180 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 26: Measuring Valve Guise Inner Diameter

Courtesy of MAZDA MOTORS CORP.

5. Calculate the valve stem to guide clearance by subtracting the outer diameter of the valve stem from the inner diameter of the corresponding valve guide.



If it exceeds the specification, replace the valve and/or the valve guide.

Valve stem to guide clearance (Standard)

IN: 0.024-0.069 mm {0.0009-0.0027 in}

EX: 0.029-0.074 mm {0.0012-0.0029 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 27: Calculating Valve Stem To Guide Clearance

Courtesy of MAZDA MOTORS CORP.

Valve stem to guide clearance (Maximum) 0.10 mm {0.004 in}

6. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat.



If not within the specified, replace the valve guide.

Valve guide protrusion height (standard) 12.2-12.8 mm {0.481-0.503 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 28: Measuring Protrusion Height (Dimension A) Of Each Valve Guide

Courtesy of MAZDA MOTORS CORP.

VALVE GUIDE REPLACEMENT

Valve Guide Removal

1. Remove the valve guide from the combustion chamber side using the SST .

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 29: Removing Valve Guide From Combustion Chamber Side

Courtesy of MAZDA MOTORS CORP.

Valve Guide Installation

1. Assemble the SSTs so that depth L is as specified.

Valve guide protrusion height (standard)

12.2-12.8 mm {0.481-0.503 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 30: Measuring Valve Guide Protrusion Height

Courtesy of MAZDA MOTORS CORP.

2. Tap the valve guide in from the top of the cylinder head until the SSTs contacts the cylinder head.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 31: Installing Valve Guide

Courtesy of MAZDA MOTORS CORP.

3. Verify that the valve guide protrusion height (dimension A) is within the specification.

Valve guide protrusion height (standard)

12.2-12.8 mm {0.481-0.503 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 32: Verifying Valve Guide Height

Courtesy of MAZDA MOTORS CORP.

VALVE SEAT INSPECTION/REPAIR

1. Measure the seat contact width.



If not within the specification, resurface the valve seat using a 45° valve seat cutter and/or resurface the valve face.

Valve seat contact width (Standard)

1.2-1.6 mm {0.048-0.062 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 33: 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 out side, correct the valve seat using a 70° (IN) or 65° (EX) cutter, and a 45° cutter.

2. If the seating position is too inner side, correct the valve seat using a 35° (IN) cutter, and a 30°

(EX) cutter, and a 45° cutter.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 34: Positioning Center Of Valve Face

Courtesy of MAZDA MOTORS CORP.

3. Inspect the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem.



If not specified, replace the cylinder head.

Valve protrusion height (Standard)

IN: 40.64-42.24 mm {1.600-1.662 in}

EX: 40.50-42.10 mm {1.595-1.657 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 35: Measuring Protruding Length (Dimension L) Of Valve Stem

Courtesy of MAZDA MOTORS CORP.

VALVE SPRING INSPECTION

1. Apply pressing force to the pressure spring and inspect the spring height.



If it is less than the specification, replace the valve spring.

Valve spring pressing force

390 N {39.76 kgf, 87.67 lbf}

Valve spring standard height H

28.68 mm {1.129 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 36: Performing Valve Spring Inspection

Courtesy of MAZDA MOTORS CORP.

2. Measure the out-of-square of the valve spring, using a square, as shown in the figure.

1. Rotate the valve spring one full turn and measure "A" at the point where the gap is the largest.



If it exceeds the specification, replace the valve spring.

Valve spring out-of-square (Maximum)

1.95 mm {0.0767 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 37: Measuring Valve Spring Out-Of-Square

Courtesy of MAZDA MOTORS CORP.

CAMSHAFT INSPECTION

1. Set the No. 1 and No.5 journals on V-blocks.

2. Measure the camshaft runout.



If it exceeds the specification, replace the camshaft.

Maximum runout (Maximum)

0.03 mm {0.0012 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 38: Measuring Camshaft Runout

Courtesy of MAZDA MOTORS CORP.

3. Measure the cam lobe height at the two points as shown in the figure.



If it is less than the specification, replace the camshaft.

Camshaft standard height (mm {in})

With variable valve timing mechanism

IN: 42.44 {1.671}

EX: 41.18 {1.621}

Without variable valve timing mechanism

IN: 42.12 {1.659}

EX: 41.08 {1.618}

Camshaft minimum height (mm {in})

With variable valve timing mechanism

IN: 42.33 {1.666}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

EX: 41.06 {1.616}

Without variable valve timing mechanism

IN: 42.01 {1.653}

EX: 40.96 {1.612}

Fig. 39: Measuring Cam Lobe Height At Two Points

Courtesy of MAZDA MOTORS CORP.

4. Measure the journal diameters in X and Y directions at the two points (A and B) as indicated in the figure.



If it is less than the specification, replace the camshaft.

Camshaft journal diameter (Standard)

24.96-24.98 mm {0.9827-0.9834 in}

Camshaft journal diameter (Minimum)

24.95 mm {0.982 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 40: Measuring Journal Diameters In X And Y Directions At Two Points (A And B)

Courtesy of MAZDA MOTORS CORP.

5. Remove the tappet.

6. Position a plastigage atop the journals in the axial direction.

7. Install the camshaft cap. (See CAMSHAFT ASSEMBLY NOTE ).

8. Remove the camshaft cap. (See CAMSHAFT CAP DISASSEMBLY NOTE ).

9. Measure the oil clearance.



If it exceeds the specification, replace the cylinder head.

Camshaft journal oil clearance (Standard)

0.035-0.080 mm {0.0014-0.0031 in}

Camshaft journal oil clearance (Maximum)

0.09 mm {0.0035 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 41: Measuring Oil Clearance Using Plastigauge

Courtesy of MAZDA MOTORS CORP.

10. Install the camshaft cap. (See CAMSHAFT ASSEMBLY NOTE ).

11. Measure the camshaft end play.



If it exceeds the specification, replace the cylinder head or camshaft.

Camshaft end play (Standard)

0.09-0.24 mm {0.0035-0.0094 in}

Camshaft end play (Maximum)

0.25 mm {0.0098 in}

12. Remove the camshaft cap. (See CAMSHAFT CAP DISASSEMBLY NOTE ).

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 42: Measuring Camshaft End Play

Courtesy of MAZDA MOTORS CORP.

TAPPET INSPECTION

1. Measure the tappet hole inner diameter in X and Y directions at the two points (A and B) shown in the figure.

Tappet bore diameter (Standard)

31.000-31.030 mm {1.2205-1.2216 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 43: Measuring Tappet Hole Inner Diameter

Courtesy of MAZDA MOTORS CORP.

2. Measure the tappet body outer diameter in X and Y directions at the two points (A and B) shown in the figure.

Tappet diameter (Standard)

30.970-30.980 mm {1.2193-1.2196 in}

3. Subtract the tappet body outer diameter from the tappet hole inner diameter.



If it exceeds the specification, replace the tappet or cylinder head.

Tappet-to-Tappet bore oil clearance (Standard)

0.02-0.06 mm {0.0008-0.0023 in}

Tappet-to-Tappet bore oil clearance (Maximum)

0.15 mm {0.006 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 44: Measuring Tappet Body Outer Diameter In X And Y Directions At Two Points (A And B)

Courtesy of MAZDA MOTORS CORP.

CYLINDER BLOCK INSPECTION

1. Measure the distortion of the cylinder block top surface in six directions as indicated in the figure.



If it exceeds the maximum, replace the cylinder block.

Cylinder head gasket contact surfaces distortion (Maximum)

0.10 mm {0.004 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 45: Measuring Distortion Of Cylinder Block Top Surface In Six Directions

Courtesy of MAZDA MOTORS CORP.

2. Measure the cylinder bores in X and Y directions at 42 mm {1.65 in} below the top surface.



If not within the specification, replace the cylinder block.

Cylinder bore diameter (Standard)

87.500-87.530 mm {3.4449-3.4460 in}

Minimum / maximum bore diameter limit

87.440-87.590 mm {3.4425-3.4484 in}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 46: Measuring Cylinder Bores In X And Y Directions At Below Top Surface

Courtesy of MAZDA MOTORS CORP.

OIL JET VALVE INSPECTION

1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B.



If air does not flow, replace the oil jet valve.

Oil jet valve air pressure

216-274 kPa {2.2-2.7 kgf.cm

31.4-39.7 psi}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 47: Inspecting Oil Jet Valve

Courtesy of MAZDA MOTORS CORP.

PISTON INSPECTION

CAUTION:



The piston and connecting rod cannot be disassembled.

When replacing the piston, piston pin, piston ring and connecting rod, replace them together as a single unit.

1. Measure the outer diameter of each piston at right angle 90° to the piston pin, 10.0 mm {0.40 in} above the under of the piston.



If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Piston diameter (Standard)

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

87.465-87.495 mm {3.4435-3.4446 in}

2. Measure the piston-to-cylinder clearance.

 If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Fig. 48: Measuring Piston-To-Cylinder Clearance

Courtesy of MAZDA MOTORS CORP.

Piston-to-cylinder clearance (Standard)

0.025-0.045 mm {0.0010-0.0017 in}

Piston-to-cylinder clearance (Maximum)

0.11 mm {0.0043 in}

3. Measure the piston ring-to-ring groove clearance around the entire circumference.



If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Piston ring-to-ring groove clearance (Standard)

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Top: 0.03-0.08 mm {0.0012-0.0031 in}

Second: 0.03-0.07 mm {0.0012-0.0027 in}

Oil: 0.03-0.07 mm {0.0012-0.0027 in}

Piston ring-to-ring groove clearance (Maximum)

Top: 0.17 mm {0.0067 in}

Second, Oil: 0.15 mm {0.0059 in}

Fig. 49: Measuring Piston Ring-To-Ring Groove Clearance

Courtesy of MAZDA MOTORS CORP.

4. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.

5. Measure each piston ring end gap with a feeler gauge.



If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Piston end gap (Standard)

Top: 0.16-0.31 mm {0.0063-0.0122 in}

Second: 0.33-0.48 mm {0.0130-0.0189 in}

Oil (rail): 0.20-0.70 mm {0.0079-0.0275 in}

Piston end gap (Maximum)

1.0 mm {0.0393 in}

Fig. 50: Measuring Each Piston Ring End Gap With Feeler Gauge

Courtesy of MAZDA MOTORS CORP.

CRANKSHAFT INSPECTION

1. Install the main bearing cap. (See MAIN BEARING CAP ASSEMBLY NOTE ).

2. Measure the crankshaft end play.



If it exceeds the specification, replace the thrust bearing or crankshaft so that the specified end play is obtained.

Crankshaft end play (Standard)

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

0.22-0.45 mm {0.0087-0.0177 in}

Crankshaft end play (Maximum)

0.55 mm {0.0216 in}

Fig. 51: Measuring Crankshaft End Play

Courtesy of MAZDA MOTORS CORP.

3. Remove the main bearing cap. (See MAIN BEARING CAP DISASSEMBLY NOTE ).

4. Measure the crankshaft runout.



If it exceeds the specification, replace the crankshaft.

Crankshaft runout (Maximum)

0.05 mm {0.0019 in}

5. Measure the journal diameter in X and Y directions at the two points (A and B) as indicated in the figure.



If it exceeds the specification, replace the crankshaft or grind the journal and install the undersize bearing.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 52: Measuring Crankshaft Runout

Courtesy of MAZDA MOTORS CORP.

Main journal bearing size

STD: 51.980-52.000 mm {2.0464-2.0472 in}

US0.25: 51.730-51.750 mm {2.0366-2.0373 in}

Main journal out of round (Maximum)

0.05 mm {0.0019 in}

Crank pin journal diameter [LF]

STD: 46.980-47.000 mm {1.8497-1.8503 in}

US0.25: 46.730-46.750 mm {1.8398-1.8405 in}

Crank pin journal diameter [L3]

STD: 49.980-50.000 mm {1.9677-1.9685 in}

US0.25: 49.730-49.750 mm {1.9579-1.9586 in}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Crank pin out of round (Maximum)

0.05 mm {0.0019 in}

Fig. 53: Measuring Journal Diameter In X And Y Directions At Two Points (A And B)

Courtesy of MAZDA MOTORS CORP.

6. Install the main bearing caps and crankshaft.

7. Position a plastigage atop the journals in the axial direction.

8. Install the main bearing caps and cylinder block. (See MAIN BEARING CAP ASSEMBLY NOTE ).

9. Remove the main bearing caps. (See MAIN BEARING CAP DISASSEMBLY NOTE ).

10. Measure the main journal oil clearance.



If it exceeds the specification, replace the main bearing using the main bearing selection table or grind the main journal and install the oversize bearings so that the specified oil clearance is obtained.

Main journal oil clearance (Standard)

0.019-0.035 mm {0.0007-0.0013 in}

Main journal oil clearance (Maximum)

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

0.10 mm {0.0039 in}

Main bearing size

STD: 2.506-2.509 mm {0.0987-0.0988 in}

OS0.25: 2.628-2.634 mm {0.1034-0.1037 in}

Fig. 54: Measuring Main Journal Oil Clearance

Courtesy of MAZDA MOTORS CORP.

CONNECTING ROD INSPECTION

CAUTION:



The piston and connecting rod cannot be disassembled.

When replacing the piston, piston pin, piston ring and connecting rod, replace them together as a single unit.

1. Install the connecting rod cap. (See CONNECTING ROD CAP ASSEMBLY NOTE ).

2. Measure the connecting rod large end side clearance.



If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata single unit.

Connecting rod side clearance (Standard)

0.14-0.36 mm {0.0056-0.0141 in}

Connecting rod side clearance (Maximum)

0.435 mm {0.0172 in}

Fig. 55: Measuring Connecting Rod Large End Side Clearance

Courtesy of MAZDA MOTORS CORP.

3. Remove the connecting rod cap.

4. Position plastigage atop the journals in the axial direction.

5. Install the connecting rod bearing and connecting rod cap. (See CONNECTING ROD CAP

ASSEMBLY NOTE ).

6. Remove the connecting rod cap.

7. Measure the connecting rod oil clearance.



If it exceeds the specification, replace the connecting rod bearing or grind the crank pin and use oversize bearings so that the specified clearance is obtained.

Connecting rod bearing oil clearance (Standard)

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

0.026-0.052 mm {0.0011-0.0020 in}

Connecting rod bearing oil clearance (Maximum)

0.1 mm {0.0039 in}

Connecting rod bearing size [LF]

STD: 1.498-1.504 mm {0.0589-0.0592 in}

OS0.25: 1.623-1.629 mm {0.0639-0.0641 in}

Connecting rod bearing size [L3]

STD: 1.496-1.502 mm {0.0589-0.0591 in}

OS0.25: 1.621-1.627 mm {0.0639-0.0641 in}

Fig. 56: Measuring Connecting Rod Oil Clearance

Courtesy of MAZDA MOTORS CORP.

BOLT INSPECTION

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

1. Measure the length of each bolt.



If it exceeds the specification, replace the bolt.

Bolt length (mm {in})

Cylinder head bolt (With washer)

Standard: 149.2-149.8 {5.87-5.90}

Maximum: 150.5 {5.91}

Cylinder head bolt (Without washer)

Standard: 145.2-145.8 {5.72-5.74}

Maximum: 146.5 {5.77}

Connecting rod bolt

Standard: 44.7-45.3 {1.75-1.78}

Maximum: 46.0 {1.81}

Main bearing cap bolt (Plastic region tightening bolt only)

Standard: 110.0-110.6 {4.33-4.35}

Maximum: 111.3 {4.38}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 57: Measuring Length Of Each Bolt

Courtesy of MAZDA MOTORS CORP.

VARIABLE VALVE TIMING ACTUATOR INSPECTION [WITH VARIABLE VALVE TIMING

MECHANISM]

CAUTION:



Variable valve timing actuator cannot be disassembled because it is a precision unit.

1. Confirm that the groove of the rotor and notch of the cover at the variable valve timing actuator are aligned and fixed.



If the notch and the bump are not aligned, rotate the rotor toward the valve timing retard position by hand until they are in place.



If the rotor and cover are not fixed even though their notch and groove are aligned, replace the variable valve timing actuator.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 58: Aligning Actuator Rotor Groove & Notch

Courtesy of MAZDA MOTORS CORP.

OIL CONTROL VALVE (OCV) INSPECTION [WITH VARIABLE VALVE TIMING MECHANISM]

Coil Resistance Inspection

1. Disconnect the negative battery cable.

2. Disconnect the oil control valve (OCV) connector.

3. Measure the resistance between terminals A and B using an ohmmeter.



If not as specified, replace the oil control valve (OCV).

Specification

6.9-7.9 ohms [20 °C {68 °F}]

4. Connect the oil control valve (OCV) connector.

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Fig. 59: Identifying Coil Control Valve Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Spool Valve Operation Inspection

1. Disconnect the negative battery cable.

2. Remove the oil control valve (OCV).

3. Verify that the spool valve in the oil control valve (OCV) is in the maximum valve timing retard position as indicated in the figure.



If it exceeds the specification, replace the oil control valve (OCV).

4. Verify that the battery is fully charged.

 If it is less than specification, recharge the battery.

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2007 Mazda MX-5 Miata Sport

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Fig. 60: Identifying Spool Valve

Courtesy of MAZDA MOTORS CORP.

5. Apply battery positive voltage between the oil control valve (OCV) terminals and verify that the spool valve operates and moves to the maximum valve timing advance position.



If it exceeds the specification, replace the oil control valve (OCV).

NOTE:



When applying battery positive voltage between the oil control valve

(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

Microsoft

2007 Mazda MX-5 Miata Sport

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Fig. 61: Positioning Spool Valve Operates And Moves To Maximum Valve Timing Advance

Courtesy of MAZDA MOTORS CORP.

6. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing retard position.



If it exceed the specification, replace the oil control valve (OCV).

VALVE CLEARANCE INSPECTION

1. Measure the valve clearance as follows.

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.

 If the valve clearance exceeds the standard, replace the tappet. (See VALVE CLEARANCE

ADJUSTMENT ).

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 62: Measuring Valve Clearance At Point A

Courtesy of MAZDA MOTORS CORP.

NOTE:



Make sure to note the measured values for choosing the suitable replacement tappets.

Valve clearance [Engine cold]

IN: 0.22-0.28 mm {0.0087-0.0110 in}

EX: 0.27-0.33 mm {0.0106-0.0130 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.



If the valve clearance exceeds the standard, replace the tappet. (See VALVE CLEARANCE

ADJUSTMENT ).

NOTE:



Make sure to note the measured values for choosing the suitable replacement tappets.

Valve clearance [Engine cold]

IN: 0.22-0.28 mm {0.0087-0.0110 in}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

EX: 0.27-0.33 mm {0.0106-0.0130 in}

VALVE CLEARANCE ADJUSTMENT

1. Remove the engine front cover lower blind plug.

2. Remove the engine front cover upper blind plug.

3. Remove the cylinder block lower blind plug.

4. Install the SST as shown in the figure.

Fig. 63: Locating Engine Front Cover Upper & Lower Blind Plug

Courtesy of MAZDA MOTORS CORP.

CAUTION:



Removal of this SST is extremely important. If you crank the engine with this SST installed, the cylinder block will be damaged.

5. Turn the crankshaft clockwise so that the crankshaft is in the No. 1 cylinder TDC position.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 64: Locating Cylinder Block SST

Courtesy of MAZDA MOTORS CORP.

6. Loosen the timing chain.

1. Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.

2. Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain.

3. Placing the suitable bolt (M6 x 1.0 Length 25-35 mm {0.9-1.3 in}) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 65: Loosening Timing Chain

Courtesy of MAZDA MOTORS CORP.

7. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 66: Holding Camshaft Using Suitable Wrench On Cast Hexagon

Courtesy of MAZDA MOTORS CORP.

8. Remove the exhaust camshaft sprocket.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 67: Removing Exhaust Camshaft Sprocket

Courtesy of MAZDA MOTORS CORP.

9. Loosen the camshaft cap bolts in several passes in the order shown in the figure.

NOTE:



The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position. When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.

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Fig. 68: Identifying Loosening Sequence Of Camshaft Cap Bolts

Courtesy of MAZDA MOTORS CORP.

10. Remove the camshaft.

11. Remove the tappet.

12. Select proper adjustment shim.

New adjustment shim

= Removed shim thickness + Measured valve clearance - Standard valve clearance (IN: 0.25 mm

{0.0098 in}, EX: 0.30 mm {0.0118 in})

Valve clearance [Engine cold]

IN: 0.22-0.28 mm {0.0087-0.0110 in}

EX: 0.27-0.33 mm {0.0106-0.0130 in}

13. Install the camshaft with No. 1 cylinder aligned with the TDC position.

14. Tighten the camshaft cap bolt using the following two steps.

Tightening torque

5.0-9.0 N.m

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

{51.0-91.7 kgf.cm, 44.3-79.5 in.lbf}

14.0-17.0 N.m

{1.43-1.73 kgf.m, 10.4-12.5 ft.lbf}

Fig. 69: Camshaft Cap Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

15. Install a new washer (except for Mazda6).

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2007 Mazda MX-5 Miata Sport

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Fig. 70: Camshaft Sprocket Washer

Courtesy of MAZDA MOTORS CORP.

16. Install the exhaust camshaft sprocket.

NOTE:



Do not tighten the bolt for the camshaft sprocket during this step.

First confirm the valve timing, then tighten the bolt.

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Fig. 71: Exhaust Camshaft Sprocket

Courtesy of MAZDA MOTORS CORP.

17. Install the SST to the camshaft as shown in the figure.

18. Remove the M6 x 1.0 bolt from the engine front cover to apply tension to the timing chain.

19. Turn the crankshaft clockwise so that the crankshaft is in the No. 1 cylinder TDC position.

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2007 Mazda MX-5 Miata Sport

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Fig. 72: Installing SST To Camshaft

Courtesy of MAZDA MOTORS CORP.

20. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.

21. Tighten the exhaust camshaft sprocket lock bolt.

Tightening torque

69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}

22. Remove the SST from the camshaft.

23. Remove the SST from the block lower blind plug.

24. Rotate the crankshaft clockwise two turns until the TDC position.



If not aligned, loosen the camshaft sprocket lock bolt and repeat from Step 17.

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 73: Holding Camshaft Using Suitable Wrench On Cast Hexagon

Courtesy of MAZDA MOTORS CORP.

25. Install the new engine front cover upper blind plug.

Tightening torque

8.0-11.5 N.m {82-117 kgf.cm, 71-101 in.lbf}

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2007 Mazda MX-5 Miata Sport

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Fig. 74: Installing Engine Front Cover Upper Blind Plug

Courtesy of MAZDA MOTORS CORP.

26. Install the cylinder block lower blind plug.

Tightening torque

18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf}

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 75: Installing Cylinder Block Lower Blind Plug

Courtesy of MAZDA MOTORS CORP.

27. Install the new engine front cover lower blind plug.

Tightening torque

10-14 N.m {102-142 kgf.cm, 89-123 in.lbf}

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Fig. 76: Identifying Engine Front Cover Lower Blind Plug

Courtesy of MAZDA MOTORS CORP.

CYLINDER BLOCK (I) ASSEMBLY

1. Assemble in the order indicated in the table.

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Fig. 77: Exploded View Of Cylinder Block (I) Assembly & Torque Specification

Courtesy of MAZDA MOTORS CORP.

Main Bearing Cap Assembly Note

1. Install the main bearing caps in the order indicated in the figure.

2. Tighten the main bearing cap bolts using the SST (49 D032 316).

Tightening torque

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Plastic region tightening bolt (Bolt stem length 110 mm)

44-46 N.m {4.5-4.6 kgf.m, 32.5-33.9 ft.lbf}

175°-185°

Elastic region tightening bolt (Bolt stem length 104 mm)

Apply engine oil to all bolts.

3-7 N.m {30.6-71.3 kgf.cm, 26.6-61.9 in.lbf}

23-27 N.m {2.4-2.7 kgf.m, 17-19.9 ft.lbt}

38-42 N.m {3.9-4.2 kgf.m, 28.1-30.9 ft.lbt}

Loosen all the bolts. (no remaining torque).

3-7 N.m {30.6-71.3 kgf.cm, 26.6-61.9 in.lbt}

18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbt}

87.5°-92.5°

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 78: Tightening Sequence Of Main Bearing Cap Bolts

Courtesy of MAZDA MOTORS CORP.

Piston Ring Assembly Note

1. Install the two oil control ring segments and spacer.

2. Verify that the second ring is installed with scraper face side downward.

3. Verify that the top ring is installed with scraper face side inner of upper.

Fig. 79: Identifying Piston Rings

Courtesy of MAZDA MOTORS CORP.

Piston Assembly Note

1. Position the end gap of each ring as indicated in the figure.

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Fig. 80: Positioning End Gap Of Each Ring

Courtesy of MAZDA MOTORS CORP.

2. Insert the piston and connecting rod into the cylinder with the arrow mark to front of the engine.

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Fig. 81: Inserting Piston And Connecting Rod Into Cylinder Bore

Courtesy of MAZDA MOTORS CORP.

Connecting Rod Bearing Assembly Note

1. Install the connecting rod bearing to the connecting rod and connecting rod caps, as shown in the figure.

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Fig. 82: Installing Connecting Rod Bearing

Courtesy of MAZDA MOTORS CORP.

Connecting Rod Cap Assembly Note

CAUTION:



When assembling the connecting rod caps, align the broken, rough faces of the connecting rods and connecting rod caps.

1. Tighten the connecting rod bolts in two steps using the SST (49 D032 316).

Tightening torque

26-32 N.m

{2.7-3.2 kgf.m, 19.2-23.6 ft.lbf}

80°-100°

Balancer Unit Assembly Note

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2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

1. Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly.



If there is any damage or malfunction, replace the balancer unit.

CAUTION:



Due to the precision interior construction of the balancer unit, it cannot be disassembled.

2. Install the SST as shown in the figure.

Fig. 83: Attaching SST To Balancer

Courtesy of MAZDA MOTORS CORP.

3. Turn the crankshaft clockwise the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is attached to the SST ).

4. Install the adjustment shim to the seat face of the balancer unit.

5. With the balancer unit marks at the exact top center, assemble the unit to the cylinder block.

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Fig. 84: Identifying Marks At Exact Top Center

Courtesy of MAZDA MOTORS CORP.

6. Set the SST as shown, then measure the gear backlash using a dial gauge.

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Fig. 85: Measuring Gear Backlash Using Dial Gauge

Courtesy of MAZDA MOTORS CORP.

NOTE:



For an accurate measurement of gear backlash, insert a screwdriver into the crankshaft No. 1 balance weight area and set both the rotation and the thrust direction with the screwdriver, using a prying action, as shown in the figure.

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Fig. 86: Measuring Gear Backlash

Courtesy of MAZDA MOTORS CORP.



If the backlash exceeds the specified range, remeasure the backlash and, using the adjustment shim selection table, select the proper shim, according to the following procedure.

CAUTION:



When measuring the backlash, rotate the crankshaft one full rotation and verify that it is within the specified range at all of the following six positions: 10°, 30°, 100°, 190°, 210°, 280° ATDC.

Value range

0.005-0.101 mm {0.00019-0.0039 in}

1. Using master adjustment shim (No.50), assemble the balancer unit to the cylinder block, then measure the backlash.

2. Select the proper adjustment shim according to the measured value.

3. Install the selected adjustment shim to the balancer unit, then assemble the balancer unit to the cylinder block.

Adjustment shim selection table

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

ADJUSTMENT SHIM SELECTION CHART

Backlash mm {in}

Selection shim (No).

Shim thickness mm {in}

0.267-0.273

{0.01051-

0.01074}

0.260-0.266

{0.01023-

0.01047}

1.15 {0.0452}

1.16 {0.0456}

0.253-0.259

{0.00996-

0.01019}

17 1.17 {0.0460}

0.246-0.252

{0.00968-

0.00992}

0.239-0.245

{0.00940-

0.00964}

0.232-0.238

{0.00913-

0.00937}

0.225-0.231

{0.00885-

0.00909}

0.218-0.224

{0.00858-

0.00881}

1.18 {0.0464}

1.19 {0.0468}

1.20 {0.0472}

1.21 {0.0476}

1.22 {0.0480}

0.211-0.217

{0.00830-

0.00854}

0.204-0.210

{0.00803-

0.00826}

0.197-0.203

{0.00775-

0.00799}

0.190-0.196

{0.00748-

0.00771}

0.183-0.189

{0.00720-

0.00744}

0.176-0.182

{0.00692-

0.00716}

1.23 {0.0484}

1.24 {0.0488}

1.25 {0.492}

1.26 {0.496}

1.27 {0.499}

1.28 {0.503}

Backlash mm {in}

0.127-0.133

{0.00500-0.00523}

0.120-0.126

{0.00472-0.00496}

0.113-0.119

{0.00444-0.00468}

0.106-0.112

{0.00417-0.00440}

0.099-0.105

{0.00389-0.00413}

0.092-0.098 .087

{0.00362-0.00385}

0.085-0.091

{0.00334-0.00358}

0.078-0.084

{0.00307-0.00330}

0.071-0.077

{0.00279-0.00303}

0.064-0.070

{0.00251-0.00275}

0.057-0.063

{0.00224-0.00248}

0.050-0.056

{0.00196-0.00220}

0.043-0.049

{0.00169-0.00192}

0.036-0.042

{0.00141-0.00165}

Microsoft

Thursday, July 09, 2009 2:43:26 PM Page 88

Selection shim (No).

Shim thickness mm {in}

1.35 {0.0531}

1.36 {0.0535}

1.37 {0.0539}

1.38{0.0543}

1.39 {0.0547}

1.40 {0.0551}

1.41 {0.0555}

1.42 {0.0559}

1.43 {0.0562}

1.44 {0.0566}

1.45 {0.0570}

1.46 {0.0574}

1.47 {0.0578}

1.48 {0.0582}

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

0.169-0.175

{0.00665-

0.00688}

0.162-0.168

{0.00637-

0.00661}

0.155-0.161

{0.00610-

0.00633}

0.148-0.154

{0.00582-

0.00606}

0.141-0.147

{0.00555-

0.00578}

0.134-0.140

{0.00527-

0.00551}

CYLINDER BLOCK (II) ASSEMBLY

1. Assemble in the order indicated in the table.

1.29 {0.507}

0.029-0.035

{0.00114-0.00137}

49 1.49 {0.0586}

1.30 {0.511}

0.022-0.028

{0.000866-0.00110}

50 (master) 1.50 {0.0590}

1.31 {0.515}

0.015-0.021

{0.00059-0.000826}

51 1.51 {0.0594}

1.32 {0.519}

0.008-0.014

{0.000314-0.000551}

1.33 {0.523}

0.001-0.007

{0.00003-0.000275}

1.34 {0.527}

0.000-0.000 {0.000-

0.000}

1.52 {0.0598}

1.53 {0.0602}

1.54 {0.0606}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 87: Exploded View Of Cylinder Block (II) Assembly & Torque Specification

Courtesy of MAZDA MOTORS CORP.

Rear Oil Seal Assembly Note

1. Apply clean engine oil to the new oil seal lip.

2. Install the rear oil seal using the SST as shown in the figure.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 88: Installing Rear Oil Seal Using SST

Courtesy of MAZDA MOTORS CORP.

3. Tighten the rear oil seal bolts in the order as shown in the figure.

Tightening torque

8.0-11.5 N.m

{81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 89: Rear Oil Seal Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Drive Plate (ATX), Flywheel (MTX) Assembly Note

1. Hold the crankshaft using the SST .

2. Tighten the bolts in the 3 steps in the figure.

Tightening torque

46-54 N.m

{4.70-5.50 kgf.m, 34.0-39.8 ft.lbf

76-84 N.m

{7.75-8.56 kgf.m, 56.1-61.9 ft.lbf

108-116 N.m

{11.1-11.8 kgf.m, 79.7-85.5 ft.lbf

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 90: Tightening Sequence Of Drive Plate Or Flywheel Bolts (Performed In 3 Steps)

Courtesy of MAZDA MOTORS CORP.

Oil pan Assembly Note

1. Apply a continuous bead of silicone sealant to the oil pan as indicated in the figure.

CAUTION:



Install the oil pan within 10min of applying the silicone sealant

Make sure that there is no oil or dust on the seal side of oil pan.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 91: Installing Silicone Sealant To Oil Pan

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

2. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side.

Fig. 92: Using Square Ruler To Align Oil Pan & Cylinder Block

Courtesy of MAZDA MOTORS CORP.

3. Tighten the rear oil pan bolts in the order as shown in the figure.

Tightening torque

17-23 N.m

{1.8-2.3 kgf.m, 12.6-16.9 ft.lbf}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 93: Rear Oil Pan Bolts Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD (I) ASSEMBLY

1. Assemble in the order indicated in the table.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 94: Exploded View Of Cylinder Head (I) Assembly & Torque Specification

Courtesy of MAZDA MOTORS CORP.

Valve Seal Assembly Note

1. Press the valve seal onto the valve guide by hand.

2. Lightly tap the SST using a plastic hammer.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 95: Pressing Valve Seal

Courtesy of MAZDA MOTORS CORP.

Valve Keeper Assembly Note

1. Install the valve keeper using the SSTs .

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 96: Installing Valve Keeper

Courtesy of MAZDA MOTORS CORP.

CYLINDER HEAD (II) ASSEMBLY

1. Assemble in the order indicated in the table.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 97: Exploded View Of Cylinder Head (II) Assembly & Torque Specification

Courtesy of MAZDA MOTORS CORP.

Cylinder Head Bolt Assembly Note

1. Tighten the cylinder head bolts in the order indicated in the figure in 5 steps using the SST (49 D032

316).

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Tightening torque

3-11 N.m

{30.6-112 kgf.cm, 26.6-97.3 in.lbf}

13-17 N.m

{1.4-1.7 kgf.m, 9.6-12.5 ft.lbf}

43-47 N.m

{4.4-4.7 kgf.m, 31.8-34.6 ft.lbf}

88°-92°

Fig. 98: Cylinder Head Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Camshaft Assembly Note

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

1. Set the cam position of No. 1 cylinder at the top dead center (TDC) and install the camshaft.

2. Temporarily tighten the camshaft bearing caps evenly in 2-3 steps.

3. Tighten the camshaft cap bolt in the order shown two steps.

Tightening torque

5.0-9.0 N.m

{51.0-91.7 kgf.cm, 44.3-79.5 in.lbf}

14-17 N.m

{1.43-1.73 kgf.m, 10.4-12.5 ft.lbf}

Fig. 99: Camshaft Cap Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note

1. Temporarily tighten the camshaft sprocket or variable valve timing actuator installation bolts by hand until the timing chain is installed.

2. Fully tighten the camshaft sprocket or variable valve timing actuator installation bolts after timing chain

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata installation.

TIMING CHAIN ASSEMBLY

1. Assemble in the order indicated in the table.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 100: Exploded View Of Timing Chain Assembly & Torque Specification

Courtesy of MAZDA MOTORS CORP.

Oil Pump Sprocket Assembly Note

1. Hold the oil pump sprocket using the SST .

Fig. 101: Assembling Oil Pump Sprocket

Courtesy of MAZDA MOTORS CORP.

Timing Chain Assembly Note

1. Install the SST to the camshaft, then align the No. 1 camshaft position with the TDC.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 102: Installing SST To Camshaft

Courtesy of MAZDA MOTORS CORP.

2. Remove the cylinder block lower blind plug.

3. Install the SST as shown in the figure.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 103: Installing SST In Place Of Cylinder Block Lower Blind Plug

Courtesy of MAZDA MOTORS CORP.

4. Turn the crankshaft clockwise so that the crankshaft is in the No. 1 cylinder TDC position.

5. Install the timing chain.

6. Install the chain tensioner and remove the retaining wire.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 104: Chain Tensioner Retaining Wire

Courtesy of MAZDA MOTORS CORP.

Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note

1. Hold the camshaft using a suitable wrench on the cast hexagon as shown in the figure.

2. Tighten the camshaft sprocket lock bolt.

Tightening torque

69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 105: Holding Camshaft Using Suitable Wrench On Cast Hexagon

Courtesy of MAZDA MOTORS CORP.

Front Oil Seal Assembly Note

1. Apply clean engine oil to the oil seal.

2. Push the oil seal slightly in by hand.

3. Compress the oil seal using the SST and a hammer.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 106: Installing Front Oil Seal

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 107: Using SST And Hammer

Courtesy of MAZDA MOTORS CORP.

Engine Front Cover Assembly Note

1. Apply silicone sealant to the engine front cover as shown in the figure.

CAUTION:



Install the cylinder head cover within 10 min of applying the silicone sealant.

Silicone sealant is not need in area C as indicated below due to an existing. (With variable valve timing mechanism)

Make sure that there is no oil or dust on the seal side of oil pan.

Thickness

A: 2.2-3.2 mm {0.087-0.125 in}

B: 1.5-2.5 mm {0.059-0.098 in}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 108: Applying Silicone Sealant To Engine Front Cover

Courtesy of MAZDA MOTORS CORP.

2. Install the cylinder head cover bolts in the order as shown in the figure.

CYLINDER HEAD COVER BOLTS SPECIFICATION

Bolt No.

Tightening torque N.m {kgf.m, ft.lbf}

Microsoft

1-18

19-22

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

8.0-11.5 N.m

{81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}

40-55 {4.1-5.6, 29.6-40.5}

Fig. 109: Engine Front Cover Bolt Tightening Sequence

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Crankshaft Pulley Lock Bolt Assembly Note

1. Install the SST to the camshaft as shown in the figure.

Fig. 110: Installing SST To Camshaft

Courtesy of MAZDA MOTORS CORP.

2. Install the M6 x 1.0 bolt in by hand.

3. Turn the crankshaft clockwise so that the crankshaft is in the No. 1 cylinder TDC position.

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 111: Installing M6 X 1.0 Bolt On Crankshaft Pulley

Courtesy of MAZDA MOTORS CORP.

4. Hold the crankshaft pulley using the SST .

5. Tighten the crankshaft pulley lock bolt in the order shown following two steps using the SST (49 D032

316).

Tightening torque

96-104 N.m

{9.8-10.6 kgf.m, 70.9-76.7 ft.lbf}

87°-93°

6. Remove the M6 x 1.0 bolt.

7. Remove the SST from the camshaft.

8. Remove the SST from the block lower blind plug.

9. Rotate the crankshaft clockwise two turns until the TDC position.



If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.

10. Install the cylinder block lower blind plug.

Tightening torque

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf}

Fig. 112: Locking Flywheel Using SST

Courtesy of MAZDA MOTORS CORP.

Cylinder Head Cover Assembly Note

1. Apply silicone sealant to the mating faces as shown in the figure.

CAUTION:



Install the cylinder head cover within 10 min of applying the silicone sealant.

Dot diameter

4.0-6.0 mm {0.16-0.23 in}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 113: Applying Silicone Sealant To Mating Faces

Courtesy of MAZDA MOTORS CORP.

2. Install the cylinder head cover with a new gasket.

3. Tighten the bolts in the order shown in the figure.

Tightening torque

8.0-10.5 N.m

{81.6-107.1 kgf.cm, 70.9-92.9 in.lbf}

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 114: Cylinder Head Cover Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

01-50 TECHNICAL DATA

ENGINE TECHNICAL DATA

ENGINE TECHNICAL DATA SPECIFICATION

Item

Cylinder head gasket contact surface distortion

(Maximum)

Manifold contact surfaces distortion (Maximum)

Manifold contact surfaces distortion (Maximum grinding)

Valve head margin thickness (Minimum)

Valve length (Standard)

Valve length (Minimum)

Microsoft

Thursday, July 09, 2009 2:43:26 PM

Specification

0.10 mm {0.004 in}

0.15 mm {0.006 in}

IN: 1.62 mm {0.0637 in}

EX: 1.82 mm {0.0716 in}

IN: 102.99-103.79 mm {4.055-4.086 in}

EX: 104.25-105.05 mm {4.105-4.135 in}

IN: 102.99 mm {4.055 in}

EX: 104.25 mm {4.104 in}

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Valve stem diameter (Standard)

Valve stem diameter (Minimum)

Valve guide inner diameter (Standard)

Valve stem to guide clearance (Standard)

Valve stem to guide clearance (Maximum)

Valve guide protrusion height (standard)

Valve seat contact width (Standard)

Valve protrusion height (Standard)

Valve spring pressing force

Valve spring standard height H

Valve spring out-of-square (Maximum)

Maximum runout (Maximum)

Camshaft standard height (mm {in})

Camshaft minimum height (mm {in})

Camshaft journal diameter (Standard)

Camshaft journal diameter (Minimum)

Camshaft journal oil clearance (Standard)

Camshaft journal oil clearance (Maximum)

Camshaft end play (Standard)

Camshaft end play (Maximum)

Tappet bore diameter (Standard)

Tappet diameter (Standard)

Tappet-to-Tappet bore oil clearance (Standard)

Tappet-to-Tappet bore oil clearance (Maximum)

Cylinder head gasket contact surfaces distortion

(Maximum)

Cylinder bore diameter (Standard)

Minimum / maximum bore diameter limit

Oil jet valve air pressure

Microsoft

Thursday, July 09, 2009 2:43:26 PM

IN: 5.470-5.485 mm {0.2154-0.2159 in}

EX: 5.465-5.480 mm {0.2152-0.2157 in}

IN: 5.440 mm {0.2142 in}

EX: 5.435 mm {0.2140 in}

5.509-5.539 mm {0.2169-0.2180 in}

IN: 0.024-0.069 mm {0.0009-0.0027 in}

EX: 0.029-0.074 mm {0.0012-0.0029 in}

0.10 mm {0.004 in}

12.2-12.8 mm {0.481-0.503 in}

1.2-1.6 mm {0.048-0.062 in}

IN: 40.64-42.24 mm {1.600-1.662 in}

EX: 40.50-42.10 mm {1.595-1.657 in}

390 N {39.76 kgf, 87.67 lbf}

28.68 mm {1.129 in}

1.95 mm {0.0767 in}

0.03 mm {0.0012 in}

With variable valve timing mechanism

IN: 42.44 {1.671}

EX: 41.18 {1.621}

Without variable valve timing mechanism

IN: 42.12 {1.659}

EX: 41.08 {1.618}

With variable valve timing mechanism

IN: 42.33 {1.666}

EX: 41.06 {1.616}

Without variable valve timing mechanism

IN: 42.01 {1.653}

EX: 40.96 {1.612}

24.96-24.98 mm {0.9827-0.9834 in}

24.95 mm {0.982 in}

0.035-0.080 mm {0.0014-0.0031 in}

0.09 mm {0.0035 in}

0.09-0.24 mm {0.0035-0.0094 in}

0.25 mm {0.0098 in}

31.000-31.030 mm {1.2205-1.2216 in}

30.970-30.980 mm {1.2193-1.2196 in}

0.02-0.06 mm {0.0008-0.0023 in}

0.15 mm {0.006 in}

0.10 mm {0.004 in}

87.500-87.530 mm {3.4449-3.4460 in}

87.440-87.590 mm {3.4425-3.4484 in}

216-274 kPa {2.2-2.7 kgf.cm

31.4-39.7 psi}

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Piston diameter (Standard)

Piston-to-cylinder clearance (Standard)

Piston-to-cylinder clearance (Maximum)

Piston ring-to-ring groove clearance (Standard)

Piston ring-to-ring groove clearance (Maximum)

Piston end gap (Standard)

Piston end gap (Maximum)

Crankshaft end play (Standard)

Crankshaft end play (Maximum)

Crankshaft runout (Maximum)

Main journal bearing size

Main journal out of round (Maximum)

Crank pin journal diameter [LF]

Crank pin journal diameter [L3]

Crank pin out of round (Maximum)

Main journal oil clearance (Standard)

Main journal oil clearance (Maximum)

Main bearing size

Connecting rod side clearance (Standard)

Connecting rod side clearance (Maximum)

Connecting rod bearing oil clearance (Standard)

Connecting rod bearing oil clearance (Maximum)

Connecting rod bearing size [LF]

Connecting rod bearing size [L3]

Bolt length (mm {in})

Microsoft

Thursday, July 09, 2009 2:43:26 PM

87.465-87.495 mm {3.4435-3.4446 in}

0.025-0.045 mm {0.0010-0.0017 in}

0.11 mm {0.0043 in}

Top: 0.03-0.08 mm {0.0012-0.0031 in}

Second: 0.03-0.07 mm {0.0012-0.0027 in}

Oil: 0.03-0.07 mm {0.0012-0.0027 in}

Top: 0.17 mm {0.0067 in}

Second, Oil: 0.15 mm {0.0059 in}

Top: 0.16-0.31 mm {0.0063-0.0122 in}

Second: 0.33-0.48 mm {0.0130-0.0189 in}

Oil (rail): 0.20-0.70 mm {0.0079-0.0275 in}

1.0 mm {0.0393 in}

0.22-0.45 mm {0.0087-0.0177 in}

0.55 mm {0.0216 in}

0.05 mm {0.0019 in}

STD: 51.980-52.000 mm {2.0464-2.0472 in}

US0.25: 51.730-51.750 mm {2.0366-2.0373 in}

0.05 mm {0.0019 in}

STD: 46.980-47.000 mm {1.8497-1.8503 in}

US0.25: 46.730-46.750 mm {1.8398-1.8405 in}

STD: 49.980-50.000 mm {1.9677-1.9685 in}

US0.25: 49.730-49.750 mm {1.9579-1.9586 in}

0.05 mm {0.0019 in}

0.019-0.035 mm {0.0007-0.0013 in}

0.10 mm {0.0039 in}

STD: 2.506-2.509 mm {0.0987-0.0988 in}

OS0.25: 2.628-2.634 mm {0.1034-0.1037 in}

0.14-0.36 mm {0.0056-0.0141 in}

0.435 mm {0.0172 in}

0.026-0.052 mm {0.0011-0.0020 in}

0.1 mm {0.0039 in}

STD: 1.498-1.504 mm {0.0589-0.0592 in}

OS0.25: 1.623-1.629 mm {0.0639-0.0641 in}

STD: 1.496-1.502 mm {0.0589-0.0591 in}

OS0.25: 1.621-1.627 mm {0.0639-0.0641 in}

Cylinder head bolt (With washer)

Standard: 149.2-149.8 {5.87-5.90}

Maximum: 150.5 {5.91}

Cylinder head bolt (Without washer)

Standard: 145.2-145.8 {5.72-5.74}

Maximum: 146.5 {5.77}

Connecting rod bolt

Standard: 44.7-45.3 {1.75-1.78}

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Maximum: 46.0 {1.81}

Main bearing cap bolt (Plastic region tightening bolt only)

Standard: 110.0-110.6 {4.33-4.35}

Maximum: 111.3 {4.38}

IN: 0.22-0.28 mm {0.0087-0.0110 in}

EX: 0.27-0.33 mm {0.0106-0.0130 in}

0.005-0.101 mm {0.00019-0.0039 in}

Valve clearance [Engine cold]

Value range

01-60 SERVICE TOOLS

ENGINE SST

1. Mazda SST number

2. Global SST number

Example

1. 49 UN20 5072

2. 205-072

Holder

Microsoft

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Fig. 115: Identifying Engine SST Holder

Courtesy of MAZDA MOTORS CORP.

ENGINE SERVICE TOOLS SPECIFICATION

1: -

2: 303-507

Crankshaft TDC setting peg

1: 49 E011

1A0

2:-

Ring gear brake set

1: 49 UN30

3465

2: 303-465

Camshaft

Alignment timing Tool

1: 49 G032 354

2:-

Adjusting wrench

1: 49 B012

015

2:-

Valve guide installer

1: 49 0636 100B

2:-

Valve spring lifter arm

Microsoft

Thursday, July 09, 2009 2:43:26 PM

1: 49 L010

1: 49 B012 0A2

2:-

Pivot

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

1A0

2:-

Engine hanger set

1: 49 H010 401

2:-

Oil seal installer

1: 49 0107 680A

2:-

Engine stand

1: 49 L012 0A0B

2:-

Valve seal and valve guide installer set

1: 49 T032

302

2:-

Bearing installer

1: 49

UN30

3328

2: 303-328

Rear oil seal replacer

1: 49 S120 170

2:-

Valve seal remover

1: 49 D032 316

2:-

Protractor

1: 49 G011 201

2:-

Attachment

Microsoft

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

2007 BRAKES

On-Board Diagnostic (ABS) - MX-5 Miata

ABS SYSTEM WIRING DIAGRAM

Fig. 1: ABS System Wiring Diagram

Courtesy of MAZDA MOTORS CORP.

ON-BOARD DIAGNOSIS [ABS]

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

ON-BOARD DIAGNOSTIC (OBD) TEST DESCRIPTION



The OBD test inspects the integrity and function of the ABS and outputs the results when requested by the specific tests.

On-board diagnostic test also:



Provides a quick inspection of the ABS usually performed at the start of each diagnostic procedure.





Provides verification after repairs to ensure that no other faults occurred during service.

The OBD test is divided into 3 tests:



Read/clear diagnostic results, PID monitor and record and active command modes.

READ/CLEAR DIAGNOSTIC RESULTS



This function allows you to read or clear DTCs in the ABS HU/CM memory.

PID/DATA MONITOR AND RECORD



This function allows you to access certain data values, input signals, calculated values, and system status information.

ACTIVE COMMAND MODES

 This function allows you to control devices through the M-MDS.

READING DTCS PROCEDURE

1. Connect the M-MDS to the DLC-2.

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.



When using the IDS (laptop PC)



Select the "Toolbox" tab.

Select "Self Test".



Select "Modules".



 Select "ABS".

When using the PDS (Pocket PC)



Select "Modules Tests".

Select "ABS".



Select "Self Test".

3. Verify the DTC according to the directions on the screen.



If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.

4. After completion of repairs, clear all DTCs stored in the ABS.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

Fig. 2: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

CLEARING DTCS PROCEDURES

1. Connect the M-MDS to the DLC-2.

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.



When using the IDS (laptop PC)



Select the "Toolbox" tab.



Select "Self Test".

Select "Modules".



Select "ABS".

 When using the PDS (Pocket PC)



Select "Modules Tests".



Select "ABS".

Select "Self Test".

3. Verify the DTC according to the directions on the screen.

4. Press the clear button on the DTC screen to clear the DTC.

5. Verify that no DTC are displayed.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

Fig. 3: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

PID/DATA MONITOR AND RECORD PROCEDURE

1. Connect the M-MDS to the DLC-2.

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.



When using the IDS (laptop PC)



Select the "Toolbox" tab.



Select "DataLogger".

Select "Modules".



Select "ABS".

 When using the PDS (Pocket PC)



Select "Modules Tests".



Select "Optional" tab.

Select "ABS".



Select "DataLogger".

3. Select the applicable PID from the PID table.

4. Verify the PID data according to the directions on the screen.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

Fig. 4: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

NOTE: The PID data screen function is used for monitoring the calculated value.

Therefore, if the monitored value of the output parts is not within specification, inspection of the monitored value of input parts corresponding to applicable output part control is necessary. In addition, because the system does not display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output part individually using a active command modes function.

ACTIVE COMMAND MODES PROCEDURE

1. Connect the M-MDS to the DLC-2.

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.



When using the IDS (laptop PC)



Select the "Toolbox" tab.



Select "DataLogger".

Select "Modules".

Microsoft





Select "ABS".

When using the PDS (Pocket PC)



Select "Modules Tests".

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Select "ABS".



Select "DataLogger".

3. Select the active command modes from the PID table.

4. Perform the active command modes, inspect the operations for each parts.



If there is no operation sound from the relay, motor, and solenoid after the active command mode inspection is performed, it is possible that there is an open or short circuit in the wiring harness, relay, motor or solenoid, or sticking and operation malfunction.

Fig. 5: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

DTC TABLE

DTC

M-MDS

B1317

B1318

B1342

B1484

B2477

Microsoft

Thursday, July 09, 2009 3:17:55 PM

System malfunction location

Power supply system

ABS HU/CM system

Brake switch system

ABS HU/CM configuration

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

C1168

C1175

C1178

C1186

C1194

C1198

C1210

C1214

C1233

C1234

C1235

C1236

C1242

C1095

C1096

C1141

C1142

C1143

C1144

C1145

C1148

C1155

C1158

C1165

C1246

C1250

C1254

C1266

C1805

DTC U0073, U2516[MULTIPLEX

COMMUNICATION SYSTEM]

DTC TABLE[MULTIPLEX

COMMUNICATION SYSTEM]

DTC TABLE[MULTIPLEX

COMMUNICATION SYSTEM]

PID/DATA MONITOR TABLE

PID name

(definition) Unit/Condition

Operation condition

(reference)

Pump motor, motor relay system

LF ABS sensor rotor system

RF ABS sensor rotor system

LR ABS sensor rotor system

RR ABS sensor rotor system

RF ABS wheel-speed sensor system

LF ABS wheel-speed sensor system

RR ABS wheel-speed sensor system

LR ABS wheel-speed sensor system

Fail-safe relay system

LF outlet solenoid valve system

LF inlet solenoid valve system

RF outlet solenoid valve system

RF inlet solenoid valve system

LF ABS wheel-speed sensor/ABS sensor rotor system

RF ABS wheel-speed sensor/ABS sensor rotor system

RR ABS wheel-speed sensor/ABS sensor rotor system

LR ABS wheel-speed sensor/ABS sensor rotor system

LR outlet solenoid valve system

RR outlet solenoid valve system

LR inlet solenoid valve system

RR inlet solenoid valve system

Fail-safe relay system

Incorrect ABS HU/CM installed

CAN system communication error

Communication error to other module

Abnormal message from PCM

Action

ABS HU/CM terminal

Microsoft

ABS_VOLT

(System battery voltage value)

ABSLF_I

(Left front inlet solenoid valve output state)

ABSLF_O

(Left front outlet solenoid valve output state)

ABSLR_I

(Left rear inlet solenoid valve output state)

ABSLR_O

(Left rear outlet solenoid valve output state)

ABSPMPRLY

(Motor relay output state)

ABSRF_I

(Right front inlet solenoid valve output state)

On/Off

ABSRF_O

(Right front outlet solenoid valve output state)

On/Off

ABSRR_I

(Right rear inlet

Microsoft

Thursday, July 09, 2009 3:17:55 PM

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Ignition switch at

Inspect the power

ON: supply circuit.

(See ABS SYSTEM

Approx. 12.2 V

INSPECTION .)

Idling: Approx.

14.1 V

Solenoid valve activated: On

Solenoid valve not activated:

Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Solenoid valve activated: On

Solenoid valve not activated:

Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Solenoid valve activated: On

Solenoid valve not activated:

Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Solenoid valve activated: On

Solenoid valve not activated:

Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Relay activated:

Relay not activated: Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Solenoid valve activated: On

Solenoid valve not activated:

Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Solenoid valve activated: On

Solenoid valve not activated:

Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Solenoid valve activated: On

Inspect the ABS

HU/CM.

Page 8

solenoid valve output state)

ABSRR_O

(Right rear outlet solenoid valve output state)

ABSVLVRLY

(Fail-safe relay output state)

BOO_ABS

(Brake pedal switch input)

On/Off

CCNTABS

(Number of continuous codes)

LF_WSPD

(Left front ABS wheel-speed sensor input)

LR_WSPD

(Left rear ABS wheel-speed sensor input)

PMP_MOTOR

(Pump motor output state)

KPH, MPH

On/Off

RF_WSPD

(Right front ABS wheel-speed sensor input)

RR_WSPD

(Right rear ABS wheel-speed sensor input)

KPH, MPH

Microsoft

Thursday, July 09, 2009 3:17:55 PM

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Solenoid valve not activated:

Off

(See ABS HU/CM

INSPECTION .)

Solenoid valve activated: On

Solenoid valve not activated:

Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Fail-safe relay is activated: On

Inspect ABS HU/CM.

(See ABS HU/CM

Fail-safe relay is deactivated: Off

INSPECTION )

Brake pedal depressed: On

Inspect the brake switch.



Brake pedal released: Off

DTCs detected:

1-255

Perform the DTC inspection.

No DTCs detected: 0

Vehicle stopped:

0 KPH, 0 MPH

Inspect the ABS wheel-speed sensor.

Vehicle running:

Vehicle speed

Vehicle stopped:

0 KPH, 0 MPH

Inspect the ABS wheel-speed sensor.



Vehicle running:

Vehicle speed

Pump motor activated: On

Pump motor not activated: Off

Inspect the ABS

HU/CM.

(See ABS HU/CM

INSPECTION .)

Vehicle stopped:

0 KPH, 0 MPH

Inspect the ABS wheel-speed sensor.



Vehicle running:

Vehicle speed

Vehicle stopped:

0 KPH, 0 MPH

Inspect the ABS wheel-speed sensor.



Vehicle running:

Vehicle speed

Page 9

E, F

G, H

M, O

I, L

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

ACTIVE COMMAND MODES TABLE

Command name Output part

LF_INLET LF inlet solenoid valve

LF_OUTLET

LR_INLET

LR_OUTLET

LF outlet solenoid valve

LR inlet solenoid valve

LR outlet solenoid valve

PMP_MOTOR

RF_INLET

RF_OUTLET

RR_INLET

RR_OUTLET

Pump motor

RF inlet solenoid valve

RF outlet solenoid valve

RR inlet solenoid valve

RR outlet solenoid valve

Operation

On/Off

Operating condition

Ignition switch at ON

DTC B1317, B1318 [ABS]

DTC B1317, B1318 POSSIBLE CAUSE TABLE

DTC B1317, B1318 Power supply system

DETECTION CONDITION

POSSIBLE CAUSE



B1317





The voltage at ABS HU/CM terminal J is 16.8 V or more.

B1318



The vehicle speed exceeds 6 km/h and the voltage at ABS HU/CM terminal J is less than 9.6 V



ENGINE 15 A fuse malfunction

Open circuit or short to ground in the wiring harness between the ABS HU/CM terminal J and the battery



Open circuit or faulty ground in the wiring harness between the ABS HU/CM terminal D and the body ground

Battery deterioration



Generator malfunction

Poor connection at connectors (female terminal)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

DIAGNOSTIC PROCEDURE

DTC B1317, B1318 DIAGNOSTIC PROCEDURE TABLE

STEP

1 INSPECT BATTERY

VOLTAGE

INSPECTION

Yes



INSPECT BATTERY

GRAVITY

 Is battery specific gravity as specified?

INSPECT CHARGING

SYSTEM



Is the battery terminal voltage normal?

Are the generator and drive belt tensions normal?

Yes

ACTION

Make sure that battery terminal connection is normal. Go to the next step.

Charge or replace the battery, then go to Step 6.

(See BATTERY RECHARGING

[LF] .)

(See BATTERY

REMOVAL/INSTALLATION

[LF] .)

Go to the next step.

Replace the battery, then go to Step 6.

(See BATTERY

REMOVAL/INSTALLATION

[LF] .)

Go to the next step.

Replace generator and/or drive belt as necessary, then go to Step 6.

(See DRIVE BELT

REPLACEMENT [LF] .)

(See GENERATOR

REMOVAL/INSTALLATION

[LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

INSPECT ABS HU/CM

POWER SUPPLY FOR

OPEN CIRCUIT



Start the engine.



Measure the voltage between ABS HU/CM terminal J and ground.



Is the voltage approx.

10 V?

INSPECT ABS HU/CM

GROUND FOR POOR

GROUND OR OPEN

CIRCUIT



Turn the ignition switch off.

Measure the resistance between ground and

ABS HU/CM terminal

Is the resistance within

0-1 ohm?

VERIFY

TROUBLESHOOTING

COMPLETED



Make sure to reconnect all disconnected connectors.

Clear the DTC from the memory.



(See CLEARING

DTCS

PROCEDURES .)

Start the engine and drive the vehicle at 10 km/h {6.2 mph} or more.



Is the same DTC present?

VERIFY AFTER REPAIR

PROCEDURE

Microsoft

Thursday, July 09, 2009 3:17:55 PM

Yes

Go to the next step.

Repair or replace the wiring harness for open circuit between the ABS HU/CM and ground, then go to Step 6.

Go to the next step.

If there is no continuity.



Repair or replace the wiring harness for open circuit between the ABS HU/CM and ground, then go to the next step.

If the resistance is not within 0-1 ohm:

Repair or replace harness for poor ground, then go to the next step.

Replace the ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

Go to the next step.

Yes

Page 12

Go to the applicable DTC inspection.

(See DTC Table .)

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Are any other DTCs present?

No DTC troubleshooting completed.

DTC B1342 [ABS]

DTC B1342 POSSIBLE CAUSE TABLE

DTC B1342

DETECTION CONDITION

POSSIBLE CAUSE

ABS HU/CM system



The ABS HU/CM on-board diagnostic function detects control module malfunction.



ABS HU/CM internal malfunction

DIAGNOSTIC PROCEDURE

DTC B1342 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION

1 VERIFY CURRENT

STATUS OF

MALFUNCTION

Yes



Clear the DTC from the memory.

(See CLEARING

DTCS

PROCEDURES .)



Is same DTC present?

VERIFY AFTER REPAIR

PROCEDURE



Are any other DTCs present?

Yes

ACTION

Replace the ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

DTC B1484 [ABS]

DTC B1484 POSSIBLE CAUSE TABLE

DTC B1484

DETECTION CONDITION

POSSIBLE CAUSE

Microsoft

Thursday, July 09, 2009 3:17:55 PM

Brake switch system



Open circuit in the wiring harness between the ABS HU/CM terminal and the brake switch terminal



Brake switch malfunction

Open circuit in the wiring harness between the ABS HU/CM terminal N and the brake switch terminal D

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

DIAGNOSTIC PROCEDURE

DTC B1484 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION

1 INSPECT ABS HU/CM

TO BRAKE SWITCH

FOR OPEN CIRCUIT

Yes



Turn the ignition switch off.

Disconnect the ABS

HU/CM and brake switch connector.



Inspect for continuity

ABS HU/CM terminal

N and brake switch terminal D.



Is there continuity?

INSPECT BRAKE

SWITCH

Yes



Inspect the brake switch.

(See BRAKE

SWITCH

INSPECTION .)



Is the brake switch normal?

VERIFY

TROUBLESHOOTING

COMPLETED

Yes

Microsoft

Thursday, July 09, 2009 3:17:55 PM

ACTION

Go to the next step.

Repair or replace the wiring harness for open circuit between ABS HU/CM and brake switch, then go to the next step.

Go to the next step.

Replace the brake switch, then go to the next step.

(See BRAKE PEDAL

REMOVAL/INSTALLATION .)

Page 14

Replace the ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Make sure to reconnect all disconnected connectors.



Clear the DTC from the memory.

 (See CLEARING

DTCS

PROCEDURES .)



Are the same DTCs present?

VERIFY AFTER REPAIR Yes

PROCEDURE

 Are any other DTC present?

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

DTC B2477 [ABS]

DTC B2477 POSSIBLE CAUSE TABLE

DTC B2477

DETECTION CONDITION

POSSIBLE CAUSE

ABS HU/CM configuration



Configuration setting failure is detected.



Module configuration procedure was not completed properly.

DIAGNOSTIC PROCEDURE

DTC B2477 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION

1 VERIFY

CONFIGURATION

Yes



Has the ABS HU/CM configuration been performed?

VERIFY DTC

TROUBLESHOOTING

COMPLETED

Yes



Clear the DTC from the memory.



(See CLEARING

DTCS

Microsoft

Thursday, July 09, 2009 3:17:55 PM Page 15

ACTION

Go to the next step.

Perform configuration using the M-

MDS.

(See ABS CONFIGURATION .)

Repeat the inspection from Step 1.

If the malfunction recurs, replace the

ABS HU/CM.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

PROCEDURES .) No

 Is the same DTC present?

VERIFY AFTER REPAIR Yes

PROCEDURE



Are any other DTCs present?

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

DTC C1095, C1096 [ABS]

DTC C1095, C1096 POSSIBLE CAUSE TABLE

DTC C1095, C1096 Pump motor, motor relay system

DETECTION CONDITION



C1095



When the pump motor monitor voltage remains at 2.0 V or more for 1 s

 ABS motor monitor OFF signal is input within specified time limit when the motor signal is switched from ON to

OFF by ABS HU/CM.



C1096

 When the difference between the battery power supply voltage and pump motor power supply voltage remains at

4.0 V or more for 0.1 s or more while the pump motor is operating

POSSIBLE CAUSE



ABS 40 A fuse malfunction



Open or short to ground circuit in the wiring harness between the battery and the ABS

HU/CM terminal B

Open circuit in the wiring harness between the ABS HU/CM terminal A and the body ground



Open or short circuit in the ABS HU/CM internal motor relay, or stuck motor relay

Open or short circuit in the ABS HU/CM internal motor, or frozen motor



Fail-safe relay malfunction

Poor connection at connectors (female terminal)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

DIAGNOSTIC PROCEDURE

DTC C1095, C1096 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION

1 INSPECT ABS FUSE

CONDITION

Yes



Is the ABS 40A fuse normal?

