torque spec MAZDA MX-5 1997 Factory Owner's Guide

TORQUE SPECIFICATIONS (MPV)
Power Plant Frame-To-Differential
Side Mounting Bolts (Long)77-91 (104-123)
Spacer Bolt (Short)27-38 (37-52)
Power Plant Frame-To-Transmission Side Mounting Bolts (Long)77-91 (104-123)
Ring Gear Retaining Bolts51-61 (69-83)
Wheel Lug Nuts65-87 (88-118)
ApplicationFt. Lbs. (N.m)
AFW Extension Housing Mount Nut (4WD)49-72 (66-98)
Brake Pipe Union10-16 (14-22)
Differential Carrier Bearings Cap Bolts Front Differential27-38 (37-52)
Differential Carrier Bearings Cap Bolts Rear Differential54-78 (73-106)
Differential Carrier Bearings Lock Plate Bolt13-19 (18-26)
Differential Carrier-To-Housing Nuts/Bolts17-19 (23-26)
Differential-To-Chassis Mount Nuts (4WD)49-72 (66-98)
Drive Pinion Lock Nut94-210 (127-284)
Drive Shaft Companion Flange Nuts37-43 (50-58)
Filler Plug29-40 (39-54)
Lower Ball Joint-To-Control Arm Bolts (4WD)75-101 (102-137)
Lower Ball Joint-To-Control Arm Nut (4WD)94-127 (127-172)
Rear ABS Wheel Speed Sensor Bolt12-16 (16-22)
Rear Axle Shaft Assembly-To-Axle Shaft Housing Retaining Nuts40-49 (54-66)
Rear Brake Caliper Bolts37-43 (50-58)
Ring Gear Retaining Bolts51-61 (69-83)
Skid Plate Bolts (4WD)12-17 (16-23)
Tie Rod End Nut (4WD)43-58 (58-78)
Wheel Lug Nuts65-87 (88-118)

