lock MAZDA MIATA 1991 Factory Service Manual

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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to field coil housing. If continuity exists, repair or replace field coil.
OVERRUNNING CLUTCH PINION DRIVE
Hold overrunning clutch housing and turn pinion gear by hand. If pinion turns in both directions, clutch is faulty
and must be replaced. DO NOT clean overrunning clutch with solvent, as it is packed with grease and sealed by
manufacturer.
REMOVAL & INSTALLATION
1. Disconnect negative battery cable. Raise vehicle on hoist. Remove undercover. Disconnect wiring from
starter. Remove differential lock assembly (4WD models). On Protege (M/T) and 323 models, remove
support brace from under intake manifold. Remove starter mounting bolts. Remove lowest mounting bolt
last. Remove starter from under side of vehicle.
2. To install starter, reverse removal procedure. Tighten mounting bolts to 23-24 ft. lbs. (31-46 N.m).
Tighten battery terminal nut to 87-104 INCH lbs. (9.8-12 N.m).
OVERHAUL
DISASSEMBLY & ASSEMBLY
1. Mark rear cover, field coil housing and front drive housing for reassembly reference. Remove solenoid
and shims, rear cover and brush plate. Remove field coil housing and pull armature and yoke lever from
front drive housing. See Fig. 4
& Fig. 5. Use arbor press to remove circlip, stopper and pinion drive from
armature shaft. See Fig. 6
.
2. To assemble, reverse removal procedures. Lubricate solenoid plunger, yoke lever and armature bushings.
Use arbor press and pinion drive to install stopper and circlip on armature shaft. See Fig. 6
. Ensure brush
plate, rear cover and field coil housin
g are aligned when installing through bolts.

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
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STEERING COLUMN
1991 STEERING Mazda - Steering Columns
DESCRIPTION
The steering column consists of solid steering shaft with a lower joint assembly. Miata and RX7 convertible
models are equipped with Air Bag Restraint System consisting of an air bag module and clockspring connector
assembly located in the steering column.
REMOVAL & INSTALLATION
STEERING WHEEL & HORN PAD
Removal & Installation (B2200, B2600i, MPV & 929)
Unsnap horn pad cover. Remove steering wheel lock nut. Use a puller to remove steering wheel. To install,
reverse removal procedure.
Removal & Installation (Miata & RX7)
1. On Miata and RX7 convertible models, remove air bag module. See AIR BAG RESTRAINT SYSTEM
article in the ACCESSORIES/SAFETY EQUIPMENT section. For all models, remove horn cap (if
equipped).
2. Remove steering wheel nut. Remove steering wheel with steering wheel puller. To install, reverse
removal procedure. Tighten steering wheel nut and air bag nuts to specification. See TORQUE
SPECIFICATIONS TABLE at end of article. WARNING:Wait about 10 minutes after disabling air bag system before servicing. Air
bag system voltage is maintained for about 10 minutes after system is
disabled. Failure to wait 10 minutes before servicing system may cause
accidental air bag deployment and possible personal injury.
CAUTION: DO NOT strike steering shaft with a hammer as it may collapse.
WARNING:Before servicing Miata and RX7 convertible models, disconnect and
shield battery ground. Use caution when working around steering column
as air bag could deploy.
WARNING:Wait about 10 minutes after disabling air bag system before servicing. Air
bag system voltage is maintained for about 10 minutes after system is
disabled. Failure to wait 10 minutes before servicing system may cause
accidental air bag deployment and possible personal injury.

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns
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Removal & Installation (MX-6 & 626)
Pry ornament cap from horn pad with wide-blade screwdriver. Remove steering wheel nut. Use a puller to
remove steering wheel. To install, reverse removal procedure.
Removal & Installation (Protege & 323)
Remove 2 horn pad screws from behind steering wheel. Remove horn pad. Remove steering wheel nut. Use a
puller to remove steering wheel. To install, reverse removal procedure.
COMBINATION SWITCH
Removal (Miata & RX7 Convertible)
See STEERING WHEEL & HORN PAD under REMOVAL & INSTALLATION. Remove steering wheel.
Remove column covers. Remove screws and remove combination switch with clockspring connector assembly.
Installation
1. Install combination switch and clockspring assembly. Before installing steering wheel, center
clockspring. To center clockspring, set front wheels straight ahead. Turn clockspring connector clockwise
until it stops. DO NOT force it.
2. Return connector 2 3/4 turns (counterclockwise). Rotate clockspring connector further (if necessary) to
align marks on connector and outer housing. See Fig. 1
.
3. Install steering wheel. Tighten steering wheel nut to specification. See TORQUE SPECIFICATIONS
TABLE at end of article. Install air bag module. See AIR BAG article in the ACCESSORIES/SAFETY
EQUIPMENT section.

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns
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Fig. 1: Aligning Clockspring Connector Alignment Marks
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (All Others)
Remove steering wheel. See STEERING WHEEL & HORN PAD under REMOVAL & INSTALLATION.
Remove steering column covers. Disconnect combination switch connectors. Remove combination switch. To
install, reverse removal procedure.
IGNITION SWITCH & STEERING LOCK
Removal & Installation (All Models)
1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and
COMBINATION SWITCH.
2. Remove ignition switch connectors. Remove ignition switch-to-steering lock screw. Remove ignition
switch.
3. With a hammer and chisel, make a groove on steering lock assembly shear screws. Remove 2 shear
screws with screwdriver. Remove ignition switch/steering lock assembly. To install, reverse removal
procedure. Tighten NEW shear screws until head breaks off.
STEERING COLUMN
CAUTION: Excessive pressure or impact to mainshaft during service may cause
column to collapse.