INSPECT MOTOR

RELAY POWER SUPPLY

Yes

FOR OPEN CIRCUIT

ACTION

Go to the next step.

Replace the fuse, then go to Step 5.

Go to the next step.



Turn the ignition switch off.



Disconnect ABS

HU/CM connector.

Turn the ignition switch to the ON position (engine off).

 Measure voltage between ABS HU/CM terminal B (harnessside) and ground.



Is the voltage B+ ?

INSPECT PUMP MOTOR Yes

Microsoft

Thursday, July 09, 2009 3:17:55 PM Page 17

Repair or replace the wiring harness for open circuit between battery positive terminal and ABS HU/CM terminal B, then go to Step 5.

Go to the next step.

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

GROUND FOR OPEN

CIRCUIT



Turn the ignition switch off.



Inspect for continuity between ABS HU/CM terminal A (harnessside) and ground.



Is there continuity?

VERIFY PUMP MOTOR

OPERATION

Yes



Turn the ignition switch off.

Connect the M-MDS to the DLC-2.



Turn the ignition switch to the ON position (engine off).

Access PMP_MOTOR active command modes using M-MDS.

 Does the pump motor operate?

VERIFY

TROUBLESHOOTING

COMPLETED

Yes



Make sure to reconnect all disconnected connectors.

Clear the DTC from the memory.



(See CLEARING

DTCS

PROCEDURES .)

Start the engine and drive the vehicle at 10 km/h {6.2 mph} or more.

Gradually slow down and stop the vehicle.

Microsoft

Thursday, July 09, 2009 3:17:55 PM Page 18

Repair or replace the wiring harness for open circuit between ABS HU/CM terminal A and ground, then go to Step

Go to the next step.

Replace the ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

Replace the ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION

Go to the next step.

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Is the same DTC present?

VERIFY AFTER REPAIR Yes

PROCEDURE



Are any other DTCs present?

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

DTC C1141, C1142, C1143, C1144 [ABS]

DTC C1141, C1142, C1143, C1144 POSSIBLE CAUSE TABLE

DTC

C1141

C1142

C1143

C1144

DETECTION CONDITION

POSSIBLE CAUSE

LF ABS sensor rotor system

RF ABS sensor rotor system

LR ABS sensor rotor system

RR ABS sensor rotor system



Periodic abnormality is detected in the signal wave pattern from the ABS wheel-speed sensors.



ABS wheel-speed sensor malfunction

ABS sensor rotor malfunction (foreign material adhering)



Improper installation of

ABS wheel-speed sensor and/or sensor rotor

Excessive clearance between the ABS wheelspeed sensor and sensor rotor

DIAGNOSTIC PROCEDURE

DTC C1141, C1142, C1143, C1144 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION

ACTION

Go to Step 4.

INSPECT PID FOR ABS

WHEEL-SPEED SENSOR

Yes

OUTPUT ERROR USING

M-MDS



Turn the ignition switch off.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Connect the M-MDS to the DLC-2.

Select the following

PIDs using the M-

MDS:

LF_WSPD

LR_WSPD

RF_WSPD

RR_WSPD



Drive the vehicle.

Verify that the vehicle speeds detected by the four ABS wheel-speed sensors are approximately the same.



Are the vehicle speeds approximately the same?

INSPECT IF

MALFUNCTION

OCCURRED DUE TO

IMPROPER SENSOR

CLEARANCE.

Yes



Inspect the clearance between the ABS wheel-speed sensor and the ABS sensor rotor.

(See FRONT ABS

WHEEL-SPEED

SENSOR

INSPECTION .)

(See REAR ABS

WHEEL-SPEED

SENSOR

INSPECTION .)



Is the clearance normal?

Microsoft

Thursday, July 09, 2009 3:17:55 PM Page 20

Go to the next step.

Replace the ABS wheel-speed sensor,

(See

(See then go to Step 4.

FRONT ABS WHEEL-SPEED

SENSOR

REMOVAL/INSTALLATION .)

REAR ABS WHEEL-SPEED

SENSOR

REMOVAL/INSTALLATION .)

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

Clearance Front:

0.3-1.0 mm {0.012-

0.057 in}

Rear: 0.8-1.6 mm

{0.032-0.062 in}

VISUALLY INSPECT

ABS SENSOR ROTOR

FOR FOREIGN

MATERIAL ADHERING

OR IMPROPER

INSTALLATION

Yes



Is the result normal?

VERIFY THAT THE

SAME DTC IS NOT

PRESENT

Yes



Clear the DTCs from the memory.

(See CLEARING

DTCS

PROCEDURES .)



Start the engine and drive the vehicle at 10 km/h {6.2 mph} or more.

Are the same DTCs present?

VERIFY THAT NO

OTHER DTCS ARE

PRESENT

Yes



Are any other DTCs output?

Go to the next step.

Replace the front wheel hub component or rear drive shaft, then go to the next step.

(See WHEEL HUB, STEERING

KNUCKLE

REMOVAL/INSTALLATION .)

(See REAR DRIVE SHAFT

REMOVAL/INSTALLATION .)

Repeat the inspection from Step 1.

If the malfunction recurs, replace the

ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

DTC C1145, C1155, C1165, C1175 [ABS]

DTC C1145, C1155, C1165, C1175 POSSIBLE CAUSE TABLE

Microsoft

Thursday, July 09, 2009 3:17:55 PM

C1145

Page 21

RF ABS wheel-speed sensor

(open circuit) system

LF ABS wheel-speed sensor

DTC

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

DETECTION CONDITION

POSSIBLE CAUSE

Microsoft

Thursday, July 09, 2009 3:17:55 PM

C1155

C1165

C1175

Page 22

(open circuit) system

RR ABS wheel-speed sensor

(open circuit) system

LR ABS wheel-speed sensor

(open circuit) system



Open circuit or short to ground has been detected in the ABS wheel-speed sensor wiring harness on any of the four vehicle wheels.



Open circuit or short to ground in the wiring harness between the following ABS

HU/CM terminal and the

ABS wheel-speed sensor terminal:



ABS HU/CM terminal

M-RF ABS wheelspeed sensor terminal



ABS HU/CM terminal

O-RF ABS wheelspeed sensor terminal



ABS HU/CM terminal

F-LF ABS wheelspeed sensor terminal



ABS HU/CM terminal

E-LF ABS wheelspeed sensor terminal



ABS HU/CM terminal

I-RR ABS wheelspeed sensor terminal



ABS HU/CM terminal

L-RR ABS wheelspeed sensor terminal



ABS HU/CM terminal

G-LR ABS wheelspeed sensor terminal

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



ABS HU/CM terminal

H-LR ABS wheelspeed sensor terminal



ABS wheel-speed sensor malfunction

 Poor connection at connectors (female terminal)

DIAGNOSTIC PROCEDURE

DTC C1145, C1155, C1165, C1175 DIAGNOSTIC PROCEDURE TABLE

STEP

INSPECTION

INSPECT PID TO

VERIFY THAT WHEEL

SPEED-SIGNALS ARE

TRANSMITTED FROM

ABS WHEEL - SPEED

SENSOR USING M-MDS

Yes Go to Step 3.

ACTION



Turn the ignition switch off.

Connect the M-MDS to the DLC-2.



Select the following

PIDs using the M-

MDS:

LF_WSPD

LR_WSPD

No Go to the next step.

RF_WSPD

RR_WSPD

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Drive the vehicle.

Verify that the wheel speed-signals are transmitted from each

ABS wheel-speed sensor.

 Are the wheel-speed signals transmitted?

INSPECT FOR OPEN

CIRCUIT IN WIRING

HARNESS BETWEEN

ABS HU/CM AND ABS

WHEEL-SPEED SENSOR



Turn the ignition switch off.



Disconnect the ABS

HU/CM connector and

ABS wheel-speed sensor.

Inspect for continuity in the wiring harness between the following

ABS wheel-speed sensor connectors on the vehicle wiring harness-side and ABS

HU/CM connectors.



RF ABS wheelspeed sensor

(+): M-A



RF ABS wheelspeed sensor (-):

O-B



LF ABS wheelspeed sensor

(+): F-A



LF ABS wheelspeed sensor (-):

E-B



RR ABS wheelspeed sensor

(+): I-A



RR ABS wheel-

Microsoft

Thursday, July 09, 2009 3:17:55 PM

Yes Replace the ABS wheel-speed sensor, then go to the next step.

(See

FRONT ABS WHEEL-SPEED

SENSOR

REMOVAL/INSTALLATION .)

REAR ABS WHEEL-SPEED

SENSOR

REMOVAL/INSTALLATION .)

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

4 speed sensor (-):

L-B

 LR ABS wheelspeed sensor

(+): G-A



LR ABS wheelspeed sensor (-):

H-B



Is there continuity?

VERIFY THAT THE

SAME DTC IS NOT

PRESENT



Clear the DTCs from the memory.

(See CLEARING

DTCS

PROCEDURES .)



Start the engine and drive the vehicle at 10 km/h {6.2 mph} or more.



Are the same DTCs present?

VERIFY THAT NO

OTHER DTCS ARE

PRESENT



Are any other DTCs output?

Yes

Repair or replace the wiring harness, then go to the next step.

Repeat the inspection from Step 1.

If the malfunction recurs, replace the

ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

DTC C1148, C1158, C1168, C1178 [ABS]

DTC C1148, C1158, C1168, C1178 POSSIBLE CAUSE TABLE

DTC

DETECTION CONDITION

Microsoft

Thursday, July 09, 2009 3:17:55 PM

C1148

C1158

C1168

C1178

Page 25

RF ABS wheel-speed sensor/ABS sensor rotor system

LF ABS wheel-speed sensor/ABS sensor rotor system

RR ABS wheel-speed sensor/ABS sensor rotor system

LR ABS wheel-speed sensor/ABS sensor rotor system



Vehicle wheel speed signals of any of the four vehicle

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

POSSIBLE CAUSE

 wheels indicate abnormal acceleration that exceeds specification.

Vehicle wheel speed signals of any of the four vehicle wheels indicate speed that exceeds specification.



ABS wheel-speed sensor malfunction (low output, metal shavings on sensor)



ABS sensor rotor malfunction (chipping of sensor rotor teeth)

Poor installation of ABS wheel-speed sensor and/or sensor rotor (If the sensor rotor is installed at an angle, it may cause output of abnormal wave pattern at high speeds.)

Excessive clearance between the ABS wheelspeed sensor and sensor rotor

DIAGNOSTIC PROCEDURE

DTC C1148, C1158, C1168, C1178 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION

1 INSPECT PID FOR

ABNORMAL OUTPUT

FROM ABS WHEEL-

SPEED SENSOR USING

M-MDS

Yes Go to Step 4.

ACTION



Turn the ignition switch off.

Connect the M-MDS to the DLC-2.



Select the following

PIDs using the M-

MDS:

LF_WSPD

No If there is a difference in speeds of the four wheels, go to the next step.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

LR_WSPD

RF_WSPD

RR_WSPD



Start the engine and drive the vehicle.

Verify that the PIDs of the four ABS wheelspeed sensors correspond approximately.



Do the vehicle speeds correspond?

INSPECT IF

MALFUNCTION

OCCURRED DUE TO

IMPROPER SENSOR

CLEARANCE



Inspect the clearance between the ABS wheel-speed sensor and the ABS sensor rotor.

Clearance

Front: 0.3-1.0 mm

{0.012-0.057 in}

Rear: 0.8-1.6 mm

{0.032-0.062 in}

VISUALLY INSPECT

ABS SENSOR ROTOR

FOR FOREIGN

MATERIAL ADHERING

OR IMPROPER

INSTALLATION



Is the result normal?

4 VERIFY DTC

TROUBLESHOOTING

COMPLETED

Microsoft

Thursday, July 09, 2009 3:17:55 PM

Yes

Go to the next step.

Replace the rear ABS wheel-speed sensor, then go to Step 4.

(See

FRONT ABS WHEEL-SPEED

SENSOR

REMOVAL/INSTALLATION .)

REAR ABS WHEEL-SPEED

SENSOR

REMOVAL/INSTALLATION .)

Yes

Page 27

Go to the next step.

Replace the front wheel hub component or rear drive shaft, then go to the next step.

(See WHEEL HUB, STEERING

KNUCKLE

REMOVAL/INSTALLATION .)

(See REAR DRIVE SHAFT

REMOVAL/INSTALLATION .)

Repeat the inspection from Step 1.

If the malfunction recurs, replace the

DSC HU/CM.

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Make sure to reconnect all disconnected connectors.



Clear the DTC from the memory.

 (See Clearing DTCs

Procedures .)



Start the engine and drive the vehicle at 10 km/h {6.2 mph} or more.

Are the same DTCs present?

VERIFY AFTER REPAIR

PROCEDURE



Are any other DTCs present?

Yes

(See DSC HU/CM

REMOVAL/INSTALLATION .)

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

DTC C1186, C1266 [ABS]

DTC C1186, C1266 POSSIBLE CAUSE TABLE

DTC C1186, C1266

DETECTION CONDITION

Fail-safe relay system



C1186



ABS HU/CM internal valve relay remains OFF when valve relay ON is commanded.



C1266



ABS HU/CM internal valve relay remains ON (stuck) when valve relay

OFF is commanded.

POSSIBLE CAUSE



ABS 30 A fuse malfunction



Open circuit or short to ground in the wiring harness between the battery and the ABS

HU/CM terminal C

Open or short circuit in the ABS HU/CM internal valve relay, or stuck valve relay



Poor connection at connectors (female terminal)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

DIAGNOSTIC PROCEDURE

DTC C1186, C1266 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION

1 INSPECT ABS FUSE

CONDITION

Yes



Is the ABS 30 A fuse normal?

INSPECT VALVE

RELAY POWER SUPPLY

FOR OPEN CIRCUIT

Yes

ACTION

Go to the next step.

Replace the fuse, then go to Step 3.

Go to the' next step.



Turn the ignition switch off.



Disconnect ABS

HU/CM connector.

Turn the ignition switch to the ON position (engine off).



Measure voltage between ABS HU/CM terminal C (harnessside) and ground.



Is voltage B+?

Repair or replace the wiring harness for open circuit between battery positive terminal and DSC HU/CM terminal C, then go to the next step.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

VERIFY

TROUBLESHOOTING

COMPLETED



Clear the DTC from the memory.



(See CLEARING

DTCS

PROCEDURES .)



Is the same DTC present?

VERIFY AFTER REPAIR

PROCEDURE



Are any other DTCs present?

Yes

Replace the ABS HU/CM, then go to next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254 [ABS]

DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254 POSSIBLE CAUSE TABLE

C1194

C1198

C1210

LF outlet solenoid valve system

LF inlet solenoid valve system

RF outlet solenoid valve system

DTC

C1214

C1242

C1246

C1250

C1254

RF inlet solenoid valve system

LR outlet solenoid valve system

RR outlet solenoid valve system

LR inlet solenoid valve system

RR inlet solenoid valve system

DETECTION CONDITION



Solenoid valve operation does not correspond to solenoid ON/OFF commands from the ABS HU/CM.

POSSIBLE CAUSE



Open or short circuit in the ABS

HU/CM internal solenoid valves



Solenoid valve malfunction



Poor connection at connectors

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

(female terminal)

DIAGNOSTIC PROCEDURE

DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION ACTION

1 VERIFY SOLENOID

VALVE OPERATION

Yes Go to the next step.



Turn the ignition switch off.

Connect the M-MDS to the DLC-2.



Turn the ignition switch to the ON position (engine off).

Access the active command mode for the solenoid valve using the M-MDS.



Does the solenoid valve operate?

VERIFY DTC

TROUBLESHOOTING

COMPLETED



Clear the DTC from the memory.



(See CLEARING

DTCS

PROCEDURES .)

Start the engine and drive the vehicle at 10 km/h {6.2 mph} or more.

 Gradually slow down and stop vehicle.



Are the same DTCs present?

VERIFY AFTER REPAIR

PROCEDURE

Yes

Replace the ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

Repeat the inspection from Step 1.

If the malfunction recurs, replace the

ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

 Are any other DTCs present?

Microsoft

Thursday, July 09, 2009 3:17:55 PM

Page 31

DTC troubleshooting completed.

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

DTC C1233, C1234, C1235, C1236 [ABS]

DTC C1233, C1234, C1235, C1236 POSSIBLE CAUSE TABLE

DTC

DETECTION CONDITION

POSSIBLE CAUSE

Microsoft

Thursday, July 09, 2009 3:17:55 PM

C1233

C1234

C1235

C1236

Page 32

LF ABS wheel-speed sensor

(short to ground) system

RF ABS wheel-speed sensor

(short to ground) system

RR ABS wheel-speed sensor

(short to ground) system

LR ABS wheel-speed sensor

(short to ground) system



The vehicle wheel speed of any of the four vehicle wheels is 2.75 km/h {1.71 mph} or less when driving at the specified vehicle speed or more.



Short to ground in the wiring harness between the following ABS HU/CM terminal and the ABS wheel-speed sensor terminal:



ABS HU/CM terminal M-RF ABS wheel-speed sensor terminal A



ABS HU/CM terminal O-RF ABS wheel-speed sensor terminal B



ABS HU/CM terminal F-LF ABS wheel-speed sensor terminal A



ABS HU/CM terminal E-LF ABS wheel-speed sensor terminal B



ABS HU/CM terminal I-RR ABS wheel-speed sensor terminal A

 ABS HU/CM

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



 terminal L-RR ABS wheel-speed sensor terminal B

ABS HU/CM terminal G-LR ABS wheel-speed sensor terminal A



ABS HU/CM terminal H-LR ABS wheel-speed sensor terminal B

ABS wheel-speed sensor malfunction



Poor connection at connectors (female terminal)

DIAGNOSTIC PROCEDURE

DTC C1233, C1234, C1235, C1236 DIAGNOSTIC PROCEDURE TABLE

STEP INSPECTION

1 INSPECT PID TO

VERIFY THAT WHEEL

SPEED-SIGNALS ARE

TRANSMITTED FROM

ABS WHEEL - SPEED

SENSOR USING M-MDS

Yes Go to Step 3.

ACTION



Turn the ignition switch off.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata



Connect the M-MDS to the DLC-2.

Select the following

PIDs using the M-

MDS:

LF_WSPD

LR_WSPD

RF_WSPD

RR_WSPD



Drive the vehicle.

Verify that the wheel speed-signals are transmitted from each

ABS wheel-speed sensor.



Are the wheel-speed signals transmitted?

INSPECT A SHORT TO

GROUND IN THE

WIRING HARNESS

BETWEEN THE ABS

HU/CM AND THE ABS

WHEEL-SPEED SENSOR



Turn the ignition switch off.

Disconnect the ABS

HU/CM connector and the ABS wheel-speed sensor connector.



Inspect for a short to ground in the wiring harness between the following ABS wheelspeed sensor connectors on the vehicle wiring harness-side and ABS

HU/CM connectors.



RF ABS wheel-

Microsoft

Thursday, July 09, 2009 3:17:55 PM

Yes

Go to the next step.

Replace the ABS wheel-speed sensor, then go to the next step.

(See

FRONT ABS WHEEL-SPEED

SENSOR

REMOVAL/INSTALLATION .)

REAR ABS WHEEL-SPEED

SENSOR

REMOVAL/INSTALLATION .)

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

4 speed sensor

(+): M-A

 RF ABS wheelspeed sensor (-):

O-B



LF ABS wheelspeed sensor

(+): F-A



LF ABS wheelspeed sensor (-):

E-B



RR ABS wheelspeed sensor

(+): I-A



RR ABS wheelspeed sensor (-):

L-B



LR ABS wheelspeed sensor

(+): G-A



LR ABS wheelspeed sensor (-):

H-B



Is there continuity?

VERIFY THAT THE

SAME DTC IS NOT

PRESENT



Clear the DTCs from the memory.



(See CLEARING

DTCS

PROCEDURES .)

Start the engine and drive the vehicle at 10 km/h {6.2 mph} or more.



Are the same DTCs present?

VERIFY THAT NO

OTHER DTCS ARE

PRESENT



Are any other DTCs

Microsoft

Thursday, July 09, 2009 3:17:55 PM

Yes

Repair or replace the wiring harness, then go to the next step.

Repeat the inspection from Step 1.

If the malfunction recurs, replace the

ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION

Go to the next step.

Go to the applicable DTC inspection.

(See DTC Table .)

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata output?

DTC C1805 [ABS]

DTC C1805 POSSIBLE CAUSE TABLE

DTC C1805

DETECTION CONDITION

POSSIBLE CAUSE

Incorrect ABS HU/CM installed



The programmed vehicle information and the data received from the CAN do not correspond.



The correct ABS HU/CM is not installed.

DIAGNOSTIC PROCEDURE

DTC C1805 DIAGNOSTIC PROCEDURE TABLE

STEP

INSPECTION

VERIFY THAT THE

CORRECT ABS HU/CM

IS INSTALLED

Yes



Verify the part number of the ABS HU/CM.



Is the part number correct?

PERFORM

CONFIGURATION

Yes



Was configuration performed normally?

VERIFY DTC

TROUBLESHOOTING

COMPLETED

Yes



Make sure to reconnect all disconnected connectors.



Clear the DTC from the memory.

(See CLEARING

DTCS

PROCEDURES .)



Is the same DTC present?

Microsoft

Thursday, July 09, 2009 3:17:55 PM

Page 36

(See

ACTION

Go to the next step.

After replacing the ABS, go to Step 3.

ABS HU/CM

REMOVAL/INSTALLATION

Go to the next step.

Replace the ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION .)

Repeat the inspection from Step 1.

If the malfunction recurs, replace the

ABS HU/CM, then go to the next step.

(See ABS HU/CM

REMOVAL/INSTALLATION

Go to the next step.

2007 Mazda MX-5 Miata Sport

2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata

VERIFY AFTER REPAIR

PROCEDURE



Are any other DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC Table .)

DTC troubleshooting completed.

Microsoft

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

2007 ACCESSORIES & BODY, CAB

Security and Locks (Advanced Keyless System) - MX-5 Miata

POWER DOOR LOCK SYSTEM AND KEYLESS ENTRY SYSTEM LOCATION

INDEX[ADVANCED KEYLESS SYSTEM]

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 1: Identifying Power Door Lock System And Keyless Entry System Components Location

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

THEFT-DETERRENT SYSTEM LOCATION INDEX[ADVANCED KEYLESS

SYSTEM]

Fig. 2: Identifying Hood Latch

Courtesy of MAZDA MOTORS CORP.

IMMOBILIZER SYSTEM LOCATION INDEX[ADVANCED KEYLESS SYSTEM]

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 3: Identifying Immobilizer System Components Location

Courtesy of MAZDA MOTORS CORP.

DOOR KEY CYLINDER REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM

1. Remove the following parts:

1. Door trim (See DOOR TRIM REMOVAL/INSTALLATION .)

2. Door glass (See DOOR GLASS REMOVAL/INSTALLATION .)

3. Door speaker (See DOOR SPEAKER REMOVAL/INSTALLATION .)

4. Door unit (See DOOR UNIT REMOVAL/INSTALLATION .)

5. Outer handle (See OUTER HANDLE REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM] .)

2. Detach the door key cylinder rod.

3. Turn the door key cylinder so that the tab is aligned with the notch.

4. Remove the door key cylinder by pulling it out from the front door.

5. Install in the reverse order of removal.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 4: Turning Door Key Cylinder

Courtesy of MAZDA MOTORS CORP.

DOOR LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION

[ADVANCED KEYLESS SYSTEM]

1. Remove the following parts:

1. Door trim (See DOOR TRIM REMOVAL/INSTALLATION .)

2. Door glass (See DOOR GLASS REMOVAL/INSTALLATION .)

3. Door speaker (See DOOR SPEAKER REMOVAL/INSTALLATION .)

4. Door unit (See DOOR UNIT REMOVAL/INSTALLATION .)

2. Detach the cables from the inner handle and the door lock knob.

3. Detach the rods from the key cylinder and the outer handle.

4. Remove the screws, then remove the door latch and lock actuator.

5. Install in the reverse order of removal.

Fig. 5: Identifying Door Latch And Lock Actuator

Courtesy of MAZDA MOTORS CORP.

DOOR LOCK SWITCH REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

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1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

3. Remove the screws, then remove the door lock switch.

4. Install in the reverse order of removal.

Fig. 6: Identifying Power Door Lock Switch And Screw

Courtesy of MAZDA MOTORS CORP.

DOOR LOCK SWITCH INSPECTION[ADVANCED KEYLESS SYSTEM]

1. Inspect for continuity between the door lock switch terminals.



If not as specified, replace the door lock switch.

Fig. 7: Door Lock Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

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Fig. 8: Door Lock Switch Connector Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

DOOR LOCK STRIKER REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

1. Remove the screws, and then remove the door lock striker.

2. Install in the reverse order of removal.

3. Adjust the door. (See DOOR ADJUSTMENT .)

Fig. 9: Identifying Front Door Lock Striker And Screw With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

DOOR LOCK ACTUATOR INSPECTION[ADVANCED KEYLESS SYSTEM]

DOOR LOCK ACTUATOR

1. Disconnect the door lock actuator connector.

2. Apply battery positive voltage and connect the ground to the corresponding door lock actuator terminals and inspect the door lock actuator operation.



If not as specified, replace the door lock actuator.

DOOR LOCK ACTUATOR OPERATION CHART

Connection

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Actuator operation B+ GNB lock

(F)

(E)

Unlock

(E)

(F)

(): RH

Fig. 10: Identifying Door Lock Actuator Connector Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

DOOR LOCK-LINK SWITCH

1. Disconnect the door lock actuator connector.

2. Inspect for continuity between the door lock-link switch terminals.



If not as specified, replace the door lock actuator.

Fig. 11: Door Lock-Link Switch Continuity Chart

Courtesy of MAZDA MOTORS CORP.

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Fig. 12: Identifying Door Lock-Link Switch Connector Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

DOOR KEY CYLINDER SWITCH

1. Disconnect the door lock actuator connector.

2. Inspect for continuity between the door lock-link switch terminals.



If not as specified, replace the door lock actuator.

Fig. 13: Door Key Cylinder Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

Fig. 14: Identifying Door Key Cylinder Switch Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

OUTER HANDLE REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

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1. Remove the following parts:

1. Door trim (See DOOR TRIM REMOVAL/INSTALLATION .)

2. Door glass (See DOOR GLASS REMOVAL/INSTALLATION .)

3. Door speaker (See DOOR SPEAKER REMOVAL/INSTALLATION .)

4. Door unit (See DOOR UNIT REMOVAL/INSTALLATION .)

2. Detach the rod from the outer handle.

3. Remove the cover.

4. Remove the bolts.

Fig. 15: Identifying Outer Handle Bolts With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

5. Secure the rear part of the front outer handle and, with the front outer handle lever pulled outward (1), remove the rear part of the front outer handle from the front door.

6. Pull out the front part of the front outer handle from the front door.

7. Install in the reverse order of removal.

Fig. 16: Removing Rear Part Of Front Outer Handle From Front Door

Courtesy of MAZDA MOTORS CORP.

INNER HANDLE REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

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1. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

2. Remove the screws, then remove the inner handle.

3. Detach the cables from the inner handle and door lock knob.

4. Install in the reverse order of removal.

Fig. 17: Identifying Inner Handle And Cable

Courtesy of MAZDA MOTORS CORP.

OPEN HOOK REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM]

1. Remove the following parts:

1. Console (See CONSOLE REMOVAL/INSTALLATION .)

2. Quarter trim (See QUARTER TRIM REMOVAL/INSTALLATION .)

3. Scuff plate (See SCUFF PLATE REMOVAL/INSTALLATION .)

4. Tire house trim (See TIRE HOUSE TRIM REMOVAL/INSTALLATION .)

5. Aeroboard (See AEROBOARD REMOVAL/INSTALLATION .)

6. Seat back bar garnish (See SEAT BACK BAR GARNISH REMOVAL/INSTALLATION .)

7. Back trim (See BACK TRIM REMOVAL/INSTALLATION .)

8. Seat back bar lower garnish (See SEAT BACK BAR LOWER GARNISH

REMOVAL/INSTALLATION .)

2. Remove the bolts.

3. Remove the open hook.

4. Install in the reverse order of removal.

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Fig. 18: Identifying Open Hook

Courtesy of MAZDA MOTORS CORP.

FUEL-FILLER LID OPENER REMOVAL/INSTALLATION[ADVANCED

KEYLESS SYSTEM]

1. To remove the fuel-filler lid opener, remove the trunk side trim (LH). (See TRUNK SIDE TRIM

REMOVAL/INSTALLATION .)

2. When removing the fuel-filler lid opener lever and cable, perform the following procedure:

1. Remove the seats. (See SEAT REMOVAL/INSTALLATION .)

2. Remove the back trim. (See BACK TRIM REMOVAL/INSTALLATION .)

3. Remove the seat back bar lower garnish. (See SEAT BACK BAR LOWER GARNISH

REMOVAL/INSTALLATION .)

3. Remove in the order indicated in the table.

Fig. 19: Identifying Fuel-Filler Lid Opener Remove/Install Components With Torque

Specifications

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

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

COIL ANTENNA REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

NOTE:



Do not remove the coil antenna unless you are replacing it.

When only the coil antenna is replaced, the immobilizer system reprogram procedure is not necessary.

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the column cover.

3. Remove in the order indicated in the table.

Fig. 20: Identifying Coil Antenna And Connector

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

COIL ANTENNA INSTALLATION NOTE

1. Install the hole of coil antenna to the tab of steering lock.

2. Install the hook of coil antenna to the steering lock.

Fig. 21: Identifying Hole Of Coil Antenna And Tab Of Steering Lock

Courtesy of MAZDA MOTORS CORP.

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IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND

CLEARING[ADVANCED KEYLESS SYSTEM]

FOREWORD



When performing the following procedures, the immobilizer resetting procedure using the M-MDS must also always be performed: "Keyless control module replacement", "PCM replacement", "Steering lock unit replacement", "Keyless control module and PCM joint replacement", "Keyless control module, PCM, and steering lock unit joint replacement", and "Key ID number clearing". The engine will not start unless all work is performed using the M-MDS.



A card key that can start the engine is necessary for the key programming. If there is no card key that can start the engine, perform the key programming after the card key programming.(See CARD KEY ID

CODE REGISTRATION[ADVANCED KEYLESS SYSTEM] .)

There are two ways to add supplemental key: Using the M-MDS or using two keys that can start the engine to program.



When replacing any of the immobilizer system component parts, adding/clearing keys, or performing other functions, refer to the following table and perform the applicable procedure (No.1 to 5).

Verify that the room fuse is equipped.

IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND CLEARING

PROCEDURE [ADVANCED KEYLESS SYSTEM]

Ref.

No.

Condition

Items necessary for procedure (prepare before starting procedure)

Cautionary notes

Since two or more keys that can start the engine are necessary, make a spare key. Or program an additional key.

If there is only one key that can start the engine, make a spare key. If there is no key, program an additional key.



Programming key

Programmed card key

Programming key

M-MDS



The M-MDS is necessary for the additional key programming if "Customer spare key programming disable" is performed before the procedure using the M-MDS. In this case, perform No. 2.

Replacing the PCM only.



New PCM

Programmed card key

Programming keys (two or more)



M-MDS

Changing the additional

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4 key programming procedure. (Method for programming other keys using two keys that can start the engine is disabled.)

Changing the additional key programming procedure. Allows programming using two keys that can start the engine.

Clearing the programmed key ID number.



M-MDS



The additional key programming using No.

1 cannot be performed after the procedure.

It is possible to restore the setting. For restoring the setting, the M-MDS is necessary.

New vehicles have this setting.

Replacing all the keys.

(Steering lock unit is not replaced)



Programming keys (two or more)

M-MDS



Programmed card key

 Programming keys (two or more)



M-MDS



Carry out the following procedure using the

M-MDS, then go to NO.5 RESETTING

PROCEDURE FOR THE

IMMOBILIZER SYSTEM WHEN

REPLACING THE RELATED PARTS

(PCM, KEYLESS CONTROL

MODULE, INSTRUMENT CLUSTER,

OR STEERING LOCK UNIT )

Replacing the steering lock unit.



New steering lock unit

Programmed card key



New keys (two or more)

M-MDS



Ignition Key Code Erase



Carry out the following procedure using the

M-MDS, then go to NO.5 RESETTING

PROCEDURE FOR THE

IMMOBILIZER SYSTEM WHEN

REPLACING THE RELATED PARTS

(PCM, KEYLESS CONTROL

MODULE, INSTRUMENT CLUSTER,

OR STEERING LOCK UNIT )



Ignition Key Code Erase

STEERING LOCK UNIT

PROGRAMMING

Replacing the keyless control module.

Microsoft

Thursday, July 09, 2009 3:36:54 PM



New keyless control module



Card key

Programming keys (two or more)



Carry out the following procedure using the

M-MDS, then go to NO.5 RESETTING

PROCEDURE FOR THE

IMMOBILIZER SYSTEM WHEN

REPLACING THE RELATED PARTS

(PCM, KEYLESS CONTROL

MODULE, INSTRUMENT CLUSTER,

OR STEERING LOCK UNIT )



Ignition Key Code Erase

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2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Replacing the instrument cluster.

Replacing the coil antenna.



M-MDS

New instrument cluster

Card key

Programming keys (two or more)

M-MDS



New coil antenna



CARD KEY PROGRAMMING

STEERING LOCK UNIT

PROGRAMMING



Carry out the following procedure using the

M-MDS, then go to NO.5 RESETTING

PROCEDURE FOR THE

IMMOBILIZER SYSTEM WHEN

REPLACING THE RELATED PARTS

(PCM, KEYLESS CONTROL

MODULE, INSTRUMENT CLUSTER,

OR STEERING LOCK UNIT )



Ignition Key Code Erase

 Parameter Reset

 Immobilizer system resetting is not necessary.

CAUTION:



The following conditions may cause poor signal communication between the key and vehicle, resulting in the engine not starting or a key registration error. Do not perform any work under the following conditions:



Placing the following items close to the key grip or contacting it.



Spare keys

Keys for other vehicles equipped with an immobilizer system



Any metallic object

Any electronic device, or any credit or other card with magnetic strips

Do not place the following devices in the vehicle while programming, otherwise programming cannot be performed:



M-MDS

Personal computer

Devices that can send/receive the radio waves

NOTE:



The "valid key" used in this manual indicates the key that can start the engine.



If the key adding, programming, clearing, and immobilizer system construction parts replacement are performed, verify that the all keys can start the engine within 5 s after the procedure.

When verifying that the engine starts, wait at least 5 s or more before

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

 starting the engine using the next key.

If the engine cannot be started using a programmed key, repeat the procedure from the beginning.

Do not start the engine unless indicated in the procedure. If the engine is started during the programming procedure, programming is stopped at that point. Repeat the procedure starting from the beginning if the engine is started before completion.

Do not place the card key in the vehicle or bring it within approx. 1 m of the vehicle unless indicated in the procedure.



Two or more key ID numbers must be programmed for the engine to start.

A maximum of eight key ID numbers can be programmed for one vehicle.

The M-MDS can be used to verify the number of key ID numbers programmed to a single vehicle.



Do not select a M-MDS screen menu other than one indicated in the procedure.

M-MDS CONNECTING PROCEDURE

CAUTION:



Do not place the M-MDS in the vehicle while programming, otherwise programming cannot be performed.

1. Fully lower the door glass.

2. Connect the M-MDS to the DLC-2.

3. Pull out the M-MDS cable from the door glass opening and set the M-MDS outside the vehicle.

CAUTION:



Protect the cable and body contact area with a clean rag, otherwise they could be damaged.

Fig. 22: Identifying DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

NO.1 ADDITIONAL KEY PROGRAMMING PROCEDURE (USING TWO VALID KEYS)

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CAUTION:

Condition



Have two or more valid keys.

NOTE:



Do not place the following devices in the vehicle while programming, otherwise programming cannot be performed:



Card key

M-MDS

Personal computer

Devices that can send/receive the radio waves



A maximum of eight keys can be programmed for one vehicle. If key programming is not successful and DTC 15 appears even though the procedure was performed properly, use the PID/data monitor function of the M-MDS and verify the number of keys that have been programmed.

If eight keys have already been programmed, and it is necessary to program other keys, the previously programmed key ID numbers must first be cleared. To clear the key, refer to "NO.3 PCM REPLACEMENT

PROCEDURE".

Procedure

Fig. 23: Identifying Valid Key And Key For Registration

Courtesy of MAZDA MOTORS CORP.

1. Prepare key 3 for programming.

2. Start the engine using key 1.

3. Verify that the security light illuminates for approx. 3 s , and then goes out.

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4. Turn the ignition switch to the LOCK position.

5. Using key 1, turn the ignition switch to the ON position.

6. Verify that the security light illuminates for approx. 3 s, and then goes out.

7. Using key 1, turn the ignition switch to the LOCK position within approx. 4 s after the security light goes out.

8. Remove key 1.

9. Repeat Steps 2-5 using key 2 instead of key 1.

10. Repeat Steps 5-8 using key 3 instead of key 1.

11. If additional keys need to be programmed, repeat Steps 1-10, and replace key 3 in Step 10 with the key to be programmed (key 4).

NO. 2 KEY ADDITIONAL PROGRAMMING PROCEDURE (USING THE M-MDS)

Condition



There is only one valid key. Or, there is no valid key but there is a card key that can start the engine.

NOTE:



A maximum of eight keys can be programmed for one vehicle. If key registration is not successful and DTC 15 appears even though the procedure was performed properly, use the PID/data monitor function of the M-MDS and verify the number of keys that have been programmed.

If eight keys have already been programmed, and it is necessary to program other keys, the previously programmed key ID numbers must first be cleared. To clear the key ID number, refer to " NO.3 PCM

REPLACEMENT PROCEDURE".

Procedure

1. Prepare key 1 for programming.

2. Start the engine using a valid key or card key.

CAUTION:



Do not place the card key in the vehicle when starting the engine with the valid key, otherwise programming cannot be performed. If the engine is started with the card key, remove the card key from the vehicle after the engine is started.

3. Verify that the security light illuminates for approx. 3 s , and then goes out.

4. Turn the ignition switch to the LOCK position.

5. Connect the M-MDS to the DLC-2. (See M-MDS CONNECTING PROCEDURE .)

6. Using key 1, turn the ignition switch to the ON position.

NOTE:



Although the security light flashes and DTC 15 is displayed, this does

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7. Select "BODY/SECURITY/PATS functions" from the M-MDS screen menu.

8. Select "Program additional ignition key" from the M-MDS screen menu.

NOTE: not indicate an improper procedure. Continue to perform the procedure as indicated.



After selecting the above menu, "operation is successful" is displayed. At this point, the key that turned the ignition switch to the

ON position is completely programmed.



In this procedure, the necessary number of the keys are completely programmed. To finish the additional key programming, go to Step 13.

If additional keys need to be programmed, go to the next step.

9. Perform the security access according to the directions on the M-MDS screen. (See SECURITY

ACCESS PROCEDURE[ADVANCED KEYLESS SYSTEM] .)

10. After verifying that the PATS function menu is displayed again on the M-MDS screen, turn the ignition switch to the LOCK position and remove key 1.

11. Using the key to be programmed, turn the ignition switch to the ON position.

12. Return to the Step 6.

13. After verifying that the PATS function menu is displayed again on the M-MDS screen, select the "Exit

(From This Menu)" to finish the M-MDS procedure.

14. After Step 10, wait 5 s or more , and then turn the ignition switch to the LOCK position.

NO.3 PCM REPLACEMENT PROCEDURE

Condition

 Have two or more keys to be programmed after the key ID number clearing.

CAUTION:



Before starting Step 1, complete the procedure for PCM replacement.

Procedure

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Fig. 24: Identifying Key For Resistration

Courtesy of MAZDA MOTORS CORP.

1. Prepare two or more keys to be programmed after the key ID number clearing.

2. Connect the M-MDS to the DLC-2. (See M-MDS CONNECTING PROCEDURE .)

3. Using key 1, turn the ignition switch to the ON position.

NOTE:

4. Verify that the keyless warning light illuminates for approx. 3 s , and then goes out.

5. Select "BODY/SECURITY/PATS functions" from the menu.

6. Perform the security access according to the direction of the M-MDS screen. (See SECURITY ACCESS

PROCEDURE[ADVANCED KEYLESS SYSTEM] .)

7. Select "Parameter Reset" from the M-MDS screen menu.

8. After verifying that the PATS function menu is displayed again on the M-MDS screen, select "Exit (From

This Menu)" to finish the M-MDS procedure.

9. After Step 8, wait 5 s or more , and then turn the ignition switch to the LOCK position.

10. Using key 1, turn the ignition switch to the ON position.

11. After verifying that the security light and keyless warning light illuminates for 3 s or more turn the ignition switch to the LOCK position and remove key 1.

NOTE:



Although the security light flashes and DTC 15 or 21 is displayed, this does not indicate an improper procedure. Continue to perform the procedure as indicated.



Although the security light flashes and DTC 21 is displayed, this does not indicate an improper procedure. Continue to perform the procedure as indicated.

12. Using key 2, turn the ignition switch to the ON position.

13. Verify that the security light and keyless warning light illuminates for approx. 3 s , and then goes out.

14. After verifying that the security light goes out, turn the ignition switch to the LOCK position using key 2, and then remove key 2.

15. If an additional key needs to be programmed, repeat Steps 13-14 with the additional key being key 3. If the ignition switch is held in the ON position for 1 min or more , the additional key programming procedure according to Steps 13-14 will not be possible. If this occurs, refer to " NO.1 ADDITIONAL

KEY PROGRAMMING PROCEDURE (USING TWO VALID KEYS )" to register any additional keys.

16. Start the engine with the key 1.

17. Verify that the security light and keyless warning light operate as follows:



From the point when the ignition switch is turned to the ON position, the security light illuminates for approx. 3 s and goes out.

The keyless warning light illuminates with the ignition switch turned to the ON position, and after approx. 1 s after the engine is started, it goes out and displays the number of programmed keys.

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Fig. 25: Security Light And Keyless Warning Light Blinking Pattern

Courtesy of MAZDA MOTORS CORP.

18. After verifying that the keyless warning light goes out, turn the ignition switch to the LOCK position using key 1.

19. Repeat Steps 17-18 using key 2 instead of key 1.

NOTE:



Perform Steps 17-18 as well when there are three or more programmed keys.

20. Start the engine with the card key and remove any key from the key cylinder.

CAUTION:



Remove any key from the key cylinder.

21. Verify that the security light and keyless warning light operate as follows:



From the point when the ignition switch is turned to the ON position, the security light illuminates for approx. 3 s , and goes out.

The keyless warning light illuminates when the ignition switch is turned to the ON position, and after approx. 1 s after the engine is started, it goes out.

22. Turn the ignition switch to the LOCK position after verifying that the keyless warning light goes out.

NO. 4 KEY ADDITIONAL PROGRAMMING PROCEDURE CHANGING

NOTE:



This procedure is performed for enabling/disabling the "No.1 Additional

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Procedure

1. Using the key, turn the ignition switch to the ON position. (The key can be either the valid key or an unprogrammed key)

NOTE:



Key Programming Procedure (Using Two Valid Keys)" setting.

This procedure is possible when the vehicle is new, and when replacing the keyless unit with a new one.

If "No.1 Additional Key Programming Procedure (Using Two Valid Keys)" is set to disable, the additional key programming can be only performed using the M-MDS preventing the forging of a spare key by using two keys that can start the engine. This function is for use by rental car agencies or other companies with vehicle fleets.



Although the security light flashes and DTC 15 is displayed when an unprogrammed key is used, this does not indicate an improper procedure. Continue to perform the procedure as indicated.

2. Connect the M-MDS to the DLC-2.

3. Select "BODY/SECURITY/PATS functions" from the M-MDS screen menu.

4. Select "Customer spare key programming enable" or "Customer spare key programming disable" from the M-MDS screen menu. The key additional programming procedure is as follows according to the selected menu:

ADDITIONAL KEY PROGRAMMING PROCEDURE

Setting

Customer spare key programming enable

Additional key programming procedure

Method using two valid keys Method using the M-MDS

Customer spare key programming disable

-: Available x: Unavailable x -

5. Perform the security access according to the directions on the M-MDS screen. (See SECURITY

ACCESS PROCEDURE[ADVANCED KEYLESS SYSTEM] .)

6. After verifying that the PATS function menu is displayed again on the M-MDS screen, select "Exit (From

This Menu)" to finish the M-MDS procedure.

7. After Step 6, wait 5 s or more and then turn the ignition switch to the LOCK position.

NO.5 RESETTING PROCEDURE FOR THE IMMOBILIZER SYSTEM WHEN REPLACING THE

RELATED PARTS (PCM, KEYLESS CONTROL MODULE, INSTRUMENT CLUSTER, OR

STEERING LOCK UNIT)

Condition

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

When the keyless control module is replaced



Have one or more card keys to be programmed after the replacement.



Have two or more keys to be programmed after the replacement.



When the keyless control module is not to be replaced



Have one or more card keys to be programmed.



Have two or more keys to be programmed after the replacement.

CAUTION:



Perform the procedures in the following order: "Ignition Key Code

Erase", "Program Additional card key", "Steering lock unit programming", and "Program additional ignition key". If there is a failure in the programming, the engine may not be started.

When replacing only the PCM, start from Step 2. Key 1 in the procedure can be any valid key.

Perform the "card key programming procedure" in Step 11 only when the keyless control module is replaced.

Perform the "steering lock unit programming procedure" in Step 12 only when either the keyless control module or steering lock unit is replaced.

Procedure

Fig. 26: Identifying Key For Registration

Courtesy of MAZDA MOTORS CORP.

1. Prepare two or more keys to be programmed after the key ID number is cleared.

2. Connect the M-MDS to the DLC-2. (See M-MDS CONNECTING PROCEDURE .)

3. Using key 1, turn the ignition switch to the ON position.

4. Verify that the keyless warning light illuminates for approx. 3 s and then goes out.

5. Select "BODY/SECURITY/PATS functions" from the M-MDS screen menu.

6. Select "Ignition Key Code Erase" from the M-MDS screen menu and perform the procedure according to the M-MDS screen.

7. Perform the security access according to the directions on the M-MDS screen. (See SECURITY

ACCESS PROCEDURE[ADVANCED KEYLESS SYSTEM] .

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CAUTION:



The M-MDS displays "At least two or more keys must be programmed", however, do not perform the key programming and proceed to Step 8. If the procedure is not followed, the engine may not be started.

The key programming procedure is performed at Step 13-16.

8. Select "Parameter Reset" from the M-MDS screen menu.

9. Perform security access again as indicated on the M-MDS screen. (See SECURITY ACCESS

PROCEDURE[ADVANCED KEYLESS SYSTEM] .)

10. Select the replaced part as indicated on the M-MDS screen.



When replacing only the PCM: Select "PCM".



When replacing only the instrument cluster: Select "HEC".

When replacing only the keyless control module: Select "RKE".

NOTE:



At this time, do not select any other parts from the M-MDS screen menu.

11. Perform "Program Additional card key". (When replacing keyless control module) (See CARD KEY ID

CODE REGISTRATION[ADVANCED KEYLESS SYSTEM] .)

12. Perform "Steering Lock Unit Programming". (When steering lock unit) (See STEERING LOCK UNIT

ID CODE REGISTRATION[ADVANCED KEYLESS SYSTEM] .)

13. After verifying that the PATS function menu is displayed again on the M-MDS screen, select "Exit (From

This Menu)" to finish the M-MDS procedure.

14. After Step 13, wait 5 s or more and then turn the ignition switch to the LOCK position.

15. Using key 1, turn the ignition switch to the ON position.

16. After verifying that the security light and keyless warning light illuminate for 3 s or more, turn the ignition switch to the LOCK position and remove key 1.

NOTE:



Although the security light flashes and DTC 21 is displayed, this does not indicate an improper procedure. Continue to perform the procedure as indicated.

17. Using key 2, turn the ignition switch to the ON position.

18. Verify that the security light and keyless warning light illuminate for approx. 3 s, and then goes out.

19. After verifying that the security light goes out, turn the ignition switch to the LOCK position using key 2, and then remove key 2.

20. If additional keys need to be programmed, repeat Steps 13-14 with the additional key to be programmed being key 3. If the ignition switch is held in the ON position for 1 min or more , additional key programming according to Steps 18-19 will not be possible. If this occurs, refer to " NO.1

ADDITIONAL KEY PROGRAMMING PROCEDURE (USING TWO VALID KEYS )" to program

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata any additional keys.

21. Start the engine with key 1.

22. Verify that the security light and keyless warning light operate as follows:



From the point when the ignition switch is turned to the ON position, the security light illuminates for approx. 3 s , and goes out.



The keyless warning light illuminates when the ignition switch is turned to the ON position, and the light goes out after approx. 1 s, and then displays the number of the programmed keys.

Fig. 27: Security Light And Keyless Warning Light Blinking Pattern

Courtesy of MAZDA MOTORS CORP.

23. After verifying that the keyless warning light goes out, turn the ignition switch to the LOCK position using key 1, and then remove the key.

24. Repeat Steps 22-23 using key 2 instead of key 1.

NOTE:



Perform Steps 22-23 as well when three or more keys are to be programmed.

25. Start the engine using the card key.

CAUTION:



Remove any key from the key cylinder.

26. Verify that the security light and keyless warning light operate as follows:



From the point that ignition switch is turned to the ON position, the security light illuminates for

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

 approx. 3 s, and goes out.

The keyless warning light illuminate when the ignition switch is turned to the ON position for approx. 1 min, and goes out.

27. After verifying that the keyless warning light goes out, turn the ignition switch to the LOCK position.

HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION

[ADVANCED KEYLESS SYSTEM]

1. Remove in the order indicated in the table.

Fig. 28: Identifying Hood Latch And Release Lever Remove/Install Components With Torque

Specifications

Courtesy of MAZDA MOTORS CORP.

2. Install in the reverse order of removal.

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

HOOD RELEASE LEVER REMOVAL NOTE

1. Pull the lever.

2. While pushing the tab in the direction of the arrow using a tape-wrapped, small flathead screwdriver, detach it from the dashboard.

CAUTION:



Remove the hood release lever while taking care not to damage the hood release cable with the flathead screwdriver.

3. Under the condition in Step 2, pull the hood release lever outward, then remove it from the dashboard.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 29: Removing Hood Release Lever From Dashboard

Courtesy of MAZDA MOTORS CORP.

HOOD LATCH SWITCH INSPECTION[ADVANCED KEYLESS SYSTEM]

1. Open the hood.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect the hood latch switch connector.

4. Inspect for continuity between the hood latch switch terminals A and B.



If there is no continuity, replace the hood latch switch.

Fig. 30: Identifying Hood Latch Switch Terminals A And B

Courtesy of MAZDA MOTORS CORP.

5. Lock the hood latch using a flathead screwdriver or equivalent as shown.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

6. Inspect for continuity between the hood latch switch terminals A and B



If there is continuity, replace the hood latch.

CAUTION:



After the inspection, unlock the hood latch. If closing the hood with the hood latch locked, the hood latch and/or hood striker may be broken.

Fig. 31: Locking Hood Latch Using Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

OPEN HOOK REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM]

1. Remove the following parts:

1. Console (See CONSOLE REMOVAL/INSTALLATION .)

2. Quarter trim (See QUARTER TRIM REMOVAL/INSTALLATION .)

3. Scuff plate (See SCUFF PLATE REMOVAL/INSTALLATION .)

4. Tire house trim (See TIRE HOUSE TRIM REMOVAL/INSTALLATION .)

5. Aeroboard (See AEROBOARD REMOVAL/INSTALLATION .)

6. Seat back bar garnish (See SEAT BACK BAR GARNISH REMOVAL/INSTALLATION .)

7. Back trim (See BACK TRIM REMOVAL/INSTALLATION .)

8. Seat back bar lower garnish (See SEAT BACK BAR LOWER GARNISH

REMOVAL/INSTALLATION .)

2. Remove the bolts.

3. Remove the open hook.

4. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 32: Identifying Open Hook

Courtesy of MAZDA MOTORS CORP.

HOOD STRIKER REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

1. Remove the bolt, then remove the hood striker. HOOD STRIKER

2. Install in the reverse order of removal.

Fig. 33: Identifying Hood Striker And Bolt With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CARD KEY BATTERY REPLACEMENT[ADVANCED KEYLESS SYSTEM]

CARD KEY TYPE

1. Pull out the auxiliary key.

2. Replace the cap using a flathead screwdriver, then rotate and remove the cap.

CAUTION:



Do not turn the cap excessively. The cap may be damaged.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 34: Pulling Out Auxiliary Key

Courtesy of MAZDA MOTORS CORP.

Fig. 35: Removing Cap

Courtesy of MAZDA MOTORS CORP.

3. Insert a flathead screwdriver into the crack and press the battery out.

Fig. 36: Removing Battery

Courtesy of MAZDA MOTORS CORP.

4. Insert the new battery (CR2025) with the positive pole (+) facing the (+) mark on the cap.

Battery specification

Lithium CR2025 x 1

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

NOTE:



The batteries will last about 1 years when used 10 times a day.

Fig. 37: Positions For Inserting New Battery

Courtesy of MAZDA MOTORS CORP.

5. Rotate and close the cap.

6. Reinsert the auxiliary key.

Fig. 38: Closing Cap

Courtesy of MAZDA MOTORS CORP.

KEYLESS CONTROL MODULE REMOVAL/INSTALLATION[ADVANCED

KEYLESS SYSTEM]

NOTE:



If the keyless control module is replaced, always perform the following procedure.

Without immobilizer system



Card key programming (See CARD KEY ID CODE REGISTRATION

[ADVANCED KEYLESS SYSTEM].)



Steering lock unit programming (See STEERING LOCK UNIT ID CODE

REGISTRATION[ADVANCED KEYLESS SYSTEM].)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

With immobilizer system



Card key programming (See CARD KEY ID CODE REGISTRATION

[ADVANCED KEYLESS SYSTEM].)



Steering lock unit programming (See STEERING LOCK UNIT ID CODE

REGISTRATION[ADVANCED KEYLESS SYSTEM].)



Immobilizer system resetting (with immobilizer system) (See

IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION

AND CLEARING[ADVANCED KEYLESS SYSTEM].)

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the side panel. (See SIDE PANEL REMOVAL/INSTALLATION .)

3. Remove the bolt and nut.

4. While inclining the keyless control module along the body panel in the direction indicated by the arrow, disengage the bracket tab from the hole in the body panel.

5. Disconnect the keyless control module connector.

6. Remove the keyless control module.

Fig. 39: Disengaging Bracket Tab

Courtesy of MAZDA MOTORS CORP.

7. Remove the screw, then remove the bracket.

NOTE:



The screw which fixes the keyless control module and bracket is for a body ground connection. Be sure to secure the screw when installing.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 40: Removing Bracket & Screw

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

KEYLESS CONTROL MODULE INSPECTION[ADVANCED KEYLESS

SYSTEM]

1. Measure the voltage or inspect for continuity according to the Terminal Voltage Table (Reference).



If the voltage is not as specified in the Terminal Voltage Table (Reference), inspect the parts under

"Inspection item(s)" and related wiring harnesses.

TERMINAL VOLTAGE TABLE (REFERENCE)

Fig. 41: Identifying Keyless Control Module Wiring Harness Side Connector Terminals

Courtesy of MAZDA MOTORS CORP.

KEYLESS CONTROL MODULE TERMINALS VOLTAGE TABLE (REFERENCE)

Terminal Signal name Connected to

Measured condition

Voltage

(V)/Continuity

Inspection item(s)

Door unlock control

Door lock actuator

(driver's side)

Door lock actuator unlocking

Other

1.0 or less --> B+ --

> 1.0 or less

1.0 or less

 Door lock actuator

(driver's side)



Related wiring harnesses

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

2BB

GND

Door lock control

Door unlock control

Power supply

GND

Door lock actuator

(except driver's side)

Door lock actuator unlocking

D.LOCK 30

A fuse

ROOM 15 A fuse

Under any condition: Inspect for continuity to

GND.

Door lock actuator locking

Other

Under any condition

Continuity detected

1.0 or less rarr; B+ rarr; 1.0 or less

1.0 or less

1.0 or less rarr; B+ rarr; 1.0 or less

1.0 or less

B+

B+ keyless antenna

(exterior, RF)(+) keyless antenna

(exterior, RF) keyless antenna

(exterior, RF)(-) keyless antenna

(exterior, LF)(+) keyless antenna

(exterior, LF)(-) keyless antenna

(exterior, rear)

(+) keyless antenna

(exterior, RF) keyless antenna

(exterior, LF) keyless antenna

(exterior, rear)

Under any condition: Inspect for continuity to keyless antenna.

Continuity detected keyless antenna

(exterior, RF)

Continuity detected keyless antenna

(exterior, RF)

Continuity detected keyless antenna

(exterior, LF)

Continuity detected keyless antenna

(exterior, LF)

Continuity detected keyless antenna

(exterior, rear)



Related wiring harnesses



Door lock actuator

Related wiring harnesses



Door lock actuator

(except driver's side)

 Related wiring harnesses



D.LOCK 30

A fuse



Battery



ROOM 15 A fuse

Battery keyless antenna keyless

Microsoft

Thursday, July 09, 2009 3:36:54 PM

Under any

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

)

(exterior, rear) (keyless antenna

(interior, trunk)

(+) keyless antenna

(interior, trunk)

(-) keyless antenna

(interior, rear)

(+) antenna

(exterior, rear) keyless antenna

(interior, trunk) keyless antenna

(interior, trunk) condition: Inspect for continuity to keyless antenna.

Under any condition: Inspect for continuity to keyless antenna.

keyless antenna

(interior, rear)

Under any condition: Inspect for continuity to keyless antenna.

3C keyless antenna

(interior, rear) (-) keyless antenna

(interior, rear)

Under any condition: Inspect for continuity to keyless antenna.

keyless antenna

(interior, middle)

(+) keyless antenna

(interior, middle) keyless antenna

(interior, middle)

(-) keyless antenna

(interior, middle)

IG1

GND

ENGINE 10

A fuse body ground

Under any condition: Inspect for continuity to keyless antenna.

Ignition switch is at

ON position

Ignition switch is at

LOCK or ACC position

Under any condition: Inspect for continuity to ground.

Security light keyless antenna

(interior, front)

(+)

Instrument cluster keyless antenna

(interior, front)

Under any condition: Inspect for continuity to instrument cluster.

Under any condition: Inspect for continuity to keyless antenna.

Continuity detected

B+

1.0 or less

Continuity detected GND

Continuity detected Instrument cluster

Continuity detected keyless antenna

(exterior, rear) keyless antenna

(interior, trunk) keyless antenna

(interior, rear) keyless antenna

(interior, middle) keyless antenna

(interior, middle)

ENGINE 10 A fuse keyless antenna

(interior, front)

Under any keyless antenna keyless

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

)

(interior, front)(-

ACC antenna

(interior, front) condition: Inspect for continuity to keyless antenna.

Ignition switch is at

METER 10 A

ACC position fuse

Ignition switch is at

LOCK or ON position

Continuity detected

B+

1.0 or less keyless antenna

(interior, front)

METER 10 A fuse

Buzzer (interior)

Instrument cluster

Buzzer operated

Other

Start knob is Pushed

5.0

1.0 or less

Start knob (push switch)

Steering lock unit

Key reminder switch

Steering lock unit

B+

Other

Key reminder switch is ON

Other

1.0 or less

B+

1.0 or less

Instrument cluster

Steering lock unit

(1)

Communication

(steering lock unit)

Steering lock unit

TPMS signal

Instrument cluster

Under any condition: Inspect for continuity to steering lock unit.

Under any condition: Inspect for continuity to instrument cluster.

Continuity detected Steering lock unit

Continuity detected Instrument cluster

Power supply

(keyless receiver, front)

Keyless receiver, front

Under any condition

Communicatio n

Keyless

(keyless receiver, front receiver, front)

Under any condition: Inspect for continuity to keyless receiver, front.

Power supply

(keyless receiver, rear)

Keyless receiver, rear

Under any condition

Communicatio n

Keyless

(keyless receiver, rear) receiver, rear

Under any condition: Inspect for continuity to keyless receiver, rear.

Ignition switch is at

ON position

Tx-SKE Coil antenna Ignition switch is at

LOCK or ACC position

B+

Continuity detected

B+

Continuity detected

B+

1.0 or less

Keyless receiver, front

Keyless receiver, rear

Coil antenna

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

3AA

(1)

Trunk open signal

Rx-SKE

Lock/unlock input

Lock signal input

Lock/unlock input

Trunk compartment light switch

Trunk lid open

(trunk compartment light switch on)

Trunk lid closed

(trunk compartment light switch off)

B+

Coil antenna

Instrument cluster

1.0 or less

Ignition switch is at

ON position

Ignition switch is at

LOCK or ACC position

5.0

1.0 or less

Ignition switch is at

ON position

Ignition switch is at

LOCK or ACC position

B+

1.0 or less

Door lock switch

Instrument cluster

Door locklink switch

(driver-side)

Driver-side door key cylinder switch

Microsoft

Thursday, July 09, 2009 3:36:54 PM



Trunk compartment light switch

Related wiring harness

Coil antenna

Instrument cluster

Door lock switch is locked

Door lock switch is unlocked

2.5

1.0 or less



Door lock switch

(driver-side)

Door lock switch

(passengerside)

Other

At the moment key cylinder is unlocked

1.0 or less



Related wiring harnesses

Ignition switch is at

ON position

Ignition switch is at

LOCK or ACC position

B+

1.0 or less

Instrument cluster

Driver-side door is locked: Inspect for continuity to ground.

Continuity detected

Driver-side door is unlocked: Inspect for continuity to ground.

No continuity

Door lock-link switch (driver-side)

At the moment key cylinder is locked

2.5



Driver-side door key cylinder switch

At the moment key cylinder is neutral



Related wiring

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Request switch input (RH)

Unlock signal input

Request switch input (LH)

Request switch (RH)

Door locklink switch

(driver-side)

Request switch (LH) position harnesses

Request switch (RH) is ON: Inspect for Continuity detected continuity to ground.

Request switch

(RH) Request switch (RH) is OFF: Inspect for No continuity continuity to ground.

Driver-side door is unlocked: Inspect for continuity to ground.

Continuity detected

Driver-side door is locked: Inspect for continuity to ground.

No continuity

Door lock-link switch (driver-side)

Request switch (LH) is ON: Inspect for Continuity detected continuity to ground.

Request switch

(LH) Request switch (LH) is OFF: Inspect for No continuity continuity to ground.

Unlock input

(trunk lid)

Request switch input (trunk lid)

Hazard output

Trunk key cylinder switch

Request switch (trunk lid)

Hazard warning light

At the moment key cylinder is unlocked

At the moment key cylinder is neutral position

1.0 or less



Trunk key cylinder switch

Related wiring harnesses

Trunk lid request switch is ON:

Inspect for continuity to ground.

Continuity detected

Request switch

(trunk lid) Trunk lid request switch is OFF:

Inspect for continuity to ground.

No continuity

Press the LOCK button (transmitter)

B+ rarr; 1.0 or less rarr; B+



Hazard warning light

Press the UNLOCK button (transmitter)

B+rarr;1.0 or lessrarr;B+rarr;1.0 or lessrarr;B+

Other B+



Related wiring harnesses

Door switch signal (RH) output

Door switch

Microsoft

Thursday, July 09, 2009 3:36:54 PM

Door open (RH)

(Door switch on)

Door closed (RH)

Page 39

B+

1.0 or less 



Door switch

(RH)

Related wiring

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

(2)

Unlock signal input

Serial communication

Door switch signal (LH) output

Horn on/off

Hood switch signal

Keyless buzzer output

Door locklink switch

(passengerside)

(Door switch off) harnesses

Passenger-side door is unlocked: Inspect for continuity to ground.

Continuity detected

Door lock-link switch (passengerside) Passenger-side door is locked: Inspect for No continuity continuity to ground.

Power window main switch

Because this terminal is for communication, good/no good judgment by terminal voltage is not possible.



Power window main switch

Related wiring harnesses

Door switch

Door open(LH)

(Door switch on)

Door closed (LH)

(Door switch off)

B+

1.0 or less



Door switch

(LH)



Related wiring harnesses

Horn relay

Hood switch

Keyless buzzer

Other

Transmitter LOCK button is pressed twice within 5 s.

Hood open (Hood latch switch off)

Hood closed

(Hood latch switch on)

Keyless buzzer operated

Other

Under any condition:

B+

Brarr;1.0or lessrarr;B+

B+

1.0 or less

B+

1.0 or less



Horn relay

Related wiring harnesses

Hood latch switch

Related wiring harnesses

Keyless buzzer

4Z HS-CAN+ PCM

Microsoft

Thursday, July 09, 2009 3:36:54 PM

 Inspect for continuity to

PCM.



