1991 MAZDA MIATA battery

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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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
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STEERING COLUMN
1991 STEERING Mazda - Steering Columns
DESCRIPTION
The steering column consists of solid steering shaft with a lower joint assembly. Miata and RX7 convertible
models are equipped with Air Bag Restraint System consisting of an air bag module and clockspring connector
assembly located in the steering column.
REMOVAL & INSTALLATION
STEERING WHEEL & HORN PAD
Removal & Installation (B2200, B2600i, MPV & 929)
Unsnap horn pad cover. Remove steering wheel lock nut. Use a puller to remove steering wheel. To install,
reverse removal procedure.
Removal & Installation (Miata & RX7)
1. On Miata and RX7 convertible models, remove air bag module. See AIR BAG RESTRAINT SYSTEM
article in the ACCESSORIES/SAFETY EQUIPMENT section. For all models, remove horn cap (if
equipped).
2. Remove steering wheel nut. Remove steering wheel with steering wheel puller. To install, reverse
removal procedure. Tighten steering wheel nut and air bag nuts to specification. See TORQUE
SPECIFICATIONS TABLE at end of article. WARNING:Wait about 10 minutes after disabling air bag system before servicing. Air
bag system voltage is maintained for about 10 minutes after system is
disabled. Failure to wait 10 minutes before servicing system may cause
accidental air bag deployment and possible personal injury.
CAUTION: DO NOT strike steering shaft with a hammer as it may collapse.
WARNING:Before servicing Miata and RX7 convertible models, disconnect and
shield battery ground. Use caution when working around steering column
as air bag could deploy.
WARNING:Wait about 10 minutes after disabling air bag system before servicing. Air
bag system voltage is maintained for about 10 minutes after system is
disabled. Failure to wait 10 minutes before servicing system may cause
accidental air bag deployment and possible personal injury.

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns

1991 Mazda MX-5 Miata
STEERING COLUMN 1991 STEERING Mazda - Steering Columns
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MAZDA
1.6L & 1.8L 4-Cylinder - 1986-95
MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE
For 1992 and earlier model years, the manufacturer recommends the belt be replaced every 60,000 miles. For
1993-95 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles
sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and
replace timing belt at 105,000 miles.
REMOVAL & INSTALLATION
TIMING BELT
Removal (MX-3, Protege & 323)
1. Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right
splash panels.
2. Remove drive belts and water pump pulley. See Fig. 1
, Fig. 2 or Fig. 3 . Align crankshaft pulley timing
mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft stationary, and remove
crankshaft pulley bolts and pulley. Remove crankshaft pulley hub bolt and hub.
3. Remove timing belt covers. If timing belt is to be reused, mark timing belt rotation direction. Align
timing marks on camshaft sprocket(s). See Fig. 4
(SOHC) or Fig. 5 (DOHC) . Loosen timing belt
tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully expanded. Remove
timin
g belt.

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

1991 Mazda MX-5 Miata
MAZDA 1.6L & 1.8L 4-Cylinder - 1986-95
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Fig. 5: Aligning Camshaft Timing Marks (DOHC 1.8L Engines)
Courtesy of MAZDA MOTORS CORP.
Removal (MX-5 Miata - DOHC)
1. Disconnect negative battery cable. Drain cooling system. Remove radiator hose and by-pass hoses from
thermostat housing. Remove air cleaner intake duct assembly from throttle body to air cleaner filter
housing. Remove splash shield.
2. Remove drive belt(s) and water pump pulley. See Fig. 6
. Align crankshaft pulley timing mark with
cylinder No. 1 at TDC of compression stroke. Hold crankshaft pulley stationary. Remove crankshaft
pulley bolts. Remove pulley. Remove crankshaft pulley hub bolt and hub.
3. Remove cylinder head cover. Remove upper, center and lower timing belt cover. If timing belt is to be
reused, mark timing belt rotation direction. Ensure timing marks on camshaft sprockets are aligned. See
Fig. 7
. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully
expanded. Remove timin
g belt.

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