Engine control MAZDA MX-5 1997 Factory Owner's Manual

2. Disconnect throttle cable. Remove fuel lines from fuel rail and pressure regulator. Remove throttle body
intake duct housing and throttle body. Remove by-pass air control valve and solenoid valves. Remove
upper intake manifold (if equipped).
3. Remove intake manifold support bracket from underneath manifold. Disconnect injector harness
connectors, and remove injectors/fuel rail assembly. Remove intake manifold and gasket.
Installation
1. Ensure all gasket surfaces are clean and flat. Using NEW gasket, install intake manifold to cylinder head.
Tighten manifold bolts/nuts evenly to specification, starting from center bolt and alternating outward. See
TORQUE SPECIFICATIONS
. Install support bracket underneath intake manifold.
2. Install gasket and upper intake manifold (if equipped). Tighten bolts/nuts evenly to specification,
alternating from top to bottom. See TORQUE SPECIFICATIONS
.
3. To complete installation, reverse removal procedure. Ensure throttle cable has .04-.12" (1-3 mm) free
play. Ensure injectors twist freely and are not cocked in insulator "O" rings. Refill engine with coolant.
EXHAUST MANIFOLD
Removal & Installation
1. Remove air cleaner intake duct from top of radiator/fan assembly (if equipped). Disconnect oxygen
sensor. Remove heat shields. Disconnect down pipe from exhaust manifold. Remove exhaust manifold.
2. To install, reverse removal procedure. Ensure all mating surfaces are clean and flat. Install NEW exhaust
manifold gasket to cylinder head. Tighten manifold bolts evenly to specification, starting from center bolt
and alternating outward. See TORQUE SPECIFICATIONS
.
CYLINDER HEAD
Removal
1. Release residual pressure from fuel system. See FUEL PRESSURE RELEASE & PRIMING . Drain
engine coolant. Note locations and disconnect all necessary electrical connectors, ground wires, vacuum
hoses, fuel hoses, coolant hoses and control cables for cylinder head removal. Plug all fuel hoses to avoid
leakage.
2. Remove spark plug wires from spark plugs. Remove all drive belts. Remove water pump pulley. Remove
timing belt. See TIMING BELT
. Remove camshaft/rocker cover.
3. Remove front exhaust pipe. Remove intake manifold support bracket. Loosen all cylinder head bolts
evenly, in 3 steps, in reverse of tightening sequence. See Fig. 7
. Remove bolts and cylinder head
assembly.
Inspection
Carefully clean carbon and gasket material from all mating surfaces. Clean threads of cylinder head bolts. Use a
tap to clean threads in engine block. Check cylinder head for warpage. Resurface or replace head if it is not
within specification. Check valve train components. Replace or resurface components if they are not within

