MAZDA MX-5 1997 Factory Repair Manual

TENSION SPECIFICATIONS (MX-5 MIATA)
TENSION SPECIFICATIONS (PROTEGE)
TROUBLE SHOOTING
Application(1) Specification - Lbs. (kg)
New Belt (2)
Alternator110-167 (50-76)
A/C Compressor110-132 (50-60)
Power Steering Pump110-132 (50-60)
Used Belt
Alternator110-158 (50-72)
A/C Compressor95-110 (43-50)
Power Steering Pump95-110 (43-50)
Wear Limit
Alternator77 (35)
A/C Compressor55 (25)
Power Steering Pump55 (25)
(1)Measure tension using Tension Gauge (49 9200 020), or equivalent.
(2)Used on for less than 5 minutes.
Application(1) Specification - Lbs. (kg)
New Belt (2)
Alternator110-160 (50-76)
Power Steering Pump110-130 (50-60)
Used Belt
Alternator110-150 (50-72)
Power Steering Pump95-110 (43-50)
Wear Limit
Alternator77 (35)
Power Steering Pump55 (25)
(1)Measure tension using Tension Gauge (49 9200 020), or equivalent.
(2)Used on for less than 5 minutes.
NOTE: Ensure drive belts are not worn, cracked or frayed and are correctly mounted
on pulleys. See Fig. 29
.

1997 Mazda MX-5 Miata
1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5
Miata & Protege

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Sunday, July 05, 2009 1:57:33 PMPage 33 © 2005 Mitchell Repair Information Company, LLC.

Fig. 29: Identifying Correct Belt Mounting
Courtesy of MAZDA MOTORS CORP.
B2500, B3000 & B4000
To check drive belt for proper operation, with engine running, check drive belt tracking (position of drive belt
on one of the grooveless pulleys, idlers or drive belt tensioner). If edge of drive belt rides beyond edge of
pulley, noise and premature wear may result. If a drive belt tracking condition exists, visually check drive belt
tensioner for damage, especially mounting pad surface. If drive belt tensioner is not installed correctly with
locating pins in locating holes, mounting surface pad will be out of position. This will result in abnormal drive
belt tension and chirp and squeal noises.
If above procedures do not correct drive belt noise, try replacing drive belt with a known good drive belt.
However, drive belt noise may return, with mileage, if one of above conditions still exists uncorrected.
CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and
may cause drive belt to come off drive pulleys.
NOTE: Replace belts if tensioner indicates belt is out of adjustment range. DO NOT
apply belt dressing to serpentine belt. Use illustration to help align serpentine
belt and to check belt routing and tension. See Fig. 15
through Fig. 17 .

1997 Mazda MX-5 Miata
1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5
Miata & Protege

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With engine running, visually observe grooves in pulleys (not pulley flanges) for excessive wobble. Replace
components as required. Check all accessories, mounting brackets and drive belt tensioner, for any interference
that would prevent component from mounting properly. Correct any interference conditions and recheck belt
tracking. Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification.
Replace drive belt is excessive cracking or wear, severe glazing or frayed cords are present. Minor cracks in
back of drive belt are considered acceptable.
SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS (1997 2300)
COOLING SYSTEM SPECIFICATIONS (1998 B2500, B3000 & B4000)
ModelSpecification
B2300
Coolant Replacement
Interval(1) 50,000 Miles Or 48
Months
Coolant Capacity
With A/C7.2 Qts. (6.8L)
Without A/C6.5 Qts. (6.2L)
Pressure Cap12 psi
Thermostat Open Temperature
Starts192°F (89°C)
Fully Open212°F (100°C)
Thermostat Open Lift.13" (3.2 mm)
(1)Every 30,000 miles, and every 36 months thereafter.
ModelSpecification
B2500
Coolant Replacement
Interval(1) 50,000 Miles Or 48
Months
Coolant Capacity
With A/C7.2 Qts. (6.8L)
Without A/C6.5 Qts. (6.2L)
Pressure Cap14.4-17.6 psi
Thermostat Open Temperature
Starts183-190°F (84-88°C)
Fully Open212°F (100°C)
Thermostat Open Lift.13" (3.2 mm)

1997 Mazda MX-5 Miata
1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5
Miata & Protege

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Sunday, July 05, 2009 1:57:33 PMPage 35 © 2005 Mitchell Repair Information Company, LLC.

