Mazda MX-5 2008 Workshop Manual

PDF Download

Document

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).

Microsoft

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.

Microsoft

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

Microsoft

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

Microsoft

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata



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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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,

Microsoft

2008 Mazda MX-5 Miata Grand Touring

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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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: 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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 .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata



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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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: 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 .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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: View Of Side Air Bag Sensor & Components

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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: View Of Clock Spring Components

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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 .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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 .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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:



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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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:



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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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:



Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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:



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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 RESTRAINTS Air Bag System - MX-5 Miata

 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

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.

Microsoft

Thursday, July 09, 2009 3:43:37 PM Page 75

Off On

2008 Mazda MX-5 Miata Grand Touring

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

2008 BRAKES Antilock Brake System - MX-5 Miata

ABS LOCATION INDEX

2008 BRAKES

Antilock Brake System - MX-5 Miata

Fig. 1: Identifying Location Of ABS Components

Courtesy of MAZDA MOTORS CORP.

ABS SYSTEM WIRING DIAGRAM

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

Thursday, July 09, 2009 5:49:02 PM Page 3

Command

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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)

LF wheelspeed sensor

(ground)

Ground point

Battery

Ground point

LF ABS wheel-speed sensor

Microsoft

Thursday, July 09, 2009 5:49:02 PM

Continuity

Voltage

Continuity

A-ground point

Page 11

Under any condition

D-ground point

E-LF ABS wheel-speed sensor connector terminal B

Continuity detected

B+

Continuity detected



Wiring harness (Aground point)



Wiring harness (Bbattery)



Wiring harness (Cbattery)



Wiring harness (Dground point)



Wiring harness (E-

LF ABS wheel-speed sensor connector

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Antilock Brake System - MX-5 Miata

LF wheelspeed sensor

(single)

LR wheelspeed sensor

(signal)

LR wheelspeed sensor

(ground)

RR wheelspeed sensor

(signal)

Power supply

(system)

LF ABS wheel-speed sensor

LR ABS wheel-speed sensor

RR ABS wheel-speed sensor

Ignition switch

Continuity

Voltage

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

I-RR ABS wheel-speed sensor connector terminal A

Ignition switch at ON

Continuity detected

B+ terminal B)



Wiring harness (F-

LF ABS wheel-speed sensor connector terminal A)

 Wiring harness (G-

LR ABS wheel-speed sensor connector terminal A)



Wiring harness (H-

LR ABS wheel-speed sensor connector terminal B)



Wiring harness (I-

RR ABS wheel-speed sensor connector terminal A)



Wiring harness (Jignition switch)

Microsoft

Thursday, July 09, 2009 5:49:02 PM

RR wheelspeed sensor

(ground)

RR ABS wheel-speed sensor

Continuity

Ignition switch is off.

1 V or less

L-RR ABS wheel-speed

Page 12 sensor connector terminal B

Continuity detected



Wiring harness (L-

RR ABS wheel-speed sensor connector terminal B)



Wiring

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Antilock Brake System - MX-5 Miata

RF wheelspeed sensor

(signal)

RF ABS wheel-speed sensor

Continuity

Brake switch Brake switch Voltage

M-RF ABS wheel-speed sensor connector terminal A

Continuity detected

N-brake switch

(Brake pedal depressed)

Y-brake switch

(Brake pedal not depressed)

B+

1 V or less

RF wheelspeed sensor

(ground)

RF ABS wheel-speed sensor

Continuity

O-RF ABS wheel-speed sensor connector terminal B

Continuity detected

CAN_L

CAN_H

DLC-2

(CAN_L)

DLC-2

(CAN_H)

Continuity

Y-DLC-2 terminal

CAN_L.

Z-DLC-2 terminal

CAN_H

Continuity detected

Continuity detected harness (M-

RF ABS wheel-speed sensor connector terminal A)



Wiring harness (Nbrake switch)



Brake switch



Wiring harness (O-

RF ABS wheel-speed sensor connector terminal B)



Wiring harness (Y-

DLC-2 terminal

CAN_L)



Wiring harness (Z-

DLC-2 terminal

CAN_H)

FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION

1. Remove the mudguard.

2. Remove in the order indicated in the table.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Antilock Brake System - MX-5 Miata

3. Install in the reverse order of removal.

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Antilock Brake System - MX-5 Miata

4. Calculate the clearance between the front ABS wheel-speed sensor and the ABS sensor rotor using the following formula:

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Antilock Brake System - MX-5 Miata

SENSOR OUTPUT VALUE INSPECTION

CAUTION:



Resistance inspection using other testers may cause damage to the

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Antilock Brake System - MX-5 Miata



If there is any malfunction, replace the front ABS wheel-speed sensor.

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Antilock Brake System - MX-5 Miata

CLEARANCE INSPECTION

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 BRAKES Conventional Brake System - MX-5 Miata

2008 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.

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 11: Identifying Master Cylinder Components (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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 16: Brake Fluid Sensor Terminal Continuity Table

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 19: Inspecting Vacuum Loss Function - Without DSC

Courtesy of MAZDA MOTORS CORP.

WITH DSC

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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})

Fluid pressure (kPa {kgf/cm

, psi})

200 {20.4, 44.9} 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)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 21: View Of Clutch Pipe & Components (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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 22: View Of Cooler Hose (LO) Bracket

Courtesy of MAZDA MOTORS CORP.

4. Remove in the order indicated in Fig. 23 .

Fig. 23: Identifying Power Brake Unit Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 24: View Of Dual Proportioning Valve Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

2. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

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.)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 40: Measuring Rear 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. 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 46: Identifying Stopper Nut & 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

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 49: View Of Caliper (Rear) Components (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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Conventional Brake System - MX-5 Miata

Fig. 54: Identifying Brake Hose (Rear) Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 ELECTRICAL Charging System - MX-5 Miata

2008 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 .)

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 2: Identifying Removal Order Of Battery & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

BATTERY COVER REMOVAL NOTE

1. Remove the rubber hose from the battery cover.

Fig. 3: View Of Rubber Hose

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

2. Remove the battery cover from its right side.

Fig. 4: View Of Right Side Battery Cover

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. 5 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 5: 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:

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 6: 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

2008 Mazda MX-5 Miata Grand Touring

2008 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. 7: 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]

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 8: 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 9: 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 5:57:02 PM Page 12

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 10: 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 11: 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. 12 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 12: Stator Coil Terminal Continuity Check Table

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 13: 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Brush

Fig. 14: 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 15: Inspecting Brushes For Wear

Courtesy of MAZDA MOTORS CORP.

Brush Spring

1. Measure the force of the brush spring using a spring pressure gauge.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 16: 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

Microsoft

Thursday, July 09, 2009 5:57:02 PM

Continuity

Yes

P1, P2, P3, P4, P5, P6

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Yes

Fig. 17: 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

Microsoft

Thursday, July 09, 2009 5:57:02 PM

P1, P2, P3, P4, P5, P6

Page 21

Continuity

Yes

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 18: Identifying Diodes

Courtesy of MAZDA MOTORS CORP.

Bearing

1. Inspect for abnormal noise, looseness, and sticking.



Replace the bearing if necessary.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 19: 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ELECTRICAL Charging System - MX-5 Miata

Fig. 20: Identifying Disassemble Order Of Generator (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 DRIVELINE/AXLES Differential - MX-5 Miata

2008 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.

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 5: Identifying Oil-Fill Plug Hole & 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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 .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 12: View Of 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Differential - MX-5 Miata one of the pinion gear teeth.

Fig. 26: View Of 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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})

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 36: Measuring Pinion Height Adjustment Value

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Differential - MX-5 Miata

Fig. 50: Identifying Heel & Face Contact Points

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

2008 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.

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 5: Using Hammer To Remove 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 9: View Of Rear Drive Shaft Components

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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 12: View Of 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

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 13: Removing Snap Ring

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

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Drive Shaft - MX-5 Miata

Fig. 14: View Of 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 DRIVELINE/AXLES Propeller Shaft - MX-5 Miata

2008 DRIVELINE/AXLES

Propeller Shaft - MX-5 Miata

PROPELLER SHAFT LOCATION INDEX

Fig. 1: Identifying Propeller Shaft

Courtesy of MAZDA MOTORS CORP.

PROPELLER SHAFT REMOVAL/INSTALLATION

1. Remove the member and the middle pipe.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [LF] .)

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Propeller Shaft - MX-5 Miata

Fig. 2: Identifying Propeller Shaft Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

PROPELLER SHAFT REMOVAL NOTE

CAUTION:



When replacing with a new propeller shaft, mark the companion flange to match the position of the tag on the propeller shaft.

1. Before removing the propeller shaft, make alignment marks on the yoke and differential companion flange.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Propeller Shaft - MX-5 Miata

Fig. 3: Identifying Alignment Marks On Yoke & Companion Flange

Courtesy of MAZDA MOTORS CORP.

2. Install the SST to the extension housing.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Propeller Shaft - MX-5 Miata

Fig. 4: Identifying SST To Extension Housing

Courtesy of MAZDA MOTORS CORP.

PROPELLER SHAFT INSTALLATION NOTE

1. Align the marks and install the propeller shaft.

2. When installing a new propeller shaft, align the differential companion flange mark with the tag on the propeller shaft and assemble.

Fig. 5: Identifying Differential Companion Flange Mark And Tag

Courtesy of MAZDA MOTORS CORP.

PROPELLER SHAFT INSPECTION

1. Use a dial gauge to measure the runout of the propeller shaft at each position.

 If it exceeds the maximum specification, replace the propeller shaft.

Maximum runout

0.4 mm {0.016 in}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Propeller Shaft - MX-5 Miata

Fig. 6: Identifying Runout Measuring Points

Courtesy of MAZDA MOTORS CORP.

2. Inspect the play and rotation of the joint by turning the universal joint in the direction shown by the arrow

Initial torque (Reference value)

0.29-0.98 N.m

{3.0-10 kgf.cm, 2.7-8.6 in.lbf}



If there is excessive play or initial torque, replace the propeller shaft.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Propeller Shaft - MX-5 Miata

Fig. 7: Inspecting Play & Rotation Of Joint By Turning Universal Joint In Direction

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 BRAKES Dynamic Stability Control - MX-5 Miata

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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)

LR wheelspeed sensor

(signal)

Ground point

Battery

Ground point

LF ABS wheel-speed sensor

LR ABS wheel-speed sensor

Measured item

Measured terminal

(measured condition)

Continuity A-ground point

Voltage

Continuity D-ground point

Continuity

Under any condition

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

Standard

Continuity detected

B+

Continuity detected

Inspection item

(s)



Wiring harness

(A-ground point)



Wiring harness (Bbattery)



Wiring harness (Cbattery)



Wiring harness (Dground point)



Wiring harness (E-

LF ABS wheelspeed sensor connector terminal B)



Wiring harness (F-

LF ABS wheelspeed sensor connector terminal A)



Wiring harness (G-

LR ABS wheelspeed sensor connector

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Dynamic Stability Control - MX-5 Miata

LR wheelspeed sensor

(ground)

LR ABS wheel-speed sensor

RR wheelspeed (signal)

Power supply

(system)

RR ABS wheel-speed sensor

Ignition switch

Continuity

H-LR ABS wheel-speed sensor connector terminal B

I-RR ABS wheel-speed sensor connector terminal A

Continuity detected

Voltage

Ignition switch at ON

B+

Ignition switch is off.

1 V or less -

terminal A)



Wiring harness (H-

LR ABS wheelspeed sensor connector terminal B)



Wiring harness (I-

RR ABS wheelspeed sensor connector terminal A)



Wiring harness (Jignition switch)

RR wheelspeed sensor

(ground)

RF wheelspeed sensor

(signal)

RR ABS wheel-speed sensor

RF ABS wheel-speed sensor

Continuity

L-RR ABS wheel-speed sensor connector terminal B

M-RF ABS wheel-speed sensor connector terminal A

N-ground point

(Brake pedal depressed)

Continuity detected

B+



Wiring harness (L-

RR ABS wheelspeed sensor connector terminal B)



Wiring harness (M-

RF ABS wheelspeed sensor connector terminal A)



Wiring harness (Nbrake switch)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Dynamic Stability Control - MX-5 Miata



Brake switch

Brake switch Brake switch

RF wheelspeed sensor

(ground)

DSC OFF switch

CAN_L

CAN_H

Ground

(combined sensor)

RF ABS wheel-speed sensor

DSC OFF switch

DLC-2

(CAN_L)

DLC-2

(CAN_H)

Combined sensor

Microsoft

Thursday, July 09, 2009 5:49:57 PM

Voltage

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

Continuity detected



Wiring harness (O-

RF ABS wheelspeed sensor connector terminal B)



Wiring harness (P-

DSC OFF switch connector terminal A)

Continuity

W-DLC-2 terminal

CAN_L

X-DLC-2 terminal

CAN_H

Y-combined sensor connector terminal F

Page 16

Continuity detected



Wiring harness

(W-DLC-2 terminal

CAN_L)

 Wiring harness (X-

DLC-2 terminal

CAN_H)



Wiring harness (Ycombined sensor connector terminal F)



Wiring

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Dynamic Stability Control - MX-5 Miata

Yaw rate

(signal)

Yaw rate (test signal)

Combined sensor

AH -

Yaw rate

(reference signal)

Combined sensor

Lateral-G

(signal)

Combined sensor

AK -

AL -

AM -

AN -

AO -

AP -

AQ -

AR -

AS -

AT -

Microsoft

Thursday, July 09, 2009 5:49:57 PM

Combined sensor

Continuity

AA-combined sensor connector terminal B

AB-combined sensor connector terminal C

Continuity detected

Continuity detected harness

(AAcombined sensor connector terminal B)



Wiring harness

(ABcombined sensor connector terminal C)

Continuity

AE-combined sensor connector terminal A

Continuity detected



Wiring harness

(AEcombined sensor connector terminal A)

Continuity

AI-combined sensor connector terminal D

Page 17

Continuity detected



Wiring harness

(AIcombined sensor connector terminal D)

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Dynamic Stability Control - MX-5 Miata

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.



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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Dynamic Stability Control - MX-5 Miata

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

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 .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Dynamic Stability Control - MX-5 Miata

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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 15: Tilting Combined Sensor Left & 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

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Dynamic Stability Control - MX-5 Miata

Fig. 16: Tilting Combined Sensor Left & 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 MAZDA MX-5 Miata

2008 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 .

2008 Mazda MX-5 Miata Grand Touring

2008 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

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 .

Deck Panel Motor (Left)

Deck Panel Motor (Right)

Evaporative System Leak Detection Pump

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 .

Front Door Lock Actuator (Left/Right)

Fuel Pump Unit

Mix Air Actuator

In respective front door. See

Behind right side of dash. See

Fig. 36

Under rear center of vehicle. See Fig. 6

Fig. 22 .

Power Outer Mirror (Left/Right)

Power Window Motor (Left/Right)

Roof Motor (Left)

Roof Motor (Right)

Starter

Trunk Lid Opener

Washer Motor

Wiper Motor

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

Brake Fluid Level Sensor

Camshaft Position Sensor

Microsoft

Thursday, July 09, 2009 5:57:55 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 .

In brake fluid reservoir. See Fig. 46 .

Right rear of engine. See Fig. 12 .

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

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

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

Location

Rear of engine. See Fig. 12 .

Top of engine. See Fig. 13 .

Inside valve control body on transmission. See Fig. 20 .

Magnetic Clutch

Oil Control Valve

Purge Solenoid Valve

Shift Solenoids A, B, C, D, E, F & G

TCC Control Solenoid

Variable Intake Air Solenoid Valve

Left front of engine, on A/C compressor. See

Right front of engine. See

Left side of engine compartment. See

Left side of engine. See

Fig. 23

Fig. 12

Inside valve control body on transmission. See Fig. 20 .

Fig. 12

SWITCHES

SWITCHES LOCATION

Component

Back-Up Light Switch

Brake Switch

Buckle Switch (Left/Right)

Microsoft

Thursday, July 09, 2009 5:57:55 PM Page 3

Location

On transmission. See Fig. 42 .

Top of brake pedal assembly. See Fig. 14 .

On respective seat belt buckle. See Fig. 26 .

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Clutch Pedal Position Switch

Deck Panel Limit Switch

Door Lock-Link Switch (Left)

Door Lock-Link Switch (Right)

Door Switch (Left/Right)

Top of clutch pedal assembly. See Fig. 14 .

Right side of retractable top storage compartment. See Fig. 53 .

In driver's door. See Fig. 34 .

In passenger door. See Fig. 36 .

On respective "B" pillar. See Fig. 48 .

Hood Latch Switch

Key Reminder Switch

Neutral Switch

Center front of engine compartment. See Fig. 36 .

On steering column. See Fig. 45 .

On transmission. See Fig. 14 .

Oil Pressure Switch

Parking Brake Switch

On left side of engine. See

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

Starter Interlock Switch

Transmission Range Switch

Trunk Compartment Light Switch

Trunk Lid Opener Cancel Switch

Left front of engine. See Fig. 13 .

Right front of engine compartment. See Fig. 21 .

Behind left side of dash. See Fig. 8 .

