oil MAZDA MIATA 1991 Factory Service Manual

Raise and support vehicle. Remove rear wheels. Remove brake rotor. Remove upper and lower return springs.
See Fig. 21
. Remove hold-down springs and pins. Remove parking brake shoes. Separate adjuster and
operating lever. Minimum lining thickness is .04" (1 mm).
Fig. 21: Exploded View of Parking Brake Assembly (929)

Courtesy of MAZDA MOTORS CORP.
Installation
Connect operating lever to parking brake cable. Set marked side (with arrow) of operating lever to front side.
Position shoes and adjuster. Ensure threaded side of adjuster faces forward on left wheel and rearward on right
wheel. To complete installation, reverse removal procedure. Adjust parking brake. See PARKING BRAKE
under ADJUSTMENTS
at beginning of article.
REAR AXLE BEARING & OIL SEAL
Removal (B2200 & B2600i)
1. Remove wheel and brake drum. Disconnect parking brake cable and brake line. Remove backing plate
bolts. Remove backing plate and rear axle assembly. Remove axle bearing lock nut using Holder (49-
NOTE: For information on models with sealed wheel bearings, see appropriate article
in the SUSPENSION Section.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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S120-645A) and Wrench (49-0603-635A).
2. Using Puller (49-S120-520A) and Adapter (49-S120-523A), remove rear axle bearings. Remove oil seal
from axle housing.
Installation
1. Install oil seal in axle housing. Install bearing inner race. Install and position oil seal flush with end of
axle casing. Apply multipurpose grease to oil seal lip. Install spacer with concave side facing backing
plate.
2. Press axle bearing onto axle shaft. Using wrench, install and tighten lock nut to 145-217 ft. lbs. (197-295
N.m). Install axle shaft assembly. Install backing plate. Reconnect brake line and parking brake cable.
Install brake drum and wheel. Bleed brake system.
MASTER CYLINDER
Removal
1. Disconnect fluid level sensor coupler (if equipped). Disconnect and plug hydraulic lines at master
cylinder to prevent entry of dirt and loss of fluid.
2. Remove nuts attaching master cylinder to firewall or power brake unit. Remove master cylinder from
vehicle. On RX7, remove proportioning valve by-pass bolt.
Installation
1. Place Adjustment Gauge (49-F043-001) onto master cylinder. Turn screw on adjuster gauge until it
contacts piston. Remove adjuster gauge. Apply 19.7 in. Hg to power brake unit.
2. Invert adjuster gauge and place it on power brake unit. Adjust push rod on power brake unit until there is
no clearance between push rod and adjuster gauge screw. Install master cylinder. Bleed hydraulic system.
POWER BRAKE UNIT
Removal & Installation
1. Remove master cylinder from power brake unit. See MASTER CYLINDER under REMOVAL &
INSTALLATION . Disconnect vacuum line at power brake unit. From inside vehicle, remove cotter pin
and clevis pin. Separate push rod from brake pedal.
2. Remove power brake unit-to-firewall nuts. Remove power brake unit. See Fig. 22
To install, reverse
removal procedure. Bleed hydraulic system. NOTE: Left wheel lock nut has left-hand threads.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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Fig. 7: Testing Alternator Stator, Rotor & Brushes
Courtesy of MAZDA MOTORS CORP.
ROTOR RESISTANCE SPECIFICATIONS
Stator
Check continuity between stator coil leads and stator core. See Fig. 7 . If there is continuity, replace stator.
Check continuity between leads of stator coil. If there is no continuity, replace stator.
Brushes
Replace brushes if worn to limit line. See Fig. 7 . Replace brush springs if corroded. For brush replacement
procedure, see OVERHAUL.
OVERHAUL
DISASSEMBLY
1. Place a 200-watt soldering iron against rear bearing for 3-4 minutes to heat rear cover to 122-140°F (50-
60°C). Carefull
y separate front case and rotor from rear cover and stator. See Fig. 8 , Fig. 10and Fig. 11.
ApplicationOhms
MPV2.7-2.9
RX72.0-4.0
All Others3.5-4.5

