1997 MAZDA MX-5 engine

929
1. Depress brake pedal several times. Depress parking brake pedal several times with a force of 44 lbs. (20
kg). If stroke is 5-7 notches, parking brake is properly adjusted. If stroke is not 5-7 notches, rotate
adjusting nut, located under parking brake pedal, until stroke is within specification.
2. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake pedal is
depressed one notch.
BRAKE PEDAL FREE PLAY
With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal
free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS
. Adjust play by loosening push rod lock
nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).
BRAKE PEDAL FREE PLAY SPECIFICATIONS
BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH
Miata, MPV, MX-3, MX-6, RX7, 626 & 929
1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.
Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Rotate switch away
from pedal. Loosen push rod lock nut. Rotate push rod until correct pedal height is obtained. See
BRAKE PEDAL HEIGHT SPECIFICATIONS
.
2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
. Tighten push rod lock nut to 18-25 ft. lbs.
(24-34 N.m).
3. Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight
switch lock nut 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.
4. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure.
5. Measure applied pedal hei
ght. See BRAKE PEDAL HEIGHT SPECIFICATIONS . If distance is not NOTE: On B2300, B3000 & B4000, brake pedal free play is built into pedal linkage and
is not adjustable.
ApplicationIn. (mm)
Miata, MPV & MX-3.16-.28 (4-7)
Millenia, MX-6, Protege & 626.16-.47 (4-12)
RX7.12-.31 (3-8)
929.12-.47 (8-12)
NOTE: B2300, B3000 & B4000 are equipped with dual brake master cylinder and
vacuum booster. System is designed to permit full stroke of master cylinder
when brake pedal is fully depressed. Brake pedal height adjustment is not
required.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
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as specified, check for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.
BRAKE PEDAL HEIGHT SPECIFICATIONS
Millenia & Protege
1. Released pedal height is measured between brake pedal and stoplight switch mounting bracket. See Fig.
3 . Disconnect stoplight switch electrical connector and remove switch. Measure length "L" between
stoplight switch mounting bracket and brake pedal. See Fig. 3
. On Millenia, length should be .79-
.90" (20-23 mm). On Protege, length should be .71-.86" (18-22 mm).
2. On all models, if clearance is as specified, install stoplight switch. No adjustment is necessary. If
clearance is not as specified, loosen lock nut "B" and rotate self-locking nut "A" counterclockwise until it
does not contact brake pedal.
3. Loosen push rod lock nut and rotate push rod until correct clearance between brake pedal and stoplight
switch mounting bracket is obtained. Tighten push rod lock nut. Rotate self-locking nut "A" clockwise
until clearance between brake pedal and end of self-locking nut "A" is .004-.039 (.1-1.0 mm). See Fig. 3
.
Tighten lock nut "B".
4. Install NEW stoplight switch. Stoplight switch is automatically adjusted by pulling back on brake pedal
until stoplight switch click noise is heard. Reconnect stoplight switch electrical connector. Check
stoplight operation. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
. Tighten push rod lock
nut to 18-25 ft. lbs. (24-34 N.m).
5. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure. On Millenia, distance should be 2.7" (70
mm). On Protege, distance should be 3.8" (95 mm). On all models, if distance is not as specified, check
ApplicationIn. (mm)
Pedal Released
Miata6.8-7.1 (171-181)
MPV7.5-7.9 (191-201)
MX-37.6-7.7 (193-196)
MX-6 & 6267.5-7.7 (191-196)
RX76.5-6.9 (165-176)
9297.4-7.7 (188-195)
Pedal Applied (1)
Miata3.7 (95)
MPV, MX-6 & 6263.3 (85)
MX-32.8 (70)
RX73.9 (100)
9291.6 (40)
(1)Minimum height.
NOTE: When adjusting brake pedal height, a NEW stoplight switch must be used.
Stoplight switch can only be adjusted one time.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
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POWER BRAKE UNIT
1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake
pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal
does not move as specified, go to next step.
2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is
longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is
operating. If length of strokes is equal, check valve and vacuum hose between vacuum source and power
brake unit. Repair as necessary, and go to next step.