On transmission. See Fig. 8 .

Right rear of luggage compartment. See Fig. 39 .

Lower center rear of luggage compartment. See 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)

Joint Connector (C-20)

Microsoft

Thursday, July 09, 2009 5:57:55 PM

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 .

Behind center of dash. See Fig. 15 .

Page 4

Right front of luggage compartment. See Fig.

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Joint Connector (C-21)

Joint Connector (C-22)

Keyless Antenna (Center)

Keyless Antenna (Instrument Panel)

Keyless Antenna (Left/Right)

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)

Seat Warmer (Left/Right)

Selector Lever Component

Transmission Fluid Temperature Connector

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 .

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

In respective seat cushion. See

Fig. 21

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)

C-15 (32 Pin)

C-16 (32 Pin)

Microsoft

Thursday, July 09, 2009 5:57:55 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 .

Behind right kick panel. See Fig. 29 .

Behind left kick panel. See Fig. 29 .

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

C-17 (4 Pin)

GROUNDS

G16

G17

G18

G19

G20

G10

G11

G12

G13

G14

G15

GROUNDS LOCATION

Component

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

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 1: Relay & Main Fuse Block

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 2: Ground System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 3: Ground System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 4: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 5: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 6: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 7: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 8: Dash & Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 9: Engine Control System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 10: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 11: Dash & Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 12: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 13: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 14: Engine Control System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 15: Dash & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 16: Engine Compartment & Rear Of Vehicle

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 17: Dash & Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 18: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 19: Automatic Transmission Control System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 20: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 21: Dash & Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 22: Dash

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 23: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 24: Air Bag System

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 25: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 26: Seats

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 27: Passenger Seat

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 28: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 29: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 30: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 31: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 32: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 33: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 34: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Fig. 35: Dash & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 36: Engine Compartment & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 37: Dash

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 38: Rear Of Vehicle

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 39: Rear Of Vehicle

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 40: Dash

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 41: Dash

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 42: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 43: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 44: Dash & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 45: Dash

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 46: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 47: Engine Compartment & Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 48: Vehicle Overview

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 49: Engine Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 MAZDA MX-5 Miata

Fig. 55: Retractable Top Storage Compartment

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 8: View Of 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] ).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 11: View Of Evaporative Hose On 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

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 13: Identifying Evaporative Emission System Leak Detection Pump & Evaporative Hose (With

Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

7. Remove the bracket from the EVAP system leak detection pump.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 14: View Of Bracket & 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 19: View Of Purge Solenoid Valve & 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

2008 Mazda MX-5 Miata Grand Touring

2008 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).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 23: View Of Service Hole Cover (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

6. Remove the harness bracket.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 24: View Of Harness Bracket

Courtesy of MAZDA MOTORS CORP.

7. Disconnect the heater hose and move the heater pipe slightly out of the way.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 27: View Of EGR Valve & Engine Coolant Hose Components (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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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]

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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 & Evaporative Hose

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 38: Identifying Locations Of Different 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 42: View Of 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 45: Releasing Locks Between Retainer & 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

2008 Mazda MX-5 Miata Grand Touring

2008 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: View Of Checker Tab & Quick Release Connector

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

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata



Fig. 47: View Of Checker Tab & Quick Release Connector

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

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 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: View Of New Retainer & Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Emission System - MX-5 Miata

Fig. 50: View Of Checker Tab & Quick Release Connector

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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 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

2008 DRIVELINE/AXLES Front Axle - MX-5 Miata

2008 DRIVELINE/AXLES

Front Axle - MX-5 Miata

FRONT AXLE LOCATION INDEX

Fig. 1: Identifying Front Axle Assembly

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB, STEERING KNUCKLE INSPECTION

WHEEL BEARING LOOSENESS INSPECTION

1. Install the magnetic vase and dial gauge as shown in Fig. 2 , and inspect the wheel bearing for axial looseness.



If it exceeds the maximum specification, replace the wheel hub component.

Maximum front wheel bearing play

0.05 mm {0.002 in}

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Front Axle - MX-5 Miata

Fig. 2: Inspect Wheel Bearing For Axial Looseness

Courtesy of MAZDA MOTORS CORP.

FRONT WHEEL HUB BOLT REPLACEMENT

1. Remove the brake caliper component and disc plate.

2. Remove the wheel hub bolt using the SST as shown in Fig. 3 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Front Axle - MX-5 Miata

Fig. 3: Removing Wheel Hub Bolt Using SST

Courtesy of MAZDA MOTORS CORP.

3. Place a new wheel hub bolt in the wheel hub.

4. Install the wheel hub bolt by placing a proper sized washer on the hub, and tightening the nut as shown in

Fig. 4 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Front Axle - MX-5 Miata

Fig. 4: Installing Wheel Hub Bolt By Placing Proper Sized Washer On Hub & Tightening Nut

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB, STEERING KNUCKLE 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, disconnect the ABS wheel-speed sensor harness connector (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Remove in the order indicated in Fig. 5 .

2. Install in the reverse order of removal.

3. After installation, inspect front wheel alignment. (See FRONT WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Front Axle - MX-5 Miata

Fig. 5: Identifying Wheel Hub, Steering Knuckle 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.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Front Axle - MX-5 Miata

Fig. 6: Suspending Brake Caliper

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB BOLT REMOVAL NOTE

NOTE:



Remove the wheel hub bolt only if there is an abnormality.

1. Remove the wheel hub bolts from the wheel hub using a press.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Front Axle - MX-5 Miata

Fig. 7: Removing Wheel Hub Bolts From Wheel Hub Using Press

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB BOLT INSTALLATION NOTE

1. Press in new wheel hub bolts into the wheel hub using a press.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Front Axle - MX-5 Miata

Fig. 8: Pressing New Wheel Hub Bolts Into Wheel Hub Using Press

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 SUSPENSION Front Suspension - MX-5 Miata

2008 SUSPENSION

Front Suspension - MX-5 Miata

FRONT SUSPENSION LOCATION INDEX

Fig. 1: Identifying Location Of Front Suspension Components

Courtesy of MAZDA MOTORS CORP.

FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION

CAUTION:



1. Remove the front suspension tower bar. (See FRONT SUSPENSION TOWER BAR

REMOVAL/INSTALLATION .)

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

4. Inspect the front wheel alignment, and adjust it if necessary. (See FRONT WHEEL ALIGNMENT .)

Fig. 2: Identifying Front Shock Absorber & Coil Spring Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY

WARNING:



Removing/installing the shock absorber and coil spring is dangerous. The shock absorber and coil spring could fly off and cause serious injury or death, and damage the vehicle.

1. Remove the front shock absorber and coil spring. (See FRONT SHOCK ABSORBER AND COIL

SPRING REMOVAL/INSTALLATION .)

2. Remove in the order indicated in Fig. 3 .

3. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 3: Identifying Front Shock Absorber & Coil Spring Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

PISTON ROD NUT REMOVAL NOTE

WARNING:



Before removing the piston rod nut, secure the shock absorber and spring in the SSTs. Otherwise, the shock absorber and spring could fly off under tremendous pressure and cause serious injury or death, or damage to vehicle parts.

1. Protect the coil spring from scratches using a piece of cloth and install the SSTs .

2. Compress the coil spring using the SSTs and remove the piston rod nut.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 4: Compressing Coil Spring Using SST's & Removing Piston Rod Nut

Courtesy of MAZDA MOTORS CORP.

COIL SPRING INSTALLATION NOTE

1. Protect the coil spring from scratches using a piece of cloth and install the SSTs .

2. Compress the coil spring using the SSTs .

3. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 5: Compressing Coil Spring Using SSTs

Courtesy of MAZDA MOTORS CORP.

UPPER SPRING SEAT INSTALLATION NOTE

1. Align the mark on the upper spring seat with the dust boot projection.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 6: Aligning Mark On Upper Spring Seat With Dust Boot Projection

Courtesy of MAZDA MOTORS CORP.

2. Install the upper spring seat so that the upper spring seat stud is at a 27°-33° angle to the shock absorber installation shaft (lower side).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 7: Identifying Upper Spring Seat Stud Angle

Courtesy of MAZDA MOTORS CORP.

FRONT SHOCK ABSORBER INSPECTION

1. Remove the front shock absorber.

2. Inspect for damage and oil leakage.

3. Compress and extend the shock absorber piston rod at least three times at a steady speed. From the fourth compression stroke, verify that the operational force does not change and that there is no unusual noise.



If there is any malfunction, replace the shock absorber.

FRONT SHOCK ABSORBER DISPOSAL

WARNING:



Whenever drilling into a shock absorber, wear protective eye wear.

The gas in the shock absorber is pressurized, and could spray metal chips into the eyes and face when drilling.

1. Clamp the shock absorber on a flat surface.

2. Drill a 2-3 mm {0.08-0.12 in} hole at a point 25 mm {0.98 in} from the bottom of the tube, so that the gas can escape.

3. Turn the hole downwards.

4. The oil can be collected by moving the piston rod several times up and down and cutting the tube at the end.

5. Dispose of waste oil according to local waste disposal law.

Microsoft

NOTE:

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata



Shock absorber gas contains nitrogen gas.

Shock absorber oil contains mineral oil.

Fig. 8: Drilling Hole From Bottom Of Tube

Courtesy of MAZDA MOTORS CORP.

FRONT LOWER ARM REMOVAL/INSTALLATION

CAUTION:



1. Remove in the order indicated in Fig. 9 .

2. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 9: Identifying Front Lower Arm Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CALIPER AND MOUNTING SUPPORT REMOVAL NOTE

1. Remove the caliper and mounting support from the steering knuckle and suspend it with a cable in a location out of the way.

FRONT LOWER ARM BALL JOINT REMOVAL NOTE

1. Disconnect the front lower arm ball joint from the steering knuckle using the SST .

NOTE:



When removing the front lower arm ball joint, the steering knuckle

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata bushing may also come off. If it comes off, replace the steering knuckle.

Fig. 10: Disconnecting Front Lower Arm Ball Joint From Steering Knuckle Using SST

Courtesy of MAZDA MOTORS CORP.

FRONT UPPER ARM BALL JOINT REMOVAL NOTE

1. Loosen the bolts on the vehicle side.

2. Disconnect the upper arm ball joint using the SST .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 11: Disconnecting Front Upper Arm Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

BUSHING (REAR SIDE) REMOVAL NOTE

CAUTION:



Be careful not to damage the front lower arm. If it is damaged, replace it.

1. Mark the front upper arm as shown in Fig. 12 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 12: Identifying Mark On Front Upper Arm

Courtesy of MAZDA MOTORS CORP.

2. Remove the bushing using the SSTs .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 13: Removing Bushing Using SST's

Courtesy of MAZDA MOTORS CORP.

BUSHING (FRONT SIDE) REMOVAL NOTE

CAUTION:



Be careful not to damage the front lower arm. If it is damaged, replace it.

1. Cut off the stopper plate rubber using a razor.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 14: Cutting Off Stopper Plate Rubber Using Razor

Courtesy of MAZDA MOTORS CORP.

2. Cut off 5-6 mm {0.20-0.23 in} from each side of the knob end of the bushing using a hacksaw.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 15: Cutting Off From Each Side Of Knob End Of Bushing Using Hacksaw

Courtesy of MAZDA MOTORS CORP.

3. Remove the bushing using the SSTs .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 16: Removing Bushing Using SST's

Courtesy of MAZDA MOTORS CORP.

BUSHING (SHOCK ABSORBER LOWER SIDE CONNECTING PART) REMOVAL NOTE

CAUTION:



Be careful not to damage the front lower arm. If it is damaged, replace it.

1. Remove the bushing using the SSTs .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 17: Removing Bushing Using SSTs

Courtesy of MAZDA MOTORS CORP.

BUSHING (SHOCK ABSORBER LOWER SIDE CONNECTING PART) INSTALLATION NOTE

1. Compress the bushing using the SSTs .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 18: Compressing Bushing Using SSTs

Courtesy of MAZDA MOTORS CORP.

BUSHING (FRONT SIDE) INSTALLATION NOTE

1. Press the bushing in using the SSTs .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 19: Pressing Bushing In Using SSTs

Courtesy of MAZDA MOTORS CORP.

2. Insert the stopper plate rubber into the inner pipe of the bushing (front side).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 20: Inserting Stopper Plate Rubber Into Inner Pipe Of Bushing (Front Side)

Courtesy of MAZDA MOTORS CORP.

BUSHING (REAR SIDE) INSTALLATION NOTE

1. Align the marks placed during removal and install the bushing.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 21: Aligning Match Marks

Courtesy of MAZDA MOTORS CORP.

2. Press the bushing in using the SSTs .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 22: Pressing Bushing In Using SSTs

Courtesy of MAZDA MOTORS CORP.

CLIP INSTALLATION NOTE

1. Wipe the grease off the ball joint stud.

2. Fill the inside of the new dust boot with grease.

3. Install the dust boot to the ball joint.

4. Install the clip using the SST .

5. Verify that the clip is installed securely to the groove.

Fig. 23: Installing Dust Boot To Ball Joint

Courtesy of MAZDA MOTORS CORP.

6. Wipe off any excess grease.

FRONT LOWER ARM INSTALLATION NOTE

1. Install the front lower arm rear side bushing part horizontally.

2. Install the front lower arm front side bushing part.

FRONT LOWER ARM INSPECTION

1. Remove the front lower arm from the vehicle. (See FRONT LOWER ARM

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

REMOVAL/INSTALLATION .)

2. Inspect the front lower arm for bending or damage. If there is any malfunction, replace it.

3. Inspect the ball joint for excessive play. If there is any malfunction, replace the front lower arm.

4. Rotate the ball joint 5 times .

5. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench.

Front lower arm ball joint rotational torque

0.4-2.9 N.m {5-29 kgf.cm, 4-25 in.lbf}



If not within the specification, replace the front lower arm. (See FRONT LOWER ARM

REMOVAL/INSTALLATION .)

Fig. 24: Measuring Ball-Joint Rotational Torque

Courtesy of MAZDA MOTORS CORP.

FRONT UPPER ARM INSPECTION

1. Remove the front upper arm from the vehicle. (See FRONT UPPER ARM

REMOVAL/INSTALLATION .)

2. Inspect the front upper arm for bending or damage. If there is any malfunction, replace it.

3. Inspect the ball joint for excessive play, and if there is any malfunction, replace the front upper arm.

4. Rotate the ball joint 5 times .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

5. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench.

Front upper arm ball joint rotational torque

0.3-2.2 N.m {4-22 kgf.cm, 3-19 in.lbf}



If not within the specification, replace the front upper arm. (See FRONT UPPER ARM

REMOVAL/INSTALLATION .)

Fig. 25: Measuring Ball-Joint Rotational Torque Using Allen Wrench & Torque Wrench

Courtesy of MAZDA MOTORS CORP.

FRONT UPPER ARM REMOVAL/INSTALLATION

CAUTION:



1. Remove in the order indicated in Fig. 26 .

2. Install in the reverse order of removal.

3. Inspect the front wheel alignment and adjust it if necessary. (See FRONT WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 26: Identifying Front Upper Arm Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

FRONT UPPER ARM BALL JOINT REMOVAL NOTE

1. Remove the front upper arm ball joint from the steering knuckle using the SST .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 27: Removing Front Upper Arm Ball Joint From Steering Knuckle Using SST

Courtesy of MAZDA MOTORS CORP.

FRONT SHOCK ABSORBER, COIL SPRING AND FRONT UPPER ARM REMOVAL NOTE

1. Loosen the shock absorber upper nuts.

2. Remove the front shock absorber lower bolt and nut.

FRONT UPPER ARM REMOVAL NOTE

1. Remove the front upper arm bolts.

2. Push down the front lower arm, and then remove the front upper arm from the gap between the shock absorber lower end and the front lower arm.

FRONT STABILIZER REMOVAL/INSTALLATION

CAUTION:



1. Remove in the order indicated in the table.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

2. Install in the reverse order of removal.

Fig. 28: Identifying Front Stabilizer Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

STABILIZER BRACKET INSTALLATION NOTE

1. Apply rubber grease to the inner side of the stabilizer bushing.

2. Align the outer side of the stabilizer slide stopper with the stabilizer bushing.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 29: Aligning Outer Side Of Stabilizer Slide Stopper With Stabilizer Bushing

Courtesy of MAZDA MOTORS CORP.

3. Install the stabilizer bracket.

FRONT STABILIZER CONTROL LINK INSPECTION

1. Remove the stabilizer control link from the vehicle. (See FRONT STABILIZER

REMOVAL/INSTALLATION .)

2. Inspect the stabilizer control link for bending or damage. If there is any malfunction, replace it.

3. Rotate the ball joint stud 10 times , and then rock it side to side 10 times .

4. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench.

Stabilizer control link ball joint rotational torque

0.2-2.0 N.m {3-20 kgf.cm, 2-17 in.lbf}



If not within the specification, replace the stabilizer control link. (See FRONT STABILIZER

REMOVAL/INSTALLATION .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 30: Measuring Ball-Joint Rotational Torque

Courtesy of MAZDA MOTORS CORP.