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
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3. Using Bearing Nut Wrench (49 0603 635A ) and Shaft Holder (49 S120 645A ), remove bearing lock nut
from axle shaft. Remove bearing and bearing retainer from axle using Puller (49 S120 520A ). Remove
outer race from hub.
END PLAY SPECIFICATIONS
(1)
Installation
1. Press new oil seal and bearing outer race into bearing retainer. Coat bearing race and outer seal with
grease. Tap inner oil seal flush with end of axle housing. Coat inner seal lip with grease.
2. Position brake backing plate onto axle shaft. Install spacer against backing plate with chamfer facing
backing plate. Using Press Attachment (49 S120 748 ) and a press, install wheel bearing onto axle shaft.
Standard press force is 4.6-6.7 tons (4200-6100 kg). If press fit force is too high or too low, replace the
bearing collar or shaft.
3. Using Bearing Nut Wrench (49 0603 635A ), install bearing lock nut to axle shaft and tighten to 145-217
ft. lbs. (196-245 N.m). Bend tab up into groove. Install one axle shaft into axle housing. Tighten backing
plate nuts to specification. Install dial indicator on backing plate and check drive axle end play.
4. To adjust end play, remove axle and insert appropriate size adjustment shim between axle hub and
housing. End play for second drive axle installed should be set to normal end play clearance of .002-
.010" (.05-.25 mm), with both axles installed.
5. Install parking brake cable, attaching pin and brake line. Install brake shoes and actuating hardware.
Bleed brake system. Install wheel and tire.
BEARING RETAINER SHIMS (B2200 & B2600i)
MPV 4WD
NOTE: On B2200 and B2600i, left axle bearing lock nut has left-hand threads.
ApplicationIn. (mm)
B2200 & B2600i
One Axle Installed.026-.037 (.65-.95)
Both Axles Installed.002-.010 (.05-.25)
(1)Check at axle flange with dial indicator.
NOTE: Ensure end play for first drive axle is within specification before inserting
second drive axle. Use shims to adjust end play if necessary.
Part NumberThickness In. (mm)
083 26 165.004 (.10)
083 26 166.006 (.15)
083 26 167.020 (.50)
083 26 168.030 (.75)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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Fig. 7: Removing Reamer Bolt Sleeve (Miata)
Courtesy of MAZDA MOTORS CORP.
OVERHAUL
DIFFERENTIAL HOUSING & DRIVE PINION
Disassembly
1. Mount carrier in repair stand. Mark side bearing caps for reassembly purposes. Remove adjuster lock
plates. See Fig. 8
.
2. Loosen side bearing and slightly back off adjusters. Remove bearing caps and adjusters. Withdraw
differential assembly from carrier. Ensure side bearing races remain with their respective bearings.
3. Remove drive pinion lock nut. Remove companion flange using a gear puller. Remove drive pinion,
spacer, rear bearing and collapsible spacer assembly from carrier. Remove oil seal and front bearing.
NOTE: Mark position of all components before disassembly.