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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OIL PUMP
Removal & Disassembly
1. Disconnect negative battery cable. Remove dipstick, tube and "O" ring. Drain engine oil and coolant.
Remove drive belts, crankshaft and water pump pulleys. Remove generator, A/C compressor and
mounting bracket. Without disconnecting A/C hoses, secure A/C compressor away from engine. Remove
timing belt and related components. See TIMING BELT
under REMOVAL & INSTALLATION.
2. Hold crankshaft sprocket in place and remove crankshaft sprocket bolt. Remove crankshaft sprocket
using steering wheel puller. Leave crankshaft Woodruff key in place.
3. Remove oil pan and oil pump pick-up tube. See OIL PAN
under REMOVAL & INSTALLATION.
Remove oil pump housing assembly. Using a screwdriver protected with a rag, drive oil seal out from
inside of oil pump housing assembly.
4. Remove pump cover screws (use a manual impact screwdriver, if necessary). See Fig. 22
. Remove pump
cover. Note location of alignment marks on inner and outer rotors. Remove inner and outer rotors. To
remove pressure relief valve, remove spring seat, pressure spring and control plunger.
Inspection
Replace pressure relief valve spring if length is not as specified. See OIL PUMP SPECIFICATIONS. Ensure
plunger slides freely in bore. Replace oil pump housing assembly if clearances are not as specified. See OIL
PUMP SPECIFICATIONS .
Reassembly & Installation
1. Apply oil to friction surfaces. Install inner and outer rotors with marks aligned. See Fig. 23 . Install
pressure relief valve components. Apply oil to lip of NEW oil seal. Press oil seal into bore until even with
face of oil pump housing assembly.
2. Install pump cover. Tighten screws to 53-78 INCH lbs. (6-9 N.m). To complete installation, reverse
removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
.
OIL PUMP SPECIFICATIONS
ApplicationW/O Filter Qts. (L)W/Filter Qts. (L)
Miata & Protege3.8 (3.6)4.0 (3.8)
ApplicationMaximum Clearance In. (mm)
Maximum Rotor Tip Clearance (1) .0079 (.20)
Maximum Rotor-To-Pump Body Clearance (2) .0079 (.20)
Maximum Rotor Side Clearance (3) .0055 (.14)
Pressure Relief Spring Free Length1.809 (45.94)
(1)See Fig. 23 .
(2)Insert feeler gauge between outer rotor and pump body.
Place straightedge across pump body and check clearance between straightedge and both rotors.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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Check for damage, excessive wear and signs of bearing seizure. Inspect steering knuckle and hub for cracks,
scoring and rust. Check for damaged dust cover and poor fit with steering knuckle. Replace components as
necessary.
Installation
To install, reverse removal procedure. Adjust wheel bearing preload. See WHEEL BEARING
ADJUSTMENT under ADJUSTMENTS. Stake axle nut.
LOWER CONTROL ARM & BALL JOINT
Removal
1. Raise and support vehicle. Remove wheel assembly. Remove engine splash shield (if equipped). Separate
tie rod end from steering knuckle (as necessary). Remove stabilizer bar from lower control arm.
2. Remove shock lower mounting bolt and separate lower shock from lower control arm. Remove lower
control arm ball joint cotter pin and nut. Separate lower control arm ball joint stud from knuckle using
Puller (49 T028 3A0). Remove lower control arm pivot bolts and remove lower control arm.
Inspection
Check lower control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check
ball joint for excessive wear. Examine dust boot for damage. Replace components as necessary.
Bushing Replacement
Cut or press old bushing from control arm. Coat NEW bushing with paraffin-based oil. Press new bushing into
control arm.
Installation (All Models)
To install, reverse removal procedure. Tighten lower control arm-to-frame bolts to specification with vehicle
resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS
.
UPPER CONTROL ARM & BALL JOINT
Removal
Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor
harness band. Remove shock lower mounting bolt, and separate lower shock from lower control arm. Remove
upper control arm ball joint cotter pin and nut. Separate upper control arm ball joint stud from knuckle using
Puller (49-0118-850C). Remove upper control arm pivot bolts and remove upper control arm.
Inspection
Check upper control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check
ball joint for excessive wear. Examine dust boot for damage. Replace components as necessary.

1997 Mazda MX-5 Miata
1997-2000 SUSPENSION Front - Miata
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Bushing Replacement
Cut or press old bushing from control arm. Coat new bushing with paraffin-based oil. Press new bushing into
control arm.
Installation (All Models)
To install, reverse removal procedure. Tighten upper control arm pivot bolts to specification with vehicle
resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS
.
SHOCK ASSEMBLY
Removal (1997)
Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor
harness band. Remove stabilizer link bolt. Remove upper control arm ball joint cotter pin and nut. Separate
upper control arm ball joint stud from knuckle using Puller (49-0118-850C). Loosen lower control arm pivot
bolts. Remove shock upper mount nuts and lower bolt. Move lower control arm just enough to remove shock
assembly. DO NOT damage brake line.
Removal (1999 & 2000)
Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor.
Remove stabilizer link bolt. Separate lower control arm ball joint stud from knuckle using Puller (49-T028-
3A0). Loosen lower control arm pivot bolts. Inside engine compartment, on 1999 models, remove strut bar. See
FRONT STRUT BAR (1999)
. On 2000 models, remove shock upper mount nuts. On all models, under car,
remove lower bolt. Move lower control arm just enough to remove shock assembly. DO NOT damage brake
line.
Disassembly
Clamp upper shock mount in vise. Loosen piston lock nut 2 turns only. Compress coil spring using coil spring
compressor. Remove piston lock nut. Slowly release compressor tension. Remove components. Remove coil
spring. Remove shock from vise.
Inspection
Check shock tube for damage, oil leakage and abnormal noise. Check rubber components for deterioration or
damage. Inspect coil spring for signs of fatigue or damage. Replace components as necessary.
Reassembly (1997)
Clamp shock in vise. Install coil spring and components in reverse order of disassembly. Ensure coil spring is
well seated in upper and lower spring seats. See Fig. 2
. Tighten piston rod nut. See TORQUE
SPECIFICATIONS .