3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal
height remains at same height, power brake unit is operating. If pedal height recedes, check valve and
vacuum hose between vacuum source and power brake unit. Repair as necessary.
REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
Removal & Installation (B2300, B3000 & B4000)
1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake
fluid from master cylinder reservoir. Raise and support vehicle. Remove front wheel assemblies. Place a
large "C" clamp on caliper.
2. Tighten clamp to bottom piston in cylinder bore. Remove clamp. Remove 2 caliper pin bolts. Remove
caliper from rotor and wire aside. Slide brake pads off caliper anchor plate. Remove anchor plate (if
necessary). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING
SPECIFICATIONS (FRONT) .
3. To install, reverse removal procedure. Use "C" clamp and old pad to push caliper piston into piston bore
until piston bottoms out. Bleed air from brake system (if necessary).
Removal & Installation (Miata, Millenia, MPV, MX-6, 626 & 929)
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt.
See Fig. 4
, Fig. 5 or Fig. 6 . Pivot caliper upward and support using rope.
2. Remove pads, shims, guide plates or pad guides and "V" springs (if equipped). Replace pad if lining
thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT)
.
3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push
piston full
y inward to install disc pads.
(38-46)

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
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GENERATOR & REGULATOR
1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
DESCRIPTION & OPERATION
Generator is a conventional 3-phase, self-rectifying type with 6 diodes (3 positive and 3 negative) that rectify
current. Internal regulator is solid-state type.
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
TROUBLE SHOOTING
TROUBLE SHOOTING PRECAUTIONS
Observe the following precautions when trouble shooting or testing charging system:
Obtain code number and deactivate audio anti-theft system before disconnecting battery (if equipped).
DO NOT reverse battery cable connections. Rectifier will be damaged.
DO NOT use high voltage type testers.
Battery voltage should always exist at generator terminal "B".
DO NOT ground generator terminal "L" while engine is running.
DO NOT start engine with connector disconnected from generator terminals "L" and "S".
DO NOT apply battery voltage to terminal "L".
ON-VEHICLE TESTING
* PLEASE READ FIRST *
Application(1) Deflection - In. (mm)
New Belt0.22-0.28 (5.5-7.0)
Used Belt0.24-0.30 (6.0-7.5)
(1)With 22 lbs. (10 kg) applied to belt.
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
Microsoft
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GENERATOR OUTPUT
1. Connect an ammeter (100-amp minimum) in-line between generator terminal "B" connector and terminal
"B" of wiring harness connector. See Fig. 1
. Turn headlights and all accessories on. Depress brake pedal.
Operate engine at 2500-3000 RPM.
2. Measure and record generator output. See GENERATOR MAXIMUM RATED OUTPUT
table. If
amperage is as specified, go to next step. If amperage is not as specified, repair or replace generator.
3. Turn off headlights and all accessories. Release brake pedal. Operate engine at 2500-3000 RPM and
measure amperage under no-load condition. No-load amperage should be 5 amps or greater. If amperage
is as specified, go to next step. If amperage is not as specified, repair or replace generator.
4. Operate engine at 2500-3000 RPM. Measure voltage between ground and terminals "S" and "L". If 14.1-
14.7 volts does not exist, repair or replace generator. If 14.1-14.7 volts exists, generator output is okay.
GENERATOR MAXIMUM RATED OUTPUT NOTE: Check generator 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 generator terminal "B" does not contact ground.
ApplicationAmps
A/T70
M/T65

1997 Mazda MX-5 Miata
GENERATOR & REGULATOR 1997 STARTING & CHARGING SYSTEMS Mazda - Generators & Regulators
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Submerge other end of hose in container of brake fluid.
2. Fill reservoir with DOT 3 brake fluid. Have an assistant press and release clutch pedal several times, then
hold pedal down. With pedal pressed, loosen bleeder screw to let air and fluid escape.