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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4. Set pinion height gauge on top of gauge block. Set dial indicator to measure distance to a point where
side bearing sits. Measure lowest point. See Fig. 11
. Measure both sides. Add both measurements
together and divide sum by 2.
5. If measurement is not zero, replace pinion spacer. Spacers are available in a range of .1213-
.1366" (3.081-3.470 mm), in .001" (.03 mm) increments. Remove dummy pinion shaft. Press rear pinion
bearing on pinion shaft.
6. Install pinion shaft, spacer, front bearing, collapsible spacer and companion flange in differential housing.
DO NOT install pinion seal at this time. DO NOT exceed one ton force or collapsible spacer will be
damaged.
7. Temporarily tighten drive pinion nut. Turn companion flange by hand to seat bearing. Tighten drive
pinion nut to 94-130 ft. lbs. (128-177 N.m). Check pinion bearing preload, at drive pinion nut. See
PINION PRELOAD SPECIFICATIONS
. If pinion bearing preload is not as specified, replace
collapsible spacer and recheck preload.
8. Remove drive pinion nut and companion flange. Install pinion seal. Apply oil to seal lip. Install
companion flange. Using a new drive pinion nut, tighten nut to 94-130 ft. lbs. (128-177 N.m). Recheck
pinion bearing preload.
PINION PRELOAD SPECIFICATIONS
4WD &
929
Miata49 N027 001
ApplicationINCH lbs. (N.m)
B2200 & 92911.3-15.6 (1.3-1.8)
B2600i 4WD
Front11.3-15.6 (1.3-1.8)
Rear7.8-12.2 (0.9-1.4)
Miata & Protege 4WD (Rear)2.6-6.1 (0.3-0.7)
MPV 4WD
Front7.8-12.2 (0.9-1.4)
Rear11.3-15.6 (1.3-1.8)
RX7
Non-Turbo7.8-12.1 (0.9-1.4)
Turbo11.3-15.6 (1.3-1.8)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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Fig. 11: Checking Pinion Installation & Position
Courtesy of MAZDA MOTORS CORP.
Pinion Assembly (RX7)
1. Using a press, install rear pinion bearing outer race in differential housing. Install center bearing outer
race. Using original rear bearing spacer, install rear bearing on Setting Pinion (49 F027 001 ).
2. Position drive pinion in carrier and install center bearing, long collar and companion flange. Tighten
pinion nut just enough so pinion can be turned by hand.
3. Place a dial indicator on Pinion Height Gauge (49 0727 570 ). Place pinion height gauge on a flat surface
and zero dial indicator. Position Gauge Block (49 0305 555 ) on top of Setting Pinion (49 F027 001 ).
4. Set pinion height gauge on top of gauge block. Set dial indicator to measure distance to lowest point
where side bearing sits. See Fig. 11
. Measure both sides. Add both measurements together and divide
sum by 2.
5. If measurement is not zero, replace pinion spacer. Spacers are available in a range of .1213-
.1366" (3.081-3.470 mm) in .001" (.03 mm) increments. Remove setting pinion, select spacer and press
rear pinion bearing on drive pinion shaft.
6. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential
housing. DO NOT install pinion seal yet. Press center bearing onto drive pinion using Adapter (49 1243
465A ). DO NOT exceed one-ton force or collapsible spacer will be damaged. Two different collapsible
spacers are available, ensure correct one is used.
RX7 DRIVE PINION COLLAPSIBLE SPACERS
7. Lubricate ends of long collar with grease and install. Using a press, install front bearing using Adapter
(49 F027 009 ). Press fit with a 2-3 ton force. DO NOT install oil seal yet. Install companion flange and
nut. Tighten drive pinion nut to 94 ft. lbs. (128 N.m). Turn companion flange by hand to seat bearing.
8. Pinion bearing preload at drive pinion nut should be 11.3-15.6 INCH lbs. (1.3-1.8 N.m). Adjust preload
by tightening drive pinion nut. If correct preload cannot be obtained within drive pinion nut tightening
range of 94-210 ft. lbs. (128-284 N.m), replace collapsible spacer and recheck preload.
9. Remove drive pinion nut and companion flange. Install pinion seal. Apply oil to seal lip. Install
companion flange. Using a new drive pinion nut, tighten nut to specification established for correct
preload.
Carrier Assembly (All Models)
1. Position differential assembly into differential housing. Install side bearing adjusters. Position side
bearing caps. Align marks made during disassembly. Install side bearing cap bolts. DO NOT tighten yet.
2. Tighten side bearing adjusters equally until adjuster contact bearing races. Mark ring gear in 4 locations,
90 degrees apart. Position a dial indicator against ring gear to check ring gear backlash.
3. Check backlash at all 4 locations. Ti
ghten side bearing adjusters equally until backlash is .0035-
ApplicationLength In. (mm)
Non-Turbo1.923-1.935 (48.85-49.15)
Turbo2.238-2.250 (56.85-57.15)

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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CONTROL UNITS LOCATION
SENDING UNITS & SENSORS
SENDING UNITS & SENSORS LOCATION
MOTORS
MOTORS LOCATION
SOLENOIDS & SOLENOID VALVES
SOLENOIDS & SOLENOID VALVES LOCATION
ComponentLocation
ABS Control UnitBehind center of dash, near ECU.
Cruise Control UnitBehind left side of dash, above fuse block.
Engine Control Unit (ECU)Behind center of dash. See Fig. 2 .
Supplemental Safety Restraint (SRS)
ModuleBehind left side of dash. See Fig. 3 .
ComponentLocation
ABS Wheel SensorsOn each front & rear wheel hub
assembly.
Airflow MeterConnected to air filter housing. See Fig.
2 .
Atmospheric Pressure SensorBuilt-in ECU.
Brake Fluid Level SensorInside brake master cylinder.
Coolant Temperature SensorOn water outlet, at left rear of engine. See
Fig. 2
.
Cooling Fan ThermoswitchOn thermostat housing.
Crank Angle SensorOn right rear side of cylinder head. See
Fig. 2
.
Intake Air ThermosensorIn airflow sensor unit.
Oil Pressure SensorOn left side of engine near oil filter.
SRS Crash/Impact Sensors
FrontOn center, left and right front of
vehicle. See Fig. 3
.
CenterBehind center of dash. See Fig. 3 .
Throttle Position Sensor (TPS)Mounted on side of throttle body. See
Fig. 2
.
ComponentLocation
A/C-Heater Blower MotorBehind left side of dash.
Wiper MotorOn right side of firewall.

