1991 MAZDA MIATA Factory Service Manual

Miata
Front
Lower58-65 (78-88)
Upper33-40 (45-54)
Rear33-43 (45-59)
MPV61-69 (83-93)
MX-6 & 626
Front23-30 (31-41)
Rear12-17 (16-24)
Protege & 323
Front(1)
Rear33-43 (45-59)
RX7
Front
Single-Piston Caliper23-30 (31-41)
4-Piston Caliper(1)
Rear12-17 (16-24)
929
Front61-69 (83-93)
Rear12-17 (16-24)
Caliper Mounting Bracket Bolt
B2200, B2600i & MPV65-80 (88-108)
Miata
Front36-51 (49-69)
Rear33-43 (45-59)
MX-6 & 626
Front58-72 (78-98)
Rear33-49 (45-67)
Protege & 323
Front(1)
Rear33-43 (45-59)
RX7
Front
Single-Piston Caliper58-72 (78-98)
4-Piston Caliper(1)
Rear33-40 (45-54)
929
Front58-86 (78-117)
Rear33-50 (45-68)
Hub Bolt (4WD)22-25 (30-34)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:09 PMPage 38 © 2005 Mitchell Repair Information Company, LLC.

DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
Rotor-To-Hub Bolt
B2200 & B2600i40-51 (54-69)
MX-6 & 62636-43 (49-58)
32333-40 (45-54)
Wheel Bearing Lock Nut
B2200 & B2600i (Rear)145-217 (197-295)
323 (Front)116-174 (158-237)
Wheel Lug Nut
B2200 & B2600i
Standard Wheel65-87 (88-118)
Styled Wheel87-108 (118-147)
Navajo85-115 (115-155)
All Others65-87 (88-118)
INCH Lbs. (N.m)
Parking Brake Cable Lock Nut
B2200 & B2600i60-84 (7-10)
All Others168-252 (19-29)
Wheel Cylinder Mounting Bolt
B2200 & B2600i 2WD108-144 (12-16)
B2600i 4WD180-216 (20-24)
Except B2200, B2600i & Navajo (2) 84-108 (10-12)
(1)These bolts secure caliper directly to steering knuckle. On Protege, tighten to 29-36 ft. lbs. (39-49
N.m). On RX7, tighten to 58-72 ft. lbs. (78-98 N.m).
(2)Information is not available from manufacturer for Navajo.
ApplicationIn. (mm)
B2200 & B2600i 2WD Front (1)
Original Thickness.79 (20)
Discard Thickness.71 (18)
B2600i 4WD Front (1)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Miata
Front (2)
Original Thickness.71 (18)
Discard Thickness.63 (16)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:09 PMPage 39 © 2005 Mitchell Repair Information Company, LLC.

Rear (2)
Original Thickness.35 (9)
Discard Thickness.28 (7)
MPV Front (2)
Original Thickness.94 (24)
Discard Thickness.87 (22)
MX-6 & 626
Front (2)
Original Thickness.94 (24)
Discard Thickness.87 (22)
Rear (2)
Original Thickness.39 (10)
Discard Thickness.31 (8)
Navajo Front (3)
Original Thickness.94 (24)
Discard Thickness.81 (21)
Protege & 323
Front (2)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Rear (2)
Original Thickness.35 (9)
Discard Thickness.28 (7)
RX7
Front (2)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Rear (2)
Solid Rotor
Original Thickness.39 (10)
Discard Thickness.31 (8)
Ventilated Rotor
Original Thickness.79 (20)
Discard Thickness.71 (18)
929
Front (2)
Original Thickness.87 (22)
Discard Thickness.79 (20)
Rear (2)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:09 PMPage 40 © 2005 Mitchell Repair Information Company, LLC.

DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS
.71 (18)
Discard Thickness.63 (16)
(1)Maximum lateral runout is .006" (.15 mm).
(2)Maximum lateral runout is .004" (.10 mm).
(3)Maximum lateral runout is .003" (.08 mm).
ApplicationIn. (mm)
B2200 & B2600i
Drum Diameter
Original10.24 (260.0)
Minimum10.30 (261.5)
Wheel Cylinder Bore Diameter
B2200 & B2600i 2WD0.750 (19.05)
B2600i 4WD0.688 (17.46)
MPV
Drum Diameter
Original10.24 (260)
Minimum10.30 (261.5)
Wheel Cylinder Bore Diameter0.690 (17.50)
MX-6 & 626
Drum Diameter
Original9.00 (228.6)
Minimum9.06 (230.1)
Wheel Cylinder Bore Diameter0.875 (22.22)
Navajo
Drum Diameter
Original
9"9.00 (228.6)
10"10.00 (254.0)
Minimum
9"9.09 (230.8)
10"10.09 (256.3)
Protege & 323
Drum Diameter
Original9.00 (228.6)
Minimum9.04 (229.6)
Wheel Cylinder Bore Diameter0.875 (22.22)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:09 PMPage 41 © 2005 Mitchell Repair Information Company, LLC.

