1991 MAZDA MIATA oil

drive axle lock nut. Check axial play. See WHEEL BEARING under ADJUSTMENTS & INSPECTION.
STRUT ASSEMBLY
Removal & Disassembly
1. Raise vehicle and remove fuel tank filler pipe protector. Remove rear wheel assembly. Remove stabilizer
bar nut and bolt. Remove 2 upper strut mount-to-body nuts. Remove lower strut bolt. Loosen upper and
lower arm bolts. Lower arms and remove strut assembly.
2. Clamp strut securely in soft-jawed vise. Compress coil spring. Remove lock nut and washer. Remove
remaining components and note order for reassembly.
Inspection
Check strut for leaks or abnormal noise. Inspect parts for wear or damage. Check for loose installation of bolts
and nuts. Replace parts as necessary.
Reassembly & Installation
To reassemble, reverse disassembly procedure. To install, reverse removal procedure. Ensure coil spring is well
seated in upper and lower seats. Check rear wheel toe-in. See SPECIFICATIONS & PROCEDURES article in
the WHEEL ALIGNMENT section.
LOWER ARM
Removal
Raise and support vehicle. Remove wheel assembly. Remove stabilizer bar control link nut and bolt. See Fig.
1 . Remove lower strut bolt. Remove lower arm-to-crossmember bolts. Remove lower arm-to-knuckle bolts.
Remove lower arm. Inspect arm for dama
ge, cracks and deformation. Check for damaged or worn bushings.

1991 Mazda MX-5 Miata
SUSPENSION - REAR 1991 SUSPENSION Rear
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SOLENOID PULL-IN TEST
Connect positive battery lead to solenoid "S" terminal and negative battery lead to solenoid case. Starter pinion
drive gear should extend quickly and maintain this position. If starter pinion drive gear does not extend, replace
solenoid. See Fig. 2
.
SOLENOID RETURN TEST
Connect positive battery lead to solenoid "M" terminal and ground negative battery lead to starter body. Using
screwdriver, pry overrunning clutch pinion drive outward. Release screwdriver and ensure overrunning clutch
pinion drive returns to original position. See Fig. 2 .
SOLENOID
1. Disconnect all wires to solenoid. Using ohmmeter, ensure continuity between "S" and "M" terminals, and
between "S" terminal and solenoid body. See Fig. 1
. If continuity does not exist between these terminals,
solenoid must be replaced.
2. Next ensure continuity does not exist between "M" and "B" terminals. If continuity exists between these
terminals, solenoid is shorted and must be replaced.
PINION GAP ADJUSTMENT
1. Ensure field wire is disconnected from solenoid "M" terminal. Connect positive battery lead to "S"
terminal and negative battery lead to starter case. Starter pinion drive gear will extend outward and stop.
2. Quickly measure pinion gap clearance between end of pinion drive and circlip retainer. See Fig. 3
. DO
NOT operate starter solenoid for more than 10 seconds. Pinion gap clearance should be .02-.08" (0.5-2.0
mm).
3. If pinion gap clearance is not within specification, adjust by increasing or decreasing thickness of
solenoid shims located between solenoid and drive housin
g. NOTE: Solenoid tests must be performed with starter assembled and field lead ("M"
terminal wire) disconnected at the solenoid.
CAUTION: Do not engage starter solenoid for more than 10 seconds during testing or
damage to coil winding may result.

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
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ARMATURE TESTING
1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly
rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.
2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If
continuity exists, the armature is shorted and must be replaced. Check continuity between commutator
and shaft. If continuity exists, replace armature.
3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace
armature.
COMMUTATOR TESTING
1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted,
turn commutator in a lathe.
2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after
turning. See COMMUTATOR SPECIFICATIONS table.
3. Commutator mica undercut depth should be .02 -.03" (.5 -.8 mm). Minimum mica undercut depth
is .008" (.20 mm). If not within specification, undercut to standard depth.
COMMUTATOR SPECIFICATIONS
BRUSH TESTING
1. Connect ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity
exists, brush holder assembly is shorted and must be replaced.
2. Check brush length. If less than specification, replace brushes. See BRUSH LENGTH
SPECIFICATIONS table. Use brush spring scale to check spring tension. Spring tension is measured at
point where spring separates from brush.Tension should be greater than 2 lbs. (0.9 kg). Tension
specification for a new spring is 3.1-5.7 lbs. (1.4-2.6 kg). Brushes must move freely in holders.
BRUSH LENGTH SPECIFICATIONS
FIELD COIL TESTING
1. Connect one ohmmeter lead to field coil lead ("M" terminal lead). Connect other lead to soldered portion
of brush lead. If continuity does not exist, repair or replace field coil.
2. Check field coil for shorts to
ground by connecting ohmmeter lead to field coil lead. Connect other lead
Application
Maximum Runout In.
(mm)Minimum Diameter
In. (mm)
B2200 (M/T)
Protege (M/T) & 323.004 (.10)1.22 (31)
Miata.001 (.03)1.22 (31)
ApplicationStandard In. (mm)Minimum In. (mm)
All Models.67 (17.0).45 (11.5)

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
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to field coil housing. If continuity exists, repair or replace field coil.
OVERRUNNING CLUTCH PINION DRIVE
Hold overrunning clutch housing and turn pinion gear by hand. If pinion turns in both directions, clutch is faulty
and must be replaced. DO NOT clean overrunning clutch with solvent, as it is packed with grease and sealed by
manufacturer.
REMOVAL & INSTALLATION
1. Disconnect negative battery cable. Raise vehicle on hoist. Remove undercover. Disconnect wiring from
starter. Remove differential lock assembly (4WD models). On Protege (M/T) and 323 models, remove
support brace from under intake manifold. Remove starter mounting bolts. Remove lowest mounting bolt
last. Remove starter from under side of vehicle.
2. To install starter, reverse removal procedure. Tighten mounting bolts to 23-24 ft. lbs. (31-46 N.m).
Tighten battery terminal nut to 87-104 INCH lbs. (9.8-12 N.m).
OVERHAUL
DISASSEMBLY & ASSEMBLY
1. Mark rear cover, field coil housing and front drive housing for reassembly reference. Remove solenoid
and shims, rear cover and brush plate. Remove field coil housing and pull armature and yoke lever from
front drive housing. See Fig. 4
& Fig. 5. Use arbor press to remove circlip, stopper and pinion drive from
armature shaft. See Fig. 6
.
2. To assemble, reverse removal procedures. Lubricate solenoid plunger, yoke lever and armature bushings.
Use arbor press and pinion drive to install stopper and circlip on armature shaft. See Fig. 6
. Ensure brush
plate, rear cover and field coil housin
g are aligned when installing through bolts.

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
Microsoft
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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 sprocket(s). For SOHC, see Fig. 4
. For DOHC, see Fig. 5 or Fig. 7 . Ensure
crankshaft timing mark is at TDC. Install belt around crankshaft sprocket, then working in a
counterclockwise direction, route belt around camshaft sprocket(s).
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. On all engines, check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 8
.
Ensure timing belt deflection is within specification. See TIMING BELT DEFLECTION
table. Adjust
drive belts to proper tension.
TIMING BELT DEFLECTION
Application(1) Deflection - In. (mm)
1986-89.47-.51 (11.9-13.0)
1990-95
DOHC.35-.45 (9.0-11.5)
SOHC.43-.51 (11.0-13.0)
(1)Deflection measurement is with 22 lbs. (10 kg) of pressure applied to timing belt. See Fig. 8.

1991 Mazda MX-5 Miata
MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95
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