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns
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Removal & Installation (B2200, B2600i, Miata, Protege, RX7,
323 & 929)
1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and
COMBINATION SWITCH
under REMOVAL & INSTALLATION. See Fig. 2 -8. Remove steering
lock assembly. See IGNITION SWITCH & STEERING LOCK
under REMOVAL &
INSTALLATION.
2. Remove lower panel and air duct (if necessary). Remove steering column-to-intermediate shaft "U" joint
bolt. Remove steering column-to-firewall nuts. Remove lower joint dust cover (if equipped). Remove
steering column upper bracket bolts. Remove steering column.
3. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
TABLE at end of article.

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns
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Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MPV, MX-6 & 626)
1. Remove steering wheel and combination switch. See STEERING WHEEL & HORN PAD and
COMBINATION SWITCH
under REMOVAL & INSTALLATION. Remove steering lock assembly.
See IGNITION SWITCH & STEERING LOCK
under REMOVAL & INSTALLATION.
2. Remove lower dash panel and A/C duct. Remove lower column cover and steering shaft-to-intermediate
shaft "U" joint bolt. On MPV with A/T, remove shift lever mechanism.
3. On all models, separate steering shaft from intermediate shaft. Remove steering column upper bracket
bolts. Remove steering column. To install, reverse removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS TABLE
at end of article.
OVERHAUL
STEERING COLUMN
Disassembly
Remove wiring and switches. Clamp column in vise. Turn steering shaft to remove. With a hammer and chisel,
make a groove in steering lock assembly shear screws. Remove shear screws. Remove steering lock.
Inspection
Check all components for damage or wear. Check steering shaft for bends, damage or sheared plastic pins.
Check bearings for excessive play. Replace parts as necessary. Measure length of steering shaft. See Fig. 9
.
Reassembly
To reassemble, reverse disassembly procedure. Grease steering shaft, bushings and bearings. Always use NEW
shear screws.
STEERING SHAFT DIMENSIONS
(1) NOTE: Steering shaft dimension for 929 is not available from manufacturer.
ApplicationLength - In. (mm)
B2200 & B2600i32.69-32.99 (830.0-835.6)
Miata22.09-23.02 (561.1-584.7)
MPV24.05-24.17 (611.0-614.0)
MX-6 & 62624.00-24.05 (609.6-611.1)
Protege & 32323.86-23.94 (606.0-608.0)
RX732.05-32.17 (814.0-817.0)
929(2)
See Fig. 9 for measuring points.

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns
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MAZDA
1.6L & 1.8L 4-Cylinder - 1986-95
MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE
For 1992 and earlier model years, the manufacturer recommends the belt be replaced every 60,000 miles. For
1993-95 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles
sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and
replace timing belt at 105,000 miles.
REMOVAL & INSTALLATION
TIMING BELT
Removal (MX-3, Protege & 323)
1. Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right
splash panels.
2. Remove drive belts and water pump pulley. See Fig. 1
, Fig. 2 or Fig. 3 . Align crankshaft pulley timing
mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft stationary, and remove
crankshaft pulley bolts and pulley. Remove crankshaft pulley hub bolt and hub.
3. Remove timing belt covers. If timing belt is to be reused, mark timing belt rotation direction. Align
timing marks on camshaft sprocket(s). See Fig. 4
(SOHC) or Fig. 5 (DOHC) . Loosen timing belt
tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully expanded. Remove
timin
g belt.

1991 Mazda MX-5 Miata
MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95

1991 Mazda MX-5 Miata
MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95
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Fig. 5: Aligning Camshaft Timing Marks (DOHC 1.8L Engines)
Courtesy of MAZDA MOTORS CORP.
Removal (MX-5 Miata - DOHC)
1. Disconnect negative battery cable. Drain cooling system. Remove radiator hose and by-pass hoses from
thermostat housing. Remove air cleaner intake duct assembly from throttle body to air cleaner filter
housing. Remove splash shield.
2. Remove drive belt(s) and water pump pulley. See Fig. 6
. Align crankshaft pulley timing mark with
cylinder No. 1 at TDC of compression stroke. Hold crankshaft pulley stationary. Remove crankshaft
pulley bolts. Remove pulley. Remove crankshaft pulley hub bolt and hub.
3. Remove cylinder head cover. Remove upper, center and lower timing belt cover. If timing belt is to be
reused, mark timing belt rotation direction. Ensure timing marks on camshaft sprockets are aligned. See
Fig. 7
. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully
expanded. Remove timin
g belt.

1991 Mazda MX-5 Miata
MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95
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Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or
roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary.
Installation (All Models)
1. Position notch on crankshaft sprocket to 12 o'clock position (aligned with mark on oil pump). Align
timing marks on camshaft sprocket(s). For SOHC, see Fig. 4
. For DOHC, see Fig. 5 or Fig. 7 . Ensure
crankshaft timing mark is at TDC. Install belt around crankshaft sprocket, then working in a
counterclockwise direction, route belt around camshaft sprocket(s).
2. Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Snug tensioner lock
bolt. Rotate crankshaft 2 complete turns in direction of normal engine rotation. Ensure timing marks
align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation
procedure.
3. On all engines, check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 8
.
Ensure timing belt deflection is within specification. See TIMING BELT DEFLECTION
table. Adjust
drive belts to proper tension.
TIMING BELT DEFLECTION
Application(1) Deflection - In. (mm)
1986-89.47-.51 (11.9-13.0)
1990-95
DOHC.35-.45 (9.0-11.5)
SOHC.43-.51 (11.0-13.0)
(1)Deflection measurement is with 22 lbs. (10 kg) of pressure applied to timing belt. See Fig. 8.

1991 Mazda MX-5 Miata
MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95
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