3. Repeat step 2) until no more air bubbles emerge from hose. Tighten bleeder screw. Fill reservoir. Operate
clutch while inspecting for leaks. Check clutch and brake operation.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal (B2300, B2500, B3000 & B4000)
1. Disconnect negative battery cable. Shift transmission into Neutral. Remove gearshift lever. Raise and
support vehicle. Mark drive shaft flanges for installation reference. Remove drive shaft. Using Clutch
Disconnect Tool (T88T-70522-A), disconnect hydraulic line at transmission. See Fig. 2
. Plug hydraulic
line to prevent contamination. Disconnect wiring at transmission.
2. Remove starter. Remove exhaust components as necessary for clearance. On 4WD models, remove skid
plate and transfer case. On all models, secure transmission jack under transmission. Remove transmission
mount-to-crossmember nuts and bolts.
3. Remove nuts securing crossmember to frame side rails, and remove crossmember. Lower transmission
enough to gain access to transmission-to-engine block bolts. Remove transmission-to-engine block bolts.
Remove transmission.
4. If clutch parts are going to be reused, mark clutch cover and flywheel for reassembly reference. Loosen
pressure plate bolts evenly in crisscross pattern until springs are not under tension. Remove clutch cover
and clutch disc.
Inspection (B2300, B2500, B3000 & B4000)
1. Inspect disc for loose rivets, worn or defective springs, excessive wear, or oil contamination. Inspect
flywheel and clutch cover for burns, scoring, or grooves.
2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond
specification. See CLUTCH RUNOUT (MAXIMUM)
table.
3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT
(MAXIMUM) table. Inspect disc hub and input shaft splines for excessive wear. Hub must slide
smoothly on input shaft splines.
4. Inspect pilot bearing for wear. Apply inward pressure while rotating pilot bearing. If bearing sticks or has
excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect
release bearing for smooth operation, wear, damage, or looseness. Replace bearing as necessary.
CLUTCH RUNOUT (MAXIMUM)
ApplicationIn. (mm)
Disc0.028 (0.7)
Flywheel0.008 (0.20)

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Installation (B2300, B2500, B3000 & B4000)
1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide
grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a
crisscross pattern to specification. See TORQUE SPECIFICATIONS
.
2. Raise transmission into position. Install and tighten transmission-to-engine block bolts. See TORQUE
SPECIFICATIONS . Install crossmember.
3. On 4WD models, install NEW transfer case gasket. Install transfer case. Tighten transfer case bolts to
specification is sequence. See Fig. 3
. See TORQUE SPECIFICATIONS .
4. On all models, to complete installation, reverse removal procedure. Bleed hydraulic clutch system. See
HYDRAULIC SYSTEM BLEEDING
under ADJUSTMENTS.
Fig. 3: Tightening Transfer Case Bolts (B2300, B2500, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.
Removal (Miata)
1. Disconnect negative battery cable. Remove gearshift knob, console, and shift lever. See Fig. 4. Raise and
support vehicle. Remove engine undercover. Disconnect exhaust pipe from manifold. Mark drive shaft
flanges for installation reference. Remove drive shaft.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
Microsoft
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Fig. 4: Exploded View Of Drive Line (Miata)
Courtesy of MAZDA MOTORS CORP.
2. Remove clutch release cylinder. Remove starter. Disconnect speedometer cable from transmission. Note
locations, and disconnect wiring harness from Power Plant Frame (PPF).
3. Remove PPF bracket from rear transmission extension housing. Remove PPF-to-differential side bolts.
Pry out spacer. Remove PPF/differential mounting spacer. See Fig. 5
.
4. Thread M14 X 1.5 bolt into sleeve. See Fig. 6
. Twist bolt side to side while pulling it downward. Thread
M6 X 1 bolt into hole in housing block to hold sleeve. Remove long bolt. Remove short bolt.
5. Remove PPF side bolts. Remove PPF. Remove transmission-to-engine block bolts. Remove transmission.
Remove clutch cover bolts evenl
y in crisscross pattern. Remove clutch cover and disc. See Fig. 7.
NOTE: Do not remove spacers attached to top of Power Plant Frame (PPF). If they
are removed, replace PPF.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
Microsoft
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