check engine MAZDA MX-5 1997 Factory Service Manual

Fig. 26: Identifying Drive Belt Routing & Deflection Check Point (MX-5 Miata, 3 Of 3)
Courtesy of MAZDA MOTORS CORP.

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 1:57:32 PMPage 27 © 2005 Mitchell Repair Information Company, LLC.

Fig. 27: Identifying Drive Belt Routing & Deflection Check Point (Protege, 1 Of 2)
Courtesy of MAZDA MOTORS CORP.

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 1:57:32 PMPage 28 © 2005 Mitchell Repair Information Company, LLC.

Fig. 28: Identifying Drive Belt Routing & Deflection Check Point (Protege, 2 Of 2)
Courtesy of MAZDA MOTORS CORP.
ADJUSTMENT SPECIFICATIONS
DEFLECTION SPECIFICATIONS (MILLENIA, 2.5L)
NOTE: Check belt deflection when engine is cold, or has bin off for 30 minutes.
Application(1) Specification - In. (mm)
New Belt (2)
Alternator0.22-0.25 (5.5-6.5)
Power Steering Pump0.24-0.27 (6-7)
Used Belt
Alternator0.25-0.29 (6.5-7.5)
Power Steering Pump0.27-0.31 (7-8)
Wear Limit
Alternator0.31 (8)
Power Steering Pump0.35 (9)
(1)Deflection with 22 lbs. (10 kg) pressure applied midway on belt run.

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 1:57:32 PMPage 29 © 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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Sunday, July 05, 2009 1:57:33 PMPage 34 © 2005 Mitchell Repair Information Company, LLC.

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.

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
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Sunday, July 05, 2009 1:38:08 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

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 upper control arm pivot bolts to specification with vehicle
resting on ground and suspension unloaded. See TORQUE SPECIFICATIONS
.
SHOCK ASSEMBLY
Removal (1997)
Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor
harness band. Remove stabilizer link bolt. Remove upper control arm ball joint cotter pin and nut. Separate
upper control arm ball joint stud from knuckle using Puller (49-0118-850C). Loosen lower control arm pivot
bolts. Remove shock upper mount nuts and lower bolt. Move lower control arm just enough to remove shock
assembly. DO NOT damage brake line.
Removal (1999 & 2000)
Raise and support vehicle. Remove wheel assembly. Remove engine splash shield. Remove wheel speed sensor.
Remove stabilizer link bolt. Separate lower control arm ball joint stud from knuckle using Puller (49-T028-
3A0). Loosen lower control arm pivot bolts. Inside engine compartment, on 1999 models, remove strut bar. See
FRONT STRUT BAR (1999)
. On 2000 models, remove shock upper mount nuts. On all models, under car,
remove lower bolt. Move lower control arm just enough to remove shock assembly. DO NOT damage brake
line.
Disassembly
Clamp upper shock mount in vise. Loosen piston lock nut 2 turns only. Compress coil spring using coil spring
compressor. Remove piston lock nut. Slowly release compressor tension. Remove components. Remove coil
spring. Remove shock from vise.
Inspection
Check shock tube for damage, oil leakage and abnormal noise. Check rubber components for deterioration or
damage. Inspect coil spring for signs of fatigue or damage. Replace components as necessary.
Reassembly (1997)
Clamp shock in vise. Install coil spring and components in reverse order of disassembly. Ensure coil spring is
well seated in upper and lower spring seats. See Fig. 2
. Tighten piston rod nut. See TORQUE
SPECIFICATIONS .

1997 Mazda MX-5 Miata
1997-2000 SUSPENSION Front - Miata
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Sunday, July 05, 2009 1:38:08 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Installation
To install, reverse removal procedure. Fully tighten all bolts with vehicle resting on ground and suspension
unloaded. See TORQUE SPECIFICATIONS
. Check front wheel alignment. See SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
STABILIZER BAR
Removal & Installation
Raise and support vehicle. Remove engine splash shield. Remove frame brackets and bushings. Remove
stabilizer control links. Align bushing with installation mark on stabilizer. Reverse removable procedure for
installation. See TORQUE SPECIFICATIONS
.
FRONT STRUT BAR (1999)
Removal & Installation
1. To remove strut bar located in engine compartment mounted on top of shock towers, loosen lock nuts on
joint bolt and loosen joint bolt. Remove nut, washer and bolt retaining strut bar to strut plate. Remove
strut bar from vehicle.
2. To install, reverse removal procedure. Rotate joint bolt counterclockwise to 3.5-5.2 INCH lbs. (.4-.6 N.m)
to set tension. Tighten lock nuts to 87-121 INCH lbs. (10-14 N.m). Tighten strut bar-to-strut plate nut.
See TORQUE SPECIFICATIONS
.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Axle Lock Nut123-159 (167-215)
Brake Caliper Bracket Bolts37-50 (50-68)
Lower Ball Joint-To-Knuckle Nut42-57 (57-77)
Lower Ball Joint-To-Lower Control
199754-69 (73-94)
1999 & 2000
Bolt & Nut69-86 (94-117)
Bolt54-69 (73-94)
Lower Control Arm-To-Frame
1997
Front Adjusting Bolt Lock Nut69-83 (94-112)
Rear Adjusting Bolt Lock Nut62-75 (84-102)
1999 & 200069-83 (94-112)
Shock Assembly-To-Lower Control Arm Bolt/Nut
199754-68 (73-93)

1997 Mazda MX-5 Miata
1997-2000 SUSPENSION Front - Miata
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Sunday, July 05, 2009 1:38:08 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.

