Mazda MX-5 Miata Sport 2007 Manual Download Page 40

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Fig. 40: Measuring Journal Diameters In X And Y Directions At Two Points (A And B)

Courtesy of MAZDA MOTORS CORP.

5. Remove the tappet.

6. Position a plastigage atop the journals in the axial direction.

7. Install the camshaft cap. (See

CAMSHAFT ASSEMBLY NOTE

8. Remove the camshaft cap. (See

CAMSHAFT CAP DISASSEMBLY NOTE

9. Measure the oil clearance.



If it exceeds the specification, replace the cylinder head.

Camshaft journal oil clearance (Standard)

0.035-0.080 mm {0.0014-0.0031 in}

Camshaft journal oil clearance (Maximum)

0.09 mm {0.0035 in}

2007 Mazda MX-5 Miata Sport

2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata

Microsoft

Thursday, July 09, 2009 2:43:25 PM

Page 40

Summary of Contents for MX-5 Miata Sport 2007

Page 1: ...de 2 0L 4 Cylinder LF 2 3L 4 Cylinder L3 WARNING Continuous exposure with USED engine oil has caused skin cancer in laboratory mice Protect your skin by washing with soap and water immediately after t...

Page 2: ...3 Adjust the SSTs bolts so that less than 20 mm 0 79 in of thread is exposed 4 Make the SSTs arms and plate parallel by adjusting the SSTs bolts and nuts 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Me...

Page 3: ...en the SSTs bolts and nuts to affix the SSTs firmly Fig 3 Identifying SST Bolts Nuts Parallel Plates 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Mi...

Page 4: ...ightening torque 22 30 N m 2 2 3 1 kgf m 16 22 ft lbf DISMOUNTING Dismount in the reverse order of mounting TIMING CHAIN DISASSEMBLY 1 Disassemble in the order indicated in the table WARNING Self lock...

Page 5: ...Lock Bolt Disassembly Note 1 Install the SST to the ring gear to lock the crankshaft against rotation 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata...

Page 6: ...ZDA MOTORS CORP Front Oil Seal Disassembly Note 1 Remove the oil seal using a screwdriver 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thu...

Page 7: ...le screw driver or equivalent tool 2 Slowly press the tensioner piston 3 Hold the chain tensioner piston with a 1 5 mm 0 06 in wire or paper clip 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical...

Page 8: ...l Pump Sprocket Disassembly Note 1 Hold the oil pump sprocket using the SST 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09...

Page 9: ...CYLINDER HEAD I DISASSEMBLY 1 Disassemble in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July...

Page 10: ...Actuator Lock Bolt Disassembly Note 1 Hold the camshaft by using a wrench on the cast hexagon as shown and loosen the camshaft sprocket 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul...

Page 11: ...le valve timing mechanism Fig 10 Using Wrench On Cast Hexagon Courtesy of MAZDA MOTORS CORP With variable valve timing mechanism 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF...

Page 12: ...mshaft caps bolts in 2 3 steps in the order shown in the figure NOTE The camshaft caps are numbered to make sure they are assembled in their original positions When removed keep the caps with the cyli...

Page 13: ...der shown in the figure NOTE The tappets are numbered to make sure they are assembled in their original positions When removed keep the tappets with the cylinder head they were removed from Do not mix...

Page 14: ...LINDER HEAD II DISASSEMBLY 1 Disassemble in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09...

Page 15: ...TORS CORP Valve Keeper Disassembly Note 1 Remove the valve keeper using the SSTs 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday Jul...

Page 16: ...Valve Seal Disassembly Note 1 Remove the valve seal using the SST 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009 2 43...

Page 17: ...R BLOCK I DISASSEMBLY 1 Disassemble in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009...

Page 18: ...X Flywheel MTX Disassembly Note 1 Hold the crankshaft using the SST 2 Remove the bolts in several passes 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miat...

Page 19: ...S CORP CYLINDER BLOCK II DISASSEMBLY 1 Disassemble in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursd...