Inspect for continuity to instrument cluster.

Under any condition:

Continuity detected -

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

4AA HS-CANPCM



Inspect for continuity to

PCM.

Inspect for continuity to instrument cluster.

Continuity detected -

(1) With immobilizer system

(2) With exterior open function (Power window system)

CARD KEY ID CODE REGISTRATION[ADVANCED KEYLESS SYSTEM]

CAUTION:



Do not place the following devices in the vehicle while programming, otherwise programming cannot be performed.



M-MDS

Personal computer



Device that can send/receive radio waves

Verify that the other transmitter is not being operated around the servicing area during card key programming.

NOTE:



Use the M-MDS and start programming if the condition corresponds to the following:



One or No Programmed Card Keys



Keyless control module is replaced

If six card keys are already programmed, the programming mode does not activate. If programming is needed, use the M-MDS to erase the unnecessary card key programming.

WITH TWO PROGRAMMED CARD KEYS

1. Bring the programmed card keys (2) and a unprogrammed card key into the vehicle.

2. Close all doors.

3. Insert the supplementary key into the ignition key cylinder.

NOTE:



Complete the procedures up to Step 7 within 30 s after the supplementary key is inserted.

4. Turn the ignition switch to the ON position.

5. Press the UNLOCK button on card key 1.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

6. Press the UNLOCK button on card key 2.

7. From the ignition switch in the ON position, switch the ignition switch in the order indicated below.



ACC-->ON-->ACC-->ON-->ACC-->ON

8. Open the driver-side front door, press the door switch twice , and then close the door.

NOTE:



After Step 3 is completed and the card key programming mode is activated, the door lock actuator operates to lock, and then operates to unlock.

If the door lock actuator does not operate, repeat the procedure from

Step 2.

9. Press the UNLOCK button on the unprogrammed card key twice.

NOTE:



After Step 8 is completed and the card key is programmed, the door lock actuator operates to lock, and then operates to unlock.

10. If programming more card keys, remove the supplementary key once, and then repeat the procedure from

Step 2.

USING M-MDS

1. Fully lower the driver-side door glass.

2. Connect the M-MDS to the DLC-2.

3. Pull out the M-MDS cable from the door glass opening and set the M-MDS outside the vehicle.

CAUTION:



Protect the cable and body contact area with a clean rag, otherwise they could be damaged.

Fig. 42: Identifying DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

4. After the vehicle is identified, select the following items from the initialization screen of the M-MDS.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata



When using the IDS (laptop PC)



1. Select "BODY"

2. Select "SECURITY"

3. Select "PATS functions"

When using the PDS (Pocket PC)

1. Select "Programming".

2. Select "PATS functions"

5. Then, select items from the screen menu in the following order.

1. Select "Program Additional Card Key".

6. Security access begins and the M-MDS displays the "OUT-CODE".

NOTE:



When "OUT-CODE" is first displayed, turning the ignition switch from the LOCK to the ON position 5 times will change the "OUT-CODE".

7. Input the "IN-CODE" that corresponds to the "OUT-CODE "displayed on the M-MDS screen.

8. Select "CARD KEY PROGRAMMING" from the M-MDS screen menu.

NOTE:



After Step 8 is completed and the card key programming is activated, the door lock actuator operates to lock, and then operates to unlock.

9. Press the unprogrammed card key UNLOCK button twice.

NOTE:



After Step 9 is completed and the card key is programmed, the door lock actuator operates to lock, and then operates to unlock.

10. If programming more card keys, remove the supplementary key once, and then repeat the procedure from

Step 7 by following the instructions on the M-MDS screen.

CLEARING CARD KEY[ADVANCED KEYLESS SYSTEM]

1. Fully lower the driver-side door glass.

2. Connect the M-MDS to the DLC-2.

3. Pull out the M-MDS cable from the door glass opening and set the M-MDS outside the vehicle.

CAUTION:



Protect the cable and body contact area with a clean rag, otherwise they could be damaged.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 43: Identifying DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

4. After the vehicle is identified, select the following items from the initialization screen of the M-MDS.



When using the IDS (laptop PC)

1. Select "BODY"

2. Select "SECURITY"

 When using the PDS (Pocket PC)

1. Select "Programming".

5. Then, select items from the screen menu in the following order.

1. Select "PATS functions".

2. Select "Card Key Code Erase".

6. Security access begins and the M-MDS displays the "OUT-CODE".

NOTE:



When "OUT-CODE" is first displayed, turning the ignition switch from the LOCK to the ON position 5 times will change the "OUT-CODE".

7. Input the "IN-CODE" that corresponds to the "OUT-CODE" displayed in the M-MDS screen.

STEERING LOCK UNIT ID CODE REGISTRATION[ADVANCED KEYLESS

SYSTEM]

CAUTION:



Do not place the following devices in the vehicle while programming, otherwise programming cannot be performed.



M-MDS

Personal computer

Device that can send/receive radio waves

NOTE:



The steering lock unit and steering lock component are a single unit.

Therefore, replace the steering lock component when replacing steering

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

 lock unit. (See STEERING WHEEL AND COLUMN

REMOVAL/INSTALLATION .)

For this procedure, a programmed card key is necessary. If there is no programmed card key, perform the steering lock unit programming after the card key programming.

1. Bring the programmed card key into the vehicle.

2. Fully lower the driver-side door glass.

3. Connect the M-MDS to the DLC-2.

4. Pull out the M-MDS cable from the door glass opening and set the M-MDS outside the vehicle.

5. After the vehicle is identified, select the following items from the initialization screen of the M-MDS.



When using the IDS (laptop PC)

1. Select "BODY"



2. Select "SECURITY"

When using the PDS (Pocket PC)

1. Select "Programming".

6. Then, select items from the screen menu in the following order.

1. Select "PATS Functions"

2. Select "Steering Lock Unit Programming"

7. Perform the security access according to the directions on the M-MDS screen. (See SECURITY

ACCESS PROCEDURE[ADVANCED KEYLESS SYSTEM] .)

Fig. 44: Identifying DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

8. The security access begins and the M-MDS displays "OUT-CODE".

NOTE:



When "OUT-CODE" is first displayed, turning the ignition switch from the LOCK to the ON position 5 times will change the "OUT-CODE".

9. Input the "IN-CODE" that corresponds to the "OUT-CODE" displayed on the M-MDS screen.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

KEYLESS CONTROL MODULE CONFIGULATION[ADVANCED KEYLESS

SYSTEM]

1. Connect the M-MDS to the DLC-2 connector.

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.



When using the IDS (laptop PC)

1. Select "Module Programming".

 When using the PDS (Pocket PC)

1. Select "Programming".

2. Select "Module Programming".

3. Then, select the "Programmable Module Installation" and "RKE" from the screen menu.

4. Perform the configuration according to the directions on the screen.

5. Retrieve DTCs using the M-MDS, then verify if DTCs are present.



If a DTC is present, perform the applicable DTC inspection. (See DTC TABLE [IMMOBILIZER

SYSTEM (ADVANCED KEYLESS SYSTEM)] .)

Fig. 45: Identifying DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

CUSTOMIZED FUNCTION SETTING PROCEDURE[ADVANCED KEYLESS

SYSTEM]

1. Connect the M-MDS to the DLC-2 connector.

2. After the vehicle is identified, select the following items from the initialization screen of the M-MDS.

 When using the IDS (laptop PC)

1. Select "Module Programming".



When using the PDS (Pocket PC)

1. Select "Programming".

2. Select "Module programming".

3. Then, select items from the screen menu in the following order.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

1. Select "Programmable parameters".

2. Select "RKE".

4. Select the item name, and than select either "ON/ OFF".

Fig. 46: Identifying DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

Items



Automatic Lock

Answer Back Buzzer



Card Key Battery Low Warning

KEYLESS RECEIVER REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

FRONT

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the glove compartment lid. (See GLOVE COMPARTMENT

REMOVAL/INSTALLATION .)

3. Disconnect the keyless receiver module connector.

4. Remove the nut, then remove the keyless receiver (front).

5. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 47: Identifying Keyless Receiver Remove/Install Components (Front)

Courtesy of MAZDA MOTORS CORP.

REAR

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the trunk side trim. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

3. Remove the nuts.

4. Disconnect the connector.

5. Remove the keyless receiver (rear).

6. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 48: Identifying Keyless Receiver Remove/Install Components (Rear)

Courtesy of MAZDA MOTORS CORP.

KEYLESS RECEIVER INSPECTION[ADVANCED KEYLESS SYSTEM]

1. Measure the voltage or inspect for continuity according to the Terminal Voltage Table (Reference).



If the voltage is not as specified in the Terminal Voltage Table (Reference), inspect the parts under

"Inspection item(s)" and related wiring harnesses.

TERMINAL VOLTAGE TABLE (REFERENCE)

Fig. 49: Identifying Keyless Receiver Connector Terminals

Courtesy of MAZDA MOTORS CORP.

KEYLESS RECEIVER TERMINALS VOLTAGE TABLE (REFERENCE)

Terminal

Signal

Connected to

Microsoft

Thursday, July 09, 2009 3:36:54 PM

Measured condition

Page 49

Voltage (V)/

Inspection item(s)

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

C name

Power supply

Data

Keyless control module

E GND Body ground

Under any condition

Under any condition: Inspect the wiring harness between the keyless receiver and keyless control module terminal 3U for continuity.

Under any condition: Inspect for continuity to ground.

Continuity

B+



Keyless control module

Related wiring harnesses

Continuity detected



Keyless control module



Related wiring harnesses

Continuity detected

GND

KEYLESS ANTENNA REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

DRIVER-SIDE/PASSENGER-SIDE DOOR

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

3. Remove the screws.

4. Disconnect the connector, then remove the keyless antenna.

5. Install in the reverse order of removal.

Fig. 50: Identifying Keyless Antenna Remove/Install Components (Door)

Courtesy of MAZDA MOTORS CORP.

EXTERIOR, REAR

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

2. Remove the nuts.

3. Disconnect the connector, then remove the keyless antenna.

4. Install in the reverse order of removal.

Fig. 51: Identifying Keyless Antenna And Nut

Courtesy of MAZDA MOTORS CORP.

INTERIOR, FRONT

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the scuff plate. (See SCUFF PLATE REMOVAL/INSTALLATION .)

3. Remove the side panel. (See SIDE PANEL REMOVAL/INSTALLATION .)

4. Partially peel back the floor covering so that the foot support can be removed.

5. Remove the foot support.

6. Disconnect the connector, then remove the screws.

7. Remove the keyless antenna.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 52: Identifying Keyless Antenna And Foot Support

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

INTERIOR, MIDDLE

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

3. Remove the side wall. (See SIDE WALL REMOVAL/INSTALLATION .)

4. Remove the console panel. (See CONSOLE PANEL REMOVAL/INSTALLATION .)

5. Remove the clips.

6. Disconnect the connector, then remove the keyless antenna.

7. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 53: Identifying Keyless Antenna And Fastener

Courtesy of MAZDA MOTORS CORP.

INTERIOR, REAR

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

3. Remove the back trim. (See BACK TRIM REMOVAL/INSTALLATION .)

4. Remove the nuts.

5. Disconnect the connector, then remove the keyless antenna.

6. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 54: Identifying Keyless Antenna And Nut

Courtesy of MAZDA MOTORS CORP.

INTERIOR, TRUNK

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the trunk side trim. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

3. Remove the nuts.

4. Disconnect the connector, then remove the keyless antenna.

5. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 55: Identifying Keyless Antenna And Nut

Courtesy of MAZDA MOTORS CORP.

KEYLESS BEEPER REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the trunk side trim. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

3. Remove the nuts.

4. Disconnect the connector.

5. Remove the keyless beeper.

6. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 56: Identifying Keyless Beeper Remove/Install Components

Courtesy of MAZDA MOTORS CORP.

REQUEST SWITCH REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

DEIVER-SIDE/PASSENGER-SIDE

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .)

3. Remove the outer handle. (See OUTER HANDLE REMOVAL/INSTALLATION[ADVANCED

KEYLESS SYSTEM] .)

4. Remove the screws A, then remove the handle seat and plate.

5. Remove screw B, then remove the request switch.

6. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 57: Identifying Request Switch Remove/Install Components (Driver-Side/Passenger-Side)

Courtesy of MAZDA MOTORS CORP.

TRUNK LID

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Open the trunk lid.

3. Remove the request switch.

4. Install in the reverse order of removal.

Fig. 58: Identifying Request Switch And Connector

Courtesy of MAZDA MOTORS CORP.

REQUEST SWITCH INSPECTION[ADVANCED KEYLESS SYSTEM]

1. Inspect for continuity between request switch terminals A and B.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata



If not as specified, replace the request switch.

: Continuity

Fig. 59: Request Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

Fig. 60: Identifying Request Switch Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

SECURITY ACCESS PROCEDURE[ADVANCED KEYLESS SYSTEM]

1. Connect the M-MDS to the DLC-2.

2. Select "BODY/SECURITY/PATS functions" from the M-MDS screen menu.

3. Select the items to be performed from the following:



Program Additional card key



Card Key Code Erase

Steering Lock Unit Programming



Program additional ignition key (with immobilizer system)

Ignition Key Code Erase (with immobilizer system)



Customer Spare Key Programming Enable (with immobilizer system)

 Customer Spare Key Programming Disable (with immobilizer system)

4. The security access begins and the M-MDS displays the "OUT-CODE".

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 61: Identifying DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

NOTE:



When "OUT-CODE" is first displayed, turning the ignition switch from the LOCK to the ON position 5 times will change the "OUT-CODE".

5. Input "IN-CODE" corresponding to "OUT-CODE" displayed on the M-MDS screen.

6. If the security access is successful, selected item can be performed.

TRUNK LID STRIKER REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

1. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)

2. Remove the bolts, then remove the trunk lid striker.

3. Install in the reverse order of removal.

Fig. 62: Identifying Trunk Lid Striker And Bolt With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

TRUNK LID OPENER INSPECTION[ADVANCED KEYLESS SYSTEM]

1. Apply battery positive voltage and connect the ground to the corresponding the trunk lid opener terminals, and inspect the trunk lid opener operation.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata



If the trunk lid opener does not operate as indicated in the table, replace the trunk lid opener.

TRUNK LID OPENER OPERATION REFERENCE

Operation

Terminal

A B

Unlocks B+ Ground

Fig. 63: Identifying Trunk Lid Opener Connector Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

TRUNK LID OPENER REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)

3. Detach the rod.

4. Disconnect the trunk lid opener connector and the trunk compartment light connector.

5. Remove the bolts, then remove the trunk lid opener.

6. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 64: Identifying Trunk Lid Opener Remove/Install Components With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

TRUNK LID OPENER SWITCH REMOVAL/INSTALLATION[ADVANCED

KEYLESS SYSTEM]

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Using a small flathead screwdriver, detach the tabs of the trunk lid opener switch from the dashboard.

3. Push the trunk lid opener switch into the dashboard and remove.

4. Disconnect the trunk lid opener switch connector.

5. Install in the reverse order of removal.

Fig. 65: Removal/Installation View Of Trunk Lid Opener Switch

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

TRUNK LID OPEN CANCEL SWITCH REMOVAL/INSTALLATION

[ADVANCED KEYLESS SYSTEM]

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)

3. Squeeze the tabs of the trunk lid opener cancel switch and pull it forward to remove it.

4. Disconnect the trunk lid opener cancel switch connector.

5. Remove the trunk lid opener cancel switch.

6. Install in the reverse order of removal.

Fig. 66: Identifying Trunk Lid Opener Cancel Switch And Tab

Courtesy of MAZDA MOTORS CORP.

TRUNK LID OPEN CANCEL SWITCH INSPECTION[ADVANCED KEYLESS

SYSTEM]

1. Remove the trunk lid open cancel switch.

2. Inspect for continuity between the trunk lid open cancel switch terminals.



If not as specified, replace the trunk lid open cancel switch.

: Continuity

Fig. 67: Trunk Lid Open Cancel Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

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2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 68: Identifying Trunk Lid Open Cancel Switch Connector Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

TRUNK KEY CYLINDER REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM]

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)

3. Detach the rod.

4. Remove the nuts, then remove the trunk key cylinder.

5. Install in the reverse order of removal.

Fig. 69: Identifying Trunk Key Cylinder Remove/Install Components With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

TRUNK KEY CYLINDER SWITCH INSPECTION[ADVANCED KEYLESS

SYSTEM]

1. Remove the trunk key cylinder switch.

2. Inspect for continuity between the trunk key cylinder switch terminals.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata



If not as specified, replace the trunk key cylinder.

: Continuity

Fig. 70: Trunk Key Cylinder Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

Fig. 71: Identifying Trunk Key Cylinder Switch Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

TRUNK LID OPENER SWITCH INSPECTION[ADVANCED KEYLESS

SYSTEM]

1. Remove the trunk lid open switch.

2. Inspect for continuity between the trunk lid open switch terminals.



If not as specified, replace the trunk lid open switch.

: Continuity

Fig. 72: Trunk Lid Opener Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata

Fig. 73: Identifying Trunk Lid Opener Switch Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

TOP LOCK SWITCH INSPECTION[ADVANCED KEYLESS SYSTEM]

1. Remove the front header trim. (See FRONT HEADER TRIM REMOVAL/INSTALLATION .)

2. Disconnect the striker switch connector.

3. Verify that the continuity between the striker switch terminals is as indicated in the table.



If not as indicated in the table, replace the striker.

: Continuity

Fig. 74: Striker Switch Continuity Chart

Courtesy of MAZDA MOTORS CORP.

Fig. 75: Identifying Striker Switch Terminals With Circuit

Courtesy of MAZDA MOTORS CORP.

Microsoft

LOCATION INDEX

2008 RESTRAINTS Air Bag System - MX-5 Miata

2008 RESTRAINTS

Air Bag System - MX-5 Miata

Fig. 1: Identifying Location Of Airbag Components

Courtesy of MAZDA MOTORS CORP.

AIR BAG SYSTEM SERVICE WARNINGS

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

AIR BAG MODULE INSPECTION



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

Fig. 2: Inspecting Air Bag Module Caution

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE HANDLING



Before removing the air bag module or disconnecting the air bag module connector, always turn the ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power.

Handling a live (undeployed) air bag module that is pointed toward your body could result in serious injury if the air bag module were to accidentally operate (deploy). When carrying a live

(undeployed) air bag module, point the deployment surface away from your body to lessen the chance of injury in case it operates (deploys).

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2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 3: Air Bag Module Handling (1 Of 2)

Courtesy of MAZDA MOTORS CORP.



A live (undeployed) air bag module placed with its deployment surface to ground is dangerous. If the air bag module were to accidentally operate (deploy), it could cause serious injury. Always place a live (undeployed) air bag module with its deployment surface up.

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2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 4: Air Bag Module Handling (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

SIDE AIR BAG MODULE HANDLING



When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad, frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat back that has been reused, a serious accident may result. After a side air bag has operated

(deployed), always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After servicing, verify that the seat operates normally and that the wiring harness is not caught.

SEAT WEIGHT SENSOR HANDLING



The passenger-side seat and the seat weight sensor may become deformed or otherwise damaged due to operation (deployment) of the front or side air bag in an accident. This may cause the passenger sensing function to operate improperly and result in a serious accident. Always replace the passenger seat and seat weight sensor with new ones after the front or side air bags have operated (deployed). After servicing, verify that the seat operates normally and that the wiring harness is not caught. If the collision is not hard enough to cause the front or side air bags to operate (deploy), inspect the seat weight sensor and replace it if there is any malfunction.

SAS CONTROL MODULE HANDLING



Removing the SAS control module or disconnecting the SAS control module connector with the ignition switch at the ON position can activate the sensor in the SAS control module and operate

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2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata



(deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the SAS control module or disconnecting the SAS control module connector, always turn the ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power.

Connecting the SAS control module connector with the SAS control module not securely fixed to the vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pretensioner seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix the SAS control module to the vehicle.

Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts have operated (deployed) due to a collision or other causes, the SAS control module must be replaced with a new one even if the used one does not have any visible external damage or deformation. The used SAS control module may have been damaged internally, which may cause improper operation. If the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy) normally, which could result in a serious accident. Always replace the

SAS control module with a new one. The SAS control module cannot be bench-checked or selfchecked.

CRASH ZONE SENSOR HANDLING



Removing the crash zone sensor or disconnecting the crash zone sensor connector with the ignition switch at the ON position can activate the crash zone sensor and operate (deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the crash zone sensor or disconnecting the crash zone sensor connector, always turn the ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power.



If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bags and pretensioner seat belts may accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a serious accident. Do not subject the crash zone sensor to shock or disassemble the sensor.

Because a sensor is built into the crash zone sensor, once the air bags and pre-tensioner seat belts have operated (deployed) due to a collision or other causes, the crash zone sensor must be replaced with a new one even if the used one does not have any visible external damage or deformation. If the crash zone sensor is reused, the air bags and pre-tensioner seat belts may not operate (deploy) normally, which could result in a serious accident. Always replace the crash zone sensor with a new one. The crash zone sensor cannot be bench-checked or self-checked.

SIDE AIR BAG SENSOR HANDLING



Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition switch at the ON position can activate the side air bag sensor and operate (deploy) the side air bag, which may cause serious injury. Before removing the side air bag sensor or disconnecting the side air bag sensor connector, always turn the ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the

SAS control module to deplete its stored power.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata



If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.



Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to a collision or other causes, the side air bag sensor must be replaced with a new one even if the used one does not have any visible external damage or deformation. If the side air bag sensor is reused, the side air bag may not operate (deploy) normally, which could result in a serious accident.

Always replace the side air bag sensor with a new one. The side air bag sensor cannot be benchchecked or self-checked.

PRE-TENSIONER SEAT BELT INSPECTION



Inspecting a pre-tensioner seat belt using a tester can operate (deploy) the pre-tensioner seat belt, which may cause serious injury. Do not use a tester to inspect a pre-tensioner seat belt. Always use the on-board diagnostic function to diagnose the pre-tensioner seat belt for malfunctions.

Fig. 5: Inspecting Pre-Tensioner Seat Belt Using Tester Caution

Courtesy of MAZDA MOTORS CORP.

AIR BAG SYSTEM SERVICE CAUTIONS

AIR BAG SYSTEM COMPONENT DISASSEMBLY

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2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata



Disassembling the air bag system components could cause it to not operate (deploy) normally.

Never disassemble any air bag system components.

Fig. 6: Air Bag System Service Cautions

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE, PRE-TENSIONER SEAT BELT HANDLING



Oil, grease, or water on the air bag modules may cause the air bags and pre-tensioner seat belts to fail to operate (deploy) in an accident. Never allow oil, grease, or water to get on the air bag modules or pre-tensioner seat belts.



Inserting a screwdriver or similar object into the connector of an air bag module or a pre-tensioner seat belt may damage the connector and cause the air bag module or the pre-tensioner seat belt to operate (deploy) improperly, which may cause serious injury. Never insert any foreign objects into the air bag module or seat belt connectors.

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Fig. 7: Air Bag Module & Pre-Tensioner Seat Belt Handling Caution

Courtesy of MAZDA MOTORS CORP.

SEAT WEIGHT SENSOR HANDLING



The seat weight sensor has a built-in strain gauge which may operate improperly if the sensor is dropped by itself or when installed to the seat. If it is dropped, replace the seat weight sensor with a new one.

Oil, grease, or water on the seat weight sensor may cause the system to operate (deploy) improperly. Never allow oil, grease, or water to get on the seat weight sensor.



Foreign material in the seat weight sensor components may cause the system to operate (deploy) improperly. Always make sure that no foreign material can get into the seat weight sensor.

Disassembling the seat weight sensor, or tightening any of the nuts and bolts installed to the sensor body may cause it to operate (deploy) improperly. Never disassemble the seat weight sensor or tighten any of the nuts or bolts installed to the body of the sensor.

AIR BAG MODULE, PRE-TENSIONER SEAT BELT REUSE



Even if an air bag module or a pre-tensioner seat belt does not operate (deploy) in a collision and does not have any external signs of damage, it may have been damaged internally, which may cause improper operation. Before reusing a live (undeployed) air bag module and the pre-tensioner seat belts, always use the on-board diagnostic to diagnose the air bag module and the pre-tensioner seat belts to verify that they have no malfunction.

AIR BAG WIRING HARNESS REPAIR

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

Incorrectly repairing an air bag wiring harness can accidentally operate (deploy) the air bag module and pre-tensioner seat belts. If a problem is found in the air bag wiring harness, always replace the wiring harness with a new one.

Fig. 8: Identifying Air Bag Wiring Harness Repair Caution

Courtesy of MAZDA MOTORS CORP.

PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR

REMOVAL/INSTALLATION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove the following parts:

1. Side wall (See SIDE WALL REMOVAL/INSTALLATION .)

2. Center panel unit (See CENTER PANEL UNIT REMOVAL/INSTALLATION .)

3. Remove the glove compartment. (See GLOVE COMPARTMENT

REMOVAL/INSTALLATION .)

4. Decoration panel (See DECORATION PANEL REMOVAL/INSTALLATION .)

4. Remove in the order indicated in Fig. 9 .

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Fig. 9: View Of Passenger Air Bag Deactivation (PAD) Indicator & Components

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION

WARNING:



Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Read the air bag system service warnings and cautions before handling the air bag module. (See AIR BAG SYSTEM SERVICE WARNINGS .) (See AIR

BAG SYSTEM SERVICE CAUTIONS .)

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove in the order indicated in Fig. 10 .

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Fig. 10: View Of Driver-Side Air Bag Module & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

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6. Turn the ignition switch to the ON position.

7. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

CONNECTOR REMOVAL NOTE

1. Using a flathead screwdriver, pry out the connector stopper plate.

Fig. 11: Prying Out Connector Stopper Plate

Courtesy of MAZDA MOTORS CORP.

2. Disconnect the connector.

PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION

WARNING:



Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Read the air bag

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

 system service warnings and cautions before handling the air bag module. (See AIR BAG SYSTEM SERVICE WARNINGS .) (See AIR

BAG SYSTEM SERVICE CAUTIONS .)

If the passenger-side air bag module is installed with debris in the module, it may be scattered when the air bag module operates

(deploys), causing injury. Verify that there is no debris in the passenger-side air bag module before installation.

If a damaged passenger-side air bag module is installed, the vehicle may be damaged or the passenger may be injured when the air bag module operates (deploys). Verify that the passenger-side air bag has no damage before installation.

Due to the adoption of 2-step deployment control in the passengerside air bag module, depending on the impact force, it is possible that inflator No.2 might not deploy. In such cases, before disposing of the air bag module, make sure to follow the inflator deployment procedures and verify complete deployment of inflators No.1 and 2.

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove the glove compartment. (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)

5. Remove in the order indicated in Fig. 12 .

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Fig. 12: View Of Passenger-Side Air Bag Module & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

7. Turn the ignition switch to the ON position.

8. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate, refer to RESTRAINTS -- ON-BOARD

DIAGNOSTIC system (air bag system) and perform inspection of the system.

PASSENGER-SIDE AIR BAG MODULE REMOVAL NOTE

1. Remove the passenger-side air bag module in the order indicated below.

1. Disengage the tab locks by sliding the passenger-side air bag module upward.

2. Slide the passenger-side air bag module rearward.

3. Remove the passenger-side air bag module by pulling it from the backside and then down.

Fig. 13: View Of Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

CONNECTOR REMOVAL NOTE

1. Using a flathead screwdriver, pry out the connector stopper plate.

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Fig. 14: Prying Out Connector Stopper Plate

Courtesy of MAZDA MOTORS CORP.

2. Disconnect the connector.

CAP INSTALLATION NOTE

1. The cap cannot be reused. Replace the cap with a new one when the cap or the passenger-side air bag module has been removed.

SIDE AIR BAG MODULE REMOVAL/INSTALLATION

WARNING:



Handling the air bag module improperly can accidentally operate

(deploy) the air bag module, which may seriously injure you. Read the air bag system service warnings and cautions before handling the air bag module. (See AIR BAG SYSTEM SERVICE WARNINGS .)

(See AIR BAG SYSTEM SERVICE CAUTIONS .)

If the side air bag module is installed with debris in the seat back,

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2008 RESTRAINTS Air Bag System - MX-5 Miata the foreign material may be scattered when the side air bag module operates (deploys), causing injury. Verify that there is no foreign material in the seat back before installing the side air bag module.

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove the seat. (See SEAT REMOVAL/INSTALLATION .)

5. Detach the tab as shown in Fig. 15 and remove the connector from the seat connector.

Fig. 15: Detaching Tab

Courtesy of MAZDA MOTORS CORP.

6. Partially peel back the seat back trim.

7. Partially peel back the seat back pad.

8. Remove in the order indicated in Fig. 16 .

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Fig. 16: View Of Side Air Bag Module & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

9. Install in the reverse order of removal.

10. Turn the ignition switch to the ON position.

11. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

CRASH ZONE SENSOR REMOVAL/INSTALLATION

WARNING:



Handling the crash zone sensor improperly can accidentally deploy the air bags and pre-tensioner seat belts, which may seriously injure you. Read the air bag system service warnings and cautions before handling the crash zone sensor. (See AIR BAG SYSTEM SERVICE

WARNINGS .) (See AIR BAG SYSTEM SERVICE CAUTIONS .)

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

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3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

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

5. Remove the fresh-air duct. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

6. Remove in the order indicated in Fig. 17 .

Fig. 17: View Of Crash Zone Sensor & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

8. Turn the ignition switch to the ON position.

9. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

SAS CONTROL MODULE REMOVAL/INSTALLATION

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WARNING:



Handling the SAS control module improperly can accidentally deploy the air bag modules and pre-tensioner seat belt, which may seriously injure you. Read the air bag system service warnings and cautions before handling the SAS control module. (See AIR BAG

SYSTEM SERVICE WARNINGS .) (See AIR BAG SYSTEM SERVICE

CAUTIONS .)

CAUTION:



Handling the SAS control module improperly can accidentally deploy the air bag modules and pre-tensioner seat belt, which may seriously injure you. If configuration is not completed before removing the SAS control module, DTC B2477 will be displayed.

1. Perform SAS control module configuration when replacing it. (See SAS CONTROL MODULE

CONFIGURATIONS .)

2. Turn the ignition switch to the LOCK position.

3. Remove the battery cover.

4. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

5. Remove the following parts:

1. Console (See CONSOLE REMOVAL/INSTALLATION .)

2. Side wall (See SIDE WALL REMOVAL/INSTALLATION .)

3. Console panel (See CONSOLE PANEL REMOVAL/INSTALLATION .)

6. Remove in the order indicated in Fig. 18 .

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Fig. 18: View Of SAS Control Module Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

8. Turn the ignition switch to the ON position.



If the SAS control module is replaced, turn the ignition switch to the ON position for 20 s or more after completing the configuration. (See SAS CONTROL MODULE CONFIGURATION .)

9. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

SAS CONTROL MODULE CONFIGURATION

1. Connect the M-MDS to the DLC-2 Connector.

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Fig. 19: Identifying DLC-2 Location

Courtesy of MAZDA MOTORS CORP.

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.

 When using the IDS (Laptop PC)

1. Select "Programming".



When using the PDS (Pocket PC)

1. Select "Programming".

2. Select "Module Programming".

3. Then Select the "Programmable Module Installation" and "RCM" from the screen menu.

4. Perform the configuration according to the directions on the screen.

5. Retrieve DTCs using the M-MDS, then verify if DTCs are present.



If a DTC is present, perform the applicable DTC inspection.

SEAT TRACK POSITION SENSOR REMOVAL/INSTALLATION

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove the driver's seat. (See SEAT REMOVAL/INSTALLATION .)

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5. Detach the tab as shown in Fig. 20 and remove the connector from the seat connector.

Fig. 20: Detaching Seat Connector Tab & Removing Connector From Seat Connector

Courtesy of MAZDA MOTORS CORP.

6. Remove in the order indicated in Fig. 21 .

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Fig. 21: Removing Connector From Seat Connector

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

SEAT TRACK POSITION SENSOR INSTALLATION NOTE



Verify that the seat track position sensor is not contacting the metal plate.

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Fig. 22: View Of Seat Track Position Sensor

Courtesy of MAZDA MOTORS CORP.

SEAT WEIGHT SENSOR CONTROL MODULE REMOVAL/INSTALLATION

CAUTION:



When the seat weight sensor control module is replaced with a new one, perform the seat weight sensor calibration using the WDS or equivalent. (See SEAT WEIGHT SENSOR CALIBRATION .)

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove in the order indicated in Fig. 23 .

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Fig. 23: View Of Seat Weight Sensor Control Module

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

SEAT WEIGHT SENSOR CALIBRATION

CAUTION:



If any of the following work is performed, perform the seat weight sensor calibration using the WDS or equivalent.



Replacement with a new seat weight sensor



Replacement with a new seat weight sensor control module



Replacement with new passenger-side seat parts



Disassembly of the passenger-side seat

If any of the following work is performed, perform the seat weight sensor inspection using the WDS or equivalent. (See SEAT WEIGHT

SENSOR INSPECTION .)

Removal of the passenger-side seat



Loosening and retightening of passenger's seat fixing bolts

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

Or, the vehicle is involved in a collision

1. Have two 20 kg {44 lb} weights ready to use.

2. Connect the WDS or equivalent to the DLC-2 (16-pin).

Fig. 24: Identifying DLC-2 Location

Courtesy of MAZDA MOTORS CORP.

3. Select "Body" from the menu.

4. Select "Restraints".

5. Select "Seat Weight Sensor ReZero Procedure".

6. Perform calibration following the procedures on the WDS or equivalent screen.

NOTE:



When "Lightly pat the passenger seat cushion" is displayed on the

WDS or equivalent screen, lightly pat horizontally approx. five times on the headrest or upper side of the seat back trim of the passengerside front seat.

SEAT WEIGHT SENSOR INSPECTION

CAUTION:



If any of the following work is performed, perform the seat weight

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 sensor inspection using the WDS or equivalent.



Removal of the passenger-side seat



Loosening and retightening of passenger's seat fixing bolts



Or, the vehicle is involved in a collision

If any of the following work is performed, perform the seat weight sensor calibration using the WDS or equivalent. (See SEAT WEIGHT

SENSOR CALIBRATION .)



Replacement with a new seat weight sensor

Replacement with a new seat weight sensor control module



Replacement with new passenger-side seat parts



Disassembly of the passenger-side seat

1. Connect the WDS or equivalent to the DLC-2 (16-pin).

Fig. 25: Identifying DLC-2 Location

Courtesy of MAZDA MOTORS CORP.

2. Select "Body" from the menu.

3. Select "Restraints".

4. Select "Seat Weight Sensor ReZero Procedure".

5. Perform inspection following the procedures on the WDS or equivalent screen.

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PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH

REMOVAL/INSTALLATION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove the side panel. (See SIDE PANEL REMOVAL/INSTALLATION .)

4. Disconnect the connector.

5. Remove the PAD switch.

Fig. 26: View Of Passenger Air Bag Deactivation (PAD) Switch

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

7. Turn the ignition switch to the ON position.

8. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH INSPECTION

1. Remove the PAD switch. (See PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH

REMOVAL/INSTALLATION .)

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2. Verify that the continuity between the PAD switch terminals is as indicated in Fig. 27 .



If not as indicated in Fig. 27 , replace the PAD switch.

Fig. 27: PAD Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

Fig. 28: Inspecting Passenger Air Bag Deactivation (PAD) Switch Connector Terminals

Courtesy of MAZDA MOTORS CORP.

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SIDE AIR BAG SENSOR REMOVAL/INSTALLATION

WARNING:



Handling the side air bag sensor improperly can accidentally operate (deploy) the air bag module, which may seriously injure you.

Read the air bag system service warnings and cautions before handling the side air bag sensor. (See AIR BAG SYSTEM SERVICE

WARNINGS .) (See AIR BAG SYSTEM SERVICE CAUTIONS .)

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove the quarter trim. (See QUARTER TRIM REMOVAL/INSTALLATION .)

5. Remove the scuff plate. (See SCUFF PLATE REMOVAL/INSTALLATION .)

6. Remove the tire house trim. (See TIRE HOUSE TRIM REMOVAL/INSTALLATION .)

7. Remove in the order indicated in Fig. 29 .

Fig. 29: View Of Side Air Bag Sensor & Components

Courtesy of MAZDA MOTORS CORP.

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8. Install in the reverse order of removal.

9. Turn the ignition switch to the ON position and hold for 5 s or more .

10. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

CLOCK SPRING REMOVAL/INSTALLATION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove the following parts:

1. Driver-side air bag module (See DRIVER-SIDE AIR BAG MODULE

REMOVAL/INSTALLATION .)

2. Steering wheel (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)

3. Column cover (See COLUMN COVER REMOVAL/INSTALLATION .)

4. Remove in the order indicated in Fig. 30 .

Fig. 30: View Of Clock Spring Components

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Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

6. Turn the ignition switch to the ON position.

7. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

CLOCK SPRING INSTALLATION NOTE

CAUTION:



If the clock spring is not adjusted, the spring wire in the clock spring could over-wind and break when the steering wheel is turned. Always adjust the clock spring after installing it.

1. Adjust the clock spring after installing it. (See CLOCK SPRING ADJUSTMENT .)

CLOCK SPRING ADJUSTMENT

NOTE:



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

1. Set the front tires straight-ahead.

CAUTION:



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

2. Turn the clock spring clockwise until it stops.

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Fig. 31: Turning Clock Spring Clockwise

Courtesy of MAZDA MOTORS CORP.

3. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns .

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Fig. 32: Turning Clock Spring Counterclockwise 2 3/4 Turns

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. 33: Aligning Mark On Clock Spring With Mark On Outer Housing

Courtesy of MAZDA MOTORS CORP.

CLOCK SPRING INSPECTION

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

REMOVAL/INSTALLATION .)

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

REMOVAL/INSTALLATION .)

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

4. Verify that the continuity is as indicated in Fig. 34 .

 If not as indicated in Fig. 34 , replace the clock spring.

NOTE:



When the vehicle-side connector for the clock spring is disconnected, terminals 1A, 1B, 1C and 1D are shorted to prevent unexpected operation (deployment) of the air bag module.

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Fig. 34: Clock Spring Continuity Reference Table

Courtesy of MAZDA MOTORS CORP.

Fig. 35: Identifying Clock Spring Connector Terminals

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT

PROCEDURES

WARNING:



A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy) when it is disposed of and cause serious injury. Do not dispose of a live (undeployed) air bag module and pre-tensioner seat belt. If the SSTs (Deployment tool and

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

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CAUTION:



If the vehicle is to be scrapped, or when disposing of any air bag modules or pre-tensioner seat belts, operate (deploy) them inside the vehicle by following the deployment procedure below and using the SST

(Deployment tool).

When disposing of an operated (deployed) air bag module and pre-tensioner seat belt, refer to AIR BAG

MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES .

DEPLOYMENT PROCEDURE 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 doors and windows.

3. Turn the ignition switch to the LOCK position.

4. Remove the battery cover.

5. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

6. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.

DRIVER-SIDE AIR BAG MODULE

WARNING:



Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules and pre-tensioner seat belts outside the vehicle.



The driver-side air bag module is a dual inflator type. If one inflator is forced to operate (deploy), the other may operate (deploy) accidentally. To prevent injury while disposing of the air bag module, make sure to operate (deploy) both driver-side air bag module inflators simultaneously, following the procedure below.

NOTE:



The SSTs , two types of adapter harnesses (for inflators No.1 and No.2) and two deployment tools are to be used to operate (deploy) the driverside air bag module.

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

REMOVAL/INSTALLATION .)

2. Connect the SSTs (Adapter harness) to the driver-side air bag module as shown in Fig. 36 .

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

REMOVAL/INSTALLATION .)

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Fig. 36: Connecting SSTs (Adapter Harness) To Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

Fig. 37: Connecting SSTs (Deployment tool) To SSTs (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

6. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.

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

8. Press the activation switch on the SST (Deployment tool) connected with 49 L066 002 (a yellow

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2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata connector) of the SST (Adapter harness), and after 3 s , press the activation switch on the other SST

(Deployment tool) to operate (deploy) the air bag module (both inflators).

Fig. 38: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

WARNING:



Verify that air bag module operation (explosive) sound occurs twice. If no operation (explosive) sound was heard or a single operation (explosive) sound was heard, both inflators would not have operated (deployed) properly. This may cause serious injury if the air bag module operates (deploy) unexpectedly. If the two operation (explosive) sounds are not heard, perform

Step 8 again. If a total of two operation (explosive) sounds cannot be verified even though step 8 is performed again, leave the air bag module alone for 30 min or more before approaching it again.

The air bag module is very hot immediately after it is operated

(deployed). You can get burned. Do not touch the air bag module for at least 15 min after deployment.

9. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

PASSENGER-SIDE AIR BAG MODULE

WARNING:



The passenger-side air bag module is a dual inflator type. If one

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata inflator is forced to operate (deploy), the other may operate (deploy) accidentally. To prevent injury while disposing of the air bag module, make sure to operate (deploy) both passenger-side air bag module inflators simultaneously, following the procedure below.

NOTE:



The SSTs , two types of adapter harnesses (for inflators No.1 and No.2) and two deployment tools are to be used to operate (deploy) the passenger-side air bag module.

1. Remove the glove compartment. (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)

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

3. Connect the SSTs (Adapter harness) to the passenger-side air bag module as shown in Fig. 39 .

4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

Fig. 39: Connecting SSTs (Adapter Harness) To Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

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Fig. 40: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

6. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.

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

8. Press the activation switch on the SST (Deployment tool) connected with 49 L066 002 (a yellow connector) of the SST (Adapter harness), and after 3 s , press the activation switch on the other SST

(Deployment tool) to operate (deploy) the air bag module (both inflators).

Fig. 41: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

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WARNING:



Step 8 again. If a total of two operation (explosive) sounds cannot be verified even though Step 8 is performed again, leave the air bag module alone for 30 min or more before approaching it again.

The air bag module is very hot immediately after it is operated

(deployed). You can be burned. Do not touch the air bag module for at least 15 min after deployment.

9. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

SIDE AIR BAG MODULE

1. Disconnect the seat connector.

2. Connect the SST (Adapter harness) to the side air bag module as shown in Fig. 42 .

Fig. 42: Connecting SST (Adapter Harness) To Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

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3. Connect the SST (Deployment tool) to the SST (Adapter harness).

4. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

5. Verify that the red lamp on the SST (Deployment tool) is illuminated.

6. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

Fig. 43: Connecting SST (Deployment Tool) To SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

7. Press the activation switch on the SST (Deployment tool) to operate (deploy) the side air bag module.

8. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

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Fig. 44: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

PRE-TENSIONER SEAT BELT

1. Remove the back trim. (See BACK TRIM REMOVAL/INSTALLATION .)

2. Remove the pre-tensioner seat belt and connect the SST (Adapter harness) as shown in Fig. 45 . (See

SEAT BELT REMOVAL/INSTALLATION .)

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Fig. 45: View Of Pre-Tensioner Seat Belt & SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

3. Install the pre-tensioner seat belt.

4. Connect the SST (Deployment tool) to the SST (Adapter harness).

5. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

6. Verify that the red lamp on the SST (Deployment tool) is illuminated.

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

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Fig. 46: Connecting SST (Deployment Tool) To SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

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

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Fig. 47: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

9. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

DEPLOYMENT PROCEDURE FOR OUTSIDE OF VEHICLE

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

2. Turn the ignition switch to the LOCK position.

3. Remove the battery cover.

4. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

5. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.

DRIVER-SIDE AIR BAG MODULE

WARNING:



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

REMOVAL/INSTALLATION .)

2. Connect the SSTs (Adapter harness) to the driver-side air bag module as shown in Fig. 48 .

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Fig. 48: Connecting SSTs (Adapter Harness) To Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

3. Place the driver-side air bag module on the center of the tire wheel with the padded surface facing up. To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm

{0.002 in

} or more ) through the wheel and the bolt installation holes of the air bag module at least 4 times .

WARNING:



If the air bag module is not properly installed to the tire wheel, serious injury may occur when the module is operated

(deployed). When installing the air bag module to the tire wheel, make sure the padded surface is facing up.

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Fig. 49: Placing Driver-Side Air Bag Module On Center Of Tire Wheel

Courtesy of MAZDA MOTORS CORP.

4. Stack three tires without wheels on top of the tire with the driver-side air bag module, and then stack another tire with a wheel on the very top.

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Fig. 50: Stacking Tires Without Wheels On Top Of Tire With Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

5. Secure the tires with wire.

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Fig. 51: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

6. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

7. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

8. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.

9. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

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Fig. 52: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

10. Press the activation switch on the SST (Deployment tool) connected with 49 L066 002 (a yellow connector) of the SST (Adapter harness), and after 3 s , press the activation switch on the other SST

(Deployment tool) to operate (deploy) the air bag module (both inflators).

WARNING:



The air bag module is very hot immediately after it is operated

(deployed). You can be burned. Do not touch the air bag module for at least 15 min after deployment.

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Fig. 53: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

PASSENGER-SIDE AIR BAG MODULE

WARNING:



The passenger-side air bag module is a dual inflator type. If one inflator is forced to operate (deploy), the other may operate (deploy) accidentally. To prevent injury while disposing of the air bag module, make sure to operate (deploy) both passenger-side air bag module inflators simultaneously, following the procedure below.

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

REMOVAL/INSTALLATION .)

2. Connect the SSTs (Adapter harness) to the passenger-side air bag module as shown in Fig. 54 .

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Fig. 54: Connecting SSTs (Adapter Harness) To Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

3. Place the padded surface of the passenger-side air bag module facing the center of the tire as shown in

Fig. 55 . To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm

{0.002 in

2 or more ) through the tire and the brackets at least 4 times as shown in Fig. 55 .

}

WARNING:



If the air bag module is not properly secured to the tire, the tires may fall over by the impact of operation (deployment) and cause serious injury. To prevent this, secure the air bag module properly with the padded surface facing the center of the tire.

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Fig. 55: Wrapping Wire Through Tire & Brackets

Courtesy of MAZDA MOTORS CORP.

4. Stack the tire with the passenger-side air bag module on top of two tires without wheels. Stack a tire without a wheel on top of the tire with the passenger-side air bag module, and then stack another tire with a wheel on the very top.

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Fig. 56: Stacking Tire With Passenger-Side Air Bag Module On Top Of Two Tires Without Wheels

Courtesy of MAZDA MOTORS CORP.

5. Secure the tires with wire.

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Fig. 57: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

6. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

7. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

8. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.

9. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

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Fig. 58: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

(Deployment tool) to operate (deploy) the air bag module (both inflators).

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Fig. 59: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

WARNING:



The air bag module is very hot immediately after it is operated

(deployed). You can be burned. Do not touch the air bag module for at least 15 min after deployment.

11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

SIDE AIR BAG MODULE

1. Remove the side air bag module. (See SIDE AIR BAG MODULE REMOVAL/INSTALLATION .)

2. Install the nuts to the side air bag module as shown in Fig. 60 , and connect the SST (Adapter harness).

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Fig. 60: View Of Nuts On Side Air Bag Module & SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

3. Place the padded surface of the side air bag module facing the center of the tire as shown in Fig. 61 . To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm

{0.002 in

} or more ) through the tire and around the bolts at least 4 times .

WARNING:



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Fig. 61: Placing Padded Surface Of Side Air Bag Module Facing Center Of Tire

Courtesy of MAZDA MOTORS CORP.

4. Connect the SST (Adapter harness) to the side air bag module as shown in Fig. 62 .

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Fig. 62: Connecting SST (Adapter Harness) To Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

5. Stack the tire with the side air bag module on top of two tires without wheels. Stack a tire without a wheel on top of the tire with the side air bag module, and then stack another tire with a wheel on the very top.

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Fig. 63: Stacking Tire With Side Air Bag Module On Top Of Tires Without Wheels

Courtesy of MAZDA MOTORS CORP.

6. Secure the tires with wire.

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Fig. 64: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

7. Connect the SST (Deployment tool) to the SST (Adapter harness).

8. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

9. Verify that the red lamp on the SST (Deployment tool) is illuminated.

10. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

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Fig. 65: Connecting SST (Deployment Tool) To SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

11. Press the activation switch on the SST (Deployment tool) to operate (deploy) the side air bag module.

12. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

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Fig. 66: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

PRE-TENSIONER SEAT BELT

1. Remove the pre-tensioner seat belt. (See SEAT BELT REMOVAL/INSTALLATION .)

2. Connect the SST (Adapter harness) to the pre-tensioner seat belt as shown in Fig. 67 .

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Fig. 67: Connecting SST (Adapter Harness) To Pre-Tensioner Seat Belt

Courtesy of MAZDA MOTORS CORP.

3. Put the pre-tensioner seat belt inside the tire and secure it to the tire by wrapping a wire (cross section of

1.25 mm

{0.002 in

} or more ) through the tire and the bolt installation holes at least 4 times .

WARNING:



If the pre-tensioner seat belt is not properly installed to the tire, serious injury may occur when the pre-tensioner part is operated (deployed). When installing the pre-tensioner seat belt to the tire, make sure the pre-tensioner part is inside the tire.

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Fig. 68: Putting Pre-Tensioner Seat Belt Inside Tire & Secure To Tire By Wrapping Wire

Courtesy of MAZDA MOTORS CORP.

4. Stack the tire with the pre-tensioner seat belt on two of tires without wheels. Stack a tire without a wheel on top of the tire with the pre-tensioner seat belt, and then stack another tire with a wheel on the very top.

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Fig. 69: Stacking Tire With Pre-Tensioner Seat Belt On Two Of Tires Without Wheels

Courtesy of MAZDA MOTORS CORP.

5. Secure the tires with wire.

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Fig. 70: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

6. Connect the SST (Deployment tool) to the SST (Adapter harness).

7. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

8. Verify that the red lamp on the SST (Deployment tool) is illuminated.

9. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

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Fig. 71: Connecting SST (Deployment Tool) To SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

10. Press the activation switch on the SST (Deployment tool) to operate (deploy) the pre-tensioner seat belt.

11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

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Fig. 72: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL

PROCEDURES

WARNING:



A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy) when it is disposed of and cause serious injury. Always refer to the AIR BAG MODULE AND PRE-

TENSIONER SEAT BELT DEPLOYMENT PROCEDURES and dispose of air bag modules and pre-tensioner seat belts in a deployed condition.

The air bag modules and the pre-tensioner seat belts are very hot immediately after they are deployed. You can be burned. Do not touch an air bag module and pre-tensioner seat belt for at least 15 min 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 or pre-tensioner seat belt may contain deposits of sodium hydroxide, a caustic byproduct of the gasgenerated combustion. If this substance gets into your eyes or on your hands, it can cause irritation and itching. When handling the

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 deployed air bag module and pre-tensioner seat belt, wear gloves and safety glasses.

Due to the adoption of 2-step deployment control in both the driver and passenger-side air bag modules, depending on the impact force, it is possible that inflator No. 2 might not operate (deploy). Before disposing of the air bag module, always follow the inflator deployment procedures and verify the complete operation

(deployment) of inflators No. 1 and 2.

1. Remove the deployed air bag module or pre-tensioner seat belt.

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

Fig. 73: Putting Air Bag Module Or Pre-Tensioner Seat Belt In Plastic Bag

Courtesy of MAZDA MOTORS CORP.

INSPECTION OF SST (DEPLOYMENT TOOL)

1. Before using the SST (49 H066 002), inspect its operation.

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Fig. 74: Inspecting SST (Deployment Tool)

Courtesy of MAZDA MOTORS CORP.

INSPECTION PROCEDURE

1. Follow the steps below to inspect the SST (49 H066 002).



If not as indicated in SST INSPECTION REFERENCE TABLE , replace the SST (49 H066

002) because it has a malfunction.

WARNING:



Do not use a malfunctioning SST (49 H066 002), otherwise it could cause the air bag module or pre-tensioner seat belt to accidentally operate (deploy).

CAUTION:



Because the permissible voltage for the SST (49 H066 002) is 12

V, do not connect a 24 V power source because it will damage the SST. Always connect only a 12 V power source.

SST INSPECTION REFERENCE TABLE

Step Inspection procedure

Light condition

Green Red

On Off

Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

Connect connectors A and B.

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Thursday, July 09, 2009 3:43:37 PM Page 75

Off On

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2008 RESTRAINTS Air Bag System - MX-5 Miata

Press the activation switch.

On Off

Fig. 75: Inspecting Activation Switch

Courtesy of MAZDA MOTORS CORP.

Microsoft

LOCATION INDEX

2007 RESTRAINTS Air Bag System - MX-5 Miata

2007 RESTRAINTS

Air Bag System - MX-5 Miata

Fig. 1: Identifying Location Of Airbag Components

Courtesy of MAZDA MOTORS CORP.

AIR BAG SYSTEM SERVICE WARNINGS

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

AIR BAG MODULE INSPECTION



Fig. 2: Inspecting Air Bag Module Caution

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE HANDLING



Handling a live (undeployed) air bag module that is pointed toward your body could result in serious injury if the air bag module were to accidentally operate (deploy). When carrying a live

(undeployed) air bag module, point the deployment surface away from your body to lessen the chance of injury in case it operates (deploys).

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Fig. 3: Air Bag Module Handling (1 Of 2)

Courtesy of MAZDA MOTORS CORP.



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Fig. 4: Air Bag Module Handling (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

SIDE AIR BAG MODULE HANDLING



SEAT WEIGHT SENSOR HANDLING



SAS CONTROL MODULE HANDLING



Removing the SAS control module or disconnecting the SAS control module connector with the ignition switch at the ON position can activate the sensor in the SAS control module and operate

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2007 Mazda MX-5 Miata Sport

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

SAS control module with a new one. The SAS control module cannot be bench-checked or selfchecked.

CRASH ZONE SENSOR HANDLING



SIDE AIR BAG SENSOR HANDLING



SAS control module to deplete its stored power.

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2007 Mazda MX-5 Miata Sport

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

Always replace the side air bag sensor with a new one. The side air bag sensor cannot be benchchecked or self-checked.

PRE-TENSIONER SEAT BELT INSPECTION



Fig. 5: Inspecting Pre-Tensioner Seat Belt Using Tester Caution

Courtesy of MAZDA MOTORS CORP.

AIR BAG SYSTEM SERVICE CAUTIONS

AIR BAG SYSTEM COMPONENT DISASSEMBLY

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

Disassembling the air bag system components could cause it to not operate (deploy) normally.

Never disassemble any air bag system components.

Fig. 6: Air Bag System Service Cautions

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE, PRE-TENSIONER SEAT BELT HANDLING



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Fig. 7: Air Bag Module & Pre-Tensioner Seat Belt Handling Caution

Courtesy of MAZDA MOTORS CORP.

SEAT WEIGHT SENSOR HANDLING



Oil, grease, or water on the seat weight sensor may cause the system to operate (deploy) improperly. Never allow oil, grease, or water to get on the seat weight sensor.



Foreign material in the seat weight sensor components may cause the system to operate (deploy) improperly. Always make sure that no foreign material can get into the seat weight sensor.

AIR BAG MODULE, PRE-TENSIONER SEAT BELT REUSE



AIR BAG WIRING HARNESS REPAIR

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

Fig. 8: Identifying Air Bag Wiring Harness Repair Caution

Courtesy of MAZDA MOTORS CORP.

PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR

REMOVAL/INSTALLATION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove the following parts:

1. Side wall (See SIDE WALL REMOVAL/INSTALLATION .)

2. Center panel unit (See CENTER PANEL UNIT REMOVAL/INSTALLATION .)

3. Remove the glove compartment. (See GLOVE COMPARTMENT

REMOVAL/INSTALLATION .)

4. Decoration panel (See DECORATION PANEL REMOVAL/INSTALLATION .)

4. Remove in the order indicated in Fig. 9 .

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Fig. 9: Removing/Installing Passenger Air Bag Deactivation (PAD) Indicator

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION

WARNING:



BAG SYSTEM SERVICE CAUTIONS .)

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove in the order indicated in Fig. 10 .

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Fig. 10: Removing/Installing Driver-Side Air Bag Module (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

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6. Turn the ignition switch to the ON position.

7. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

CONNECTOR REMOVAL NOTE

1. Using a flathead screwdriver, pry out the connector stopper plate.

Fig. 11: Prying Out Connector Stopper Plate

Courtesy of MAZDA MOTORS CORP.

2. Disconnect the connector.

PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION

WARNING:



Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Read the air bag

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata



 system service warnings and cautions before handling the air bag module. (See AIR BAG SYSTEM SERVICE WARNINGS .) (See AIR

BAG SYSTEM SERVICE CAUTIONS .)

If the passenger-side air bag module is installed with debris in the module, it may be scattered when the air bag module operates

(deploys), causing injury. Verify that there is no debris in the passenger-side air bag module before installation.

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove the glove compartment. (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)

5. Remove in the order indicated in Fig. 12 .

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 12: Removing/Installing Passenger-Side Air Bag Module (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

7. Turn the ignition switch to the ON position.

8. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate, refer to RESTRAINTS -- ON-BOARD

DIAGNOSTIC system (air bag system) and perform inspection of the system.

PASSENGER-SIDE AIR BAG MODULE REMOVAL NOTE

1. Remove the passenger-side air bag module in the order indicated below.

1. Disengage the tab locks by sliding the passenger-side air bag module upward.

2. Slide the passenger-side air bag module rearward.

3. Remove the passenger-side air bag module by pulling it from the backside and then down.

Fig. 13: Removing Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

CONNECTOR REMOVAL NOTE

1. Using a flathead screwdriver, pry out the connector stopper plate.

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2007 Mazda MX-5 Miata Sport

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Fig. 14: Prying Out Connector Stopper Plate

Courtesy of MAZDA MOTORS CORP.

2. Disconnect the connector.

CAP INSTALLATION NOTE

1. The cap cannot be reused. Replace the cap with a new one when the cap or the passenger-side air bag module has been removed.

SIDE AIR BAG MODULE REMOVAL/INSTALLATION

WARNING:



Handling the air bag module improperly can accidentally operate

(deploy) the air bag module, which may seriously injure you. Read the air bag system service warnings and cautions before handling the air bag module. (See AIR BAG SYSTEM SERVICE WARNINGS .)

(See AIR BAG SYSTEM SERVICE CAUTIONS .)

If the side air bag module is installed with debris in the seat back,

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata the foreign material may be scattered when the side air bag module operates (deploys), causing injury. Verify that there is no foreign material in the seat back before installing the side air bag module.

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove the seat. (See SEAT REMOVAL/INSTALLATION .)

5. Detach the tab as shown in Fig. 15 and remove the connector from the seat connector.

Fig. 15: Detaching Tab

Courtesy of MAZDA MOTORS CORP.

6. Partially peel back the seat back trim.

7. Partially peel back the seat back pad.

8. Remove in the order indicated in Fig. 16 .

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2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 16: Removing Side Air Bag Module (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

9. Install in the reverse order of removal.

10. Turn the ignition switch to the ON position.

11. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

CRASH ZONE SENSOR REMOVAL/INSTALLATION

WARNING:



WARNINGS .) (See AIR BAG SYSTEM SERVICE CAUTIONS .)

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

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

5. Remove the fresh-air duct. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

6. Remove in the order indicated in Fig. 17 .

Fig. 17: Removing/Installing Crash Zone Sensor (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

8. Turn the ignition switch to the ON position.

9. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

SAS CONTROL MODULE REMOVAL/INSTALLATION

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WARNING:



SYSTEM SERVICE WARNINGS .) (See AIR BAG SYSTEM SERVICE

CAUTIONS .)

CAUTION:



1. Perform SAS control module configuration when replacing it. (See SAS CONTROL MODULE

CONFIGURATIONS .)

2. Turn the ignition switch to the LOCK position.

3. Remove the battery cover.

4. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

5. Remove the following parts:

1. Console (See CONSOLE REMOVAL/INSTALLATION .)

2. Side wall (See SIDE WALL REMOVAL/INSTALLATION .)

3. Console panel (See CONSOLE PANEL REMOVAL/INSTALLATION .)

6. Remove in the order indicated in Fig. 18 .

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Fig. 18: Removing/Installing SAS Control Module (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

8. Turn the ignition switch to the ON position.



If the SAS control module is replaced, turn the ignition switch to the ON position for 20 s or more after completing the configuration. (See SAS CONTROL MODULE CONFIGURATION .)

9. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

SAS CONTROL MODULE CONFIGURATION

1. Connect the M-MDS to the DLC-2 Connector.

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Fig. 19: Identifying DLC-2 Location

Courtesy of MAZDA MOTORS CORP.

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.

 When using the IDS (Laptop PC)

1. Select "Programming".



When using the PDS (Pocket PC)

1. Select "Programming".

2. Select "Module Programming".

3. Then Select the "Programmable Module Installation" and "RCM" from the screen menu.

4. Perform the configuration according to the directions on the screen.

5. Retrieve DTCs using the M-MDS, then verify if DTCs are present.



If a DTC is present, perform the applicable DTC inspection.

SEAT TRACK POSITION SENSOR REMOVAL/INSTALLATION

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove the driver's seat. (See SEAT REMOVAL/INSTALLATION .)

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

5. Detach the tab as shown in Fig. 20 and remove the connector from the seat connector.

Fig. 20: Detaching Seat Connector Tab & Removing Connector From Seat Connector

Courtesy of MAZDA MOTORS CORP.

6. Remove in the order indicated in Fig. 21 .

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 21: Removing Connector From Seat Connector

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

SEAT TRACK POSITION SENSOR INSTALLATION NOTE



Verify that the seat track position sensor is not contacting the metal plate.

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Fig. 22: Installing Seat Track Position Sensor

Courtesy of MAZDA MOTORS CORP.

SEAT WEIGHT SENSOR CONTROL MODULE REMOVAL/INSTALLATION

CAUTION:



When the seat weight sensor control module is replaced with a new one, perform the seat weight sensor calibration using the WDS or equivalent. (See SEAT WEIGHT SENSOR CALIBRATION .)

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove in the order indicated in Fig. 23 .

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 23: Removing/Installing Seat Weight Sensor Control Module

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

SEAT WEIGHT SENSOR CALIBRATION

CAUTION:



If any of the following work is performed, perform the seat weight sensor calibration using the WDS or equivalent.



Replacement with a new seat weight sensor



Replacement with a new seat weight sensor control module



Replacement with new passenger-side seat parts



Disassembly of the passenger-side seat

If any of the following work is performed, perform the seat weight sensor inspection using the WDS or equivalent. (See SEAT WEIGHT

SENSOR INSPECTION .)

Removal of the passenger-side seat



Loosening and retightening of passenger's seat fixing bolts

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

Or, the vehicle is involved in a collision

1. Have two 20 kg {44 lb} weights ready to use.

2. Connect the WDS or equivalent to the DLC-2 (16-pin).

Fig. 24: Identifying DLC-2 Location

Courtesy of MAZDA MOTORS CORP.

3. Select "Body" from the menu.

4. Select "Restraints".

5. Select "Seat Weight Sensor ReZero Procedure".

6. Perform calibration following the procedures on the WDS or equivalent screen.

NOTE:



When "Lightly pat the passenger seat cushion" is displayed on the

WDS or equivalent screen, lightly pat horizontally approx. five times on the headrest or upper side of the seat back trim of the passengerside front seat.

SEAT WEIGHT SENSOR INSPECTION

CAUTION:



If any of the following work is performed, perform the seat weight

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

 sensor inspection using the WDS or equivalent.



Removal of the passenger-side seat



Loosening and retightening of passenger's seat fixing bolts



Or, the vehicle is involved in a collision

If any of the following work is performed, perform the seat weight sensor calibration using the WDS or equivalent. (See SEAT WEIGHT

SENSOR CALIBRATION .)



Replacement with a new seat weight sensor

Replacement with a new seat weight sensor control module



Replacement with new passenger-side seat parts



Disassembly of the passenger-side seat

1. Connect the WDS or equivalent to the DLC-2 (16-pin).

Fig. 25: Identifying DLC-2 Location

Courtesy of MAZDA MOTORS CORP.

2. Select "Body" from the menu.

3. Select "Restraints".

4. Select "Seat Weight Sensor ReZero Procedure".

5. Perform inspection following the procedures on the WDS or equivalent screen.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH

REMOVAL/INSTALLATION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove the side panel. (See SIDE PANEL REMOVAL/INSTALLATION .)

4. Disconnect the connector.

5. Remove the PAD switch.

Fig. 26: Removing/Installing Passenger Air Bag Deactivation (PAD) Switch

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

7. Turn the ignition switch to the ON position.

8. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH INSPECTION

1. Remove the PAD switch. (See PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH

REMOVAL/INSTALLATION .)

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

2. Verify that the continuity between the PAD switch terminals is as indicated in Fig. 27 .



If not as indicated in Fig. 27 , replace the PAD switch.

