engine MAZDA MIATA 1997 Factory Owner's Manual

GENERATOR OUTPUT
1. Connect an ammeter (100-amp minimum) in-line between generator terminal "B" connector and terminal
"B" of wiring harness connector. See Fig. 1
. Turn headlights and all accessories on. Depress brake pedal.
Operate engine at 2500-3000 RPM.
2. Measure and record generator output. See GENERATOR MAXIMUM RATED OUTPUT
table. If
amperage is as specified, go to next step. If amperage is not as specified, repair or replace generator.
3. Turn off headlights and all accessories. Release brake pedal. Operate engine at 2500-3000 RPM and
measure amperage under no-load condition. No-load amperage should be 5 amps or greater. If amperage
is as specified, go to next step. If amperage is not as specified, repair or replace generator.
4. Operate engine at 2500-3000 RPM. Measure voltage between ground and terminals "S" and "L". If 14.1-
14.7 volts does not exist, repair or replace generator. If 14.1-14.7 volts exists, generator output is okay.
GENERATOR MAXIMUM RATED OUTPUT NOTE: Check generator wiring harness connections and drive belt tension. Battery
must be fully charged before testing. Wait at least 30 seconds after starting
engine before measuring system voltage.
CAUTION: Ensure generator terminal "B" does not contact ground.
ApplicationAmps
A/T70
M/T65

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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Submerge other end of hose in container of brake fluid.
2. Fill reservoir with DOT 3 brake fluid. Have an assistant press and release clutch pedal several times, then
hold pedal down. With pedal pressed, loosen bleeder screw to let air and fluid escape.
3. Repeat step 2) until no more air bubbles emerge from hose. Tighten bleeder screw. Fill reservoir. Operate
clutch while inspecting for leaks. Check clutch and brake operation.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal (B2300, B2500, B3000 & B4000)
1. Disconnect negative battery cable. Shift transmission into Neutral. Remove gearshift lever. Raise and
support vehicle. Mark drive shaft flanges for installation reference. Remove drive shaft. Using Clutch
Disconnect Tool (T88T-70522-A), disconnect hydraulic line at transmission. See Fig. 2
. Plug hydraulic
line to prevent contamination. Disconnect wiring at transmission.
2. Remove starter. Remove exhaust components as necessary for clearance. On 4WD models, remove skid
plate and transfer case. On all models, secure transmission jack under transmission. Remove transmission
mount-to-crossmember nuts and bolts.
3. Remove nuts securing crossmember to frame side rails, and remove crossmember. Lower transmission
enough to gain access to transmission-to-engine block bolts. Remove transmission-to-engine block bolts.
Remove transmission.
4. If clutch parts are going to be reused, mark clutch cover and flywheel for reassembly reference. Loosen
pressure plate bolts evenly in crisscross pattern until springs are not under tension. Remove clutch cover
and clutch disc.
Inspection (B2300, B2500, B3000 & B4000)
1. Inspect disc for loose rivets, worn or defective springs, excessive wear, or oil contamination. Inspect
flywheel and clutch cover for burns, scoring, or grooves.
2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond
specification. See CLUTCH RUNOUT (MAXIMUM)
table.
3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT
(MAXIMUM) table. Inspect disc hub and input shaft splines for excessive wear. Hub must slide
smoothly on input shaft splines.
4. Inspect pilot bearing for wear. Apply inward pressure while rotating pilot bearing. If bearing sticks or has
excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect
release bearing for smooth operation, wear, damage, or looseness. Replace bearing as necessary.
CLUTCH RUNOUT (MAXIMUM)
ApplicationIn. (mm)
Disc0.028 (0.7)
Flywheel0.008 (0.20)