Page 20: ...plastic hammer Main Bearing Cap Disassembly Note 1 Before removing main bearing cap inspect the crankshaft end play See CRANKSHAFT NOTE The tappets are numbered to make sure they are assembled in thei...

Page 21: ...following and repair or replace if necessary 1 Sunken valve seats 2 Excessive camshaft oil clearance and end play 3 Measure the cylinder head for distortion in six directions as shown in the figure If...

Page 22: ...CORP 4 Measure the manifold contact surface distortion as shown in the figure 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 0...

Page 23: ...distortion Maximum grinding 0 15 mm 0 006 in VALVE VALVE GUIDE INSPECTION 1 Measure the valve head margin thickness of each valve If it is less than the specification replace the valve Valve head mar...

Page 24: ...in Valve length Minimum IN 102 99 mm 4 055 in EX 104 25 mm 4 104 in Fig 24 Measuring Length Of Each Valve Courtesy of MAZDA MOTORS CORP 3 Measure the stem diameter of each valve in X and Y directions...

Page 25: ...4 Measure the inner diameter of each valve guide in X and Y directions at the three points A B and C as indicated in the figure If not as specified replace the valve guide Valve guide inner diameter S...

Page 26: ...corresponding valve guide If it exceeds the specification replace the valve and or the valve guide Valve stem to guide clearance Standard IN 0 024 0 069 mm 0 0009 0 0027 in EX 0 029 0 074 mm 0 0012 0...

Page 27: ...sion A of each valve guide without lower valve spring seat If not within the specified replace the valve guide Valve guide protrusion height standard 12 2 12 8 mm 0 481 0 503 in 2007 Mazda MX 5 Miata...

Page 28: ...GUIDE REPLACEMENT Valve Guide Removal 1 Remove the valve guide from the combustion chamber side using the SST 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5...

Page 29: ...1 Assemble the SSTs so that depth L is as specified Valve guide protrusion height standard 12 2 12 8 mm 0 481 0 503 in 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Ma...

Page 30: ...e valve guide in from the top of the cylinder head until the SSTs contacts the cylinder head 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft...

Page 31: ...ght dimension A is within the specification Valve guide protrusion height standard 12 2 12 8 mm 0 481 0 503 in 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX...

Page 32: ...cification resurface the valve seat using a 45 valve seat cutter and or resurface the valve face Valve seat contact width Standard 1 2 1 6 mm 0 048 0 062 in 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE...

Page 33: ...correct the valve seat using a 70 IN or 65 EX cutter and a 45 cutter 2 If the seating position is too inner side correct the valve seat using a 35 IN cutter and a 30 EX cutter and a 45 cutter 2007 Maz...

Page 34: ...of the valve stem If not specified replace the cylinder head Valve protrusion height Standard IN 40 64 42 24 mm 1 600 1 662 in EX 40 50 42 10 mm 1 595 1 657 in 2007 Mazda MX 5 Miata Sport 2006 08 ENGI...

Page 35: ...he spring height If it is less than the specification replace the valve spring Valve spring pressing force 390 N 39 76 kgf 87 67 lbf Valve spring standard height H 28 68 mm 1 129 in 2007 Mazda MX 5 Mi...

Page 36: ...pring one full turn and measure A at the point where the gap is the largest If it exceeds the specification replace the valve spring Valve spring out of square Maximum 1 95 mm 0 0767 in 2007 Mazda MX...

Page 37: ...n V blocks 2 Measure the camshaft runout If it exceeds the specification replace the camshaft Maximum runout Maximum 0 03 mm 0 0012 in 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2...

Page 38: ...mm in With variable valve timing mechanism IN 42 44 1 671 EX 41 18 1 621 Without variable valve timing mechanism IN 42 12 1 659 EX 41 08 1 618 Camshaft minimum height mm in With variable valve timing...

Page 39: ...the two points A and B as indicated in the figure If it is less than the specification replace the camshaft Camshaft journal diameter Standard 24 96 24 98 mm 0 9827 0 9834 in Camshaft journal diameter...