FRONT CROSSMEMBER REMOVAL/INSTALLATION

CAUTION:



1. Remove the front suspension tower bar. (See FRONT SUSPENSION TOWER BAR

REMOVAL/INSTALLATION .)

2. Remove the front stabilizer (See FRONT STABILIZER REMOVAL/INSTALLATION .)

3. Remove the transverse members (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)

4. Remove the steering gear and linkage, and suspend it using a cable.

5. Remove in the order indicated in Fig. 31 .

6. Install in the reverse order of removal.

7. Inspect the front wheel alignment. (See FRONT WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 31: Identifying Front Crossmember Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

AXLE AND HUB COMPONENT REMOVAL NOTE

1. Loosen the front upper arm inner bolts.

2. Remove the axle and hub component.

FRONT CROSSMEMBER COMPONENT REMOVAL NOTE

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

1. Secure the chain to install the SST to the position shown in Fig. 32 using the bolts ( M10 x 1.5

, length 30 mm {1.18 in} ).

Fig. 32: Identifying Chain Bolt Location

Courtesy of MAZDA MOTORS CORP.

2. Suspend the engine.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 33: Suspending Engine

Courtesy of MAZDA MOTORS CORP.

3. Support the front crossmember using a jack.

WARNING:



Verify that the crossmember component is securely supported by a jack. If the crossmember component falls, it could cause serious injury or death, or damage to the vehicle.

4. Lower the front crossmember component slightly.

5. Remove the engine mounting rubber, pipes and hoses installed to the front crossmember.

6. Remove the front crossmember component.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 34: Supporting Front Crossmember Using Jack

Courtesy of MAZDA MOTORS CORP.

TRANSVERSE MEMBER REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 35 .

2. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 35: Identifying Transverse Member And Under Cover (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

TRANSVERSE MEMBER REMOVAL NOTE

1. Support the crossmember using a jack.

2. Remove the transverse member.

UNDER COVER INSTALLATION NOTE

1. Align projection A with the transverse member opening to temporarily support the under cover.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 36: Aligning Projection A With Transverse Member

Courtesy of MAZDA MOTORS CORP.

2. Tighten the bolts in the order of A, B and C.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 37: Tightening Transverse Member Bolts In Sequence

Courtesy of MAZDA MOTORS CORP.

FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 38 .

2. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 38: Identifying Front Suspension Tower Bar Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

PLATE INSTALLATION NOTE

1. Install the plates with the identification marks facing upward.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Front Suspension - MX-5 Miata

Fig. 39: Identifying Plate Identification Marks

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 ENGINE Fuel System - MX-5 Miata

2008 ENGINE

Fuel System - MX-5 Miata

FUEL SYSTEM FLOW DIAGRAM [LF]

Fig. 1: Fuel System - Flow Diagram

Courtesy of MAZDA MOTORS CORP.

FUEL SYSTEM LOCATION INDEX [LF]

ENGINE COMPARTMENT SIDE

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 2: Identifying Location Of Fuel System Components (LF)

Courtesy of MAZDA MOTORS CORP.

FUEL TANK SIDE

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 3: Identifying Location Of Fuel Tank Side Components

Courtesy of MAZDA MOTORS CORP.

BEFORE SERVICE PRECAUTION [LF]

WARNING:



Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure".

A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.

CAUTION:



If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.

FUEL LINE SAFETY PROCEDURE

1. Remove the fuel-filler cap to release the pressure inside the fuel tank.

2. Remove the fuel pump relay.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 4: View Of Fuel Pump Relay

Courtesy of MAZDA MOTORS CORP.

3. Start the engine.

4. After the engine stalls, crank the engine several times .

5. Turn the ignition switch to the LOCK position.

6. Install the fuel pump relay.

AFTER SERVICE PRECAUTION [LF]

WARNING:



Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Leakage Inspection .

FUEL LEAKAGE INSPECTION

WARNING:



Using M-MDS or Equivalent

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

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

Fig. 5: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

2. Start the fuel pump using the "FP" simulation function.

3. Verify that there is no fuel leakage from the pressurized parts.



If there is leakage, replace the fuel hoses and clips.



If there is damage on the seal on the fuel pipe side, replace the fuel pipe.

Standard

There shall be no leakage after 5 min.

4. After reinstallation, repeat step 2-3 in the fuel leakage inspection.

Not Using SST (M-MDS or Equivalent)

1. Remove the battery cover.

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

3. Short the check connector terminal F/P to ground using a jumper wire.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 6: Checking Connector Terminal F/P To Ground

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 7: Identifying F/P Connector Terminal

Courtesy of MAZDA MOTORS CORP.

4. Connect the negative battery cable.

5. Turn the ignition switch to the ON position to operate the fuel pump.

6. Verify that there is no fuel leakage from the pressurized parts.



If there is leakage, replace the fuel hoses and clips.

If there is damage on the seal on the fuel pipe side, replace the fuel pipe.

Standard

There shall be no leakage after 5 min.

7. After reinstallation, repeat step 5 thru 6 in the fuel leakage inspection.

FUEL LINE PRESSURE INSPECTION [LF]

WARNING:



Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata engine stopped.

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF] .)

3. Disconnect the negative battery cable.

4. Disconnect the quick release connector (in the engine compartment). (See QUICK RELEASE

CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF] .)

5. Turn the lever of the SST parallel to the hose as shown in Fig. 8 .

6. Insert the SST quick release connector into the fuel pipe until a click is heard.

Fig. 8: Inserting SST Quick Release Connector Into Fuel Pipe Until Click Is Heard

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

7. Verify that the quick release connector is firmly connected by pulling it by hand.

8. Start the fuel pump using the following procedure:

Using M-MDS or equivalent

1. Connect the negative battery cable.

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

Fig. 9: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

3. Start the fuel pump using the "FP" simulation function.

Not using M-MDS or equivalent

1. Short the check connector terminal F/P to ground using a jumper wire.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 10: Checking Connector Terminal F/P To Ground Using Jumper Wire

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 11: Identifying F/P Connector Terminal

Courtesy of MAZDA MOTORS CORP.

2. Turn the ignition switch to the ON position to operate the fuel pump.

9. Operate the fuel pump for 10 s .

10. Measure the fuel line pressure.

 If not within the specification, inspect the following:

If it less than the specification:



Fuel pump unit



Fuel line leakage

If it exceeds the specification:



Fuel line clogging

Fuel pressure (Reference)

350-410 kPa {3.57-4.18 kgf/cm

, 50.8-59.4 psi}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

11. Stop the fuel pump using the following procedure:

Using M-MDS or equivalent

1. Stop the fuel pump using the "FP" simulation function.

Not using M-MDS or equivalent

1. Turn the ignition switch to off to stop the fuel pump.

12. Measure the fuel hold pressure after 5 min .



If not within the specification, inspect the following:



Fuel line for clogging or leakage

Fuel hold pressure (Reference)

250 kPa {2.55 kgf/cm

,36.2 psi} or more

13. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

14. Disconnect the SST .

15. Connect the quick release connector to the fuel distributor. (See QUICK RELEASE CONNECTOR

(FUEL SYSTEM) REMOVAL/INSTALLATION [LF] .)

16. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [LF] .)

FUEL TANK REMOVAL/INSTALLATION [LF]

WARNING:



Installation".

A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

1. Park the vehicle on a level surface.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

3. Remove the battery cover.

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

5. Remove the following parts.

1. Middle pipe (See EXHAUST SYSTEM REMOVAL/INSTALLATION [LF] .)

2. Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION .)

3. Power plant frame (See POWER PLANT FRAME REMOVAL NOTE .) (See POWER

PLANT FRAME REMOVAL NOTE .) (See POWER PLANT FRAME REMOVAL NOTE .)

4. Rear drive shaft (See REAR DRIVE SHAFT REMOVAL/INSTALLATION .)

5. Rear differential (See REAR DIFFERENTIAL REMOVAL/INSTALLATION .)

6. Rear crossmember component (See REAR CROSSMEMBER REMOVAL/INSTALLATION .)

6. Perform the following procedure to remove the service hole cover.

1. To remove the back trim, 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. Front seat bar garnish (See SEAT BACK BAR GARNISH

REMOVAL/INSTALLATION .)

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

3. Remove the service hole cover.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 12: Identifying Service Hole Cover

Courtesy of MAZDA MOTORS CORP.

7. Disconnect the quick release connector using the SST from the fuel pump unit. (See QUICK RELEASE

CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF] .)

8. Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [LF] .)

9. Siphon the fuel from the fuel tank.

10. Remove in the order indicated in Fig. 13 .

11. Install in the reverse order of removal.

12. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [LF] .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 13: Identifying Fuel System Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

PROTECTOR REMOVAL NOTE

1. Remove the trunk side trim. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

FUEL TANK REMOVAL NOTE

1. Move the dust cover slightly out of the way.

2. Move the charcoal canister slightly out of the way. (See CHARCOAL CANISTER

REMOVAL/INSTALLATION [LF] .)

INSULATOR REMOVAL NOTE

CAUTION:



Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.

NOTE:



The insulator is installed using rivets.

When reinstalling the rivet, install the same rivet or M5 bolt and nut.

1. Push out the mandrel using a hammer and punch ( 2-2.8 mm {0.08-0.11 in} diameter).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 14: Pushing Out Mandrel Using Hammer & Punch

Courtesy of MAZDA MOTORS CORP.

2. Remove the flange using a drill ( 5 mm {0.20 in} drill bit).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 15: Removing Flange Using Drill

Courtesy of MAZDA MOTORS CORP.

BREATHER HOSE INSTALLATION NOTE

1. Install the breather hose and clamp as shown in Fig. 16 .

Fig. 16: Installing Breather Hose & Clamp

Courtesy of MAZDA MOTORS CORP.

JOINT HOSE INSTALLATION NOTE

1. Install the joint hose and clamp as shown in Fig. 17 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 17: View Of Joint Hose & Clamp

Courtesy of MAZDA MOTORS CORP.

2. Install the clamp between the spool and stopper without overlapping the stopper.

FUEL TANK INSPECTION [LF]

NOTE:



The two rollover valves built into the fuel tank and check valves (two-way) built into the rollover valves are inspected in this inspection.

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

2. Remove the battery cover.

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

4. Remove the fuel tank with the fuel pump unit. (See FUEL TANK REMOVAL/INSTALLATION

[LF] .)

5. Perform the following procedure to verify the fuel tank airtightness.

1. Plug the fuel pump unit pipe, port B and port C.

Fig. 18: Identifying Plug Fuel Pump Unit Pipe & Ports

Courtesy of MAZDA MOTORS CORP.

2. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port A and wait for a while.

3. Verify that there is no air leakage from the fuel tank.



If there is airflow, replace the fuel tank.

6. Plug the fuel pump unit pipe and port B.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 19: Identifying Plug

Courtesy of MAZDA MOTORS CORP.

7. Level the fuel tank.

8. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port C and wait for a while.

9. With the pressure still applied, verify that there is airflow from port A and the pressure is 0- 3 kPa {0-22 mmHg, 0- 0.8 inHg} .



If there is no airflow, replace the fuel tank.

10. Apply a pressure of -0.5 kPa {-3.8 mmHg, -0.1 inHg} to port C and wait for a while.

11. With the pressure still applied, verify that there is airflow from port A and the pressure is -0.5- 0 kPa {-

3.8- 0 mmHg, -0.2- 0 inHg} .



If there is no airflow, replace the fuel tank.



If there is airflow, place the fuel tank upside down.

12. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port C and wait for a while.

13. With the pressure still applied, verify that there is no airflow from port A.



If there is airflow, replace the fuel tank.

NON-RETURN VALVE INSPECTION [LF]

WARNING:



Fuel is very flammable liquid. If fuel spills or leaks from the

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the " FUEL LINE SAFETY PROCEDURE ", while referring to the "BEFORE SERVICE PRECAUTION [LF]".

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

2. Remove the battery cover.

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

4. Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [LF] .)

5. Siphon the fuel from the fuel tank.

NOTE:



Non-return valve is integrated in the fuel tank.

The non-return valve is normally closed by the spring force.

6. Verify that the non-return valve is closed.



If the non-return valve is stuck open and dose not open even when pulled up by a finger, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [LF] .)

FUEL PUMP UNIT REMOVAL/INSTALLATION [LF]

WARNING:



Installation".

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

2. Remove the battery cover.

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

4. Perform the following procedure to remove the service hole cover.

1. To remove the back trim, remove the following parts:

1. Console (See CONSOLE REMOVAL/INSTALLATION .)

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

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. Front seat back bar garnish (See SEAT BACK BAR GARNISH

REMOVAL/INSTALLATION .)

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

3. Remove the service hole cover.

Fig. 20: Identifying Service Hole Cover

Courtesy of MAZDA MOTORS CORP.

5. Disconnect the quick release connector from the fuel pump unit. (See QUICK RELEASE

CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF] .)

6. Disconnect the fuel pump unit connector.

7. Remove in the order indicated in Fig. 21 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 21: Identifying Fuel Pump Unit (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

9. Complete the "AFTER SERVICE PRECAUTION" (See AFTER SERVICE PRECAUTION [LF] .)

FUEL LEAKAGE INSPECTION AFTER PUMP UNIT INSTALLATION

1. Before installing the fuel tank, verify that there is no leakage when a pressure of 5.9 kPa {44 mmHg, 1.7 inHg} is applied to the fuel tank.

2. Install the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [LF] .)

3. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.

4. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the fuel pump unit.

FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY [LF]

WARNING:



Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.

1. Disassemble in the order indicated in Fig. 22 .

2. Assemble in the reverse order of disassembly.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 22: View Of Fuel Pump Unit Components

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

FUEL PUMP UNIT INSPECTION [LF]

WARNING:



Installation".

FUEL PUMP OPERATION INSPECTION

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

2. Remove the fuel-filler cap.

3. Start the fuel pump using the following procedure:

Using M-MDS

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 23: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

2. Start the fuel pump using the "FP" simulation function.

Not using M-MDS or equivalent

1. Short the check connector terminal F/P to ground using a jumper wire.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 24: Checking Connector Terminal F/P To Ground Using Jumper Wire

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 25: Identifying F/P Connector Terminal

Courtesy of MAZDA MOTORS CORP.

2. Turn the ignition switch to the ON position to operate the fuel pump.

4. Verify that operation sound is heard from the fuel pump.



If the operation sound cannot be verified, measure the voltage at fuel pump unit wiring harness-side connector terminal B.



If as specified, inspect the following:



Fuel pump unit continuity



If not within the specification, inspect the following:



Fuel pump unit relay

Wiring harnesses and connectors between main relay and fuel pump relay



Wiring harnesses and connectors between fuel pump relay and PCM

Wiring harnesses and connectors between battery and fuel pump relay



Wiring harnesses and connectors between fuel pump relay and fuel pump unit

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 26: Identifying Fuel Pump Unit Connector Terminal

Courtesy of MAZDA MOTORS CORP.

Standard

B+ (Ignition switch at ON)

CONTINUITY INSPECTION

1. Remove the battery cover.

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

3. Disconnect the fuel pump unit connector. (See FUEL PUMP UNIT REMOVAL/INSTALLATION

[LF] .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 27: Disconnecting Fuel Pump Unit Connector

Courtesy of MAZDA MOTORS CORP.

4. Inspect for continuity between fuel pump unit terminals B and D.



If there is continuity, perform the CIRCUIT OPEN/SHORT INSPECTION .

If there is no continuity, replace the fuel pump. (See FUEL PUMP UNIT

DISASSEMBLY/ASSEMBLY [LF1] .)

CIRCUIT OPEN/SHORT INSPECTION

1. Inspect the following wiring harnesses for an open or short circuit (continuity check).

Open circuit



If there is no continuity, the circuit is open. Repair or replace the harness.



Fuel pump unit terminal D and body ground

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 28: Identifying Fuel Pump Unit Terminal

Courtesy of MAZDA MOTORS CORP.

FUEL STATIC PRESSURE INSPECTION

NOTE:



The fuel static pressure inspection cannot be performed because the pressure regulator is integrated with the fuel pump unit.

QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION

[LF]

WARNING:



QUICK RELEASE CONNECTOR TYPE

CAUTION:



There are two types of quick release connectors. Verify the type and location, and install/remove properly.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 29: Identifying Quick Release Connector (Fuel System)

Courtesy of MAZDA MOTORS CORP.

TYPE A REMOVAL

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

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 fuel hose can be removed by pushing it to the pipe side to release the lock.

2. Rotate the release tab on the quick release connector to the stopper position.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 30: Releasing Tab On Quick Release Connector To Stopper Position

Courtesy of MAZDA MOTORS CORP.

3. Pull out the fuel hose straight from the fuel pipe and disconnect it.

Fig. 31: View Of Fuel Hose & Fuel Pipe

Courtesy of MAZDA MOTORS CORP.

4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from becoming scratched or dirty.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 32: Covered Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

TYPE B 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. (See BEFORE SERVICE PRECAUTION [LF] .)

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

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 33: Setting SST Parallel To 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

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 34: Raising Retainer Tab Using SST & Removing Retainer

Courtesy of MAZDA MOTORS CORP.

6. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.