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
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differential housing block.
2. Tighten PPF/differential mounting spacer bolts to 28-38 ft. lbs. (38-52 N.m). See Fig. 4
. Install PPF to
differential. Hand-tighten long bolts. Ensure PPF-to-differential large shank reamer bolt and spacer are
properly installed.
3. When PPF is properly aligned between transmission and differential, tighten all long mounting bolts to
specification. Install rear transmission-to-PPF bracket and tighten to specification. See TORQUE
SPECIFICATIONS . To complete installation, reverse removal procedure. Before installing M/T shift
lever, add gear oil to transmission through shifter hole. Fill all fluids to correct level. Prime fuel system
before attempting to start engine. See FUEL PRESSURE RELEASE & PRIMING. Bleed cooling system.
See COOLING SYSTEM BLEEDING.
Fig. 4: Locating PPF
-To-Differential Reamer Bolt, Sleeve & Spacer
NOTE: Reamer bolt is the front long bolt attaching PPF to differential. This bolt
aligns PPF with drive train.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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Sunday, July 05, 2009 1:55:15 PMPage 6 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Removing Engine Components (Protege)
Courtesy of MAZDA MOTORS CORP.
2. Lower vehicle. Remove air cleaner assembly. Remove battery/carrier assembly. Remove throttle cable
and air intake duct across radiator (if equipped).
3. Remove all drive belts. DO NOT disconnect power steering hoses or A/C compressor hoses. Unbolt
power steering pump and A/C compressor from engine, and wire aside.
4. Note locations and disconnect all necessary electrical connectors, ground wires, vacuum hoses, fuel
hoses, coolant hoses and control cables for engine removal.
5. Plug all fuel hoses to avoid leakage. Attach engine support bar or engine hoist to secure engine. Raise
vehicle. Disconnect exhaust manifold down pipe and exhaust brackets from engine. On A/T models,
remove shift control cable.
6. On M/T models, remove shift control linkage and extension bar. Remove clutch release cylinder and fluid
line bracket from transaxle housing, leaving fluid line connected to cylinder. Secure cylinder away from
transaxle.
7. On all models, remove transmission wiring harness connectors and speedometer cable. Remove axle shaft
nuts from hubs. Disconnect stabilizer bar from lower control arms. Separate lower ball joints and steering
tie-rod ends from steering knuckles.
8. Pry axle shafts out of transaxle. Remove and discard circlip from axle shafts. For further information on
axle shafts, see appropriate article in DRIVE AXLES.
9. Remove transaxle mount nuts from crossmember and loosen crossmember bolts. See Fig. 6
. Lower
vehicle and attach engine hoist for engine removal. Remove engine front mount and transaxle top mount
from inner fender panels. Remove transaxle crossmember. Remove engine and transaxle assembly from
top of vehicle.
10. To install, reverse removal procedure. Tighten bolts and nuts to specifications. See TORQUE
SPECIFICATIONS . Fill all fluids to correct level. Prime fuel system before attempting to start engine.
See FUEL PRESSURE RELEASE & PRIMING
. Bleed cooling system. See COOLING SYSTEM
BLEEDING.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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2. Disconnect throttle cable. Remove fuel lines from fuel rail and pressure regulator. Remove throttle body
intake duct housing and throttle body. Remove by-pass air control valve and solenoid valves. Remove
upper intake manifold (if equipped).
3. Remove intake manifold support bracket from underneath manifold. Disconnect injector harness
connectors, and remove injectors/fuel rail assembly. Remove intake manifold and gasket.
Installation
1. Ensure all gasket surfaces are clean and flat. Using NEW gasket, install intake manifold to cylinder head.
Tighten manifold bolts/nuts evenly to specification, starting from center bolt and alternating outward. See
TORQUE SPECIFICATIONS
. Install support bracket underneath intake manifold.
2. Install gasket and upper intake manifold (if equipped). Tighten bolts/nuts evenly to specification,
alternating from top to bottom. See TORQUE SPECIFICATIONS
.
3. To complete installation, reverse removal procedure. Ensure throttle cable has .04-.12" (1-3 mm) free
play. Ensure injectors twist freely and are not cocked in insulator "O" rings. Refill engine with coolant.
EXHAUST MANIFOLD
Removal & Installation
1. Remove air cleaner intake duct from top of radiator/fan assembly (if equipped). Disconnect oxygen
sensor. Remove heat shields. Disconnect down pipe from exhaust manifold. Remove exhaust manifold.
2. To install, reverse removal procedure. Ensure all mating surfaces are clean and flat. Install NEW exhaust
manifold gasket to cylinder head. Tighten manifold bolts evenly to specification, starting from center bolt
and alternating outward. See TORQUE SPECIFICATIONS
.
CYLINDER HEAD
Removal
1. Release residual pressure from fuel system. See FUEL PRESSURE RELEASE & PRIMING . Drain
engine coolant. Note locations and disconnect all necessary electrical connectors, ground wires, vacuum
hoses, fuel hoses, coolant hoses and control cables for cylinder head removal. Plug all fuel hoses to avoid
leakage.
2. Remove spark plug wires from spark plugs. Remove all drive belts. Remove water pump pulley. Remove
timing belt. See TIMING BELT
. Remove camshaft/rocker cover.
3. Remove front exhaust pipe. Remove intake manifold support bracket. Loosen all cylinder head bolts
evenly, in 3 steps, in reverse of tightening sequence. See Fig. 7
. Remove bolts and cylinder head
assembly.
Inspection
Carefully clean carbon and gasket material from all mating surfaces. Clean threads of cylinder head bolts. Use a
tap to clean threads in engine block. Check cylinder head for warpage. Resurface or replace head if it is not
within specification. Check valve train components. Replace or resurface components if they are not within

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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specification. See CYLINDER HEAD and VALVES & VALVE SPRINGS tables under ENGINE
SPECIFICATIONS .
Installation
Install cylinder head gasket, cylinder head assembly and bolts. Tighten cylinder head bolts in 2 steps, and in
sequence, to specification. See Fig. 7
. See TORQUE SPECIFICATIONS . To complete installation, reverse
removal procedure.
Fig. 7: Cylinder Head Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.
CRANKSHAFT FRONT SEAL
Removal
Disconnect negative battery cable. Remove drive belts and crankshaft pulley. Remove water pump pulley,
timing belt covers and timing belt. See TIMING BELT
. Use Crankshaft Lock Tool (49-D011-102) to lock
crankshaft sprocket into position. Remove crankshaft sprocket bolt. Remove crankshaft sprocket usin
g steering

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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Sunday, July 05, 2009 1:55:15 PMPage 11 © 2005 Mitchell Repair Information Company, LLC.