COOLING SYSTEM SPECIFICATIONS (1994-97 MIATA)
B3000
Coolant Replacement
Interval(1) 50,000 Miles Or 48
Months
Coolant Capacity
With A/C10.2 Qts. (9.6L)
Without A/C9.5 Qts. (9.0L)
Pressure Cap14.4-17.6 psi
Thermostat Open Temperature
Starts183-190°F (84-88°C)
Fully Open212°F (100°C)
Thermostat Open Lift.13" (3.2 mm)
B4000
Coolant Replacement
Interval(1) 50,000 Miles Or 48
Months
Coolant Capacity
With A/C8.6 Qts. (8.1L)
Without A/C7.8 Qts. (7.4L)
Pressure Cap
199712 psi
199814.4-17.6 psi
Thermostat Open Temperature (1997)
Starts192°F (89°C)
Fully Open212°F (100°C)
Thermostat Open Lift (1997).13" (3.2 mm)
Thermostat Open Temperature (1998)
Starts183-190°F (84-88°C)
Fully Open212°F (100°C)
Thermostat Open Lift (1998).13" (3.2 mm)
(1)Every 30,000 miles, and every 36 months thereafter.
ModelSpecification
Miata
Coolant Replacement
1994-95
Interval24,000 Miles Or 30 Months
1996-97
Interval(1) 45,000 Miles Or 36

1997 Mazda MX-5 Miata
1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5
Miata & Protege

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Sunday, July 05, 2009 1:57:33 PMPage 36 © 2005 Mitchell Repair Information Company, LLC.

COOLING SYSTEM SPECIFICATIONS (1997-98 MILLENIA)
COOLING SYSTEM SPECIFICATIONS (1997-98 MPV)
Months
Coolant Capacity6.3 Qts. (6.0L)
Pressure Cap10.7-14.9 psi
Thermostat Open Temperature
Starts
Main Valve188-193°F (86.5-89.5°C)
Sub Valve183-188°F (83.5-86.5°C)
Fully Open212°F (100°C)
Thermostat Open Lift
Main Valve.31" (8 mm)
Sub Valve.06" (1.5 mm)
(1)Every 30,000 miles, and every 24 months thereafter.
ModelSpecification
Millenia
Coolant Replacement
Interval(1) 45,000 Miles Or 36
Months
Coolant Capacity7.9 Qts. (7.5L)
Pressure Cap13.5-17.7 psi
Thermostat Open Temperature
Starts176-183°F (80-84°C)
Fully Open203°F (95°C)
Thermostat Open Lift.33" (8.5 mm)
(1)Every 30,000 miles, and every 24 months thereafter.
ModelSpecification
MPV
Coolant Replacement
Interval(1) 45,000 Miles Or 36
Months
Coolant Capacity10.3 Qts. (9.7L)
Pressure Cap10.7-14.9 psi
Thermostat Open Temperature (1997)
Starts179-184°F (81.5-84.5°C)
Fully Open205°F (96°C)
Thermostat Open Lift (1997).35" (9.0 mm)
Thermostat Open Temperature (1998)

1997 Mazda MX-5 Miata
1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5
Miata & Protege

Microsoft
Sunday, July 05, 2009 1:57:33 PMPage 37 © 2005 Mitchell Repair Information Company, LLC.

COOLING SYSTEM SPECIFICATIONS (1995-98 PROTEGE)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (MILLENIA, 2.5L)
TORQUE SPECIFICATIONS (MPV)
Starts176-183°F (80-84°C)
Fully Open203°F (95°C)
Thermostat Open Lift (1998).33" (8.5 mm)
(1)Every 30,000 miles, and every 24 months thereafter.
ModelSpecification
Protege
Coolant Replacement
1995
Interval24,000 Miles Or 30 Months
1996-98
Interval(1) 45,000 Miles Or 36
Months
Coolant Capacity6.3 Qts. (6.0L)
Pressure Cap10.7-14.9 psi
Thermostat Open Temperature (1995)
Starts
Main Valve188-193°F (86.5-89.5°C)
Sub Valve183-188°F (83.5-86.5°C)
Fully Open212°F (100°C)
Thermostat Open Lift (1995)
Main Valve.31" (8 mm)
Sub Valve.06" (1.5 mm)
Thermostat Open Temperature (1996-98)
Starts183-193°F (83.5-89.5°C)
Fully Open212°F (100°C)
Thermostat Open Lift (1996-98).33" (8.5 mm)
(1)Every 30,000 miles, and every 24 months thereafter.
ApplicationFt. Lbs. (N.m)
Alternator Locknut24-33 (32-46)
Power Steering Pump Locknut24-33 (32-46)
ApplicationFt. Lbs. (N.m)
Alternator Adjusting Bolt

1997 Mazda MX-5 Miata
1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5
Miata & Protege

Microsoft
Sunday, July 05, 2009 1:57:33 PMPage 38 © 2005 Mitchell Repair Information Company, LLC.

