1997 MAZDA MX-5 engine

Fig. 1: Connecting Pressure Gauge/Valve (Typical)
Courtesy of MAZDA MOTORS CORP.
Gear Fluid Pressure Test
1. Ensure steering pump pressure is within specification. See PUMP FLUID PRESSURE TEST . To
measure steering gear fluid pressure, open gauge valve completely. Increase engine speed to 1000-1500
RPM.
2. Turn steering wheel from lock to lock. Measure steering gear fluid pressure. Ensure gear pressure is
within specification. See HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS
table. If
pressure is not within specification, replace gear.
HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS
(1)
Applicationpsi (kg/cm2 )
Miata & MPV1102-1209 (77-85)
MX-31138-1152 (80-81)
Millenia, MX-6 & 6261209-1280 (85-90)
Protege1244-1350 (87-95)
RX71110-1209 (78-85)
9291066-1137 (75-80)
(1)Specifications are measured at 1000-1500 RPM, with fluid temperature at 122-140°F (50-60°C).

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

LUBRICATION
FLUID CAPACITY
POWER STEERING FLUID CAPACITY
FLUID TYPE
Dexron-II or Mazda M-III fluid is recommended for all models.
FLUID LEVEL CHECK
Check fluid level on oil pump dipstick (if equipped) or reservoir. Fluid should be between marks on level gauge
dipstick (if equipped) or reservoir. If fluid level is low, fill as necessary. Recheck fluid level. DO NOT overfill.
HYDRAULIC SYSTEM BLEEDING
1. Raise and support front of vehicle. With ignition off, turn steering wheel from lock to lock several times.
Check fluid level. Add fluid as necessary. Repeat procedure until fluid level no longer decreases.
2. Start engine and operate at idle. Turn steering wheel from lock to lock 5 times. Check fluid level. Add
fluid as necessary. Continue procedure until fluid is clear of air bubbles and does not decrease in level.
ADJUSTMENTS
PINION PRELOAD
Miata & Protege
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover to 43 INCH lbs. (4.9 N.m), then loosen adjusting cover. See Fig. 2
. Repeat loosening and
ti
ghtening procedure 3 times. After tightening adjusting cover the third time, loosen adjusting cover 25
ApplicationQts. (L)
Miata & Protege.85 (.80)
MPV.95 (.90)
MX-3
4-Cylinder.85 (.80)
V61.27 (1.20)
Millenia, MX-6 & 6261.32 (1.25)
RX71.01 (.96)
9291.80 (1.70)
NOTE: Pinion preload should be checked when steering gear assembly has been
disassembled or overhauled. Check preload after steering gear assembly has
been reassembled, but tie rods have not yet been installed.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

frame mounting bolts. Remove steering gear and linkage from vehicle. On MPV, remove steering gear
bracket-to-frame mounting bolts. Remove steering gear and linkage with steering bracket from vehicle.
Remove 4 steering gear-to-bracket bolts and separate gear from bracket.
4. On all models, to install, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS table. On MPV, tighten steering gear-to-bracket bolts in sequence: left front, right
front, left rear, right rear. On all models, fill and bleed power steering system. Check and adjust front
wheel alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (Millenia)
1. Disconnect negative battery cable. Support engine using Engine Support (49-G017-5A0 ). Raise and
support front of vehicle. Remove front wheel assemblies. Remove cotter pins and castle nuts from tie rod
ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. Remove transverse
member bolts and remove transverse member. See Fig. 6
Disconnect pressure and return line connections
from steering gear. Remove intermediate shaft pinch bolt.
3. Reference mark lower steering column-to-intermediate shaft. Remove engine mount member. Remove
No. 1 engine mount bolts. Remove upper lateral link bolt and separate upper lateral link from
crossmember. Remove lower control arm-to-crossmember mounting bolt and gusset. Separate lower
control arm from crossmember.
4. Remove stabilizer link-to-lower control arm nut. Separate stabilizer link from lower control arm. Using a
jack, support front suspension crossmember. Remove crossmember retaining nuts. Carefully lower
crossmember. Disconnect stabilizer link from stabilizer bar. Remove stabilizer bar brackets, bushings and
stabilizer bar. Remove steering gear mounting nuts. Remove steering gear assembly.
5. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table. Tighten steering gear mounting nuts in sequence: right front, left rear, right rear, left front. Fill and
bleed power steering system. Check and adjust front wheel alignment. See SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 10 © 2005 Mitchell Repair Information Company, LLC.