wheel puller. Pry out seal.
Installation
1. Apply light oil coat to seal lip. Using a hammer and seal installer, tap seal into oil pump body until it is
flush with edge of pump body. DO NOT bottom seal in pump body. Align keyway slots, and install
crankshaft sprocket and Woodruff key with tapered side toward oil pump body. Install crankshaft
sprocket bolt.
2. Using Crankshaft Lock Tool (49-D011-102), lock crankshaft sprocket into position. Tighten lock bolt to
specification. See TORQUE SPECIFICATIONS
.
3. Install timing belt. See TIMING BELT
under REMOVAL & INSTALLATION. Install timing belt
covers, pulleys and drive belts. Reconnect negative battery cable and ensure timing is correct.
TIMING BELT
Removal (Miata)
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 between throttle body and air cleaner
filter housing.
2. Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at
TDC of compression stroke. Hold crankshaft pulley stationary. Remove crankshaft pulley bolts and
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. 8
. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully
expanded. Remove timing belt.
Removal (Protege)
1. Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right
side cover and undercover.
2. Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at
TDC of compression stroke. Hold crankshaft stationary. Remove crankshaft pulley bolts and 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. 8
. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully
expanded. Remove timin
g belt. NOTE: For 1997-98 vehicles, the manufacturer recommends the belt be replaced at
60,000 mile intervals for vehicles sold outside of California and Massachusetts.
For vehicles sold in California and Massachusetts, inspect timing belt at 60,000
and 90,000 miles, and replace timing belt at 105,000 miles.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
Microsoft
Sunday, July 05, 2009 1:55:15 PMPage 12 © 2005 Mitchell Repair Information Company, LLC.

Installation
Insert HLA in original location. To complete installation, reverse removal procedure. Tighten camshaft bearing
caps evenly in sequence to specification. See Fig. 10
or Fig. 11 . See TORQUE SPECIFICATIONS .
CAMSHAFT
Removal
Remove cylinder head cover. Remove timing belt. See TIMING BELT. Remove distributor/camshaft position
sensor. Reference mark camshafts, caps and sprockets, and remove sprockets. Loosen camshaft bearing cap
bolts evenly in 5-6 steps, in sequence. See Fig. 10
or Fig. 11 . Remove camshafts.
Inspection
Check camshaft end play. Check camshaft journal diameters and bearing clearances. Check camshaft lobes for
wear. See CAMSHAFT
under ENGINE SPECIFICATIONS. If any measurement is not within specification,
replace camshaft and/or cylinder head.
Installation
To install, reverse removal procedure. On both camshafts, apply small amount of silicone sealant to contact area
of cylinder head/camshaft seal cover cap. Tighten camshaft bearing cap bolts evenly in sequence to
specification. See Fig. 10
or Fig. 11 . See TORQUE SPECIFICATIONS. NOTE: On Miata, exhaust camshaft has a slot for camshaft position sensor drive. On
Protege, exhaust camshaft has a slot for distributor drive. On all models, match
mark camshafts and sprockets for installation reference.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
Microsoft
Sunday, July 05, 2009 1:55:15 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.