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Installation (B2300, B2500, B3000 & B4000)
1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide
grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a
crisscross pattern to specification. See TORQUE SPECIFICATIONS
.
2. Raise transmission into position. Install and tighten transmission-to-engine block bolts. See TORQUE
SPECIFICATIONS . Install crossmember.
3. On 4WD models, install NEW transfer case gasket. Install transfer case. Tighten transfer case bolts to
specification is sequence. See Fig. 3
. See TORQUE SPECIFICATIONS .
4. On all models, to complete installation, reverse removal procedure. Bleed hydraulic clutch system. See
HYDRAULIC SYSTEM BLEEDING
under ADJUSTMENTS.
Fig. 3: Tightening Transfer Case Bolts (B2300, B2500, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.
Removal (Miata)
1. Disconnect negative battery cable. Remove gearshift knob, console, and shift lever. See Fig. 4. Raise and
support vehicle. Remove engine undercover. Disconnect exhaust pipe from manifold. Mark drive shaft
flanges for installation reference. Remove drive shaft.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 4: Exploded View Of Drive Line (Miata)
Courtesy of MAZDA MOTORS CORP.
2. Remove clutch release cylinder. Remove starter. Disconnect speedometer cable from transmission. Note
locations, and disconnect wiring harness from Power Plant Frame (PPF).
3. Remove PPF bracket from rear transmission extension housing. Remove PPF-to-differential side bolts.
Pry out spacer. Remove PPF/differential mounting spacer. See Fig. 5
.
4. Thread M14 X 1.5 bolt into sleeve. See Fig. 6
. Twist bolt side to side while pulling it downward. Thread
M6 X 1 bolt into hole in housing block to hold sleeve. Remove long bolt. Remove short bolt.
5. Remove PPF side bolts. Remove PPF. Remove transmission-to-engine block bolts. Remove transmission.
Remove clutch cover bolts evenl
y in crisscross pattern. Remove clutch cover and disc. See Fig. 7.
NOTE: Do not remove spacers attached to top of Power Plant Frame (PPF). If they
are removed, replace PPF.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 7: Exploded View Of Clutch Assembly (Typical)
Courtesy of MAZDA MOTORS CORP.
Inspection (Miata)
1. Inspect disc for loose rivets, worn springs, excessive wear, or oil contamination. Inspect flywheel and
clutch cover for burns, scoring, or grooves.
2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond
specification. See CLUTCH RUNOUT (MAXIMUM)
table. If flywheel ring gear is replaced, ensure
chamfer on flywheel teeth faces engine.
3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT
(MAXIMUM) table. Inspect disc hub and input shaft splines for excessive wear. Hub must slide
smoothly on input shaft splines.
4. Inspect pilot bearing for wear. Apply inward pressure while rotating pilot bearing. If bearing sticks or has
excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect
release bearing for smooth operation, wear, damage, or looseness. Replace bearing as necessary.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Installation (Miata)
1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide
grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a
crisscross pattern to specification. See TORQUE SPECIFICATIONS
.
2. Place a wooden block on jack, and position jack under front of oil pan. Raise front of engine to ease
transmission installation. Install transmission. Tighten transmission-to-engine block bolts to specification.
See TORQUE SPECIFICATIONS
. Place jack (from front of engine) under transmission.
3. Raise transmission until level with engine. Position Power Plant Frame (PPF) in place. Install
PPF/differential mounting spacer, and tighten bolts to 27-38 ft. lbs. (37-51 N.m). Install and tighten PPF
side mounting bolts.
4. Install sleeve into PPF housing block. Install spacer and bolts. Install reamer bolt into front hole, and
tighten bolt. See Fig. 5
.
5. Install transmission-to-PPF bracket. Install remaining PPF bolts, and tighten to specification. See
TORQUE SPECIFICATIONS
. To complete installation, reverse removal procedure.
RELEASE BEARING & FORK
Removal (B2300, B2500, B3000 & B4000)
With transmission removed, twist release bearing and carrier assembly until preload spring pushes bearing
assembly from slave cylinder. See Fig. 8
.
Installation
Lubricate bearing bore and bearing carrier with NIGI No. 2 (lithium base) grease. Push release bearing
assembl
y onto clutch slave cylinder. NOTE: Front PPF-to-differential side mounting bolt is the reamer bolt, used to
align frame.
NOTE: Use only lithium base grease on release bearing. DO NOT use petroleum base
lubricants.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 11: Exploded View Of Clutch Release Cylinder (Miata)
Courtesy of MAZDA MOTORS CORP.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE: Use exploded view of clutch release cylinder for overhaul procedure. See Fig.
11 .
ApplicationFt. Lbs. (N.m)
B2300, B2500, B3000 & B4000
Clutch Cover Bolts (1) 17-24 (23-32)
Crossmember Nuts39-53 (53-72)
Drive Shaft Bolts65-87 (88-119)
Flywheel-To-Crankshaft Nuts54-67 (73-91)
Gearshift Lever Bolt20-30 (27-40)
Starter Mounting Bolts17-20 (23-27)
Transfer Case Bolts (4WD) (2) 35-46 (47-62)
Transmission-To-Engine Block Bolts37-50 (50-68)
Miata
Clutch Cover Bolts (1) 13-19 (18-26)
Drive Shaft Nuts37-43 (50-58)
Flywheel-To-Crankshaft Bolts71-76 (96-103)
PPF-To-Differential Mounting Spacer Bolt (Short)27-38 (37-51)
PPF-To-Differential Side Mounting Bolts (Long)77-91 (104-123)
PPF-To-PPF Bracket Bolt27-40 (37-54)