Fig. 6: Removing Steering Gear Assembly (Millenia)
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MX-3 & Protege)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. On MX-3 DOHC, remove
support bracket bolt, nut and rubber insulator. Remove steering gear insulator bolts and remove insulator.
On all models, remove intermediate shaft dust cover.
3. Mark steering column intermediate shaft-to-steering column gear pinion for installation reference.
Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Disconnect pressure and
return line connections from steering gear.
4. On M/T, remove mounting nuts and bolts from extension bar and control rod. Remove extension rod and
control rod. On all models, remove steering gear mounting nuts. Remove steering gear and linkage from

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 11 © 2005 Mitchell Repair Information Company, LLC.

vehicle through passenger side wheelwell.
5. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS table. Tighten steering gear mounting nuts in sequence: left rear, right rear, left
front, right front. Fill and bleed power steering system. Check and adjust front wheel alignment. See
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (MX-6 & 626)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove cotter pins and castle nuts from tie rod ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. On 2.5L engines, remove
transverse member bolts and remove transverse crossmember. Remove front exhaust pipe and catalytic
converter assembly nuts and remove assembly.
3. On all models, support engine using Engine Support (49-G017-5A0 ), and remove engine mount. Mark
steering column intermediate shaft-to-steering column gear pinion for installation reference. Remove
steering column intermediate shaft-to-steering gear pinion shaft bolt.
4. Disconnect pressure and return line connections from steering gear. Remove steering gear mounting nuts.
Remove steering gear and linkage from vehicle through passenger's side wheelwell.
5. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table. Tighten steering gear mounting nuts in sequence: left front, right front, right rear, left rear. Fill and
bleed power steering system. Check and adjust front wheel alignment. See SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (RX7)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends. Using Puller Set (49-
T028-3A0 ), separate tie rod ends from steering knuckles.
2. Remove stabilizer bar-to-frame bolts and brackets. Disconnect pressure and return line connections from
steering gear. Mark steering column intermediate shaft-to-steering column gear pinion for installation
reference.
3. Remove steering column intermediate shaft-to-steering gear pinion shaft bolt. Remove steering gear
mounting bolts. Support crossmember with jack and remove crossmember nuts and bolts. Slowly lower
jack and remove steering gear and linkage from vehicle.
4. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS table. Tighten steering gear mounting bolts in sequence: left rear, right rear, left
front, right front. Fill and bleed power steering system. Check and adjust front wheel alignment. See
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Removal & Installation (929)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove engine undercover. Remove cotter pins and castle nuts from tie rod ends. Using Puller Set (49-
T028-3A0 ), separate tie rod ends from steering knuckles.
2. Disconnect pressure and return line connections from steerin
g gear. Mark steering column intermediate

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 12 © 2005 Mitchell Repair Information Company, LLC.