ALTERNATOR & REGULATOR
1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
DESCRIPTION
Alternators are conventional 3-phase, self-rectifying type units containing 6 diodes (3 positive and 3 negative)
which are used to rectify current. See Fig. 1
. An internally-mounted, Integrated Circuit (IC) regulator is used
on all models.
Fig. 1: Charging System Wiring Schematic

Courtesy of MAZDA MOTORS CORP.
ADJUSTMENTS
BELT DEFLECTION
Measure belt deflection in center of longest pulley-to-pulley span. See BELT DEFLECTION
SPECIFICATIONS table. If belt deflection is not as specified, adjust as necessary.
BELT DEFLECTION SPECIFICATIONS
ApplicationDeflection - In. (mm)

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
Microsoft
Sunday, July 05, 2009 2:14:53 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, July 05, 2009 2:14:58 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.

TROUBLE SHOOTING
CHARGING SYSTEM
B2200
New Belt0.28-0.31 (7.0-8.0)
Used Belt0.31-0.35 (8.0-9.0)
B2600i
New Belt0.39-0.47 (10.0-12.0)
Used Belt0.43-0.51 (11.0-13.0)
Miata
New Belt0.31-0.35 (8.0-9.0)
Used Belt0.35-0.39 (9.0-10.0)
MPV
4-Cylinder Engine
New Belt0.39-0.47 (10-12)
Used Belt0.43-0.57 (11-13)
V6 Engine
New Belt0.35-0.39 (9-10)
Used Belt0.39-0.47 (10-12)
MX-3
4-Cylinder Engine
New Belt0.31-0.35 (8.0-9.0)
Used Belt0.35-0.39 (9.0-10.0)
V6 Engine
New Belt0.24-0.28 (6.0-7.0)
Used Belt0.28-0.31 (7.0-8.0)
MX-6 & 626
New Belt0.24-0.31 (6.0-8.0)
Used Belt0.28-0.35 (7.0-9.0)
Protege & 323
New Belt0.31-0.35 (8.0-9.0)
Used Belt0.35-0.39 (9.0-10.0)
RX7
New Belt0.47-0.59 (12.0-15.0)
Used Belt0.55-0.67 (14.0-17.0)
929
New Belt0.35-0.39 (9.0-10.0)
Used Belt0.39-0.47 (10.0-12.0)
- With 22 lbs. (98N) applied to belt.

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
Microsoft
Sunday, July 05, 2009 2:14:54 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

CHARGING SYSTEM TROUBLE SHOOTING
TROUBLE SHOOTING PRECAUTIONS
Miata
Obtain code number and deactivate audio anti-theft system before disconnecting battery.
All Models
DO NOT reverse battery cable connections. Rectifier will be damaged.
DO NOT use high voltage type testers.
PROBLEM Possible CauseAction
NO START CONDITION
Dead BatteryCheck/Replace Battery
Bad Cable ConnectionsClean/Replace Cables
Ignition Switch/Circuit FaultCheck Switch/Circuit
CHARGING SYSTEM WARNING LIGHT STAYS ON
Loose/Worn Alternator BeltTighten/Replace Belt
Loose Alternator ConnectionsCheck/Repair
Connections
Warning Light WiringCheck/Repair Wiring
Faulty Stator/DiodesTest/Repair Alternator
Faulty Voltage RegulatorTest/Repair Regulator
WARNING LIGHT OFF WITH IGNITION SWITCH ON
Blown FuseCheck/Replace Fuse
Faulty AlternatorTest Alternator
Bad Warning Light BulbTest/Replace Bulb
WARNING LIGHT ON WITH IGNITION SWITCH OFF
Alternator Wiring ShortCheck/Repair Wiring
Faulty Rectifier BridgeTest/Repair Alternator
AMMETER INDICATES DISCHARGE
Loose/Worn Alternator BeltTighten/Replace Belt
Loose Alternator ConnectionsCheck/Repair
Connections
Faulty AmmeterTest/Replace Ammeter
NOISY Defective BatteryReplace Battery
Defective AlternatorTest/Repair Alternator
Defective RegulatorTest/Repair Regulator
NOTE: Observe the following precautions when trouble shooting or testing charging
system:

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
Microsoft
Sunday, July 05, 2009 2:14:54 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Battery voltage is always applied to terminal "B".
DO NOT ground terminal "L" while engine is running.
DO NOT start engine with connector disconnected from terminals "L" and "S".
DO NOT apply battery voltage to terminal "L".
ON-VEHICLE TESTING
ALTERNATOR OUTPUT
1. Connect an ammeter (80-amp minimum) in-line between terminal "B" connector and wire. See Fig. 2
,
Fig. 3
and Fig. 4 . Turn all headlights and accessories on and depress brake pedal. With engine operating
at 2500-3000 RPM, measure output amperage. NOTE: Check alternator wiring harness connections and drive belt tension. Battery
must be fully charged before testing. Wait at least 30 seconds after starting
engine before measuring system voltage.
CAUTION: Ensure alternator terminal "B" does not contact ground.

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
Microsoft
Sunday, July 05, 2009 2:14:54 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.