oil pressure MAZDA MX-5 1997 Factory Repair Manual

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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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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SOLENOIDS & SOLENOID VALVES
SOLENOIDS & SOLENOID VALVES
SWITCHES
SWITCHES
MISCELLANEOUS
MISCELLANEOUS
Vehicle Speed Sensor (VSS)On speedometer assembly.
Water Temperature Sender UnitOn center of engine. See Fig. 1 .
Washer Fluid Level SensorOn washer fluid reservoir. See Fig. 1 .
ComponentComponent Location
AT Interlock SolenoidIn steering column, near ignition switch. See Fig. 2 .
EC-AT Solenoid ValveOn left side of transmission.
EGR Solenoid Valve (Vacuum)On right side of engine compartment. See Fig. 1 .
EGR Solenoid Valve (Vent)On right side of engine compartment. See Fig. 1 .
Fourth Gear Solenoid ValveOn left side of transmission.
Idle Air Control ValveOn right side, front of engine compartment. See Fig. 1 .
PRC Solenoid ValveOn right side, front of engine. See Fig. 1 .
Purge Solenoid ValveOn right strut tower. See Fig. 1 .
ComponentComponent Location
Back-Up Lamp Switch (M/T)On right side of transmission. See Fig. 1 .
Brake SwitchOn bracket, above brake pedal. See Fig. 2 .
Buckle SwitchOn driver side seat belt buckle. See Fig. 3 .
Clutch Switch (M/T)On bracket, above clutch pedal. See Fig. 2 .
Hold SwitchUnder right side of center console.
Key Reminder SwitchIn steering column, near ignition switch.
Neutral Switch (M/T)On right side of transmission. See Fig. 1 .
Oil Pressure SwitchOn right side of engine. See Fig. 1 .
"P" Range SwitchUnder center console, on base of gear selector.
Parking Brake SwitchOn base of parking brake lever. See Fig. 4 .
Power Steering Pressure SwitchOn power steering pump assembly.
Refrigerant Pressure SwitchIn front of engine compartment, near radiator support. See Fig. 1 .
Starter Interlock Switch (M/T)On bracket, above clutch pedal. See Fig. 2 .
ThermoswitchUnder right side of dash.
Transmission Range SwitchOn left side of transmission.
ComponentComponent Location

1997 Mazda MX-5 Miata
1997 MAZDA MX-5 Miata
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1997-98 ENGINES
1.8L 4-Cylinder
ENGINE IDENTIFICATION
Engines can be identified by engine model and number. See ENGINE IDENTIFICATION CODE. On Miata,
engine model and number are stamped on flange at upper right rear of cylinder block deck, as viewed from
flywheel. On Protege, engine model and number are stamped on flange at upper left rear of cylinder block deck,
as viewed from flywheel.
ENGINE IDENTIFICATION CODE
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
REMOVAL & INSTALLATION
FUEL PRESSURE RELEASE & PRIMING
Releasing Pressure (Miata)
Locate and remove fuel pump relay from under left side of dash, near steering column. Start engine and allow to
stall. After engine stalls, attempt to restart engine to ensure no residual pressure exists. Turn ignition off and
reinstall fuel pump relay. When disconnecting fuel hoses, cover connection with shop rag to catch fuel leakage.
To avoid excessive cranking after servicing, prime fuel system before starting engine.
Releasing Pressure (Protege)
NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.
ApplicationCode
Miata & Protege (1.8L DOHC)BP
NOTE: Valve clearance is not adjustable. Some Hydraulic Lash Adjuster (HLA) noise
may occur during engine start-up. Noise should disappear after engine reaches
normal operating temperature. If noise persists and oil level is okay, change
engine oil. If oil change does not reduce noise, check with manufacturer for
modified HLA.
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on engine hood and other
major assemblies before removal.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
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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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Inspection (All Models)
Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or
roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary.
Installation (All Models)
1. Position notch on crankshaft sprocket to 12 o'clock position (aligned with mark on oil pump). Align
timing marks on camshaft sprockets. See Fig. 8
. Ensure crankshaft timing mark is at TDC. Install belt
around crankshaft sprocket, then working in a counterclockwise direction, route belt around camshaft
sprockets.
2. Loosen timing belt tensioner lock bolt and allow spring to apply tension on belt. Snug tensioner lock bolt.
Rotate crankshaft 2 complete turns in direction of normal engine rotation. Ensure timing marks align. If
timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure.
3. Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 9
. Ensure timing
belt deflection is within specification. See TIMING BELT DEFLECTION
.
TIMING BELT DEFLECTION
Application(1) Deflection In. (mm)
Miata & Protege.35-.45 (9.0-11.5)
(1)Deflection measurement is with 22 lbs. (10 kg) of pressure applied to timing belt. See Fig. 9 .

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.

