MAZDA MIATA 1991 Factory Service Manual

Stabilizer Link Bolt/Nut12-17 (16-23)
Steering Angle Transfer Shaft-To-Steering Gear Bolt13-19 (18-26)
Steering Bracket-To-Frame Mounting Bolt46-69 (63-93)
Steering Gear Mounting Bolt
Miata34-43 (46-58)
MPV55-69 (74-93)
MX-6 & 62627-40 (36-54)
Protege, RX7, 323 & 92923-34 (31-46)
Steering Rack-To-Tie Rod
Miata58-72 (78-98)
MPV, MX-6, RX7 & 62687 (118)
Protege, 323 & 92943-58 (60-78)
Tie Rod Castle Nuts
All Models Except MPV21-32 (29-44)
MPV44-58 (59-78)
Valve Housing Bolt (929)14-22 (20-29)

1991 Mazda MX-5 Miata
STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion
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SUSPENSION - REAR
1991 SUSPENSION Rear
DESCRIPTION
Rear suspension consists of MacPherson-type struts, crossmember, upper and lower arms and stabilizer bar with
control link. Upper and lower arms attach to crossmember and knuckle. A stabilizer bar with control link is
mounted to lower arm and crossmember. Rear wheel alignment is adjusted by turning adjusting cams on lower
arm.
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
See WHEEL ALIGNMENT SPECIFICATIONS AND PROCEDURES article in the WHEEL ALIGNMENT
section.
WHEEL BEARING
Raise vehicle and support. Remove wheel assembly. Remove caliper assembly and wire aside. Remove brake
rotor. Attach dial indicator to axle hub and measure bearing play. Maximum bearing play is .002" (.05 mm). If
play exceeds specification, check rear axle lock nut torque or replace wheel bearing.
REMOVAL & INSTALLATION
WHEEL BEARING
Removal
1. Raise and support vehicle. Remove wheel assembly. Remove drive axle lock nut. Remove brake caliper
assembly, and wire aside. Remove screws and rotor. Disconnect ABS speed sensor. Remove knuckle
assembly from upper and lower arms.
2. Using a press, Installer (49-G030-727) and Puller (49-F026-103), remove hub from knuckle. Remove
snap ring from knuckle. Using a press, installer and Puller (49-0636-145), remove wheel bearing inner
race from hub. Remove wheel bearing outer race from knuckle using a press and Adapter (49-F027-005).
Inspection
Check wheel hub and knuckle for cracks and damage. Check dust cover for deformation. Check bearing for
excessive wear or seizure.
Installation
Press new wheel bearing into knuckle using Installer (49-F027-007) and Adapter (49-F027-009). Press hub into
knuckle using installer. To install, reverse removal procedure. Tighten drive axle lock nut to specification. Stake

1991 Mazda MX-5 Miata
SUSPENSION - REAR 1991 SUSPENSION Rear

1991 Mazda MX-5 Miata
SUSPENSION - REAR 1991 SUSPENSION Rear
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drive axle lock nut. Check axial play. See WHEEL BEARING under ADJUSTMENTS & INSPECTION.
STRUT ASSEMBLY
Removal & Disassembly
1. Raise vehicle and remove fuel tank filler pipe protector. Remove rear wheel assembly. Remove stabilizer
bar nut and bolt. Remove 2 upper strut mount-to-body nuts. Remove lower strut bolt. Loosen upper and
lower arm bolts. Lower arms and remove strut assembly.
2. Clamp strut securely in soft-jawed vise. Compress coil spring. Remove lock nut and washer. Remove
remaining components and note order for reassembly.
Inspection
Check strut for leaks or abnormal noise. Inspect parts for wear or damage. Check for loose installation of bolts
and nuts. Replace parts as necessary.
Reassembly & Installation
To reassemble, reverse disassembly procedure. To install, reverse removal procedure. Ensure coil spring is well
seated in upper and lower seats. Check rear wheel toe-in. See SPECIFICATIONS & PROCEDURES article in
the WHEEL ALIGNMENT section.
LOWER ARM
Removal
Raise and support vehicle. Remove wheel assembly. Remove stabilizer bar control link nut and bolt. See Fig.
1 . Remove lower strut bolt. Remove lower arm-to-crossmember bolts. Remove lower arm-to-knuckle bolts.
Remove lower arm. Inspect arm for dama
ge, cracks and deformation. Check for damaged or worn bushings.

1991 Mazda MX-5 Miata
SUSPENSION - REAR 1991 SUSPENSION Rear
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Fig. 1: Exploded View of Rear Lower Arm Assembly
Courtesy of MAZDA MOTORS CORP.
Installation
To install, reverse removal procedure. Tighten all bolts with vehicle resting on ground and suspension
unloaded. Adjust rear wheel toe-in. See SPECIFICATIONS & PROCEDURES article in the WHEEL
ALIGNMENT section.
UPPER ARM
Removal
Raise and support vehicle. Remove wheel assembly. Remove upper arm-to-crossmember bolts. Remove upper
arm-to-knuckle bolts. Remove upper arm. Inspect arm for damage, cracks and deformation. Check for damaged
or worn bushings.