Fig. 27: PAD Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

Fig. 28: Inspecting Passenger Air Bag Deactivation (PAD) Switch Connector Terminals

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

SIDE AIR BAG SENSOR REMOVAL/INSTALLATION

WARNING:



Handling the side air bag sensor improperly can accidentally operate (deploy) the air bag module, which may seriously injure you.

Read the air bag system service warnings and cautions before handling the side air bag sensor. (See AIR BAG SYSTEM SERVICE

WARNINGS .) (See AIR BAG SYSTEM SERVICE CAUTIONS .)

1. Turn the ignition switch to the LOCK position.

2. Remove the battery cover.

3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

4. Remove the quarter trim. (See QUARTER TRIM REMOVAL/INSTALLATION .)

5. Remove the scuff plate. (See SCUFF PLATE REMOVAL/INSTALLATION .)

6. Remove the tire house trim. (See TIRE HOUSE TRIM REMOVAL/INSTALLATION .)

7. Remove in the order indicated in Fig. 29 .

Fig. 29: Removing/Installing Side Air Bag Sensor

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

8. Install in the reverse order of removal.

9. Turn the ignition switch to the ON position and hold for 5 s or more .

10. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

CLOCK SPRING REMOVAL/INSTALLATION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove the following parts:

1. Driver-side air bag module (See DRIVER-SIDE AIR BAG MODULE

REMOVAL/INSTALLATION .)

2. Steering wheel (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)

3. Column cover (See COLUMN COVER REMOVAL/INSTALLATION .)

4. Remove in the order indicated in Fig. 30 .

Fig. 30: Clock Spring Removing/Installing Steps

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2007 RESTRAINTS Air Bag System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

6. Turn the ignition switch to the ON position.

7. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.



If the air bag system warning light does not operate normally, refer to RESTRAINTS -- ON-

BOARD DIAGNOSTIC system (air bag system) and perform inspection of the system.

CLOCK SPRING INSTALLATION NOTE

CAUTION:



If the clock spring is not adjusted, the spring wire in the clock spring could over-wind and break when the steering wheel is turned. Always adjust the clock spring after installing it.

1. Adjust the clock spring after installing it. (See CLOCK SPRING ADJUSTMENT .)

CLOCK SPRING ADJUSTMENT

NOTE:



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

1. Set the front tires straight-ahead.

CAUTION:



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

2. Turn the clock spring clockwise until it stops.

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Fig. 31: Turning Clock Spring Clockwise

Courtesy of MAZDA MOTORS CORP.

3. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns .

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Fig. 32: Turning Clock Spring Counterclockwise 2 3/4 Turns

Courtesy of MAZDA MOTORS CORP.

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

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2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 33: Aligning Mark On Clock Spring With Mark On Outer Housing

Courtesy of MAZDA MOTORS CORP.

CLOCK SPRING INSPECTION

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

REMOVAL/INSTALLATION .)

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

REMOVAL/INSTALLATION .)

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

4. Verify that the continuity is as indicated in Fig. 34 .

 If not as indicated in Fig. 34 , replace the clock spring.

NOTE:



When the vehicle-side connector for the clock spring is disconnected, terminals 1A, 1B, 1C and 1D are shorted to prevent unexpected operation (deployment) of the air bag module.

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2007 Mazda MX-5 Miata Sport

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Fig. 34: Clock Spring Continuity Reference Table

Courtesy of MAZDA MOTORS CORP.

Fig. 35: Identifying Clock Spring Connector Terminals

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT

PROCEDURES

WARNING:



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

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

CAUTION:



(Deployment tool).

When disposing of an operated (deployed) air bag module and pre-tensioner seat belt, refer to AIR BAG

MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES .

DEPLOYMENT PROCEDURE 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 doors and windows.

3. Turn the ignition switch to the LOCK position.

4. Remove the battery cover.

5. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

6. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.

DRIVER-SIDE AIR BAG MODULE

WARNING:



NOTE:



The SSTs , two types of adapter harnesses (for inflators No.1 and No.2) and two deployment tools are to be used to operate (deploy) the driverside air bag module.

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

REMOVAL/INSTALLATION .)

2. Connect the SSTs (Adapter harness) to the driver-side air bag module as shown in Fig. 36 .

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

REMOVAL/INSTALLATION .)

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 36: Connecting SSTs (Adapter Harness) To Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

Fig. 37: Connecting SSTs (Deployment tool) To SSTs (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

6. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.

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

8. Press the activation switch on the SST (Deployment tool) connected with 49 L066 002 (a yellow

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata connector) of the SST (Adapter harness), and after 3 s , press the activation switch on the other SST

(Deployment tool) to operate (deploy) the air bag module (both inflators).

Fig. 38: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

WARNING:



The air bag module is very hot immediately after it is operated

(deployed). You can get burned. Do not touch the air bag module for at least 15 min after deployment.

9. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

PASSENGER-SIDE AIR BAG MODULE

WARNING:



The passenger-side air bag module is a dual inflator type. If one

Microsoft

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata inflator is forced to operate (deploy), the other may operate (deploy) accidentally. To prevent injury while disposing of the air bag module, make sure to operate (deploy) both passenger-side air bag module inflators simultaneously, following the procedure below.

NOTE:



The SSTs , two types of adapter harnesses (for inflators No.1 and No.2) and two deployment tools are to be used to operate (deploy) the passenger-side air bag module.

1. Remove the glove compartment. (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)

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

3. Connect the SSTs (Adapter harness) to the passenger-side air bag module as shown in Fig. 39 .

4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

Fig. 39: Connecting SSTs (Adapter Harness) To Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

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Fig. 40: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

6. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.

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

(Deployment tool) to operate (deploy) the air bag module (both inflators).

Fig. 41: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

WARNING:



The air bag module is very hot immediately after it is operated

(deployed). You can be burned. Do not touch the air bag module for at least 15 min after deployment.

9. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

SIDE AIR BAG MODULE

1. Disconnect the seat connector.

2. Connect the SST (Adapter harness) to the side air bag module as shown in Fig. 42 .

Fig. 42: Connecting SST (Adapter Harness) To Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

3. Connect the SST (Deployment tool) to the SST (Adapter harness).

4. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

5. Verify that the red lamp on the SST (Deployment tool) is illuminated.

6. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

Fig. 43: Connecting SST (Deployment Tool) To SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

7. Press the activation switch on the SST (Deployment tool) to operate (deploy) the side air bag module.

8. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

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Fig. 44: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

PRE-TENSIONER SEAT BELT

1. Remove the back trim. (See BACK TRIM REMOVAL/INSTALLATION .)

2. Remove the pre-tensioner seat belt and connect the SST (Adapter harness) as shown in Fig. 45 . (See

SEAT BELT REMOVAL/INSTALLATION .)

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2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 45: Removing Pre-Tensioner Seat Belt & Connect SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

3. Install the pre-tensioner seat belt.

4. Connect the SST (Deployment tool) to the SST (Adapter harness).

5. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

6. Verify that the red lamp on the SST (Deployment tool) is illuminated.

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

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2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 46: Connecting SST (Deployment Tool) To SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

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

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Fig. 47: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

9. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

DEPLOYMENT PROCEDURE FOR OUTSIDE OF VEHICLE

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

2. Turn the ignition switch to the LOCK position.

3. Remove the battery cover.

4. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY

REMOVAL/INSTALLATION [LF] .)

5. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.

DRIVER-SIDE AIR BAG MODULE

WARNING:



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

REMOVAL/INSTALLATION .)

2. Connect the SSTs (Adapter harness) to the driver-side air bag module as shown in Fig. 48 .

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Fig. 48: Connecting SSTs (Adapter Harness) To Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

3. Place the driver-side air bag module on the center of the tire wheel with the padded surface facing up. To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm

{0.002 in

} or more ) through the wheel and the bolt installation holes of the air bag module at least 4 times .

WARNING:



If the air bag module is not properly installed to the tire wheel, serious injury may occur when the module is operated

(deployed). When installing the air bag module to the tire wheel, make sure the padded surface is facing up.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 49: Placing Driver-Side Air Bag Module On Center Of Tire Wheel

Courtesy of MAZDA MOTORS CORP.

4. Stack three tires without wheels on top of the tire with the driver-side air bag module, and then stack another tire with a wheel on the very top.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 50: Stacking Tires Without Wheels On Top Of Tire With Driver-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

5. Secure the tires with wire.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 51: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

6. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

7. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

8. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.

9. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 52: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

(Deployment tool) to operate (deploy) the air bag module (both inflators).

WARNING:



The air bag module is very hot immediately after it is operated

(deployed). You can be burned. Do not touch the air bag module for at least 15 min after deployment.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 53: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

PASSENGER-SIDE AIR BAG MODULE

WARNING:



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

REMOVAL/INSTALLATION .)

2. Connect the SSTs (Adapter harness) to the passenger-side air bag module as shown in Fig. 54 .

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 54: Connecting SSTs (Adapter Harness) To Passenger-Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

3. Place the padded surface of the passenger-side air bag module facing the center of the tire as shown in

Fig. 55 . To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm

{0.002 in

2 or more ) through the tire and the brackets at least 4 times as shown in Fig. 55 .

}

WARNING:



Microsoft

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 55: Wrapping Wire Through Tire & Brackets

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 56: Stacking Tire With Passenger-Side Air Bag Module On Top Of Two Tires Without Wheels

Courtesy of MAZDA MOTORS CORP.

5. Secure the tires with wire.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 57: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

6. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

7. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

8. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.

9. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 58: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

(Deployment tool) to operate (deploy) the air bag module (both inflators).

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 59: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

WARNING:



The air bag module is very hot immediately after it is operated

(deployed). You can be burned. Do not touch the air bag module for at least 15 min after deployment.

11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

SIDE AIR BAG MODULE

1. Remove the side air bag module. (See SIDE AIR BAG MODULE REMOVAL/INSTALLATION .)

2. Install the nuts to the side air bag module as shown in Fig. 60 , and connect the SST (Adapter harness).

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 60: Installing Nuts To Side Air Bag Module & Connect SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

3. Place the padded surface of the side air bag module facing the center of the tire as shown in Fig. 61 . To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm

{0.002 in

} or more ) through the tire and around the bolts at least 4 times .

WARNING:



Microsoft

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 61: Placing Padded Surface Of Side Air Bag Module Facing Center Of Tire

Courtesy of MAZDA MOTORS CORP.

4. Connect the SST (Adapter harness) to the side air bag module as shown in Fig. 62 .

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 62: Connecting SST (Adapter Harness) To Side Air Bag Module

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 63: Stacking Tire With Side Air Bag Module On Top Of Tires Without Wheels

Courtesy of MAZDA MOTORS CORP.

6. Secure the tires with wire.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 64: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

7. Connect the SST (Deployment tool) to the SST (Adapter harness).

8. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

9. Verify that the red lamp on the SST (Deployment tool) is illuminated.

10. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 65: Connecting SST (Deployment Tool) To SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

11. Press the activation switch on the SST (Deployment tool) to operate (deploy) the side air bag module.

12. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 66: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

PRE-TENSIONER SEAT BELT

1. Remove the pre-tensioner seat belt. (See SEAT BELT REMOVAL/INSTALLATION .)

2. Connect the SST (Adapter harness) to the pre-tensioner seat belt as shown in Fig. 67 .

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 67: Connecting SST (Adapter Harness) To Pre-Tensioner Seat Belt

Courtesy of MAZDA MOTORS CORP.

3. Put the pre-tensioner seat belt inside the tire and secure it to the tire by wrapping a wire (cross section of

1.25 mm

{0.002 in

} or more ) through the tire and the bolt installation holes at least 4 times .

WARNING:



Microsoft

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 68: Putting Pre-Tensioner Seat Belt Inside Tire & Secure To Tire By Wrapping Wire

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 69: Stacking Tire With Pre-Tensioner Seat Belt On Two Of Tires Without Wheels

Courtesy of MAZDA MOTORS CORP.

5. Secure the tires with wire.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 70: Tying Tires Together With Wire

Courtesy of MAZDA MOTORS CORP.

6. Connect the SST (Deployment tool) to the SST (Adapter harness).

7. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

8. Verify that the red lamp on the SST (Deployment tool) is illuminated.

9. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 71: Connecting SST (Deployment Tool) To SST (Adapter Harness)

Courtesy of MAZDA MOTORS CORP.

10. Press the activation switch on the SST (Deployment tool) to operate (deploy) the pre-tensioner seat belt.

11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 72: Identifying Activation Switch

Courtesy of MAZDA MOTORS CORP.

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL

PROCEDURES

WARNING:



A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy) when it is disposed of and cause serious injury. Always refer to the AIR BAG MODULE AND PRE-

TENSIONER SEAT BELT DEPLOYMENT PROCEDURES and dispose of air bag modules and pre-tensioner seat belts in a deployed condition.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

 deployed air bag module and pre-tensioner seat belt, wear gloves and safety glasses.

(deployment) of inflators No. 1 and 2.

1. Remove the deployed air bag module or pre-tensioner seat belt.

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

Fig. 73: Putting Air Bag Module Or Pre-Tensioner Seat Belt In Plastic Bag

Courtesy of MAZDA MOTORS CORP.

INSPECTION OF SST (DEPLOYMENT TOOL)

1. Before using the SST (49 H066 002), inspect its operation.

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2007 Mazda MX-5 Miata Sport

2007 RESTRAINTS Air Bag System - MX-5 Miata

Fig. 74: Inspecting SST (Deployment Tool)

Courtesy of MAZDA MOTORS CORP.

INSPECTION PROCEDURE

1. Follow the steps below to inspect the SST (49 H066 002).



If not as indicated in SST INSPECTION REFERENCE TABLE , replace the SST (49 H066

002) because it has a malfunction.

WARNING:



Do not use a malfunctioning SST (49 H066 002), otherwise it could cause the air bag module or pre-tensioner seat belt to accidentally operate (deploy).

CAUTION:



Because the permissible voltage for the SST (49 H066 002) is 12

V, do not connect a 24 V power source because it will damage the SST. Always connect only a 12 V power source.

SST INSPECTION REFERENCE TABLE

Step

Inspection procedure

Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.

Light condition

Green Red

On Off

2 Connect connectors A and B.

Off On

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2007 RESTRAINTS Air Bag System - MX-5 Miata

3 Press the activation switch.

On Off

Fig. 75: Inspecting Activation Switch

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 BRAKES Antilock Brake System - MX-5 Miata

ABS LOCATION INDEX

2007 BRAKES

Antilock Brake System - MX-5 Miata

Fig. 1: Identifying Location Of ABS Components

Courtesy of MAZDA MOTORS CORP.

ABS SYSTEM WIRING DIAGRAM

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 2: ABS System Wiring Diagram

Courtesy of MAZDA MOTORS CORP.

ABS SYSTEM INSPECTION

ABS HYDRAULIC UNIT ON-VEHICLE INSPECTION

Preparation

1. Verify that battery is fully charged.

2. Turn the ignition switch to the ON position and verify that the ABS warning light goes out after approx.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

3s .

3. Turn the ignition switch off.

4. Jack up the vehicle and support it evenly on safety stands.

5. Shift to neutral.

6. Release the parking brake.

7. Verify that all four wheels rotate.

8. Rotate the wheels by hand, and verify there is no brake drag.



If there is any brake drag, perform regular brake inspection.

If there is no brake drag, perform ABS HU/CM operation inspection.

Operation Inspection

1. Perform "Preparation".

2. Connect the M-MDS or equivalent to the DLC-2.

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

Fig. 3: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

ACTIVE COMMAND MODE INSPECTION REFERENCE TABLE

Command name

Operation

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Thursday, July 09, 2009 3:16:19 PM Page 3

Command

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata condition

Brake pressure retention

Brake pressure reduction

PMP_MOTOR

OFF

RF_OUTLET

OFF

RF_INLET transmission type

Manual

The ACTIVE COMMAND MODE INSPECTION REFERENCE TABLE above shows an example of a right front wheel inspection.

CAUTION:



To protect the ABS HU/CM, the solenoid valve and the pump motor used during active command mode stay on for only 10 s or less each time they are switched on.

NOTE:



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

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

5. Performing the inspection above determines the following:



The ABS HU/CM brake lines are normal.

The ABS HU/CM hydraulic system is not significantly abnormal (including inside ABS HU/CM).



The ABS HU/CM internal electrical parts (solenoid, motor and other parts) are normal.

The ABS HU/CM output system wiring harnesses (solenoid valve, relay system) are normal.





However, the following items cannot be verified.

Malfunction of ABS HU/CM input system wiring harnesses and parts



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



Malfunction with intermittent occurrence of the above items

ABS HU/CM REMOVAL/INSTALLATION

CAUTION:



When replacing the DSC HU/CM with a new one, configuration procedure must be performed before removing the DSC HU/CM. If configuration is not completed before removing the DSC HU/CM, DTC

B2477 will be detected.

The internal parts of the ABS HU/CM could be damaged if dropped.

Be careful not to drop the ABS HU/CM. Replace the ABS HU/CM if it is subjected to an impact.

1. Perform ABS configuration. (See ABS CONFIGURATION .)

2. Remove in the order indicated in Fig. 4 .

3. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 4: Identifying ABS HU/CM Steps (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

ABS HU/CM CONNECTOR REMOVAL NOTE

1. Pull the lock lever up in the direction of the arrow.

2. Pull the connector toward the vehicle rear and remove it.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 5: Identifying Lock Lever Position

Courtesy of MAZDA MOTORS CORP.

BRAKE PIPE REMOVAL NOTE

1. Place an alignment mark on the brake pipe and ABS HU/CM.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 6: Placing Alignment Mark On Brake Pipe & ABS HU/CM

Courtesy of MAZDA MOTORS CORP.

2. Apply protective tape to the connector to prevent brake fluid from entering.

3. Remove the brake pipe.

BRAKE PIPE (ABS HU/CM-BRAKE PIPE JOINT) INSTALLATION NOTE

1. Align with the mark made before removing the brake pipe and temporarily install the brake pipe to the

ABS HU/CM.

CAUTION:



If the brake pipe is tightened to the specified torque, it may be difficult to install it to the vehicle. Therefore, only temporarily tighten the brake pipe so that it can still be moved.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 7: Identifying Aligning Marks

Courtesy of MAZDA MOTORS CORP.

BRAKE PIPE INSTALLATION NOTE

1. Align the marks made before removal and install the brake pipe to the ABS HU/CM and brake pipe joint referring to Fig. 7 .

2. Tighten the brake pipe to the specified torque using the SST (49 0259 770B).

ABS HU/CM CONNECTOR INSTALLATION NOTE

1. After connecting the connector, verify that the lock lever Is completely pushed in.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 8: Verifying Lock Lever Is Completely Pushed In

Courtesy of MAZDA MOTORS CORP.

ABS CONFIGURATION

1. Connect the M-MDS or equivalent to the DLC-2.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 9: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

2. After the Vehicle is identified, select the following items from the initial screen of the M-MDS.



When using the IDS (laptop PC)

1. Select the "Module Programming".



When using the PDS (Pocket PC)

1. Select "Programming".

2. Select "Module Programming".

3. Then, select the "Programmable Module Installation" and "ABS" from the screen menu.

4. Perform the configuration according to the directions on the screen.

5. Retrieve DTCs using the M-MDS, then verify if DTCs are present.



If a DTC is present, perform the applicable DTC inspection. (See ON-BOARD DIAGNOSTIC

(ABS) -- MX-5 MIATA )

ABS HU/CM INSPECTION

1. Disconnect the ABS HU/CM connector.

2. Connect the negative battery cable.

3. Attach the tester lead to the ABS HU/CM harness side connector, then inspect voltage, continuity or resistance according to the standard (reference value) on STANDARD (REFERENCE VALUE)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

TABLE .

STANDARD (REFERENCE VALUE)

Fig. 10: Identifying ABS HU/CM Connector Terminals

Courtesy of MAZDA MOTORS CORP.

STANDARD (REFERENCE VALUE) TABLE

Terminal Signal name Connected to

Measured item

Measured terminal

(measured condition)

Standard

Inspection

Item(s)

Ground (ABS motor)

Power supply

(ABS motor operation)

Power supply

(solenoid)

Ground (ABS system)

Ground point

Battery

Ground point

Microsoft

Thursday, July 09, 2009 3:16:19 PM

Continuity

Voltage

Continuity

Page 11

A-ground point

Under any condition

D-ground point

Continuity detected

B+

Continuity detected



Wiring harness

(Aground point)



Wiring harness

(Bbattery)



Wiring harness

(Cbattery)



Wiring harness

(Dground point)

 Wiring harness

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

LF wheelspeed sensor

(ground)

LF ABS wheel-speed sensor

LF wheelspeed sensor

(single)

LF ABS wheel-speed sensor

LR wheelspeed sensor

(signal)

LR ABS wheel-speed sensor

LR wheelspeed sensor

(ground)

LR ABS wheel-speed sensor

RR wheelspeed sensor

(signal)

RR ABS wheel-speed sensor

Microsoft

Thursday, July 09, 2009 3:16:19 PM

Continuity

E-LF ABS wheel-speed sensor connector terminal B

F-LF ABS wheel-speed sensor connector terminal A

G-LR ABS wheel-speed sensor connector terminal A

H-LR ABS wheel-speed sensor connector terminal B

Continuity detected



Wiring harness

(G-LR

ABS wheelspeed sensor connector terminal



Wiring harness

(H-LR

ABS wheelspeed sensor connector terminal

(E-LF

ABS wheelspeed sensor connector terminal

 Wiring harness

(F-LF

ABS wheelspeed sensor connector terminal

Continuity

Page 12

I-RR ABS wheel-speed sensor connector terminal A

Continuity detected



Wiring harness

(I-RR

ABS wheelspeed sensor connector

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Power supply

(system)

Ignition switch

Voltage

Ignition switch at ON

B+ terminal



Wiring harness

(Jignition switch)

RR wheelspeed sensor

(ground)

RR ABS wheel-speed sensor

Ignition switch is off.

1 V or less

Continuity

L-RR ABS wheel-speed sensor connector terminal B

Continuity detected



Wiring harness

(L-RR

ABS wheelspeed sensor connector terminal

RF wheelspeed sensor

(signal)

RF ABS wheel-speed sensor

Continuity

M-RF ABS wheel-speed sensor connector terminal A

Continuity detected



Wiring harness

(M-RF

ABS wheelspeed sensor connector terminal

Brake switch Brake switch

RF wheelspeed sensor

(ground)

RF ABS wheel-speed

Microsoft

Thursday, July 09, 2009 3:16:19 PM sensor

Voltage

N-brake switch (Brake pedal depressed)

Y-brake switch (Brake pedal not depressed)

B+

1 V or less



Wiring harness

(N-brake switch)

Brake switch

Continuity

Page 13

O-RF ABS wheel-speed sensor connector

Continuity detected



Wiring harness

(O-RF

ABS wheelspeed sensor

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

CAN_L

CAN_H

DLC-2

(CAN_L)

DLC-2

(CAN_H) terminal B

Continuity Y-DLC-2 terminal

CAN_L.

Continuity Z-DLC-2 terminal

CAN_H

Continuity detected

FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION

1. Remove the mudguard.

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.



Wiring harness

(Y-DLC-

2 terminal

CAN_L)



Wiring harness

(Z-DLC-

2 terminal

CAN_H)

connector terminal

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 11: Identifying Front ABS Wheel-Speed Sensor (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

FRONT ABS WHEEL-SPEED SENSOR INSPECTION

INSTALLATION VISUAL INSPECTION

1. Inspect the following items:



If there is any malfunction, replace the applicable part.

1. Excessive play of the ABS wheel-speed sensor

2. Deformation of the ABS wheel-speed sensor

CLEARANCE INSPECTION

1. Remove the front ABS wheel-speed sensor.

2. Measure the distance between the front ABS wheel-speed sensor installation surface and the ABS sensor rotor. This is dimension A.

3. Measure the distance between the front ABS wheel-speed sensor installation surface and the tip of ABS wheel-speed sensor. This is dimension B.

4. Calculate the clearance between the front ABS wheel-speed sensor and the ABS sensor rotor using the following formula:

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Clearance (mm {in}) = A - B

5. Verify that the clearance between the ABS sensor rotor and the front ABS wheel-speed sensor is as indicated below.



If there is any malfunction, replace it.

Clearance

0.3-1.0 mm {0.012-0.057 in}

Fig. 12: Measuring Distance Between Front ABS Wheel-Speed Sensor Installation Surface & ABS

Wheel-Speed Sensor Tip

Courtesy of MAZDA MOTORS CORP.

SENSOR OUTPUT VALUE INSPECTION

CAUTION:



Resistance inspection using other testers may cause damage to the

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

ABS wheel-speed sensor internal circuit. Be sure to use the M-MDS or equivalent to inspect the ABS wheel-speed sensor.

1. Turn the ignition switch off.

2. Connect the M-MDS or equivalent to the DLC-2.

Fig. 13: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

3. Select the following PIDs using the M-MDS or equivalent:



LF_WSPD

(LF wheel-speed sensor)



RF_WSPD

(RF wheel-speed sensor)

4. Start the engine and drive the vehicle.

5. Verify that the display of the M-MDS or equivalent shows the same value as the speedometer.



If there is any malfunction, replace the front ABS wheel-speed sensor.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION

1. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)

2. Remove the partition board. (See PARTITION BOARD REMOVAL/INSTALLATION .)

3. Remove the trunk side trim. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

4. Remove the fuel-filler pipe protector. (See FUEL TANK REMOVAL/INSTALLATION [LF] .)

5. Remove in the order indicated in Fig. 14 .

6. Install in the reverse order of removal.

Fig. 14: Identifying Rear ABS Wheel-Speed Sensor (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

REAR ABS WHEEL-SPEED SENSOR INSPECTION

INSTALLATION VISUAL INSPECTION

1. Inspect the following items:



If there is any malfunction, replace the applicable part.

1. Excessive looseness or play of the ABS wheel-speed sensor

2. Deformation of the ABS wheel-speed sensor

3. Deformation or damage of the ABS sensor rotor

CLEARANCE INSPECTION

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

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



If there is any malfunction, check for improper installation, and replace if necessary.

Clearance

0.8-1.6 mm {0.032-0.062 in}

Fig. 15: Inspecting ABS Sensor-To-Rotor Clearance

Courtesy of MAZDA MOTORS CORP.

SENSOR OUTPUT VALUE INSPECTION

1. Turn the ignition switch off.

2. Connect the M-MDS or equivalent to the DLC-2.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Antilock Brake System - MX-5 Miata

Fig. 16: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

3. Select the following PIDs using the M-MDS or equivalent:



LR_WSPD

(LR wheel-speed sensor)



RR_WSPD

(RR wheel-speed sensor)

4. Start the engine and drive the vehicle.

5. Verify that the display of the M-MDS or equivalent shows the same value as the speedometer.



If there is any malfunction, replace the rear ABS wheel-speed sensor.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

2006-08 TRANSMISSION

Automatic Transmission Overhaul - MX-5 Miata & RX-8

05-13 AUTOMATIC TRANSMISSION

AUTOMATIC TRANSMISSION DISASSEMBLY

Precaution

The following are precautions that must be followed performing removal/installation.

1. Handle electronic parts with care



Do not pull the wiring harness forcibly when disconnecting the connector. Unlock the first and pull the connector.



When connecting the connector, verify that it is inserted until it is properly locked. (Verify that a click sound is heard.)

Do not apply shock to electronic parts. Replace with new parts if they have been dropped or subjected to shock.

2. Prevent foreign matter from penetrating



Be sure to remove foreign matter such as dust and sand from the automatic transaxle before removing parts.



Protect removed parts from dust with an object such as a vinyl sheet.

Do not use cotton work gloves or shop rags as frayed strings might get caught in the unit. Work with bare hands or use vinyl gloves.

3. Prevent scratching



Do not pry with a screwdriver forcibly. Slightly tap the case with a plastic hammer when separating component cases at seams.



Do not pull the valve forcibly.

Be careful not to get the wiring harness caught between parts during installation.

4. Prevent incorrect or insufficient, installation or missing parts

 Be careful not to install parts incorrectly or lose parts since there are similar types of O-rings, snap rings, bearings and races. Be careful to for straighten parts and check their installation direction.



Be careful not to drop small parts such as check balls or lose them during installation.

5. Wash parts and apply oil



Wash each part before installing and dry using compressed air, and then apply the specified ATF type JWS3309.



Soak discs in ATF type JWS3309 before installing. In particular, soak a new disc for 2 h or more so that the oil seeps into the lining.

If the thrust bearing or race falls during installation, use a small amount of yellow petrolatum grease.



Apply ATF type JWS3309 to contact and rotating surfaces.

2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8



Do not apply oil or drive the vehicle immediately after installing a part applied with sealant. Leave it for one hour or more.



Do not wash aluminum parts or rubber parts with alkaline chemicals.

Do not wash rubber parts with isopropyl alcohol (IPA).

6. ATF care



If ATF is spilled on the floor, wipe it off immediately, as it is quite slippery and dangerous.



Be sure to use JWS3309 type ATF.

Disassembly

Components

Fig. 1: Disassembled View Of Automatic Transmission Components (1 Of 5)

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 2: Disassembled View Of Automatic Transmission Components (2 Of 5)

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 3: Disassembled View Of Automatic Transmission Components (3 Of 5)

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 4: Disassembled View Of Automatic Transmission Components (4 Of 5)

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 5: Disassembled View Of Automatic Transmission Components (5 Of 5)

Disassembly procedure

1. Remove the drain plug and gasket.

CAUTION:



Do not damage the oil seal.

Do not drop the torque converter.

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 6: Identifying Drain Plug And Gasket

2. Remove the torque converter.

Fig. 7: Identifying Torque Converter

3. Remove the breather hose and breather pipe.

CAUTION:



Do not damage the turbine sensor.

4. Remove the turbine sensor.

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Thursday, July 09, 2009 1:42:23 PM

Fig. 8: Identifying Breather Tube And Pipe

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

CAUTION:



Do not damage the VSS.

5. Remove the VSS.

Fig. 9: Identifying Turbine Sensor

Fig. 10: Identifying VSS

6. Lift up the lock washer using a flathead screwdriver.

Fig. 11: Lifting Up Lock Washer Using Flathead Screwdriver

7. Remove the nut and lock washer.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

CAUTION:



Do not damage the TR switch.

8. Remove the TR switch.

Fig. 12: Identifying Nut And Lock Washer

Fig. 13: Identifying TR Switch

9. Remove the bolts as shown in the figure.

CAUTION:



Do not damage the fitting surface of the transmission case and the converter housing.

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Fig. 14: Identifying Bolts

10. Using a plastic hammer, tap the converter housing to remove it.

CAUTION:



Do not damage the fitting surface of the extension housing and the extension dust deflector.

Fig. 15: Tapping Converter Housing Using Plastic Hammer

11. Using a plastic hammer and slab of wood, tap the extension dust deflector to remove it.

CAUTION:



Do not damage the extension housing.

Fig. 16: Tapping Extension Dust Deflector Using Plastic

Hammer

12. Using a flathead screwdriver, remove the extension housing shroud.

CAUTION:



Do not damage the extension housing.

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Fig. 17: Removing Extension Housing Shroud Using Flathead

Screwdriver

13. Using a flathead screwdriver, remove the oil seal.

Fig. 18: Removing Oil Seal Using Flathead Screwdriver

14. Remove the bolts as shown in the figure.

CAUTION:



Do not damage the fitting surface of the transmission case and the extension housing.

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Thursday, July 09, 2009 1:42:23 PM

Fig. 19: Identifying Bolts

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

15. Using a plastic hammer, tap the extension housing to remove it.

Fig. 20: Tapping Extension Housing Using Plastic Hammer

16. Remove the snap ring using snap ring pliers.

CAUTION:



Do not damage the fitting surface of the transmission case and the oil pan.

Do not deform the oil pan.

Fig. 21: Removing Snap Ring Using Snap Ring Pliers

17. Remove the bolt as shown in the figure and remove the oil pan and gasket.

18. Remove the magnet from the oil pan.

NOTE:



Inspect the oil pan for foreign material and determine the worn areas of the transmission. For ferrous metal related areas, check for wear of the bearings, gears, and plates. For brass related metal (nonmagnetized), check for bushing wear.

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Fig. 22: Identifying Bolts

Fig. 23: Locating Magnet In Oil Pan

19. Remove the oil strainer from the control valve body component.

20. Remove the O-ring from the oil strainer.

Fig. 24: Identifying Oil Strainer Bolts

21. Disconnect the solenoid connectors from the solenoids.

22. Disconnect the coupler component from the clamps.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 25: Identifying Solenoid Connectors

23. Remove the lock plate from the control valve body component.

CAUTION:



When installing the control valve body, make sure that it does not interfere with the coupler component.

24. Disconnect the transmission fluid temperature switch from the control valve body component.

Fig. 26: Identifying Lock Plate

25. Fix the coupler component with tape to the transmission case as shown in the figure.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 27: Identifying Tape

26. Disconnect the detent spring cover and detent spring from the control valve body component.

CAUTION:



Do not drop the control valve body component.

Fig. 28: Identifying Detent Spring And Bolt

27. Remove the bolts from transmission case.

Fig. 29: Identifying Bolts

28. Disconnect the manual valve link and remove the control valve body component.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 30: Identifying Manual Valve Link

29. Remove the check valve subcomponent and compression spring from transmission case.

Fig. 31: Identifying Check Valve Subcomponent And Compression Spring

30. Remove the transmission case gasket and brake drum gasket from transmission case.

CAUTION:



Be careful of the accumulator pistons A and B as they pop out.

Fig. 32: Identifying Transmission Case And Brake Drum Gasket

31. Blow compressed air from the oil passage shown in the figure and remove accumulator pistons A and B

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 and the compression spring from the transmission case.

Fig. 33: Locating Oil Passage

32. Using a flathead screwdriver, remove the snap ring from accumulator pistons A and B.

33. Remove the compression spring from accumulator piston A and B.

CAUTION:



Do not damage the accumulator pistons.

Fig. 34: Identifying Snap Ring On Accumulator Pistons A And B

34. Using a flathead screwdriver, remove the O-ring from accumulator piston A and B.

CAUTION:



Be careful of the accumulator pistons C as they pop out.

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Fig. 35: Identifying O-Ring On Accumulator Piston A And B

35. Blow compressed air from the oil passage shown in the figure and remove accumulator pistons C and the compression springs from the transmission case.

36. Using a flathead screwdriver, remove the O-ring from accumulator pistons C.

37. Remove the accumulator valve and compression springs from the transmission case.

Fig. 36: Locating Oil Passage

38. Remove the bracket.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 37: Identifying Bracket Bolts

39. Remove the parking rod from the manual valve lever.

Fig. 38: Identifying Parking Rod On Manual Valve Lever

40. Pull out the shaft parking pawl and spring.

CAUTION:



Be careful not to apply too much force to the torsion spring.

41. Using a flathead screwdriver, remove the driven plate from shaft parking pawl.

42. Remove the parking pawl.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 39: Identifying Shaft Parking Pawl And Spring

43. Using a flathead screwdriver and hammer, remove the manual shaft washer.

CAUTION:



Do not damage the manual valve component.

Fig. 40: Removing Manual Shaft Washer Using Flathead

Screwdriver And Hammer

44. Using a hammer and pin punch, remove the pin.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 41: Removing Pin Using Hammer And Pin Punch

45. Pull out the manual shaft and remove the manual valve component.

Fig. 42: Identifying Manual Shaft And Manual Valve Component

46. Using a flathead screwdriver, remove the oil seal.

CAUTION:



Do not damage the transmission case component.

Fig. 43: Removing Oil Seal Using Flathead Screwdriver

47. Remove the bolts from the oil pump as shown in the figure.

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Fig. 44: Identifying Bolts On Oil Pump

48. Using a flathead screwdriver, remove the oil pump.

CAUTION:



Do not damage the oil pump.

Fig. 45: Removing Oil Pump Using Flathead Screwdriver

49. Remove the O-ring from the oil pump.

50. Remove the thrust needle bearing and bearing race from oil pump.

Fig. 46: Identifying O-Ring, Thrust Needle Bearing And Bearing Race On Oil Pump

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51. Remove the clutch drum component.

Fig. 47: Identifying Clutch Drum Component

52. Remove the thrust needle bearing and bearing race from the clutch drum component.

Fig. 48: Identifying Thrust Needle Bearing And Bearing Race

53. Remove the thrust washer and F2 one-way clutch component from the clutch drum component.

Fig. 49: Identifying Thrust Washer And F2 One-Way Clutch Component On Clutch Drum

Component

54. Using a flathead screwdriver, remove the snap ring from the transmission case component.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 50: Removing Snap Ring From Transmission Case Using Flathead Screwdriver

55. Remove the retaining plates, drive and driven plates.

Fig. 51: Identifying Drive And Driven Plates

56. Inspect the lining of all drive plates.



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts.

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 52: Identifying Print Mark Location

57. Remove the snap ring from transmission case using snap ring pliers.

Fig. 53: Removing Snap Ring From Transmission Case Using Snap Ring Pliers

58. Remove the B2 brake piston component and F1 one-way clutch.

Fig. 54: Identifying B2 Brake Piston Component

59. Remove the bearing race and thrust washer from the F1 one-way clutch component.

60. Remove the F1 one-way clutch component from the B3 brake piston component.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 55: Identifying F1 One-Way Clutch, B3 Brake Piston Component, Bearing Race And Thrust

Washer

61. Remove the front planetary gear component and thrust washer.

Fig. 56: Identifying Planetary Gear Component And Thrust Washer

62. Remove the front and middle ring gear component.

63. Remove the bearing race and thrust needle bearing from front and middle ring gear component.

Fig. 57: Identifying Front And Middle Ring Gear Component, Thrust Needle Bearing And Bearing

Race

64. Remove the retaining plates, drive and driven plates.

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Fig. 58: Identifying Retaining Plates, Drive And Driven Plates

65. Inspect the lining of all drive plates.



NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

Fig. 59: Identifying Print Mark Location

66. Remove the middle planetary gear component and sun gear.

67. Remove the bearing race and thrust needle bearing from middle planetary gear component.

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 60: Identifying Middle Planetary Gear Component And Sun Gear

68. Using a flathead screwdriver, remove the snap ring from transmission case component.

Fig. 61: Removing Snap Ring Using Flathead Screwdriver

69. Remove the piston return spring and B1 brake piston component.

Fig. 62: Identifying Piston Return Spring And B1 Brake Piston Component

70. Using a flathead screwdriver, remove the snap ring from transmission case.

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 63: Removing Snap Ring Using Flathead Screwdriver

71. Remove the driven plate.

Fig. 64: Identifying Driven Plate

72. Remove the retaining plates, drive and driven plates.

Fig. 65: Identifying Drive And Driven Plates

73. Remove the piston return spring.

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 66: Identifying Piston Return Spring

74. Inspect the lining of all drive plates



NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

Fig. 67: Identifying Print Mark Location

75. Blow compressed air into the oil passage as shown in the figure while pressing the B2 brake piston component by hand and remove the B2 brake piston component from the transmission case.

Air pressure

392 kPa {4 kgf/cm

, 57 psi}

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Fig. 68: Identifying Oil Passage Location

76. Remove the stopper spring from the transmission case.

Fig. 69: Identifying Stopper Spring On Transmission Case

77. Remove the snap ring from the transmission case using snap ring pliers.

Fig. 70: Removing Snap Ring From Transmission Case Using Snap Ring Pliers

78. Remove the following parts from the transmission case and disassemble in the order indicated below.

1. Inner race

2. F3 one-way clutch

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3. Rear ring gear component

4. Bearing race

5. Needle bearing

6. Bearing race

7. Intermediate shaft

Fig. 71: Identifying Intermediate Shaft Components

Fig. 72: Disassembled View Of Transmission Case Components

79. Remove the retaining plates, drive and driven plates.

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Fig. 73: Identifying Retaining Plates, Drive And Driven Plates

80. Inspect the lining of all drive plates.



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts.

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

Fig. 74: Identifying Print Mark Location

81. Remove the rear planetary gear component and bearing race and thrust needle bearing.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 75: Identifying Rear Planetary Gear Component, Bearing Race And Thrust Needle Bearing

82. Remove the brake tube.

CAUTION:



Make sure that the snap ring is not expanded excessively.

Fig. 76: Identifying Brake Tube

83. Compress the piston return spring using the SSTs and remove the snap ring.

Fig. 77: Identifying SSTs For Compressing Piston Return Spring

84. Remove the piston return spring.

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Fig. 78: Identifying Piston Return Spring

85. Blow compressed air into the oil passage as shown in the figure while pressing the B4 brake piston component by hand and remove the B4 brake piston component from the transmission case.

Air pressure

392 kPa {4 kgf/cm

, 57 psi}

Fig. 79: Blowing Compressed Air Into Oil Passage

86. Remove the inner brake piston and sleeve and B4 brake piston.

Fig. 80: Identifying Inner Brake Piston And Sleeve And B4 Brake Piston

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87. Remove the O-ring from the inner brake piston.

Fig. 81: Identifying O-Ring On Inner Brake Piston

88. Remove the O-ring from sleeve.

Fig. 82: Identifying O-Ring On Sleeve

89. Remove the O-ring from B4 brake piston.

Fig. 83: Identifying O-Ring On B4 Brake Piston

OIL PUMP DISASSEMBLY

Components

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Fig. 84: Disassembled View Of Oil Pump Components

Disassembly

1. Remove the O-ring from the oil pump component.

Fig. 85: Identifying O-Ring On Oil Pump

2. Remove the seal ring from the oil pump shaft.

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Fig. 86: Identifying Seal Ring

3. Put an installation mark on the pump housing and oil pump shaft.

Fig. 87: Identifying Fitting Mark On Pump Housing

4. Remove the screw from the oil pump.

Fig. 88: Identifying Screw On Oil Pump

5. Remove the oil pump shaft from the pump housing.

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Fig. 89: Identifying Oil Pump Shaft

6. Remove the O-ring from the pump housing.

Fig. 90: Identifying O-Ring On Pump Housing

7. Remove the inner oil pump gear and outer oil pump gear from the pump housing.

Fig. 91: Identifying Inner And Outer Oil Pump Gear

8. Using a flathead screwdriver, remove the oil seal from the pump housing.

CAUTION:



Do not damage the bushing on the pump housing.

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Fig. 92: Removing Oil Seal From Pump Housing Using Flathead

Screwdriver

OIL PUMP INSPECTION

1. Using a dial gauge, measure the inner diameter of the pump housing component bushings.

Pump housing bushing inner diameter

38.113-38.138 mm {1.50051-1.50150 in}

CAUTION:



Measure at different places and take an average. If it exceeds the specification, replace the pump housing component with a new one.

When the pump housing component is replaced, inspect the contact surface opposed to the torque converter.

If the surface of it is scratched or has changed color, replace the torque converter with a new one.

Fig. 93: Measuring Inner Diameter Of Pump Housing

Component Bushings Using Dial Gauge

2. Using a dial gauge, measure the inner diameter of the oil pump shaft bushings.

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Oil pump shaft bushing inner diameter

21.501-21.527 mm {0.846496-0.847520 in}

CAUTION:



Measure at different places and take an average. If it exceeds the specification, replace the oil pump shaft with a new one.

When the oil pump shaft is replaced, inspect the contact surface opposed to the input shaft.

If the surface of it is scratched or has changed color, replace the input shaft with a new one.

3. Press the gear oil pump towards the outer side of one side of the pump housing. Measure the clearance using a feeler gauge.

Oil pump gear outer standard clearance

0.10-0.17 mm {0.004-0.006 in}

CAUTION:

Fig. 94: Measuring Inner Diameter Of Oil Pump Shaft Bushings

Using Dial Gauge



If it exceeds the specification, replace the pump housing with a new one.

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Fig. 95: Measuring Oil Pump Gear Outer Clearance Using Feeler

Gauge

4. Measure the clearance between the inner and outer oil pump gears using a feeler gauge.

Oil pump gear inner standard clearance 0.07-0.15 mm {0.0028-0.0059 in}

CAUTION:



If it exceeds the specification, replace the pump housing with a new one.

Fig. 96: Measuring Oil Pump Gear Inner Clearance

5. Measure the side clearance of both gears using a steel straight edge and feeler gauge.

Oil pump gear side standard clearance 0.02-0.04 mm {0.0008-0.0015 in}

Oil pump gear size (mm {in})

OIL PUMP GEAR SIZE REFERENCE

Identification mark Thickness

9.946-9.952

9.953-9.959

9.960-9.966

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9.967-9.973

9.974-9.980

9.981-9.987

9.988-9.994

Fig. 97: Measuring Side Clearance Of Both Gears Using Steel Straight Edge And Feeler Gauge

CAUTION:



If the measurement exceeds the maximum specification, replace the inner oil pump gear and outer oil pump gear with a new one so that the side clearance is within the maximum specification.

If the side clearance still exceeds the maximum specification, replace the oil pump with a new one.

OIL PUMP ASSEMBLY

Components

Fig. 98: Exploded View Of Oil Pump Assembly

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Assembly Procedure

1. Apply ATF to the inner oil pump gear, outer oil pump gear and sliding surface of the pump housing.

2. Install the inner oil pump gear and outer oil pump gear to the pump housing as shown in the figure.

3. Apply ATF to the new O-ring.

Fig. 99: Identifying Alignment Marks On Oil Pump Gear

4. Install the O-ring to the pump housing.

Fig. 100: Identifying O-Ring On Pump Housing

5. Align the oil pump shaft with the mark on the pump housing, and install it.

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Fig. 101: Identifying Fitting Mark On Pump Housing

6. Align the oil pump shaft with bolt hole on the pump housing, and temporarily tighten.

7. Tighten the bolts.

Tightening torque

9.8-11.8 N.m {100.0-120.3 kgf.cm, 86.8-104.4 in.lbf}

8. Apply ATF to the sliding surface of the new seal ring and oil pump.

Fig. 102: Identifying Bolts

CAUTION:



Do not expand the seal ring too much.

Be careful not to shorten the seal rings too much, when installing the seal rings.

9. Compress the seal rings as shown in the figure, then install the seal rings to the oil pump shaft.

NOTE:



Verify that oil seal rings rotate smoothly after installing them.

10. Apply ATF to the new O-rings.

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Fig. 103: Identifying Seal Rings

11. Install the O-rings to the oil pump component.

Fig. 104: Identifying O-Rings

12. Turn the drive gear with flathead screwdrivers and verify it rotates smoothly.

Fig. 105: Turning Drive Gear Using Flathead Screwdrivers

13. Using a hammer, install the new oil seal to the pump housing.

CAUTION:



Do not damage the oil seal.

14. Apply grease to the oil seal lip.

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Fig. 106: Installing Oil Seal To Pump Housing Using Hammer

CLUTCH DRUM COMPONENT AND F4 ONE-WAY CLUTCH COMPONENT DISASSEMBLY

Components

Fig. 107: Clutch Drum Component And F4 One-Way Clutch Component Disassembled View (1 Of 2)

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Fig. 108: Clutch Drum Component And F4 One-Way Clutch Component Disassembled View (2 Of 2)

Disassembly Procedure

1. Using a flathead screwdriver, remove the snap ring from the C3 clutch piston component.

2. Remove the clutch hub component from the C3 clutch piston component.

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Fig. 109: Removing Snap Ring From C3 Clutch Piston Component Using Screwdriver

3. Remove the retaining plate and the drive plate and the driven plate from the clutch hub component.

Fig. 110: Identifying Retaining Plate, Drive Plate And Driven Plate

4. Remove the retaining plate from the C3 clutch piston component.

Fig. 111: Identifying Retaining Plate On C3 Clutch Piston Component

5. Remove the thrust needle bearing from the clutch hub.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 112: Identifying Thrust Needle Bearing On Clutch Hub

6. Remove the clutch hub from the C3 clutch piston component.

Fig. 113: Identifying Clutch Hub

7. Remove the thrust bearing, the bearing race and the thrust washer from clutch hub.

Fig. 114: Identifying Thrust Bearing, Bearing Race And Thrust Washer

8. Remove the C1, C4 clutch component from the C2, C3 clutch drum.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 115: Identifying Clutch Component

9. Remove the bearing race from the C3 clutch piston component.

Fig. 116: Identifying Bearing Race

10. Remove the clutch hub and F4 one-way clutch from the C1, C4 clutch component.

Fig. 117: Identifying Clutch Hub And F4 One-Way Clutch

11. Remove the bearing race from the C1, C4 clutch component.

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2007 Mazda MX-5 Miata Sport

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Fig. 118: Identifying Bearing Race

12. Remove the F4 one-way clutch from the clutch hub.

Fig. 119: Identifying F4 One-Way Clutch

13. Using a flathead screwdriver, remove the snap ring from the input shaft component.

Fig. 120: Removing Snap Ring From Input Shaft Component Using Flathead Screwdriver

14. Remove the retaining plate (C1) and the drive plate (C1) and the driven plate (C1) from the input shaft component.

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Fig. 121: Identifying Retaining Plate, Drive And Driven Plate

15. Using a flathead screwdriver, remove the snap ring from the input shaft component.

Fig. 122: Removing Snap Ring From Input Shaft Component Using Flathead Screwdriver

16. Remove the retaining plate (C4) and the drive plate (C4) and the driven plate (C4) from the input shaft component.

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Fig. 123: Identifying Retaining Plate, Drive And Driven Plate

17. Place the SST on the seal plate and compress the piston return spring with a press.

CAUTION:



Be careful not to expand the snap ring too much.

18. Remove the snap ring using snap ring pliers.

Fig. 124: Removing/Installing Snap Ring Using Snap Ring Pliers

19. Remove the C4 clutch seal plate and the piston return spring from the input shaft component.

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Fig. 125: Identifying C4 Clutch Seal Plate And Piston Return Spring

20. Apply compressed air into the oil passage as shown in the figure and remove the C4 clutch piston and C1 clutch piston from the input shaft component.

Air pressure

392 kPa (4.02 kgf/cm

, 57 psi)

21. When applying compressed air, shut the oil passages of the input shaft component.

Fig. 126: Applying Compressed Air Into Oil Passage

22. Remove the O-ring from the input shaft component.

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Fig. 127: Identifying O-Ring On Input Shaft Component

23. Remove the D-ring from the C1 clutch seal plate.

Fig. 128: Identifying D-Ring On C1 Clutch Seal Plate

24. Remove the seal ring from the input shaft component.

Fig. 129: Identifying Seal Ring On Input Shaft Component

25. Using a flathead screwdriver, remove the snap ring (C3) from the C2, C3 clutch drum.

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Fig. 130: Removing Snap Ring (C3) From C2, C3 Clutch Drum

26. Using a flathead screwdriver, remove the snap ring (C2) from the C2, C3 clutch drum.

Fig. 131: Removing Snap Ring (C2) From C2, C3 Clutch Drum

27. Remove the retaining plate (C2) and the drive plate (C2) and the driven plate (C2) from the input shaft component.

Fig. 132: Identifying Retaining Plate, Drive And Driven Plate

28. Install the SST as shown in the figure, and compress the C2 clutch piston return spring.

CAUTION:



Be careful not to expand the snap ring too much.

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Fig. 133: Identifying SST

29. Remove the snap ring using snap ring pliers.

Fig. 134: Removing/Installing Snap Ring Using Snap Ring Pliers

30. Remove the seal plate and the C2 clutch piston return spring from the C3 clutch drum.

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Fig. 135: Identifying Seal Plate And C2 Clutch Piston Return Spring

31. Apply compressed air into the oil passage as shown in the figure and remove the C2 clutch piston and C3 clutch piston from the input shaft component.

Air pressure

392 kPa (4.02 kgf/cm

, 57 psi)

32. When applying compressed air, shut the oil passage of the input shaft component.

Fig. 136: Identifying Oil Passage For Applying Compressed Air

33. Remove the O-ring from the C2 clutch seal plate.

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Fig. 137: Identifying O-Ring On C2 Clutch Seal Plate

34. Remove the O-ring from the C2 clutch piston.

Fig. 138: Identifying O-Ring On C2 Clutch Piston

35. Install the SST using a M10-1.25

bolt with a length of 100 mm as shown in the figure to compress the piston return spring.

CAUTION:



Be careful not to expand the snap ring too much.

Fig. 139: Identifying SST

36. Remove the snap ring using snap ring pliers.

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Fig. 140: Removing Snap Ring Using Snap Ring Pliers

37. Remove the seal plate piston return spring from the C3 clutch piston component.

Fig. 141: Identifying Seal Plate Piston Return Spring On C3 Clutch Piston Component

38. Remove the C2, C3 clutch drum C3 clutch piston component.

Fig. 142: Identifying C2, C3 Clutch Drum And C3 Clutch Piston Component

39. Remove the O-ring from the C3 clutch piston component.

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Fig. 143: Identifying O-Ring On C3 Clutch Piston Component

40. Remove the O-ring from the C2, C3 clutch drum.

Fig. 144: Identifying O-Ring On C2, C3 Clutch Drum

CLUTCH DRUM COMPONENT AND F4 ONE-WAY CLUTCH INSPECTION

1. Inspect the lining of all drive plates. (C1)



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate.



When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate.

If they are scratched or have changed color, replace with new parts.

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

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2. Inspect the lining of all drive plates. (C4)



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate.

When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate.

 If they are scratched or have changed color, replace with new parts.

NOTE:



Fig. 145: Identifying Print Mark On Drive Plates (C1)

Before replacing with new drive plates, soak them at least 2 h in

ATF.

Fig. 146: Identifying Print Mark On Drive Plates (C4)

3. Using vernier calipers, measure the free length of the piston return spring.

C1, C4 clutch return spring free length

Standard: 26.29 mm {1.04 in}



If it less than the specification, replace the piston return spring with a new one.

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Fig. 147: Measuring Free Length Of Piston Return Spring

4. Inspect the lining of all drive plates. (C2)



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate.

When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate.



If they are scratched or have changed color, replace with new parts.

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

Fig. 148: Identifying Print Mark On Drive Plates (C2)

5. Inspect the lining of all drive plates. (C3)



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate.

When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate.



If they are scratched or have changed color, replace with new parts.

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

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ATF.

Fig. 149: Identifying Print Mark On Drive Plates (C3)

6. Using vernier calipers, measure the free length of the piston return spring.

C2 clutch return spring free length

Standard: 20.02 mm {0.79 in}



If it less than the specification, replace the piston return spring with a new one.

Fig. 150: Measuring Free Length Of Piston Return Spring

7. Using vernier calipers, measure the free length of the piston return spring.

C3 clutch return spring free length

Standard: 21.03 mm {0.83 in}

 If it less than the specification, replace the piston return spring with a new one.

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Fig. 151: Measuring Free Length Of Piston Return Spring

8. Using a dial gauge, measure the inner diameter of the input shaft component bushings.

Input shaft component bushing inner diameter

18.000-18.025 mm {0.7087-0.7096 in}

CAUTION:



Measure at different places and take an average. If it exceeds the specification, replace the input shaft component with a new one.

When the input shaft component is replaced, inspect the contact surface opposed to the intermediate shaft.

If the surface of it is scratched or has changed color, replace the intermediate shaft with a new one.

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Thursday, July 09, 2009 1:42:24 PM

Fig. 152: Measuring Inner Diameter Of Input Shaft Component

Bushings Using Dial Gauge

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

9. Using a dial gauge, measure the inner diameter of the clutch hub bushings.

Clutch hub bushing inner diameter

Front side: 23.037-23.062 mm {0.90697-0.90795 in}

Rear side: 23.037-23.062 mm {0.90697-0.90795 in}

CAUTION:



Measure at different places and take an average. If it exceeds the specification, replace the clutch hub with a new one.

When the clutch hub is replaced, Inspect the contact surface opposed to the input shaft component.

If the surface of it is scratched or has changed color, replace the input shaft component with a new one.

Fig. 153: Measuring Inner Diameter Of Clutch Hub Bushings

Using Dial Gauge

10. Using a dial gauge, measure the inner diameter of the clutch hub component bushings.

Clutch hub component bushing inner diameter

Front side: 33.312-33.337 mm {1.31150-1.31248 in}

Rear side: 33.312-33.337 mm {1.31150-1.31248 in}

CAUTION:

Microsoft

Thursday, July 09, 2009 1:42:24 PM



Measure at different places and take an average. If it exceeds the specification, replace the clutch hub component with a new one.

2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8



When the clutch hub component is replaced, inspect the contact surface opposed to the clutch hub.

If the surface of it is scratched or has changed color, replace the clutch hub with a new one.

Fig. 154: Measuring Inner Diameter Of Clutch Hub Component

Bushings Using Dial Gauge

11. Verify that the F4 one-way clutch rotates when the clutch hub is secured and rotated clockwise, and that it does not rotate when the clutch hub is rotated counterclockwise.

Fig. 155: Identifying F4 One-Way Clutch Rotation Positions

CLUTCH DRUM COMPONENT AND F4 ONE-WAY CLUTCH COMPONENT ASSEMBLY

Components

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Fig. 156: Exploded View Of Clutch Drum Component And F4 One-Way Clutch Component (1 Of 2)

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Fig. 157: Exploded View Of Clutch Drum Component And F4 One-Way Clutch Component (2 Of 2)

Assembly Procedure

1. Apply ATF to the new O-ring

2. Install the O-rings to the C2, C3 clutch drum.

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3. Apply ATF to the new O-rings.

Fig. 158: Identifying O-Ring On C2, C3 Clutch Drum

4. Install the O-rings to the C3 clutch piston component.

5. Apply ATF to the C2, C3 clutch drum and the C3 clutch piston component.

CAUTION:



Do not damage the O-ring.

6. Install the C2, C3 clutch drum to the C3 clutch piston component.

7. Apply ATF to the seal plate and the piston return spring.

CAUTION:



Fig. 159: Identifying O-Rings On C3 Clutch Piston Component

Do not damage the O-ring.

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Fig. 160: Identifying C2, C3 Clutch Drum

8. Install the seal plate and the piston return spring to the C3 clutch hub component.

Fig. 161: Identifying Seal Plate And Piston Return Spring

9. Install the SST using a M10-1.25

bolt with a length of 100 mm as shown in the figure to compress the piston return spring.

CAUTION:



Do not expand the snap ring too much.

Fig. 162: Identifying SST

10. Remove the snap ring using snap ring pliers.

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Fig. 163: Removing Snap Ring Using Snap Ring Pliers

11. Apply ATF to the new O-rings.

12. Install the O-rings to the C2 clutch piston.

13. Apply ATF to the new O-rings.

Fig. 164: Identifying O-Rings On C2 Clutch Piston

14. Install the O-rings to the C2 clutch seal plate.

15. Apply ATF to the C2 clutch piston and the C2, C3 clutch drum.

CAUTION:



Do not damage the O-ring.

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Thursday, July 09, 2009 1:42:24 PM

Fig. 165: Identifying O-Rings On C2 Clutch Seal Plate

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

16. Install the C2 clutch piston and the C2, C3 clutch drum.

17. Apply ATF to the C2 clutch seal plate and the C2, C3 clutch drum.

Fig. 166: Identifying C2 Clutch Seal Plate

18. Install the C2 clutch seal plate and the C2 clutch piston return spring to the C2, C3 clutch drum.

Fig. 167: Identifying C2 Clutch Seal Plate And C2 Clutch Piston Return Spring

19. Install the SST as shown in the figure, and compress the C2 clutch piston return spring.

CAUTION:



Do not expand the snap ring too much.

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Fig. 168: Identifying SST

20. Install the snap ring using snap ring pliers.

21. Apply ATF to the driven plate (C2) and the drive plate (C2) and the retaining plate (C2).

Fig. 169: Removing/Installing Snap Ring Using Snap Ring Pliers

22. Install the driven plate (C2), the drive plate (C2), the retaining plate (C2) to the C2, C3 clutch drum.

CAUTION:



Inspect the number of drive and driven plates.

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Fig. 170: Identifying Driven, Drive Plate And Retaining Plate

23. Using a flathead screwdriver, install the snap ring (C2) to the C2, C3 clutch drum.

CAUTION:



When installing the snap ring, set the end gap of the snap ring as shown in the figure.

Fig. 171: Installing Snap Ring Using Flathead Screwdriver

24. Measure the retaining plate travel distance at both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure, and calculate the average value.

Verify that the piston moves smoothly.

Air pressure

200 kPa (2 kgf/cm

, 28 psi)

THICKNESS REFERENCE

Identification mark Thickness (mm {in})

0 2.95-3.05{0.016-0.120}

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3.05-3.15{0.120-0.124}

3.15-3.25{0.124-0.128}

3.25-3.35{0.128-0.132}

3.35-3.45{0.132-0.136}

3.45-3.55{0.136-0.140}

3.55-3.65{0.140-0.144}

3.65-3.75{0.144-0.148}

3.75-3.85{0.148-0.152}

Fig. 172: Measuring Retaining Plate Travel Distance At Both Ends Across Diameter Using Dial

Gauge

CAUTION:



If the C2 clutch pack clearance exceeds the maximum specification, select another retaining plate.

25. Using a flathead screwdriver, install the snap ring (C3) to the C2, C3 clutch drum.

CAUTION:



When installing the snap ring, set the end gap of the snap ring as shown in the figure.

26. Apply ATF to the retaining plate (C3), the driven plate (C3), the drive plate (C3).

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Fig. 173: Installing Snap Ring Using Flathead Screwdriver

CAUTION:



Inspect the number of drive and driven plates.

27. Install the retaining plate (C3) and the driven plate (C3) and the drive plate (C3) and the sleeve to the C2,

C3 clutch drum.

CAUTION:



When installing the snap ring, set the end gap of the snap ring as shown in the figure.

Fig. 174: Identifying Retaining Plate, Driven Plate, Drive Plate

And Sleeve

28. Using a flathead screwdriver, install the snap ring (C3) to the C2, C3 clutch drum.

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Fig. 175: Installing Snap Ring Using Flathead Screwdriver

29. Measure the driven plate travel distance of the reverse piston travel distance and driven plate at the both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure, and calculate the average value. Verify that the piston moves smoothly.

Fig. 176: Measuring Driven Plate Travel Distance Using Dial Gauge

Air pressure

200 kPa (2 kgf/cm

, 28 psi)

Standard travel distance A

1.62-2.68 mm {0.06-0.10 in}

Standard travel distance B

1.22-1.67 mm {0.05-0.06 in}

Standard gap

0.40-0.70 mm {0.01-0.03 in}

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THICKNESS REFERENCE

Identification mark Thickness (mm {in})

0 2.35-2.45 {0.093-0.096}

2.45-2.55 {0.096-0.100}

2.55-2.65 {0.100-0.104}

2.65-2.75 {0.104-0.108}

2.75-2.85 {0.108-0.112}

2.85-2.95 {0.112-0.116}

2.95-3.05 {0.116-0.120}

3.05-3.15 {0.120-0.124}

3.15-3.25 {0.124-0.128}

3.25-3.35 {0.128-0.132}

3.35-3.45 {0.132-0.136}

3.45-3.55 {0.136-0.140}

CAUTION:



If the C3 clutch pack clearance exceeds the maximum specification, select another retaining plate.

30. Apply ATF to the sliding surface of the new seal ring input shaft.

CAUTION:



Do not expand the seal ring too much.

Be careful not to shorten the seal rings too much, when installing them.

31. Compress the seal rings as shown in the figure and install them to the input shaft component.

NOTE:



Verify that oil seal rings rotate smoothly after installing them.

32. Apply ATF to the new D-ring.

Fig. 177: Compressing Seal Rings

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33. Install the D-ring to the C4 clutch seal plate.

34. Apply ATF to the new O-ring.

Fig. 178: Identifying D-Ring On C4 Clutch Seal Plate

35. Install the O-ring to the input shaft component.

36. Apply ATF to the C1 clutch piston and the C4 clutch piston to the input shaft component.

Fig. 179: Identifying O-Ring On Input Shaft Component

37. Install the C1 clutch piston and the C4 clutch piston to the input shaft component.

38. Apply ATF to the C1 clutch seal plate and the input shaft component.

Fig. 180: Identifying C1 Clutch Piston And C4 Clutch Piston

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39. Install the C1 clutch seal plate and the piston return spring to the input shaft component.

CAUTION:



Do not damage the D-ring.

40. Place the SST on the C1 clutch seal plate and compress the piston return spring with a press.

CAUTION:



Do not expand the snap ring too much.

Fig. 181: Identifying C1 Clutch Seal Plate And Piston Return

Spring

41. Install the snap ring using snap ring pliers.

Fig. 182: Removing/Installing Snap Ring Using Snap Ring Pliers

42. Apply ATF to the retaining plate (C4), the driven plate (C4), the drive plate (C4).

CAUTION:



Inspect the number of drive and driven plates.

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Fig. 183: Identifying Retaining Plate, Driven And Drive Plate

43. Install the retaining plate (C4), the driven plate (C4), the drive plate (C4) to the input shaft component.

44. Using a flathead screwdriver, install the snap ring to the input shaft component.

Fig. 184: Installing Snap Ring To Input Shaft Component Using Flathead Screwdriver

45. Measure the retaining plate travel distance at both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure, and calculate the average value.