1991 Mazda MX-5 Miata
ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS
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SUSPENSION - FRONT
1990-91 SUSPENSION Front
DESCRIPTION
An independent front suspension with MacPherson struts is used on all models except Miata. Miata uses a
double wishbone design with coil over shock absorbers. See Fig. 1
. Strut assemblies mount between steering
knuckle and upper fender panels. Strut assemblies consist of inner shock absorbers and coil springs surrounding
outside of strut tube housing.
The steering knuckle is connected to lower control arm and strut. Lower control arm pivots at crossmember and
is connected by ball joint to steering knuckle. All models are equipped with a stabilizer bar which attaches to
each lower control arm and frame. See Fig. 1
- Fig. 5 . Some models may also be equipped with Auto Adjust
Suspension (AAS). For more information on this system, see ELECTRONIC SUSPENSION article in the
SUSPENSION section.
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
See WHEEL ALIGNMENT SPECIFICATIONS AND PROCEDURES article in the WHEEL ALIGNMENT
section.
WHEEL BEARING
Miata, Protege & 323
Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Remove rotor.
Install a dial indicator against wheel hub and measure axial movement. Axial movement should be .002" (.05
mm) maximum. If specification is exceeded, check and adjust lock nut torque or replace bearing on Protege and
323 or hub and bearing assembly on Miata.
MPV & 929
Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Install a dial
indicator against wheel hub and measure axial movement. Maximum axial movement should be .002" (.05
mm). If specification is exceeded, check and adjust lock nut torque or replace bearing on MPV 4WD and 929 or
hub and bearing assembly on MPV 2WD.
RX7
1. Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Install a dial
indicator against hub and measure axial movement. Axial movement should be zero. If specification is
exceeded, adjust preload or replace wheel bearing.
2. To ad
just preload, remove grease cap, cotter pin and set cover. Loosen lock nut. Tighten to 14-22 ft. lbs.

1991 Mazda MX-5 Miata
SUSPENSION - FRONT 1990-91 SUSPENSION Front

1991 Mazda MX-5 Miata
SUSPENSION - FRONT 1990-91 SUSPENSION Front
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1. Raise and support vehicle. Remove wheel assembly. Remove axle lock nut. Remove cotter pin, and
disconnect tie rod from steering knuckle. Remove and wire aside brake caliper.
2. Separate lower control arm from ball joint. Remove bolt attaching ball joint to steering knuckle. Remove
bolts retaining steering knuckle to strut assembly. Separate hub and knuckle from drive shaft. Remove
wheel hub and rotor from knuckle. Remove bearings and oil seals.
Removal (MX-6 & 626)
1. Raise and support vehicle. Remove wheel assembly. Disconnect tie rod end from steering knuckle.
Disconnect stabilizer bar from lower control arm. Remove axle lock nut.
2. Disconnect brake line from strut assembly. Remove and wire aside brake caliper. Remove wheel speed
sensor. Remove bolt attaching ball joint to steering knuckle. Remove bolts attaching steering knuckle to
strut assembly. Remove steering knuckle.
3. Remove wheel hub from knuckle using Puller Set (49-G033-1A1). Remove snap ring. Remove wheel
bearing from steering knuckle using Remover (49-G033-106).
Removal (Protege, 323 & 929)
1. Raise and support vehicle. Remove wheel assembly. Remove axle lock nut. Remove cotter pin, and
disconnect tie rod from steering knuckle. Remove and wire aside brake caliper. Separate lower control
arm from ball joint. Remove bolts retaining steering knuckle to strut assembly.
2. On Protege and 323, separate hub and knuckle from drive shaft. Remove wheel hub and rotor from
knuckle. Place alignment marks on rotor and wheel hub. Separate and remove dust cover. Remove
bearings, oil seals, bearing outer races and spacer.
3. On 929, remove hub and rotor. Remove grease seal, sensor ring and circlip. Press bearing from hub
assembly. DO NOT reuse old bearing once pressed from hub.
Removal (RX7)
Raise and support vehicle. Remove wheel assembly. Remove and wire aside brake caliper. Remove grease cap,
cotter pin, nut lock and spindle nut. Remove washer and outer wheel bearing. Remove hub and rotor assembly.
Remove wheel speed sensor ring. Remove inner oil seal and wheel bearing.
Inspection (All Models)
Wash all disassembled parts before inspection. 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.
Installation (All Models)
To install, reverse removal procedure. Adjust wheel bearing preload. See WHEEL BEARING under
ADJUSTMENTS & INSPECTION
. NOTE: If bearings need to be replaced on RX7, also replace hub.

1991 Mazda MX-5 Miata
SUSPENSION - FRONT 1990-91 SUSPENSION Front
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