1997 MAZDA MX-5 length

Fig. 15 .
3. Lightly push on end of adjusting gauge rod to ensure it is properly seated. Verify no gap exists between
adjusting nut and adjusting gauge body. Remove adjusting gauge from power brake unit without
disturbing adjusting nut. Place adjusting gauge on master cylinder.
4. Lightly push on end of adjusting gauge rod to ensure gauge rod is bottomed in master cylinder piston.
Ensure no clearance exists between adjusting gauge body and adjusting nut (clearance "B") or between
body and master cylinder (clearance "C"). Perform STEP 2. See Fig. 15
.
5. If clearance "B" exists, push rod is too short. If clearance "C" exists, push rod is too long. To adjust
clearance "B", go to next step. To adjust clearance "C", go to step 8).
6. To adjust clearance "B", lightly push on end of adjusting gauge rod. Using a feeler gauge, measure
clearance between adjusting nut and adjusting gauge. Perform STEP 3. See Fig. 15
.
7. Using Push Rod Adjuster (49-B043-004) and Adapter (49-B043-003), turn push rod nut to lengthen
power brake booster push rod an amount equal to amount measured at clearance "B" in step 6). Perform
STEP 4. See Fig. 15
.
8. To adjust clearance "C", measure and record adjusting gauge rod height D1. Perfrom STEP 5. See Fig.
15 . Turn adjusting nut until adjusting gauge body sits squarely on master cylinder.
9. Turn adjusting nut only enough for body to touch adjusting gauge. Measure and record adjusting gauge
height D2 of adjusting gauge rod. Perform STEP 6. See Fig. 15
. Subtract D1 from D2 measurement.
10. Using push rod adjuster and adapter, turn push rod nut to shorten power brake booster push rod an
amount equal to difference between hei
ght D1 and D2. Perform STEP 4. See Fig. 15 . NOTE: When lightly pushing on end of adjusting gauge rod in step 4), only use
enough pressure to bottom rod in piston. Too much pressure may cause a
false reading.
NOTE: Push rod threads are specially designed so bolt becomes harder to turn
past a certain point to prevent loosening of bolt. Turn bolt only within this
range.

1997 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock
Microsoft
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Fig. 3: Measuring Clip Outer Diameter
Courtesy of MAZDA MOTORS CORP. NOTE: For rear axle shaft length, see REAR AXLE SHAFT LENGTH
table.

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:37 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of MAZDA MOTORS CORP.
Reassembly
1. To reassemble, reverse disassembly procedure. Wrap tape around drive axle shaft ends before sliding CV
joint boots onto drive axle shaft. See Fig. 12
.
2. Align marks on cage and inner ring. Install balls to inner ring. Install cage, inner ring and ball assembly to
axle shaft in direction shown. See Fig. 14
. Larger diameter of cage should be facing snap ring groove.
3. Install a NEW snap ring in axle shaft snap ring groove. Apply specified amount of grease to joints and
boots. See LUBRICATION SPECIFICATION
table. Align marks and install NEW clip.
4. Ensure that boots are not dented or twisted. Set axle shaft to standard length. See AXLE SHAFT
LENGTH table. Release any trapped air from boots by carefully lifting up small end of each boot with a
cloth-wrapped screwdriver. Ensure that axle shaft length is within standard. If drive shaft length is not
within standard, repeat this step.
5. Fold NEW band back by pulling on end with pliers. See Fig. 15
. Band should be folded in direction
opposite forward revolving direction of axle shaft. Lock end of band by bending locking clips.
Fig. 12: Installing CV Joint Boot

Courtesy of MAZDA MOTORS CORP. NOTE: Inner and outer CV joint boots differ in design and/or diameter. CV joint boots
are stamped DOJ (wheel side) and BJ (differential side). Ensure correct boot is
installed at proper end when reassembling axle shaft. See REAR AXLE SHAFT
BOOT IDENTIFICATION table. See Fig. 13 .

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:37 PMPage 12 © 2005 Mitchell Repair Information Company, LLC.

Fig. 15: Installing Boot Band
Courtesy of MAZDA MOTORS CORP.
AXLE SHAFT BOOT IDENTIFICATION
LUBRICATION SPECIFICATION
AXLE SHAFT LENGTH
TORQUE SPECIFICATIONS
ApplicationWheel Side Diameter - In. (mm)
Differential Side Diameter - In.
(mm)
Miata3.58 (90.8)3.44 (87.4)
ApplicationQuantify
Differential Side CV Joint Boot3-3.71 oz. (85-105 g)
Wheel Side CV Joint Boot1.94-2.65 oz. (55-75 g)
ApplicationIn. (mm)
199730.21-30.60 (767.3-777.3)
1999-200130.42-30.81 (772.6-782.6)

