MAZDA MX-5 1997 Factory Repair Manual

INTERIOR FUSE PANEL IDENTIFICATION
Fig. 5: Interior Fuse Panel Identification

Courtesy of MAZDA MOTOR OF AMERICA, INC.
Fuse & Circuit Breaker Identification
1 - 10 Amp (Red) Interior Light, Warning Buzzers, Radio/Cassette and Compact Disc Player and Clock
2 - Empty
3 - Empty
4 - 15 Amp (Blue) Tail Lights
5 - 15 Amp (Blue) Shift Lock, Cruise Control, Horn, Brakelights
6 - 15 Amp (Blue) Hazard Warning Lights
7 - Empty
8 - Empty
9 - 15 Amp (Blue) Radio/Cassette and Compact Disc Player and Clock, Cigarette Lighter
10 - Empty
11 - 20 Amp (Yellow) Wipers, Washer

1997 Mazda MX-5 Miata
MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information
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12 - 30 Amp (Green) Power Windows
13 - Empty
14 - Empty 15 - 15 Amp (Blue) Gauges, Warning Lights, Turn-Signal Lights, Cruise Control
16 - 15 Amp (Blue) Cooling Fan
17 - 30 Amp (Pink) Heater
18 - Empty
19 - Empty
20 - 10 Amp Defog (Some Models)
21 - 10 Amp Antenna (Some Models)
22 - Empty

1997 Mazda MX-5 Miata
MAINTENANCE INFORMATION 1997 MAINTENANCE Mazda Maintenance Information
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1997-98 MANUAL TRANSMISSION SERVICING
Mazda
APPLICATION
TRANSMISSION APPLICATIONS
LUBRICATION
SERVICE INTERVALS
Fluid Inspection & Replacement
Check fluid level(s) at least once a year. Change transmission/transaxle and transfer case fluids every 60,000
miles for normal driving conditions and every 30,000 miles for severe driving conditions.
CHECKING FLUID LEVEL
Transaxle Fluid
Remove fill plug from transaxle. Fluid should be up to bottom of fill hole on side of case.
Transmission Fluid (RWD Models)
Remove fill plug from transmission. Fluid should be up to bottom of fill hole on side of case.
Transfer Case Fluid (4WD)
Remove fill plug from transfer case. Fluid should be up to bottom of fill hole on side of transfer case.
RECOMMENDED FLUID
FLUID SPECIFICATIONS
Vehicle ApplicationTransmission/Transaxle Model
B2300, B2500, B3000 & B4000M50D-R1
MiataM15M-D
MX-6 & 626G25M-R
ProtegeF25M-R
NOTE: Mazda B2300, B2500, B3000 and B4000 are referred to as B-Series throughout
this article.
ApplicationRecommended Fluid
Transmission

1997 Mazda MX-5 Miata
1997-98 MANUAL TRANSMISSION SERVICING Mazda

1997 Mazda MX-5 Miata
1997-98 MANUAL TRANSMISSION SERVICING Mazda
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FLUID CAPACITIES
TRANSMISSION/TRANSAXLE REFILL CAPACITIES
TRANSFER CASE REFILL CAPACITY
ADJUSTMENTS
GEARSHIFT LINKAGE
No external linkage adjustment is required.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
B-SeriesMERCON Or M-III
ATF
All Other Models
All-Season Usage(1) SAE 75W-90
Temp. Greater Than 50°F (10°C)(1) SAE 80W-90
Transfer Case
B-SeriesDexron-II Or MERCON
ATF
(1)API GL-4 or GL-5.
ApplicationQts. (L)
B-Series2.8 (2.6)
Miata2.1 (2.0)
MX-6 & 6262.9 (2.7)
Protege2.9 (2.7)
ApplicationQts. (L)
B-Series1.3 (1.2)
ApplicationFt. Lbs. (N.m)
Drain Plug (1)
B-Series30-43 (40-58)
Miata, MX-6, Protege & 62630-43 (40-58)
Fill Plug
B-Series30-43 (40-58)
Miata18-29 (24-39)
MX-6, Protege & 62630-43 (40-58)
Transfer Case Plug (B-Series)14-22 (19-30)

1997 Mazda MX-5 Miata
1997-98 MANUAL TRANSMISSION SERVICING Mazda
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INCH Lbs. (N.m)
Speedometer Gear Bolt (FWD)69-95 (8-11)
(1)Install NEW washer.