1997 Mazda MX-5 Miata
1997-2000 SUSPENSION Front - Miata
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Installation
To install, reverse removal procedure. Fully tighten all bolts with vehicle resting on ground and suspension
unloaded. See TORQUE SPECIFICATIONS
. Check front wheel alignment. See SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
STABILIZER BAR
Removal & Installation
Raise and support vehicle. Remove engine splash shield. Remove frame brackets and bushings. Remove
stabilizer control links. Align bushing with installation mark on stabilizer. Reverse removable procedure for
installation. See TORQUE SPECIFICATIONS
.
FRONT STRUT BAR (1999)
Removal & Installation
1. To remove strut bar located in engine compartment mounted on top of shock towers, loosen lock nuts on
joint bolt and loosen joint bolt. Remove nut, washer and bolt retaining strut bar to strut plate. Remove
strut bar from vehicle.
2. To install, reverse removal procedure. Rotate joint bolt counterclockwise to 3.5-5.2 INCH lbs. (.4-.6 N.m)
to set tension. Tighten lock nuts to 87-121 INCH lbs. (10-14 N.m). Tighten strut bar-to-strut plate nut.
See TORQUE SPECIFICATIONS
.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Axle Lock Nut123-159 (167-215)
Brake Caliper Bracket Bolts37-50 (50-68)
Lower Ball Joint-To-Knuckle Nut42-57 (57-77)
Lower Ball Joint-To-Lower Control
199754-69 (73-94)
1999 & 2000
Bolt & Nut69-86 (94-117)
Bolt54-69 (73-94)
Lower Control Arm-To-Frame
1997
Front Adjusting Bolt Lock Nut69-83 (94-112)
Rear Adjusting Bolt Lock Nut62-75 (84-102)
1999 & 200069-83 (94-112)
Shock Assembly-To-Lower Control Arm Bolt/Nut
199754-68 (73-93)

1997 Mazda MX-5 Miata
1997-2000 SUSPENSION Front - Miata
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ELECTRICAL COMPONENT LOCATIONS
OPERATION
All air control doors are controlled manually by cable from control panel. Blower resistor determines blower
speed. With blower switch in high position, blower motor is grounded directly through blower switch. With
blower switch in all other positions, blower motor is grounded through blower resistor and blower switch.
A/C compressor clutch circuit is completed when A/C relay is energized and pressure switch is closed. A/C
relay is energized when Powertrain Control Module (PCM) grounds the solenoid circuit of the relay. The PCM
energizes A/C relay if evaporator thermoswitch is closed and A/C and blower switches are on. The PCM also
controls A/C relay operation according to engine load.
ADJUSTMENTS
TESTING
A/C SYSTEM PERFORMANCE
1. Connect manifold gauge set. Operate engine at 1500 RPM. Operate A/C at maximum cooling, recirculate,
fan on high, vent mode. Close all doors and windows. Place thermometer at center vent outlet.
2. Allow A/C to stabilize. Ensure high pressure is 200-227 psi (14.0-16.0 kg/cm
2 ). Read temperature at
center vent outlet. Ensure temperature is within 39-43°F (3-6°C)
A/C COMPRESSOR CLUTCH CIRCUIT
ComponentLocation
A/C RelayRight Front Corner Of Engine Compartment
Condenser FanRight Front Corner Of Engine Compartment
Blower ResistorBottom Of Blower Case
Evaporator ThermoswitchOn Evaporator Upper Case
Pressure SwitchIn High-Pressure Line, Between Receiver-Drier &
Evaporator
NOTE: For door control cable adjustments, see ADJUSTMENTS in HEATER SYSTEM

article.
WARNING:To avoid injury from accidental air bag deployment, read and follow all
SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG
SYSTEM procedures in AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT section.
NOTE: For test procedures not covered in this article, see TESTING in HEATER
SYSTEM article.