Verify that the piston moves smoothly.

Air pressure

200 kPa (2 kgf/cm

, 28 psi)

Standard travel distance

0.02-1.01 mm {0.0008-0.0397 in}

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Standard gap

0.4-0.7 mm {0.0158-0.0275 in}

THICKNESS REFERENCE

Identification mark Thickness (mm {in})

0 2.95-3.05{0.116-0.120}

1 3.05-3.15{0.120-0.124}

3.15-3.25{0.124-0.128}

3.25-3.35{0.128-0.132}

3.35-3.45{0.132-0.136}

3.45-3.55{0.136-0.140}

3.55-3.65{0.140-0.144}

3.65-3.75{0.144-0.148}

3.75-3.85{0.148-0.152}

3.85-3.95{0.152-0.156}

Fig. 185: Measuring Retaining Plate Travel Distance At Both Ends Across Diameter Using Dial

Gauge

CAUTION:



If the C4 clutch pack clearance exceed the maximum specification, select another retaining plate.

46. Apply ATF to the retaining plate (C1), the driven plate (C1), the drive plate (C1).

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CAUTION:



Inspect the number of drive and driven plates.

47. Install the retaining plate (C1), the driven plate (C1), the drive plate (C1) to the input shaft component.

Fig. 186: Identifying Retaining Plate, Driven Plate And Drive Plate

48. Using a flathead screwdriver, install the snap ring to the input shaft component.

Fig. 187: Installing Snap Ring Using Flathead Screwdriver

49. Measure the retaining plate travel distance at both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure, and calculate the average value.

Verify that the piston moves smoothly.

Air pressure

200 kPa (2 kgf/cm

, 28 psi)

Standard travel distance

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

0.14-0.17 mm {0.0056-0.0066 in}

Standard gap

0.56-0.86 mm {0.0221-0.0338 in}

CAUTION:



If the C1 clutch pack clearance exceed the maximum specification, select another retaining plate.

50. Apply ATF to the F4 one-way clutch and the thrust washer.

Fig. 188: Measuring Retaining Plate Travel Distance At Both Ends Across Diameter Using Dial

Gauge

51. Install the F4 one-way clutch to the clutch hub.

52. Apply ATF to the bearing race.

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Fig. 189: Identifying F4 One-Way Clutch And Thrust Washer

53. Install the bearing race to the C1, C4 clutch component.

Fig. 190: Identifying Bearing Races

54. Install the clutch hub to the C1, C4 clutch component.

55. Apply ATF to the bearing race.

Fig. 191: Identifying Clutch Hub

56. Install the bearing race to the C3 clutch piston component.

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Fig. 192: Identifying Bearing Race On C3 Clutch Piston Component

57. Install the C1, C4 clutch component to the C2, C3 clutch drum.

58. Apply ATF to the thrust bearing, the bearing race and the thrust washer.

Fig. 193: Identifying C1, C4 Clutch Component

59. Install the thrust bearing, bearing race and thrust washer.

Fig. 194: Identifying Thrust Bearing, Bearing Race And Thrust Washer

60. Install the clutch hub to the C3 clutch piston component.

61. Apply ATF to the thrust needle spring.

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Fig. 195: Identifying Clutch Hub On C3 Clutch Piston Component

62. Install the thrust needle spring to the clutch hub.

63. Apply ATF to the retaining plate.

Fig. 196: Identifying Thrust Needle Bearing On Clutch Hub

64. Install the retaining plate to the C3 clutch piston component.

Fig. 197: Identifying Retaining Plate On C3 Clutch Piston Component

65. Install the clutch hub component to the C3 clutch piston component.

66. Apply ATF to the retaining plate, the drive plate, the driven plate.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

CAUTION:



Inspect the number of drive and driven plates.

Fig. 198: Identifying Clutch Hub Component

67. Install the retaining plate (C3), the drive plate (C3), and the driven plate (C3) to the clutch hub component.

Fig. 199: Identifying Retaining Plate, Drive Plate And Driven Plate

68. Using a flathead screwdriver, install the snap ring to the C3 clutch piston component.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 200: Installing Snap Ring To C3 Clutch Piston Component Using Flathead Screwdriver

B1, B3 BRAKE AND F1, F2 ONE-WAY CLUTCH COMPONENT DISASSEMBLY

Components

Fig. 201: B1, B3 Brake And F1, F2 One-Way Clutch Component Disassembled View

Disassembly Procedure

1. Remove the B3 brake cylinder from the F1 one-way clutch.

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Fig. 202: Identifying B3 Brake Cylinder

2. Remove the F1 one-way clutch and the thrust washer from the bearing race.

Fig. 203: Identifying F1 One-Way Clutch And Thrust Washer

3. Using a flathead screwdriver, remove the snap ring from the B3 brake cylinder.

Fig. 204: Removing Snap Ring From B3 Brake Cylinder Using Flathead Screwdriver

4. Remove the piston return spring from the B3 brake piston.

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Fig. 205: Identifying Piston Return Spring

5. While pushing the B3 brake piston, apply compressed air into the oil passage as shown in the figure and remove the B3 brake piston from the B3 brake cylinder.

Air pressure

392 kPa (4.0 kgf/cm

, 57 psi)

Fig. 206: Locating Oil Passage

6. Remove the O-ring from the B3 brake piston.

Fig. 207: Identifying O-Ring On B3 Brake Piston

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7. While pushing the B1 brake piston, apply compressed airinto the oil passage as shown in the figure and remove the B1 brake piston from the B1 brake cylinder.

Air pressure

392 kPa (4.0 kgf/cm

, 57 psi)

Fig. 208: Locating Oil Passage

8. Remove the O-ring from the B1 brake piston.

Fig. 209: Identifying O-Ring On B1 Brake Piston

B1, B3 BRAKE AND F1, F2 ONE-WAY CLUTCH INSPECTION

1. Using vernier calipers, measure the free length of the piston return spring.

B3 brake return spring free length

Standard: 15.72 mm {0.62 in}



If it less than the specification, replace the piston return spring with a new one.

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Fig. 210: Measuring Free Length Of Piston Return Spring Using Vernier Caliper

2. Inspect the lining of all drive plates. (B3)



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate.

When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate.



If they are scratched or have changed color, replace with new parts.

Fig. 211: Identifying Print Mark Location

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

3. Using vernier calipers, measure the free length of the piston return spring.

B1 brake return spring free length

Standard: 17.05 mm {0.67 in}



If it less than the specification, replace the piston return spring with a new one.

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Fig. 212: Measuring Free Length Of Piston Return Spring

4. Inspect the lining of all drive plates. (B1)



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate.

 When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate.



If they are scratched or have changed color, replace with new parts.

Fig. 213: Identifying Print Mark Location

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

5. Verify that the F1 one-way clutch rotates when the bearing race is secured and rotated clockwise, and that it does not rotate when the bearing race is rotated counterclockwise.

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Fig. 214: Identifying F1 One-Way Clutch Rotation Positions

6. Verify that the F2 one-way clutch rotates when the clutch hub is secured and rotated clockwise, and that it does not rotate when the clutch hub is rotated counterclockwise.

Fig. 215: Identifying F2 One-Way Clutch Rotation Positions

B1, B3 BRAKE AND F1, F2 ONE-WAY CLUTCH COMPONENT ASSEMBLY

Components

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Fig. 216: Exploded View Of B1, B3 Brake And F1, F2 One-Way Clutch Component

Assembly Procedure

1. Apply ATF to the new O-ring.

2. Install the O-rings to the B1 brake piston.

3. Apply ATF to the B1 brake piston and the B1 brake cylinder.

CAUTION:



Do not damage the O-ring.

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Fig. 217: Identifying O-Rings On B1 Brake Piston

4. Install the B1 brake piston to the B1 brake cylinder.

5. Apply ATF to the new O-rings.

Fig. 218: Identifying B1 Brake Piston On B1 Brake Cylinder

6. Install the O-rings to the B3 brake piston.

7. Apply ATF to the B3 brake cylinder to the B3 brake piston.

CAUTION:



Do not damage the O-ring.

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Thursday, July 09, 2009 1:42:25 PM

Fig. 219: Identifying O-Rings On B3 Brake Piston

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

8. Install the B3 brake piston to the B3 brake cylinder.

Fig. 220: Identifying B3 Brake Piston On B3 Brake Cylinder

9. Install the piston return spring to the B3 brake piston.

Fig. 221: Identifying Piston Return Spring

10. While holding the snap ring with a finger, install it to the brake cylinder using a flathead screwdriver.

11. Apply ATF to the thrust washer.

12. Install the bearing race to the thrust washer.

Fig. 222: Installing Brake Cylinder Using Flathead Screwdriver

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13. Install the F1 one-way clutch to the bearing race.

Fig. 223: Identifying F1 One-Way Clutch

14. Install the B3 brake cylinder to the F1 one-way clutch.

Fig. 224: Identifying B3 Brake Cylinder

PLANETARY GEAR COMPONENT DISASSEMBLY

Components

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Fig. 225: Planetary Gear Component Disassembled View

Disassembly Procedure

1. Using a flathead screwdriver, remove the snap ring from the middle planetary ring gear.

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Fig. 226: Removing Snap Ring From Middle Planetary Ring Gear Using Flathead Screwdriver

2. Remove the front planetary ring gear flange from the middle planetary ring gear.

Fig. 227: Identifying Front Planetary Ring Gear Flange

3. Using a flathead screwdriver, remove the snap ring from the middle planetary ring gear.

Fig. 228: Removing Snap Ring From Middle Planetary Ring Gear

4. Remove the front planetary ring gear from the middle planetary ring gear.

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Fig. 229: Identifying Front Planetary Ring Gear

5. Using a flathead screwdriver, remove the snap ring from the rear planetary ring gear.

Fig. 230: Removing Snap Ring From Rear Planetary Ring Gear Using Flathead Screwdriver

6. Remove the rear planetary ring gear flange from the rear planetary ring gear.

Fig. 231: Identifying Rear Planetary Ring Gear Flange

PLANETARY GEAR COMPONENT INSPECTION

1. Using a dial gauge, measure the inner diameter of the front planetary ring gear flange bushings.

Front planetary ring gear bushing inner diameter

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

46.038-46.063 mm {1.81252-1.81350 in}

CAUTION:



Measure at different places and take an average. If it exceeds the specification, replace the front planetary ring gear flange with a new one.

When the front planetary ring gear flange is replaced, inspect the contact surface opposed to the middle planetary gear component.

If the surface of it is scratched or has changed color, replace the middle planetary gear component with a new one.

2. Using a dial gauge, measure the inner diameter of the front planetary gear component bushings.

Front planetary gear component bushing inner diameter

48.755-48.780 mm {1.91949-1.92047 in}

CAUTION:

Fig. 232: Measuring Inner Diameter Of Front Planetary Ring

Gear Flange Bushings



Measure at different places and take an average. If it exceeds the specification, replace the front planetary gear component with a new one.

When the front planetary gear component is replaced, inspect the contact surface opposed to the clutch hub.

If the surface of it is scratched or has changed color, replace the clutch hub with a new one.

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3. Using a dial gauge, measure the inner diameter of the rear planetary gear component bushings.

Rear planetary gear component bushing inner diameter

18.000-18.025 mm {0.7087-0.7096 in}

CAUTION:

Fig. 233: Measuring Inner Diameter Of Front Planetary Gear

Component Bushings



Measure at different places and take an average. If it exceeds the specification, replace the Rear planetary gear component with a new one.

When the front planetary gear component is replaced, inspect the contact surface opposed to the intermediate shaft.

If the surface of it is scratched or has changed color, replace the intermediate shaft with a new one.

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Fig. 234: Measuring Inner Diameter Of Rear Planetary Gear

Component Bushings

PLANETARY GEAR COMPONENT ASSEMBLY

Components

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Fig. 235: Exploded View Of Planetary Gear Components

Assembly Procedure

1. Install the rear planetary gear flange to the rear planetary ring gear.

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Fig. 236: Identifying Rear Planetary Gear Flange

2. Using a flathead screwdriver, install the snap ring to the rear planetary ring gear.

Fig. 237: Installing Snap Ring To Rear Planetary Ring Gear

3. Install the front planetary ring gear to the middle planetary ring gear.

Fig. 238: Identifying Front Planetary Ring Gear

4. Using a flathead screwdriver, install the snap ring to the middle planetary ring gear.

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Fig. 239: Installing Snap Ring To Middle Planetary Ring Gear

5. Install the middle planetary ring gear flange to the middle planetary ring gear.

Fig. 240: Identifying Middle Planetary Ring Gear Flange

6. Using a flathead screwdriver, install the snap ring to the middle planetary ring gear.

Fig. 241: Installing Snap Ring To Middle Planetary Ring Gear

B2, B4 BRAKE AND F3 ONE-WAY CLUTCH COMPONENT DISASSEMBLY

Components

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Fig. 242: B2, B4 Brake And F3 One-Way Clutch Component Disassembled View

Disassembly Procedure

1. Blow compressed air into the oil passage as shown in the figure while pressing the B2 brake piston and brake cylinder by hand and remove the B2 brake piston.

Air pressure

392 kPa (4.0 kgf/cm

, 57 psi)

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Fig. 243: Locating Oil Passage

2. Remove the O-ring from the B2 brake piston.

Fig. 244: Identifying O-Ring On B2 Brake Piston

3. Remove the inner race from the F3 one-way clutch component.

Fig. 245: Identifying Inner Race On F3 One-Way Clutch Component

4. Remove the O-ring from the B4 brake piston.

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Fig. 246: Identifying O-Ring On B4 Brake Piston

5. Remove the O-ring from the sleeve.

Fig. 247: Identifying O-Ring On Sleeve

6. Remove the O-ring from the inner brake piston.

Fig. 248: Identifying O-Ring On Inner Brake Piston

B2, B4 BRAKE AND F3 ONE-WAY CLUTCH INSPECTION

1. Using vernier calipers, measure the free length of the piston return spring.

B2 brake return spring free length

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Standard: 22.66 mm {0.89 in}



If it less than the specification, replace the piston return spring with a new one.

Fig. 249: Measuring Free Length Of Piston Return Spring

2. Inspect the lining of all drive plates. (B2)



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate.

When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate.



If they are scratched or have changed color, replace with new parts.

Fig. 250: Identifying Print Mark Location

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

3. Using vernier callpers, measure the free length of the piston return spring.

B4 brake return spring free length

Standard: 13.84 mm {0.54 in}

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

If it less than the specification, replace the piston return spring with a new one.

Fig. 251: Measuring Free Length Of Piston Return Spring

4. Inspect the lining of all drive plates. (B2)



If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate.

When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate.



If they are scratched or have changed color, replace with new parts.

Fig. 252: Identifying Print Mark Location

NOTE:



Before replacing with new drive plates, soak them at least 2 h in

ATF.

5. Verify that the inner race rotates when the F3 one-way clutch is secured and rotated clockwise, and that it does not rotate when the F3 one-way clutch is rotated counterclockwise.

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Fig. 253: F3 One-Way Clutch Rotation Position

B2, B4 BRAKE AND F3 ONE-WAY CLUTCH COMPONENT ASSEMBLY

Components

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Fig. 254: Exploded View Of B2, B4 Brake And F3 One-Way Clutch Components

Assembly Procedure

1. Apply ATF to the new O-rings.

2. Install the O-rings to the B4 brake piston.

3. Apply ATF to the new O-rings.

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Fig. 255: Identifying O-Rings On B4 Brake Piston

4. Install the O-rings to the sleeve.

5. Apply ATF to the new O-ring.

Fig. 256: Identifying O-Ring On Sleeve

6. Install the O-rings to the B4 brake piston.

7. Apply ATF to the inner race and the F3 one-way clutch component.

Fig. 257: Identifying O-Ring On B4 Brake Piston

8. Install the inner race to the F3 one-way clutch component.

9. Apply ATF to the new O-ring.

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Fig. 258: Identifying Inner Race On F3 One-Way Clutch Component

10. install the O-ring to the B2 brake piston.

11. Apply ATF to the brake cylinder and the B2 brake piston.

CAUTION:



Do not damage the O-ring.

Fig. 259: Identifying O-Ring On B2 Brake Piston

12. Install the B2 brake piston to the brake cylinder.

Fig. 260: Identifying B2 Brake Piston On Brake Cylinder

CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY

Components

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Fig. 261: Exploded View Of Control Valve Body

Disassembly Procedure

CAUTION:



Do not damage the solenoid.

1. Remove the shift solenoid C from the control valve body.

CAUTION:



Do not damage the solenoid.

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2. Remove the shift solenoid B shift solenoid D from the control valve body.

3. Remove the bolt and the wiring harness clip.

CAUTION:



Fig. 262: Identifying Shift Solenoid C

Do not damage the solenoid.

Fig. 263: Identifying Shift Solenoid B

4. Remove the shift solenoid A from the control valve body.

CAUTION:



Do not damage the solenoid.

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Fig. 264: Identifying Shift Solenoid A

5. Remove the shift solenoid E from the control valve body.

Fig. 265: Identifying Shift Solenoid E

Assembly Procedure

CAUTION:



Do not damage the solenoid.

1. Install the shift solenoid E to the control valve body.

Tightening torque

8.0-12.0 N.m {81.6-122.3 kgf.cm, 70.9-106.1 in.lbf}

2. Install the bolt and the wiring harness clip.

CAUTION:



Do not damage the solenoid.

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3. Install the shift solenoid A to the control valve body.

Tightening torque

8.0-12.0 N.m {81.6-122.3 kgf.cm, 70.9-106.1 in.lbf}

CAUTION:



Fig. 266: Identifying Shift Solenoid E

Do not damage the solenoid.

4. Install the shift solenoid B and the shift solenoid D to the control valve body.

Tightening torque

8.0-12.0 N.m {81.6-122.3 kgf.cm, 70.9-106.1 in.lbf}

CAUTION:



Fig. 267: Identifying Shift Solenoid A

Do not damage the solenoid.

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Fig. 268: Identifying Shift Solenoid B

5. Install the shift solenoid C to the control valve body.

Tightening torque

8.0-12.0 N.m {81.6-122.3 kgf.cm, 70.9-106.1 in.lbf}

Fig. 269: Identifying Shift Solenoid C

AUTOMATIC TRANSMISSION ASSEMBLY

Assembly

Bearing and race locations

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Fig. 270: Exploded View Of Automatic Transmission Assembly With Bearing And Race Locations (1 Of

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Fig. 271: Exploded View Of Automatic Transmission Assembly With Bearing And Race Locations (2 Of

BEARING REFERENCE

Bearing race

(Front)

(mm)

Outer diameter

87.74

{3.45}

Bearing

(mm)

Inner diameter

Outer diameter

Inner diameter

74.2

{2.92}

85.6

{3.37}

71.9

{2.83}

B C

35.6

{1.40}

92.6

{3.65}

20.00

{0.79}

63.8

{2.51}

41.0

{1.61}

20.0

{0.79}

Bearing race

(Rear)

(mm)

Outer diameter

Inner diameter

D E F G

102.7

{4.04}

96.7

{3.81}

83.6

{3.29}

50.8

{1.20}

44.9

{1.77}

56.7

{2.23}

51.2

{2.02}

89.3

{3.52}

76.3

{3.00}

60.0

{2.36}

34.9

{1.37}

53.1

{2.09}

73.5

{2.89}

38.6

{1.52}

58.5

{2.30}

71.2

{2.80}

54.8

{2.16}

29.6

{1.06}

43.85

{1.73}

27.8

{1.09}

43.7

{1.72}

27.8

{1.09}

43.3

{1.70}

37.0

{1.46}

58.0

{2.28}

52.5

{2.07}

40.6

{1.60}

36.1

{1.42}

51.0

{2.01}

36.1

{1.42}

Components

Fig. 272: Exploded View Of Automatic Transmission Components (1 Of 2)

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Fig. 273: Exploded View Of Automatic Transmission Components (2 Of 2)

Disassembly Procedure

1. Apply ATF to the new O-ring.

CAUTION:



Do not damage the O-ring and B4 brake piston.

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2. Install the O-ring to the B4 brake piston.

3. Apply ATF to the new O-rings.

CAUTION:



Do not damage the O-ring and sleeve.

4. Install the O-ring to the sleeve.

5. Apply ATF to the new O-rings

CAUTION:



Fig. 274: Identifying O-Ring And B4 Brake Piston

Do not damage the O-ring and inner brake piston.

Fig. 275: Identifying O-Ring And Sleeve

6. Install the O-ring to the inner brake piston.

7. Apply ATF to the sliding surface of the transmission case.

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Fig. 276: Identifying O-Ring And Inner Brake Piston

8. Install the inner brake piston, sleeve and B4 brake piston to the transmission case.

Fig. 277: Identifying Inner Brake Piston, Sleeve And B4 Brake Piston

9. Install the piston return spring.

Fig. 278: Identifying Piston Return Spring

10. Using the SST, compress the piston return spring and install the snap ring into the groove.

CAUTION:



Do not expand the snap ring too much.

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Fig. 279: Identifying SST For Compressing Piston Return Spring

11. Install the brake tube to the transmission case as shown in the figure.

CAUTION:



Align the tabs of the brake tube with the position shown in the figure.

Fig. 280: Identifying Tabs Of Brake Tube

12. Verify that B4 brake piston moves smoothly when the compressed air atomization equipment lever is pulled/released while blowing compressed air into the transmission case.

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Fig. 281: Blowing Compressed Air Into Transmission Case

13. Measure the level difference (length A) between the brake tube upper surface and the retaining plate contact surface at the both ends across the B4 brake piston diameter using a vernier caliper, and calculate the average value.

NOTE:



Install the B4 brake piston to the transmission case securely.

Dimension A

23.32-24.18 mm {0.92-0.95 in}

14. Measure the thickness of all the driven plates and drive plate components (5), and driven plates (4) at the both ends across the diameter using a vernier caliper, and calculate the average value.

Dimension B

21.92-22.72 mm {0.87-0.89 in}

15. Calculate the pack clearance using the following formula.

Dimension A-Dimension B-0.18 mm {0.007 in}-Thickness H

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Fig. 282: Identifying Dimension A And B

16. If the pack clearance exceeds the maximum specification, select the retaining plate with a clearance that is the maximum specification and install it.

Pack clearance

0.5-0.8 mm {0.02-0.03 in}

NOTE:



There are 8 types of retaining plates for the pack clearance adjustment. Select the one with the most suitable thickness.

Retaining plate thickness H (mm {in})

RETAINING PLATE THICKNESS

Identification mark Thickness (mm {in}

0 0

2 0.15-0.25{0.006-0.010}

0.35-0.45 {0.014-0.0177}

0.55-0.65 {0.022-0.026}

0.75-0.85 {0.030-0.033}

0.95-1.05 {0.037-0.041}

1.15-1.25 {0.045-0.049}

1.35-1.45 {0.054-0.057}

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17. Apply ATF to the bearing race, thrust needle bearing and install to the rear planetary gear component.

Fig. 283: Identifying Bearing Race, Thrust Needle Bearing And Rear Planetary Gear Component

18. Install the rear planetary gear component to the transmission case.

Fig. 284: Identifying Rear Planetary Gear Components

19. Install the retaining plates, drive plates and driven plates to the transmission case as shown in the figure.

CAUTION:



Inspect the number and order of the retaining plate, drive and driven plates.

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Fig. 285: Identifying Retaining Plates, Drive And Driven Plates

20. Install the retaining plate, drive plates and driven plates in the order indicated in the figure.

Fig. 286: Identifying Retaining Plate, Drive Plates And Driven Plates

21. Apply ATF to the bearing race, needle bearing race and install to the intermediate shaft.

Fig. 287: Identifying Bearing Race And Needle Bearing Race

22. Install the rear ring gear component, F3 one-way clutch and inner race to the intermediate shaft.

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Fig. 288: Identifying Rear Ring Gear Component, F3 One-Way Clutch And Inner Race

23. Install the intermediate shaft component to the transmission case.

Fig. 289: Identifying Intermediate Shaft Component

24. Verify that the snap ring is correctly positioned.

CAUTION:



If the snap ring is not installed in the correct direction, the automatic transmission may not operate normally.

Fig. 290: Identifying Snap Ring Position

25. Install snap ring to the transmission case using snap ring pliers.

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Fig. 291: Installing Snap Ring To Transmission Case Using Snap Ring Pliers

26. Install the stopper spring to the transmission case.

Fig. 292: Identifying Stopper Spring On Transmission Case

27. Install the brake piston and brake cylinder to the transmission case.

CAUTION:



Align the opening of the snap ring with the position shown in the figure.

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Thursday, July 09, 2009 1:42:25 PM

Fig. 293: Positions For Aligning Opening Of Snap Ring

2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

28. Verify that B2 brake piston moves smoothly when the compressed air atomization equipment lever is pulled/released while blowing compressed air into the transmission case.

Fig. 294: Blowing Compressed Air Into Transmission Case

29. Measure the level difference (length A) between the brake piston upper surface and the snap ring contact surface at the both ends across the brake piston diameter using a vernier caliper, and calculate the average value.

NOTE:



Install the B2 brake piston to the transmission case securely.

Dimension A

21.19-21.90 mm {0.84-0.86 in}

30. Measure the thickness of all the driven plates and drive plate components (4), and driven plates (3) at the both ends across the diameter using a vernier caliper, and calculate the average value.

Dimension B

16.52-17.15 mm {0.65-0.67 in}

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Fig. 295: Identifying Dimension A, B And H

31. Calculate the pack clearance using the following formula.

Dimension A-Dimension B-1.6 mm {0.063 in}-Thickness H

32. If the pack clearance exceeds the maximum specification, select the retaining plate with a clearance that is the maximum specification and install it.

Pack clearance

0.6-0.9 mm {0.024-0.035 in}

NOTE:



There are 8 types of retaining plates for the pack clearance adjustment. Select the one with the most suitable thickness.

Retaining plate thickness H (mm {in})

RETAINING PLATE THICKNESS

Identification mark Thickness (mm {in})

1.95-2.05 {0.077-0.081}

2.05-2.15 {0.081-0.085}

2.15-2.25 {0.085-0.089}

2.25-2.35 {0.089-0.093}

2.35-2.45 {0.093-0.096}

2.45-2.55 {0.096-0.100}

2.55-2.65 {0.100-0.104}

2.65-2.75 {0.104-0.108}

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33. Install the return spring to the transmission case.

CAUTION:



Inspect the number and order of the retaining plate, drive and driven plates.

Fig. 296: Identifying Piston Return Spring

34. Install the retaining plate, drive plate and driven plates to the transmission case as shown in the figure.

Fig. 297: Identifying Retaining Plate, Drive Plate And Driven Plates

35. Install the retaining plate, drive plate component, and driven plates in the order indicated in the figure.

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Fig. 298: Identifying Retaining Plate, Drive Plate Component And Driven Plates

36. Install the retaining plate to the transmission case.

Fig. 299: Identifying Retaining Plate

37. Install the SST as shown in the figure, and compress the piston return spring.

CAUTION:



Align the opening of the snap ring with the position shown in the figure.

Fig. 300: Identifying SST

38. Using a flathead screwdriver, install the snap ring into the groove.

CAUTION:



Align the hole of the brake piston and brake cylinder with the position shown in the figure.

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Fig. 301: Position For Installing Snap Ring

39. Install the B1 brake piston component and return spring to the transmission case as shown in the figure.

Fig. 302: Positions For Installing B1 Brake Piston Component And Return Spring

40. Install the SST as shown in the figure, and compress the piston return spring.

Fig. 303: Identifying SST

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41. Using a flathead screwdriver, install the snap ring to the transmission case.

CAUTION:



Align the opening of the snap ring with the position shown in the figure.

Fig. 304: Position For Installing Snap Ring

42. Verify that B1 brake piston moves smoothly when the compressed air atomization equipment lever is pulled/released while blowing compressed air into the transmission case.

Fig. 305: Blowing Compressed Air Into Transmission Case

43. Measure the level difference (length A) between the B1 brake piston upper surface and retaining plate contact surface at the both ends across the B1 brake piston diameter using a vernier caliper, and calculate the average value.

NOTE:



Install the B1 brake piston component to the transmission case securely.

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Dimension A

15.27-15.92 mm {0.61-0.62 in}

44. Measure the thickness of all the driven plates and drive plate components (3), and driven plates (3) at the both ends across the diameter using a vernier caliper, and calculate the average value.

Dimension B

12.52-12.92 mm {0.493-0.508 in}

Fig. 306: Identifying Dimension A, B And H

45. Calculate the pack clearance using the following formula.

Dimension A-Dimension B-Thickness H

46. If the pack clearance exceeds the maximum specification, select the retaining plate with a clearance that is the maximum specification and install it.

Pack clearance

0.42-0.72 mm {0.017-0.028 in}

NOTE:



There are four types of retaining plates for the pack clearance adjustment. Select the one with the most suitable thickness.

Retaining plate thickness H (mm {in})

RETAINING PLATE THICKNESS

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2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Identification mark Thickness (mm {in})

0 1.95-2.05 {0.077-0.081}

2.15-2.25 {0.085-0.089}

2.35-2.45 {0.093-0.096}

2.55-2.65 {0.100-0.104}

CAUTION:



Inspect the number and order of the retaining plate, drive and driven plates.

47. Install the drive plate, driven plates and retaining plate to the transmission component as shown in the figure.

Fig. 307: Identifying Drive Plate, Driven Plates And Retaining Plate

48. Install the driven plates, drive plate, and the retaining plate in the order indicated in the figure.

49. Install the bearing race and thrust needle bearing to the middle planetary gear component.

Fig. 308: Identifying Driven Plates, Drive Plate And Retaining Plate

50. Install the middle planetary gear component and sun gear.

51. Apply ATF to the bearing race and thrust needle bearing.

52. Install the bearing race and thrust needle bearing to the middle planetary gear component.

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Fig. 309: Identifying Middle Planetary Gear Component And Sun Gear

53. Install the front and middle planetary gear ring component.

54. Apply ATF to the thrust washer.

Fig. 310: Identifying Front And Middle Planetary Gear Ring Component And Thrust Needle

Bearing

55. Install the thrust washer to the front planetary gear component.

56. Apply ATF to the thrust washer and install it to the bearing race.

Fig. 311: Identifying Thrust Washer And Front Planetary Gear Component

57. Install the F1 one-way clutch component to the bearing race.

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Fig. 312: Identifying F1 One-Way Clutch Component

58. Install the brake piston to the transmission case as shown in the figure.

CAUTION:



Align the hole of the brake piston with the position shown in the figure

Fig. 313: Position For Aligning Hole Of Brake Piston

59. Verify that the snap ring is correctly positioned.

CAUTION:



If the snap ring is not installed in the correct direction, the automatic transmission may not operate normally.

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Fig. 314: Position For Installing Snap Ring

60. Using snap ring pliers, install snap ring into the groove.

NOTE:



Align the opening of the snap ring with the position shown in the figure.

Fig. 315: Installing Snap Ring Using Snap Ring Pliers

61. Install the drive plate and driven plate as shown in the figure.

NOTE:



Inspect the number and order of the retaining plate, drive and driven plates.

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Fig. 316: Identifying Retaining Plate, Drive And Driven Plates

62. Install the driven plates, drive plate and the retaining plate in the order indicated in the figure.

Fig. 317: Identifying Driven Plates, Drive Plate And Retaining Plate

63. Using a flathead screwdriver, install the snap ring into the groove.

CAUTION:



Align the opening of the snap ring with the position shown in the figure.

64. Apply ATF to the thrust washer and install it to the F2 one-way clutch component.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 318: Installing Snap Ring Using Flathead Screwdriver

65. Install the F2 one-way clutch component to the clutch drum component.

66. Apply ATF to the bearing race and thrust needle bearing.

Fig. 319: Identifying F2 One-Way Clutch Component To Clutch Drum Component

67. Install the bearing race and thrust needle bearing to the clutch drum component and the F2 one-way clutch component.

Fig. 320: Identifying Bearing Race, Thrust Needle Bearing And Clutch Drum Component

68. Install the clutch drum component and F2 one-way clutch component.

CAUTION:



Do not drop the clutch drum component and the F2 one-way clutch component.

69. Apply ATF to the new O-ring.

70. Install the O-ring to the oil pump component.

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Fig. 321: Identifying Clutch Drum Component

71. Apply ATF to the thrust needle bearing, bearing race and install it to the oil pump component.

Fig. 322: Identifying Thrust Needle Bearing, Bearing Race And O-Ring

72. Install the oil pump as shown in the figure.

CAUTION:



Do not drop the oil pump.

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2007 Mazda MX-5 Miata Sport

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Fig. 323: Identifying Oil Pump

73. Install the bolt as shown in the figure.

Tightening torque

17.6-24.5 N.m {1.8-2.4 kgf.m, 13.0-18.0 ft.lb}

Fig. 324: Identifying Bolt

74. Apply ATF to the thrust needle bearing and the bearing race.

75. Install the thrust needle bearing and bearing race to the front planetary gear component.

76. Install snap ring using snap ring pliers.

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Fig. 325: Installing Thrust Needle Bearing And Bearing Race

77. Measure the clearance between snap ring and bearing race using a thickness gauge.

Standard

0.02-0.12 mm {0.0008-0.0047 in}



If not within the specification, select an appropriate bearing race.

Fig. 326: Measuring Clearance Between Snap Ring And Bearing Race Using Thickness

Gauge

Retaining plate size

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 327: Retaining Plate Size Reference Chart

78. Verify that the input shaft turns smoothly.

79. Using a dial indicator, measure the input shaft end play.

Input shaft end play

0.35-1.05 mm {0.014-0.041 in}

Fig. 328: Measuring Input Shaft End Play Using Dial Indicator

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80. Using the SST and a hammer, install a new oil seal.

CAUTION:



Do not damage the transmission case.

Fig. 329: Installing Oil Seal Using SST And Hammer

81. Install a new manual shaft washer to the manual valve.

82. Insert the manual shaft into the transmission case and assemble it to the manual valve.

Fig. 330: Identifying Manual Shaft Washer And Manual Valve

83. Tap in a new pin using a hammer.

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Fig. 331: Tapping Pin Using Hammer

84. Align the manual shaft groove with the spacer hole and crimp them using a punch.

85. Verify that the manual shaft turns smoothly.

Fig. 332: Locating Spacer Hole

86. Install the parking pawl.

87. Install the driven plate to the parking pawl shaft.

88. Install the parking pawl shaft, spring.

CAUTION:



Be careful not to apply too much force to the spring.

Fig. 333: Identifying Driven Plate, Parking Pawl Shaft And

Parking Pawl

89. Connect the parking rod to the manual valve.

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Fig. 334: Identifying Parking Rod On Manual Valve Lever

90. Install the bracket.

Tightening torque

5.9-8.8 N.m {60.2-89.7 kgf.cm, 52.3-77.8 in.lbf}

Fig. 335: Identifying Bracket Bolts

91. Set the manual valve to the P position and verify that the parking pawl shaft is properly engaged with the front planetary gear component.

Fig. 336: Engaging Parking Pawl Shaft

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92. Install the accumulator valve and compression spring to the transmission case.

CAUTION:



Do not damage the O-ring and accumulator piston.

Fig. 337: Identifying Accumulator Valve And Compression

Spring

93. Apply ATF to the new O-ring and install the accumulator pistons C.

Fig. 338: Identifying O-Ring And Accumulator Pistons C

94. Install the accumulator piston C, compression spring to the transmission case.

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Fig. 339: Identifying Accumulator Piston C And Compression Spring

95. Apply ATF to the new O-ring and install the accumulator pistons A, B.

Fig. 340: Identifying O-Ring On Accumulator Pistons A, B

96. Using a flathead screwdriver, install the compression spring, snap ring to the accumulator pistons A, B.

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Fig. 341: Identifying Snap Ring On Accumulator Pistons A, B

97. Install the accumulator pistons A, B and the compression spring to the transmission case.

CAUTION:



Do not damage gasket.

Fig. 342: Identifying Accumulator Pistons A, B And

Compression Spring

98. Apply ATF to the new transmission case gasket, new brake drum gasket and install the transmission case.

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Fig. 343: Identifying Transmission Case And Brake Drum Gasket

99. Install the check valve subcomponent and compression spring to the transmission case.

Fig. 344: Identifying Check Valve Subcomponent And Compression Spring

100. Connect the manual valve link, and install the control valve body component.

CAUTION:



When installing the control valve body component, route the wiring harness correctly to the separate plate depression inside the control valve body component shown in the figure.

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Fig. 345: Identifying Manual Valve Link

2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Fig. 346: Position For Installing Control Valve Body Component

101. Temporarily tighten the bolts to the transmission case as shown in the figure.

Bolt length (measured from below the head)

25 mm {0.98 in}

36 mm {1.42 in}

45 mm {1.77 in}

50 mm {1.97 in}

NOTE:



Aligning the bolt holes, temporarily tighten the bolts by hand.

Fig. 347: Identifying Transmission Case Bolts



Tighten the bolts from the inner side.

102. Tighten the bolts.

Tightening torque

10.0-12.0 N.m {102-122 kgf.cm, 89-105 in.lbf}

103. Install the detent spring cover and detent spring to the control valve body component.

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2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Tightening torque

8.0-12.0 N.m {82-122 kgf.cm, 72-105 in.lbf}

104. Install the TFT sensor, lock plate to control valve body component.

Tightening torque

8.0-12.0 N.m {82-122 kgf.cm, 72-105 in.lbf}

105. Clamp the coupler component.

106. Connect the solenoid connector to the solenoid.

107. Apply ATF to the new O-ring and install the oil strainer.

Fig. 348: Identifying Solenoid Connector

108. Install the oil strainer to the control valve body component.

Tightening torque

8.0-12.0 N.m {82-122 kgf.cm, 72-105 in.lbf}

CAUTION:



Make sure that lint or dirt does not penetrate the transmission.

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Fig. 349: Identifying Bolts On Control Valve Body

109. Clean the contact surface of the oil pan and transmission case.

NOTE:



Wash the magnets before installing them.

110. Install the magnet to the oil pan.

CAUTION:



Do not damage the contact surface of the oil pan and transmission case.

Do not deform the oil pan.

Fig. 350: Locating Magnet On Oil Pan

111. Install the new oil pan gasket and oil pan to the transmission case.

CAUTION:



Because the oil pan gasket is made of cork, the oil pan gasket may be damaged if it is tightened with excessive force.

112. Install the bolts to the transmission case.

Tightening torque

3.9-4.9 N.m {39.8-49.9 kgf.cm, 34.6-43.3 in.lbf}

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Fig. 351: Identifying Transmission Case Bolts

113. Remove the silicons sealant and be careful not to spill any oil on the contact surface of the transmission case and extension housing.

114. Clean the contact surface of the transmission case and the extension housing, and the bolt holes.

NOTE:



Completely remove sealant and oil with isoproply alcohol (IPA) or similar.

115. Apply sealant to the extension housing as shown in the figure.

NOTE:



Spread sealant over the contact surface.

116. Install the extension housing and transmission case.

Fig. 352: Identifying Sealant Application Area On Extension Housing

117. Temporarily tighten the bolts by hand as shown in the figure.

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Fig. 353: Locating Bolts On Transmission Case

TRANSMISSION CASE BOLTS REFERENCE

Bolt number Bolt size Length (measured from below the head) (mm {in}}

A M10-1.5

35 {1.38}

B M 10-1.5

45 {1.77}

NOTE:



Do not apply sealant to the transmission case.

The characters shown in the figure indicate the bolt type.

118. Tighten the bolts.

Tightening torque

26.5-41.2 N.m {2.71-4.20 kgf.m, 19.6-30.3 ft.lbf}

119. .Assemble a new oil seal to the extension housing in the position shown in the figure using the SST and a hammer.

CAUTION:



Do not damage the oil seal.

Do not damage the extension housing.

120. Apply grease to the oil seal lip.

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Fig. 354: Position For Installing Oil Seal To Extension Housing

121. Using the SST and a hammer, install the new extension housing shroud to the extension housing as shown in the figure.

CAUTION:



Do not damage the oil seal.

Do not damage the extension housing.

Do not damage the extension housing shroud.

Fig. 355: Position For Installing Extension Housing Shroud To

Extension Housing

122. Using a hammer and slab of wood, install the new extension dust deflector to the extension housing as shown in the figure.

CAUTION:



Do not damage extension housing.

Do not damage extension dust deflector.

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Fig. 356: Position For Installing Extension Dust Deflector

123. Temporarily tighten the bolts A and new bolts B, C by hand as shown in the figure.

Fig. 357: Identifying Bolts

BOLTS REFERENCE CHART

Bolt number Bolt size Length (measured from below the head) (mm {in}}

A M10-1.5

35 {1.38}

M 10-1.5

M10-1.75

35 {1.38}

38 {1.50}

124. Tighten the bolts.

Tightening torque

A, B: 26.5-41.2 N.m {2.71-4.20 kgf.m, 19.6-30.3 ft.lbf}

C: 47.0-66.6 N.m {4.80-6.79 kgf.m, 34.7-49.1 ft.lbf}

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125. Turn the manual shaft fully to the extension housing side and turn it back two steps so that the N position is selected.

126. Install the TR switch and temporarily tighten the new TR switch installation bolt.

CAUTION:



If the TR switch is not adjusted correctly, adjust it correctly, otherwise the AT may not operate normally.

Fig. 358: Identifying TR Switch Positions

127. Verify that the scribed line on the TR switch and the manual shaft notch are aligned.

Fig. 359: Identifying TR Switch And Manual Shaft Notch Align Position

128. Install the washer, lock washer and nut.

Tightening torque

5.9-7.8 N.m {61-79 kgf.cm, 53-69 in.lbf}

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Fig. 360: Identifying Washer, Lock Washer And Nut

129. Using a flathead screwdriver, bend the tab of lock washer.

130. Tighten the TR switch installation bolt.

Tightening torque

9.8-15.7 N.m {1.0-1.6 kgf.m, 7.3-11.6 ft.lbf}

Fig. 361: Bending Tab Of Lock Washer Using Flathead Screwdriver

131. Install the VSS.

Tightening torque

3.9-6.9 N.m {40-70 kgf.cm, 35-61 in.lbf}

CAUTION:



Do not damage the VSS.

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132. Install the turbine sensor.

Tightening torque

3.9-6.9 N.m {40-70 kgf.cm, 35-61 in.lbf}

CAUTION:



Fig. 362: Identifying VSS

Do not damage the turbine sensor.

133. Install the breather tube.

Tightening torque

3.9-6.9 N.m {40-70 kgf.cm, 35-61 in.lbf}

CAUTION:



Fig. 363: Identifying Turbine Sensor

Do not damage the breather tube.

134. Install the breather pipe.

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Fig. 364: Identifying Breather Tube And Pipe

135. Using a flathead screwdriver, position the drive gear on the oil pump component in the center. Then install the torque converter component to the transmission.

CAUTION:



Do not damage the oil seal.

Do not drop the torque converter.

Fig. 365: Identifying Torque Converter

136. 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 (between the end of the torque converter and the end of the converter housing)

26.2 mm {1.0 in}

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Fig. 366: Identifying Distance A

137. Clean the drain plug.

CAUTION:



Install the drain plug being careful of the drain plug gasket direction.

138. Install the new drain plug gasket and drain plug to the oil pan.

Tightening torque

17.5-22.5 N.m {1.8-2.2 kgf.m, 13.0-16.5 ft.lbf}

Fig. 367: Identifying Oil Pan Drain Plug Gasket And Drain Plug

05-50 TECHNICAL DATA

TRANSMISSION TECHNICAL DATA

Item

Pump housing bushing inner diameter

Oil pump shaft bushing inner diameter

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Specification

38.113-38.138 mm {1.50051-1.50150 in}

21.501-21.527 mm {0.846496-0.847520

2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

Oil pump gear outer standard clearance

Oil pump gear inner standard clearance

Oil pump gear side standard clearance

C1, C4 clutch return spring free length

C2 clutch return spring free length

C3 clutch return spring free length

Input shaft component bushing inner diameter

Clutch hub bushing inner diameter in}

0.10-0.17 mm {0.004-0.006 in}

0.07-0.15 mm {0.0028-0.0059 in}

0.02-0.04 mm {0.0008-0.0015 in}

Standard: 26.29 mm {1.04 in}

Standard: 20.02 mm {0.79 in}

Standard: 21.03 mm {0.83 in}

18.000-18.025 mm {0.7087-0.7096 in}

Front side: 23.037-23.062 mm

{0.90697-0.90795 in}

Rear side: 23.037-23.062 mm

{0.90697-0.90795 in}

Clutch hub component bushing inner diameter

B3 brake return spring free length

B1 brake return spring free length

Front planetary ring gear bushing inner diameter

Front planetary gear component bushing inner diameter

Rear planetary gear component bushing inner diameter

B2 brake return spring free length

B4 brake return spring free length

Input shaft end play

Distance A (between the end of the torque converter and the end of the converter housing)

Front side: 33.312-33.337 mm

{1.31150-1.31248 in}

Rear side: 33.312-33.337 mm

{1.31150-1.31248 in}

Standard: 15.72 mm {0.62 in}

Standard: 17.05 mm {0.67 in}

46.038-46.063 mm {1.81252-1.81350 in}

48.755-48.780 mm {1.91949-1.92047 in}

18.000-18.025 mm {0.7087-0.7096 in}

Standard: 22.66 mm {0.89 in}

Standard: 13.84 mm {0.54 in}

0.35-1.05 mm {0.014-0.041 in}

26.2 mm {1.0 in}

05-60 SERVICE TOOLS

TRANSMISSION SST

49 S019 006

Oil seal installer

49 G030 797

Handle

49 B025 001

Body

Microsoft

49 W027 003

Support block

49 HD64 377

Attachment

49 N019 002

Compressor

2007 Mazda MX-5 Miata Sport

2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8

49 H019 001

Attachment

49 HD64 376

Body

49 N019 003

Extension

49 T019 003

Body

49 G033 102

Handle

49 N019 004

Attachment

49 N019 005

Attachment

49 T019 014

Body

49 G019 027

Attachment

49 G019 029

Nut

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2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

2007 ACCESSORIES & BODY, CAB

Body Panels - MX-5 Miata

BODY PANELS LOCATION INDEX

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 1: Identifying Location Of Body Panel Components

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

FUEL-FILLER LID REMOVAL/INSTALLATION

1. Remove the bolts.

2. Remove the fuel-filler lid.

3. Install in the reverse order of removal.

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

Fig. 2: Removing Fuel-Filler Lid (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

FUEL-FILLER LID ADJUSTMENT

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

2. Loosen the fuel-filler lid installation bolts, and adjust the fuel-filler lid.

Standard clearance a.

1.7-3.7 mm {0.07-0.14 in} b.

-0.5 -1.5 mm {-0.02-0.05 in} c.

-1.0-1.0 mm {0.04-0.03 in} d.

-0.75-1.25 mm {-0.03-0.04 in}

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3. Tighten the bolts.

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 3: Identifying Gap & Height Difference Between Fuel-Filler Lid & Body

Courtesy of MAZDA MOTORS CORP.

FRONT BUMPER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Disconnect the front fog light connectors for vehicles with front fog lights.

3. Disconnect the side marker light connectors.

4. Remove in the order indicated in Fig. 4 .

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 4: Removing/Installing Front Bumper (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

6. Adjust the front fog light aiming for vehicles with the front fog lights. (See FRONT FOG LIGHT

AIMING .)

FRONT BUMPER DISASSEMBLY/ASSEMBLY

1. To disassemble the front bumper, remove the following parts:

1. Front fog lights (Vehicles with the front fog lights) (See FRONT FOG LIGHT

REMOVAL/INSTALLATION .)

2. Front side marker light. (See FRONT SIDE MARKER LIGHT

REMOVAL/INSTALLATION .)

2. Disassemble in the order indicated in Fig. 5 .

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 5: Disassembling/Assembling Front Bumper

Courtesy of MAZDA MOTORS CORP.

3. Assemble in the reverse order of disassembly.

FRONT BUMPER REINFORCEMENT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

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

3. Remove the front combination light. (See FRONT COMBINATION LIGHT

REMOVAL/INSTALLATION .)

4. Remove the fresh air duct. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

5. Remove the horn. (See HORN REMOVAL/INSTALLATION .)

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

6. Remove in the order indicated in Fig. 6 .

Fig. 6: Removing/Installing Front Bumper Reinforcement (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

7. Install in the reverse order of removal.

REAR BUMPER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)

3. Remove the partition board. (See PARTITION BOARD REMOVAL/INSTALLATION .)

4. Remove the trunk side trim. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

5. Remove the rear combination lights. (See REAR COMBINATION LIGHT

REMOVAL/INSTALLATION .)

6. Remove the screws.

7. Splash shield, detach tabs A, and then remove the splash shield.

Fig. 7: Removing Splash Shield

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

8. Remove in the order indicated in the table.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 8: Removing Rear Bumper

Courtesy of MAZDA MOTORS CORP.

9. Install in the reverse order of removal.

REAR BUMPER REMOVAL NOTE

1. Pull the rear bumper ends (wheel arch) outward to detach from the bumper slider.

CAUTION:



When detaching the rear bumper from the bumper slider, the rear bumper could fall and be damaged. Secure the rear bumper so that it does not fall.

Fig. 9: Pulling Rear Bumper Ends (Wheel Arch) Outward From Bumper Slider

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

REAR BUMPER INSTALLATION NOTE

1. Spread the rear bumper ends (wheel arches) apart.

2. Attach the rear bumper to the body.

3. Press the rear bumper connecting area into the body to engage with the bumper slider.

REFLECTOR REMOVAL NOTE

1. Lift the reflector up in the direction of the arrow, then unhook it from rear bumper.

Fig. 10: Identifying Reflector

Courtesy of MAZDA MOTORS CORP.

REAR BUMPER REINFORCEMENT REMOVAL/INSTALLATION

1. Remove the following parts:

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Trunk end trim (See TRUNK END TRIM REMOVAL/INSTALLATION .)

3. Partition board. (See PARTITION BOARD REMOVAL/INSTALLATION .)

4. Trunk side trim. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

5. Rear combination lights. (See REAR COMBINATION LIGHT

REMOVAL/INSTALLATION .)

6. Rear bumper (See REAR BUMPER REMOVAL/INSTALLATION .)

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

2. Remove the nuts, then remove the rear bumper reinforcement.

3. Install in the reverse order of removal.

Fig. 11: Removing Rear Bumper Reinforcement (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

FRONT FENDER PANEL REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

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

3. Remove the front combination lights. (See FRONT COMBINATION LIGHT

REMOVAL/INSTALLATION .)

4. Remove the side step molding (See SIDE STEP MOLDING REMOVAL .) (See SIDE STEP

MOLDING INSTALLATION .)

5. Remove in the order indicated in Fig. 12 .

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 12: Removing/Installing Front Fender Panel (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

HOOD REMOVAL/INSTALLATION

WARNING:



Removing the hood without proper support can be dangerous. The

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata hood may fall and injure you. Always perform the following procedure with at least another person.

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. To remove the hood hinge, remove the following parts:

1. Front bumper (See FRONT BUMPER REMOVAL/INSTALLATION .)

2. Front combination lights (See FRONT COMBINATION LIGHT

REMOVAL/INSTALLATION .)

3. Side step molding (See SIDE STEP MOLDING REMOVAL .) (See SIDE STEP MOLDING

INSTALLATION .)

4. Front fender panel (See FRONT FENDER PANEL REMOVAL/INSTALLATION .)

3. Remove in the order indicated in Fig. 13 .

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 13: Removing/Installing Hood (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

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

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

HOOD ADJUSTMENT

GAP ADJUSTMENT

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the following parts:

1. Front bumper (See FRONT BUMPER REMOVAL/INSTALLATION .)

2. Front combination lights (See FRONT COMBINATION LIGHT

REMOVAL/INSTALLATION .)

3. Side step molding (See SIDE STEP MOLDING REMOVAL .) (See SIDE STEP MOLDING

INSTALLATION .)

4. Front fender panel (See FRONT FENDER PANEL REMOVAL/INSTALLATION .)

3. Loosen the hood hinge installation bolts and adjust the hood.

4. Tighten the bolts.

Fig. 14: Adjusting Hood Hinge

Courtesy of MAZDA MOTORS CORP.

5. Verify that the gap between the hood and the body is within the specification.

Standard clearance a.

3.5-6.5 mm {0.14-0.25 in}

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata b.

3.0-5.0 mm {0.12-0.19 in}

Fig. 15: Identifying Gap Between Hood & Body

Courtesy of MAZDA MOTORS CORP.

HEIGHT DIFFERENCE ADJUSTMENT

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

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 16: Turning Stop Rubber To Adjust Height Of Hood

Courtesy of MAZDA MOTORS CORP.

2. Verify that the height difference between the hood and the body is within the specification.

Standard clearance a.

-1.0-2.0 mm {-0.04-0.07 in} b.

-1.5-1.5 mm {-0.06-0.05 in} c.

-0.5-1.5 mm {-0.02-0.05 in}

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 17: Identifying Height Difference Between Hood & Body

Courtesy of MAZDA MOTORS CORP.

TRUNK LID REMOVAL/INSTALLATION

WARNING:



Removing the stay damper without supporting the trunk lid can be dangerous. The trunk lid may fall and injure you. Be sure to open the trunk lid completely and support it securely before removing the stay damper.

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Disconnect the trunk lid wiring harness connector, then take the trunk lid harness out from the vehicle.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 18: Disconnecting Trunk Lid Wiring Harness Connector

Courtesy of MAZDA MOTORS CORP.

3. Remove the clips that secure the trunk lid wiring harness.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 19: Removing Trunk Lid Wiring Harness Clips

Courtesy of MAZDA MOTORS CORP.

4. Pry off the stay damper band using a flathead screwdriver.

5. Pry out the connecting part of the stay damper and the hinge with a flathead screwdriver to disconnect them, then remove the stay damper.

Fig. 20: Prying Out Connecting Part Of Stay Damper & Hinge With Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

6. Remove nuts A, then remove the trunk lid.

7. Remove nuts B, then remove the trunk lid hinge.

8. Install in the reverse order of removal.

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

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 21: Removing Trunk Lid Hinge (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

TRUNK LID ADJUSTMENT

1. Measure the gap and height difference between the trunk lid and the body.

2. Loosen the trunk lid hinge installation nuts or the trunk lid lock striker installation screws, and adjust the trunk lid.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 22: Adjusting Trunk Lid

Courtesy of MAZDA MOTORS CORP.

Standard clearance a.

4.5-7.5 mm {0.18-0.29 in} (Except Power Retractable Hardtop) 5.5-8.5 mm {0.22-0.33 in}

(Power Retractable Hardtop) b.

5.0-9.0 mm {0.20-0.35 in} c.

3.0-6.0 mm {0.12-0.23 in} (Except Power Retractable Hardtop) 4.0-8.0 mm {0.16-0.31 in}

(Power Retractable Hardtop) d.

3.0-5.0 mm {0.12-0.19 in}

3. Tighten the nuts.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 23: Identifying Trunk Lid Standard Clearance

Courtesy of MAZDA MOTORS CORP.

STAY DAMPER DISPOSAL

NOTE:



The gas in the stay damper is colorless, odorless, and non-toxic.

1. Wear protective eye wear.

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

2. Lay the stay damper flat.

3. Saw 2-3 mm {0.08-0.11 in} into the stay damper using a hacksaw, and allow the gas to escape from the stay damper.

4. Verify that the gas has escaped from the stay damper.

5. Discard the stay damper.

Fig. 24: Cutting Into Stay Damper Using Hacksaw

Courtesy of MAZDA MOTORS CORP.

SEAT BACK CROSSMEMBER ASSEMBLY REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

3. Remove the quarter trim. (See QUARTER TRIM REMOVAL/INSTALLATION .)

4. Remove the scuff plate. (See SCUFF PLATE REMOVAL/INSTALLATION .)

5. Remove the tire house trim. (See TIRE HOUSE TRIM REMOVAL/INSTALLATION .)

6. Remove the aeroboard. (See AEROBOARD REMOVAL/INSTALLATION .)

7. Remove the seat back bar garnish. (See SEAT BACK BAR GARNISH

REMOVAL/INSTALLATION .)

8. Remove the open hook lever. (See BACK TRIM REMOVAL/INSTALLATION .)

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

9. Remove the back trim. (See BACK TRIM REMOVAL/INSTALLATION .)

10. Remove the open hook. (See OPEN HOOK REMOVAL/INSTALLATION[ADVANCED KEYLESS

SYSTEM] .)

11. Remove the rear speaker. (See REAR SPEAKER REMOVAL/INSTALLATION .)

12. Remove the seat belt set plate. (See SEAT BELT REMOVAL/INSTALLATION .)

13. Remove the clips, then remove the speaker wiring harness.

14. Remove in the order indicated in Fig. 25 .

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2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

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2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata

Fig. 25: Removing/Installing Seat Back Crossmember Assembly (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

15. Half open the power retractable hardtop

CAUTION: If the seat back crossmember component is removed with the power retractable hardtop fully opened, it may contact the middle roof and damage the roof. Half open the power retractable hardtop before removing the seat back crossmember component.

Fig. 26: Power Retractable Hardtop

16. Remove the clips, then remove the speaker wiring harness.

17. Remove in the order indicated in the table.

18. Install in the reverse order of removal.

SEAT BACK CROSSMEMBER ASSEMBLY INSTALLATION NOTE

1. After temporarily tightening all of the bolts and nuts, tighten them to the specified torque. Tightening

Torque: 20.0-28.0 N.m {2.04-2.85 kgf.m, 14.7-20.6 lb.ft}

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2007 BRAKES Conventional Brake System - MX-5 Miata

2007 BRAKES

Conventional Brake System - MX-5 Miata

CONVENTIONAL BRAKE SYSTEM LOCATION INDEX

Fig. 1: Identifying Location Of Conventional Brake System Components

Courtesy of MAZDA MOTORS CORP.

AIR BLEEDING

CAUTION:



Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately.

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

NOTE:



Keep the fluid level in the reserve tank at 3/4 full or more during the air bleeding.

Begin air bleeding with the master cylinder and then continue with the brake caliper that is furthest away from the master cylinder. Finish by bleeding air from the master cylinder again.

Brake fluid type

SAE J1703, FMVSS 116 DOT-3

1. Remove the bleeder cap from the brake caliper, and connect a vinyl tube to the bleeder screw.

2. Place the other end of the vinyl tube in a clear container, and fill the container with fluid during air bleeding.

3. Working with two people, one should depress the brake pedal a few times and then depress and hold the pedal down.

4. While the brake pedal is being held down, the other person should loosen the bleeder screw using the

SST , and bleed any fluid containing air bubbles. Once completed, tighten the bleeder screw.

Tightening torque

Front: 6.9-9.8 N.m {71-99 Kgf.cm, 62-86 in.lbf}

Rear: 6.0-8.0 N.m {62-81 Kgf.cm, 54-70 in.lbf}

5. Repeat Steps 3 and 4 until no air bubbles are seen.

6. Perform air bleeding as described in the above procedures for all brake calipers.

7. After air bleeding, inspect the following:



Brake operation

Fluid leakage



Fluid level

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 2: Brake Bleeding Procedure

Courtesy of MAZDA MOTORS CORP.

VACUUM LINE INSPECTION

1. Remove the vacuum hose between the power brake unit and the intake manifold using pliers.

2. Verify that air can be blown from the power brake unit side of the vacuum hose towards the intake manifold side, and that air cannot be blown in the opposite direction.

 If there is any malfunction of the inner check valve, replace it together with the vacuum hose as a single unit.

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2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 3: Inspecting Vacuum Line Check Valve

Courtesy of MAZDA MOTORS CORP.

BRAKE PEDAL INSPECTION

BRAKE PEDAL HEIGHT INSPECTION

1. Measure the distance from the center of the upper surface of the pedal pad to the insulator and verify that it is as specified.



If not within the specification, adjust the pedal height.

Brake pedal height (reference value) 167 mm {6.57 in}

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 4: Inspecting Brake Pedal Height

Courtesy of MAZDA MOTORS CORP.

BRAKE PEDAL HEIGHT ADJUSTMENT

CAUTION:



The brake switch may not operate normally after adjusting the pedal height. Whenever adjusting the pedal height, replace the brake switch with a new one.

The interlock cable may not operate normally after adjusting the pedal height. Whenever adjusting the pedal height, refer to the interlock cable installation note. (See INTERLOCK CABLE

INSTALLATION NOTE .)

1. Loosen the locknut and turn the push rod to adjust the pedal height.

2. Tighten the locknut.

Tightening torque

20.4-30.6 N.m {2.09-3.12 Kgf.m, 15.0-22.5 ft.lbf}

3. After adjustment, inspect the pedal play.

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2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 5: Adjusting Brake Pedal Height

Courtesy of MAZDA MOTORS CORP.

BRAKE PEDAL PLAY INSPECTION

1. Depress the pedal several times to release the vacuum in the power brake unit.

2. Gently depress the pedal by hand, and measure the pedal play.



If not within the specification, inspect the wear of the clevis pin and replace it if there is any malfunction.

Brake pedal play

2-5 mm {0.08-0.19 in}

NOTE:



If there is no malfunction in the clevis pin, there is a possibility that the power brake unit has some malfunction. Verify that there are no malfunctions, and replace it if necessary.

PEDAL-TO-FLOOR CLEARANCE INSPECTION

1. Start the engine and depress the pedal with a pedal force of 147 N {15.0 kgf, 33.0 lbf} .

2. Measure the distance between the pedal pad center and the insulator, and verify that it is as specified.



If the pedal-to-floor clearance is less than the specification, check for air in the brake system.

Brake pedal-to-floor clearance (Brake pedal when depressed at 147 N {15.0 kgf, 33.0 lbf}

106.9 mm {4.209 in} or more

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 6: Inspecting Pedal-To-Floor Clearance

Courtesy of MAZDA MOTORS CORP.

BRAKE PEDAL REMOVAL/INSTALLATION

CAUTION:



The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch connector is connected after the brake switch has been properly installed. If the brake switch is not properly installed or the connector is connected before installation, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake switch is properly installed before connecting the connector.

Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again. Therefore, replace the switch with a new

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

 one when replacing the power brake unit or the pedal, or performing any procedure that changes the pedal stroke.

When replacing the brake pedal (AT), it is possible that the installation of the interlock cable could become defective. Always refer to the interlock cable installation note when replacing the brake pedal. (See INTERLOCK CABLE INSTALLATION NOTE .)

NOTE:



When the brake switch connector is connected to the brake switch, the clearance between the pedal and the brake switch is adjusted automatically. However, this mechanism will only function one time.

1. Remove in the order indicated in Fig. 7 .

2. Install in the reverse order of removal.

Fig. 7: Identifying Brake Pedal Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

BRAKE PEDAL REMOVAL NOTE

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

1. Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.

2. Remove the brake pedal.

BRAKE SWITCH INSTALLATION NOTE

1. Install the new brake switch to the brake pedal (MT) or the interlock cable (AT), and secure it by turning it clockwise 45° (AT) or counterclockwise 45° (MT).

Fig. 8: Identifying Brake Switch Installing Angle

Courtesy of MAZDA MOTORS CORP.

BRAKE SWITCH CONNECTOR INSTALLATION NOTE

1. Inspect the brake pedal. (See BRAKE PEDAL INSPECTION .)

2. With the brake pedal in its original position, install the brake switch to the brake switch connector.

BRAKE SWITCH INSPECTION

CAUTION:



If the brake switch is removed from the brake pedal or the interlock unit, its proper functioning cannot be guaranteed when reinstalled.

Therefore, inspect the brake switch with it still installed, or replace

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata the brake switch if it is removed.

1. Verify continuity as indicated in Fig. 9 .



If not as indicated in Fig. 9 replace the brake switch.

Fig. 9: Terminal Continuity Reference Table

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 10: Identifying Brake Switch Connector

Courtesy of MAZDA MOTORS CORP.

MASTER CYLINDER REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 11 .

2. Install in the reverse order of removal.

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Fig. 11: Identifying Master Cylinder Removing/Installing Steps (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

MASTER CYLINDER INSTALLATION NOTE

CAUTION:



If the master cylinder is installed at an angle, the master cylinder piston may push against the push rod retainer of the power brake unit causing poor air bleeding, brake drag, or other malfunctions. Be sure to install the master cylinder at a perpendicular angle to the power brake unit.

1. Install the SST to the power brake unit and tighten to the specified torque.

Tightening torque

13.7-21.6 N.m {1.4-2.2 kgf.m, 10.2-15.9 ft.lbf}

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Fig. 12: Identifying Special Tool To Power Brake Unit

Courtesy of MAZDA MOTORS CORP.

2. Apply a vacuum of 66.7 kPa {500 mmHg, 19.7 inHg} to the power brake unit using a vacuum gauge.

NOTE:



Use any commercially available vacuum gauge.