TYPE A INSTALLATION

NOTE:



If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 35: Identifying Checker Tab

Courtesy of MAZDA MOTORS CORP.

1. Inspect the fuel hose and fuel pipe 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 fuel pipe.

3. Reconnect the fuel hose straight to the fuel pipe 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.

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.

5. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [LF] .)

TYPE B INSTALLATION

CAUTION:



Always replace the retainer with a new one when using SST 49 E042

001, otherwise, fuel leakage could result.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

NOTE:



If the quick release connector O-ring is damaged or has slipped, replace the piping component.

1. Inspect the fuel hose and fuel pipe 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 fuel pipe.

3. Install a new retainer to the quick release connector.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 36: Identifying Quick Release Connector

Courtesy of MAZDA MOTORS CORP.

4. Reconnect the hose straight to the pipe until a click is heard.

5. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

6. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [LF] .)

FUEL INJECTOR REMOVAL/INSTALLATION [LF]

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

WARNING:



1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

2. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)

3. Remove the battery cover.

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

5. Disconnect the fuel injector connector and move the harness slightly out of the way.

6. Remove in the order indicated in Fig. 37 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 37: View Of Fuel Injector Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

7. Install in the reverse order of removal.

8. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [LF] .)

FUEL INJECTOR REMOVAL NOTE

CAUTION:



Use of a deformed injector clip will cause the fuel injector to be connected incorrectly and could result in fuel leakage. It will also cause the injector to rotate. Therefore, always replace the clip when the injector is removed.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

1. Insert a flathead screwdriver between the injector cup and clip finger.

Fig. 38: Inserting Flathead Screwdriver Between Injector Cup & Clip Finger

Courtesy of MAZDA MOTORS CORP.

NOTE:



When pushing the clip finger outward, deform the finger until it is removed completely from the cup notch.

2. Push the clip finger outward using a flathead screwdriver.

3. Remove the injector with the clip.

4. Remove the clip from the fuel injector using the following procedure:

NOTE:



The clip will not be reused.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 39: Identifying Clip Finger And Notch

Courtesy of MAZDA MOTORS CORP.

1. Hold the clip using pliers.

2. Pull the clip parallel to the injector groove and remove it from the injector.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 40: Pulling Clip Parallel To Injector Groove

Courtesy of MAZDA MOTORS CORP.

FUEL INJECTOR INSTALLATION NOTE

1. Apply a small amount of clean oil to the injector groove and the O-ring.

2. Temporarily attach a new clip to the injector groove.

NOTE:



When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned.

3. Hold the injector firmly and push the clip into the injector until the clip stops sliding.

4. Verify that the injector connector position is correct.

5. Press the injector into the injector cup. Continue pressing until the clip contacts the lower surface of the injector cup.

6. Verify that the injector and clip are correctly installed with the clip locked onto the injector cup notch.

Fig. 41: View Of Fuel Injector

Courtesy of MAZDA MOTORS CORP.

FUEL INJECTOR INSPECTION [LF]

NOTE:

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata



Perform the following inspection only when directed.

RESISTANCE INSPECTION

1. Remove the battery cover.

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

3. Disconnect the fuel injector connector.

4. Inspect the resistance between fuel injector terminals A and B using a tester.



If within the specification, perform the CIRCUIT OPEN/SHORT INSPECTION .

 If not within the specification, replace the fuel injector. (See FUEL INJECTOR

REMOVAL/INSTALLATION [LF] .)

Fuel injector resistance

11.4-12.6 ohms [20°C {68°F}]

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 42: Identifying Fuel Injector Terminals A & B Using Tester

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).

Fig. 43: Identifying Fuel Injector Connector & PCM Connector Terminal

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Open Circuit



If there is no continuity, there is an open circuit. Repair or replace the wiring harness.



Fuel injector No.1 terminal B and PCM terminal 2BB

 Fuel injector No.2 terminal B and PCM terminal 2BC



Fuel injector No.3 terminal B and PCM terminal 2BD



Fuel injector No.4 terminal B and PCM terminal 2AZ



Fuel injector No.1 terminal A and main relay



Fuel injector No.2 terminal A and main relay



Fuel injector No.3 terminal A and main relay



Fuel injector No.4 terminal A and main relay

Short Circuit



If there is continuity, there is a short circuit. Repair or replace the wiring harness.



Fuel injector No.1 terminal B and body ground



Fuel injector No.1 terminal B and power supply



Fuel injector No.2 terminal B and body ground



Fuel injector No.2 terminal B and power supply



Fuel injector No.3 terminal B and body ground



Fuel injector No.3 terminal B and power supply



Fuel injector No.4 terminal B and body ground



Fuel injector No.4 terminal B and power supply



Fuel injector No.1 terminal A and body ground



Fuel injector No.2 terminal A and body ground



Fuel injector No.3 terminal A and body ground



Fuel injector No.4 terminal A and body ground

LEAKAGE INSPECTION

WARNING:



Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the engine stopped.

1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

2. Remove the battery cover.

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

4. Remove the fuel injector and fuel distributor as a single unit. (See FUEL INJECTOR

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

REMOVAL/INSTALLATION [LF] .)

5. Fix the fuel injector to the fuel distributor with a wire or the equivalent.

Fig. 44: Fixing Fuel Injector To Fuel Distributor With Wire

Courtesy of MAZDA MOTORS CORP.

6. Connect the fuel hose.

7. Start the fuel pump using the following procedure:

Using M-MDS

1. Connect the negative battery cable.

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

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 45: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

3. Start the fuel pump using the "FP" simulation function.

Not using M-MDS

1. Short the check connector terminal F/P to ground using a jumper wire.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 46: Checking Connector Terminal F/P To Ground Using Jumper Wire

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 47: Identifying F/P Connector Terminal

Courtesy of MAZDA MOTORS CORP.

2. Turn the ignition switch to the ON position to operate the fuel pump.

NOTE:



Prepare a container to collect the gasoline.

8. Tilt the fuel injector at an angle of 24° to inspect for leakage.

 If not within the specification, replace the fuel injector. (See FUEL INJECTOR

REMOVAL/INSTALLATION [LF] .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 48: Tilting Fuel Injector

Courtesy of MAZDA MOTORS CORP.

Fuel injector leakage amount

Less than 1 drop/2 min

9. Stop the fuel pump using the following procedure:

Using M-MDS

1. Stop the fuel pump using the "FP" simulation function.

Not using M-MDS

1. Turn the ignition switch to off to stop the fuel pump.

10. Remove the battery cover.

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

12. Remove the wire or equivalent securing the fuel injector.

13. Install the fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)

14. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [LF] .)

INJECTION VOLUME INSPECTION

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

WARNING:



1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

2. Remove the battery cover.

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

4. Remove the fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)

5. Connect the fuel injector to the fuel injector tester.

6. Start the fuel pump using the following procedure:

Using M-MDS

1. Connect the negative battery cable.

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

Fig. 49: Locating DLC-2 Connector

Courtesy of MAZDA MOTORS CORP.

3. Start the fuel pump using the "FP" simulation function.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Not using M-MDS

1. Short the check connector terminal F/P to ground using a jumper wire.

Fig. 50: Checking Connector Terminal F/P To Ground Using Jumper Wire

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 51: Identifying F/P Connector Terminal

Courtesy of MAZDA MOTORS CORP.

2. Turn the ignition switch to the ON position to operate the fuel pump.

7. Measure the injection volume of each fuel injector.



If not within the specification, replace the fuel injector. (See FUEL INJECTOR

REMOVAL/INSTALLATION [LF] .)

Fuel injection volume

204-216 ml {204-216 cc, 12.5-13.1 cu in}/min

8. Turn the ignition switch to off to stop the fuel pump.

9. Install the fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)

10. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [LF] .)

ATOMIZATION INSPECTION

1. Inspect the atomization status.

 If not normal, replace the fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION

Microsoft

[LF] .)

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Fuel System - MX-5 Miata

Fig. 52: Inspecting Atomization Status

Courtesy of MAZDA MOTORS CORP.

Microsoft

HVAC BASIC SYSTEM

2008 HVAC Basic System - MX-5 Miata

2008 HVAC

Basic System - MX-5 Miata

Fig. 1: Identifying Location Of HVAC Basic System Components

Courtesy of MAZDA MOTORS CORP.

AIR DISTRIBUTION UNIT REMOVAL/INSTALLATION

1. Remove the battery cover.

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

3. Discharge the refrigerant from the system. (See REFRIGERANT RECOVERY .) (See

REFRIGERANT CHARGING .)

4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

5. Disconnect from A/C unit in the order in Fig. 2 .

CAUTION:



If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other malfunction could occur. Always plug open fittings immediately after removing any refrigeration cycle parts.

Fig. 2: View Of A/C Unit Pipe Lines & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

6. Remove the following parts:

1. Console (See CONSOLE REMOVAL/INSTALLATION .)

2. Glove compartment (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)

3. Side wall (See SIDE WALL REMOVAL/INSTALLATION .)

4. Console panel (See CONSOLE PANEL REMOVAL/INSTALLATION .)

5. Center panel unit (See CENTER PANEL UNIT REMOVAL/INSTALLATION .)

6. Lower panel (See LOWER PANEL REMOVAL/INSTALLATION .)

7. Knee bolster

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

8. Column cover (See COLUMN COVER REMOVAL/INSTALLATION .)

9. Driver-side air bag module (See DRIVER-SIDE AIR BAG MODULE

REMOVAL/INSTALLATION .)

10. Steering wheel (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)

11. Combination switch (See COMBINATION SWITCH REMOVAL/INSTALLATION .)

12. Steering shaft (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)

13. Meter hood (See METER HOOD REMOVAL/INSTALLATION .)

14. Instrument cluster (See INSTRUMENT CLUSTER REMOVAL/INSTALLATION .)

15. Side panel (See SIDE PANEL REMOVAL/INSTALLATION .)

16. Hood release lever (See HOOD LATCH AND RELEASE LEVER

REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] .)

17. Female bracket (See CONVERTIBLE TOP DISASSEMBLY/ASSEMBLY .)

18. A-pillar trim (See A-PILLAR TRIM REMOVAL/INSTALLATION .)

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

20. Front side trim (See FRONT SIDE TRIM REMOVAL/INSTALLATION .)

21. Fuse box No.1

22. Dashboard (See DASHBOARD REMOVAL/INSTALLATION .)

7. Remove the air distribution unit and A/C unit.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 3: View Of Air Distribution Unit & A/C Unit

Courtesy of MAZDA MOTORS CORP.

8. Disassemble the air distribution unit as shown in Fig. 4 .

9. Install in the reverse order of removal.

10. Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE

TEST .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 4: Identifying Air Distribution Unit

Courtesy of MAZDA MOTORS CORP.

AIR DISTRIBUTION UNIT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in Fig. 5 .

CAUTION:



If a non-specified grease is used, it may result in abnormal noise or improper operation of the links. Apply only the specified grease to each link.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 5: Exploded View Of Air Distribution Unit Components

Courtesy of MAZDA MOTORS CORP.

2. Assemble in the reverse order of disassembly.

A/C UNIT REMOVAL/INSTALLATION

1. Remove battery cover.

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

3. Discharge the refrigerant from the system. (See REFRIGERANT RECOVERY .) (See

REFRIGERANT CHARGING .)

4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

5. Disconnect from A/C unit in the order in Fig. 6 .

CAUTION:



Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 6: View Of Refrigerant Line From A/C Unit & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

6. Remove the A/C unit and air distribution unit. (See AIR DISTRIBUTION UNIT

REMOVAL/INSTALLATION .)

7. Disassembly the A/C unit as shown in Fig. 7 .

8. Install in the reverse order of removal.

9. Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE

TEST .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 7: Identifying A/C Unit

Courtesy of MAZDA MOTORS CORP.

A/C UNIT DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in Fig. 8 .

CAUTION:



If a non-specified grease is used, it may result in abnormal noise or improper operation of the links. Apply only the specified grease to each link.

If the air mix damper is removed and reinstalled improperly because the original installation position cannot be specified, the air mix damper and air mix actuator may be damaged when it is operated. Therefore, set the air mix to the middle position before disassembling so that the installation position can be specified.

2. Assemble in the reverse order of disassembly.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 8: Exploded View Of A/C Unit Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

EVAPORATOR TEMPERATURE SENSOR ASSEMBLY NOTE

1. Assemble the evaporator temperature sensor as shown in Fig. 9 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 9: Assembling Evaporator Temperature Sensor

Courtesy of MAZDA MOTORS CORP.

EVAPORATOR INSPECTION

1. Inspect the evaporator for damage, cracks and oil leakage.



If there is any malfunction, replace the evaporator.

2. Visually inspect the fins for bending.



If there is any bending, use the end of a flathead screwdriver to straighten the fins.

HEATER CORE INSPECTION

1. Inspect the heater core for damage, cracks and water leakage.



If there is any malfunction, replace the heater core.

2. Visually inspect the fins for bending.



If there is any bending, use the end of a flathead screwdriver to straighten the fins.

3. Visually inspect the heater hose for deformation.



Repair with pliers if there is deformation. If there is any malfunction, replace the heater core.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

AIRFLOW MODE MAIN LINK REMOVAL/INSTALLATION

1. Remove the battery cover.

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

3. Remove the airflow mode actuator. (See AIRFLOW MODE ACTUATOR

REMOVAL/INSTALLATION .)

4. Remove the airflow mode main link as shown in Fig. 10 .

5. Install in the reverse order of removal.

Fig. 10: View Of Airflow Mode Main Link

Courtesy of MAZDA MOTORS CORP.

A/C COMPRESSOR REMOVAL/INSTALLATION

1. Remove the battery cover.

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

3. Discharge the refrigerant from the system. (See REFRIGERANT CHARGING .)

4. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

5. Remove the PCM. (See PCM REMOVAL/INSTALLATION [LF] .)

6. Remove the drive belt. (See DRIVE BELT REPLACEMENT [LF] .)

7. Do not allow remaining compressor oil in the A/C compressor and pipes to spill, and remove in the order indicated in Fig. 11 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

CAUTION:



Fig. 11: View Of A/C Compressor Pipe Hose & Lines (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

9. Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE

TEST .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

A/C COMPRESSOR INSTALLATION NOTE

CAUTION:



Due to the high moisture-absorption characteristics of the compressor oil, it may absorb moisture if left over a long period of time thereby negatively affecting A/C operation. Drain the compressor oil and refill within 10 min. of each other.

1. Rotate new A/C compressor shaft six to eight revolutions while draining new refrigerant oil in a clean measuring device. Use this refrigerant oil to refill new compressor. Do not allow refrigerant oil to become contaminated.

2. Rotate old A/C compressor shaft six to eight revolutions while draining old refrigerant oil in a separate, clean measuring device.

3. Compare those oil amounts. The amount of the oil drained from the new A/C compressor should be greater than the old one.

4. Pour the same amount oil of drained from the old A/C compressor back into the new A/C compressor.

A/C compressor oil type

DH-PR

A/C compressor oil sealed volume (approx. quantity)

130 ml {130 cc, 4.39 fl oz}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 12: Pouring Drained Oil From Old A/C Compressor Into New A/C Compressor

Courtesy of MAZDA MOTORS CORP.

CONDENSER REMOVAL/INSTALLATION

1. Remove the battery cover.

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

3. Discharge the refrigerant from the system. (See REFRIGERANT CHARGING .)

4. Remove the splash shields.

5. Remove the under cover.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

6. Remove the cooling pipe installation bolts.

7. Do not allow remaining compressor oil in the condenser and pipes to spill, and remove in the order indicated in Fig. 13 .

CAUTION:



Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 13: View Of Cooling Pipe & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

9. Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE

TEST .)

CONDENSER INSTALLATION NOTE

1. When replacing the new condenser, add compressor oil to the refrigeration cycle.

Supplemental amount (approx. quantity)

20 ml {20 cc, 0.7 fl oz}

CONDENSER INSPECTION

1. Inspect the condenser for cracks, damage, and oil leakage.



If there is any malfunction, replace the condenser.

2. Visually inspect the fins for clogging of foreign material.



If any fins are clogged, remove the foreign material.

3. Visually inspect the fins for bending.



If there is any bending, use the end of a flathead screwdriver to straighten fins.

REFRIGERANT LINES REMOVAL/INSTALLATION

1. Remove the battery cover.

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

3. Discharge the refrigerant from the system. (See REFRIGERANT CHARGING .)

4. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

5. Remove the splash shield.

6. Remove the under cover.

7. Do not allow remaining compressor oil in the piping and connecting parts to spill, and remove in the order indicated in Fig. 14 .

CAUTION:



Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 14: View Of Refrigerant Lines & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

8. Install in the reverse order of removal.

9. Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE

TEST .)

REFRIGERANT LINE REMOVAL NOTE

1. Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, and then remove the connection bolt or nut.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 15: Disconnecting Block Joint Type Pipes

Courtesy of MAZDA MOTORS CORP.