1997 Mazda MX-5 Miata
1997-98 MANUAL TRANSMISSION SERVICING Mazda
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STEERING SYSTEM - POWER RACK & PINION
1997 STEERING Mazda Power Rack & Pinion
DESCRIPTION
Steering system is a power-assisted rack and pinion. The system consists of a rack and pinion steering gear and
power-assist pump/reservoir. The steering gear and pump/reservoir are connected by flexible lines.
TESTING
HYDRAULIC SYSTEM PRESSURE TEST
Pump Fluid Pressure Test
1. Disconnect pressure line from steering gear and steering pump. Connect pressure gauge/valve between
steering pump and steering gear. See Fig. 1
. Bleed air from system.
2. Completely open valve. Start engine and operate at idle. Turn steering wheel from lock to lock to increase
fluid temperature to 122-140°F (50-60°C). To measure pump fluid pressure, close gauge valve
completely.
3. Increase engine speed to 1000-1500 RPM. Measure oil pump fluid pressure. Ensure pump pressure is
within specification. See HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS
table. If
pressure is not within specification, replace pump.
CAUTION: DO NOT leave gauge valve closed for more than 15 seconds, or pump may
be damaged.

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

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Fig. 1: Connecting Pressure Gauge/Valve (Typical)
Courtesy of MAZDA MOTORS CORP.
Gear Fluid Pressure Test
1. Ensure steering pump pressure is within specification. See PUMP FLUID PRESSURE TEST . To
measure steering gear fluid pressure, open gauge valve completely. Increase engine speed to 1000-1500
RPM.
2. Turn steering wheel from lock to lock. Measure steering gear fluid pressure. Ensure gear pressure is
within specification. See HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS
table. If
pressure is not within specification, replace gear.
HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS
(1)
Applicationpsi (kg/cm2 )
Miata & MPV1102-1209 (77-85)
MX-31138-1152 (80-81)
Millenia, MX-6 & 6261209-1280 (85-90)
Protege1244-1350 (87-95)
RX71110-1209 (78-85)
9291066-1137 (75-80)
(1)Specifications are measured at 1000-1500 RPM, with fluid temperature at 122-140°F (50-60°C).

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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LUBRICATION
FLUID CAPACITY
POWER STEERING FLUID CAPACITY
FLUID TYPE
Dexron-II or Mazda M-III fluid is recommended for all models.
FLUID LEVEL CHECK
Check fluid level on oil pump dipstick (if equipped) or reservoir. Fluid should be between marks on level gauge
dipstick (if equipped) or reservoir. If fluid level is low, fill as necessary. Recheck fluid level. DO NOT overfill.
HYDRAULIC SYSTEM BLEEDING
1. Raise and support front of vehicle. With ignition off, turn steering wheel from lock to lock several times.
Check fluid level. Add fluid as necessary. Repeat procedure until fluid level no longer decreases.
2. Start engine and operate at idle. Turn steering wheel from lock to lock 5 times. Check fluid level. Add
fluid as necessary. Continue procedure until fluid is clear of air bubbles and does not decrease in level.
ADJUSTMENTS
PINION PRELOAD
Miata & Protege
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover to 43 INCH lbs. (4.9 N.m), then loosen adjusting cover. See Fig. 2
. Repeat loosening and
ti
ghtening procedure 3 times. After tightening adjusting cover the third time, loosen adjusting cover 25
ApplicationQts. (L)
Miata & Protege.85 (.80)
MPV.95 (.90)
MX-3
4-Cylinder.85 (.80)
V61.27 (1.20)
Millenia, MX-6 & 6261.32 (1.25)
RX71.01 (.96)
9291.80 (1.70)
NOTE: Pinion preload should be checked when steering gear assembly has been
disassembled or overhauled. Check preload after steering gear assembly has
been reassembled, but tie rods have not yet been installed.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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degrees.
2. Center steering rack. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure
pinion preload using spring scale. Pinion preload should be 2.2-2.6 lbs. (1.0-1.2 kg).
3. If preload is not as specified, repeat steps 1) and 2). If preload is as specified, apply thread sealant to
adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 29-36 ft. lbs.
(39-49 N.m) on Protege or 44-54 ft. lbs. (60-73 N.m) on Miata.
Fig. 2: Tightening Adjusting Cover (Miata Shown; Others Are Similar)

Courtesy of FORD MOTOR CO.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Fig. 3: Checking Pinion Preload (Miata Shown; Others Are Similar)
Courtesy of FORD MOTOR CO.
Millenia
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover 14-22 ft. lbs. (19-30 N.m), then loosen cover. Again, tighten adjusting cover to 15 ft. lbs.
(20 N.m), then loosen adjusting cover 25-35 degrees.
2. Apply thread sealant to exposed adjusting cover threads. Install and tighten adjusting cover lock nut 37-
50 ft. lbs. (50-68 N.m). Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure
pinion preload using spring scale. Pinion preload shoul d be 1.8-3.3 lbs. (.8-1.5 kg). If preload is not as
specified, repeat steps 1) and 2).
MPV
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover to 15 ft. lbs. (20 N.m), then loosen cover. Again, tighten adjusting cover to 15 ft. lbs. (20
N.m) then loosen cover.
2. Tighten adjusting cover 44-56 INCH lbs. (5.0-6.3 N.m), then loosen adjusting cover 35-45 degrees.
Apply thread sealant to exposed adjusting cover threads. Install and tighten adjusting cover lock nut 37-
43 ft. lbs. (50-58 N.m).

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