1. Drain engine coolant. Disconnect battery cable. Position No. 1 cylinder at TDC of compression stroke.
On Protege, remove right side cover and undercover.
2. On Miata, remove air cleaner intake duct from between throttle body and air cleaner/filter assembly. On
all models, remove upper radiator hose and by-pass hoses from thermostat housing.
3. Remove drive belts and water pump pulley. Remove power steering pump with hoses attached and secure
pump away from engine (if necessary). Remove timing belt, tensioner and idler. See TIMING BELT.
4. Unbolt water inlet pipe from water pump. Water pump inlet pipe has lower radiator hose and by-pass pipe
attached to it. Remove bolts from water pump. To install, reverse removal procedure. Tighten bolt to
specification. See TORQUE SPECIFICATIONS
.
OIL PAN
Removal & Installation (Miata)
1. Disconnect negative battery cable. Drain engine oil. Remove dipstick, tube and "O" ring. Raise vehicle on
hoist. Remove engine undercover. Disconnect steering column shaft at steering rack coupling. See Fig.
14 . Remove engine mount nuts. Lift and support engine using jack.
2. Support crossmember using transmission jack and remove crossmember bolts. Slowly and carefully lower
crossmember until clearance between oil pan and steering rack is about 4 inches. Remove oil pan bolts
from engine block and transmission.
3. DO NOT damage sealant contact surfaces. Remove oil pan by prying between oil pan and transmission
support. Remove oil pan baffle by prying it from engine. See Fig. 14
. DO NOT deform oil pan baffle.
Replace oil pan baffle if deformed. Clean sealant from oil pan, bolts, engine block and both sides of oil
pan baffle.
4. To install, apply oil resistant sealant to engine block and oil pan. Install oil pan baffle and oil pan within 5
minutes of applying sealant. To complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS
. Fill engine with oil to specification. See ENGINE
LUBRICATION SYSTEM under ENGINE OILING. NOTE: For further information on cooling systems, see SPECIFICATIONS & ELECTRIC
COOLING FANS article in ENGINE COOLING.
NOTE: On Miata, engine must be supported in order to remove oil pan.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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Courtesy of MAZDA MOTORS CORP.
Removal & Installation (Protege)
1. Disconnect negative battery cable. Remove engine undercovers. Drain engine oil. Remove exhaust header
downpipe and brackets from front exhaust system. Remove oil pan retaining bolts.
2. DO NOT damage sealant contact surfaces. Remove oil pan by prying between oil pan and mounting
surface. On Protege, remove stiffener by prying between stiffener and cylinder block. On all models,
clean all sealant from oil pan, bolts, engine block and both sides of stiffener (Protege).
3. On Protege, apply oil resistant sealant to engine block and stiffener. Install stiffener. On all models, apply
sealant and install oil pan within 5 minutes of applying sealant. To complete installation, reverse removal
procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS
. Fill engine with oil to
specification. See ENGINE LUBRICATION SYSTEM
under ENGINE OILING.
OVERHAUL
CYLINDER HEAD
Cylinder Head
Clean carbon and gasket material from all mating surfaces. Using a tap, clean cylinder head threads. Check
cylinder head warpage. If warpage exceeds specification, resurface head, but DO NOT exceed grinding limit.
See CYLINDER HEAD
under ENGINE SPECIFICATIONS. After resurfacing cylinder head, check cylinder
head height. Replace cylinder head if height is less than minimum specification.
Valve Springs
Ensure valve spring free length, out-of-square and compressed length are within specification. See VALVES &
VALVE SPRINGS under ENGINE SPECIFICATIONS. Replace valve spring if necessary.
Valve Stem Oil Seals
1. On Miata, use Installer Set (49-L012-0A0) to install valve seals. See Fig. 15 . Adjust installer dimension
"L" to seal depth of .720-.744" (18.3-18.9 mm). Using hand pressure ONLY, install seal until it contacts
cylinder head. Lightly oil valve seal lip.
2. On Protege, use Installer Set (49-L012-0A0) to install valve seals. See Fig. 15
. Adjust installer
dimension "L" to seal depth of .783" (19.9 mm). Using hand pressure, install seal until it contacts cylinder CAUTION: If reusing old oil pan bolts, remove old sealant from bolt threads.
Failure to remove old sealant may result in cracked block at bolt
holes.
NOTE: Intake and exhaust valve stem seals are different. Exhaust seals can be
identified by ridges molded into top of seal. Intake seals do not have identifying
ridges. Incorrect installation of valve stem seals will cause premature failure.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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3. Install main bearing caps with square mark facing front of engine. Tighten main bearing cap bolts in 2-3
step, working outward from center bearing. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Thrust Bearing - Install thrust bearing before installing crankshaft. Check
crankshaft end play with crankshaft bearings and caps installed, but without connecting rods attached to
crankshaft. DO NOT turn crankshaft until bearings are lubricated. If crankshaft end play exceeds
specification, grind crankshaft and replace thrust bearings with oversize thrust bearings, or replace
crankshaft and thrust bearings. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

under ENGINE SPECIFICATIONS.
Cylinder Block
Check cylinder bore out-of-round, taper, ridge and piston-to-cylinder bore clearance. Check head gasket surface
for warpage. If warpage is not within specification, machine or replace cylinder block as necessary. See
CYLINDER BLOCK
under ENGINE SPECIFICATIONS. Remove, clean and install oil jets for piston oil
spraying.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
NOTE: See cross-sectional view of engine oil circuit. See Fig. 21
.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
Microsoft
Sunday, July 05, 2009 1:55:15 PMPage 31 © 2005 Mitchell Repair Information Company, LLC.