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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PPF-To-Transmission Side Mounting Bolts (Long)77-91 (104-123)
Starter Mounting Bolts28-38 (38-51)
Transmission-To-Engine Block Bolts48-65 (64-89)
Transmission-To-PPF Bracket Bolts27-40 (37-54)
(1)Tighten in a crisscross pattern.
(2)Tighten in sequence. See Fig. 3 .

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CLUTCH 1997-98 CLUTCHES Mazda - RWD
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GENERAL INFORMATION
Computer Relearn Procedures
COMPUTER RELEARN PROCEDURES
Vehicles equipped with engine or transmission computers may require a relearn procedure after vehicle battery
is disconnected. Many vehicle computers memorize and store vehicle operation patterns for optimum
driveability and performance. When vehicle battery is disconnected, this memory is lost. The computer will use
default data until new data from each key start is stored. As computer memorizes vehicle operation for each
new key start, driveability is restored. Vehicle computers may memorize vehicles operation patterns for 40 of
more key starts.
Customers often complain of driveability problems during relearn stage because vehicle acts differently then
before being serviced. Depending on type and make of vehicle and how it is equipped, the following complaints
(driveability problems) may exist:
Harsh Or Poor Shift Quality
Rough Or Unstable Idle
Hesitation Or Stumble
Rich Or Lean Running
Poor Fuel Mileage
These symptoms and complaints should disappear after a number of drive cycles have been memorized. To
reduce the possibility of complaints, after any service which requires battery power to be disconnected, vehicle
should be road tested.
GENERIC COMPUTER RELEARN PROCEDURES
Some manufacturers identify a specific relearn procedure which will help establish suitable driveability during
relearn stage. These procedures are especially important if vehicle is equipped with and electronically
controlled automatic transmission or transaxle. Always complete procedure before returning vehicle to
customer. The following general procedures are to be used if driveability problems are encountered after power
loss or battery has been disconnected. These procedures may provide an aid in eliminating these problems.
Automatic Transmission
Set parking brake, start engine in "P" or "N" position. Warm-up vehicle to normal operating temperature
or until cooling fan cycles.
Allow vehicle to idle for one minute in "N" position. Select "D" and allow engine to idle for one minute.
Accelerate at normal throttle position (20-50%) until vehicle shifts into top gear.
Cruise at light to medium throttle.
Decelerate to a stop, allowing vehicle to downshift, and use brakes normally.
Process may be repeated as necessary.

1997 Mazda MX-5 Miata
GENERAL INFORMATION Computer Relearn Procedures

1997 Mazda MX-5 Miata
GENERAL INFORMATION Computer Relearn Procedures
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Manual Transmission
Place transmission in Neutral position.
Ensure emergency brake has been set and all accessories are turned off.
Start engine and bring to normal operating temperature.
Allow vehicle to idle in Neutral for one minute.
Initial relearn is complete, and process will be completed during normal driving.

1997 Mazda MX-5 Miata
GENERAL INFORMATION Computer Relearn Procedures
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