1991 MAZDA MIATA battery

Fig. 1: Testing A/C & Blower Switch
Courtesy of MAZDA MOTORS CORP.
A/C RELAY
1. Remove relay. Check continuity between specified terminals of relay connector. See A/C RELAY TEST
table. See Fig. 2 . Ensure test lead polarity is correct. If continuity is not as specified, replace relay.
2. If continuity is as specified, apply battery positive lead to terminal "D" and negative lead to terminal "A".
Check continuity between terminals "E" and "C". If there is continuity, relay is okay. If there is no
continuity, replace relay.
A/C RELAY TEST
Fig. 2: A/C Relay Connector Terminal ID

Courtesy of MAZDA MOTORS CORP.
Terminal (+)(1) Terminal (-)(2) Continuity
ABYes
ADYes
BANo
CENo
DANo
ECYes
(1)Connect ohmmeter positive lead to this terminal.
(2)Connect ohmmeter negative lead to this terminal.

1991 Mazda MX-5 Miata
A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems
Microsoft
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BLOWER MOTOR
Disconnect 2-wire connector from bottom of blower motor case. Apply battery voltage across blower motor
terminals. Replace blower motor if it does not operate.
BLOWER RESISTOR
Note 4-wire connector and 1-wire connector attached to seam where upper and lower blower cases meet. Wires
in these connectors lead to blower resistor on bottom of blower case. Disconnect both connectors. If continuity
does not exist between 1-wire connector terminal and each terminal of 4-wire connector, replace blower
resistor.
CONDENSER (ADDITIONAL) FAN MOTOR
Disconnect condenser fan connector. Apply battery voltage across condenser fan terminals. Replace condenser
fan motor if it does not operate.
EVAPORATOR THERMOSWITCH
1. Remove glove box. Run engine at idle. Turn off A/C switch. Turn blower switch to 4th position (high) for
a few minutes to ensure evaporator temperature is greater than 32°F (0°C). Turn off blower switch and
engine.
2. Disconnect evaporator thermoswitch connector. Check continuity between switch terminals. If there is
continuity, thermoswitch is okay. If there is no continuity, replace thermoswitch.
PRESSURE SWITCH
1. Turn ignition off. Connect manifold pressure gauges to system. If high-side pressure is less than 31.2 psi
(2.2 kg/cm
2 ), check system for proper refrigerant charge.
2. If high-side pressure is greater than 31.2 psi (2.2 kg/cm
2 ), disconnect pressure switch connector. Check
continuity between switch terminals. If there is continuity, switch is okay. If there is no continuity,
replace switch.
REMOVAL & INSTALLATION
AIR BAG WARNING
BLOWER CASE
Removal & Installation
WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG article in the
ACCESSORIES/SAFETY EQUIPMENT Section.

1991 Mazda MX-5 Miata
A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems
Microsoft
Sunday, July 05, 2009 2:11:52 PMPage 6 © 2005 Mitchell Repair Information Company, LLC.

Disconnect electrical connectors from blower case. Remove glove box. Loosen seal plate between blower motor
case and evaporator case. Remove blower motor case nuts. Remove case and seal plate. To install, reverse
removal procedure.
COMPRESSOR
Removal & Installation
1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling
equipment. Disconnect compressor clutch connector. Disconnect refrigerant lines from compressor.
Remove drive belt.
2. Raise and support vehicle. Remove compressor mounting bolts and remove compressor. To install,
reverse removal procedure. Adjust drive belt to specified tension. Evacuate and charge system.
CONDENSER & RECEIVER-DRIER
Removal & Installation
Discharge A/C system using approved refrigerant recovery/recycling equipment. Raise and support vehicle.
Remove splash shield and air guide. Remove condenser and receiver-drier as an assembly. To install, reverse
removal procedure. Evacuate and charge system.
CONTROL PANEL
Removal & Installation
Remove rear console assembly. See Fig. 4 . Remove vent outlets from center panel assembly. Remove center
panel assembly. Remove control panel screws. Pull control panel from hole. Disconnect door control cables
from back of control panel and remove panel. To install, reverse removal procedure.
EVAPORATOR CORE & THERMOSWITCH
Removal & Installation
1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove condenser and
receiver-drier as an assembly. Disconnect low-pressure and high-pressure pipes from evaporator tubes at
engine compartment firewall.
2. Remove right undercover and glove box. Disconnect thermoswitch electrical connector. Loosen left seal
plate (between heater case and evaporator case). Loosen right seal plate (between evaporator case and
blower motor case).
3. Remove evaporator case. Disassemble evaporator case, and remove evaporator core and thermoswitch.
See Fig. 3
. To install, reverse removal procedure. Evacuate and charge system.

1991 Mazda MX-5 Miata
A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems
Microsoft
Sunday, July 05, 2009 2:11:52 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Removal & Installation
Obtain code number and deactivate audio anti-theft system. Disconnect negative battery cable. Remove all
components in order listed in illustration. See Fig. 4
. To install, reverse removal procedure.
Fig. 4: Exploded View of Instrument Panel