REFRIGERANT LINE INSTALLATION NOTE

1. Temporarily tighten the joint bolt by hand.

2. Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, and then tighten the connection bolt or nut with a torque wrench.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 HVAC Basic System - MX-5 Miata

Fig. 16: Connecting Block Joint Type Pipes

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 ENGINE Ignition System - MX-5 Miata

2008 ENGINE

Ignition System - MX-5 Miata

IGNITION SYSTEM LOCATION INDEX [LF]

Fig. 1: Identifying Location Of Ignition System Components

Courtesy of MAZDA MOTORS CORP.

IGNITION COIL REMOVAL/INSTALLATION [LF]

1. Remove the battery cover.

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

3. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)

4. Remove the front suspension tower bar (joint). (See FRONT SUSPENSION TOWER BAR

REMOVAL/INSTALLATION .)

5. Remove in the order indicated in Fig. 2 .

6. Install in the reverse order of removal.

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Ignition System - MX-5 Miata

Fig. 2: Identifying Removal Order Of Ignition Coil (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

IGNITION COIL INSPECTION [LF]

IGNITION COIL INSPECTION

1. Perform the spark test and identify the malfunctioning cylinder.

2. Replace the ignition coil of the malfunctioning cylinder with that of a normal cylinder, and re-perform the spark test.



If the spark is not normal due to a malfunctioning ignition coil, replace that ignition coil.



It is unlikely that all four ignition coils fail to operate properly. To prevent replacing a normal component, perform the above procedure, identify the malfunctioning ignition coil, and replace it.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Ignition System - MX-5 Miata

IGNITION COIL WITH BUILT-IN IGNITER INSPECTION

1. Disconnect the ignition coil connector.

2. Measure the resistance between each terminal on the ignition coil connector using an analog circuit tester.



If the measurement corresponds to the table, replace the ignition coil.

TESTER CONNECTION POSITION

Item

Tester Connection Position

Positive Negative

C A

Terminal

B A

Condition

0 ohm is not normal

(Infinity ohm is normal)

Infinity or 0 ohm is not normal (several kilohm is normal)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Ignition System - MX-5 Miata

Fig. 3: Identifying Ignition Coil Connector Terminals

Courtesy of MAZDA MOTORS CORP.

SPARK PLUG REMOVAL/INSTALLATION [LF]

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Ignition System - MX-5 Miata

CAUTION:



If a spark plug that is not as specified is installed, engine performance will be deteriorated. Install only the specified spark plug when replacing.

1. Remove the battery cover.

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

3. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)

4. Remove the front suspension tower bar (joint). (See FRONT SUSPENSION TOWER BAR

REMOVAL/INSTALLATION .)

5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [LF] .)

6. Remove the spark plugs using a plug-wrench.

7. Install in the reverse order of removal.

Tightening torque

10-14 N.m {1.1-1.4 kgf.m. 8-10 ft.lbf}

SPARK PLUG INSPECTION [LF]

SPECIFICATION

Spark plug type

L3G2 18 110, L3Y1 18 110

PLUG GAP INSPECTION

CAUTION:



To avoid possible damage to the tip, do not adjust the plug gap.

To prevent damaging the tip, use a wire type plug gap gauge when inspecting the plug gap.

1. Measure the spark plug gap using a wire type plug gap gauge.



If it exceeds the specification, replace the spark plug.

Spark plug gap

1.25-1.35 mm {0.050-0.053 in}

CLEANING

CAUTION:



Carbon may adhere to the tip of the spark plug during vehicle delivery or repeated short distance driving during the winter time. If

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Ignition System - MX-5 Miata



 there is any malfunction such as rough idling or start difficulty due to carbon adhesion causing plug fouling, burn off the carbon by performing no-load racing of the engine.

When performing the no-load racing, apply the side brake and foot brake, move the shift lever to neutral (MT), or the selector lever to P position (AT) to prevent an accident and serious injury.

To avoid possible damage to the spark plug tip, do not use a wire brush for cleaning.

NOTE:



To avoid possible damage to the tip, use gasoline to clean the spark plugs after removing dirt.

If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not indicate a malfunction.

Do not perform no-load racing at high engine speed continuously for 10s or more.

1. If there is carbon adhering to the spark plug, perform no-load racing at 4,000 rpm for 2 min, 2 times .

VISUAL INSPECTION

1. Inspect the following items:



If any of the following malfunction are indicated, replace the spark plug.



Insulator breakage

Worn electrode



Damaged gasket

Badly burned insulator (sparking side)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Ignition System - MX-5 Miata

Fig. 4: Inspecting Spark Plug

Courtesy of MAZDA MOTORS CORP.

RESISTANCE INSPECTION

1. Measure the resistance of the spark plug using a tester as shown in Fig. 5 .



If not within the specification, replace the spark plug.

Spark plug resistance [25°C {77°F}]

3.0-7.5 kilohms

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Ignition System - MX-5 Miata

Fig. 5: Measuring Resistance Of Spark Plug

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

2008 ENGINE PERFORMANCE

Intake Air System - MX-5 Miata

INTAKE AIR SYSTEM LOCATION INDEX [LF]

Fig. 1: Identifying Intake Air System Components

Courtesy of MAZDA MOTORS CORP.

Intake Air System Location Index [LF]

Intake-air system

Air cleaner

Fresh-air duct

Variable intake air solenoid valve

Variable intake air shutter valve actuator

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Variable tumble solenoid valve (AT)

Variable tumble shutter valve actuator (AT)

Throttle body

Dynamic chamber

10 Intake manifold

11 Accelerator pedal

INTAKE AIR SYSTEM DIAGRAM [LF]

Fig. 2: Intake Air System Diagram

Courtesy of MAZDA MOTORS CORP.

INTAKE AIR SYSTEM HOSE ROUTING DIAGRAM [LF]

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 3: Intake Air System Hose Routing Diagram

Courtesy of MAZDA MOTORS CORP.

INTAKE MANIFOLD VACUUM INSPECTION [LF]

1. Verify that the intake air hoses are installed securely.

2. Disconnect the vacuum hose connecting the intake manifold and the purge solenoid valve (purge solenoid valve side) and install the vacuum gauge.

3. Warm up the engine.

4. Measure the intake manifold vacuum while idling (no load) using the vacuum gauge.



If not within the specification, perform the following inspections.



Compression pressure (See COMPRESSION INSPECTION [LF] .)



Air intake



Each hose installation part



Throttle body installation part

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata



Fuel injector installation part



PCV valve installation part

Dynamic chamber installation port



Intake manifold installation part

Standard

-60 kPa {-450 mmHg, -17.7 inHg} or more

INTAKE AIR SYSTEM REMOVAL/INSTALLATION [LF]

WARNING:



A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake-air system.

"BEFORE SERVICE PRECAUTION [LF] ".

1. Remove the battery cover.

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

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 4: Identifying Removal Order Of Intake-Air System (Step 1) (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 5: Identifying Removal Order Of Intake-Air System (Step 2) (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

AIR CLEANER COVER REMOVAL NOTE

1. Remove the MAF/IAT Sensor. (See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE

(IAT) SENSOR REMOVAL/INSTALLATION [LF] .)

AIR HOSE REMOVAL NOTE

1. Move the purge solenoid valve slightly out of the way. (See PURGE SOLENOID VALVE

REMOVAL/INSTALLATION [LF] .)

FRESH-AIR DUCT REMOVAL NOTE

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

THROTTLE BODY REMOVAL NOTE

1. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)

DYNAMIC CHAMBER REMOVAL NOTE

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)

2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

3. Remove the service hole cover.

1. Remove the front 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.

6. Remove the service hole cover. (See EGR VALVE REMOVAL/INSTALLATION [LF] .)

Fig. 6: View Of Cooler Pipe No.3 & Heater Pipe

Courtesy of MAZDA MOTORS CORP.

4. Disconnect the heater hose and move the heater pipe slightly out of the way.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 7: View Of Heater Hose

Courtesy of MAZDA MOTORS CORP.

5. Disconnect the heater hose and move the heater pipe slightly out of the way.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 8: Moving Heater Pipe

Courtesy of MAZDA MOTORS CORP.

6. Remove the harness bracket.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 9: View Of Harness Bracket

Courtesy of MAZDA MOTORS CORP.

7. Remove the under cover. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)

8. Disconnect the variable intake air solenoid valve connector, EGR valve connector, CMP sensor connector and PSP switch connector.

9. Disconnect the ignition coil connector and fuel injector connector and move the harness slightly out of the way.

10. Disconnect the quick release connector from the fuel distributor. (See QUICK RELEASE

CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF] .)

11. Remove the fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)

12. Disconnect the water hose from the EGR valve.

13. Disconnect two water hoses from the thermostat.

14. Remove the heater hose and heater pipe from the dynamic chamber.

15. Remove the variable intake air solenoid valve. (See VARIABLE INTAKE AIR SOLENOID VALVE

REMOVAL/INSTALLATION [LF] .)

16. Remove the variable tumble solenoid valve. (See VARIABLE TUMBLE SOLENOID VALVE

REMOVAL/INSTALLATION [LF].)

17. Remove the dynamic chamber installation bolts.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 10: View Of Heater Hose & Heater Pipe On Dynamic Chamber

Courtesy of MAZDA MOTORS CORP.

18. Remove the EGR pipe.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 11: Identifying EGR Pipe (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

19. Disconnect the connector from the A/C compressor.

20. Disconnect the knock sensor connector.

21. Move the vacuum hose between the purge solenoid valve and the charcoal canister slightly out of the way.

22. Move the clutch release cylinder slightly out of the way. (MT) (See CLUTCH RELEASE CYLINDER

REMOVAL/INSTALLATION .)

23. Disconnect the evaporative hose with the dynamic chamber raised.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 12: Disconnecting Evaporative Hose

Courtesy of MAZDA MOTORS CORP.

24. Remove the dynamic chamber.

25. Remove the variable intake air shutter valve actuator. (See VARIABLE INTAKE AIR SHUTTER

VALVE ACTUATOR REMOVAL/INSTALLATION [LF] .)

26. Remove the MAP sensor. (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

REMOVAL/INSTALLATION [LF] .)

INTAKE MANIFOLD REMOVAL NOTE (AT)

1. Remove the intake manifold.

2. Remove the variable tumble shutter valve actuator. (See VARIABLE TUMBLE SHUTTER VALVE

ACTUATOR REMOVAL/INSTALLATION [LF].)

THROTTLE BODY INSTALLATION NOTE

1. Tighten the bolts in the order as shown in Fig. 13 .

Throttle body tightening torque 8.0-11.5 N.m {82-110 kgf.cm, 71-100 in.lbf}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 13: Identifying Tightening Sequence Of Throttle Body Bolts

Courtesy of MAZDA MOTORS CORP.

AIR CLEANER ELEMENT INSPECTION [LF]

1. Remove the air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

2. Inspect the following items:



If there is any abnormality, clean or replace the air cleaner element.



Has the replacement interval come?

Is the air cleaner element soiled, damaged, or bent?



Are the air cleaner case and the air cleaner element correctly sealed?

 Is the correct air cleaner element installed?

THROTTLE BODY INSPECTION [LF]

NOTE:



Perform the following inspection only when directed.

RESISTANCE INSPECTION

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

1. Remove the battery cover.

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

3. Disconnect the throttle body connector.

4. Measure the resistance between throttle actuator terminals A and B.



If not as specified, replace the throttle body. (See INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION [LF] .)



If as specified, carry out the Circuit Open/Short Inspection .

Specification

AMBIENT TEMPERATURE SPECIFICATION

Ambient temperature (°C {°F})

Approx. 20 {68}

Resistance (ohm)

0.3-100

Fig. 14: Identifying Throttle Actuator 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 harnesses for open or short (continuity check).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 15: Identifying Throttle Valve Actuator & PCM Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Open Circuit



If there is no continuity, the circuit is open. Repair or replace the wiring harness.



Throttle valve actuator terminal A and PCM terminal 2B



Throttle valve actuator terminal B and PCM terminal 2A

Short Circuit

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata



If there is continuity, the circuit is shorted. Repair or replace the wiring harness.



Throttle valve actuator terminal A and power supply



Throttle valve actuator terminal A and ground



Throttle valve actuator terminal B and power supply



Throttle valve actuator terminal B and ground

VARIABLE INTAKE AIR SOLENOID 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] .)

4. Move the variable tumble solenoid valve (AT), slightly out of the way. (See VARIABLE TUMBLE

SOLENOID VALVE REMOVAL/INSTALLATION [LF].)

5. Remove in the order indicated in the table. .

6. Install in the reverse order of removal.

Fig. 16: Identifying Removal Order Of Variable Intake Air Solenoid Valve (With Torque

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Specifications)

Courtesy of MAZDA MOTORS CORP.

Removal Order Of Variable Intake Air Solenoid Valve

1 Connector

Vacuum hose

Variable Intake air solenoid valve

VARIABLE INTAKE AIR SOLENOID VALVE INSPECTION [LF]

NOTE:



Perform the following inspection only when directed.

AIRFLOW INSPECTION

1. Remove the battery cover

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

3. Remove the variable intake air solenoid valve. (See VARIABLE INTAKE AIR SOLENOID VALVE

REMOVAL/INSTALLATION [LF] .)

4. Inspect airflow between the ports under the following conditions.



If not as specified, replace the variable intake air solenoid valve.



If as specified, carry out the Circuit Open/Short Inspection .

Fig. 17: Variable Intake Air Solenoid Valve Continuity Check Table

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 18: Identifying Variable Intake Air Solenoid Valve Ports

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 (continuity check).

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 19: Identifying Variable Intake Air Solenoid Valve, Main Relay & PCM Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Open Circuit



If there is no continuity, the circuit is open. Repair or replace the wiring harness.



Variable intake air solenoid valve terminal B and PCM terminal 2J



Variable intake air solenoid valve terminal A and main relay

Short Circuit

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata



If there is continuity, the circuit is shorted. Repair or replace the wiring harness.



Variable tumble solenoid valve terminal B and power supply



Variable tumble solenoid valve terminal B and body ground



Variable tumble solenoid valve terminal A and body ground

VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [LF]

1. Remove the service hole cover. (See EGR VALVE REMOVAL/INSTALLATION [LF] .)

2. Disconnect the vacuum hose from the variable tumble solenoid valve.

3. Connect a vacuum pump to the vacuum hose.

NOTE:



Verify that the variable tumble shutter valve actuator rod moves using a mirror.

4. Apply vacuum and verify that the rod moves.



If the rod does not move, replace the variable tumble shutter valve actuator. (See VARIABLE

TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF] .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 20: View Of Variable Tumble Solenoid Valve & Actuator

Courtesy of MAZDA MOTORS CORP.

VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR ROD OPERATION REFERENCE

Vacuum kPa {mmHg, inHg} Rod movement

Below -2.7 {-21, -0.9}

Above -33.4 {-251, -9.89}

Not operate

Fully pulled

VARIABLE TUMBLE SHUTTER VALVE ACTUATOR

REMOVAL/INSTALLATION [LF]

WARNING:



A hot engine and intake-air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake-air system.

Fuel line spills and leakage from the pressurized fuel system are

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the

"BEFORE SERVICE PRECAUTION [LF] ".

1. Remove the battery cover.

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

3. Remove the throttle body. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

4. Disconnect the quick release connector (Type A) (See QUICK RELEASE CONNECTOR

(EMISSION SYSTEM) REMOVAL/INSTALLATION [LF] .)

5. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)

6. Remove the service hole cover.

1. Remove the front 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. Remove the service hole cover. (See EGR VALVE REMOVAL/INSTALLATION [LF] .)

7. Remove the harness bracket.

Fig. 21: Identifying Harness Bracket

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

8. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)

9. Remove the under cover. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)

10. Disconnect the quick release connector from the fuel distributor. (See QUICK RELEASE

CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF] .)

11. Remove the fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)

12. Move the clutch release cylinder slightly out of the way. (MT) (See CLUTCH RELEASE CYLINDER

REMOVAL/INSTALLATION .)

Fig. 22: View Of Harness Bracket

Courtesy of MAZDA MOTORS CORP.

13. Remove the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)

14. Remove in the order indicated in the table. .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 23: Identifying Removal Order Of Variable Intake Air Shutter Valve Actuator (With Torque

Specifications)

Courtesy of MAZDA MOTORS CORP.

Removal Order Of Variable Intake Air Shutter Valve Actuator (With Torque Specifications)

Vacuum Hose

Variable Tumble Shutter Valve Actuator

15. Install in the reverse order of removal.

VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL NOTE

1. Disengage the variable tumble shutter valve actuator rod from the dynamic chamber on the opposite side using a suitable screwdriver or equivalent tool as shown in the figure. .

CAUTION:



Do not remove the lever, otherwise the variable tumble shutter valve opening angle will deviate. To prevent removal of the lever when removing the variable intake shutter valve actuator, press the lever firmly to the dynamic chamber side by hand.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 24: Disengaging Variable Intake Air Shutter Valve Actuator Rod From Dynamic Chamber

Courtesy of MAZDA MOTORS CORP.

VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR INSTALLATION NOTE

1. Press the variable tumble shutter valve actuator rod into the dynamic chamber on the opposite side until a click is heard, and install it.