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2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 13: Applying Vacuum To Power Brake Unit Using Vacuum Gauge

Courtesy of MAZDA MOTORS CORP.

3. Using calipers, measure dimension L as shown in Fig. 14 .

Standard L dimension

30.4-30.6 mm {1.197-1.204 in}

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2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 14: Measuring Dimension L Using Calipers

Courtesy of MAZDA MOTORS CORP.

4. If dimension L is not within the standard, remove the SST (49 G043 001) and, while stopping the push rod rotation with the SST (49 E043 003A), adjust the push rod length with the SST (49 B043 004).

5. Switch the SSTs and remeasure dimension L.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 15: Adjusting Pushrod Length

Courtesy of MAZDA MOTORS CORP.

6. Install the master cylinder to the power brake unit.

BRAKE FLUID LEVEL SENSOR INSPECTION

1. Disconnect the brake fluid level sensor connector from the master cylinder.

2. Inspect for continuity according to fluid level between the brake fluid level sensor terminals.



If not as indicated in Fig. 16 , replace the reserve tank.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 16: Brake Fluid Sensor Terminal Continuity Table

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 17: Identifying Brake Fluid Level Sensor Connector

Courtesy of MAZDA MOTORS CORP.

POWER BRAKE UNIT INSPECTION

NOTE:



The following inspection methods are simple inspection methods to judge the function of the power brake unit.

If there is any malfunction in the power brake unit, replace the power brake unit as a single unit.

WITHOUT USING SST

Operation Inspection

1. With the engine stopped, depress the pedal several times.

2. With the pedal depressed, start the engine.

3. If the pedal moves down slightly immediately after starting the engine, the unit is normal.

Vacuum Function Inspection

1. Start the engine.

2. After driving the vehicle for 1-2 min , stop the engine.

3. Depress the pedal with normal force.

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



If a problem is found, inspect for damage to or improper installation of the check valve and vacuum hose. After repairing, inspect again.

Vacuum Loss Function Inspection

1. Start the engine.

2. Depress the pedal with normal force.

3. With the pedal depressed, stop the engine.

4. Maintain the pedal depressed for approx. 30 s .

5. If the pedal height does not change during this time, the unit is normal.

USING SST

Pre-inspection Preparation

1. Install the SST (49 N043 001) in the orientation shown in Fig. 18 , (with DSC)

NOTE:



Install the SST (49 N043 001) to the master cylinder using a commercially available flare nut wrench.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata



Flare nut across flat: 12 mm {0.47 in}

2. Connect the SSTs , a vacuum gauge and a pedal force gauge to the master cylinder and bleed the air from the SSTs and the brake line. (Bleed the air from the SSTs through air bleeding valve A.)

Fig. 18: Installing SST (49 N043 001)

Courtesy of MAZDA MOTORS CORP.

WITHOUT DSC

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 19: Inspecting Vacuum Loss Function - Without DSC

Courtesy of MAZDA MOTORS CORP.

WITH DSC

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 20: Inspecting Vacuum Loss Function - With DSC

Courtesy of MAZDA MOTORS CORP.

Checking For Vacuum Loss (Loaded Condition)

1. Start the engine.

2. Depress the brake pedal with a force of 200 N {20.4 kgf, 44.9 lbf} .

3. With the brake pedal depressed, turn off the engine when the vacuum gauge reaches 68 kPa {510 mmHg,

20.1 inHg} .

4. Within 15 s right after stopping the engine, measure the lowest amount of vacuum.

5. If the lowest amount is 3.3 kPa {25 mmHg, 1.0 inHg} or less, the system is normal.

Lack of Hydraulic Pressure Inspection

1. With the engine stopped and the vacuum amount at 0 kPa {0 mmHg, 0 inHg} if the pedal force and fluid pressure correlation is within the specification, the system is normal.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Power Brake Unit Fluid Pressure

POWER BRAKE UNIT FLUID PRESSURE SPECIFICATIONS

Vacuum amount at o kPa {0 mmHg, 0 inHg}

Pedal force (N {kgf, lbf})

200 {20.4, 44.9}

Fluid pressure (kPa {kgf/cm

, psi})

620 {6.33, 90.0} or more

Hydraulic Pressure Inspection

1. Start the engine and when the vacuum amount reaches 66.7 kPa {500 mmHg, 19.7 inHg} , depress the brake pedal.

2. At this time, apply the indicated pedal force and if the fluid pressure is within the specification, the unit is normal.

Power Brake Unit Fluid Pressure

POWER BRAKE UNIT FLUID PRESSURE SPECIFICATIONS

Vacuum amount at 66.7 kPa {500 mmHg, 19.7 inHg}

Pedal force (N {kgf, lbf})

200 {20.4, 44.9}

Fluid pressure (kPa {kgf/cm

, psi})

6,340 {64.65, 919.6} or more

POWER BRAKE UNIT REMOVAL/INSTALLATION

1. Remove the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION .)

2. Remove the clutch pipe. (MT)

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 21: Removing Clutch Pipe (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

3. Remove the nut shown in Fig. 22 , then remove the cooler hose (LO) bracket from the vehicle.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 22: Removing Cooler Hose (LO) Bracket From Vehicle

Courtesy of MAZDA MOTORS CORP.

4. Remove in the order indicated in Fig. 23 .

Fig. 23: Identifying Power Brake Unit (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

5. Install in the reverse order of removal.

6. After installation, perform brake pedal inspection. (See BRAKE PEDAL INSPECTION .)

DUAL PROPORTIONING VALVE REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 24 .

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 24: Dual Proportioning Valve Removing/Installing Steps (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

2. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

BRAKE PIPE REMOVAL NOTE

1. Place an alignment mark on the brake pipe and dual proportioning valve.

Fig. 25: Placing Alignment Mark On Brake Pipe & Dual Proportioning Valve

Courtesy of MAZDA MOTORS CORP.

DUAL PROPORTIONING VALVE INSTALLATION NOTE

1. Install the dual proportioning valve so that the R marks faces the upper side of the vehicle.

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Fig. 26: Identifying Dual Proportioning Valve R Marks

Courtesy of MAZDA MOTORS CORP.

BRAKE PIPE INSTALLATION NOTE

1. Align the marks made before removal and install the brake pipe to the dual proportioning valve referring to Fig. 27 .

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Fig. 27: Aligning Brake Pipe To Dual Proportioning Valve Marks

Courtesy of MAZDA MOTORS CORP.

DUAL PROPORTIONING VALVE INSPECTION

1. Connect the SSTs to the brake pipes as shown in Fig. 28 .

2. Bleed the air from the brake system and the SSTs . (Bleed the air from the SSTs through air bleeding valve A.)

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Fig. 28: Identifying Special Tools

Courtesy of MAZDA MOTORS CORP.

3. Measure the fluid pressure of the master cylinder and the rear brake.



If not within the specification, replace the dual proportioning valve.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 29: Dual Proportioning Valve Fluid Pressure Graph

Courtesy of MAZDA MOTORS CORP.

DUAL PROPORTIONING VALVE FLUID PRESSURE SPECIFICATIONS

MASTER CYLINDER PRESSURE (kPa

{kgf/cm

, psi})

REAR BRAKE PRESSURE (kPa {kgf/cm

, psi})

A: 3,430 {34.98, 497.5}

B: 5,880 {59.96, 852.8}

A': 3,130 {31.92, 453.9} - 3,730 {38.04, 540.9}

B': 4,010 {40.9, 581.7} - 4,810 {49.05, 697.6}

FRONT BRAKE (DISC) INSPECTION

BRAKE JUDDER REPAIR HINTS

Description

1. Brake judder concern has the following 3 characteristics:

Steering Wheel Vibration

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

Floor Vibration

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

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

Brake Pedal Vibration

1. When applying brakes, a pulsating force tries to push the brake pad back. 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 The Disc Plate, The Thickness Of The Disc Plate Is Uneven

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, 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 approx. 1,000°C

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

Due To Corrosion, The Thickness And Friction Coefficient Of Disc Plate Change

1. If a vehicle is parked in 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

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 30: Front Brake Inspection & Repair Flow Procedure

Courtesy of MAZDA MOTORS CORP.

Lateral Runout Inspection

1. To secure the disc plate and the hub, insert the washer (thickness 10 mm {0.39 in} , inner diameter more than 12 mm {0.47 in} ) between each hub bolt and the hub nut, then tighten all the hub nuts.

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 {0.12-0.28 in} from the disc plate edge.

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

Front disc plate runout limit

0.05 mm {0.002 in}

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 31: Measuring Front Disc Plate Runout

Courtesy of MAZDA MOTORS CORP.

Thickness Variation Inspection

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

2. Measure the points indicated in Fig. 32 using a caliper (micrometer).

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:



Do not exceed minimum disc plate thickness.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 32: Inspecting Disc Plate-To-Pad Friction Surface

Courtesy of MAZDA MOTORS CORP.

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.

Minimum front disc plate thickness

20 mm {0.79 in}

Minimum front disc plate thickness after machining using a brake lathe on-vehicle

20.8 mm {0.82 in}

Disc Pad Thickness Inspection

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

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

2. Remove the wheel and tires.

3. Verify the remaining thickness of the pads.

Minimum front disc pad thickness

2.0 mm {0.079 in} min.

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

Fig. 33: Inspecting Disc Pad Thickness

Courtesy of MAZDA MOTORS CORP.

FRONT BRAKE (DISC) REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 34 .

2. Install in the reverse order of removal.

3. After installation, depress the brake pedal a few times, then verify that the brakes do not drag.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 34: Identifying Front Brake (Disc) Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CALIPER INSTALLATION NOTE

1. Clean the exposed area of the piston.

2. Install the piston using the SST .

3. Install the caliper.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 35: Installing Piston Using Special Tool

Courtesy of MAZDA MOTORS CORP.

DISC PAD (FRONT) REPLACEMENT

1. Remove in the order indicated in Fig. 36 .

2. Install in the reverse order of removal.

3. After installation, depress the brake pedal a few times, then verify that the brakes do not drag.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 36: Identifying Disc Pad Components (Front) (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CALIPER (FRONT) DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in Fig. 37 .

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 37: Exploded View Of Caliper (Front) (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

PISTON DISASSEMBLY NOTE

CAUTION:



The piston could be damaged if blown out with great force. Blow the compressed air slowly to prevent the piston from suddenly popping out.

1. Insert a piece of wood in the caliper as shown in Fig. 38 , and then blow compressed air through the bleeder screw hole to remove the piston from the caliper body.

Fig. 38: Removing Piston From Caliper Body By Blowing Compressed Air Through Bleeder Screw

Hole

Courtesy of MAZDA MOTORS CORP.

REAR BRAKE (DISC) INSPECTION

BRAKE JUDDER REPAIR HINTS

Description

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

1. Brake judder concern has the following 3 characteristics:

Steering Wheel Vibration

1. Steering wheel vibrates in the rotation direction. 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 the brakes, the vehicle body shakes back and forth. The seriousness of the shaking is not influenced by vehicle speed.

Brake Pedal Vibration

1. When applying brakes, a pulsating force tries to push the brake pad back. 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 the disc plate, the thickness of the disc plate is uneven.

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, 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 approx. 1,000°C

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

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

1. If a vehicle is parked in 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

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 39: Rear Brake Inspection & Repair Flow Procedure

Courtesy of MAZDA MOTORS CORP.

Lateral Runout Inspection

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.

Rear disc plate runout limit

0.05 mm {0.002 in}

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 40: Measuring Rear Disc Plate Runout By Putting Dial Gauge On Friction Surface Of Disc

Plate

Courtesy of MAZDA MOTORS CORP.

Thickness Variation Inspection

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

2. Measure the points indicated in Fig. 41 using a caliper (micrometer).

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:



Do not exceed minimum disc plate thickness.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 41: Inspecting Disc Plate-To-Pad Friction Surface

Courtesy of MAZDA MOTORS CORP.

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.

Minimum rear disc plate thickness

8 mm {0.31 in}

Minimum rear disc plate thickness after machining using a brake lathe on-vehicle

8.8 mm {0.35 in}

Disc Pad Thickness Inspection

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

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

2. Remove the wheel and tires.

3. Verify the remaining thickness of the pads.

Minimum rear disc pad thickness

2.0 mm {0.079 in} min.

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

Fig. 42: Inspecting Disc Pad Thickness

Courtesy of MAZDA MOTORS CORP.

REAR BRAKE (DISC) REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 43 .

2. Install in the reverse order of removal.

3. After installation, depress the brake pedal a few times, and inspect the following.

 The disc pad projection is securely installed to the piston groove



Parking brake lever stroke



Brake drag

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 43: Identifying Rear Brake (Disc) Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

DISC PLATE REMOVAL NOTE

1. Mark the wheel hub and disc plate.

2. Remove the disc plate.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 44: Identifying Wheel Hub & Disc Plate Mark

Courtesy of MAZDA MOTORS CORP.

DISC PLATE INSTALLATION NOTE

1. Remove any rust or foreign material from the wheel hub and disc plate.

2. Align the marks made before removal and install the disc plate to the wheel hub.

CALIPER INSTALLATION NOTE

1. Clean the exposed area of the piston.

2. Rotate the piston clockwise slowly using the SST and push the piston completely until the piston grooves are in the position shown in Fig. 45 .

3. Install the caliper.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 45: Rotating Piston Clockwise Using SST

Courtesy of MAZDA MOTORS CORP.

PARKING BRAKE CABLE INSTALLATION NOTE

1. After installing the parking brake cable, verify that the operating lever returns to the stopper nut with the parking brake lever released.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 46: Identifying Stopper Nut And Operating Lever

Courtesy of MAZDA MOTORS CORP.

DISC PAD (REAR) REPLACEMENT

1. Remove in the order indicated in Fig. 47 .

2. Install in the reverse order of removal.

3. After installation, depress the brake pedal a few times, and inspect the following.



The disc pad projection is securely installed to the piston groove



Parking brake lever stroke



Brake drag

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 47: Identifying Disc Pad (Rear) Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CALIPER INSTALLATION NOTE

1. Clean the exposed area of the piston.

2. Rotate the piston clockwise slowly using the SST and push in the piston completely until the piston grooves are in the position shown in Fig. 48 .

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 48: Rotating Piston Clockwise Using SST

Courtesy of MAZDA MOTORS CORP.

3. Install the caliper.

CALIPER (REAR) DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in Fig. 49 .

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 49: Exploded View Of Caliper (Rear) (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

PISTON DISASSEMBLY NOTE

1. Rotate the piston counter-clockwise using the SST , remove the piston from the caliper body.

Fig. 50: Rotating Piston Counter-Clockwise Using SST

Courtesy of MAZDA MOTORS CORP.

DUST SEAL, PISTON ASSEMBLY NOTE

1. Assemble the dust seal to the piston.

2. Assemble the lip of the dust seal to the groove of the caliper body with the dust seal is assembled to the piston as shown in Fig. 51 .

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2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 51: Assembling Lip Of Dust Seal

Courtesy of MAZDA MOTORS CORP.

3. Rotate the piston clockwise using the SST slowly and push the piston inwards completely.

4. Verify that the dust seal is installed into the groove of the piston securely.

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2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 52: Rotating Piston Clockwise Using SST

Courtesy of MAZDA MOTORS CORP.

BRAKE HOSE (FRONT) REMOVAL/INSTALLATION

1. Remove in the order indicated in FIG.....

2. Install in the reverse order of removal.

3. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See AIR BLEEDING .)

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 53: Identifying Brake Hose (Front) Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

BRAKE HOSE (REAR) REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

3. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See AIR BLEEDING .)

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Conventional Brake System - MX-5 Miata

Fig. 54: Identifying Brake Hose (Rear) Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 GENERAL INFORMATION Brakes General Procedures - MX-5 Miata

2007 GENERAL INFORMATION

Brakes General Procedures - MX-5 Miata

GENERAL PROCEDURES (BRAKE)

WHEEL AND TIRE INSTALLATION

1. When installing the wheels and tires, tighten the wheel nuts in a criss-cross pattern to the following tightening torque.

Tightening torque

88-118 N.m {9.0-12.0 Kgf.m, 65.0-87.0 ft.lbf}

Fig. 1: Wheel Lug Nut Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

BRAKE LINES DISCONNECTION

2007 Mazda MX-5 Miata Sport

2007 GENERAL INFORMATION Brakes General Procedures - MX-5 Miata

1. If any brake line has been disconnected anytime during the procedures, add brake fluid, bleed the brakes, and inspect for leakage after the procedure has been completed.

CAUTION:



Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately.

BRAKE PIPE FLARE NUT TIGHTENING

1. Tighten the brake pipe flare nut using the SST (49 0259 770B) or any commercially available flare nut wrench.

CONNECTOR DISCONNECTION

1. Disconnect the negative battery cable before performing any work that requires handling of connectors.

(See BATTERY REMOVAL/INSTALLATION [LF] .)

ABS/DSC RELATED PARTS

1. Make sure that there are no DTCs in the ABS/DSC memory after working on ABS/DSC related parts. If there are any codes in the memory, clear them.

DSC RELATED PART SENSOR INITIALIZATION PROCEDURE

WARNING:



If the initialization procedure is not completed, the DSC will not operate properly and it might cause an unexpected accident.

Therefore, when replacing or removing the following parts, make sure to perform the initialization procedure to insure proper DSC operation.

1. When replacing or removing the following parts, perform the initialization procedure. (See COMBINED

SENSOR INITIALIZATION PROCEDURE .) (See STEERING ANGLE SENSOR

INITIALIZATION PROCEDURE .) (See STEERING ANGLE SIGNAL INITIALIZATION

PROCEDURE .)



DSC HU/CM



Combined sensor



Steering angle sensor

Microsoft

2007 ELECTRICAL Charging System - MX-5 Miata

2007 ELECTRICAL

Charging System - MX-5 Miata

CHARGING SYSTEM LOCATION INDEX [LF]

Fig. 1: Identifying Location Of Charging System Components

Courtesy of MAZDA MOTORS CORP.

BATTERY REMOVAL/INSTALLATION [LF]

WARNING:



For vehicles with DSC, if the negative battery cable is disconnected, the stored initial position of the steering angle sensor will be cleared and the DSC will not operate properly, making the vehicle unsafe to drive. Perform the steering angle sensor initialization procedure after connecting the negative battery cable.

1. Remove in the order indicated in Fig. 2 .

2. Install in the reverse order of removal.

3. Perform the steering angle sensor initialization procedure. (See STEERING ANGLE SENSOR

INITIALIZATION PROCEDURE .)

2007 Mazda MX-5 Miata Sport

2007 ELECTRICAL Charging System - MX-5 Miata

Fig. 2: Identifying Removal Order Of Battery (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

BATTERY DUCT REMOVAL NOTE

1. Remove the under cover.

2. Remove the battery duct.

NEGATIVE BATTERY CABLE INSTALLATION NOTE

1. When connecting the negative battery cable to the battery, connect the negative battery cable and the ground cable as shown in Fig. 3 .

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ELECTRICAL Charging System - MX-5 Miata

Fig. 3: Connecting Negative Battery Cable

Courtesy of MAZDA MOTORS CORP.

BATTERY INSPECTION [LF]

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 SPECIFIC GRAVITY

1. Measure the electrolyte specific gravity using a hydrometer.



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

Battery electrolyte specific gravity [20°C {68°F}] 1.22-1.29

BATTERY VOLTAGE

1. Inspect the battery as follows:

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2007 Mazda MX-5 Miata Sport

2007 ELECTRICAL Charging System - MX-5 Miata

BATTERY INSPECTION TABLE

Step

1 Measure the battery positive voltage.

2 Quick charge for

Using the battery load tester, apply load current (see Battery load test current) and record battery voltage after 15 s.

Is voltage more than specification?

30 min.

Inspection

and recheck voltage.

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.

Less than

12.4 V

Replace the battery.

Yes Normal

Replace the battery.

Battery load test current

46B24L (36): 135 A

STANDARD SPECIFICATION

BATTERY STANDARD SPECIFICATION

Battery temp. (°C {°F})

4 {39}

10 (50}

16 (61}

21 {70}

Minimum voltage (V)

9.3

9.4

9.5

9.6

BACK-UP CURRENT

1. Verify that the ignition switch is off (key has been removed) and that all doors are closed.

2. Remove the battery cover.

3. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

4. Connect the tester between the negative battery terminal and negative battery cable, leave the battery undisturbed for 30 min.

, and then measure the back-up current.



If not within the specification, measure the back-up current while removing the fuses one by one from the inside of the main fuse block and the inside of the fuse block.

NOTE:



If the battery is not left undisturbed for 30 min., the tester will indicate a high value (approx. 300 mA).

If the key or any electrical accessory is operated within approx. 30 min. after the tester is connected, the battery must be left undisturbed for approx. 30 min. from that point.

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2007 Mazda MX-5 Miata Sport

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CAUTION:



Operating electrical loads while the back-up current is being measured can damage the tester.

NOTE:



For vehicles with the immobilizer system, the system periodically shifts synchronization of the security light flashing. Therefore, 45 mA

(0.1s) current is supplied when the security light is illuminated, and

25 mA (2s) current is supplied when the security light is not illuminated. In addition, the measuring instrument, which shows the average value, indicates around 30 mA.

Battery back-up current

Vehicles with immobilizer system: 25-45 Ma

Vehicles without immobilizer system: 30 mA or less

5. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.

BATTERY RECHARGING [LF]

WARNING:



Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch fire, and cause serious injury.

Remove the battery filler caps when recharging to prevent battery deformation or damage.

CAUTION:



Do not quick charge for more than 30 min. It will damage the battery.

1. Remove the battery and then place it in a pan of water.

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

Battery slow charge current

46B24L (36): 3.5-4.5 A

Battery quick charge current [30 min.]

46B24L (36): 25 A

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Fig. 4: Connecting Battery Charger To Battery

Courtesy of MAZDA MOTORS CORP.

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

GENERATOR REMOVAL/INSTALLATION [LF]

WARNING:



Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

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 negative cable before performing the following operation.

CAUTION:



The generator can be damaged by the heat from the exhaust

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ELECTRICAL Charging System - MX-5 Miata manifold. Make sure the generator duct is installed securely.

1. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the drive belt. (See DRIVE BELT REPLACEMENT [LF] .)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

Fig. 5: Identifying Removal Order Of Generator (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

GENERATOR INSTALLATION NOTE

1. Tighten bolt A temporarily.

2. Tighten bolt B, C to the specified tightening torque.

3. Tighten bolt A to the specified tightening torque.

GENERATOR INSPECTION [LF]

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CAUTION:



Do not apply direct battery positive voltage to the generator terminal

D, otherwise it could cause damage to the internal parts (power transistor) of the generator.

GENERATOR WARNING LIGHT

1. Verify that the battery is fully charged.

2. Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION [LF] .)

3. With the ignition switch turned to the ON position, verify that the generator warning light illuminates.



If it does not illuminate, inspect the generator warning light and the wiring harness.



If the generator warning light and the wiring harness are normal, inspect the PCM.

4. Verify that the generator warning light goes out after the engine is started.



If it does not go out, inspect if any one of the following DTCs in the on-board diagnostic system are displayed: P0112, P0113, P2502, P2503, P2504. (See DTC TABLE [LF] .)

GENERATOR

Voltage

1. Verify that the battery is fully charged.

2. Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION [LF] .)

3. Turn off all electrical loads.

4. Start the engine.

5. Verify that the generator rotates smoothly without any noise while the engine is running.



If there is any noise, find the cause and repair or replace the generator.

6. Measure the voltage at each terminal using a tester.

Generator standard voltage [IG-ON]

Terminal B: B+

Terminal P: Approx. 1 V or less

Terminal D: Approx. 0 V

Generator standard voltage [Idle, 20°C {68°F}]

Terminal B: 13-15 V

Terminal P: Approx. 3-8 V

Terminal D: Turn the electrical loads (headlights, blower motor, rear window defroster) on and verify that the voltage reading increases.

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Fig. 6: Identifying Ignition Switch Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Current

NOTE:



Since the charging current decreases rapidly after starting the engine, carry out the following procedure quickly, and read the maximum current value.

1. Verify that the battery is fully charged.

2. Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION [LF] .)

3. Disconnect the negative battery cable.

4. Connect a tester, which can read 120 A or more , between generator terminal B and the wiring harness.

5. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

6. Turn off all electrical loads.

7. Start the engine.

8. Increase engine speed to 2,500 rpm.

NOTE:



When the electrical load of the vehicle is low, the specified current

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2007 Mazda MX-5 Miata Sport

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 will not be verified although the generator is normal. In this case, increase the electrical load (by turning on the headlight and leave it for a while, then discharge the battery or by similar methods) and recheck.

When the generator itself or the ambient temperature are too high, the specified current cannot be verified. In this case, cool down the generator and recheck.

9. Turn the following electrical loads on and verify that the current reading increases more than the minimum value indicated below.



If it is not as specified, go to the PCM AND GENERATOR SHEARING INSPECTION .



Headlights (high-beam)



Blower motor (HI)

Rear window defroster



Brake light

Generator generated current minimum value

70% of the nominal output current (nominal output current: 100 A)

[ambient temp. 20°C {68°F}, voltage 13.0-15.0 V, both engine and generator are hot]

PCM AND GENERATOR SHEARING INSPECTION

1. Connect the M-MDS or equivalent to the DLC-2.

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Fig. 7: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

2. Inspect as follows:

PCM AND GENERATOR SHEARING INSPECTION TABLE

Step Inspection

15 V or more

1 Measure the generator terminal B voltage when the electrical loads

(1) on and off.

are

13-15

13 V or less

Action

Go to Step 2.

Normal

(2)

Go to Step 3.

Monitor the ALTT V PID using the M-MDS or equivalent, or measure the voltage of PCM terminal 2AJ using a tester. Is the voltage between 13

Yes Go to Step 4.

and 15 V?

No PCM input error.

Monitor the ALTT V PID using the M-MDS or equivalent, or measure the voltage of PCM terminal 2AJ using a tester. Is the voltage between 13

Yes Go to Step 5.

and 15 V?

No PCM input error.

Thursday, July 09, 2009 3:07:38 PM Page 11

Yes PCM input error.

Monitor the ALTF PID using the M-MDS or equivalent, or calculate the duty value of the PCM terminal 2AI using an oscilloscope. Is the duty

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2007 Mazda MX-5 Miata Sport

2007 ELECTRICAL Charging System - MX-5 Miata

4 No

PCM, generator, or both are not normal.

value 100%?

Monitor the ALTF PID using the M-MDS or equivalent, or calculate the duty value of the PCM terminal 2AI using an oscilloscope. Is the duty

Yes PCM input error.

PCM, generator, or both are not normal.

value 0%?

(1) Headlights, blower motor, rear window defroster, and brake light.

(2) If the generator field coil duty value does not change when electrical loads (such as headlights, blower motor, rear window defroster, brake light) are on or off, inspection with discharged battery is needed.

GENERATOR INNER PARTS

Rotor

1. Measure the resistance between the slip rings using a tester.



If not within the specification, replace the rotor.

Generator rotor resistance (between slip rings) [20°C {68°F}]

2.0-2.3 ohm

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Fig. 8: Measuring Resistance Between Slip Rings Using Tester

Courtesy of MAZDA MOTORS CORP.

2. Verify that there is no continuity between the slip ring and core using a tester.



If there is continuity, replace the rotor.

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Fig. 9: Verifying There Is No Continuity Between Slip Ring & Core

Courtesy of MAZDA MOTORS CORP.

3. Inspect the slip ring surface condition.



If the slip ring surface is rough, use a lathe or fine sandpaper to repair it.

Stator Coil

1. Verify that the continuity is as indicated in Fig. 10 .

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Fig. 10: Stator Coil Terminal Continuity Check Table

Courtesy of MAZDA MOTORS CORP.

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Fig. 11: Identifying Stator Coil Terminals

Courtesy of MAZDA MOTORS CORP.



If there is any malfunction, replace the stator.

2. Verify that there is no continuity between the stator coil leads and core using a tester.



If there is continuity, replace the stator coil.

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Brush

Fig. 12: Inspecting Continuity Between Stator Coil Leads And Core

Courtesy of MAZDA MOTORS CORP.

1. Inspect brushes for wear.



If any brush is worn almost to or beyond the limit, replace all of the brushes.

Generator brush length

Standard: 22.5 mm {0.89 in}

Minimum: 5.0 mm {0.20 in}

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Fig. 13: Inspecting Brushes For Wear

Courtesy of MAZDA MOTORS CORP.

Brush Spring

1. Measure the force of the brush spring using a spring pressure gauge.

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Fig. 14: Measuring Force Of Brush Spring Using Spring Pressure Gauge

Courtesy of MAZDA MOTORS CORP.

2. Read the spring pressure gauge at the brush tip projection of 2 mm {0.079 in}.

 Replace the brush spring if necessary.

Generator brush spring force

Standard: 4.1-5.3 N {0.42-0.54 kgf, 0.92-1.19 lbf}

Minimum: 1.7 N {0.17 kgf, 0.38 lbf}

Rectifier (Using an analog circuit tester)

1. Inspect for continuity of the diodes using an analog circuit tester.



If not as specified, replace the rectifier.

Specification

RECTIFIER SPECIFICATION USING AN ANALOG CIRCUIT TESTER

Negative Positive

E P1, P2, P3, P4, P5, P6

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Thursday, July 09, 2009 3:07:38 PM

Continuity

Yes

P1, P2, P3, P4, P5, P6

2007 Mazda MX-5 Miata Sport

2007 ELECTRICAL Charging System - MX-5 Miata

Yes

Fig. 15: Identifying Diodes

Courtesy of MAZDA MOTORS CORP.

Rectifier (Using a digital circuit tester)

1. Inspect for continuity of the diodes using a digital circuit tester.



If not as specified, replace the rectifier.

Specification

RECTIFIER SPECIFICATION USING AN DIGITAL CIRCUIT TESTER

Negative Positive

P1, P2, P3, P4, P5, P6

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P1, P2, P3, P4, P5, P6

Page 20

Continuity

Yes

2007 Mazda MX-5 Miata Sport

2007 ELECTRICAL Charging System - MX-5 Miata

Fig. 16: Identifying Diodes

Courtesy of MAZDA MOTORS CORP.

Bearing

1. Inspect for abnormal noise, looseness, and sticking.



Replace the bearing if necessary.

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Fig. 17: Inspecting Bearing

Courtesy of MAZDA MOTORS CORP.

GENERATOR DISASSEMBLY/ASSEMBLY [LF]

CAUTION:



Melt the solder quickly, otherwise the diodes (rectifier) and regulator will be damaged by excessive heat.

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

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Fig. 18: Identifying Disassemble Order Of Generator (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

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2007 TRANSMISSION Clutch - MX-5 Miata

CLUTCH LOCATION INDEX

2007 TRANSMISSION

Clutch - MX-5 Miata

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 1: Identifying Location Of Clutch Components

Courtesy of MAZDA MOTORS CORP.

GENERAL PROCEDURES (CLUTCH)

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CAUTION:



Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If fluid does get on painted surfaces, wipe it off immediately.

NOTE:



If any hydraulic related parts of the clutch system are removed during the procedure, add brake fluid, bleed the system and inspect for leakage after the procedure has been completed.

1. Remove the clutch pipe using the SST (49 0259 770B).

2. Install the clutch pipe using a torque wrench and the SST (49 0259 770B).

CLUTCH FLUID INSPECTION

1. Inspect whether the fluid level in the brake fluid reservoir tank is between MIN and MAX.

Fig. 2: Inspecting Clutch Fluid Level

Courtesy of MAZDA MOTORS CORP.

CLUTCH FLUID REPLACEMENT

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CAUTION:



Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If fluid does get on painted surfaces, wipe it off immediately.

Keep the fluid level in the reserve tank at 3/4 full or more during air bleeding.

NOTE:



When replacing the fluid, drain the old fluid, fill the reserve tank with new fluid and then perform Steps 1 thru 6 below.

Clutch fluid

SAE J1703, FMVSS 116 DOT-3

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

2. Place the other end of the vinyl tube in a clear container, and fill fluid in the container during air bleeding.

3. Working with two people, one should depress the clutch pedal a few times and then depress and hold the pedal down.

4. While the clutch pedal is being held down, the other person should loosen the bleeder screw, and bleed any fluid containing air bubbles. Once completed, tighten the bleeder screw.

5. Continue to perform Steps 3 and 4 until no air comes from the vinyl hose.

6. Tighten the bleeder screw.

Tightening torque

5.9-8.8 N.m

{61-89 kgf.cm, 53-77 in.lbf}

7. Fill the reserve tank to MAX with the recommended fluid.

8. Perform the following inspections:



Brake operation



Fluid leakage

Fluid level

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Fig. 3: Identifying Clutch Bleeding

Courtesy of MAZDA MOTORS CORP.

CLUTCH PEDAL ADJUSTMENT

CLUTCH PEDAL STROKE INSPECTION/ADJUSTMENT

1. Measure the clutch pedal stroke.

 If there is any malfunction, loosen locknut A and adjust the pedal stroke by adjusting bolt B.

Tighten locknut A after adjustment.

Clutch pedal stroke

130 mm {5.12 in}

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Fig. 4: Adjusting Clutch Pedal (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CLUTCH PEDAL PLAY INSPECTION/ADJUSTMENT

1. Lightly depress the clutch pedal by hand until clutch resistance is felt and then measure the pedal play.

Clutch pedal play

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2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

5-15 mm {0.20-0.59 in}

Clutch pedal push rod play

At push rod setting line: 0.1-0.5 mm {0.004-0.020 in} (Reference value)

At pedal pad: 0.5-2.7 mm {0.020-0.106 in}

2. If it is not within the specification, loosen locknut C and turn push rod D to adjust the pedal play.

3. Remeasure the pedal play and, if it is within the specification, tighten locknut C.

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Fig. 5: Inspecting Clutch Pedal Play (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CLUTCH DISENGAGEMENT POINT INSPECTION

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1. Start the engine.

2. Without depressing the clutch pedal, move the shift lever slowly to the reverse position until gear noise is heard and hold the lever in that position.

3. Slowly depress the clutch pedal and hold at the point where the gear noise stops (clutch disengagement point).

4. Measure distance A (from pedal not depressed to clutch disengagement point) and verify that it is within the specification.

Clutch disengagement stroke (Reference value)

A: 80-110 mm {3.15-4.33 in}

Fig. 6: Inspecting Clutch Disengagement Point

Courtesy of MAZDA MOTORS CORP.

CLUTCH SWITCH INSPECTION

1. Remove the engine cover.

2. Remove the battery cover.

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3. Disconnect the negative battery cable.

4. Disconnect the clutch switch connector.

5. Verify continuity as indicated in Fig. 7 .

Fig. 7: Clutch Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

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Fig. 8: Identifying Clutch Switch Connector

Courtesy of MAZDA MOTORS CORP.



If there is any malfunction, replace the clutch switch.

CLUTCH PEDAL REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 9 .

2. Install in the reverse order of removal.

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

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Fig. 9: Identifying Clutch Pedal Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

STARTER INTERLOCK SWITCH INSTALLATION NOTE

CAUTION:



If the rod Is pushed in, it may not operate properly. Be careful not to push the rod in when installing the starter interlock switch.

1. Insert a new starter interlock switch into the pedal bracket hole in direction A.

2. While pushing the starter interlock switch in direction A, slide it in direction B until it locks securely.

3. Move the clutch to a fully open stroke in direction C and securely fit the terminal of the starter interlock switch.

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Fig. 10: Identifying Starter Interlock Switch And Pedal Bracket

Courtesy of MAZDA MOTORS CORP.

CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION

CAUTION:



Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If it is spilled, wipe it off immediately.

1. Remove in the order indicated in Fig. 11 .

2. Install in the reverse order of removal.

3. Bleed the air from the system.

(See CLUTCH FLUID REPLACEMENT .)

4. Inspect and adjust the clutch pedal. (See CLUTCH PEDAL ADJUSTMENT .)

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Fig. 11: Identifying Clutch Master Cylinder Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in Fig. 12 .

2. Assemble in the reverse order of disassembly.

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Fig. 12: Exploded View Of Clutch Master Cylinder Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

SNAP RING DISASSEMBLY/ASSEMBLY NOTE

1. While pressing the piston in with a cloth-wrapped pin punch to protect the push rod contacting surface, remove/install the snap ring.

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Fig. 13: Removing Snap Ring

Courtesy of MAZDA MOTORS CORP.

CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION

CAUTION:



Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If fluid does get on painted surfaces, wipe it off immediately.

1. Remove in the order indicated in Fig. 14 .

2. Install in the reverse order of removal.

3. Bleed the air from the system.

(See CLUTCH FLUID REPLACEMENT .)

4. Inspect and adjust the clutch pedal. (See CLUTCH PEDAL ADJUSTMENT .)

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Fig. 14: Identifying Clutch Release Cylinder Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in Fig. 15 .

2. Assemble in the reverse order of disassembly.

Fig. 15: Exploded View Of Clutch Release Cylinder Components (With Torque Specifications)

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Courtesy of MAZDA MOTORS CORP.

CLUTCH UNIT REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 16 .

2. Install in the reverse order of removal.

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Fig. 16: Identifying Clutch Unit Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CLUTCH COVER AND DISC REMOVAL NOTE

1. Install the SSTs.

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

3. Remove the clutch cover and disc.

Fig. 17: Identifying SSTs

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. Use the SST to remove the pilot bearing.

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Fig. 18: Removing Pilot Bearing Using SST

Courtesy of MAZDA MOTORS CORP.

PILOT BEARING INSTALLATION NOTE

1. Install the pilot bearing using the corresponding 20mm {0.79} side of a Snap-on brand millimeter size bushing driver set A160M adapter A160M7 (20-22 mm {0.79-0.86 in}) or substitution tool.

Substitution tool

Outer diameter: 21 mm {0.83 in}

Inner diameter: 19 mm {0.75 in}

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Fig. 19: Installing Pilot Bearing Using SSTs

Courtesy of MAZDA MOTORS CORP.

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Fig. 20: Identifying Pilot Bearing Installation Dimension

Courtesy of MAZDA MOTORS CORP.

FLYWHEEL REMOVAL NOTE

1. Hold the flywheel using the SST.

2. Remove the bolts evenly and gradually in a crisscross pattern.

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Fig. 21: Identifying Flywheel Bolts Removing Sequence

Courtesy of MAZDA MOTORS CORP.

3. Remove the flywheel.

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

 If there is any malfunction, replace the crankshaft rear oil seal. (See REAR OIL SEAL

REPLACEMENT [LF] .)

FLYWHEEL INSTALLATION NOTE

1. Clean the crankshaft thread holes.

2. Install the flywheel to the crankshaft.

3. Hand-tighten the flywheel lock bolts.

4. Install the SST to the flywheel.

5. Gradually tighten the flywheel lock bolts in a crisscross pattern.

Tightening torque

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2007 Mazda MX-5 Miata Sport

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108-116 N.m

{11.1-11.8 kgf.m, 79.7-85.5 ft.lbf}

Fig. 22: Identifying Flywheel Bolts Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

CLUTCH DISC INSTALLATION NOTE

1. Hold the clutch disc position using the SST.

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Fig. 23: Holding Clutch Disc Position Using SST

Courtesy of MAZDA MOTORS CORP.

CLUTCH COVER INSTALLATION NOTE

1. Install the SSTs.

2. Tighten the bolts evenly and gradually in a crisscross pattern.

Tightening torque

25.0-33.0 N.m

{2.6-3.4 kgf.m, 18.5-24.4 ft.lbf}

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2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 24: Identifying Clutch Cover Bolts Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

CLUTCH COVER INSPECTION

1. Measure the wear of the diaphragm spring fingers.



If it exceeds the maximum specification, replace the clutch cover.

Clutch disc maximum depth

0.6 mm {0.024 in}

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 25: Measuring Wear Of Diaphragm Spring Fingers

Courtesy of MAZDA MOTORS CORP.

2. Measure the flatness of the pressure plate with a straight edge and a feeler gauge.



If it exceeds the maximum specification, replace the clutch cover.

Clutch cover maximum clearance

0.5 mm {0.020 in}

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 26: Measuring Flatness Of Pressure Plate With Straight Edge & Feeler Gauge

Courtesy of MAZDA MOTORS CORP.

3. When checking the diaphragm spring fingers, mount a dial indicator on the cylinder block.

4. Rotate the flywheel and check for misaligned diaphragm spring fingers.



If it exceeds the maximum specification, replace the clutch cover.

Clutch cover maximum height difference

1.0 mm {0.039 in}

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 27: Measuring Clutch Cover Height Difference

Courtesy of MAZDA MOTORS CORP.

CLUTCH DISC INSPECTION

1. Remove the clutch disc.

2. Inspect the lining surface for discoloration and grease/oil contamination.

3. Inspect the torsion spring for weakness and the rivet for looseness.

4. Using a vernier caliper, measure the depth between the lining surface and the rivet head.

Clutch disc minimum depth

0.3 mm {0.012 in}



If it is less than the minimum specification, replace the clutch disc.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 28: Measuring Clutch Disc Minimum Depth Using Vernier Caliper

Courtesy of MAZDA MOTORS CORP.

5. Measure the clutch disc runout using a dial gauge.

Clutch disc maximum runout

0.7 mm {0.028 in}



If it exceeds the maximum specification, replace the clutch disc.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 29: Measuring Clutch Disc Maximum Runout Using Dial Gauge

Courtesy of MAZDA MOTORS CORP.

6. Install the clutch disc.

CLUTCH RELEASE COLLAR INSPECTION

CAUTION:



Do not clean the clutch release collar with cleaning fluids or a steam cleaner because it is filled with grease.

1. Remove the clutch release collar.

2. Turn the collar while applying force in the axial direction, and inspect for sticking, excessive resistance, and an abnormal noise.



If there is any malfunction, replace the clutch release collar.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 30: Inspecting Clutch Release Collar

Courtesy of MAZDA MOTORS CORP.

3. Install the clutch release collar.

PILOT BEARING INSPECTION

1. Without removing the pilot bearing, turn the bearing while applying force in the axial direction.



If there is any malfunction, replace the pilot bearing.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 31: Inspecting Pilot Bearing

Courtesy of MAZDA MOTORS CORP.

FLYWHEEL INSPECTION

1. Remove the flywheel.

NOTE:



Correct slight scratches and discoloration using sandpaper.

Inspect the runout of the surface that contacts the clutch disc with the flywheel installed to the crankshaft.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 32: Correcting Slight Scratches Using Sandpaper

Courtesy of MAZDA MOTORS CORP.

2. Inspect the surface that contacts the clutch disc for scratches, nicks, and discoloration.

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

4. Install the flywheel.

5. Measure the runout of the surface that contacts the clutch disc using a dial gauge.

Flywheel maximum runout

0.1 mm {0.004 in}



If it exceeds the maximum specification, replace the flywheel.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 TRANSMISSION Clutch - MX-5 Miata

Fig. 33: Measuring Flywheel Maximum Runout Using Dial Gauge

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 ENGINE Cooling System - MX-5 Miata

2007 ENGINE

Cooling System - MX-5 Miata

COOLING SYSTEM LOCATION INDEX [LF]

Fig. 1: Identifying Location Of Cooling System Components

Courtesy of MAZDA MOTORS CORP.

COOLING SYSTEM SERVICE WARNINGS [LF]

WARNING:



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

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata



When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

ENGINE COOLANT LEVEL INSPECTION [LF]

WARNING:



When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

NOTE:



If the "FL22" mark is shown on or near the cooling system cap, use FL22 type engine coolant.

FL22 type engine coolant is shipped as a diluted solution (55% coolant,

45% water). Use the solution as is when replacing coolant.

1. Verify that the engine coolant level in the coolant reserve tank is between the L and F marks.

2. If the engine coolant level is below L mark, add engine coolant.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 2: Identifying Proper Cooling System Cap

Courtesy of MAZDA MOTORS CORP.

ENGINE COOLANT PROTECTION INSPECTION [LF]

1. Measure the coolant temperature and specific gravity using a thermometer and a hydrometer.

CAUTION:



Use engine coolant at a concentration that meets the environmental conditions in which the vehicle is driven, otherwise engine damage could occur.

The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to prevent corrosion and freezing.

Do not use coolants containing Alcohol, Methanol, Borate or

Silicate. These coolants could damage the cooling system.

Use only soft (demineralized) water in the coolant mixture.

Water that contains minerals will cut down on the coolant's effectiveness.

Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.

NOTE:



If the "FL22" mark is shown on or near the cooling system cap, use

FL22 type engine coolant.

FL22 type engine coolant is shipped as a diluted solution (55%

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata coolant, 45% water). Use the solution as is when replacing coolant.

Fig. 3: Identifying Proper Cooling System Cap

Courtesy of MAZDA MOTORS CORP.

2. Determine the coolant protection level by referring to the graph shown in Fig. 4 .



If the coolant protection level is not correct, add water or coolant.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 4: Coolant Protection Level Graph

Courtesy of MAZDA MOTORS CORP.

ENGINE COOLANT REPLACEMENT [LF]

WARNING:



Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

NOTE:



 cause serious injury. It may also damage the engine and cooling system.

When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

CAUTION:



Use engine coolant at a concentration that meets the environmental conditions in which the vehicle is driven, otherwise engine damage could occur.

The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to prevent corrosion and freezing.

Do not use coolants containing Alcohol, Methanol, Borate or Silicate.

These coolants could damage the cooling system.

Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant's effectiveness.

Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.



If the "FL22" mark is shown on or near the cooling system cap, use FL22 type engine coolant.

FL22 type engine coolant is shipped as a diluted solution (55% coolant,

45% water). Use the solution as is when replacing coolant.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 5: Identifying Proper Cooling System Cap

Courtesy of MAZDA MOTORS CORP.

Engine coolant capacity (approx. quantity)

7.5 L {7.9 US qt, 6.6 Imp qt}

1. Remove the cooling system cap.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 6: Identifying Cooling System Cap & Reserve Tank

Courtesy of MAZDA MOTORS CORP.

2. Remove the radiator drain plug and drain the engine coolant into a container.

3. Flush the cooling system with water until all traces of color are gone.

4. Let the system drain completely.

5. Tighten the radiator drain plug.

Tightening torque

0.8-1.5 N.m {8-15 kgf.cm, 7-13 in.lbf}

6. Referring to ANTIFREEZE SOLUTION MIXTURE PERCENTAGE TABLE , select the correct volume percentage of the water and coolant.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 7: Identifying Radiator Drain Plug

Courtesy of MAZDA MOTORS CORP.

ANTIFREEZE SOLUTION MIXTURE PERCENTAGE (EXCEPT FL22 TYPE ENGINE

COOLANT)

Engine coolant protection

Volume percentage (%)

Water Coolant

Gravity at 20°C {68°F}

Above -16°C {3°F} 65 35 1.057

Above -26°C {-15°F}

Above -40°C {-40°F}

1.072

1.086

7. Refill the coolant into the coolant reserve tank up to the F mark on the tank.

8. Install the cooling system cap.

CAUTION:



If the water temperature gauge rises too high, stop the engine and decrease the water temperature to prevent overheating.

Then, verify the malfunctioning part and repair or replace it.

If the engine coolant level in the coolant reserve tank is below the L mark during engine coolant air bleeding operation, stop the engine, and after the engine coolant temperature decreases, add engine coolant. Then, resume the engine coolant air bleeding operation.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

9. Start the engine and warm up the engine by idling.

10. After the engine warms up, perform the following steps. At this time, be careful of the coolant temperature to prevent overheating.

1. Run the engine at approx. 2,500 rpm for 5 min .

2. Run the engine at approx. 3,000 rpm for 5s , then idle.

3. Repeat step 2 4-5 times.

11. Stop the engine, and inspect the coolant level after the coolant temperature decreases. If it is low, repeat steps 7 thru 10.

12. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [LF] .)

ENGINE COOLANT LEAKAGE INSPECTION [LF]

WARNING:



When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [LF] .)

2. Remove the cooling system cap.

3. Clean the installation parts of the cooling system cap.

4. Install the SST and a radiator cap tester to the coolant reserve tank filler port.

5. Apply pressure using the radiator cap tester.

CAUTION:



Applying more than 122.6 kPa {1.25 kgf/cm

, 17.8 psi} can damage the hoses, fittings, and other components, and cause leakage.

Pressure

122.6 kPa {1.25 kgf/cm

, 17.8 psi} [1 min]

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 8: Applying Pressure Using Radiator Cap Tester

Courtesy of MAZDA MOTORS CORP.

6. When pressurizing the cooling system, verify that the pressure is maintained.



If the gauge needle drops, it may indicate water leakage. Repair or replace the applicable part.

COOLING SYSTEM CAP INSPECTION [LF]

WARNING:



When you're sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Clean the cooling system cap and the sealed part.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

2. Inspect for cracks or roll up on the sealed part of the cooling system cap.



If there is any malfunction, replace the cooling system cap.

3. Attach the cooling system cap to the SST and a radiator cap tester.

4. Hold the cooling system cap downward and apply pressure gradually. Verify that the pressure is held stable for 10s .



If the pressure is not held stable, replace the cooling system cap.

Cooling system cap valve opening pressure

93.2-122.6 kPa {0.95-1.25 kgf/cm

, 13.5-17.8 psi}

Fig. 9: Attaching Cooling System Cap To SST & Radiator Cap Tester

Courtesy of MAZDA MOTORS CORP.

COOLANT RESERVE TANK REMOVAL/INSTALLATION [LF]

WARNING:



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

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

 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.

1. Drain the engine coolant until the coolant reserve tank becomes empty. (See ENGINE COOLANT

REPLACEMENT [LF] .)

2. Remove in the order indicated in Fig. 10 .

3. Install in the reverse order of removal.

4. Add engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

5. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 10: Identifying Removal Order Of Coolant Reserve Tank (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

RADIATOR REMOVAL/INSTALLATION [LF]

WARNING:



When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Remove the splash shield and under cover.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

3. Remove the battery, battery tray, and battery duct. (See BATTERY REMOVAL/INSTALLATION

[LF] .)

4. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

5. Remove the PCM and air cleaner insulator. (See PCM REMOVAL/INSTALLATION [LF] .)

6. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION

[LF] .)

7. Disconnect the ATF oil cooler hose. (AT)

8. Remove in the order indicated in the table.

9. Install in the reverse order of removal.

10. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

11. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [LF] .)

12. Inspect the ATF level. (AT) (See AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION

[SJ6A-EL] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 11: Identifying Removal Order Of Radiator (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

P/S COOLING PIPE REMOVAL NOTE

1. Remove the P/S cooling pipe with the hoses still connected.

CONDENSER REMOVAL NOTE

1. Remove the condenser with the cooler pipes still connected.

THERMOSTAT REMOVAL/INSTALLATION [LF]

WARNING:



Never remove the cooling system cap or loosen the radiator drain

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata



 plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.

When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

4. Remove the throttle body. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

5. Remove in the order indicated in Fig. 12 .

6. Install in the reverse order of removal.

7. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

8. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 12: Identifying Removal Order Of Thermostat (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

THERMOSTAT INSPECTION [LF]

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

1. Inspect the thermostat for the following.

WARNING:



During inspection, the thermostat and water are extremely hot and can cause severe burns. Do not touch the thermostat and water.



The valve should not open under normal temperature.

Opening temperature and valve lift



If there is malfunction, replace the thermostat.

Thermostat initial-opening temperature

80-84°C {176-183°F}

Thermostat full-open temperature

97°C {207°F}

Thermostat full-open lift

More than 8.0 mm {0.31 in}

WATER PUMP REMOVAL/INSTALLATION [LF]

WARNING:



When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

4. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

5. Loosen the water pump pulley bolt and remove the drive belt. (See DRIVE BELT REPLACEMENT

[LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

6. Remove in the order indicated in Fig. 13 .

7. Install in the reverse order of removal.

8. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

9. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 13: Identifying Removal Order Of Water Pump (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

FAN MOTOR REMOVAL/INSTALLATION [LF]

WARNING:



When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

1. Remove the splash shield and under cover.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

3. Remove the battery, battery tray, and battery duct. (See BATTERY REMOVAL/INSTALLATION

[LF] .)

4. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

5. Remove the PCM and air cleaner insulator. (See PCM REMOVAL/INSTALLATION [LF] .)

6. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION

[LF] .)

7. Disconnect the ATF oil cooler hose. (AT)

8. Remove the radiator and cooling fan component. (See RADIATOR REMOVAL/INSTALLATION

[LF] .)

9. Remove in the order indicated in the table.

10. Install in the reverse order of removal.

11. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

12. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [LF] .)

13. Inspect the ATF level. (AT) (See AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION

[SJ6A-EL] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 14: Identifying Removal Order Of Fan Motor (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

FAN MOTOR INSPECTION [LF]

PART INSPECTION

1. Verify that the battery is fully charged.

2. Install a tester and battery to the cooling fan motor connector (4 terminals) as shown in Fig. 15 .

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Fig. 15: Identifying Cooling Fan Motor Connector

Courtesy of MAZDA MOTORS CORP.

FAN MOTOR OPERATION TABLE

Fan motor rotation speed

Connection terminal

Positive Negative

High

Middle

A and C B and D

C B and D

Low C B

3. Verify that fan motor operates smoothly at the standard current.



If there is any malfunction, replace the applicable part.

Cooling fan motor current

Microsoft

High: 9.0-12.0 A

Middle: 6.4-9.4 A

Low: 4.8-7.8 A

2007 Mazda MX-5 Miata Sport

2007 ENGINE Cooling System - MX-5 Miata

Microsoft

2007 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

2007 ACCESSORIES & EQUIPMENT

Cruise Control System - MX-5 Miata

CRUISE CONTROL SWITCH INSPECTION [LF]

1. Disconnect the negative battery cable.

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

REMOVAL/INSTALLATION .)

3. Disconnect the audio control switch connector. (See AUDIO CONTROL SWITCH

REMOVAL/INSTALLATION .)

4. Inspect for resistance and continuity between cruise control switch terminals B-C using a tester.



If not as specified, replace the cruise control switch. (See AUDIO CONTROL SWITCH

REMOVAL/INSTALLATION .)

Fig. 1: Identifying Cruise Control Switch Terminals B & C

Courtesy of MAZDA MOTORS CORP.

CRUISE CONTROL SWITCH RESISTANCE SPECIFICATION

Switch condition

ON OFF button pressed

CANCEL button pressed

SET/- button pressed

RES/+ button pressed

Resistance (ohm)

Continuity

117-123

666-694

2,156-2,244

No button pressed

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata

No continuity

Microsoft

2007 DRIVELINE/AXLES Differential - MX-5 Miata

2007 DRIVELINE/AXLES

Differential - MX-5 Miata

REAR DIFFERENTIAL LOCATION INDEX

Fig. 1: Identifying Location Of Rear Differential Components

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL OIL INSPECTION

1. Park the vehicle on level ground for approx. 5min. to stabilize the differential oil.

2. Remove the oil-fill plug and the washer.

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 2: Identifying Oil-Fill Plug

Courtesy of MAZDA MOTORS CORP.

3. Inspect if the oil level is close to the rim of the oil-fill plug hole.

NOTE:



Each vehicle is filled with a specified amount of oil (0.7 +/- 0.1 L) when it is delivered, therefore, the oil level is lower than the lower end of the plug hole as shown in the figure. However, this has no affect on the differential function.

4. If the oil level is lower than approx. 12 mm {0.47 in} from the lower end of the oil-fill plug hole, inspect for oil leakage and add the specified oil.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 3: Identifying Oil Fill Level

Courtesy of MAZDA MOTORS CORP.

Differential oil

Grade: API service GL-5

Viscosity: SAE 90, SAE 80W-90, SAE 75W-90 (Not available from Mazda)

5. Install the oil-fill plug with a new washer and tighten.

Tightening torque

39.2-53.9 N.m {4.00-5.49 kgf.m, 29.0-39.7 ft.lbf}

DIFFERENTIAL OIL REPLACEMENT

1. Park the vehicle on level ground.

2. Remove the oil-fill plug.

3. Remove the drain plug and drain the oil.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 4: Identifying Oil Fill Plug & Drain Plug

Courtesy of MAZDA MOTORS CORP.

4. Install the drain plug with a new washer and tighten.

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 through the oil-fill plug hole until the oil level reaches the lower end of the plug hole.

Differential oil

Grade: API service GL-5

Viscosity: SAE 90, SAE 80W-90, SAE 75W-90 (Not available from Mazda)

Capacity (approx. quantity): 0.6-0.8 L {0.63-0.85 US qt, 0.53-0.70 Imp qt}

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 5: Identifying Oil-Fill Plug Hole And Differential Oil

Courtesy of MAZDA MOTORS CORP.

6. Install the oil-fill plug with a new washer and tighten.

Tightening torque

39.2-53.9 N.m

{4.00-5.49 kgf.m, 29.0-39.7 ft.lbf}

OIL SEAL (SIDE GEAR) REPLACEMENT

1. Remove the drain plug and drain the oil.

2. Install the drain plug with a new washer and tighten.

Tightening torque

39.2-53.9 N.m {4.00-5.49 kgf.m, 29.0-39.7 ft.lbf}

3. Disconnect the rear drive shaft on the differential side.

(See REAR DRIVE SHAFT, REAR KNUCKLE COMPONENT REMOVAL NOTE .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

4. Remove the clip from the rear drive shaft.

CAUTION:



To prevent damaging the inside of the differential casing, wrap cloth on the end of the flathead screwdriver.

5. Remove the oil seal from the differential carrier using a flathead screwdriver.

6. Apply differential oil to the lip of a new oil seal.

Fig. 6: Removing Oil Seal From Differential Carrier Using Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

7. Tap in the new oil seal until it reaches the differential carrier using the SSTs .

NOTE:



Install the oil seal at a straight angle.

8. After installing a new clip to the rear drive shaft, insert it into the rear differential.

(See REAR DRIVE SHAFT, REAR KNUCKLE COMPONENT INSTALLATION NOTE .)

9. Verify that the rear drive shaft is held securely by the clip by pulling the outer ring on the differential side towards the axle.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

10. Add differential oil.

11. After adding the oil, perform the oil level inspection. (See DIFFERENTIAL OIL INSPECTION .)

12. Install the oil-fill plug with a new washer and tighten.

Fig. 7: Tapping In New Oil Seal Using SSTs

Courtesy of MAZDA MOTORS CORP.

Tightening torque

39.2-53.9 N.m {4.00-5.49 kgf.m, 29.0-39.7 ft.lbf}

OIL SEAL (COMPANION FLANGE) REPLACEMENT

1. Remove the rear differential. (See REAR DIFFERENTIAL REMOVAL/INSTALLATION .)

2. Replace the oil seal (companion flange) referring to the rear differential disassembly/assembly procedure.

(See REAR DIFFERENTIAL DISASSEMBLY .) (See REAR DIFFERENTIAL ASSEMBLY .)

3. Install the rear differential. (See REAR DIFFERENTIAL REMOVAL/INSTALLATION .)

REAR DIFFERENTIAL REMOVAL/INSTALLATION

CAUTION:



Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata 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. Drain the rear differential oil.

2. Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [LF] .)

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

4. Remove the power plant frame. (See POWER PLANT FRAME REMOVAL NOTE .) (See POWER

PLANT FRAME INSTALLATION NOTE .) (See POWER PLANT FRAME REMOVAL NOTE .)

(See POWER PLANT FRAME INSTALLATION NOTE .) (See POWER PLANT FRAME

REMOVAL NOTE .) (See POWER PLANT FRAME INSTALLATION NOTE .)

5. Remove in the order indicated in Fig. 8 .

6. Install in the reverse order of removal.

7. Add rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT .)

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 8: Identifying Rear Differential Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

BRAKE CALIPER COMPONENT REMOVAL NOTE

1. Suspend the brake caliper component using a cable or equivalent.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 9: Suspending Brake Caliper

Courtesy of MAZDA MOTORS CORP.

2. Temporarily tighten the wheel nut to prevent the disc plate from falling off.

REAR DRIVE SHAFT, REAR KNUCKLE COMPONENT REMOVAL NOTE

1. Insert a tire lever or equivalent between the rear differential and differential side outer ring, and remove the rear drive shaft.

CAUTION:



The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal when removing the drive shaft from the differential.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 10: Removing Rear Drive Shaft & Rear Knuckle Components

Courtesy of MAZDA MOTORS CORP.

2. Pull the rear drive shaft and rear knuckle component to the outer side, and detach the rear drive shaft from the rear differential.

3. To hold the rear drive shaft and rear knuckle component, install the rear lateral link (upper) to the rear knuckle temporarily after disconnecting the rear drive shaft.

REAR DIFFERENTIAL REMOVAL/INSTALLATION NOTE

WARNING:



If the rear differential falls off, it can cause serious injuries or death, and damage to the vehicle. When removing/installing the rear differential, verify that it is supported securely with a jack.

1. Remove or install the rear differential, while supporting it securely with a jack, and moving the jack gradually.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 11: Supporting Differential With Jack

Courtesy of MAZDA MOTORS CORP.

REAR DRIVE SHAFT, REAR KNUCKLE COMPONENT INSTALLATION NOTE

1. Install a new drive shaft clip to the clip groove at the top of the rear drive shaft with the clip opening facing upward and the clip width within the specification.

Standard

31.2 mm {1.23 in}

2. After installing the clip, measure the outer diametric if it exceeds the specification, reinstall a new clip.

3. Apply differential oil to the differential oil seal lip.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 12: Installing New Drive Shaft Clip To Clip Groove At Top Of Rear Drive Shaft

Courtesy of MAZDA MOTORS CORP.

CAUTION:



The sharp edges of the rear drive shaft can slice or puncture the oil seal Be careful not to damage the oil seal when installing the rear drive shaft from the rear differential.

4. Insert the rear drive shaft into the rear differential with the clip opening facing upward.

5. After installation, verify that the rear drive shaft is securely held by the clip by pulling the outer ring on the differential side towards the axle.

REAR DIFFERENTIAL DISASSEMBLY

WARNING:



The engine stand is equipped with a self-lock mechanism, however, if the rear differential is tilted, the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates, it could cause injury, therefore do not maintain the rear differential tilted. When turning the rear differential, grasp the rotation handle firmly.

1. Disassemble in the order indicated in Fig. 13 .

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 13: Exploded View Of Rear Differential Components

Courtesy of MAZDA MOTORS CORP.

DIFFERENTIAL COMPONENT DISASSEMBLY NOTE

1. Install the differential component to the SSTs .

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 14: Installing Differential Component To SSTs

Courtesy of MAZDA MOTORS CORP.

BEARING CAP DISASSEMBLY NOTE

1. Mark the bearing cap and differential carrier for proper installation.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 15: Marking Bearing Cap & Differential Carrier For Installation

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENT SHIM, SIDE BEARING OUTER RACE DISASSEMBLY NOTE

1. Remove the adjustment shim using a flathead screwdriver.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 16: Removing Adjustment Shim Using Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

2. Put left and right identification marks on the removed adjustment shims and side bearing outer races.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 17: Putting Left & Right Identification Marks On Adjustment Shims & Side Bearing Outer

Races

Courtesy of MAZDA MOTORS CORP.

SIDE BEARING DISASSEMBLY NOTE

1. Remove the side bearing using the SST .

2. Put left and right identification marks on the removed side bearings.

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2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 18: Removing Side Bearing Using SST

Courtesy of MAZDA MOTORS CORP.

ROLL PIN DISASSEMBLY NOTE

1. Tap the roll pin out from the direction shown in Fig. 19 using a pin punch.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 19: Tapping Roll Pin Out Using Pin Punch

Courtesy of MAZDA MOTORS CORP.

LOCKNUT DISASSEMBLY NOTE

1. Remove the locknut while fixing the companion flange using the SST .

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 20: Removing Locknut While Fixing Companion Flange Using SST

Courtesy of MAZDA MOTORS CORP.

COMPANION FLANGE DISASSEMBLY NOTE

1. Remove the companion flange using the SST .

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 21: Removing Companion Flange Using SST

Courtesy of MAZDA MOTORS CORP.

DRIVE PINION COMPONENT DISASSEMBLY NOTE

1. Install the removed locknut to the drive pinion top to prevent damage to the thread.

2. Remove the drive pinion component by tapping the locknut lightly using a plastic hammer.

3. Remove the locknut installed in Step 1.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 22: Removing Drive Pinion Component By Tapping Locknut Using Plastic Hammer

Courtesy of MAZDA MOTORS CORP.

REAR BEARING DISASSEMBLY NOTE

CAUTION:



The drive pinion could be damaged if it falls off. Support the drive pinion with your hand when removing the rear bearing.

1. Remove the rear bearing using the SST and a press.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 23: Removing Rear Bearing Using SST & Press

Courtesy of MAZDA MOTORS CORP.