TORQUE SPECIFICATIONS (MX-3 MIATA)
TORQUE SPECIFICATIONS (PROTEGE)
"A"14-18 (19-25)
"B"28-38 (38-51)
A/C Compressor Locknut28-38 (38-51)
Power Steering Pump Locknut28-38 (38-51)
ApplicationFt. Lbs. (N.m)
Alternator Adjusting Bolt
"A"14-18 (19-25)
"B"28-38 (38-51)
A/C Compressor Locknut28-38 (38-51)
Power Steering Pump Bolt
"A"24-33 (32-46)
"B"27-39 (37-53)
"C"14-18 (19-25)
ApplicationFt. Lbs. (N.m)
Alternator Adjusting Bolt
"A"28-38 (38-51)
"B"14-18 (19-25)
Power Steering Pump Bolt
"A"32-44 (44-60)
"B"28-38 (38-51)
"C"28-38 (38-51)

1997 Mazda MX-5 Miata
1994-98 ENGINE COOLING Specifications & Drive Belt Routing - B2300, B2500, B3000, B4000, Millenia, MPV, MX-5
Miata & Protege

Microsoft
Sunday, July 05, 2009 1:57:33 PMPage 39 © 2005 Mitchell Repair Information Company, LLC.

1997-2000 SUSPENSION
Front - Miata
DESCRIPTION
Front suspension is an independent, double wishbone design using upper and lower control arms. A spring over
shock is mounted between lower control arm and upper fender panel. Upper and lower control arms pivot at
crossmember and are connected by ball joints to steering knuckle. A stabilizer bar attaches to each lower control
arm and frame. See Fig. 1
. Upper coil over shock mount plate has been redesigned for 1999-2000. New design
incorporates a urethane bumper and improves ride and cornering.
Fig. 1: Identifying Front Suspension Components

Courtesy of MAZDA MOTORS CORP.
ADJUSTMENTS
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
WHEEL BEARING ADJUSTMENT
Raise and support vehicle. Remove wheel assembly. Remove brake caliper and ABS wheel speed sensor.
Remove rotor. Attach dial indicator to axle hub, and measure bearing play. Check bearing axial play by rocking
hub assembly by hand. Maximum axial play should be .002" (.05 mm). If play exceeds specification, check and
adjust lock nut torque or replace hub and bearing assembly. See TORQUE SPECIFICATIONS
. NOTE: Mazda did not produce 1998 Miata models.
NOTE: See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

1997 Mazda MX-5 Miata
1997-2000 SUSPENSION Front - Miata

1997 Mazda MX-5 Miata
1997-2000 SUSPENSION Front - Miata
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INSPECTION
BALL JOINT CHECKING
Lower Ball Joint
Remove lower control arm. See LOWER CONTROL ARM & BALL JOINT under REMOVAL &
INSTALLATION. Rotate ball joint stud 4-5 times. Install Preload Attachment (49-0180-510B) to ball joint
stud. Measure ball joint preload using spring scale. See LOWER BALL JOINT PRELOAD
SPECIFICATIONS table. If preload is not as specified, replace lower ball joint.
LOWER BALL JOINT PRELOAD SPECIFICATIONS
Upper Ball Joint
Remove upper control arm. See UPPER CONTROL ARM & BALL JOINT under REMOVAL &
INSTALLATION. Rotate ball joint stud 4-5 times. Install Preload Attachment (49-0180-510B) to ball joint
stud. Measure ball joint preload using spring scale. See UPPER BALL JOINT PRELOAD
SPECIFICATIONS table. If preload is not as specified, replace upper control arm.
UPPER BALL JOINT PRELOAD SPECIFICATIONS
REMOVAL & INSTALLATION
WHEEL BEARING
Removal
Raise and support vehicle. Remove wheel assembly. Remove brake caliper and ABS wheel speed sensor, and
wire aside. Remove grease cap and axle lock nut. Remove brake rotor. Remove hub and bearing assembly.
Remove wheel speed sensor rotor from hub.
Inspection
ApplicationLbs. (kg)
19971.1-3.3 (0.5-1.5)
1999 & 20000.78-4.29 (0.35-1.95)
ApplicationLbs. (kg)
19970.9-3.9 (0.4-1.8)
1999 & 20000.7-5.0 (0.3-2.3)
NOTE: Refer to illustration during removal and installation. See Fig. 1
.
NOTE: Wheel bearing is not serviceable. If bearing is defective, replace hub and
bearing assembly as a unit.

1997 Mazda MX-5 Miata
1997-2000 SUSPENSION Front - Miata
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Sunday, July 05, 2009 1:38:08 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
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