1991 Mazda MX-5 Miata
SUSPENSION - REAR 1991 SUSPENSION Rear
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Installation
To install, reverse removal procedure. Tighten all bolts with vehicle resting on ground and suspension
unloaded. Adjust rear wheel toe-in. See SPECIFICATIONS & PROCEDURES article in the WHEEL
ALIGNMENT section.
STABILIZER BAR
Removal
Raise and support vehicle. Remove wheel assembly. Remove stabilizer bar-to-crossmember bolt, bracket and
bushing. See Fig. 2
. Remove stabilizer bar control link-to-lower arm nut and bolt. Remove stabilizer bar and
control link from vehicle. Separate stabilizer bar from control link.
Fig. 2: Exploded View of Rear Stabilizer Bar & Control Link

Courtesy of MAZDA MOTORS CORP.

1991 Mazda MX-5 Miata
SUSPENSION - REAR 1991 SUSPENSION Rear
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Installation
Inspect stabilizer bar and components for damage, cracks and deterioration. To install, reverse removal
procedure. Ensure bushing is aligned with White line on stabilizer. Ensure seam faces front of vehicle. Tighten
nuts and bolts to specification with vehicle resting on ground and suspension unloaded.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
ABS Speed Sensor Harness Bracket Bolts12-17 (16-23)
Caliper Assembly-To-Knuckle Bolt36-51 (49-69)
Control Link-To-Lower Arm Nut27-40 (36-54)
Lower Arm-To-Crossmember Nuts54-70 (73-95)
Lower Arm-To-Knuckle Nut46-55 (63-75)
Rear Axle Nut159-217 (216-294)
Stabilizer Bar Brackets Bolts15-21 (20-28)
Stabilizer Bar-To-Control Link Bolt27-40 (36-54)
Strut Piston Rod Lock Nut23-34 (31-46)
Strut-To-Body Nuts22-27 (29-36)
Strut-To-Lower Arm Bolt54-69 (73-93)
Upper Arm-To-Crossmember Nuts34-49 (46-67)
Upper Arm-To-Knuckle Bolt34-49 (46-67)
Wheel Lug Nuts65-87 (88-118)

1991 Mazda MX-5 Miata
SUSPENSION - REAR 1991 SUSPENSION Rear
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STARTER - DIRECT DRIVE
1990-92 ELECTRICAL Mazda Starters - Direct Drive
DESCRIPTION
Nippondenso direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is
attached to the drive housing. The overrunning clutch pinion drive is mounted directly on armature shaft drive
end.
TROUBLESHOOTING
TESTING (ON VEHICLE)
CIRCUIT TESTING
1. Turn ignition switch to START position, depress clutch and ensure starter operates. If starter does not
operate, use voltmeter to check voltage at "S" terminal when clutch is depressed and ignition is turned to
START position. See Fig. 1
.
2. If voltage is less than 8 volts, check starter interlock switch and ignition switch to starter wiring circuit for
short to ground. If voltage is greater than 8 volts and starter is inoperative, starter has an internal fault.
Repair or replace as required. NOTE: For information on B2200 and Protege models with automatic transmissions,
see STARTERS - GEAR REDUCTION article.
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL
INFORMATION section.
NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are
clean and tight and engine grounds are good.

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
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Fig. 1: Direct Drive Starter Circuit Diagrams
Courtesy of MAZDA MOTORS CORP.
STARTER INTERLOCK SWITCH (CLUTCH START SWITCH)
Switch is mounted on bracket near top front of clutch pedal. Disconnect switch harness connector. Using
ohmmeter, ensure continuity exists between switch connector terminals when clutch pedal is depressed. If

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
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continuity does not exist, adjust or replace switch.
BENCH TESTS (ASSEMBLED)
NO-LOAD TEST
Connect fully-charged 12-volt battery, voltmeter and ammeter to starter. See Fig. 2
. Using remote starter wires
or jumper, engage solenoid. Starter should spin smoothly. Note/record meter readings and check no-load
specification. See NO-LOAD TEST SPECIFICATIONS table. If not within specification, disassemble and
inspect starter components.
NO-LOAD TEST SPECIFICATIONS
ApplicationSpecification
B2200 (M/T), Miata, Protege (M/T) & 323
Voltage11.5 Volts
Current60 Amps Maximum
Shaft Speed6500 RPM

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
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Fig. 2: Testing Direct Drive Starter Circuits
Courtesy of MAZDA MOTORS CORP.
SOLENOID TESTS

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
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