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:38 PMPage 15 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, July 05, 2009 1:51:02 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 10 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of MAZDA MOTORS CORP.
Removal & Installation (Protege)
1. Disconnect negative battery cable. Remove engine undercovers. Drain engine oil. Remove exhaust header
downpipe and brackets from front exhaust system. Remove oil pan retaining bolts.
2. DO NOT damage sealant contact surfaces. Remove oil pan by prying between oil pan and mounting
surface. On Protege, remove stiffener by prying between stiffener and cylinder block. On all models,
clean all sealant from oil pan, bolts, engine block and both sides of stiffener (Protege).
3. On Protege, apply oil resistant sealant to engine block and stiffener. Install stiffener. On all models, apply
sealant and install oil pan within 5 minutes of applying sealant. To complete installation, reverse removal
procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS
. Fill engine with oil to
specification. See ENGINE LUBRICATION SYSTEM
under ENGINE OILING.
OVERHAUL
CYLINDER HEAD
Cylinder Head
Clean carbon and gasket material from all mating surfaces. Using a tap, clean cylinder head threads. Check
cylinder head warpage. If warpage exceeds specification, resurface head, but DO NOT exceed grinding limit.
See CYLINDER HEAD
under ENGINE SPECIFICATIONS. After resurfacing cylinder head, check cylinder
head height. Replace cylinder head if height is less than minimum specification.
Valve Springs
Ensure valve spring free length, out-of-square and compressed length are within specification. See VALVES &
VALVE SPRINGS under ENGINE SPECIFICATIONS. Replace valve spring if necessary.
Valve Stem Oil Seals
1. On Miata, use Installer Set (49-L012-0A0) to install valve seals. See Fig. 15 . Adjust installer dimension
"L" to seal depth of .720-.744" (18.3-18.9 mm). Using hand pressure ONLY, install seal until it contacts
cylinder head. Lightly oil valve seal lip.
2. On Protege, use Installer Set (49-L012-0A0) to install valve seals. See Fig. 15
. Adjust installer
dimension "L" to seal depth of .783" (19.9 mm). Using hand pressure, install seal until it contacts cylinder CAUTION: If reusing old oil pan bolts, remove old sealant from bolt threads.
Failure to remove old sealant may result in cracked block at bolt
holes.
NOTE: Intake and exhaust valve stem seals are different. Exhaust seals can be
identified by ridges molded into top of seal. Intake seals do not have identifying
ridges. Incorrect installation of valve stem seals will cause premature failure.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
Microsoft
Sunday, July 05, 2009 1:55:15 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.

OIL PUMP
Removal & Disassembly
1. Disconnect negative battery cable. Remove dipstick, tube and "O" ring. Drain engine oil and coolant.
Remove drive belts, crankshaft and water pump pulleys. Remove generator, A/C compressor and
mounting bracket. Without disconnecting A/C hoses, secure A/C compressor away from engine. Remove
timing belt and related components. See TIMING BELT
under REMOVAL & INSTALLATION.
2. Hold crankshaft sprocket in place and remove crankshaft sprocket bolt. Remove crankshaft sprocket
using steering wheel puller. Leave crankshaft Woodruff key in place.
3. Remove oil pan and oil pump pick-up tube. See OIL PAN
under REMOVAL & INSTALLATION.
Remove oil pump housing assembly. Using a screwdriver protected with a rag, drive oil seal out from
inside of oil pump housing assembly.
4. Remove pump cover screws (use a manual impact screwdriver, if necessary). See Fig. 22
. Remove pump
cover. Note location of alignment marks on inner and outer rotors. Remove inner and outer rotors. To
remove pressure relief valve, remove spring seat, pressure spring and control plunger.
Inspection
Replace pressure relief valve spring if length is not as specified. See OIL PUMP SPECIFICATIONS. Ensure
plunger slides freely in bore. Replace oil pump housing assembly if clearances are not as specified. See OIL
PUMP SPECIFICATIONS .
Reassembly & Installation
1. Apply oil to friction surfaces. Install inner and outer rotors with marks aligned. See Fig. 23 . Install
pressure relief valve components. Apply oil to lip of NEW oil seal. Press oil seal into bore until even with
face of oil pump housing assembly.
2. Install pump cover. Tighten screws to 53-78 INCH lbs. (6-9 N.m). To complete installation, reverse
removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
.
OIL PUMP SPECIFICATIONS
ApplicationW/O Filter Qts. (L)W/Filter Qts. (L)
Miata & Protege3.8 (3.6)4.0 (3.8)
ApplicationMaximum Clearance In. (mm)
Maximum Rotor Tip Clearance (1) .0079 (.20)
Maximum Rotor-To-Pump Body Clearance (2) .0079 (.20)
Maximum Rotor Side Clearance (3) .0055 (.14)
Pressure Relief Spring Free Length1.809 (45.94)
(1)See Fig. 23 .
(2)Insert feeler gauge between outer rotor and pump body.
Place straightedge across pump body and check clearance between straightedge and both rotors.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
Microsoft
Sunday, July 05, 2009 1:55:15 PMPage 33 © 2005 Mitchell Repair Information Company, LLC.