FRONT BEARING OUTER RACE, REAR BEARING OUTER RACE DISASSEMBLY NOTE

1. Remove the bearing outer race by lightly tapping the edge of the bearing outer race using a flathead screwdriver.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 24: Removing Bearing Outer Race By Lightly Tapping Edge Of Bearing Outer Race Using

Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

REAR DIFFERENTIAL ASSEMBLY

WARNING:



NOTE:



Clean away the old silicone sealant before applying the new silicone sealant.

Install the rear cover within 10 min after applying the silicone sealant.

Allow the sealant to set at least 30 min or more after installation before filling the differential with differential oil.

1. Assemble in the order indicated in Fig. 25 .

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 25: Identifying Rear Differential Assembly Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

WASHER ASSEMBLY NOTE

1. Assemble the side gear, thrust washer, pinion gear, and the pinion shaft to the gear case.

2. Install the dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata one of the pinion gear teeth.

Fig. 26: Installing Dial Gauge

Courtesy of MAZDA MOTORS CORP.

3. Fix either one of the side gears.

4. Move the pinion gear and measure the backlash at the pinion gear top.



If it is not within the specification, adjust by choosing the proper washer.

Backlash of pinion gear and side gear

0.1 mm {0.004 in} or less

WASHER TABLE

Identification mark

Part name

MA29 27 252

MA29 27 253

MA29 27 254

MA29 27 256

MA29 27 257

Thickness (mm {in})

0.90 {0.0354}

0.95 {0.0374}

1.00 {0.0393}

1.05 {0.0413}

1.10 {0.0433}

ROLL PIN ASSEMBLY NOTE

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

1. Align the differential gear case and pinion shaft pin holes.

2. Tap the roll pin in using a pin punch.

RING GEAR ASSEMBLY NOTE

CAUTION:



The gear case and ring gear could be damaged if the ring gear is installed with old thread-locking compound remaining on the bolt threads. Before installing the ring gear, completely remove the old thread-locking compound from the bolt threads.

1. Apply a small amount of thread-locking compound to each of points A on the back of the ring gear, and bolt thread areas B (around the entire ring).

Application thickness

Back of ring gear points A:

Approx. 0.4 cm

{0.4 cc, 0.024 cu in} (1 location approx. 0.04 cm

{0.04 cc, 0.0024 cu in})

Ring gear bolt thread points B:

Approx. 0.4 cm

{0.4 cc, 0.024 cu in} (1 location approx. 0.04 cm

{0.04 cc, 0.0024 cu in})

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 27: Identifying Ring Gear Assembly

Courtesy of MAZDA MOTORS CORP.

2. Install the ring gear to the differential gear case and tighten the bolts in a criss-cross pattern.

Tightening torque

68.6-83.3 N.m

{7.00-8.49 kgf.m, 50.6-61.4 ft.lbf}

SIDE BEARING ASSEMBLY NOTE

NOTE:



When assembling the side bearings, do not mix the left and right side bearings that were identified during disassembly.

1. Press the side bearing in using the SST and a press.

Fig. 28: Pressing Side Bearing In Using SST & Press

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

OIL SEAL (SIDE GEAR) ASSEMBLY NOTE

1. Apply differential oil to the lip of a new oil seal.

2. Assemble the oil seal using the SSTs .

Fig. 29: Assembling Oil Seal Using SSTs

Courtesy of MAZDA MOTORS CORP.

REAR BEARING OUTER RACE ASSEMBLY NOTE

1. Press the rear bearing outer race into the differential carrier using the SST and a press.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 30: Pressing Rear Bearing Outer Race Into Differential Carrier Using SST & Press

Courtesy of MAZDA MOTORS CORP.

FRONT BEARING OUTER RACE ASSEMBLY NOTE

1. Press the front bearing outer race into the differential carrier using the SST and a press.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 31: Pressing Front Bearing Outer Race Into Differential Carrier Using SST & Press

Courtesy of MAZDA MOTORS CORP.

SPACER ASSEMBLY NOTE

Pinion Height Adjustment

NOTE:



Use the installed spacer when adjusting.

Install the spacer with the chamfer on the SST side.

1. Assemble the spacer, bearing inner race (rear side), and the SST (O-ring) to the SST (49 8531 565) as shown in Fig. 32 .

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 32: Assembling Spacer, Bearing Inner Race (Rear Side) & SST (O-Ring) To SST (49 8531 565)

Courtesy of MAZDA MOTORS CORP.

2. Insert the set assembled in Step 1 from the rear side of the differential carrier.

3. Assemble the SST (49 8531 567) front bearing, companion flange, and a washer from the front side of the differential carrier.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 33: Inserting Assembled Set In From Rear Side Of Differential Carrier

Courtesy of MAZDA MOTORS CORP.

4. Tighten the locknut to the extent that the SST (49 8531 565) can be turned by hand.

5. Place the SST (49 N027 001) on top of the SST (49 8531 565).

6. Place the SST on the surface plate and set the dial gauge to zero.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 34: Placing SST On Surface Plate & Setting Dial Gauge To Zero

Courtesy of MAZDA MOTORS CORP.

7. Set the SSTs as shown in Fig. 35 .

8. Place the measuring probe of the dial gauge at the point where the side bearing is installed in the differential carrier and measure at the lowest position. Measure the left and right sides.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 35: Placing Measuring Probe Of Dial Gauge Where Side Bearing Is Installed In Differential

Carrier

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 36: Measuring Pinion Height Adjustment Value

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

9. Add the two (left and right) values obtained by the measurements taken in Step 8 and then divide the total by 2 . From this sum, subtract the sum of the number inscribed on the end of the drive pinion divided by

100 . (If there is no figure inscribed, use 0.) This is the pinion height adjustment value.

Differential pinion height

0.038 mm {0.0015 in} or less

NOTE:



When the values obtained by the measurements taken in Step 8, 9 are 0.06 mm {0.0024 in}, 0.04 mm {0.0016 in} and the tip surface of the drive pinion value is 2, the formula is ((0.06+0.04)/2)-(2/100)=0.03.

Therefore, assemble a spacer 0.03 mm {0.0012} thicker than the currently assembled one. The thickness settings are in increments of

0.015 mm {0.0006}, so choose one closest in thickness and install.

SPACER TABLE

Identification mark

Thickness (mm {in})

3.080 {0.1213}

3.095 {0.1220}

3.110 {0.1224}

3.125 {0.1230}

3.140 {0.1234}

3.155 {0.1242}

3.170 {0.1248}

3.185 {0.1254}

3.200 {0.1260}

3.215 {0.1266}

3.230 {0.1271}

3.245 {0.1278}

3.260 {0.1283}

3.275 {0.1289}

Identification mark

Thickness (mm {in})

3.290 {0.1295}

3.305 {0.1301}

3.320 {0.1307}

3.335 {0.1313}

3.350 {0.1319}

3.365 {0.1325}

3.380 {0.1331}

3.395 {0.1337}

3.410 {0.1343}

3.425 {0.1348}

3.440 {0.1354}

3.455 {0.1360}

3.470 {0.1366}

REAR BEARING ASSEMBLY NOTE

NOTE:



Install the spacer with the chamfer on the gear side.

1. Assemble the spacer selected in the pinion height adjustment to the drive pinion.

2. Press the drive pinion into the rear bearing using the SSTs and a press.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 37: Pressing Drive Pinion Into Rear Bearing Using SSTs & Press

Courtesy of MAZDA MOTORS CORP.

DRIVE PINION COMPONENT ASSEMBLY NOTE

Drive Pinion Preload Adjustment

NOTE:



Perform preload adjustment with the oil seal uninstalled.

1. Assemble the following parts to the drive pinion.



New collapsible spacer



Front bearing



New spacer

Companion flange



New washer

New locknut

2. Turn the serrated part of the drive pinion by hand to seat the bearing.

3. Tighten the locknut temporarily tightened in Step 1 from the lower limit of the specified tightening torque using the SST , and obtain the specified preload. Record the tightening torque at this time.

Tightening torque

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

150-380 N.m {15.3-38.7 kgf.m, 111-280 ft.lbf}

Drive pinion preload

1.3-1.8 N.m {14-18 kgf.cm, 12-15 in.lbf}

Fig. 38: Tighten Locknut Using SST

Courtesy of MAZDA MOTORS CORP.



If the specified preload cannot be obtained within the specified tightening torque, replace with a new collapsible spacer and adjust again.

4. Remove the locknut, washer, and companion flange.

OIL SEAL (COMPANION FLANGE) ASSEMBLY NOTE

1. Apply differential oil to the lip of a new oil seal.

2. Assemble the oil seal using the SST .

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 39: Assembling Oil Seal Using SST

Courtesy of MAZDA MOTORS CORP.

LOCKNUT ASSEMBLY NOTE

1. Tighten a new locknut with the torque recorded at the drive pinion preload adjustment using the SST .

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 40: Tightening Locknut Using SST

Courtesy of MAZDA MOTORS CORP.

2. Verify that the drive pinion preload is within the specification.



If not within the specification, perform the preload adjustment again.

Drive pinion preload

1.3-1.8 N.m {14-18 kgf.cm, 12-15 in.lbf}

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 41: Measuring Drive Pinion Preload

Courtesy of MAZDA MOTORS CORP.

ADJUSTMENT SHIM ASSEMBLY NOTE

Ring Gear Backlash Adjustment

1. Stack the side bearing race and differential gear case component on the surface plate as shown in Fig. 42 and measure the height using a caliper and a ruler. This is value A.

Standard Height A

151.4-152.6 mm {5.961-6.007 in}

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 42: Measuring Height Using Caliper & Ruler

Courtesy of MAZDA MOTORS CORP.

2. Measure the width of the section of the differential gear case component installed in the differential carrier. This is value B.

Standard width B

171 mm {6.73 in}

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 43: Measuring Width Of Differential Gear Case Component In Differential Carrier

Courtesy of MAZDA MOTORS CORP.

1. The combined thickness of the left and right adjustment shims is obtained by the following formula.

Shim thickness (mm {in}) =B-A+ (0.01-0.03 {0.0004-0.0118 in})

2. If the combined thickness of the previously assembled adjustment shims is equal to the calculated thickness, use the shims as they are.

3. If the combined thickness of the previously assembled adjustment shims is not equal to the calculated thickness, or if the adjustment shims have to be replaced, select two appropriate adjustment shims from the table below.

ADJUSTMENT SHIM TABLE

Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})

550

560

565

5.50 {0.217}

5.60 {0.220}

5.65 {0.222}

605

610

615

6.05 {0.238}

6.10 {0.240}

6.15 {0.242}

570

575

580

585

5.70 {0.224}

5.75 {0.226}

5.80 {0.228}

5.85 {0.230}

620

625

630

635

6.20 {0.244}

6.25 {0.246}

6.30 {0.248}

6.35 {0.250}

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

590

595

600

5.90 {0.232}

5.95 {0.234}

6.00 {0.236}

640

650

6.40 {0.252}

6.50 {0.256}

NOTE:



If the adjustment shims are to be reused, assemble the left and right shims that were identified during disassembly.

When assembling the side bearing races, do not mix the left and right side bearings that were identified during disassembly.

4. Assemble the differential gear case component and the side bearing race to the differential carrier.

5. Tap the selected adjustment shim between the differential carrier and the side bearing race with a plastic hammer as shown in Fig. 44 .

Fig. 44: Tapping Selected Adjustment Shim Between Differential Carrier & Side Bearing Race

With Plastic Hammer

Courtesy of MAZDA MOTORS CORP.

6. Align the bearing cap alignment marks, assemble the bearing cap, and then temporarily tighten the bolts.

7. Install the dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of one of the ring gear teeth.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 45: Measuring Probe Of Dial Gauge Attached To End Of One Of Ring Gear Teeth

Courtesy of MAZDA MOTORS CORP.

8. Secure the drive pinion and measure the backlash of the ring gear.

Backlash of drive pinion and ring gear

Standard: 0.09-0.11 mm {0.0035-0.0043 in}

Minimum value: 0.05 mm {0.0020 in} or more

Variance: 0.07 mm {0.0028 in} or less

NOTE:



Measure the backlash at 4 locations around the ring gear. Make sure all of the 4 locations are within specification, and the minimum value for the 4 locations is 0.05 mm {0.0020 in} or more and the variance is

0.07 mm {0.0028 in} or less

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 46: Measuring Backlash At 4 Locations Around Ring Gear

Courtesy of MAZDA MOTORS CORP.

9. If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.

NOTE:



When moving the gear case component in the axial direction, replace the adjustment shims. If the adjustment shim on the right side is replaced with one that is 0.05 mm {0.0020 in} thicker, replace the one on the left with one that is 0.05 mm {0.0020 in} thinner.

BEARING CAP ASSEMBLY NOTE

1. Align the bearing cap alignment marks and assemble the bearing cap with the arrow facing outward.

Tightening torque

72.6-106.9 N.m {7.41-10.91 kgf.m, 53.5-78.84 ft.lbf}

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 47: Aligning Bearing Cap Alignment Marks & Assembling Bearing Cap

Courtesy of MAZDA MOTORS CORP.

2. Perform the drive pinion and ring gear tooth contact inspection.

DRIVE PINION, RING GEAR TOOTH CONTACT INSPECTION

1. Apply tooth marking compound evenly to both surfaces of the ring gear.

2. Rotate the ring gear back and forth for several times.

3. Inspect the tooth contact pattern in 4 locations around the ring gear, and verify that the tooth contact points exhibit the pattern shown in Fig. 48 .



If the tooth contact points are normal, wipe off the marking compound.



If the tooth contact points are not normal, adjust the pinion height, then adjust the backlash.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 48: Inspecting Tooth Contact Pattern In Locations Around Ring Gear

Courtesy of MAZDA MOTORS CORP.

4. If the toe and flank contact points appear as shown in Fig. 49 after the drive pinion and ring gear teeth contact inspection, replace the spacer with a thinner one, and move the drive pinion outward.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 49: Identifying Toe Contact & Flank Contact Points

Courtesy of MAZDA MOTORS CORP.

5. If the heel and face contact points appear as shown in Fig. 50 after the drive pinion and ring gear teeth contact inspection, replace the spacer with a thicker one, and move the drive pinion inward.

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 50: Identifying Heel & Face Contact Points

Courtesy of MAZDA MOTORS CORP.

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2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata

2007 ACCESSORIES & BODY, CAB

Doors & Liftgate - MX-5 Miata

DOORS LOCATION INDEX

Fig. 1: Identifying Doors & Liftgate Components

Courtesy of MAZDA MOTORS CORP.

DOOR REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. To remove the door stay (checker), remove the following parts:

1. Door trim (See DOOR TRIM REMOVAL/INSTALLATION .)

2. Door speaker (See DOOR SPEAKER REMOVAL/INSTALLATION .)

3. To remove the door hinges, remove the following parts:

1. Front bumper (See FRONT BUMPER REMOVAL/INSTALLATION .)

2. Front combination lights (See FRONT COMBINATION LIGHT

REMOVAL/INSTALLATION .)

3. Side step molding (See SIDE STEP MOLDING REMOVAL ) (See SIDE STEP MOLDING

INSTALLATION .)

4. Mad guard

5. Front fender panel (See FRONT FENDER PANEL REMOVAL/INSTALLATION .)

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

6. Adjust the door. (See DOOR ADJUSTMENT .)

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata

Fig. 2: Removing/Installing Door (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CONNECTOR REMOVAL NOTE

1. Pull down the lever in the direction indicated by the arrow and disconnect the connector.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata

Fig. 3: Pulling Down Lever

Courtesy of MAZDA MOTORS CORP.

DOOR ADJUSTMENT

1. Measure the gap and height difference between the door and the body.

2. Loosen the door hinge installation bolts or the door lock striker installation screws, and adjust the door.

3. Tighten the bolts or screws.

Fig. 4: Identifying Gap & Height Difference Between Door & Body

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Standard clearance

A-A top and bottom (a): 3.1-5.0 mm {0.13-0.19 in}

A-A middle (a): 3.3-5.2 mm {0.13-0.20 in}

B-B top (b): -1.0-1.0 mm {-0.040-0.039 in}

B-B bottom (b): -0.5-1.5 mm {-0.020-0.059 in}

C-C top and bottom (c): 3.0-5.0 mm {0.12-0.19 in}

C-C top (c): -1.0-1.0 mm {-0.040-0.039 in}

C-C bottom (d): -0.5-1.5 mm {-0.020-0.059 in}

DOOR UNIT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

2. Remove the following parts:

1. Door trim (See DOOR TRIM REMOVAL/INSTALLATION .)

2. Door speaker (See DOOR SPEAKER REMOVAL/INSTALLATION .)

3. Disconnect the power outer mirror harness connector.

4. Disconnect the door lock actuator connector.

5. Disconnect the power window motor connector.

6. Remove screws A and B.

7. Pull the door unit outward and detach clips C.

8. Remove the door unit.

9. Install in the reverse order of removal.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata

Fig. 5: Removing/Installing Door Unit

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

2007 DRIVELINE/AXLES

Drive Shaft - MX-5 Miata

REAR DRIVE SHAFT LOCATION INDEX

Fig. 1: Identifying Location Of Rear Drive Shaft Components

Courtesy of MAZDA MOTORS CORP.

REAR DRIVE SHAFT INSPECTION

1. Verify that the drive shaft is not twisted or damaged.



If there is any malfunction, replace the applicable part.

2. Inspect the dust boot for damage and cracks.



If there is any malfunction, replace the applicable part.

3. Move the spline and joint up and down, left and right by hand and verify that there is no roughness.



If there is any malfunction, replace the applicable part.

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

REAR 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 wiring 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. Drain the rear differential oil.

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

4. Add rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 2: Identifying Rear Drive Shaft (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

LOCKNUT REMOVAL NOTE

1. Lock the disc plate by applying the brakes.

2. Knock the crimped portion of the locknut outward using a chisel and a hammer.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 3: Knocking Out Crimped Portion Of Locknut Using Chisel & Hammer

Courtesy of MAZDA MOTORS CORP.

3. Remove the locknut.

BRAKE CALIPER COMPONENT REMOVAL NOTE

1. Suspend the brake caliper component using a cable or equivalent.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 4: Suspending Brake Caliper Component

Courtesy of MAZDA MOTORS CORP.

2. Temporarily tighten the wheel nut to prevent the disc plate from falling off.

REAR DRIVE SHAFT REMOVAL NOTE

1. Temporarily install a spare nut to the end of the rear drive shaft.

2. Knock the nut with copper hammer lightly and remove the rear drive shaft from the wheel hub.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 5: Knocking Out Nut With Copper Hammer Lightly & Removing Rear Drive Shaft From

Wheel Hub

Courtesy of MAZDA MOTORS CORP.

3. Separate the rear drive shaft from the wheel hub.

4. Insert a tire lever or equivalent between the rear differential and differential side outer ring, and then remove the rear drive shaft.

CAUTION:



The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal when removing the drive shaft from the differential.

5. Pull the rear drive shaft to the outer side of the vehicle and disconnect it from the rear differential.

6. To hold the rear knuckle component, install the rear lateral link (upper) to the rear knuckle temporarily after disconnecting the rear drive shaft.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 6: Removing Rear Shaft

Courtesy of MAZDA MOTORS CORP.

CLIP INSTALLATION NOTE

1. Point the opening of the new drive shaft clip upward, install it to the clip groove at the end of the rear drive shaft with the installation width within the specification.

Standard 31.2

mm {1.23 in}

2. After installing the clip, measure the outer diameter. If it exceeds the specification, reinstall the new clip.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 7: Identifying Clip Groove End Of Rear Drive Shaft

Courtesy of MAZDA MOTORS CORP.

REAR DRIVE SHAFT INSTALLATION NOTE

1. Apply differential oil to the differential oil seal lip.

CAUTION:



The sharp edges of the rear drive shaft can slice or puncture the oil seal. Be careful not to damage the oil seal when installing the rear drive shaft from the rear differential.

2. Insert the rear drive shaft into the rear differential with the clip opening facing upward.

3. After installation, verify that the rear drive shaft is securely held by the clip by pulling the outer ring on the differential side towards the axle.

LOCKNUT INSTALLATION NOTE

1. Tighten a new locknut.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 8: Tightening New Locknut (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

2. Crimp the locknut, using a chisel and hammer.

REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in Fig. 9 .

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 9: Disassembling/Assembling Rear Drive Shaft

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

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

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 10: 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

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 11: Removing Crimp Of Clip Using Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

TRIPOD JOINT SOCKET DISASSEMBLY NOTE

1. Place an alignment mark on the drive shaft and the outer ring.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 12: Placing Alignment Mark On Drive Shaft & Outer Ring

Courtesy of MAZDA MOTORS CORP.

2. Remove the outer ring.

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

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 13: Removing Snap Ring Using Snap Ring Plier

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

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 14: Wrapping Shaft Spline With Vinyl Tape

Courtesy of MAZDA MOTORS CORP.

2. Remove the boot.

BOOT ASSEMBLY NOTE

NOTE:



The boot shapes on the axle side and the differential side are different so do not miss install 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

90-110 g {3.18-3.88 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

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

1. Align the tripod joint with the shaft mark and insert it using a brass bar.

CAUTION:



To prevent damage to the component, do not tap the roller part when installing.

Fig. 15: Aligning Tripod Joint With Shaft Mark

Courtesy of MAZDA MOTORS CORP.

2. Install the new snap ring to the shaft installation slot securely using a snap ring pliers.

TRIPOD JOINT SOCKET 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

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

CAUTION:



Do not let the grease leak.

Do not damage the boot.

Fig. 16: Releasing Trapped Air From Boot

Courtesy of MAZDA MOTORS CORP.

4. Set the drive shaft length to the specification when the inside of the boots is at ambient pressure.

Drive shaft length

Left side: 778.5-788.5 mm {30.65-31.04 in}

Right side: 818.5-828.5 mm {32.22-32.62 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.

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.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 17: Inserting End Of Boot Band Between Boot Band Clip & Fold Back Clip Tabs Using

Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

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

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 18: Identifying 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}

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 thru 4.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 19: Crimping Boot Band

Courtesy of MAZDA MOTORS CORP.

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.



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}

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2007 Mazda MX-5 Miata Sport

2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

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 thru 9.

Microsoft

2007 DRIVELINE/AXLES Technical Data - MX-5 Miata

2007 DRIVELINE/AXLES

Technical Data - MX-5 Miata

DRIVELINE/AXLE TECHNICAL DATA

Item

Maximum front wheel bearing play

Maximum rear wheel bearing play

Drive shaft length

Differential oil

Backlash of pinion gear and side gear

Differential pinion height

Differential drive pinion preload

Backlash of drive pinion and ring gear

Propeller shaft maximum runout

Propeller shaft initial torque (Reference value)

Specification

0.05 mm {0.002 in}

Left side: 778.5-788.5 {30.65-31.04}

Right side: 818.5-828.5 {32.22-32.62}

Grade: API service GL-5

Viscosity: SAE 90, SAE 80W-90, SAE 75W-90

(Not available from Mazda)

Capacity (approx. quantity):

0.6-0.8 L {0.63-0.85 US qt, 0.53-0.70 Imp qt}

0.1 mm {0.004 in} or less

0.038 mm {0.0015 in} or less

1.3-1.8 N.m {14-18 kgf.cm, 12.1-15.6 in.lbf}

Standard: 0.09-0.11 mm {0.0035-0.0043 in}

Minimum value: 0.05 mm {0.0020 in} or more

Variance: 0.07 mm {0.0028 in} or less

0.4 mm {0.016 in}

0.29-0.98 N.m

2007 BRAKES Dynamic Stability Control - MX-5 Miata

2007 BRAKES

Dynamic Stability Control - MX-5 Miata

DYNAMIC STABILITY CONTROL LOCATION INDEX

Fig. 1: Identifying Location Of Dynamic Stability Control Connector Terminals

Courtesy of MAZDA MOTORS CORP.

DSC SYSTEM WIRING DIAGRAM

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 2: DSC System Wiring Diagram

Courtesy of MAZDA MOTORS CORP.

DSC SYSTEM INSPECTION

PREPARATION

1. Verify that battery is fully charged.

2. Turn the ignition switch to the ON position, and verify that the ABS warning light goes out after approx.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

3 s .

3. Turn the ignition switch off.

4. Jack up the vehicle and support it evenly on safety stands.

5. Shift to the N position.

6. Verify that all four wheels rotate.

7. Rotate the inspected wheels by hand, and verify there is no brake drag.



If there is any brake drag, perform regular brake inspection.

 If there is no brake drag, perform DSC HU/CM operation inspection.

ABS CONTROL INSPECTION

1. Perform "Preparation".

2. Connect the M-MDS to the DLC-2.

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

Fig. 3: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

BRAKE PRESSURE RETENTION

Command name

Inspected wheels

LF RF LR RR

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

V_TRC_L

V_TRC_R

LF_OUTLET

LR_INLET

LR_OUTLET

OFF

V_STB_L

V_STB_R

LF_INLET ON

OFF

RF_INLET

RF_OUTLET

RR_INLET

RR_OUTLET

PMP_MOTOR

OFF

BRAKE PRESSURE REDUCTION

Inspected wheels

Command name

LF RF LR RR

V_TRC_L

V_TRC_R

V_STB_L

V_STB_R

OFF

LF_INLET

LF_OUTLET

LR_INLET

LR_OUTLET

RF_INLET

RF_OUTLET

RR_INLET

RR_OUTLET

PMP_MOTOR

OFF

CAUTION:



To protect the DSC HU/CM, the solenoid valve and the pump motor used during active command mode stay on for only 10 s or less each time they are switched on.

NOTE:



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

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

5. While brake pressure is maintained and a DSC HU/CM operation click sound is heard, confirm that the

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata wheel does not rotate. While brake pressure is being reduced and an DSC HU/CM operation click sound is heard, confirm that the wheel rotates.



Performing the inspection above determines the following:



The DSC HU/CM brake lines are normal.

The DSC HU/CM hydraulic system is not significantly abnormal (including DSC HU/CM).



The DSC HU/CM internal electrical parts (solenoid, motor and other parts) are normal.

The DSC unit and DSC HU/CM output system wiring harnesses (solenoid valve, relay system) are normal.



However, the following items cannot be verified.



Malfunction with intermittent occurrence of the above items



Malfunction of DSC HU/CM input system wiring harnesses and parts

 Extremely small leaks in the DSC HU/CM internal hydraulic system

DSC CONTROL INSPECTION

1. Perform "Preparation".

2. Connect the M-MDS to the DLC-2.

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

CAUTION:



To protect the DSC HU/CM, the solenoid valve and the pump motor used during active command mode stay on for only 10 s or less each time they are switched on.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 4: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

ACTIVE COMMAND MODE INSPECTION

Inspected wheels

Command name Understeer control inhibited Oversteer control inhibited

LF RF LR RR

V_TRC_L

V_TRC_R

V_STB_L

OFF

V_STB_R

LF_INLET

LF_OUTLET

LR_INLET

OFF

LR_OUTLET

RF_INLET

RF_OUTLET OFF

ON OFF

RR_INLET

RR_OUTLET

PMP_MOTOR

OFF

4. Send the command while rotating the wheel being inspected by hand in a forward direction.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

5. Confirm that the wheel does not rotate easily while a DSC HU/CM operation click sound is heard.



Performing the inspection above determines the following:



The DSC HU/CM brake lines are normal.



The DSC HU/CM hydraulic system is not significantly abnormal (including DSC HU/CM).

The DSC HU/CM internal electrical parts (solenoid, motor and other parts) are normal.



The DSC unit and DSC HU/CM output system wiring harnesses (solenoid valve, relay system) are normal.

 However, the following items cannot be verified.



Malfunction with intermittent occurrence of the above items



Malfunction of DSC HU/CM input system wiring harnesses and parts

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

DSC HU/CM REMOVAL/INSTALLATION

CAUTION:



When replacing the DSC HU/CM with a new one, configuration procedure must be performed before removing the DSC HU/CM. If configuration is not completed before removing the DSC HU/CM, DTC

B2477 will be detected.

The DSC may not function normally when the DSC HU/CM is replaced. After installation, always perform the initialization procedures for the DSC HU/CM, combined sensor and the steering angle sensor. (See COMBINED SENSOR INITIALIZATION

PROCEDURE .) (See STEERING ANGLE SENSOR INITIALIZATION

PROCEDURE .) (See STEERING ANGLE SIGNAL INITIALIZATION

PROCEDURE .)

The internal parts of the DSC HU/CM could be damaged if dropped.

Be careful not to drop the DSC HU/CM. Replace the DSC HU/CM if it is subjected to an impact.

1. Perform DSC configuration. (See DSC CONFIGURATION .)

2. Remove in the order indicated in Fig. 5 .

3. Install in the reverse order of removal.

4. After installation, perform the combined sensor initialization procedure. (See COMBINED SENSOR

INITIALIZATION PROCEDURE .)

5. After installation, perform the steering angle sensor initialization procedure. (See STEERING ANGLE

SENSOR INITIALIZATION PROCEDURE .)

6. After installation, perform the steering angle signal initialization procedure. (See STEERING ANGLE

SIGNAL INITIALIZATION PROCEDURE .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 5: Identifying DSC HU/CM With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

DSC HU/CM CONNECTOR REMOVAL NOTE

1. Pull the lock lever up in the direction of the arrow.

2. Pull the connector toward the vehicle rear and remove it.

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 6: Identifying Lock Lever Position

Courtesy of MAZDA MOTORS CORP.

BRAKE PIPE REMOVAL NOTE

1. Place an alignment mark on the brake pipe and DSC HU/CM.

2. Apply protective tape to the connector to prevent brake fluid from entering.

3. Remove the brake pipe.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 7: Brake Pipe At DSC HU/CM

Courtesy of MAZDA MOTORS CORP.

BRAKE PIPE (DSC HU/CM-BRAKE PIPE JOINT) INSTALLATION NOTE

1. Align with the mark made before removing the brake pipe and temporarily install the brake pipe to the

DSC HU/CM.

CAUTION:



If the brake pipe is tightened to the specified torque, it may be difficult to install it to the vehicle. Therefore, only temporarily tighten the brake pipe so that it can still be moved.

BRAKE PIPE INSTALLATION NOTE

1. Align the marks made before removal and install the brake pipe to the DSC HU/CM and brake pipe joint referring to the figure.

2. Tighten the brake pipe to the specified torque using the SST (49 0259 770B).

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 8: Identifying DSC HU/CM

Courtesy of MAZDA MOTORS CORP.

DSC HU/CM CONNECTOR INSTALLATION NOTE

1. After connecting the connector, verify that the lock lever is completely pushed in.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 9: Identifying Lock Lever Position

Courtesy of MAZDA MOTORS CORP.

DSC CONFIGURATION

1. Connect the M-MDS to the DLC-2 connector.

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.



When using the IDS (laptop PC)



1. Select the "Module Programming".

When using the PDS (Pocket PC)

1. Select "Programming".

2. Select "Module Programming".

3. Then, select the "Programmable Module Installation" and "ABS" from the screen menu..

4. Perform the configuration according to the directions on the screen.

5. Retrieve DTCs using the M-MDS, then verify if DTCs are present.



If a DTC is present, perform the applicable DTC inspection. (See ON-BOARD DIAGNOSTIC

(DYNAMIC STABILITY CONTROL SYSTEM) .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 10: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

DSC HU/CM INSPECTION

1. Disconnect the DSC HU/CM connector. (See DSC HU/CM REMOVAL/INSTALLATION .)

2. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Attach the tester lead to the DSC HU/CM harness side connector, then inspect voltage, continuity or resistance according to the standard (reference value) on REFERENCE VALUE TABLE .

STANDARD (REFERENCE VALUE)

Fig. 11: Identifying DSC HU/CM Connector Terminals

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2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

STANDARD REFERENCE VALUE TABLE

Terminal

Signal name Connected to

Ground (ABS motor)

Power supply

(ABS motor operation)

Power supply

(solenoid operation)

Ground (DSC system)

LF wheelspeed sensor

(ground)

LF wheelspeed sensor

(single)

Ground point

Battery

Ground point

LF ABS wheel-speed sensor

Measured item

Continuity

Voltage

Continuity

Measured terminal

(measured condition)

A-ground point

Under any condition

D-ground point

E-LF ABS wheel-speed sensor connector terminal B

F-LF ABS wheel-speed sensor connector terminal A

Standard

Continuity detected

B+

Continuity detected

Inspection item

(s)



Wiring harness

(Aground point)



Wiring harness

(Bbattery)



Wiring harness

(Cbattery)



Wiring harness

(D-ground point)



Wiring harness

(E-LF

ABS wheelspeed sensor connector terminal



Wiring harness

(F-LF

ABS wheelspeed sensor connector terminal

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

LR wheelspeed sensor

(signal)

LR ABS wheel-speed sensor

LR wheelspeed sensor

(ground)

LR ABS wheel-speed sensor

RR wheelspeed (signal)

RR ABS wheel-speed sensor

Power supply

(system)

Ignition switch

RR wheelspeed sensor

(ground)

RR ABS wheel-speed sensor

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Thursday, July 09, 2009 3:17:05 PM

Continuity

Voltage

G-LR ABS wheel-speed sensor connector terminal A

H-LR ABS wheel-speed sensor connector terminal B

I-RR ABS wheel-speed sensor connector terminal A

Ignition switch at ON

Continuity detected

B+



Wiring harness

(G-LR

ABS wheelspeed sensor connector terminal



Wiring harness

(H-LR

ABS wheelspeed sensor connector terminal



Wiring harness (I-

RR ABS wheelspeed sensor connector terminal



Wiring harness (Jignition switch)

Ignition switch is off.

1 V or less -

Continuity

L-RR ABS wheel-speed sensor connector terminal B

Page 15

Continuity detected



Wiring harness

(L-RR

ABS wheelspeed sensor connector terminal

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

RF wheelspeed sensor

(signal)

RF ABS wheel-speed sensor

Brake switch Brake switch

RF wheelspeed sensor

(ground)

RF ABS wheel-speed sensor

DSC OFF switch

Microsoft

Thursday, July 09, 2009 3:17:05 PM

Continuity

Voltage

M-RF ABS wheel-speed sensor connector terminal A

N-ground point (Brake pedal depressed)

Continuity detected

B+



Wiring harness

(M-RF

ABS wheelspeed sensor connector terminal



Wiring harness

(N-brake switch)



Brake switch

N-ground point (Brake pedal not depressed)

1 V or less -

Continuity

O-RF ABS wheel-speed sensor connector terminal B

P-DSC OFF switch connector terminal A

Page 16

Continuity detected



Wiring harness

(O-RF

ABS wheelspeed sensor connector terminal



Wiring harness

(P-DSC

OFF switch connector terminal

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

CAN_L

CAN_H

Ground

(combined sensor)

Combined sensor

Yaw rate

(signal)

Yaw rate

(reference signal)

DLC-2

(CAN_L)

DLC-2

(CAN_H)

Combined sensor

Yaw rate (test Combined signal) sensor

Combined sensor

Microsoft

Thursday, July 09, 2009 3:17:05 PM

Continuity

W-DLC-2 terminal

CAN_L

X-DLC-2 terminal

CAN_H

Y-combined sensor connector terminal F

Continuity detected



Wiring harness

(W-DLC-

2 terminal

CAN_L)



Wiring harness

(X-DLC-2 terminal

CAN_H)



Wiring harness

(Ycombined sensor connector terminal

Continuity

AA-combined sensor connector terminal B

AB-combined sensor connector terminal C

Continuity detected



Wiring harness

(AAcombined sensor connector terminal



Wiring harness

(ABcombined sensor connector terminal

Continuity

AE-combined sensor connector terminal A

Page 17

Continuity detected



Wiring harness

(AEcombined sensor connector

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Lateral-G

(signal)

Combined sensor terminal

Continuity

AI-combined sensor connector terminal D

Continuity detected



Wiring harness

(AIcombined sensor connector terminal

STEERING ANGLE SIGNAL INITIALIZATION PROCEDURE

WARNING:



If the initialization procedure of the steering angle signal is not completed, the DSC will not operate properly and may cause an accident. Therefore, always perform initialization of the DSC HU/CM steering angle signal to ensure proper DSC operation when any of the following items are performed.



Steering angle sensor replacement



DSC HU/CM replacement

1. Inspect the wheel alignment and inflation pressure.

 If there is any malfunction, adjust the applicable part.

2. Park the vehicle on level ground.

3. Turn the ignition switch off.

4. Connect the M-MDS to the DLC-2.

5. After the vehicle is identified, select the following items from the initial screen of the M-MDS.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata



When using the IDS (laptop PC)



1. Select "Chassis".

2. Select "ABS/DSC".

3. Select "Sensor Initialization".

When using the PDS (Pocket PC)

1. Select "All Tests and Calibrations".

2. Select "Sensor Initialization".

6. Perform the initialization procedure according to the directions on the screen.

7. Drive the vehicle forward.

8. After 5 min of driving, verify that the DSC system is normal.

Fig. 12: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION

1. Remove or install the front ABS wheel-speed sensor in the same order of vehicles with ABS. (See

FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION .)

FRONT ABS WHEEL-SPEED SENSOR INSPECTION

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

1. Inspect the front ABS wheel-speed sensor in the same order of vehicles with ABS. (See FRONT ABS

WHEEL-SPEED SENSOR INSPECTION .)

REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION

1. Remove or install the rear ABS wheel-speed sensor in the same order of vehicles with ABS. (See REAR

ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION .)

REAR ABS WHEEL-SPEED SENSOR INSPECTION

1. Inspect the rear ABS wheel-speed sensor in the same order of vehicles with ABS. (See REAR ABS

WHEEL-SPEED SENSOR INSPECTION .)

COMBINED SENSOR REMOVAL/INSTALLATION

CAUTION:



The internal parts of the combined sensor could be damaged if dropped. Be careful not to drop the combined sensor. Replace the combined sensor if it is subjected to an impact. Also, do not use an impact wrench or other similar air tools when removing/installing the sensor.

1. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

2. Remove in the order indicated in Fig. 13 .

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 13: Combined Sensor (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

4. After installation, perform the combined sensor initialization procedure. (See COMBINED SENSOR

INITIALIZATION PROCEDURE .)

COMBINED SENSOR INSPECTION

1. Turn the ignition switch off.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

2. Connect the M-MDS to the DLC-2.

3. Select the following PIDs, then inspect the lateral acceleration speed and the yaw rate.



LAT_ACCL: (lateral acceleration speed)



YAW_RATE: (yaw rate)

1. Lateral acceleration speed inspection

Fig. 14: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

1. Verify the LAT_ACCL change when the combined sensor is tilted to the left and right.



If there is any malfunction, replace the combined sensor.

Standard

When the sensor is tilted to the right (A):

LAT_ACCL changes negatively.

When the sensor is tilted to the left (B):

LAT_ACCL changes positively.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 15: Tilting Combined Sensor Left And Right

Courtesy of MAZDA MOTORS CORP.

2. Yaw rate inspection

1. Verify the YAW_RATE change when the combined sensor is rotated to the left and right.



If there is any malfunction, replace the combined sensor.

Standard

When the sensor is rotated to the right (A):

YAW_RATE changes negatively.

When the sensor is rotated to the left (B):

YAW RATE changes positively.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 16: Tilting Combined Sensor Left And Right

Courtesy of MAZDA MOTORS CORP.

COMBINED SENSOR INITIALIZATION PROCEDURE

WARNING:



Unless the initialization procedure of the combined sensor is completed, the DSC will not operate, causing an unexpected accident. Therefore, always perform the initialization procedure to ensure DSC operation if the combined sensor and DSC HU/CM have been removed or replaced.

1. Inspect the wheel alignment and inflation pressure.

 If there is any malfunction, adjust the applicable part.

2. Park the vehicle on level ground.

3. Turn the ignition switch off.

4. Connect the M-MDS to the DLC-2.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 17: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

5. After the vehicle is identified, select the following items from the initial screen of the M-MDS.



When using the IDS (laptop PC)

1. Select "Chassis".

2. Select "ABS/DSC".



3. Select "Sensor Initialization".

When using the PDS (Pocket PC)

1. Select "All Tests and Calibrations".

2. Select "Sensor Initialization".

6. Drive the vehicle forward.

7. After 5 min of driving, verify that the DSC system is normal.

BRAKE FLUID PRESSURE SENSOR INSPECTION

1. Turn the ignition switch off.

2. Install the SSTs to the master cylinder.

NOTE:



Install the SST (49 N043 001) to the master cylinder using a commercially available flare nut wrench.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata



Flare nut across flat: 12 mm {0.47 in}

3. Bleed the air from the SSTs and the brake line. (Bleed air from the SSTs through air bleeding valve A.)

Fig. 18: Installing SSTs To Master Cylinder

Courtesy of MAZDA MOTORS CORP.

4. Connect the M-MDS to the DLC-2.

5. Select the MCYLI P PID.

6. Start the engine.

7. Depress the brake pedal, and confirm that the fluid pressure value of the SST (Gauge) and the value shown on the M-MDS are equal.



If the fluid pressures are different, replace the DSC HU/CM.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 19: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

STEERING ANGLE SENSOR REMOVAL/INSTALLATION

NOTE:



The steering angle sensor is integrated into the combination switch to ensure sensor performance. Replace the steering angle sensor and combination switch as a single unit. (See COMBINATION SWITCH

REMOVAL/INSTALLATION .)

STEERING ANGLE SENSOR INSPECTION

1. Remove the column cover. (See COLUMN COVER REMOVAL/INSTALLATION .)

2. Measure the voltage between steering angle sensor terminal B and ground.



If there is any malfunction, inspect the wiring harness between steering angle sensor terminal B and battery, then repair or replace if necessary.

Standard voltage

B+

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 20: Identifying Steering Angle Sensor Connector Terminals

Courtesy of MAZDA MOTORS CORP.

3. Turn the ignition switch to the ON position, then measure the voltage between steering angle sensor terminal A and ground.



If there is any malfunction, inspect the wiring harness between steering angle sensor terminal A and ignition switch, then repair or replace if necessary.

Standard voltage

B+

4. Measure the voltage between steering angle sensor terminal H and the ground.



If there is any malfunction, inspect the wiring harness between steering angle sensor terminal H and ground point, then repair or replace if necessary.

Standard voltage

0 V

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

5. Turn the ignition switch off.

6. Connect the M-MDS to the DLC-2.

7. Select the SWA_POS PID.

8. Verify the SWA_POS changes when the steering wheel is turned to the left and right.



If there is any malfunction, replace the steering angle sensor.

Standard

When the steering wheel is turned to the right:

SWA_POS changes positively.

When the steering wheel is turned to the left:

SWA_POS changes negatively.

Fig. 21: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

STEERING ANGLE SENSOR INITIALIZATION PROCEDURE

WARNING:



Unless the initialization procedure of the steering angle sensor is

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata completed, the DSC will not operate, causing an unexpected accident. Therefore, always perform the initialization procedure to ensure DSC operation if the power supply to the steering angle sensor has been cut off due to disconnection of the steering angle sensor connector or negative battery cable, or any other cause.

NOTE:



The initialization value of the steering angle sensor is stored using the battery power supply. Therefore, the battery power supply of the steering angle sensor is cut and the stored initialization value is cleared when any of the following items are performed.



Negative battery cable disconnection



Steering angle sensor connector disconnection



Fuse (ROOM 15A) removal

Wiring harness disconnection between battery and steering angle sensor connector

1. Inspect the wheel alignment, inflation pressure, and the installation condition of the steering wheel.



If there is any malfunction, adjust the applicable part.

2. Connect the negative battery cable.

3. Turn the ignition switch to the ON position.

4. Confirm that the DSC indicator light illuminates and that the DSC OFF light flashes.

5. Turn the steering wheel to full right lock, then turn it to full left lock.

6. Confirm that the DSC OFF light goes out.

7. Turn the ignition switch off.

8. Turn the ignition switch to the ON position again, and confirm that the DSC indicator light goes out.



If the DSC indicator light does not go out, disconnect the negative battery cable, and perform the procedure again starting from Step 2 shown above.

9. Drive the vehicle for approx. 10 min , and confirm that the ABS warning and DSC indicator lights do not illuminate.

DSC OFF SWITCH REMOVAL/INSTALLATION

1. Remove the side panel. (See SIDE PANEL REMOVAL/INSTALLATION .)

2. Remove in the order indicated in Fig. 22 .

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 22: Identifying DSC OFF Switch

Courtesy of MAZDA MOTORS CORP.

3. Install in the reverse order of removal.

DSC OFF SWITCH CONNECTOR REMOVAL NOTE

1. Access the DSC OFF switch connector from behind of the dashboard, and squeeze the tabs of the switch connector.

2. Disconnect the DSC OFF switch connector from the DSC OFF switch.

DSC OFF SWITCH REMOVAL NOTE

1. Access the DSC OFF switch from behind of the dashboard, and squeeze the tabs of the switch.

2. Pull the DSC OFF switch towards the driver's side to remove it.

DSC OFF SWITCH INSPECTION

1. Remove the DSC OFF switch.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 BRAKES Dynamic Stability Control - MX-5 Miata

2. Verify that the continuity is as indicated in Fig. 23 .



If not as indicated in Fig. 23 replace the DSC OFF switch.

Fig. 23: DSC OFF Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.

Fig. 24: Identifying DSC OFF Switch Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 MAZDA MX-5 Miata

2007 MAZDA

MX-5 Miata

BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION

Component

A/C Relay (AIR COND)

Blower Relay (HEATER)

Cooling Fan Relay No. 1 (COOLING FAN1)

Cooling Fan Relay No. 2 (COOLING FAN2)

Cooling Fan Relay No. 3 (COOLING FAN3)

Drive-By-Wire Relay (ETV)

Front Fog Light Relay (FOG)

Fuel Pump Relay (CIRCUIT)

Headlight Relay (HEAD)

Horn Relay (HORN)

Ignition Relay (IGNITION)

Keyless Buzzer

Main Relay (EGI)

Rear Window Defroster Relay (DEFOG)

Starter Relay (ST)

TNS Relay (TAIL)

Trunk Lid Opener Relay

Location

In relay & main fuse block. See Fig. 1 .

Front of luggage compartment. See Fig. 35 .

In relay & main fuse block. See Fig. 1 .

Lower rear center of luggage compartment. See Fig. 38 .

CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION

Component

Fuse Block

Relay & Main Fuse Block

CONTROL UNITS

CONTROL UNITS LOCATION

Component

ABS HU/CM

DRL Control Module

DSC HU/CM

Flasher Control Module

Location

Behind left end of dash. See Fig. 9 .

Left side of engine compartment. See Fig. 4 .

Location

Right front of engine compartment. See Fig. 16 .

Behind left side of dash. See Fig. 40 .

Right front of engine compartment. See Fig. 17 .

Behind left side of dash. See Fig. 41 .

2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Keyless Control Module

PCM

Behind left end of dash. See Fig. 32 .

Left front corner of engine compartment. See Fig. 9 .

Power Retractable Hardtop Control Module Left side of retractable top storage compartment. See Fig. 57 .

SAS Control Module Under front of center console. See Fig. 24 .

Seat Weight Sensor Control Module Under passenger seat. See Fig. 27 .

TCM Behind left end of dash. See Fig. 19 .

MOTORS

MOTORS LOCATION

Component

Airflow Mode Actuator

Air Intake Actuator

Blower Motor

Cooling Fan Motor

Deck Panel Motor (Left)

Deck Panel Motor (Right)

Evaporative System Leak Detection

Pump

Front Door Lock Actuator (Left/Right)

Fuel Pump Unit

Mix Air Actuator

Power Outer Mirror (Left/Right)

Power Window Motor (Left/Right)

Roof Motor (Left)

Roof Motor (Right)

Starter

Trunk Lid Opener

Washer Motor

Wiper Motor

Location

Behind center of dash. See Fig. 22 .

Behind right side of dash. See Fig. 22 .

Integral to blower unit, behind right side of dash. See Fig. 21 .

Behind radiator. See Fig. 5 .

Left side of retractable top storage compartment. See Fig. 54 .

Right side of retractable top storage compartment. See Fig. 52 .

Under rear center of vehicle. See Fig. 14 .

In respective front door. See Fig. 36 .

Under rear center of vehicle. See Fig. 6 .

Behind right side of dash. See Fig. 22 .

On front respective door. See Fig. 30 .

In respective front door. See Fig. 29 .

Left side of retractable top storage compartment. See Fig. 58 .

Right Side Of Retractable Top Storage Compartment. See Fig.

50 .

Lower left side of engine. See Fig. 8 .

Lower rear center of luggage compartment lid. See Fig. 38 .

On washer fluid reservoir. See Fig. 43 .

On left side of firewall. See Fig. 43 .

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)

Accelerator Pedal Position Sensor

Microsoft

Thursday, July 09, 2009 3:08:59 PM

Location

At left front wheel. See Fig. 16 .

At left rear wheel. See Fig. 16 .

At right front wheel. See Fig. 16 .

At right rear wheel. See Fig. 16 .

Top of accelerator pedal assembly. See Fig. 11 .

2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Brake Fluid Level Sensor

Camshaft Position Sensor

Combined Sensor

Crankshaft Position Sensor

Crash Zone Sensor

Driver-Side Side Air Bag Sensor

Engine Coolant Temperature Sensor

Evaporator Temperature Sensor

Heated Oxygen Sensor (Front)

Heated Oxygen Sensor (Rear)

Knock Sensor

Manifold Absolute Pressure Sensor

Mass Air Flow Sensor

Passenger-Side Side Air Bag Sensor

Seat Track Position Sensor

Seat Weight Sensor (Left/Right)

Steering Angle Sensor

Throttle Position Sensor

Transmission Fluid Temperature Sensor

Turbine Sensor

Vehicle Speedometer Sensor

In brake fluid reservoir. See Fig. 46 .

Right rear of engine. See Fig. 12 .

Under rear of center console. See Fig. 18 .

On front of engine. See Fig. 12 .

At front center of engine compartment. See Fig. 24 .

Near base of left "B" pillar. See Fig. 25 .

Top rear of engine. See Fig. 13 .

Behind right side of dash. See Fig. 22 .

Upstream side of catalytic converter. See Fig. 10 .

Downstream side of catalytic converter. See Fig. 10 .

Left front of engine. See Fig. 10 .

Left rear of engine. See Fig. 13 .

Near left front corner of engine. See Fig. 11 .

Near base of right "B" pillar. See Fig. 25 .

Under driver's seat. See Fig. 26 .

Under respective side of passenger seat. See Fig. 27 .

In steering column. See Fig. 17 .

Left front of engine. See Fig. 12 .

Inside valve control body on transmission. See Fig. 20 .

On transmission. See Fig. 19 .

On transmission or transaxle. See Fig. 13 .

SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION

Component

EGR Valve

Fuel Injectors No. 1, 2, 3 & 4

Line Pressure Control Solenoid

Magnetic Clutch

Location

Rear of engine. See

Inside valve control body on transmission. See

Left front of engine, on A/C compressor. See

Fig. 12

Top of engine. See Fig. 13 .

Fig. 20

Fig. 23

Oil Control Valve

Purge Solenoid Valve

Shift Solenoids A, B, C, D, E, F & G

TCC Control Solenoid

Variable Intake Air Solenoid Valve

Right front of engine. See Fig. 12 .

Left side of engine compartment. See Fig. 12 .

Inside valve control body on transmission. See Fig. 20 .

Left side of engine. See Fig. 12 .

SWITCHES

SWITCHES LOCATION

Component

Back-Up Light Switch

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Thursday, July 09, 2009 3:08:59 PM Page 3

Location

On transmission. See Fig. 42 .

2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Brake Switch

Buckle Switch (Left/Right)

Clutch Pedal Position Switch

Deck Panel Limit Switch

Door Lock-Link Switch (Left)

Door Lock-Link Switch (Right)

Door Switch (Left/Right)

Hood Latch Switch

Key Reminder Switch

Neutral Switch

Oil Pressure Switch

Top of brake pedal assembly. See

On respective seat belt buckle. See

In driver's door. See

Center front of engine compartment. See

On left side of engine. See

Fig. 14

Fig. 26

Top of clutch pedal assembly. See Fig. 14 .

Right side of retractable top storage compartment. See Fig. 53 .

Fig. 34

In passenger door. See Fig. 36 .

On respective "B" pillar. See Fig. 48 .

Fig. 36

On steering column. See Fig. 45 .

On transmission. See Fig. 14 .

Fig. 47

Parking Brake Switch At base of parking brake lever. See Fig. 47 .

Power Retractable Hardtop Limit Switch Right side of retractable top storage compartment. See Fig. 51 .

Power Steering Pressure Switch

Refrigerant Pressure Switch

Left front of engine. See

Right front of engine compartment. See

Fig. 13

Fig. 21

Starter Interlock Switch

Transmission Range Switch

Trunk Compartment Light Switch

Trunk Lid Opener Cancel Switch

Behind left side of dash. See

On transmission. See

Right rear of luggage compartment. See

Lower center rear of luggage compartment. See

Fig. 8

Fig. 39

Fig. 38

MISCELLANEOUS

MISCELLANEOUS LOCATION

Component

Audio Amplifier

Check Connector

Clock Spring

Coil Antenna (Immobilizer)

Condenser (Ignition)

Condenser (Rear Window Defogger)

Data Link Connector 2

Driver-Side Air Bag Module

Driver-Side Pre-Tensioner Seat Belt

Driver-Side Side Air Bag Module

Filament (Rear Window Defogger)

Generator

Horn

Ignition Coils No. 1, 2, 3 & 4

Joint Connector (C-18)

Joint Connector (C-19)

Microsoft

Thursday, July 09, 2009 3:08:59 PM Page 4

Location

Right side of luggage compartment. See Fig.

44 .

In relay & main fuse block. See Fig. 1 .

In steering column. See Fig. 24 .

In steering column. See Fig. 37 .

Right rear of engine. See Fig. 10 .

At left "B" pillar. See Fig. 28 .

Under lower left side of dash. See Fig. 4 .

In steering wheel. See Fig. 24 .

Near base of left "B" pillar. See Fig. 25 .

In driver's seat. See Fig. 25 .

Left side of rear window. See Fig. 28 .

Right front of engine. See Fig. 7 .

Behind left side of front bumper. See Fig. 49 .

Top of engine. See Fig. 10 .

Behind left end of dash. See Fig. 15 .

2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Joint Connector (C-20)

Joint Connector (C-21)

Joint Connector (C-22)

Keyless Antenna (Center)

Keyless Antenna (Instrument Panel)

Keyless Antenna (Left/Right)

Behind center of dash. See Fig. 15 .

Right front of luggage compartment. See Fig.

44 .

Left side of retractable top storage compartment. See Fig. 56 .

Under center console. See Fig. 33 .

Behind right end of dash. See Fig. 35 .

In respective door. See Fig. 34 .

Keyless Antenna (Rear)

Keyless Antenna (Rear No. 2)

Keyless Antenna (Trunk)

Keyless Receiver

Keyless Receiver (Rear)

Passenger-Side Air Bag Module

Passenger-Side Pre-Tensioner Seat Belt

Passenger-Side Side Air Bag Module

Power Metal Oxide Semiconductor Field Effect Transistor

(Power MOS FET)

Center rear of luggage compartment. See Fig.

34 .

Rear of center console. See Fig. 33 .

Front of luggage compartment. See Fig. 33 .

Behind right side of dash. See Fig. 35 .

Front of luggage compartment. See Fig. 32 .

Behind right side of dash. See Fig. 24 .

Near base of right "B" pillar. See Fig. 25 .

In passenger's seat. See Fig. 25 .

Behind right end of dash. See Fig. 21 .

Seat Warmer (Left/Right)

Selector Lever Component

Transmission Fluid Temperature Connector

In respective seat cushion. See Fig. 31 .

Under center console. See Fig. 19 .

Behind left side of dash. See Fig. 19 .

CONNECTORS

CONNECTORS LOCATION

Component

C-02 (14 Pin)

C-03 (56 Pin)

C-04 (14 Pin)

C-05 (Except M/T) (Gray, 56 Pin)

C-05 (M/T) (Gray, 14 Pin)

C-06 (12 Pin)

C-08 (Except M/T) (56 Pin)

C-08 (M/T) (14 Pin)

C-10 (A/T) (Blue, 40 Pin)

C-10 (M/T) (Gray, 14 Pin)

C-11 (56 Pin)

C-12 (Yellow, 4 Pin)

C-13 (Yellow, 4 Pin)

C-14 (56 Pin)

Microsoft

Thursday, July 09, 2009 3:08:59 PM Page 5

Location

Left side of engine. See Fig. 10 .

Behind left side of dash. See Fig. 4 .

Behind left kick panel. See Fig. 9 .

Behind left kick panel. See Fig. 4 .

Behind left kick panel. See Fig. 6 .

Left side of engine compartment. See Fig. 8 .

Behind center of dash. See Fig. 4 .

Behind center of dash. See Fig. 24 .

Behind right kick panel. See Fig. 24 .

Behind right end of dash. See Fig. 44 .

2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

C-15 (32 Pin)

C-16 (32 Pin)

C-17 (4 Pin)

GROUNDS

G11

G12

G13

G14

G15

G16

G17

G18

G19

G20

G10

GROUNDS LOCATION

Component

Behind right kick panel. See Fig. 29 .

Behind left kick panel. See Fig. 29 .

Left side of luggage compartment. See Fig. 34 .

Location

Left rear corner of engine compartment. See Fig. 2 .

Behind left kick panel. See Fig. 2 .

Left rear corner of engine compartment. See Fig. 2 .

Right rear corner of engine compartment. See Fig. 2 .

Behind left headlight assembly. See Fig. 2 .

Behind right headlight assembly. See Fig. 2 .

Center rear of engine compartment. See Fig. 2 .

Behind right side of dash. See Fig. 3 .

Behind left side of dash. See Fig. 3 .

Behind center of dash. See Fig. 3 .

Behind right kick panel. See Fig. 3 .

Under passenger's seat. See Fig. 3 .

Under front of center console. See Fig. 3 .

Under driver's seat. See Fig. 3 .

Under rear of center console. See Fig. 3 .

Base of left "B" pillar. See Fig. 3 .

Center rear of luggage compartment. See Fig. 3 .

Base of right "B" pillar. See Fig. 2 .

Left side of retractable top storage compartment. See Fig. 59 .

Left side of retractable top storage compartment. See Fig. 55 .

COMPONENT LOCATION GRAPHICS

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

Microsoft

2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 1: Relay & Main Fuse Block

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 2: Ground System

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 3: Ground System

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 4: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 5: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 6: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 7: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 8: Dash & Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 9: Engine Control System

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 10: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 11: Dash & Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 12: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 13: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 14: Engine Control System

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 15: Dash & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 16: Engine Compartment & Rear Of Vehicle

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 17: Dash & Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 18: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 19: Automatic Transmission Control System

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 20: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 21: Dash & Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 22: Dash

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 23: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 24: Air Bag System

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 25: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 26: Seats

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 27: Passenger Seat

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 28: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 29: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 30: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 31: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 32: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 33: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 34: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Fig. 35: Dash & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 36: Engine Compartment & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 37: Dash

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 38: Rear Of Vehicle

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 39: Rear Of Vehicle

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 40: Dash

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 41: Dash

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 42: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 43: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 44: Dash & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 45: Dash

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 46: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 47: Engine Compartment & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 48: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 49: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 50: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

Fig. 51: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

Fig. 52: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 53: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

Fig. 54: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 55: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 56: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

Fig. 57: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 MAZDA MX-5 Miata

Fig. 58: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

Fig. 59: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

2007 ENGINE PERFORMANCE

Emission System - MX-5 Miata

EMISSION SYSTEM LOCATION INDEX [LF]

ENGINE COMPARTMENT SIDE

Fig. 1: Identifying Location Of Emission System Engine Compartment Side Components

Courtesy of MAZDA MOTORS CORP.

EXHAUST SYSTEM

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 2: Identifying Location Of Exhaust System Components

Courtesy of MAZDA MOTORS CORP.

FUEL TANK SIDE

Fig. 3: Identifying Location Of Fuel Tank Side Components

Courtesy of MAZDA MOTORS CORP.

FUEL-FILLER CAP INSPECTION [LF]

LEAKAGE INSPECTION

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

1. Perform the following SST (Evaporative Emission System Tester 134-01049) self-test:

NOTE:



If the tester does not work correctly during self-test, refer to the tester operators manual for more detailed procedures.

1. Verify the gas cylinder valve is closed and the control valve located on the tester is in the TEST position. All tester display should be off at this time.

2. Connect the long hose (part of SST ) to the tester.

3. Connect the manifold assembly (part of SST ) to the long hose as shown in Fig. 4 .

Fig. 4: Connecting Manifold Assembly To Long Hose

Courtesy of MAZDA MOTORS CORP.

4. Open the gas cylinder valve and verify the gas cylinder regulator left gauge reads 10 to 12 psi

(preset at factory).



If not, refer to the tester operators manual to contact tester manufacturer.

5. Press the ON/OFF switch to turn on the SST and make sure the left display reads 0.0

6. Turn the control valve on the tester to the FILL position.

7. Verify the left display reading 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.

8. Turn the control valve to TEST position and press the START switch.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

9. After the 2-min countdown (left display) is completed, the right display shows the total pressure loss for that period. A 0.5 in of water loss is acceptable on the self-test.



If the loss is more than 0.5 in of water , do one or more self-test. If the failed test repeats, check for leak 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 fuel-filler cap from the vehicle.



If the fuel-filler cap is not a genuine part, replace it.

Fig. 5: Connecting Fuel Cap Receiver Assembly

Courtesy of MAZDA MOTORS CORP.

4. Turn the control valve to the FILL position.

5. Wait ( maximum 20s ) until the left display reads 13.9 to 14 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 leak. 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 turns on, the fuel-filler cap is OK.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata



If the red light turns on, 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.

EMISSION SYSTEM DIAGRAM [LF]

Fig. 6: Identifying Emission System Diagram [LF]

Courtesy of MAZDA MOTORS CORP.

AIR FILTER REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect the evaporative hose from the air filter.

4. Cover the evaporative hose with vinyl sheets or the like to prevent them from being scratched or contaminated with foreign material.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 7: Identifying Evaporative Hose And Air Filter

Courtesy of MAZDA MOTORS CORP.

5. Remove the air filter.

6. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 8: Removing Air Filter (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

AIR FILTER INSPECTION [LF]

1. Remove the air filter. (See AIR FILTER REMOVAL/INSTALLATION [LF] ).

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. (See AIR FILTER REMOVAL/INSTALLATION

[LF] ).

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 9: Identifying Air Filter

Courtesy of MAZDA MOTORS CORP.

CHARCOAL CANISTER REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove in the order indicated in Fig. 10 .

4. Install in the reverse order of removal.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 10: Identifying Charcoal Canister Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

EVAPORATIVE HOSE INSTALLATION NOTE

1. Fit the evaporative hose onto the respective fittings, and install clamps as shown in Fig. 11 .

1. Insert the evaporative hose securely to the nipple.

2. Inspect the evaporative hose for damage and deformation.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 11: Inserting Evaporative Hose Securely To Nipple

Courtesy of MAZDA MOTORS CORP.

CHARCOAL CANISTER INSPECTION [LF]

1. Remove the charcoal canister. (See CHARCOAL CANISTER REMOVAL/INSTALLATION [LF] ).

2. Plug the EVAP leak detection pump side and purge solenoid valve side of the charcoal canister.

3. Inspect for air leakage when blowing air by mouth from the fuel tank side.



If air leaks, replace the charcoal canister. (See CHARCOAL CANISTER

REMOVAL/INSTALLATION [LF] ).

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 12: Identifying Charcoal Canister

Courtesy of MAZDA MOTORS CORP.

EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP

REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect the EVAP system leak detection pump connector.

4. Disconnect the evaporative hose from the EVAP system leak detection pump.

5. Cover the evaporative hose with vinyl sheets or the like to prevent them from being scratched or contaminated with foreign material.

6. Remove the EVAP system leak detection pump with the bracket.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 13: Identifying Evaporative Emission System Leak Detection Pump And Evaporative Hose

(With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

7. Remove the bracket from the EVAP system leak detection pump.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 14: Removing Bracket From EVAP System Leak Detection Pump

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

EVAPORATIVE HOSE INSTALLATION NOTE

1. Fit the evaporative hose onto the respective fittings, and install clamps as shown in Fig. 15 .

1. Insert the evaporative hose securely to the nipple.

2. Inspect the evaporative hose for damage and deformation.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 15: Inserting Evaporative Hose Securely To Nipple

Courtesy of MAZDA MOTORS CORP.

EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP

INSPECTION [LF]

NOTE:



Perform the following procedure only when directed.

AIRFLOW INSPECTION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove the EVAP system leak detection pump. (See EVAPORATIVE EMISSION (EVAP) SYSTEM

LEAK DETECTION PUMP REMOVAL/INSTALLATION [LF] .).

4. 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. (See EVAPORATIVE

EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP REMOVAL/INSTALLATION

[LF] ).

5. 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. (See EVAPORATIVE

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata



EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP REMOVAL/INSTALLATION

[LF] ).

If as specified, perform the following " RESISTANCE INSPECTION ".