ACCELERATOR PEDAL 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. 25 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE PERFORMANCE Intake Air System - MX-5 Miata

Fig. 25: Identifying Removal Order Of Accelerator Pedal (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

4. Install in the reverse order of removal.

Microsoft

2008 BRAKES Parking Brake System - MX-5 Miata

2008 BRAKES

Parking Brake System - MX-5 Miata

PARKING BRAKE SYSTEM LOCATION INDEX

Fig. 1: Identifying Parking Brake System Components

Courtesy of MAZDA MOTORS CORP.

PARKING BRAKE LEVER INSPECTION

STROKE INSPECTION

1. Depress the brake pedal several times.

2. Pull the parking brake lever 2-3 times.

3. Inspect the parking brake stroke by slowly pulling at point A 50 mm {1.97 in} from the end of the parking brake lever with a force of 98 N {10 kgf, 22 lbf} and counting the number of notches (clicking sound).

 If not within the specification, adjust the parking brake lever.

Parking brake lever stroke when pulled at 98 N {10 kgf, 22 lbf}

1-3 notches

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Parking Brake System - MX-5 Miata

Fig. 2: Inspecting Parking Brake Stroke

Courtesy of MAZDA MOTORS CORP.

PARKING BRAKE LEVER ADJUSTMENT

1. Depress the brake pedal several times.

2. Remove the parking brake lever boot.

3. Turn the adjusting nut and adjust the parking brake lever.

4. After adjustment, pull the parking brake lever one notch and verify that the parking brake warning light illuminates.

5. Verify that the rear brakes do not drag.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Parking Brake System - MX-5 Miata

Fig. 3: Identifying Parking Brake Lever Adjusting Nut

Courtesy of MAZDA MOTORS CORP.

PARKING BRAKE LEVER REMOVAL/INSTALLATION

1. Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [LF] .)

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

3. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

6. After installation, inspect the parking brake stroke and adjust if necessary.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Parking Brake System - MX-5 Miata

Fig. 4: Identifying Parking Brake Lever Removing/Installing Steps (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

PARKING BRAKE LEVER REMOVAL NOTE

1. Partially peel back the floor mat and remove the bolt shown in Fig. 5 .

2. Remove the two bolts.

3. Remove the parking brake lever.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Parking Brake System - MX-5 Miata

Fig. 5: Locating Bolt

Courtesy of MAZDA MOTORS CORP.

PARKING BRAKE SWITCH INSPECTION

1. Disconnect the parking brake switch connector.

2. Verify that the continuity is as indicated in Fig. 6 .



If not as indicated in Fig. 6 , replace the parking brake switch.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Parking Brake System - MX-5 Miata

Fig. 6: Parking Brake Switch Continuity Reference Table

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 BRAKES Parking Brake System - MX-5 Miata

Fig. 7: Identifying Parking Brake Switch Connector

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 STEERING Power Steering - MX-5 Miata

2008 STEERING

Power Steering - MX-5 Miata

STEERING LOCATION INDEX

Fig. 1: Identifying Location Of Steering Components

Courtesy of MAZDA MOTORS CORP.

AIR BLEEDING

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

CAUTION:



Do not turn the steering wheel during the fluid level inspection, otherwise the fluid level changes and cannot be inspected correctly.

1. Inspect the fluid level. (See POWER STEERING FLUID INSPECTION .)

2. Jack up the front of the vehicle and support it on safety stands.

3. Turn the steering wheel fully to the left and right several times with the engine not running.

4. Reinspect the fluid level.



If it has dropped, add fluid.

5. Repeat Steps 3 and 4 until the fluid level stabilizes.

6. Lower the vehicle.

7. Start the engine and let it idle.

8. Turn the steering wheel fully to the left and right several times.

9. Verify that the fluid is not foamy and that the fluid level has not dropped.



If the fluid level has dropped, add fluid as necessary and repeat Steps 8 and 9.

POWER STEERING FLUID INSPECTION

FLUID LEVEL INSPECTION

1. Inspect the power steering fluid level.



Add fluid to the specified level as necessary.

Power steering fluid type

ATF M-III or equivalent (e.g. Dexron®RII)

Power steering fluid capacity (approximate quantity)

1.19 L {1.25 US qt, 1.04 Imp qt}

FLUID LEAKAGE INSPECTION

1. Start the engine and let it idle.

2. Turn the steering wheel fully to the left and right to apply fluid pressure.

CAUTION:



If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid temperature will rise excessively and adversely affect the oil pump.

3. Inspect for fluid leakage.



If fluid leakage is found, replace related pipe or hose.

Microsoft

NOTE:

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata



The points where fluid leakage may occur are indicated in the figure.

Fig. 2: Identifying Fluid Leakage Points

Courtesy of MAZDA MOTORS CORP.

FLUID PRESSURE INSPECTION

1. Assemble the SSTs as shown in Fig. 3 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 3: Assembling SSTs

Courtesy of MAZDA MOTORS CORP.

2. Disconnect the pressure pipe from the oil pump, and connect the SSTs .

Tightening torque

29.4-44.1 N.m {3.00-4.49 kgf.m, 21.7-32.5 ft.lbf}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 4: Connecting SSTs

Courtesy of MAZDA MOTORS CORP.

3. Bleed the air from the system. (See AIR BLEEDING .)

4. Open the gauge valve fully.

5. Start the engine and turn the steering wheel fully left and right to raise the fluid temperature to 50-60°C

{122-140°F} .

6. Close the gauge valve completely.

7. Increase the engine speed to 1,000-1,500 rpm and measure the fluid pressure generated by the oil pump.



If the pressure is not within the specification, repair or replace the oil pump component.

CAUTION:



If the valve is left closed for more than 5 seconds, the fluid temperature will rise excessively and adversely affect the oil pump.

Oil pump fluid pressure

7.55-8.05 MPa {77.0-82.0 kgf/cm

, 1095-1167 psi}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 5: Inspecting Fluid Pressure (Valve Closed)

Courtesy of MAZDA MOTORS CORP.

8. Open the gauge valve fully and increase the engine speed to 1,000-1,500 rpm .

9. Turn the steering wheel fully to the left and right, then measure the fluid pressure generated at the gear housing.



If the pressure is not within the specification, repair or replace the steering gear component.

CAUTION:



If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid temperature will rise excessively and adversely affect the oil pump.

Gear housing fluid pressure

7.55-8.05 MPa {77.0-82.0 kgf/cm

,1095-1167 psi}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 6: Inspecting Fluid Pressure (Valve Open)

Courtesy of MAZDA MOTORS CORP.

10. Remove the SSTs . Install and tighten the pressure pipe to the specified torque.

Tightening torque

29.4-44.1 N.m {3.00-4.49 kgf.m, 21.7-32.5 ft.lbf}

11. Bleed the air from the system.

STEERING WHEEL AND COLUMN INSPECTION

STEERING WHEEL PLAY INSPECTION

1. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that the play is within the specification.



If the play exceeds the specification, either the steering joints are worn or the backlash of the steering gear is excessive. Correct as necessary.

Steering wheel play

0-30 mm {0-1.18 in}

STEERING WHEEL LOOSENESS INSPECTION

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

1. Move the steering wheel as shown in Fig. 7 to inspect for column bearing wear, steering shaft joint play, steering wheel looseness, and column looseness.



Repair or replace as necessary.

Fig. 7: Inspecting Steering Wheel Play

Courtesy of MAZDA MOTORS CORP.

STEERING WHEEL EFFORT INSPECTION

1. Inspect the following points:



Tire size and tire pressure



Fluid level

Drive belt deflection

2. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position.

3. Remove the air bag module.

WARNING:

Microsoft

Thursday, July 09, 2009 3:41:52 PM



Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you.

Read AIR BAG SYSTEM WARNINGS before handling the air

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata bag module. (See AIR BAG SYSTEM SERVICE WARNINGS .)

(See AIR BAG SYSTEM SERVICE CAUTIONS .)

4. Start the engine and warm the power steering fluid to 50-60°C {122-140°F} .

5. Measure the steering wheel effort using a torque wrench.



If not within the specification, verify the following:



No air in steering system

No fluid leakage at hose or connectors



Function of oil pump and steering gear

Steering wheel effort

7.8 N.m {80 kgf.cm, 58 in.lbf} max.

Fig. 8: Measuring Steering Wheel Effort Using Torque Wrench

Courtesy of MAZDA MOTORS CORP.

NOTE:



To determine whether the steering effort is satisfactory or not, perform the inspection on another vehicle of the same model and under the same conditions, and compare the results.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata



The steering wheel effort varies with conditions as shown below.



Road conditions, such as dry or wet, and asphalt or concrete.



Tire conditions, such as brand, wear, and tire pressure.

STEERING SHAFT INSPECTION

1. Inspect the following.

1. Column bearing for damage

2. Steering shaft length



Replace the steering shaft component as necessary.

Steering shaft length

247.3 mm {9.736 in}

Fig. 9: Identifying Steering Shaft Length

Courtesy of MAZDA MOTORS CORP.

2. Inspect the tilt operation.

1. Verify that the adjusting lever moves smoothly from unlock position to lock position.

2. Verify that the steering shaft is fixed firmly when the adjusting lever is locked.



Replace the steering shaft component as necessary.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 10: Inspecting Tilt Operation

Courtesy of MAZDA MOTORS CORP.

STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION

WARNING:



Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Read AIR BAG

SYSTEM WARNINGS before handling the air bag module. (See AIR

BAG SYSTEM SERVICE WARNINGS .) (See AIR BAG SYSTEM

SERVICE CAUTIONS .)

1. Remove in the order indicated in Fig. 11 .

2. Install in the reverse order of removal.

3. If the steering lock component of a vehicle equipped with the advanced keyless system is replaced, perform the following procedure after installation.



Without immobilizer system





Steering lock unit programming (See STEERING LOCK UNIT ID CODE

REGISTRATION[ADVANCED KEYLESS SYSTEM] .)

With immobilizer system



Immobilizer system resetting (See IMMOBILIZER SYSTEM COMPONENT

REPLACEMENT/KEY ADDITION AND CLEARING[ADVANCED KEYLESS

Microsoft

SYSTEM] .)

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 11: Steering Wheel & Column Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

STEERING WHEEL REMOVAL NOTE

CAUTION:



Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will collapse.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

1. Set the vehicle in the straight-ahead position.

2. Remove the steering wheel using a suitable puller.

STEERING LOCK MOUNTING BOLTS REMOVAL NOTE

1. Make a groove in the heads of the steering lock mounting bolts using a chisel and a hammer.

2. Remove the bolts using a screwdriver.

3. Disassemble the steering lock component.

Fig. 12: Removing Bolts Using Screwdriver

Courtesy of MAZDA MOTORS CORP.

STEERING LOCK MOUNTING BOLTS INSTALLATION NOTE

1. Assemble the steering lock component to the steering shaft.

2. Verify that the lock operates correctly.

3. Install new steering lock mounting bolts.

4. Tighten the bolts until the heads break off.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 13: Installing Steering Lock Mounting Bolts

Courtesy of MAZDA MOTORS CORP.

STEERING SHAFT INSTALLATION NOTE

CAUTION:



Do not apply a shock in the axial direction of the shaft.

1. Lock the tilt lever.

2. Tighten nut A.

3. Tighten nut B.

4. Tighten bolt C.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 14: Steering Shaft Nuts

Courtesy of MAZDA MOTORS CORP.

STEERING WHEEL INSTALLATION NOTE

1. Make sure the wheels in the straight-ahead position, and install the steering wheel.

STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION

CAUTION:



Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

1. Remove the ABS wheel-speed sensor. (See FRONT ABS WHEEL-SPEED SENSOR

REMOVAL/INSTALLATION .)

2. Remove the front stabilizer. (See FRONT STABILIZER REMOVAL/INSTALLATION .)

3. Remove in the order indicated in Fig. 15 .

4. Install in the reverse order of removal.

5. After installation, adjust the total toe-in. (See FRONT WHEEL ALIGNMENT .)

Fig. 15: View Of Steering Gear & Linkage Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

BOLT (INTERMEDIATE SHAFT) REMOVAL NOTE

1. Mark the pinion shaft and gear housing for proper installation.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 16: Locating Mark On Pinion Shaft & Gear Housing

Courtesy of MAZDA MOTORS CORP.

TIE-ROD END BALL JOINT REMOVAL NOTE

1. Remove the tie-rod nut.

2. Separate the tie-rod end from the steering knuckle using the SSTs .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 17: Separating Tie-Rod End From Steering Knuckle Using SSTs

Courtesy of MAZDA MOTORS CORP.

STEERING GEAR AND LINKAGE REMOVAL NOTE

1. Remove the steering gear and linkage by pulling it from the right side.

STEERING GEAR AND LINKAGE INSTALLATION NOTE

1. Tighten bolts loosely.

2. Assemble the mounting bracket with the mark on the bracket facing the vehicle rear.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 18: Locating Mark On Bracket

Courtesy of MAZDA MOTORS CORP.

3. Tighten the mounting bracket bolts to the specified torque in the order shown.

Tightening torque

74.4-104.8 N.m {7.587-10.68 kgf.m, 54.88-77.29 ft.lbf}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 19: Mounting Bracket Bolts Tightening Order

Courtesy of MAZDA MOTORS CORP.

BOLT (INTERMEDIATE SHAFT) INSTALLATION NOTE

1. Align the marks and install the intermediate shaft and bolt.

STEERING GEAR AND LINKAGE DISASSEMBLY

CAUTION:



Place copper plates, rag, or similar material in a vise, when securing the mounting bracket portion of the steering gear.

1. Disassemble in the order indicated in Fig. 20 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 20: Exploded View Of Steering Gear & Linkage

Courtesy of MAZDA MOTORS CORP.

TIE ROD DISASSEMBLY NOTE

1. Unclamp the washer.

2. Remove the tie rod.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 21: Removing Tie Rod

Courtesy of MAZDA MOTORS CORP.

PINION PLUG, PINION SHAFT COMPONENT DISASSEMBLY NOTE

1. Remove the clip and the dust cover, then remove the pinion plug using the SST .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 22: Removing Pinion Plug Using SST

Courtesy of MAZDA MOTORS CORP.

2. Remove the pinion shaft component from the gear housing.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 23: Removing Pinion Shaft Component From Gear Housing

Courtesy of MAZDA MOTORS CORP.

HOLDER DISASSEMBLY NOTE

1. Remove the crimp from the holder and cylinder ends using a hacksaw.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 24: Removing Crimp From Holder & Cylinder Ends Using Hacksaw

Courtesy of MAZDA MOTORS CORP.

2. Remove the holder using the SST .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 25: Removing Holder Using SST

Courtesy of MAZDA MOTORS CORP.

STEERING RACK, OIL SEAL (HOLDER SIDE) DISASSEMBLY NOTE

1. Install the SST to the gear housing.

2. Remove the steering rack and oil seal (holder side) using a press.

3. Remove the oil seal (holder side) from the steering rack.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 26: Removing Steering Rack, Oil Seal (Holder Side)

Courtesy of MAZDA MOTORS CORP.

OIL SEAL (GEAR HOUSING SIDE), INNER GUIDE DISASSEMBLY NOTE

1. Set the SSTs as shown.

2. Install the SST to the gear housing.

3. Remove the oil seal (gear housing side) and inner guide using a press.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 27: Disassembling Oil Seal (Gear Housing Side)

Courtesy of MAZDA MOTORS CORP.

MOUNTING RUBBER DISASSEMBLY NOTE



Press the mounting rubber out from the gear housing using the SSTs and a press.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 28: Disassembling Mounting Rubber

Courtesy of MAZDA MOTORS CORP.

STEERING GEAR AND LINKAGE INSPECTION

RACK INSPECTION

1. Inspect the rack for cracking, damage, and tooth wear. Replace it if necessary.

2. Measure the runout of the rack.

Steering rack runout

Near point A: 0.08 mm {0.003 in} max.

Near point B: 0.15 mm {0.006 in} max.

3. If not within the specification, replace the rack.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 29: Measuring Rack Runout

Courtesy of MAZDA MOTORS CORP.

TIE-ROD END INSPECTION

1. Inspect the tie-rod end for damage and boot cracks. Replace it if necessary.

2. Inspect the ball joint for looseness. Replace the tie-rod end if necessary.

3. Rotate the ball joint five times.

4. Measure the rotation torque of the ball joint using the SST and a pull scale.

Tie-rod end rotational torque

0.4-3.0 N.m {3.5-30.5 kgf.cm, 3.1-26.5 in.lbf}

[Pull scale reading: 3.5-29.9 N {0.35-3.05 kgf, 0.8-6.7 lbf}]

5. If not within the specification, replace the tie-rod end.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 30: Measuring Rotational Torque Of Ball Joint

Courtesy of MAZDA MOTORS CORP.

TIE ROD INSPECTION

1. Inspect the tie rod for bending and damage. Replace it if necessary.

2. Inspect the ball joint for looseness. Replace the tie rod if necessary.

3. Swing the tie rod five times.

4. Measure the swinging torque using a pull scale.

Tie-rod swing torque

0.1-4.1 N.m {1.1-41.8 kgf.cm, 1.0-36.2 in.lbf}

[Pull scale reading: 0.6-24.4 N {0.06-2.49 kgf, 0.2-5.4 lbf}]

5. If not within the specification, replace the tie rod.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 31: Measuring Swinging Torque

Courtesy of MAZDA MOTORS CORP.