ApplicationFt. Lbs. (N.m)
Miata
Adjusting Cover Lock Nut(1)
Intermediate Shaft-To-Pinion Shaft Bolt13-19 (18-26)
Pinion Shaft Lock Nut (1995)22-29 (30-39)
Power Steering Pump Mounting Bolts/Nuts27-40 (37-54)
Pressure Line Fitting-To-Power Steering Pump23-35 (31-47)
Pressure Line Fitting-To-Steering Gear23-35 (31-47)
Steering Gear Mounting Bolts/Nuts34-43 (46-58)
Steering Rack-To-Tie Rod58-72 (79-98)
Tie Rod Castle Nuts22-32 (30-44)
Tie Rod End-To-Tie Rod Lock Nut25-29 (34-39)
Valve Housing Bolts (1996-97)15-21 (20-29)
Wheel Lug Nuts66-86 (89-117)
Millenia
Adjusting Cover Lock Nut(1)
Intermediate Shaft-To-Pinion Shaft Bolt13-19 (18-26)
Engine Mount Member
Bolts50-69 (67-93)
Nut55-77 (75-104)
No. 1 Engine Mount Bolt32-44 (44-60)
Power Steering Pump Mounting Bolts/Nuts24-33 (33-45)
Power Steering Pump Pulley Lock Nut36-43 (49-58)
Pressure Line Fitting-To-Power Steering Pump23-35 (41-47)
Pressure Line Fitting-To-Steering Gear(2)
Steering Gear Mounting Bolts/Nuts32-44 (44-60)
Steering Rack-To-Tie Rod58-72 (79-98)
Tie Rod Castle Nuts41-59 (55-80)
Tie Rod End-To-Tie Rod Lock Nut58-72 (79-98)
Transverse Member Nuts (Millenia)40-56 (54-76)
Valve Housing Bolts13-18 (17-25)
Wheel Lug Nuts66-94 (89-127)
MPV
Adjusting Cover Lock Nut(1)
Intermediate Shaft-To-Pinion Shaft Bolt13-19 (18-26)
Pinion Shaft Lock Nut29-36 (39-49)
Power Steering Pump Mounting Bolts/Nuts23-34 (31-46)
Power Steering Pump Pulley Lock Nut29-43 (39-58)
Pressure Line Fitting-To-Power Steering Pump23-35 (31-47)
Pressure Line Fitting-To-Steering Gear23-35 (31-47)

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:27 PMPage 29 © 2005 Mitchell Repair Information Company, LLC.

STARTER - DIRECT DRIVE
1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
DESCRIPTION & OPERATION
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 end of armature shaft drive.
TROUBLE SHOOTING
ON-VEHICLE TESTING
* PLEASE READ FIRST *
CIRCUIT TESTING
If starter does not operate, check voltage at starter "S" terminal with ignition switch in START position (and
clutch depressed on M/T). See Fig. 1
. If voltage is greater than 8 volts, repair or replace starter as required. If
volta
ge is 8 volts or less, check ignition switch, park/neutral switch (A/T), interlock switch (M/T) and wiring. NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.
NOTE: On all models with anti-theft system, obtain code number and deactivate audio
anti-theft system before disconnecting battery.
NOTE: Before testing, ensure battery is fully charged, battery cables and terminals are
clean and tight, and engine grounds are good.

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
Microsoft
Sunday, July 05, 2009 1:56:15 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, July 05, 2009 1:56:20 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.

FIELD WINDING TEST
1. Connect one ohmmeter lead to field coil lead ("M" terminal wire). Connect other lead of ohmmeter to
soldered portion of brush lead. If continuity does not exist, repair or replace field coil.
2. Check field coil for short to ground by connecting one ohmmeter lead to field coil lead ("M" terminal
wire) and other ohmmeter lead 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 or does not
turn at all, clutch is faulty. Replace clutch. DO NOT clean overrunning clutch with solvent, as it is packed with
grease and sealed by manufacturer.
REMOVAL & INSTALLATION
Removal & Installation
Disconnect negative battery cable. Raise vehicle on hoist. Remove engine undercover (if equipped). Disconnect
wiring from starter. Remove starter mounting bolts and starter. To install, reverse removal procedure. Tighten
starter mounting bolts to specification. See TORQUE SPECIFICATIONS
.
OVERHAUL
(1)Information is not available at time of publication.
NOTE: On models with anti-theft system, obtain code number and deactivate audio
anti-theft system before disconnecting battery.
NOTE: Overhaul procedures are not available at time of publication. See illustration for
exploded view of starter. See Fig. 4
.

1997 Mazda MX-5 Miata
STARTER - DIRECT DRIVE 1997 STARTING & CHARGING SYSTEMS Mazda - Starters - Direct Drive
Microsoft
Sunday, July 05, 2009 1:56:16 PMPage 8 © 2005 Mitchell Repair Information Company, LLC.