Fig. 16: Identifying Evaporative Emission System Leak Detection Pump Ports

Courtesy of MAZDA MOTORS CORP.

RESISTANCE INSPECTION

1. Inspect resistance of the EVAP system leak detection pump.



If not as specified, replace the EVAP system leak detection pump. (See EVAPORATIVE

EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP REMOVAL/INSTALLATION

[LF] ).



If as specified, carry out the CIRCUIT OPEN/SHORT INSPECTION .

EVAP SYSTEM LEAK DETECTION PUMP TERMINALS RESISTANCE SPECIFICATIONS

Terminals Resistance (ohm)

A-B

A-C

A-D

20-50

26.6-32.4

MAX. 118

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 17: Identifying EVAP System Leak Detection Pump Connector Terminals

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

2. 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.



EVAP system leak detection pump terminal C and PCM terminal 1V



EVAP system leak detection pump terminal D and PCM terminal 1U

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata



EVAP system leak detection pump terminal A and main relay



EVAP system leak detection pump terminal B and body ground

Short Circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.

 EVAP system leak detection pump terminal C and body ground



EVAP system leak detection pump terminal D and body ground



EVAP system leak detection pump terminal C and power supply



EVAP system leak detection pump terminal D and power supply



EVAP system leak detection pump terminal A and body ground



EVAP system leak detection pump terminal B and power supply

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 18: Identifying PCM Wiring Harness-Side Connector

Courtesy of MAZDA MOTORS CORP.

PURGE SOLENOID VALVE REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect the purge solenoid valve connector.

4. Disconnect the vacuum hose from the purge solenoid valve.

5. Remove the purge solenoid valve from the air hose.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 19: Removing Purge Solenoid Valve From Air Hose

Courtesy of MAZDA MOTORS CORP.

6. Install in the reverse order of removal.

PURGE SOLENOID VALVE INSPECTION [LF]

NOTE:



Perform the following procedure only when directed.

AIRFLOW INSPECTION

1. Remove the purge solenoid valve without disconnecting the evaporative hose. (See PURGE

SOLENOID VALVE REMOVAL/INSTALLATION [LF] ).

2. Verify that the airflow is as indicated in PURGE SOLENOID VALVE AIRFLOW REFERENCE

TABLE .



If as specified in PURGE SOLENOID VALVE AIRFLOW REFERENCE TABLE , perform the CIRCUIT OPEN/SHORT INSPECTION .

If not as specified in PURGE SOLENOID VALVE AIRFLOW REFERENCE TABLE , inspect the purge solenoid valve. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION

[LF] .)

PURGE SOLENOID VALVE AIRFLOW REFERENCE TABLE

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Measured condition

When voltage is not applied between terminals A and B

When voltage is applied between terminals A and B

Continuity between A-B

No airflow

Airflow detected

Fig. 20: Inspecting Airflow

Courtesy of MAZDA MOTORS CORP.

CIRCUIT OPEN/SHORT INSPECTION

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

2. Inspect the following wiring harnesses for open or short circuit (continuity check).

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 21: Purge Solenoid Valve & PCM Connector

Courtesy of MAZDA MOTORS CORP.

Open Circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.



Purge solenoid valve terminal A and PCM terminal 2C



Purge solenoid valve terminal B and main relay

Short Circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.

 Purge solenoid valve terminal A and power supply



Purge solenoid valve terminal A and body ground



Purge solenoid valve terminal B and body ground

EGR VALVE REMOVAL/INSTALLATION [LF]

1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)

2. Remove the battery cover.

3. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

4. Drain the engine coolant from the radiator. (See ENGINE COOLANT REPLACEMENT [LF] .)

5. Remove the service hole cover.

1. Remove the suspension tower bar (joint), (right side) and (left side). (See FRONT SUSPENSION

TOWER BAR REMOVAL/INSTALLATION .)

2. Remove the wiper arm: (See WIPER ARM AND BLADE REMOVAL/INSTALLATION .)

3. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)

4. Remove the side cowl grille. (See SIDE COWL GRILLE REMOVAL/INSTALLATION .)

5. Move the cooler pipe No.3 and heater pipe slightly out of the way.

Fig. 22: Identifying Heater Pipe & Cooler Pipe No. 3

Courtesy of MAZDA MOTORS CORP.

6. Remove the service hole cover.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 23: Removing Service Hole Cover (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

6. Remove the harness bracket.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 24: Removing Harness Bracket

Courtesy of MAZDA MOTORS CORP.

7. Disconnect the heater hose and move the heater pipe slightly out of the way.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 25: Identifying Heater Hose & Heater Pipe

Courtesy of MAZDA MOTORS CORP.

8. Disconnect the EGR valve connector.

9. Set the SST to the EGR valve installation bolt.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 26: Setting SST (49 N013 001) To EGR Valve Installation Bolt

Courtesy of MAZDA MOTORS CORP.

10. Remove both EGR valve installation bolts.

11. Remove the EGR valve with the engine coolant hose.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 27: Removing EGR Valve With Engine Coolant Hose (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

12. Disconnect the engine coolant hose from the EGR valve.

13. Replace the EGR valve gasket.

14. Install in the reverse order of removal.

EGR VALVE INSPECTION [LF]

NOTE:



Perform the following procedure only when directed.

ON-VEHICLE INSPECTION

1. Verify that the buzzing sound (valve operation sound) is heard from the EGR valve when engine cranking.



If the buzzing sound is not heard, perform the resistance inspection.

RESISTANCE INSPECTION

1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)

2. Disconnect the battery cover.

3. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

4. Disconnect the EGR valve connector. (See EGR VALVE REMOVAL/INSTALLATION [LF] ).

5. Measure the resistance between the EGR valve terminals.



If within the specification, perform out the CIRCUIT OPEN/SHORT INSPECTION .



If not within the specification, replace the EGR valve. (See EGR VALVE

REMOVAL/INSTALLATION [LF] ).

STANDARD RESISTANCE SPECIFICATIONS

Terminal

C-E

C-A

D-B

D-F

Resistance (ohm)

12-16

Fig. 28: Identifying EGR Valve Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

CIRCUIT OPEN/SHORT INSPECTION

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

2. Inspect the following wiring harnesses 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.



EGR valve terminal A and PCM terminal 2G



EGR valve terminal B and PCM terminal 2L



EGR valve terminal E and PCM terminal 2K



EGR valve terminal F and PCM terminal 2H



EGR valve terminal C and main relay



EGR valve terminal D and main relay

Short Circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.



EGR valve terminal A and body ground



EGR valve terminal A and power supply



EGR valve terminal B and body ground



EGR valve terminal B and power supply



EGR valve terminal C and body ground

 EGR valve terminal D and body ground



EGR valve terminal E and body ground



EGR valve terminal E and power supply



EGR valve terminal F and body ground



EGR valve terminal F and power supply

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 29: Identifying EGR Valve & PCM Wiring Harness-Side Connector

Courtesy of MAZDA MOTORS CORP.

POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [LF]

1. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

2. Remove the PCV valve.

3. Verify that there is no airflow when pressure is applied to port A.



If there is airflow, replace the PCV valve.

4. Verify that there is airflow when vacuum is applied to port A.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata



If there is no airflow, replace the PCV valve.

Fig. 30: Identifying PCV Valve

Courtesy of MAZDA MOTORS CORP.

WARM-UP THREE-WAY CATALYTIC CONVERTER (WU-TWC) INSPECTION

[LF]

NOTE:



Make sure that no HO2S DTCs have been detected. If detected, this inspection is not applicable for WU-TWC inspection.

1. Connect the M-MDS or equivalent and monitor PIDs as following.



Monitor the WU-TWC using O2S11 PID for upstream HO2S and O2S12 PID for downstream

HO2S.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

2. Monitor the appropriate PIDs.

3. Drive the vehicle for 10 min at 65-96 km/h {40-60 mph} to allow the front catalytic converter to reach operating temperature.

4. Stop the vehicle and leave it 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.

Fig. 31: Identifying HO2S Graph Line (5 Inversions)

Courtesy of MAZDA MOTORS CORP.

9. Count the number of times (inversions) that the downstream HO2S graph line actually crosses the 0.5 V line.

NOTE:



Do not count the number of peaks. Refer to Fig. 31 .

10. Using the following equation, calculate the value of ratio.

Equation

RATIO = Upstream HO2S inversion divided by downstream HO2S inversion

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata



If the ratio is 1.5 or more or there is no downstream HO2S inversion, the WU-TWC is functioning properly.



If the ratio is less than 1.5

, the WU-TWC is not functioning properly. Replace the WU-TWC.

Upstream HO2S Graph Line Example

Fig. 32: Upstream HO2S Graph Line Example

Courtesy of MAZDA MOTORS CORP.

Downstream HO2S Graph Line Example 1

Equation

RATIO = 30 inversions (upstream HO2S inversions) divided by 5 inversions (downstream HO2S inversions) = 6.0 (good WU-TWC)

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 33: Downstream HO2S Graph Line Example 1

Courtesy of MAZDA MOTORS CORP.

Downstream HO2S Graph Line Example 2

Fig. 34: Downstream HO2S Graph Line Example 2

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

Downstream HO2S Graph Line Example 3

Equation

RATIO = 30 inversions (upstream HO2S inversions) divided by 27 inversions (downstream HO2S inversions) = 1.1 (bad WU-TWC)

Fig. 35: Downstream HO2S Graph Line Example 3

Courtesy of MAZDA MOTORS CORP.

ROLLOVER VALVE REMOVAL/INSTALLATION [LF]

NOTE:



The rollover valve cannot be removed as it is built into the fuel tank.

ROLLOVER VALVE INSPECTION [LF]

NOTE:



The rollover valve cannot be removed and inspected as it is built into the fuel tank.

1. Perform the fuel tank inspection. (See FUEL TANK INSPECTION [LF] .)

FUEL SHUT-OFF VALVE REMOVAL/INSTALLATION [LF]

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

NOTE:



The fuel shut-off valve cannot be removed as it is built into the fuel tank.

FUEL SHUT-OFF VALVE INSPECTION [LF]

NOTE:



The fuel shut-off valve cannot be removed and inspected as it is built into the fuel tank.

1. Perform the fuel tank inspection. (See FUEL TANK INSPECTION [LF] .)

EVAPORATIVE CHAMBER REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect the evaporative hose.

4. Remove the evaporative chamber.

5. Cover the evaporative hose with vinyl sheets or the like to prevent them from being scratched or contaminated with foreign material.

6. Install in the reverse order of removal.

Fig. 36: Identifying Evaporative Chamber And Evaporative Hose

Courtesy of MAZDA MOTORS CORP.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

EVAPORATIVE CHAMBER INSPECTION [LF]

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.

Fig. 37: Inspecting Evaporative Chamber Ports

Courtesy of MAZDA MOTORS CORP.

QUICK RELEASE CONNECTOR (EMISSION SYSTEM)

REMOVAL/INSTALLATION [LF]

QUICK RELEASE CONNECTOR TYPE

CAUTION:



There are four types of quick release connectors. Verify the type and location, and install/remove properly.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 38: Identifying Location Of Different Types Of Quick Release Connectors

Courtesy of MAZDA MOTORS CORP.

TYPE A REMOVAL

CAUTION:



The quick release connector may be damaged if the release tab is bent excessively. Do not expand the release tab over the stopper.

NOTE:



The evaporative hose can be removed by pushing it to the joint port side to release the lock.

1. Rotate the release tab on the quick release connector to the stopper position.

NOTE:



The retainer is attached to the pipe even after the connector is disconnected.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 39: Rotating Release Tab On Quick Release Connector To Stopper Position

Courtesy of MAZDA MOTORS CORP.

2. Pull out the evaporative hose straight from the joint port and disconnect it.

Fig. 40: Disconnecting Evaporative Hose Straight From Joint Port

Courtesy of MAZDA MOTORS CORP.

3. Cover the disconnected quick release connector and joint port with vinyl sheeting or a similar material to prevent it from scratches or dirt.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 41: Covering Disconnected Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

TYPE B REMOVAL

1. Squeeze the release tab until the locks are released.

NOTE:



The retainer has two internal locking tabs which retain the joint port.

Be sure that the squeezing place on the retainer is squeezed until it can be released from the joint port.

2. Pull the quick release connector straight outward.

NOTE:



The retainer is attached to the pipe even after the connector is disconnected.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 42: Removing Type B Components

Courtesy of MAZDA MOTORS CORP.

3. Cover the disconnected quick release connector and joint port with vinyl sheeting or a similar material to prevent it from becoming scratched or dirty.

TYPE C REMOVAL

CAUTION:



Be careful not to damage the pipe when unlocking the retainer.

NOTE:



If the quick release connector is removed, replace the retainer with a new one.

1. Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations.

NOTE:



The retainer is attached to the pipe even after the connector is disconnected.

2. Set the SST parallel to the quick release connector.

NOTE:



The quick release connector can be removed by pushing the center of the retainer tabs.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 43: Disconnecting Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

3. Hold the center of the retainer tabs with the SST ends and press the retainer.

4. Pull the connector side and disconnect the quick release connector.

5. Raise a retainer tab using the SST and remove the retainer.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 44: Raising Retainer Tab Using SST

Courtesy of MAZDA MOTORS CORP.

6. Cover the disconnected quick release connector and joint port with vinyl sheeting or a similar material to prevent it from becoming scratched or dirty.

TYPE D REMOVAL

CAUTION:



When releasing the retainer locks, take extreme care not to damage the evaporative hose.

1. Release the locks between the retainer and joint port by pressing each retainer lock one by one using a flathead screwdriver or a similar tool.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 45: Releasing Locks Between Retainer And Joint Port

Courtesy of MAZDA MOTORS CORP.

2. Pull out the hose straight from the joint port and disconnect it.

NOTE:



The retainer is attached to the pipe even after the connector is disconnected.

3. Cover the disconnected quick release connector and joint port with vinyl sheeting or a similar material to prevent it from becoming scratched or dirty.

TYPE A INSTALLATION

NOTE:



If the quick release connector O-ring is damaged or has slipped, replace the evaporative hose.

A checker tab is integrated with the quick release connector for new evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the joint port.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

1. Inspect the evaporative hose and joint port sealing surface for damage and deformation.

 If there is any malfunction, replace it with a new one.

2. Apply a small amount of clean engine oil to the sealing surface of the joint port.

3. Reconnect the evaporative hose straight to the joint port until a click is heard.

NOTE:

Fig. 46: Removing Checker Tab From Quick Release Connector

Completely Engaged With Joint Port

Courtesy of MAZDA MOTORS CORP.



If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.

4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move

2.0-3.0 mm {0.08-0.12 in} and is connected securely.

TYPE B INSTALLATION

NOTE:



If the quick release connector O-ring is damaged or has slipped, replace the evaporative hose.

When replacing with a new evaporative hose, disengage the release tabs from the join port.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata



Fig. 47: Removing Checker Tab From Quick Release Connector Completely Engaged With Joint Port

Courtesy of MAZDA MOTORS CORP.

1. When newly replacing the quick release connector, remove the release tab using the following procedure.

1. Widen the retainer lock using a flathead screwdriver, then pull out the release tab from the joint

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata port and remove it.

2. Inspect the quick release connector and joint port sealing surface for damage and deformation.



If there is any malfunction, replace it with a new one.

3. Apply a small amount of clean engine oil to the sealing surface of the joint port.

4. Reconnect the quick release connector straight to the joint port until a click is heard.

Fig. 48: Removing Tab From Joint Port

Courtesy of MAZDA MOTORS CORP.

NOTE:



If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.

5. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

TYPE C INSTALLATION

NOTE:



If the quick release connector O-ring is damaged or has slipped, replace the piping component.

A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata pipe.

CAUTION:



Be sure to replace the retainer with a new one to prevent gas leakage.

1. Install a new retainer to the quick release connector.

Fig. 49: Installing New Retainer To Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

2. Reconnect the hose straight to the pipe until a click is heard.

3. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

TYPE D INSTALLATION

NOTE:



If the quick release connector O-ring is damaged or has slipped, replace the evaporative hose.

When replacing with a new evaporative hose, disengage the release tabs from the join port.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 50: Removing Checker Tab From Quick Release Connector After

Connector Completely Engaged With Joint Port

Courtesy of MAZDA MOTORS CORP.

1. When newly replacing the quick release connector, remove the release tab using the following procedure.

1. Widen the retainer lock using a flathead screwdriver, then pull out the release tab from the joint port and remove it.

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2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 51: Removing Tab From Joint Port

Courtesy of MAZDA MOTORS CORP.

2. Inspect the quick release connector and joint port sealing surface for damage and deformation.



If there is any malfunction, replace it with a new one.

3. Apply a small amount of clean engine oil to the sealing surface of the joint port.

4. Reconnect the quick release connector straight to the joint port until a click is heard.

NOTE:



If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.

5. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

Microsoft

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

2007 ENGINE PERFORMANCE

Engine Control System - MX-5 Miata

CONTROL SYSTEM LOCATION INDEX [LF]

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 1: Identifying Location Of Control System Components

Courtesy of MAZDA MOTORS CORP.

CONTROL SYSTEM DIAGRAM [LF]

Fig. 2: Engine Control System - System Diagram

Courtesy of MAZDA MOTORS CORP.

CONTROL SYSTEM WIRING DIAGRAM [LF]

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 3: Engine Control System - Wiring Diagram (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 4: Engine Control System - Wiring Diagram (2 Of 2)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Courtesy of MAZDA MOTORS CORP.

PCM REMOVAL/INSTALLATION [LF]

1. When replacing the PCM, perform the following:



PCM configuration (See PCM CONFIGURATION [LF] .)

2. Remove the battery cover.

3. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

4. Remove the air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

5. Move the water hose from the PCM cover slightly out of the way.

6. Remove in the order indicated in Fig. 5 .

Fig. 5: Removing PCM (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

8. When replacing the PCM on the vehicles, perform the following:

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata



PCM parameter reset (See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY

ADDITION AND CLEARING[ADVANCED KEYLESS SYSTEM] .)

PCM CONNECTOR CONNECTED NOTE

1. Connect the PCM connector fully into the PCM and push the lever until a click is heard.

Fig. 6: Connecting PCM Connector Into PCM

Courtesy of MAZDA MOTORS CORP.

PCM INSPECTION [LF]

NOT USING THE M-MDS OR EQUIVALENT

NOTE:



The PCM terminal voltage can vary with the conditions when measuring and changes due to aged deterioration on the vehicle, causing false diagnosis. Therefore determine comprehensively where the malfunction occurs among the input systems, output systems, and the PCM.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 7: Identifying PCM Harness Side Connectors

Courtesy of MAZDA MOTORS CORP.

PCM TERMINALS VOLTAGE SPECIFICATION TABLE

Terminal

Signal

Connected to

Test condition

Voltage (V) Inspection item

(2)

Starter relay control

Clutch operation

Fuel pump control

A/C

Starter relay

Microsoft

Thursday, July 09, 2009 2:41:09 PM

Fuel pump relay

CPP switch

A/C relay

Under any condition Below 1.0



Starter relay

 Related wiring harness

Clutch pedal depressed

Below 1.0

Clutch pedal released

Ignition switch is turned to the ON position (Engine off) and a certain period has elapsed

Cranking

Idle

A/C operating

Engine running A/C not operating

B+

Below 1.0



CPP switch

Related wiring harness

Fuel pump relay

Related wiring harness

B+



A/C relay

Related wiring harness

Refrigerant pressure is more than the specification.

Page 8

Below 1.0



Refrigerant pressure

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Refrigerant pressure switch

(middle)

Cooling fan control

Refrigerant pressure switch

(middle)

Cooling fan relay No.1

(Refrigerant pressure switch

(middle) is on.)

Refrigerant pressure is less than the specification.

(Refrigerant pressure switch

(middle) is off.)

During test mode

(3)

Accelerator pedal released

Accelerator pedal depressed

During test mode

(3)

Accelerator pedal released

Accelerator pedal depressed

B+

Below 1.0



 switch

(middle)

Related wiring harness

Cooling fan relay

No.1

Related wiring harness

Cooling fan control

Cooling fan relay No.2

B+

Below 1.0



Cooling fan relay

No.2

Related wiring harness

MAF sensor ground

MAF sensor Under any condition

Below 1.0



Related wiring harness

Main relay control

Cooling fan control

Main relay

Cooling fan relay No.3

Microsoft

Thursday, July 09, 2009 2:41:09 PM

EVAP system EVAP system leak detection leak detection pump (pump) pump

Ignition switch is turned to the ON position

Ignition switch off and a certain period has elapsed

During test mode

Ignition switch is turned to the ON position

Idle.

(3)

Accelerator pedal released

Accelerator pedal depressed

Page 9

Below 1.0

B+

Below 1.0

B+



Main relay

Related wiring harness

Cooling fan relay

No.3

Related wiring harness

B+



EVAP system leak detection pump

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata wiring harness

EVAP system

EVAP system leak detection leak detection pump pump

(solenoid)

Ignition switch is turned to the ON position

Idle

B+



EVAP system leak detection pump

Related wiring harness

1W -

Shift lever is at neutral position

Below 1.0

(2)

Neutral position

Neutral switch Shift lever is not at neutral position

B+



Neutral switch



Related wiring harness 1X

1AA

(1)

Selector lever position

TR switch

Ignition switch is turned to the

ON position

P, N position

Except above

Brake pedal depressed

Brake switch

No.1

Brake switch

Brake pedal released

Below 1.0

B+



TR switch

Related wiring harness

1AB

1AC

1AD

1AE

Brake pedal depressed

Brake switch

No.2

Brake switch

Brake pedal released

Below 1.0

B+



Brake switch

 Related wiring harness

1AF

Below 1.0



Brake switch



Related wiring harness

1AG

1AH

1AI

CAN_J.

module

CAN related Because this terminal is for CAN, no valid determination of terminal voltage is possible



Related wiring harness

1AJ

Microsoft

APP sensor APP sensor Ignition switch is turned to Approx. 5.0

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

1AK

1AL

1AM

1AN

1AO

1AP

1AQ

1AR

1AS

No.2 power supply

MAF MAF sensor the ON position

Ignition switch is turned to the ON position

Idle

Approx. 0.7

Approx. 1.4

APP sensor

No.1 power supply

CAN_H

APP sensor Ignition switch is turned to the ON position.

Approx. 5.0

switch

APP sensor

No.1

APP sensor

No.2

Cruise control

Cruise

Sensor ground

CAN related module

Because this terminal is for CAN, no valid determination of terminal voltage is possible control switch

MAF/IAT sensor

APP sensor

Ignition switch is turned to the

ON position

Accelerator pedal depressed

Accelerator pedal released

Ignition switch is turned to the

ON position

Accelerator pedal depressed

Accelerator pedal released

ON OFF switch pressed in

Ignition switch is turned to the

ON position

CANCEL switch pressed in

SET/- switch pressed in

Approx. 3.9

Approx. 1.6

Approx. 3.4

Approx. 1.0

Approx. 0

Approx. 1.1

Approx. 3.1

RES/+ switch pressed in

Approx. 4.2

Except above Approx. 5.0

Under any condition Below 1.0

APP sensor

No.1 ground

APP sensor Under any condition

Microsoft

Thursday, July 09, 2009 2:41:09 PM Page 11



Related wiring harness



MAF sensor



Related wiring harness



Related wiring harness

APP sensor

Related wiring harness

APP sensor

Related wiring harness

Cruise control switch

Related wiring harness

Below 1.0



Related wiring harness



Related wiring

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

1AT

1AU

1AV

1AW

1AX

1AY

1AZ

1BA

1BB

1BC

IAT

APP sensor

No.2 ground

B+

Drive-bywire relay control

Ignition switch on

Ground

Back-up power supply

Ground

MAF/IAT sensor

APP sensor

Main relay

Drive-bywire relay

Ignition switch

Ground

Battery

(positive terminal)

Ground

Microsoft

Thursday, July 09, 2009 2:41:09 PM

Ignition switch is turned to the

ON position

IAT is 20°C

{68°F}

IAT is 60°C

{140°F}

Refrigerant pressure switch (high, low)

Ignition switch is turned to the

ON position

A/C operating

A/C not operating

Under any condition

Ignition switch off

Ignition switch is turned to the ON position

Under any condition

Ignition switch off

Ignition switch is turned to the ON position

Under any condition

Page 12

Approx. 2.4

Approx. 0.9

Below 1.0

B+

Below 1.0

B+

Below 1.0

B+

Below 1.0

B+

Below 1.0

harness



IAT sensor

 Related wiring harness



Refrigerant pressure switch

(high, low)



Related wiring harness

 Related wiring harness



Main relay



Battery

 Related wiring harness



Drive-bywire relay



Related wiring harness



Ignition switch

Related wiring harness



Related wiring harness



Battery

Related wiring harness



Related wiring harness

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

1BD

1BE

1BF

1BG

1BH

Ground

B+

Drive-bywire relay control

Ground

Throttle control (+)

Throttle control (-)

Ground

Throttle body

(Throttle valve actuator)

Under any condition Below 1.0

Main relay

Drive-bywire relay

Ground

Ignition switch off

Ignition switch is turned to the ON position

Ignition switch is turned to the

ON position

Drive-bywire system is malfunction

Drive-bywire system is normal

Under any condition

Below 1.0

B+

Below 1.0

B+

Below 1.0

Throttle body

(Throttle valve actuator)

Purge control Purge solenoid valve

OCV control OCV

Microsoft

Thursday, July 09, 2009 2:41:09 PM



Related wiring harness



Main relay



Related wiring harness



Drive-bywire relay

Related wiring harness



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Page 13



Related wiring harness



Throttle valve actuator



Related wiring harness



Throttle valve actuator



Related wiring harness



Purge solenoid valve

Related wiring harness



OCV

Related wiring harness

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

(4)

EGR valve #2 EGR valve coil control

EGR valve #4 coil control control

Variable intake air

EGR valve #3 coil control

(terminal A)

EGR valve

(terminal F)

EGR valve

(terminal B)

Vehicle speed VSS

2R -

Microsoft

Thursday, July 09, 2009 2:41:09 PM

Variable intake air solenoid valve

EGR valve #1 EGR valve coil control (terminal E)

Idle (EGR control not operating)

Ignition switch is turned to the ON position

Engine speed: less than

4,750 rpm

Engine speed: 4,750 rpm or more

Idle (EGR control not operating)



B+

Below 1.0

B+

Below 1.0

B+

Inspect using the wave profile.



EGR valve

 Related wiring harness



EGR valve



Related wiring harness



Variable intake air solenoid valve

Related wiring harness



EGR valve



Related wiring harness



EGR valve

Related wiring harness



VSS

Related wiring harness

CMP sensor ground

Rear HO2S

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

CMP sensor Under any condition Below 1.0

Rear HO2S

Idle after warm-up

Page 14

Alternates between 0 and 1.0



Related wiring harness



Rear

HO2S

Related wiring harness

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

2AA

2AB

2AC -

Microsoft

Thursday, July 09, 2009 2:41:09 PM



Inspect using the wave profile.

CMP CMP sensor (See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Power steering pressure

PSP switch

Knocking (+) KS

Knocking (-) KS

Idle

Steering wheel at straight ahead position

While turning steering wheel

Ignition switch ON (Use digital type voltmeter, because measurement voltage will be detected less than true voltage when using analog type voltmeter)

B+

Below 1.0

Approx. 4.3

Below 1.0



Inspect using the wave profile.

CKP

Ground

Front HO2S

CKP sensor ground

CKP sensor (See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Shield wire Under any condition

Front HO2S

CKP sensor

Idle after warm-up

Under any condition

Page 15

Below 1.0

Approx. 2.4

Below 1.0



CMP sensor

Related wiring harness



PSP switch

 Related wiring harness



Related wiring harness



CKP sensor



Related wiring harness



Related wiring harness



Front

HO2S

Related wiring harness

 Related wiring harness

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

2AD

2AE

2AF

2AG

2AH

Front HO2S

ECT

Manifold absolute pressure

Front HO2S

MAP sensor

ECT sensor

Idle after warm-up

Ignition switch is turned to the ON position (at sea level)

Idle

Ignition switch is turned to the

ON position

ECT is 20°C

{68°F}

ECT is 80°C

{176°F)

Approx. 2.8

Approx. 4.1

Approx. 1.2

Approx. 3.0

Approx. 0.9



Front

HO2S

Related wiring harness



MAP sensor

Related wiring harness



ECT sensor

Related wiring harness

2AI

Generator field coil control

Generator

(terminal D)



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)



Generator



Related wiring harness

2AJ

2AK

2AL

2AM

2AN

Microsoft



Inspect using the wave profile.

Generator output voltage

Generator

(terminal P)

Throttle valve opening angle

Throttle body

(TP sensor)

No. 1

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Approx. 4.5

Ignition switch is turned to the

ON position

Accelerator pedal depressed

Accelerator pedal released

Approx. 1.0

Throttle valve opening angle

Throttle body

No. 2

(TP sensor)

Ignition switch is turned to the

ON position

Accelerator pedal depressed

Accelerator pedal released

Approx. 0.5

Approx. 4.0

Constant voltage

CMP sensor Ignition switch is turned to the ON position

B+

Thursday, July 09, 2009 2:41:09 PM

Page 16



Generator

Related wiring harness

TP sensor

Related wiring harness

TP sensor

Related wiring harness



Related wiring harness

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

2AO

2AP

2AQ

2AR

2AS

2AT

2AU

2AV

2AW

2AX

2AY

2AZ

Constant voltage (Vref)

Sensor ground

Constant voltage

IGT4 ground

IGT2

IGT3

MAP sensor

ECT sensor ground

Throttle body Ignition switch is turned to

(TP sensor)

Ignition coil

(No.4 cylinders) the ON position

MAP sensor Under any condition



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Approx. 5.0

Ignition coil

(No.2 cylinders)



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Ignition coil

(No.3 cylinders)



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

ECT sensor Under any condition Below 1.0

Microsoft

Thursday, July 09, 2009 2:41:09 PM



Inspect using the wave profile.

Constant voltage (Vref)

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

MAP sensor Ignition switch is turned to the ON position

Approx. 5.0

Fuel injection

(#4)

Throttle body

(TP sensor)

CKP sensor

Fuel injector

No.4

Under any condition

Ignition switch is turned to the ON position

Below 1.0

B+

Below 1.0



Ignition coil No.2

Related wiring harness



Ignition coil No.3

 Related wiring harness



Related wiring harness



Fuel injector

No.4



Related wiring harness



Related wiring harness



Related wiring harness



Related wiring harness



Ignition coil No.4

Related wiring harness



Related wiring harness



Related wiring harness

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

2BA

2BB

2BC

2BD

2BE

2BF

2BG

2BH

IGT1

Fuel injection

(#1)

Ignition coil

(No.1 cylinders)

Fuel injector

No.1



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Fuel injection

(#2)

Fuel injector

No.2



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Fuel injection

(#3)

Fuel injector

No.3

 Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Rear HO2S heater control

Rear HO2S heater

Heavy load (Heater control not operating)

B+

Front HO2S heater control

Front HO2S heater



Inspect using the wave profile.

(See INSPECTION USING AN

OSCILLOSCOPE

(REFERENCE) .)

Rear HO2S ground

Rear HO2S Under any condition Below 1.0

(1) AT

(2) MT

Microsoft

Thursday, July 09, 2009 2:41:09 PM



Ignition coil No.1

Related wiring harness



Fuel injector

No.1

Related wiring harness



Fuel injector

No.2



Related wiring harness

 Fuel injector

No.3



Related wiring harness



Rear

HO2S heater

Related wiring harness



Front

HO2S heater

Related wiring harness

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

(3) Turn the test mode on using the M-MDS simulation function.

(4) MT without ABS/DSC

INSPECTION USING AN OSCILLOSCOPE (REFERENCE)

Throttle Control (+) Signal

PCM Terminals



2A (+)-Negative battery terminal (-)

Oscilloscope Setting



5 V/DIV (Y), 1 ms/DIV (X), DC range

Vehicle Condition



Idle (Accelerator pedal released)

Fig. 8: Waveform Graph (Throttle Control (+) Signal))

Courtesy of MAZDA MOTORS CORP.

Throttle Control (-) Signal

PCM Terminals

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata



2B (+) - Negative battery terminal (-)

Oscilloscope Setting



5 V/DIV (Y), 1 ms/DIV (X), DC range

Vehicle Condition



Idle (Accelerator pedal released)

Fig. 9: Waveform Graph (Throttle Control (-) Signal))

Courtesy of MAZDA MOTORS CORP.

Purge Control Signal

PCM Terminals



2C (+)-Negative battery terminal (-)

Oscilloscope Setting



2 V/DIV (Y), 0.1 s/DIV (X), DC range

Vehicle Condition



Idle after warm-up

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 10: Waveform Graph (Purge Control Signal)

Courtesy of MAZDA MOTORS CORP.

OCV Control Signal

PCM Terminals



2E (+)-Negative battery terminal (-)

Oscilloscope Setting



2.5 V/DIV (Y), 1 ms/DIV (X), DC range

Vehicle Condition



Idle after warm-up

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 11: Waveform Graph (OCV Control Signal)

Courtesy of MAZDA MOTORS CORP.

Vehicle Speed Signal

PCM Terminals



2O (+)-Negative battery terminal (-)

Oscilloscope Setting



1 V/DIV (Y), 10 ms/DIV (X), DC range

Vehicle Condition

 Vehicle speed is 10 km/h {6.2 mph}

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 12: Waveform Graph (Vehicle Speed Signal)

Courtesy of MAZDA MOTORS CORP.

CMP Signal

PCM Terminals



2S (+) - Negative battery terminal (-)

Oscilloscope Setting



2 V/DIV (Y), 50 ms/DIV (X), DC range

Vehicle Condition



Idle after warm-up

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 13: Waveform Graph (CMP Signal)

Courtesy of MAZDA MOTORS CORP.

CKP Signal

PCM Terminals



2W (+) - Negative battery terminal (-)

Oscilloscope Setting



2 V/DIV (Y), 10 ms/DIV (X), DC range

Vehicle Condition



Idle after warm-up

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 14: Waveform Graph (CKP Signal)

Courtesy of MAZDA MOTORS CORP.

Generator Field Coil Control Signal

PCM Terminals



2AI (+) - Negative battery terminal (-)

Oscilloscope Setting



0.5 V/DIV (Y), 1 ms/DIV (X), DC range

Vehicle Condition



Idle after warm-up

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 15: Waveform Graph (Generator Field Coil Control Signal)

Courtesy of MAZDA MOTORS CORP.

Generator Output Voltage Signal

PCM Terminals



2AJ (+) - Negative battery terminal (-)

Oscilloscope Setting

 2 V/DIV (Y), 1 ms/DIV (X), DC range

Vehicle Condition



Idle after warm-up

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 16: Waveform Graph (Generator Output Voltage Signal)

Courtesy of MAZDA MOTORS CORP.

Ignition Timing Signals

PCM Terminals



IGT1 (No.1): 2BA (+) - Negative battery terminal (-)



IGT2 (No.2): 2AW (+) - Negative battery terminal (-)

IGT3 (No.3): 2AX (+) - Negative battery terminal (-)



IGT4 (No.4): 2AT (+) - Negative battery terminal (-)

Oscilloscope Setting



2 V/DIV (Y), 50 ms/DIV (X), DC range

Vehicle Condition



Idle after warm-up

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 17: Waveform Graph (Ignition Timing Signals)

Courtesy of MAZDA MOTORS CORP.

Fuel Injection Signals

PCM Terminals



Fuel Injection No.1: 2BB (+) - Negative battery terminal (-)

Fuel Injection No.2: 2BC (+) - Negative battery terminal (-)



Fuel Injection No.3: 2BD (+) - Negative battery terminal (-)

Fuel Injection No.4: 2AZ (+) - Negative battery terminal (-)

Oscilloscope Setting



10 V/DIV (Y), 10 ms/DIV (X), DC range

Vehicle Condition



Idle after warm-up

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 18: Waveform Graph (Fuel Injection Signals)

Courtesy of MAZDA MOTORS CORP.

Front HO2S Heater Control Signal

PCM Terminals



2BG (+) - Negative battery terminal (-)

Oscilloscope Setting



5 V/DIV (Y), 50 ms/DIV (X), DC range

Vehicle Condition



Idle after warm-up (no load)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 19: Waveform Graph (Front HO2S Heater Control Signal)

Courtesy of MAZDA MOTORS CORP.

USING THE M-MDS OR EQUIVALENT

NOTE:



PIDs for the following parts are not available on this model. Go to the appropriate part inspection reference.



CMP sensor



Main relay

1. Connect the SST (M-MDS or equivalent) to the DLC-2.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 20: Locating Connector DLC-2

Courtesy of MAZDA MOTORS CORP.

2. Turn the ignition switch to ON position.

3. Measure the PID value.



If PID value is not within the specification, follow the instructions in "Inspection item (s)" column.

NOTE:



The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM. Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value for the output device. If a monitored value of an output device is out of specification, inspect the monitored value of the input device related to the output control.

For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM terminal voltage.

The simulation items that are used in the ENGINE CONTROL SYSTEM

OPERATION INSPECTION are as follows.



ACCS, ALTF, EVAPCP, FAN1, FAN2, FAN3, FP, FUELPW1,

GENVDSD, HTR11, HTR12, IMTV, INJ_1, INJ_2, INJ_3, INJ_4,

SEGRP, test, VT DUTY1 Wt

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

PID/DATA Monitor Table (Reference)

PID/DATA MONITOR TABLE

Item

(definition)

AAT

(Ambient air temperature)

Unit/Condition

°C °F

AC_REQ

(Refrigerant pressure switch

(high, low)

ACCS

(A/C relay)

AFR

(Air/fuel ratio)

AFR_ACT

(Actual air/fuel ratio)

ALTF

(Generator field coil control duty value)

ALTT V

(Generator

On/Off

Microsoft

Thursday, July 09, 2009 2:41:09 PM

Condition/Specification

(Reference)



Ignition switch is turned to the ON position: Indicate the ambient air temperature



Refrigerant pressure is more than the specification or less than the specification.

(Refrigerant pressure switch

(high, low) is off.): Off

Except above: On



A/C relay is ON:



A/C relay is OFF:

Off

Inspection item(s)



The following

PIDs



IAT



Refrigerant pressure switch

(high, low)

A/C amplifier

The following

PIDs



CPP

(1)

CPP/PNP

(1)

, ECT,

RPM, TP,

(2)

AC_REQ,

COLP



Front HO2S



Idle after warmup: Approx. 1



Idle after warmup: Approx. 1



Front HO2S

Rear HO2S

PCM terminal

1AU

2AD



Generator

2AI



Ignition switch is turned to the ON position: 0%



Idle, E/L is operating: Duty value increases.



Idle (no E/L):

Approx. 14 V



Generator

2AJ

output voltage)

APP

(Accelerator pedal position)

APP1

(APP sensor

No.1)

APP2

(APP sensor

No.2)

ARPMDES

(Target engine speed)

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

RPM

Microsoft

Thursday, July 09, 2009 2:41:10 PM

(This is an internal calculation value and differs from the terminal voltage.)



Accelerator pedal released: 0%

Accelerator pedal depressed: 100%



Accelerator pedal released: Approx.

32%

 Accelerator pedal depressed:

Approx. 78%



Accelerator pedal released: Approx.

1.6 V



Accelerator pedal depressed:

Approx. 3.9 V



The following

PIDs



APP1,

APP2

APP sensor

1AO, 1AP

1AO



Accelerator pedal released: Approx.

21%

Accelerator pedal depressed:

Approx. 67%



APP sensor 1AP



Accelerator pedal released: Approx.

1.0 V

Accelerator pedal depressed:

Approx. 3.4 V



Indicate the target engine speed.

Page 33



The following

PIDs



CPP

(1)

CPP/PNP

(1)

, ECT,

IAT,

RPM, TP,

MAF,

MAP,

VSS,

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

BARO

(Barometric pressure)

BOO

(Brake switch)

CATT11_DSD

(Catalyst temperature)

CHRGLP

(Generator warning light)

COLP

(Refrigerant pressure switch

(middle))

CPP

(1)

(Clutch kPa Bar PSI

°C

On/Off

Microsoft

Thursday, July 09, 2009 2:41:10 PM

°F

AC_REQ,

COLP



Ignition switch is turned to the ON position: Indicate the barometric pressure

 Ignition switch is turned to the ON position (at sea level): 4.1 V



Brake pedal depressed: On



Brake pedal released: Off



Ignition switch is turned to the ON position: Indicate the catalyst temperature



Idle, Generator warning light illuminate: On



Idle, Generator warning light not illuminate: Off



Refrigerant pressure is more than the specification.

(Refrigerant pressure switch

(middle) is on.):



Refrigerant pressure is less than the specification.

(Refrigerant pressure switch

(middle) is off.):

Off



Clutch pedal

Page 34



Brake switch

Generator warning light

Refrigerant pressure switch

(middle)

1AB, 1AF



CPP switch

pedal position)

CPP/PNP

(1)

(Shift lever position)

DTCCNT

(Number of

DTC detected)

ECT

(Engine coolant temperature)

EQ_RAT11

(Actual lambda signal)

EQ_RAT11_DS

(Target lambda)

ETC_ACT

(Throttle control)

ETC_DSD

(Throttle control desired)

EVAPCP

(Purge solenoid valve duty value)

Microsoft

Thursday, July 09, 2009 2:41:10 PM

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

On/Off

Drive/Neutral

°C

°F

 depressed: On

Clutch pedal released: Off.



Neutral: Neutral



Other than neutral:

Drive



Number of DTCs stored



Neutral switch



Ignition switch is turned to the ON position: Indicate the ECT



ECT is 20°C {68°

F}: Approx. 3.0 V

ECT is 80°C

{176°F}: Approx.

0.9 V



Idle after warmup: Approx. 1



ECT sensor

Front HO2S

2AH



Target lambda

(Excess air factor

= supplied air amount/theoretical air/fuel ratio)



Accelerator pedal released: Approx.

0°

 Accelerator pedal depressed:

Approx. 94.5°



Indicate the target throttle valve opening ratio



Indicate the target throttle valve opening angle



Ignition switch is turned to the ON position: 0%

Increase the

Page 35



Front HO2S

TP sensor

The following

PIDs



APP, RPM



The following

PIDs



ECT, IAT,

RPM, TP,

FAN1

(Cooling fan relay No.1 control signal)

FAN2

(Cooling fan relay No.2 control signal)

FAN3

(Cooling fan relay No.3 control signal)

FLI

(Fuel level)

(Fuel pump relay)

FUELPW

(Fuel injector duration)

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

On/Off

On/Off ms

Microsoft

Thursday, July 09, 2009 2:41:10 PM engine speed

(after warm-up):

Duty value rises



MAF,

O2S11,

O2S12,

BOO,

VPWR

Purge solenoid valve



During test mode

CTP: Off



The following

PIDs



ECT, test,

WOT: On



During test mode

CTP: Off



The following

PIDs



ECT, test,

WOT: On



During test mode

CTP: Off



The following

PIDs



ECT, test,

WOT: On.



Indicate the fuel level



Ignition switch is turned to the ON position and a certain period has elapsed: Off

Cranking: On



Idle: On



Fuel pump relay



Idle: Approx. 2.0 ms

Page 36



The following

PIDs



CPP

(1)

CPP/PNP

(1)

, ECT,

IAT,

RPM, TP,

MAF,

O2S11,

O2S12,

MAP,

VSS, TR

2BB, 2BC,

2BD, 2AZ

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

FUELSYS

(Fuel system status)

OL/CL/OL-Drive/OL-

Fault/CL-Fault

GENVDSD

(Target generator voltage)

HTR11

(Front HO2S heater control)

HTR12

(Rear HO2S heater control)

On/Off

Microsoft

Thursday, July 09, 2009 2:41:10 PM



Idle after warmup: CL

Indicate the target generated voltage

Ignition switch is turned to the ON position: Off

Idle: On

Ignition switch is turned to the ON position: Off

Idle: On

(2)

, BOO,

AC_REQ,

COLP,

VPWR



The following

PIDs



CPP

(1)

CPP/PNP

(1)

, ECT,

IAT,

RPM, TP,

MAF,

O2S11,

O2S12,

MAP,

VSS, TR

(2)

, BOO,

AC_REQ,

COLP,

VPWR



The following

PIDs





ECT, IAT,

RPM,

VSS,

ALTT V,

VPWR

Generator



The following

PIDs



ECT, IAT,

RPM, TP,

MAF,

MAP,

VPWR



The following

PIDs



ECT, IAT,

RPM, TP,

MAF,

MAP,

VPWR

2BG

2BE

 Ignition switch is

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

IAT

(Intake air temperature)

IMTV

(Variable intake air control)

INGEAR

(Gears are engaged)

IVS

(CTP condition)

KNOCKR

(Knocking retard)

LDP_EVAPCP

(EVAP system leak detection pump detect incorrect purge flow)

°C

On/Off

Idle/Off Idle

° mA

Microsoft

Thursday, July 09, 2009 2:41:10 PM

°F turned to the ON position: Indicate the IAT



IAT is 20°C {68°

F}: Approx. 2.4 V

IAT is 60°C {140°

F}: Approx. 0.9 V



Engine speed is less than 4,750 rpm: On



Engine speed is

4,750 rpm or more: Off



When the following conditions are satisfied: On

 Other than neutral



Clutch pedal released

 Except above: Off



Driving range: On



Except above: Off



Idle: Idle

Other than idle:

Off Idle



Ignition switch is turned to the ON position: 0°

 Idle: 0°



Indicate EVAP control system incorrect purge flow detection value



IAT sensor



The following

PIDs



RPM

1AT



CPP switch

Neutral switch

1D, 1X



TR switch



The following

PIDs





KS.

LDP_IDL

(EVAP system leak detection pump idle current)

LDP_MON

(EVAP system leak detection pump monitoring current)

LDP_REF

(EVAP system leak detection pump reference current)

LDP_SLDV

(EVAP system small leak detection value)

LDP_VSL_FV

(EVAP system very small leak detection fail value)

LDP_VSL_SV

(EVAP system very small leak detection safe value)

LDP_VSLDV

(2)

(EVAP system very small leak detection value)

LOAD

(Engine load)

LONGFT1

(Long term fuel trim)

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata mA mA mA mA mA/s mA/s mA/s

Microsoft

Thursday, July 09, 2009 2:41:10 PM



Indicate EVAP system leak detection pump idle current



Indicate EVAP system leak detection pump monitoring current



Indicate EVAP system leak detection pump reference current



Indicate EVAP system small leak detection value



Indicate EVAP system very small leak detection fail value



Indicate EVAP system very small leak detection safe value



Indicate EVAP system very small leak detection value



Idle after warmup: Approx. 23%

Idle after warmup: Approx.-15 -

/+15%

Page 39



The following

PIDs



MAP,

IAT,

MAF,

RPM



The following

PIDs



CPP

(1)

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

MAF

(Mass air flow)

MAP

(Manifold absolute pressure)

MIL

(Malfunction indicator lamp) kPa km

% g/s

V psi

On/Off

Bar



Ignition switch is turned to the ON position: Approx.

0 g/s



Idle: Approx. 4.0 g/s



Ignition switch is turned to the ON position: Approx.

0.7 V

Idle: Approx. 1.4



Ignition switch is turned to the ON position: Indicate the MAP



MAF sensor



Ignition switch is turned to the ON position (at sea level): 4.1 V

Idle after warmup: Approx. 1.2 V



MAP sensor



Idle, MIL illuminate: On



MIL



Idle, MIL not illuminate: Off

Mile Travelled distance since MIL illuminated

CPP/PNP

(1)

, ECT,

IAT,

RPM, TP,

MAF,

O2S11,

O2S12,

MAP,

VSS, TR

(2)

, BOO,

AC_REQ,

COLP,

VPWR

MIL_DIS

(Travelled distance since

MIL

Microsoft

Thursday, July 09, 2009 2:41:10 PM Page 40

1AK

2AG

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata illuminated)

O2S11

(Front HO2S)

O2S12

(Rear HO2S)

PSP

(PSP switch)

RFCFLAG

(PCM adaptive memory produce verification)

Learnt/Not Learnt

RO2FT1

(Rear HO2S fuel trim)

RPM

(Engine speed)

SCCS

(Cruise control switch) mA

Low/High

RPM

Microsoft

Thursday, July 09, 2009 2:41:10 PM



Idle after warmup: Approx. 0 mA



Idle after warmup: Alternates between 0 and 1.0

 Steering wheel at straight ahead position: Low



While turning steering wheel:

High



Idle (after running

PCM adaptive memory procedure drive mode): Learnt

Right after the negative battery cable is disconnected

(before running

PCM adaptive memory procedure drive mode): Not Learnt



Idle after warmup: Approx. 0



Front HO2S

Rear HO2S

PSP switch.

Verify after repair procedure

2AD



The following

PIDs



O2S12



CKP sensor



When the engine is running:

Indicate the engine speed



ON OFF switch pressed in:

Approx. 0 V

CANCEL switch pressed in:

Approx. 1.1 V



SET/- switch pressed in:

Approx. 3.1 V

Page 41



Cruise control switch

1AQ

SEGRP

(EGR control)

SEGRP DSD

(EGR valve position desired)

SELTESTDTC

(Diagnostic trouble codes)

SHRTFT1

(Short term fuel trim (front))

SHRTFT 12

(Short term fuel trim (rear))

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Microsoft

Thursday, July 09, 2009 2:41:10 PM



RES/+ switch pressed in:

Approx. 4.2 V

Except above:

Approx. 5.0 V



Ignition switch is turned to the ON position: 0 Step

Idle: 0 Step



Engine speed is

1,200-4,200 rpm:

0-52 Step



Ignition switch is turned to the ON position: 0%

Idle: 0%



Engine speed is

1,200-4,200 rpm:

0-100%

Indicate the diagnostic trouble codes



Idle after warmup: -25-25%



EGR valve

The following

PIDs



MAF, TP,

ECT,

RPM, VSS

2K, 2G,

2L, 2H



Idle after warmup: Approx. 99%

Page 42



The following

PIDs



CPP

(1)

CPP/PNP

(1)

, ECT,

IAT,

RPM, TP,

MAF,

O2S11,

O2S12,

MAP,

VSS, TR

(2)

, BOO,

AC_REQ,

COLP,

VPWR



The following

PIDs



CPP

(1)

CPP/PNP

SPARKADV

(Ignition timing)

Test

(Test mode)

TIRESIZE

(Tire revolution per mile)

TP REL

(Throttle position signal

(relative value))

TP1

(TP sensor

No.1)

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

On/Off rev/mile

Microsoft

Thursday, July 09, 2009 2:41:10 PM



Indicate the ignition timing

(1)

, ECT,

IAT,

RPM, TP,

MAF,

O2S11,

MAP,

VSS, TR

(2)

, BOO,

AC_REQ,

COLP,

VPWR



The following

PIDs

 CPP

(1)

CPP/PNP

(2)

, ECT,

IAT,

RPM, TP,

MAF,

KNOCKR,

(2)

BOO,

AC_REQ,

COLP



Test mode On: On



Test mode Off:

Off



Indicate the tire revolution per a mile



Accelerator pedal released: Approx.

10%

Accelerator pedal depressed:

Approx. 81%



Accelerator pedal released: Approx.

10%



Accelerator pedal depressed:

Approx. 90%



Accelerator pedal

Page 43



The following

PIDs



TP1, TP2

TP sensor

2AK

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

TP2

(TP sensor

No.2)

TPCT

(TP sensor voltage at CTP)

VPWR

(Battery positive voltage)

VSS

(Vehicle speed)

VT ACT1

(Actual valve timing)

VT DIFF1

(Difference between target valve timing and actual valve timing)

Km/h

Mph

VT DUTY1

Microsoft

Thursday, July 09, 2009 2:41:10 PM

 released: Approx.

0.5 V

Accelerator pedal depressed:

Approx. 4.5 V



Accelerator pedal released: Approx.

10%



Accelerator pedal depressed:

Approx. 90%



Accelerator pedal released: Approx.

4.5 V

Accelerator pedal depressed: 0.5 V



Ignition switch is turned to the ON position: Approx.

0.5 V



Indicate the battery voltage



TP sensor



The following

PIDs



TP1, TP2

Battery

2AL

1BA



Vehicle running:

Indicate the vehicle speed

Idle: Approx. 0°

Racing: 0-25°

Idle: 0°

Idle: Approx. 10%



ABS, DSC

HU/CM

(3)

VSS

(4)

TCM

(5)

 The following

PIDs





OCV

ECT,

RPM, TP,

MAF

(4)

1AM

(3)

(5)

, 1AI

(3)

(5)



The following

PIDs





OCV

ECT,

RPM, TP,

MAF



The following

(OCV control)

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

PIDs

 ECT,

RPM, TP,

MAF

(1) MT

(2) California emission regulation applicable model

(3) With ABS, DSC HU/CM

(4) MT without ABS/DSC

(5) AT without ABS/DSC

PCM CONFIGURATION [LF]

1. Connect the M-MDS or equivalent to the DLC-2.

Fig. 21: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

2. Set up the M-MDS or equivalent (including the vehicle recognition).

3. Select "Module Programming".

4. Select "Programmable Module Installation".

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

5. Select "PCM" and perform procedures according to directions on the M-MDS or equivalent screen.

NOTE:



If the PCM is replaced with a new one, the PCM stores DTC P0602 and illuminates the MIL even though no malfunction is detected. This means the PCM has not been configured yet.

6. Retrieve DTC's by the M-MDS or equivalent, then verify that there in no DTC present.



If DTC is present, perform applicable DTC inspection. (See DTC TABLE [LF] .)

NEUTRAL SWITCH INSPECTION [LF]

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flow diagram. (See

TROUBLESHOOTING PROCEDURE .)

CONTINUITY INSPECTION

1. Remove the neutral switch. (See NEUTRAL SWITCH REMOVAL/INSTALLATION [M15M-D] .)

(See NEUTRAL SWITCH REMOVAL/INSTALLATION [P66M-D] .)

2. Verify that the continuity between neutral switch terminals 1A and 2A is as indicated in Fig. 22 .

 If not as indicated in Fig. 22 , replace the neutral switch. (See NEUTRAL SWITCH

REMOVAL/INSTALLATION [M15M-D] .) (See NEUTRAL SWITCH

REMOVAL/INSTALLATION [P66M-D] .)

Fig. 22: Neutral Switch Continuity Reference Table

Courtesy of MAZDA MOTORS CORP.



If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the CIRCUIT OPEN/SHORT INSPECTION .

CIRCUIT OPEN/SHORT INSPECTION

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

2. Inspect the following wiring harness for open or short circuit (continuity Inspection).

Fig. 23: Identifying Neutral Switch & PCM Harness Side Connectors

Courtesy of MAZDA MOTORS CORP.

Open Circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.

Microsoft



Neutral switch terminal 2A and PCM terminal 1X

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata



Neutral switch terminal 1A and body ground

Short Circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.



Neutral switch terminal 2A and body ground

CLUTCH PEDAL POSITION (CPP) SWITCH INSPECTION [LF]

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flow diagram. (See

TROUBLESHOOTING PROCEDURE .)

CONTINUITY INSPECTION

1. Remove the CPP switch. (See CLUTCH PEDAL REMOVAL/INSTALLATION .)

2. Verify that the continuity between CPP switch terminals D and B is as indicated in Fig. 24 .



If not as indicated in Fig. 24 , replace the CPP switch. (See CLUTCH PEDAL

REMOVAL/INSTALLATION .)

Fig. 24: Clutch Pedal Position Switch Continuity Table

Courtesy of MAZDA MOTORS CORP.



If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the CIRCUIT OPEN/SHORT INSPECTION .

CIRCUIT OPEN/SHORT INSPECTION

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

2. Inspect the following wiring harness for open or short circuit (continuity Inspection).

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 25: Identifying CPP Switch & PCM Harness Side Connectors

Courtesy of MAZDA MOTORS CORP.

Open Circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.



CPP switch terminal B and PCM terminal 1D



CPP switch terminal D and body ground

Short Circuit

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata



If there is continuity, there is a short circuit. Repair or replace the wiring harness.



CPP switch terminal B and body ground

POWER STEERING PRESSURE (PSP) SWITCH INSPECTION [LF]

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flow diagram. (See

TROUBLESHOOTING PROCEDURE .)

CONTINUITY INSPECTION

1. Inspect the following items:



Power steering fluid amount (See POWER STEERING FLUID INSPECTION .)

Power steering-related inspection (See STEERING LOCATION INDEX .)

2. Disconnect the PSP switch connector.

3. Start the engine.

4. Verify that the continuity between PSP switch terminal A and body ground is as indicated in Fig. 26 .



If not as indicated in Fig. 26 , replace the CPP switch. (See POWER STEERING OIL PUMP

DISASSEMBLY/ASSEMBLY .)

Fig. 26: Power Steering Pressure Switch Continuity Reference Table

Courtesy of MAZDA MOTORS CORP.



If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the CIRCUIT OPEN/SHORT INSPECTION .

CIRCUIT OPEN/SHORT INSPECTION

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

2. Inspect the following wiring harness for open or short circuit (continuity Inspection).

Fig. 27: Identifying PSP Switch & PCM Harness Side Connectors

Courtesy of MAZDA MOTORS CORP.

Open Circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.



PSP switch terminal A and PCM terminal 2T

Short Circuit

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata



If there is continuity, there is a short circuit. Repair or replace the wiring harness.



PSP switch terminal A and body ground

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Drain the engine coolant from the radiator. (See ENGINE COOLANT REPLACEMENT [LF] .)

4. Remove the service hole cover.

1. Remove the suspension tower bar (joint), (right side) and (left side). (See FRONT SUSPENSION

TOWER BAR REMOVAL/INSTALLATION .)

2. Remove the wiper arm. (See WIPER ARM AND BLADE REMOVAL/INSTALLATION .)

3. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)

4. Remove the side cowl grille. (See SIDE COWL GRILLE REMOVAL/INSTALLATION .)

5. Move the cooler pipe No.3 and heater pipe slightly out of the way.

Fig. 28: Identifying Cooler Pipe No. 3 & Heater Pipe

Courtesy of MAZDA MOTORS CORP.

6. Remove the service hole cover. (See EGR VALVE REMOVAL/INSTALLATION [LF] .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

5. Disconnect the heater hose and move the heater pipe slightly out of the way.

6. Disconnect the ECT sensor connector.

Fig. 29: Identifying Heater Hose & Heater Pipe

Courtesy of MAZDA MOTORS CORP.

7. Remove the ECT sensor.

NOTE:



Put the double nut together and install the torque wrench. (See

TORQUE FORMULAS .)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 30: Identifying ECT Sensor

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

ECT sensor tightening torque

10-14 N.m {1.1-1.4 kgf.m, 7.4-10.3 ft.lbf}

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 31: Installing ECT Sensor

Courtesy of MAZDA MOTORS CORP.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [LF]

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flow diagram. (See

TROUBLESHOOTING PROCEDURE .)

RESISTANCE INSPECTION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect the ECT sensor connector.

4. Remove the ECT sensor. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR

REMOVAL/INSTALLATION [LF] .)

5. Place the ECT sensor in the water and while increasing the water temperature, measure the resistance between ECT sensor terminals A and B.



If the monitor item status/specification (reference) is not within the specification, even though the

ECT sensor resistance is within the specification, perform the CIRCUIT OPEN/SHORT

INSPECTION .

If not within the specification, replace the ECT sensor. (See ENGINE COOLANT

TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [LF] )

STANDARD ECT SENSOR RESISTANCE SPECIFICATION

Water temperature (°C {°F})

20 {68}

80 {176}

Resistance (kilohm)

35.48-39.20

3.65-4.02

CIRCUIT OPEN/SHORT INSPECTION

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

2. Inspect the following wiring harnesses for an open or short circuit. (Continuity inspection)

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 32: Identifying ECT Sensor Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 33: Identifying PCM Harness Side Connectors

Courtesy of MAZDA MOTORS CORP.

Open Circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.



ECT sensor terminal A and PCM terminal 2AH



ECT sensor terminal B and PCM terminal 2AY

Short Circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.



ECT sensor terminal A and power supply

 ECT sensor terminal A and body ground



ECT sensor terminal B and power supply

MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR

REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect MAF/IAT sensor connector.

4. Remove the MAF/IAT sensor.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 34: Identifying MAF/IAT Sensor

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

MAF/IAT sensor tightening torque

0.55-0.82 N.m {5.7-8.3 kgf.cm, 4.9-7.2 in.lbf}

MASS AIR FLOW (MAF) SENSOR INSPECTION [LF]

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flow diagram. (See

TROUBLESHOOTING PROCEDURE .)

VISUAL INSPECTION

1. Visually inspect the MAF sensor for the following:



Damage, cracks

Rusted sensor terminal



Bent sensor terminal



If there is any malfunction, replace the MAF/IAT sensor. (See MASS AIR FLOW

(MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

REMOVAL/INSTALLATION [LF] .)

VOLTAGE INSPECTION

1. Remove the MAF/IAT sensor without disconnecting the MAF/IAT sensor connector.

2. Turn the ignition switch to the ON position.

3. As the air gradually approaches the MAF detection part of the MAF/IAT sensor, verify that the MAF sensor output voltage (M-MDS PID: MAF) varies.



If it cannot be verified even though the related wiring harnesses have no malfunction, replace the

MAF/IAT sensor. (See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT)

SENSOR REMOVAL/INSTALLATION [LF] .)

CIRCUIT OPEN/SHORT INSPECTION

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

2. Inspect the following wiring harness for open or short circuit (continuity Inspection).

Open Circuit



If there is no continuity, there is an open circuit, Repair or replace the wiring harness.



MAF/IAT sensor terminal A and PCM main relay



MAF/IAT sensor terminal B and PCM terminal 1P



MAF/IAT sensor terminal C and PCM terminal 1AK

Short Circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.

 MAF/IAT sensor terminal A and body ground



MAF/IAT sensor terminal B and power supply



MAF/IAT sensor terminal C and power supply



MAF/IAT sensor terminal C and body ground

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 35: Identifying MAF/IAT Sensor & PCM Harness Side Connector

Courtesy of MAZDA MOTORS CORP.

INTAKE MAF (G/S) AND ENGINE LOAD CALCULATED VALUE SPECIFICATION

Condition MT

Intake MAF (g/s)

Engine load calculated value (%)

Idle

Engine Speed 2,500 rpm

2.1-2.6

6.1-7.5

2.3-2.8

6.7-8.3

13.5-24.0

11.5-21.5

INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [LF]

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flow diagram. (See

TROUBLESHOOTING PROCEDURE .)

RESISTANCE INSPECTION

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect the MAF/IAT sensor connector.

4. Verify that the resistance between MAF/IAT sensor terminals D and E is within the specification.



If the monitor item status/specification (reference) is not within the specification, even though the

IAT sensor resistance is within the specification, perform the CIRCUIT OPEN/SHORT

INSPECTION .



If not within the specification, replace the MAF/IAT sensor. (See MASS AIR FLOW

(MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION

Fig. 36: Identifying MAF/IAT Sensor Connectors

Courtesy of MAZDA MOTORS CORP.

STANDARD MAF/IAT SENSOR RESISTANCE SPECIFICATION

Ambient temperature (°C {°F}) Resistance (kilohm)

20 (68} 2.21-2.69

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

60 {140} 0.493-0.667

CIRCUIT OPEN/SHORT INSPECTION

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)

2. Inspect the following wiring harnesses for an open or short circuit. (Continuity inspection)

Fig. 37: Identifying MAF/IAT Sensor Harness Side Connectors

Courtesy of MAZDA MOTORS CORP.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 38: Identifying PCM Harness Side Connectors

Courtesy of MAZDA MOTORS CORP.

Open Circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.



MAF/IAT sensor terminal D and PCM terminal 1 AT



MAF/IAT sensor terminal E and PCM terminal 1 AR

Short Circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.



MAF/IAT sensor terminal E and power supply



MAF/IAT sensor terminal D and power supply



MAF/IAT sensor terminal D and body ground

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Remove the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

4. Remove the MAP sensor.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 39: Removing Manifold Absolute Pressure Sensor

Courtesy of MAZDA MOTORS CORP.

5. Install in the reverse order of removal.

MAP sensor tightening torque

2.7-3.7 N.m {28-37 kgf.cm, 24-32 in.lbf}

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSPECTION [LF]

NOTE:



Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flow diagram. (See

TROUBLESHOOTING PROCEDURE .)

1. Connect the M-MDS or equivalent to the DLC-2.

Microsoft

2007 Mazda MX-5 Miata Sport

2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata

Fig. 40: Identifying Data Link Connector DLC-2

Courtesy of MAZDA MOTORS CORP.

2. Turn the ignition switch to the ON position (Engine off).

3. Select MAP PID on the M-MDS or equivalent.

4. Verify that the MAP PID (pressure) and barometric pressure are practically equa