1997 Mazda MX-5 Miata
A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System
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HALOGEN BULBS
HEADLIGHT RETRACTOR
RADIATOR CAP
RADIATOR FAN
WARRANTY INFORMATION
BASIC NEW CAR WARRANTY
Basic components are warranted against defects in materials and workmanship for 36 months or 50,000 miles,
whichever occurs first. Tires are covered by a separate warranty offered by tire manufacturer.
ANTI-PERFORATION WARRANTY
Covers body sheet metal panels for 60 months, regardless of mileage, against perforation due to corrosion.
SAFETY RESTRAINT SYSTEM WARRANTY WARNING:Relieve fuel system pressure prior to servicing any fuel system
component (fuel injection models).
WARNING:Halogen bulbs contain pressurized gas which may explode if overheated.
DO NOT touch glass portion of bulb with bare hands. Eye protection
should be worn when handling or working around halogen bulbs.
CAUTION: If headlight retractor freezes during cold weather operation, DO NOT
attempt to force mechanism. Headlights should be kept raised at all times
in cold weather. To raise them, use only headlight retractor switch. DO
NOT use headlight switch.
CAUTION: Always disconnect the fan motor when working near the radiator fan. The
fan is temperature controlled and could start at any time even when the
ignition key is in the OFF position. DO NOT loosen or remove radiator cap
when cooling system is hot.
WARNING:Keep hands away from radiator fan. Fan is controlled by a thermostatic
switch which may come on or run for up to 15 minutes even after engine
is turned off.
CAUTION: Always refer to customer's copy of warranty information for specific
model application and/or coverage limitations.

1997 Mazda MX-5 Miata
MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information
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frame mounting bolts. Remove steering gear and linkage from vehicle. On MPV, remove steering gear
bracket-to-frame mounting bolts. Remove steering gear and linkage with steering bracket from vehicle.
Remove 4 steering gear-to-bracket bolts and separate gear from bracket.
4. On all models, to install, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS table. On MPV, tighten steering gear-to-bracket bolts in sequence: left front, right
front, left rear, right rear. On all models, fill and bleed power steering system. Check and adjust front
wheel alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (Millenia)
1. Disconnect negative battery cable. Support engine using Engine Support (49-G017-5A0 ). Raise and
support front of vehicle. Remove front wheel assemblies. Remove cotter pins and castle nuts from tie rod
ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. Remove transverse
member bolts and remove transverse member. See Fig. 6
Disconnect pressure and return line connections
from steering gear. Remove intermediate shaft pinch bolt.
3. Reference mark lower steering column-to-intermediate shaft. Remove engine mount member. Remove
No. 1 engine mount bolts. Remove upper lateral link bolt and separate upper lateral link from
crossmember. Remove lower control arm-to-crossmember mounting bolt and gusset. Separate lower
control arm from crossmember.
4. Remove stabilizer link-to-lower control arm nut. Separate stabilizer link from lower control arm. Using a
jack, support front suspension crossmember. Remove crossmember retaining nuts. Carefully lower
crossmember. Disconnect stabilizer link from stabilizer bar. Remove stabilizer bar brackets, bushings and
stabilizer bar. Remove steering gear mounting nuts. Remove steering gear assembly.
5. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table. Tighten steering gear mounting nuts in sequence: right front, left rear, right rear, left front. Fill and
bleed power steering system. Check and adjust front wheel alignment. See SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Fig. 6: Removing Steering Gear Assembly (Millenia)
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MX-3 & Protege)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. On MX-3 DOHC, remove
support bracket bolt, nut and rubber insulator. Remove steering gear insulator bolts and remove insulator.
On all models, remove intermediate shaft dust cover.
3. Mark steering column intermediate shaft-to-steering column gear pinion for installation reference.
Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Disconnect pressure and
return line connections from steering gear.
4. On M/T, remove mounting nuts and bolts from extension bar and control rod. Remove extension rod and
control rod. On all models, remove steering gear mounting nuts. Remove steering gear and linkage from

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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