1. Check WIPER fuse (20-amp) in passenger compartment fuse block. Check AD FAN (additional fan) fuse
(20-amp) in engine compartment fuse block. If fuses are okay, go to next step. If either fuse is blown,
check for shorted wiring harness before replacing fuse.
2. Operate engine at idle. Turn A/C and blower on. Using voltmeter, backprobe Black/Red wire terminal of
compressor clutch connector. If battery voltage exists, replace compressor clutch. If battery voltage is not
present, go to next step.
3. Ensure engine is running. Ensure A/C and blower are on. Using a voltmeter, backprobe Blue/Yellow wire
terminal of the A/C relay connector. If battery voltage exists, go to next step. If battery voltage does not
exist, repair open Blue/Yellow wire between AD FAN fuse and A/C relay.
4. Backprobe Blue wire terminal of A/C relay connector. If battery voltage exists, go to next step. If battery
voltage is not present, repair open Blue wire between WIPER fuse and A/C relay.
5. Backprobe Black/Red wire terminal of A/C relay connector. If battery voltage exists, repair open
Black/Red wire between A/C relay and compressor clutch. If battery voltage is not present, go to next
step.
6. Backprobe Blue/Black wire terminal of A/C relay connector. If voltage is Zero volts, replace A/C relay. I
f
voltage is not Zero volts, repair open Blue/Black wire between A/C relay and PCM. If wire is okay, check
PCM operation.
CONDENSER (ADDITIONAL) FAN CIRCUIT
1. Check ENGINE fuse (30-amp) in passenger compartment fuse block. Check AD FAN fuse (20-amp) in
engine compartment fuse block. If fuses are okay, go to next step. If either fuse is blown, check for
shorted wiring harness before replacing fuse.
2. Start engine. Turn A/C and blower switches on. Using voltmeter, backprobe Black/Yellow wire terminal
of condenser fan motor. If battery voltage exists, go to next step. If battery voltage is not present, go to
step 4).
3. Turn ignition switch off. Disconnect condenser fan connector. Using ohmmeter, check continuity
between Black wire of condenser fan connector and ground. If continuity exists, replace condenser fan. If
continuity is not present, repair open Black wire between condenser fan and ground.
4. Turn ignition on. Ensure A/C and blower switches are on. Using voltmeter, backprobe Black/White wire
terminal of condenser fan relay connector. If battery voltage exists, go to next step. If battery voltage is
not present, repair open Black/White wire between ENGINE fuse and condenser fan relay.
5. Backprobe Blue/Yellow wire terminal of condenser fan relay connector. If battery voltage exists, go to
next step. If battery voltage is not present, repair open Blue/Yellow wire between AD FAN fuse and
condenser fan relay.
6. Backprobe Black/Yellow wire terminal of condenser fan relay connector. If battery voltage exists, repair
open Black/Yellow wire between condenser fan relay and condenser fan. If battery voltage is not present,
go to next step.
7. Backprobe Blue/White wire terminal of condenser fan relay connector. If battery voltage exists, repair
Blue/White wire between condenser fan relay and PCM. If wire is okay, check PCM operation. If battery
voltage is not present, replace condenser fan relay.
A/C SWITCH

1997 Mazda MX-5 Miata
A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System
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Fig. 3: Identifying Condenser Fan Relay Terminals
Courtesy of MAZDA MOTORS CORP.
CONDENSER FAN MOTOR
Disconnect condenser fan motor connector. Connect positive battery lead to condenser fan motor Black/Yellow
wire terminal, and ground Black wire terminal. Replace condenser fan motor if it does not operate.
EVAPORATOR THERMOSWITCH
1. Remove glove box. Operate engine at idle. Turn A/C off. Turn blower switch to 4th position (high) for a
few minutes to ensure evaporator temperature is greater than 32°F (0°C). Turn blower switch and engine
off.
2. Disconnect evaporator thermoswitch connector. Check continuity between thermoswitch terminals. If
continuity exists, go to next step. If there is no continuity, replace thermoswitch.
3. Submerge thermoswitch sensing bulb in ice cold water of less than 32°F (0°C). Ensure continuity does
not exist between thermoswitch terminals. Replace thermoswitch if continuity is not as specified.
PRESSURE SWITCH
1. Turn ignition off. Connect manifold pressure gauge set to system. If high-side pressure is 37-310 psi (2.6-
22.0 kg/cm
2 ), go to next step. If pressure is not as specified, check refrigerant level.
2. Disconnect pressure switch connector. Check continuity between switch terminals. If continuity exists,
pressure switch is okay. If there is no continuity, replace pressure switch.
REMOVAL & INSTALLATION

1997 Mazda MX-5 Miata
A/C-HEATER SYSTEM - MANUAL 1997 Manual A/C-Heater System
Microsoft
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