Courtesy of MAZDA MOTORS CORP.
WIRING DIAGRAMS

1991 Mazda MX-5 Miata
A/C-HEATER SYSTEM - MANUAL 1990-92 Manual A/C-Heater Systems
Microsoft
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REMOVAL & INSTALLATION
STEERING GEAR
Removal & Installation (Miata & MPV)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheels. Remove
cotter pins and castle nuts from tie rod ends.
2. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-to-
steering gear pinion shaft bolt. Mark reference lines on pressure pipe fittings.
3. Remove pressure and return hose connections from steering gear. Remove 2 steering bracket-to-frame
mounting through bolts. Remove steering gear and linkage with steering bracket attached from under the
vehicle.
4. To install, reverse removal procedure. Fill and bleed system. Tighten bolts to specification. See
TORQUE SPECIFICATIONS
table. Tighten steering gear-to-mounting bracket bolts (4) in the
following order: left front, right front, left rear, right rear.
Removal & Installation (MX-6 & 626)
1. Disconnect negative battery cable and power steering pressure switch connectors. Raise and support front
of vehicle. Remove front wheels.
2. Remove cotter pins and castle nuts from tie rod ends. Using puller, remove tie rods from steering
knuckles. Remove steerin
g column intermediate shaft-to-steering gear pinion shaft bolt.
Used Belt.35-.39 (8.9-10.0)
MPV
V6
New Belt.28-.30 (7.1-7.6)
Used Belt.30-.32 (7.6-8.1)
4-Cylinder
New Belt.26-.28 (6.6-7.1)
Used Belt.28-.31 (7.1-7.8)
MX-6 & 626
New Belt.31-.36 (7.8-9.1)
Used Belt.35-.43 (8.9-10.9)
RX7
New Belt.43-.51 (10.9-12.9)
Used Belt.55-.63 (14.0-16.0)
929
New Belt.28-.35 (7.1-8.9)
Used Belt.35-.43 (8.9-10.9)
(1)Belt deflection is measured at midpoint between idler pulley and pump, with 22 lbs. (10 kg.) of
pressure applied.

1991 Mazda MX-5 Miata
STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion
Microsoft
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3. Remove pressure and return hose connections from steering gear. Remove mud flap on driver's side.
Remove steering gear mounting bolts. Remove steering gear through wheelwell on driver's side.
4. To install, reverse removal procedure. Fill and bleed system. Tighten bolts to specification. See
TORQUE SPECIFICATIONS
table.
Removal & Installation (Protege & 323)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheels. Remove
engine undercover. Remove cotter pins and castle nuts from tie rod ends.
2. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-to-
steering gear pinion shaft bolt. Remove pressure and return hose connections from steering gear box.
3. Remove all accessible steering gear mounting bracket upper nuts and lower bolts. On Protege, support
drive train from above. Loosen stabilizer bar left mounting bracket and remove engine mount
crossmember.
4. Remove transmission control cable clip. Remove transfer case mount nuts. Lower engine gradually until
rear engine mount bolts can be removed. Remove lower left steering gear mounting bolt from between
transaxle and transfer case.
5. On all models, remove steering gear. To install, reverse removal procedure. Fill and bleed system.
Tighten bolts to specification. See TORQUE SPECIFICATIONS
table.
Removal & Installation (RX7)
1. Remove battery. Drain cooling system. Remove fan shroud and radiator. Raise and support front of
vehicle. Remove front wheels and engine undercover.
2. Remove control links and stabilizer bar. Remove cotter pins and castle nuts from tie rod ends. Remove tie
rods from steering knuckles with puller.
3. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Remove pressure and
return hose connections from steering gear box.
4. Remove steering gear mounting bolts. Lower steering gear brackets, steering gear and linkage from
vehicle as an assembly.
5. To install, reverse removal procedure. Fill and bleed system. Tighten bolts to specification. See
TORQUE SPECIFICATIONS
table.
Removal & Installation (929)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheels. Remove
engine undercover. Disconnect pressure and return hose connections in front of steering gear.
2. Drain fluid. Disconnect return hose fitting to control valve. Remove starter for access to control valve.
Disconnect control valve and pressure switch connectors. Remove control valve. Remove cotter pins and
castle nuts from tie rod ends.
3. Using puller, remove tie rods from steering knuckles. Remove steering column intermediate shaft-to-
steering gear pinion shaft bolt. Remove steering gear mounting bolts. Remove steering gear from bottom
of vehicle.
4. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS

1991 Mazda MX-5 Miata
STEERING GEAR - POWER RACK & PINION 1991 STEERING Mazda - Power Rack & Pinion
Microsoft
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STARTER - DIRECT DRIVE
1990-92 ELECTRICAL Mazda Starters - Direct Drive
DESCRIPTION
Nippondenso direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is
attached to the drive housing. The overrunning clutch pinion drive is mounted directly on armature shaft drive
end.
TROUBLESHOOTING
TESTING (ON VEHICLE)
CIRCUIT TESTING
1. Turn ignition switch to START position, depress clutch and ensure starter operates. If starter does not
operate, use voltmeter to check voltage at "S" terminal when clutch is depressed and ignition is turned to
START position. See Fig. 1
.
2. If voltage is less than 8 volts, check starter interlock switch and ignition switch to starter wiring circuit for
short to ground. If voltage is greater than 8 volts and starter is inoperative, starter has an internal fault.
Repair or replace as required. NOTE: For information on B2200 and Protege models with automatic transmissions,
see STARTERS - GEAR REDUCTION article.
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL
INFORMATION section.
NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are
clean and tight and engine grounds are good.

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
Microsoft
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continuity does not exist, adjust or replace switch.
BENCH TESTS (ASSEMBLED)
NO-LOAD TEST
Connect fully-charged 12-volt battery, voltmeter and ammeter to starter. See Fig. 2
. Using remote starter wires
or jumper, engage solenoid. Starter should spin smoothly. Note/record meter readings and check no-load
specification. See NO-LOAD TEST SPECIFICATIONS table. If not within specification, disassemble and
inspect starter components.
NO-LOAD TEST SPECIFICATIONS
ApplicationSpecification
B2200 (M/T), Miata, Protege (M/T) & 323
Voltage11.5 Volts
Current60 Amps Maximum
Shaft Speed6500 RPM

1991 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1990-92 ELECTRICAL Mazda Starters - Direct Drive
Microsoft
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