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1997-98 ENGINES 1.8L 4-Cylinder
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Valves
Check valve face angle, head diameter, margin thickness and stem diameter. Service or replace valves if
measurements are not within specifications. See VALVES & VALVE SPRINGS
under ENGINE
SPECIFICATIONS.
Valve Seat Correction Angles
Measure seat contact width on valve. See VALVE SEAT. If seat width is not within specification or if valve
face does not contact center of valve seat, correct seat using a 70-degree grinding stone. After correcting seat,
lightly finish seat with 45-degree grinding stone.
VALVE TRAIN
Hydraulic Lash Adjusters
1. Remove camshaft cover. Check movement of each Hydraulic Lash Adjuster (HLA) by pushing
downward using hand pressure only. If HLA compresses, replace HLA. To remove HLA, remove
camshafts. See CAMSHAFT
under REMOVAL & INSTALLATION. Mark location of HLA before
removing from bore. Lift HLA from cylinder head.
2. Inspect HLA friction surfaces for wear and damage. Replace HLA if required. Coat HLA with engine oil
and install in original location. Ensure HLA moves smoothly in bore by using small magnet attached to
HLA.
CYLINDER BLOCK ASSEMBLY
Piston & Connecting Rod Assembly
1. Before removing rod cap from crankshaft, measure and record rod side play. See CONNECTING RODS
under ENGINE SPECIFICATIONS. Before removing connecting rods, measure and record connecting
rod bearing oil clearance. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
under
ENGINE SPECIFICATIONS.
2. Before separating piston from connecting rod, mark piston in relation to connecting rod. Check
oscillation movement of piston and rod assembly (hold piston horizontally, lift rod and allow rod to drop
by its own weight). If pin binds in pin bore (rod does not drop), replace piston and/or pin as necessary.
3. To separate components, press piston pin out of piston and rod assembl
y, noting pressure required to
Normal1.772-1.791 (45.00-45.50)
Serviceable1.733-1.772 (45.60-46.50)
NOTE: If hydraulic lash adjusters are persistently noisy, check with manufacturer
for availability of modified adjusters.
NOTE: During disassembly, match mark components for reassembly reference.

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1997-98 ENGINES 1.8L 4-Cylinder
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Fig. 21: Cross-Sectional View Of Engine Oil Circuit
Courtesy of MAZDA MOTORS CORP.
Crankcase Capacity
See ENGINE OIL CRANKCASE CAPACITY .
Oil Pressure
With engine at operating temperature, oil pressure should be 15-28 psi (1.0-2.0 kg/cm2 ) at 1000 RPM, and 43-
57 psi(3.0-4.0 kg/cm
2 ) at 3000 RPM.
Oil Pressure Relief Valve
Pressure relief valve opening pressure is 50-64 psi (3.5-4.5 kg/cm2). Pressure relief valve is located in oil pump
body and is not adjustable.
ENGINE OIL CRANKCASE CAPACITY

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1997-98 ENGINES 1.8L 4-Cylinder
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OIL PUMP
Removal & Disassembly
1. Disconnect negative battery cable. Remove dipstick, tube and "O" ring. Drain engine oil and coolant.
Remove drive belts, crankshaft and water pump pulleys. Remove generator, A/C compressor and
mounting bracket. Without disconnecting A/C hoses, secure A/C compressor away from engine. Remove
timing belt and related components. See TIMING BELT
under REMOVAL & INSTALLATION.
2. Hold crankshaft sprocket in place and remove crankshaft sprocket bolt. Remove crankshaft sprocket
using steering wheel puller. Leave crankshaft Woodruff key in place.
3. Remove oil pan and oil pump pick-up tube. See OIL PAN
under REMOVAL & INSTALLATION.
Remove oil pump housing assembly. Using a screwdriver protected with a rag, drive oil seal out from
inside of oil pump housing assembly.
4. Remove pump cover screws (use a manual impact screwdriver, if necessary). See Fig. 22
. Remove pump
cover. Note location of alignment marks on inner and outer rotors. Remove inner and outer rotors. To
remove pressure relief valve, remove spring seat, pressure spring and control plunger.
Inspection
Replace pressure relief valve spring if length is not as specified. See OIL PUMP SPECIFICATIONS. Ensure
plunger slides freely in bore. Replace oil pump housing assembly if clearances are not as specified. See OIL
PUMP SPECIFICATIONS .
Reassembly & Installation
1. Apply oil to friction surfaces. Install inner and outer rotors with marks aligned. See Fig. 23 . Install
pressure relief valve components. Apply oil to lip of NEW oil seal. Press oil seal into bore until even with
face of oil pump housing assembly.
2. Install pump cover. Tighten screws to 53-78 INCH lbs. (6-9 N.m). To complete installation, reverse
removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
.
OIL PUMP SPECIFICATIONS
ApplicationW/O Filter Qts. (L)W/Filter Qts. (L)
Miata & Protege3.8 (3.6)4.0 (3.8)
ApplicationMaximum Clearance In. (mm)
Maximum Rotor Tip Clearance (1) .0079 (.20)
Maximum Rotor-To-Pump Body Clearance (2) .0079 (.20)
Maximum Rotor Side Clearance (3) .0055 (.14)
Pressure Relief Spring Free Length1.809 (45.94)
(1)See Fig. 23 .
(2)Insert feeler gauge between outer rotor and pump body.
Place straightedge across pump body and check clearance between straightedge and both rotors.

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1997-98 ENGINES 1.8L 4-Cylinder
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