STEERING GEAR AND LINKAGE ASSEMBLY

CAUTION:



Place copper plates, rag, or similar material in a vise, when securing the mounting bracket portion of the steering gear.

1. Assemble in the order indicated in Fig. 32 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 32: View Of Steering Gear & Linkage Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

MOUNTING RUBBER ASSEMBLY NOTE

1. Install the mounting rubber so that two notches of mounting rubber are aligned to the steering rack.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

2. Apply soapy water to the rubber part of the mounting rubber.

Fig. 33: Aligning Notches Of Mounting Rubber

Courtesy of MAZDA MOTORS CORP.

3. Press the mounting rubber until the mounting rubber end comes out completely from the gear housing using the SSTs and a press.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 34: Installing Mounting Rubber

Courtesy of MAZDA MOTORS CORP.

4. Reverse the gear housing, then press the mounting rubber until the mounting rubber end comes out completely from the other side. At this time, the mounting rubber end and steel pipe are aligned.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 35: Aligning Mounting Rubber End & Steel Pipe

Courtesy of MAZDA MOTORS CORP.

STEELING RACK, OIL SEAL (GEAR HOUSING SIDE), INNER GUIDE ASSEMBLY NOTE

1. Apply multi-purpose grease to the oil seal (gear housing side) and Inner guide.

2. Install the plastic bag to the steering rack teeth so as not to damage the oil seal (gear housing side) and the inner guide, and install the oil seal (gear housing side) and the inner guide to the seal. Move the oil seal

(gear housing side) and the inner guide together with the plastic bag so that they pass the steering rack teeth, then remove the plastic bag.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 36: Installing Plastic Bag To Steering Rack Teeth

Courtesy of MAZDA MOTORS CORP.

3. Put the steering rack into the gear housing.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 37: Putting Steering Rack Into Gear Housing

Courtesy of MAZDA MOTORS CORP.

4. Using a press, press-in the oil seal (gear housing side) and inner guide until the press-in force increases rapidly.

OIL SEAL (HOLDER SIDE), HOLDER ASSEMBLY NOTE

1. Apply multi-purpose grease to the oil seal holder side)

2. Install the plastic bag to the steering rack end so as not to damage the oil seal (holder side) and install the oil seal (holder side) to the seal. Move the oil seal (holder side) together with the plastic bag so that they pass the steering rack end, then remove the plastic bag.

3. Install the holder and move the steering rack until it contacts the housing.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 38: Identifying Oil Seal (Holder Side), Plastic Bag And Holder

Courtesy of MAZDA MOTORS CORP.

4. Tighten the holder to the specified torque using the SST .

Tightening torque

58.9-73.5 N.m {6.00-7.49 kgf.m, 43.4-54.2 ft.lbf}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 39: Tightening Holder To Specified Torque

Courtesy of MAZDA MOTORS CORP.

5. After tightening the holder, crimp the cylinder end as shown in Fig. 40 using a flathead screwdriver so that the holder does not loosen.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 40: Crimping Cylinder End Using Flathead Screwdriver

Courtesy of MAZDA MOTORS CORP.

PINION PLUG ASSEMBLY NOTE

1. Tighten the pinion plug using the SST .

Tightening torque

39.2-44.1 N.m {4.00-4.49 kgf.m, 29.0-32.5 ft.lbf}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 41: Tightening Pinion Plug Using SST

Courtesy of MAZDA MOTORS CORP.

ADJUSTING COVER ASSEMBLY NOTE

1. Set the rack to the center position.

2. Tighten the adjusting cover to 20 N.m {2.0 kgf.m, 15 ft.lbf} .

3. Rotate the pinion shaft thoroughly three times to make sure that the pinion shaft and the rack engage smoothly, then loosen the adjusting cover.

4. Retighten the adjusting cover to 4.9 N.m {0.5 kgf.m, 3.6 ft.lbf} , then loosen it about 0 to 15° using the

SST .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 42: Tightening Adjusting Cover

Courtesy of MAZDA MOTORS CORP.

5. Measure the rotation torque in the range +/-90+/ from the pinion gear neutral point using a SST and a pull-scale.



If not within the specification, repeat Steps 2 - 4 .

Pinion shaft rotation torque

Center of rack +/-90+/-: 0.98-1.38 N.m {10.0-14.0 kgf.cm, 8.7-12.2 in.lbf}

[Pull scale reading: 9.8-13.8 N {1.00-1.40 kgf, 2.21-3.10 lbf}]

Except center of rack +/-90+/-: Less than 1.87 N.m {19.1 kgf.cm, 16.6 in.lbf}

[Pull scale reading: Less than 19.5 N {1.99 kgf, 4.38 lbf}]

6. Apply sealant to the thread of the locknut.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 43: Measuring Rotation Torque From Pinion Gear

Courtesy of MAZDA MOTORS CORP.

7. Hold the adjusting cover so as not to rotate and tighten the locknut.

Tightening torque

40.0-58.0 N.m {4.08-5.91 kgf.m, 29.5-42.7 ft.lbf}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 44: Tightening Locknut

Courtesy of MAZDA MOTORS CORP.

HERMETIC SEALING INSPECTION

1. Connect the SSTs to the power cylinder section of the gear housing.

2. Apply 53.3 kPa {400 mmHg, 15.7 inHg} vacuum with a vacuum pump and verify that it is held for at least 30 seconds .

3. If the vacuum is not held, replace the oil seal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 45: Inspecting Hermetic Sealing

Courtesy of MAZDA MOTORS CORP.

POWER STEERING OIL PUMP REMOVAL/INSTALLATION

1. Remove the drive belt. (See DRIVE BELT REPLACEMENT [LF] .)

2. Remove in the order indicated in Fig. 46 .

3. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 46: View Of Power Steering Oil Pump Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

POWER STEERING OIL PUMP DISASSEMBLY/ASSEMBLY

NOTE:



The following procedure is for replacement of the O-ring and oil seal only.

Replace the pump component if other repairs are necessary.

1. Disassemble in the order indicated in Fig. 47 .

2. Assemble in the reverse order of disassembly.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 47: Exploded View Of Power Steering Oil Pump (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

POWER STEERING OIL PUMP COMPONENT DISASSEMBLY NOTE

1. Secure the power pressure oil pump using the SST .

CAUTION:

Microsoft

Thursday, July 09, 2009 3:41:52 PM



Use the SST to prevent damage to the pump when securing it in a vise.

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 48: Securing Power Pressure Oil Pump Using SST

Courtesy of MAZDA MOTORS CORP.

OIL SEAL ASSEMBLY NOTE

1. Install the oil seal in the front pump body using the SST and plastic hammer.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 49: Installing Oil Seal In Front Pump Body Using SST & Hammer

Courtesy of MAZDA MOTORS CORP.

VANE ASSEMBLY NOTE

1. Place the vanes in the rotor with the rounded edges contacting the cam.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 50: Placing Vanes In Rotor With Rounded Edges Contacting Cam

Courtesy of MAZDA MOTORS CORP.

CAM RING ASSEMBLY NOTE

1. Install the cam ring in the front pump body with the mark facing upward.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 STEERING Power Steering - MX-5 Miata

Fig. 51: Installing Cam Ring In Front Pump Body

Courtesy of MAZDA MOTORS CORP.

REAR PUMP BODY ASSEMBLY NOTE

1. After installing the rear body, manually turn the shaft to verify that it rotates smoothly.

Microsoft

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

2008 DRIVELINE/AXLES

Rear Axle - MX-5 Miata

REAR AXLE LOCATION INDEX

Fig. 1: Identifying Rear Axle Assembly

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB COMPONENT INSPECTION

WHEEL BEARING LOOSENESS INSPECTION

1. Install the magnetic vase and dial gauge as shown in Fig. 2 , and inspect the wheel bearing for axial looseness.



If it exceeds the maximum specification, replace the wheel hub component.

Maximum rear wheel bearing play

0.05 mm {0.002 in}

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 2: View Of Magnetic Vase & Dial Gauge

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB COMPONENT REMOVAL/INSTALLATION

CAUTION:



1. Remove in the order indicated in Fig. 3 .

2. Install in the reverse order of removal.

3. After installation, inspect rear wheel alignment. (See REAR WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 3: Identifying Wheel Hub Components (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.

3. Remove the locknut.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 4: Knocking Out Crimped Portion Of Locknut Outward Using Chisel & Hammer

Courtesy of MAZDA MOTORS CORP.

BRAKE CALIPER COMPONENT REMOVAL NOTE

1. Suspend the brake caliper component using a cable or equivalent.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 5: View Of Brake Caliper Components

Courtesy of MAZDA MOTORS CORP.

REAR DRIVE SHAFT REMOVAL NOTE

1. Temporarily install a spare nut onto the end of the rear drive shaft.

2. Tap the nut with a copper hammer to loosen the drive shaft from the wheel hub.

3. Separate the rear drive shaft from the wheel hub.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 6: Separating Rear Drive Shaft From Wheel Hub

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB COMPONENT REMOVAL NOTE

1. Wind the SST and backing plate contact area with packing tape two times.

2. Remove the wheel hub component using the SSTs.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 7: Removing Wheel Hub Component Using SST's

Courtesy of MAZDA MOTORS CORP.

3. If the bearing inner race remains on the wheel hub component, use a chisel to secure a sufficient space for installing the SST between wheel hub component and bearing inner race.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 8: Removing Inner Race Remains On Wheel Hub Component

Courtesy of MAZDA MOTORS CORP.

4. Remove the bearing inner race using the SST.

5. After removing the bearing, repair any backing plate deformation.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 9: Removing Bearing Inner Race Using SST

Courtesy of MAZDA MOTORS CORP.

WHEEL BEARING REMOVAL NOTE

1. Wind the SST and backing plate contact area with packing tape two times.

2. Remove the wheel bearing from the rear knuckle using the SSTs.

3. After removing the bearing, repair any backing plate deformation.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 10: Removing Wheel Bearing From Rear Knuckle Using SST's

Courtesy of MAZDA MOTORS CORP.

DUST COVER REMOVAL NOTE

NOTE:



Remove the dust cover only if there is an abnormality.

1. Place an alignment mark on the dust cover and rear knuckle for proper installation.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 11: Placing Alignment Mark On Dust Cover & Rear Knuckle

Courtesy of MAZDA MOTORS CORP.

2. Remove the dust cover using a chisel.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 12: Removing Dust Cover Using Chisel

Courtesy of MAZDA MOTORS CORP.

BUSHING REMOVAL NOTE

1. Remove the bushing from the rear knuckle using the SSTs.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 13: Removing Bushing From Rear Knuckle Using SST's

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB BOLT REMOVAL NOTE

NOTE:



Remove the wheel hub bolt only if there is an abnormality.

1. Remove the wheel hub bolts from the wheel hub using a press.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 14: Removing Wheel Hub Bolts From Wheel Hub Using Press

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB BOLT INSTALLATION NOTE

1. Press in new wheel hub bolts into the wheel hub using a press.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 15: Pressing New Wheel Hub Bolts Into Wheel Hub Using Press

Courtesy of MAZDA MOTORS CORP.

BUSHING INSTALLATION NOTE

1. Press the new bushing into the rear knuckle using the SSTs.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 16: Pressing New Bushing Into Rear Knuckle Using SST's

Courtesy of MAZDA MOTORS CORP.

DUST COVER INSTALLATION NOTE

1. Align the new and old dust covers and place alignment marks on the new dust cover.

2. Align the marks on the new dust cover and rear knuckle.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 17: Aligning Marks On New Dust Cover & Rear Knuckle

Courtesy of MAZDA MOTORS CORP.

3. Press the new dust cover onto the rear knuckle using the SSTs.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 18: Pressing New Dust Cover Onto Rear Knuckle Using SST's

Courtesy of MAZDA MOTORS CORP.

WHEEL BEARING INSTALLATION NOTE

1. Install a new wheel bearing using the SSTs.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 19: Installing New Wheel Bearing Using SST's

Courtesy of MAZDA MOTORS CORP.

WHEEL HUB COMPONENT INSTALLATION NOTE

1. Install the wheel hub component using the SSTs.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 20: Installing Wheel Hub Components Using SST's

Courtesy of MAZDA MOTORS CORP.

LOCKNUT INSTALLATION NOTE

1. Tighten a new locknut.

2. Install a new locknut and indent as shown to crimp the locknut, using a chisel and hammer.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 DRIVELINE/AXLES Rear Axle - MX-5 Miata

Fig. 21: Installing New Locknut

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 SUSPENSION Rear Suspension - MX-5 Miata

2008 SUSPENSION

Rear Suspension - MX-5 Miata

REAR SUSPENSION LOCATION INDEX

Fig. 1: Identifying Location Of Rear Suspension Components

Courtesy of MAZDA MOTORS CORP.

REAR SHOCK ABSORBER AND COIL SPRING 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 operations, remove the ABS wheel-speed sensor (axle side), and move the sensor away from the harnesses.

1. When working on the left side, remove the fuel tank protector. (See FUEL TANK

REMOVAL/INSTALLATION [LF] .)

2. Remove in the order indicated in Fig. 2 .

3. Install in the reverse order of removal.

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 2: Identifying Rear Shock Absorber & Coil Spring (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

CALIPER REMOVAL NOTE

1. Remove the caliper, and hang the cable out of the way.

REAR SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY

WARNING:



Removing/installing the shock absorber and coil spring is dangerous. The shock absorber and coil spring could fly off and cause injury or death, and damage the vehicle.

1. Remove the rear shock absorber and coil spring. (See REAR SHOCK ABSORBER AND COIL

SPRING REMOVAL/INSTALLATION .)

2. Remove in the order indicated in Fig. 3 .

3. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 3: Identifying Rear Shock Absorber & Coil Spring Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

PISTON ROD NUT REMOVAL NOTE

WARNING:



1. Set the SSTs using cloth to prevent the spring from being damaged.

2. Using the SSTs, compress the coil spring and remove the piston rod nut.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 4: Removing Piston Rod Nut

Courtesy of MAZDA MOTORS CORP.

COIL SPRING INSTALLATION NOTE

1. Set the coil spring to the SSTs using cloth.

2. Using the SSTs, compress the coil spring.

3. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 5: Compressing Coil Spring Using SSTs

Courtesy of MAZDA MOTORS CORP.

COLLAR INSTALLATION NOTE

1. Install the collar so that the tapered side is facing downward as shown in Fig. 6 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 6: View Of Collar Tapered Side Down

Courtesy of MAZDA MOTORS CORP.

SPRING SEAT RUBBER INSTALLATION NOTE

1. Install the spring seat rubber to the upper spring seat as shown in Fig. 7 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 7: View Of Spring Seat Rubber & Upper Spring Seat

Courtesy of MAZDA MOTORS CORP.

UPPER SPRING SEAT INSTALLATION NOTE

1. Install the coil spring with the lead lower end of the lower spring seat facing the direction shown in Fig.

8 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 8: Identifying Spring Seat Facing

Courtesy of MAZDA MOTORS CORP.

REAR SHOCK ABSORBER INSPECTION

1. Inspect the rear shock absorber in the same way as the front shock absorber. (See FRONT SHOCK

ABSORBER INSPECTION .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

REAR SHOCK ABSORBER DISPOSAL

1. Dispose of the rear shock absorber in the same way as the front shock absorber. (See FRONT SHOCK

ABSORBER DISPOSAL )

REAR LATERAL LINK (UPPER) 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 operations, remove the ABS wheel-speed sensor (axle side) and move the sensor away from the harnesses.

1. Remove in the order indicated in Fig. 9 .

2. Install in the reverse order of removal.

3. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 9: Identifying Rear Lateral Link (Upper) Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

REAR LATERAL LINK (UPPER) BALL JOINT REMOVAL NOTE

1. Using the SST , disconnect the rear lateral link (upper) ball joint.

NOTE:



When removing the rear lateral link (upper) ball joint, the rear knuckle bushing may also come off. If it comes off, replace the rear knuckle.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 10: Disconnecting Rear Lateral Link (Upper) Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

DUST BOOT INSTALLATION NOTE

1. Wipe the grease off the ball joint stud.

2. Fill the inside of the new dust boot with grease.

3. Using the SST , install the dust boot to the ball joint.

4. Wipe off the excess grease.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 11: Installing Dust Boot To Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

REAR LATERAL LINK (UPPER) INSPECTION

1. Remove the rear lateral link (upper) from the vehicle. (See REAR LATERAL LINK (UPPER)

REMOVAL/INSTALLATION .)

2. Inspect the link for bending or damage. If there is any malfunction, replace the link.

3. Inspect the ball joint for looseness. If there is any malfunction, replace the ball joint.

4. Rotate the ball joint 5 times.

5. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench.

Rear lateral link (upper) ball joint rotational torque

0.4-2.8 N.m {5-28 kgf.cm, 4-24 in.lbf}



If not within the specification, replace the rear lateral link (upper). (See REAR LATERAL LINK

(UPPER) REMOVAL/INSTALLATION .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 12: Measuring Ball-Joint Rotational Torque Using Allen Wrench & Torque Wrench

Courtesy of MAZDA MOTORS CORP.

REAR LATERAL LINK (LOWER) REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 13 .

2. Install in the reverse order of removal.

3. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 13: Identifying Rear Lateral Link (Lower) Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

REAR LATERAL LINK (LOWER) BALL JOINT REMOVAL NOTE

1. Using the SST , disconnect the ball joint.

NOTE:



When removing the rear lateral link (lower) ball joint, the rear knuckle bushing may also come off. If it comes off, replace the rear knuckle.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 14: Disconnecting Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

DUST BOOT INSTALLATION NOTE

1. Wipe the grease off the ball joint stud.

2. Fill the inside of the new dust boot with grease.

3. Using the SST , install the dust boot to the ball joint.

4. Wipe off the excess grease.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 15: Installing Dust Boot To Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

REAR LATERAL LINK (LOWER) INSPECTION

1. Remove the rear lateral link (lower) from the vehicle. (See REAR LATERAL LINK (LOWER)

REMOVAL/INSTALLATION .)

2. Inspect the link for bending or damage. If there is any malfunction, replace the link.

3. Inspect the ball joint for looseness. If there is any malfunction, replace the ball joint.

4. Rotate the ball joint 5 times.

5. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench.

Rear lateral link (lower) ball joint rotational torque

0.4-2.8 N.m {5-28 kgf.cm, 4-24 in.lbf}



If not within the specification, replace the rear lateral link (lower). (See REAR LATERAL LINK

(LOWER) REMOVAL/INSTALLATION .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 16: Measuring Ball-Joint Rotational Torque Using Allen Wrench & Torque Wrench

Courtesy of MAZDA MOTORS CORP.

TOE CONTROL LINK REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 17 .

2. Install in the reverse order of removal.

3. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 17: Identifying Toe Control Link (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

DUST BOOT INSTALLATION NOTE

1. Wipe the grease off the ball joint stud.

2. Fill the inside of the new dust boot with grease.

3. Using the SST , install the dust boot to the ball joint.

4. Wipe off the excess grease.

Fig. 18: Installing Dust Boot To Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

TOE CONTROL LINK BALL JOINT INSTALLATION NOTE

1. Install the toe control link ball joint so that the ball joint stud projection is within -2-4 mm {-0.08-0.15 in}.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 19: View Of Toe Control Link Ball Joint

Courtesy of MAZDA MOTORS CORP.

TOE CONTROL LINK INSPECTION

1. Remove the toe control link from the vehicle. (See TOE CONTROL LINK

REMOVAL/INSTALLATION .)

2. Inspect the lateral link for bending or damage. If there is any malfunction, replace the lateral link.

3. Inspect the ball joint for looseness. If there is any malfunction, replace the ball joint.

4. Rotate the ball joint 5 times.

5. Install the SST to the ball stud, and measure the ball joint rotational torque using a pull scale.

Toe control link ball joint rotational torque 0.3-2.2 N.m {4-22 kgf.cm, 3-19 in.lbf}

Pull scale reading: 3-22 N {0.3-2.2 kgf, 0.7-4.9 lbf}



If not within the specification, replace the toe control link. (See TOE CONTROL LINK

REMOVAL/INSTALLATION .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 20: Measuring Ball Joint Rotational Torque Using Pull Scale

Courtesy of MAZDA MOTORS CORP.

REAR TRAILING LINK (UPPER) REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 21 .

2. Install in the reverse order of removal.

3. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 21: Identifying Rear Trailing Link (Upper) (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

REAR TRAILING LINK (UPPER) BALL JOINT REMOVAL NOTE

1. Using the SST, disconnect the ball joint.

NOTE:



When removing the rear trailing link (upper) ball joint, the rear knuckle bushing may also come off. If it comes off, replace the rear knuckle.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 22: Disconnecting Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

DUST BOOT INSTALLATION NOTE

1. Wipe the grease off the ball joint stud.

2. Fill the inside of the new dust boot with grease.

3. Using the SST, install the dust boot to the ball joint.

4. Wipe off the excess grease.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 23: Installing Dust Boot To Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

REAR TRAILING LINK (UPPER) INSPECTION

1. Remove the rear trailing link (upper) from the vehicle. (See REAR TRAILING LINK (UPPER)

REMOVAL/INSTALLATION .)

2. Inspect the link or bending or damage. If there is any malfunction, replace the rear trailing link (upper).

3. Inspect the ball joint for looseness. If there is any malfunction, replace the ball joint.

4. Rotate the ball joint 5 times.

5. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench.

Rear trailing link (upper) ball joint rotational torque

0.4-3.3 N.m {5-33 kgf.cm, 4-29 in.lbf}



If not within the specification, replace the rear trailing link (upper). (See REAR TRAILING

LINK (UPPER) REMOVAL/INSTALLATION .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 24: Measuring Ball-Joint Rotational Torque Using Allen Wrench & Torque Wrench

Courtesy of MAZDA MOTORS CORP.

REAR TRAILING LINK (LOWER) REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 25 .

2. Install in the reverse order of removal.

3. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 25: Identifying Rear Trailing Link (Lower) (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

REAR STABILIZER REMOVAL/INSTALLATION

1. Remove in the order indicated in Fig. 26 .

2. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 26: Identifying Rear Stabilizer (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

REAR STABILIZER INSTALLATION NOTE

1. Install the rear stabilizer so that the identification mark is on the right side of the vehicle.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 27: Identifying Identification Mark

Courtesy of MAZDA MOTORS CORP.

STABILIZER CONTROL LINK INSTALLATION NOTE

1. Install the stabilizer control link in the proper angle as shown in Fig. 28 .

CAUTION:



Be sure to install the stabilizer control link in the proper position. If it is not installed properly, the stabilizer control link may interfere with peripheral components when driving, causing damage to each other.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 28: Precaution For Stabilizer Control Link (1 Of 2)

Courtesy of MAZDA MOTORS CORP.

2. Place the vehicle on, the ground and verify that the stabilizer control link is installed in the angle shown in Fig. 29 .

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 29: Precaution For Stabilizer Control Link (2 Of 2)

Courtesy of MAZDA MOTORS CORP.

REAR STABILIZER CONTROL LINK INSPECTION

1. Remove the stabilizer control link from the vehicle. (See REAR STABILIZER

REMOVAL/INSTALLATION .)

2. Inspect the link for bending or damage. If there is any malfunction, replace the link.

3. Rotate the ball joint 10 times, and rock the ball joint 10 times.

4. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench.

Stabilizer control link ball joint rotational torque

0.23-0.47 N.m {2.35-4.79 kgf.cm, 2.04-4.15 in.lbf}



If not within the specification, replace the stabilizer control link ball joint. (See REAR

STABILIZER REMOVAL/INSTALLATION .)

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 30: Measuring Ball-Joint Rotational Torque Using Allen Wrench & Torque Wrench

Courtesy of MAZDA MOTORS CORP.

REAR CROSSMEMBER 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 operations, remove the ABS wheel-speed sensor (axle side) and move the sensor away from the harnesses.

1. Remove the exhaust pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [LF] .)

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

3. Remove the power plant frame. (See TRANSMISSION REMOVAL/INSTALLATION [M15M-D] .)

(See TRANSMISSION REMOVAL/INSTALLATION [P66M-D] .) (See AUTOMATIC

TRANSMISSION REMOVAL/INSTALLATION [SJ6A-EL] .)

4. Remove the rear drive shaft. (See REAR DRIVE SHAFT REMOVAL/INSTALLATION .)

5. Remove the rear differential. (See REAR DIFFERENTIAL REMOVAL/INSTALLATION .)

6. Remove in the order indicated in the table.

7. Install in the reverse order of removal.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

8. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT .)

Fig. 31: Identifying Rear Crossmember Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

REAR AXLE COMPONENT REMOVAL NOTE

NOTE:



When removing the ball joints, the rear knuckle bushings may also come off. If they come off, replace the rear knuckle.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

1. Support the knuckle using a jack.

2. Using the SST , disconnect the rear trailing link (upper) ball joint.

3. Remove the rear trailing link (lower) outer bolt.

Fig. 32: Disconnecting Rear Trailing Link (Upper) Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

4. Using the SST , disconnect the rear lateral link (upper) ball joint.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 33: Disconnecting Rear Lateral Link (Upper) Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

5. Using the SST , disconnect the rear lateral link (lower) ball joint.

6. Remove the toe control link outer bolt.

7. Remove the shock absorber lower bolt.

8. Remove the rear axle component.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 34: Disconnecting Rear Lateral Link (Lower) Ball Joint Using SST

Courtesy of MAZDA MOTORS CORP.

REAR CROSSMEMBER COMPONENT REMOVAL NOTE

WARNING:



Be sure that the crossmember component is securely supported by the jack. If not securely supported, the crossmember component could fall, resulting in serious injury or death, and damage to the vehicle.

1. Support the rear crossmember with the jack, and remove the bolt.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 SUSPENSION Rear Suspension - MX-5 Miata

Fig. 35: Supporting Rear Crossmember With Jack

Courtesy of MAZDA MOTORS CORP.

2. Remove the rear crossmember component.

Microsoft

2008 ENGINE Starting System - MX-5 Miata

2008 ENGINE

Starting System - MX-5 Miata

STARTING SYSTEM LOCATION INDEX [LF]

Fig. 1: Identifying Location Of Starting System Components

Courtesy of MAZDA MOTORS CORP.

STARTER 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 starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the negative battery cable before performing the following operation.

1. Remove the battery cover.

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

3. Remove the side cover. (LH)

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

4. Remove the under cover. (MT) (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)

5. Remove the clutch release cylinder with the pipes still connected. Position the clutch release cylinder so that it is out of the way. (MT) (See TRANSMISSION REMOVAL/INSTALLATION [M15M-D] .)

(See TRANSMISSION REMOVAL/INSTALLATION [P66M-D] .)

6. Remove in the order indicated in Fig. 2 .

7. Install in the reverse order of removal.

Fig. 2: View Of Starter Removal Order & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

STARTER INSTALLATION NOTE

NOTE:



If there is peeling on or damage to the insulator, attach a new insulator using the following procedure:

1. Peel off the insulator from the starter completely using a scraper.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 3: Identifying Starter Insulator

2. Degrease the insulator attachment area.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 4: Identifying Insulator Attachment Area

3. Attach a new insulator to the starter.

Fig. 5: Identifying New Starter Insulator

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

STARTER INSPECTION [LF]

ON-VEHICLE INSPECTION

1. Verify that the battery is fully charged.

2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.



If the starter does not operate, inspect the following:



Remove the starter, and inspect the starter unit.



Inspect the related wiring harnesses, the ignition switch, and the transmission range switch

(AT).

NO-LOAD TEST

1. Verify that the battery is fully charged.

2. Connect the starter, battery and a tester as shown in Fig. 6 .

3. Operate the starter and verify that it rotates smoothly.



If the starter does not rotate smoothly, inspect the starter unit.

4. Measure the voltage and current while the starter is operating.



If not within the specification, replace the starter.

Starter no load test voltage

11 V

Starter no load test current

90 A or less

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 6: No - Load Test - Circuit Diagram

Courtesy of MAZDA MOTORS CORP.

MAGNETIC SWITCH OPERATION INSPECTION

Pull-out Test

NOTE:



Depending on the battery charge condition, the starter motor pinion may rotate while in an extended state. This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does not indicate an abnormality.

1. Verify that the starter motor pinion is extended while battery positive voltage is connected to terminal S and the starter body is grounded.



If the starter motor pinion is not extended, repair or replace the starter.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 7: Energizing Starter S Terminal

Courtesy of MAZDA MOTORS CORP.

Return test

1. Disconnect the motor wire from terminal M.

2. Connect battery positive voltage to terminal M and ground the starter body.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 8: Connecting Battery Positive Voltage To Terminal M & Ground Starter Body

Courtesy of MAZDA MOTORS CORP.

3. Pull out the drive pinion with a screwdriver. Verify that it returns to its original position when released.



If it does not return, repair or replace the starter.

PINION GAP INSPECTION

1. Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body grounded.

CAUTION:



Applying power for more than 10 s can damage the starter. Do not apply power for more than 10s.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 9: Energizing Starter S Terminal

Courtesy of MAZDA MOTORS CORP.

2. Measure the pinion gap while the drive pinion is extended.



If not as specified, adjust with an adjustment washer (between drive housing front cover and magnetic switch).

Starter pinion gap

0.5-2.0 mm {0.02-0.07 in}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 10: Measuring Pinion Gap While Drive Pinion Is Extended

Courtesy of MAZDA MOTORS CORP.

STARTER INNER PARTS INSPECTION

Armature

1. Verify that there is no continuity between the commutator and the core at each segment using a tester.



If there is continuity, replace the armature.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 11: Inspecting Continuity Between Commutator & Core

Courtesy of MAZDA MOTORS CORP.

2. Verify that there is no continuity between the commutator and the shaft using a tester.

 If there is continuity, replace the armature.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 12: Inspecting Continuity Between Commutator & Shaft

Courtesy of MAZDA MOTORS CORP.

3. Place the armature on V-blocks, and measure the runout using a dial indicator.

Starter armature runout

0.1 mm {0.004 in} max.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 13: Measuring Armature Runout Using Dial Indicator

Courtesy of MAZDA MOTORS CORP.

4. Measure the commutator diameter.



If not within the minimum specification, replace the armature.

Starter commutator diameter

Standard: 29.4 mm {1.16 in}

Minimum: 28.8 mm {1.13 in}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 14: Measuring Commutator Diameter

Courtesy of MAZDA MOTORS CORP.

5. Measure the segment groove depth of the commutator.



If not within the minimum specification, undercut the grooves to the standard depth.

Segment groove depth of starter commutator

Standard: 0.5 mm {0.02 in}

Minimum: 0.2 mm {0.008 in}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 15: Measuring Segment Groove Depth Of Commutator

Courtesy of MAZDA MOTORS CORP.

Magnetic Switch

1. Inspect for continuity between terminals S and M using a tester.



If there is no continuity, replace the magnetic switch.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 16: Verifying If There Is Continuity Between Terminals S & M

Courtesy of MAZDA MOTORS CORP.

2. Inspect for continuity between terminal S and the body using a tester.



If there is no continuity, replace the magnetic switch.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 17: Verifying If There Is Continuity Between Terminal S & Body

Courtesy of MAZDA MOTORS CORP.

3. Verify that there is no continuity between terminals M and B using a tester.



If there is continuity, replace the magnetic switch.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 18: Verifying If There Is No Continuity Between Terminals M & B

Courtesy of MAZDA MOTORS CORP.

Brush And Brush Holder

1. Verify that there is no continuity between each insulated brush and plate using a tester.



If there is continuity, replace the brush holder.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 19: Verifying If There Is No Continuity Between Insulated Brush & Plate

Courtesy of MAZDA MOTORS CORP.

2. Measure the brush length.



If any brush is worn almost to or beyond the minimum specification, replace all of the brushes.

Starter brush length

Standard: 12.3 mm {0.48 in}

Minimum: 5.5 mm {0.22 in}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 20: Measuring Brush Length

Courtesy of MAZDA MOTORS CORP.

3. Measure the brush spring force using a spring balance.



If not within the minimum specification, replace the brush and brush holder component.

Starter brush spring force

Standard: 15.0-20.4 N {1.53-2.08 kgf, 3.38-4.58 lbf}

Minimum: 2.75 N {0.28 kgf, 0.62 lbf}

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 21: Measuring Brush Spring Force Using Spring Balance

Courtesy of MAZDA MOTORS CORP.

STARTER DISASSEMBLY/ASSEMBLY [LF]

1. Disassemble in the order indicated in Fig. 22 .

2. Assemble in the reverse order of disassembly.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 22: Identifying Disassemble Order Of Starter & Components (With Torque Specifications)

Courtesy of MAZDA MOTORS CORP.

STARTER INTERLOCK SWITCH INSPECTION [MT]

CAUTION:



Do not reuse the starter interlock switch if it is removed from the vehicle even once. Replace with a new starter interlock switch when installing.

1. Remove the battery cover.

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

3. Disconnect the starter interlock switch connector.

4. Verify that the continuity is as indicated in Fig. 23 using a tester.



If the continuity is not as indicated in Fig. 23 , replace the starter interlock switch.

Microsoft

2008 Mazda MX-5 Miata Grand Touring

2008 ENGINE Starting System - MX-5 Miata

Fig. 23: Starter Interlock Switch Continuity Check Table

Courtesy of MAZDA MOTORS CORP.

Fig. 24: Identifying Starter Interlock Switch Connector Terminals

Courtesy of MAZDA MOTORS CORP.

Microsoft

Hello! I am an AI chatbot specifically trained to assist you with the Mazda MX-5 2008 Workshop Manual. I have thoroughly reviewed the document and can help you locate the exact information you need or explain the content in clear and simple terms. Whether you’re looking for guidance on specific features, troubleshooting steps, or general usage, feel free to ask your questions. The more details you provide about your concerns or needs, the more accurately and effectively I can assist you!

Assistant typing

Assistant terminated