Page 40: ...he camshaft cap See CAMSHAFT CAP DISASSEMBLY NOTE 9 Measure the oil clearance If it exceeds the specification replace the cylinder head Camshaft journal oil clearance Standard 0 035 0 080 mm 0 0014 0...

Page 41: ...on replace the cylinder head or camshaft Camshaft end play Standard 0 09 0 24 mm 0 0035 0 0094 in Camshaft end play Maximum 0 25 mm 0 0098 in 12 Remove the camshaft cap See CAMSHAFT CAP DISASSEMBLY NO...

Page 42: ...in X and Y directions at the two points A and B shown in the figure Tappet bore diameter Standard 31 000 31 030 mm 1 2205 1 2216 in 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L...

Page 43: ...appet body outer diameter from the tappet hole inner diameter If it exceeds the specification replace the tappet or cylinder head Tappet to Tappet bore oil clearance Standard 0 02 0 06 mm 0 0008 0 002...

Page 44: ...block top surface in six directions as indicated in the figure If it exceeds the maximum replace the cylinder block Cylinder head gasket contact surfaces distortion Maximum 0 10 mm 0 004 in 2007 Mazd...

Page 45: ...ace If not within the specification replace the cylinder block Cylinder bore diameter Standard 87 500 87 530 mm 3 4449 3 4460 in Minimum maximum bore diameter limit 87 440 87 590 mm 3 4425 3 4484 in 2...

Page 46: ...lve A and verify that air passes through oil jet valve B If air does not flow replace the oil jet valve Oil jet valve air pressure 216 274 kPa 2 2 2 7 kgf cm2 31 4 39 7 psi 2007 Mazda MX 5 Miata Sport...

Page 47: ...iston piston pin piston ring and connecting rod as a single unit Piston diameter Standard CAUTION The piston and connecting rod cannot be disassembled When replacing the piston piston pin piston ring...

Page 48: ...45 mm 0 0010 0 0017 in Piston to cylinder clearance Maximum 0 11 mm 0 0043 in 3 Measure the piston ring to ring groove clearance around the entire circumference If it exceeds the specification replace...

Page 49: ...S CORP 4 Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel 5 Measure each piston ring end gap with a feeler gauge If it exceeds the specif...

Page 50: ...P CRANKSHAFT INSPECTION 1 Install the main bearing cap See MAIN BEARING CAP ASSEMBLY NOTE 2 Measure the crankshaft end play If it exceeds the specification replace the thrust bearing or crankshaft so...

Page 51: ...replace the crankshaft Crankshaft runout Maximum 0 05 mm 0 0019 in 5 Measure the journal diameter in X and Y directions at the two points A and B as indicated in the figure If it exceeds the specifica...

Page 52: ...19 in Crank pin journal diameter LF STD 46 980 47 000 mm 1 8497 1 8503 in US0 25 46 730 46 750 mm 1 8398 1 8405 in Crank pin journal diameter L3 STD 49 980 50 000 mm 1 9677 1 9685 in US0 25 49 730 49...

Page 53: ...ps See MAIN BEARING CAP DISASSEMBLY NOTE 10 Measure the main journal oil clearance If it exceeds the specification replace the main bearing using the main bearing selection table or grind the main jou...

Page 54: ...nnecting rod large end side clearance If it exceeds the specification replace the piston piston pin piston ring and connecting rod as a CAUTION The piston and connecting rod cannot be disassembled Whe...

Page 55: ...rod bearing and connecting rod cap See CONNECTING ROD CAP ASSEMBLY NOTE 6 Remove the connecting rod cap 7 Measure the connecting rod oil clearance If it exceeds the specification replace the connectin...

Page 56: ...1 in Connecting rod bearing size L3 STD 1 496 1 502 mm 0 0589 0 0591 in OS0 25 1 621 1 627 mm 0 0639 0 0641 in Fig 56 Measuring Connecting Rod Oil Clearance Courtesy of MAZDA MOTORS CORP BOLT INSPECTI...

Page 57: ...tandard 145 2 145 8 5 72 5 74 Maximum 146 5 5 77 Connecting rod bolt Standard 44 7 45 3 1 75 1 78 Maximum 46 0 1 81 Main bearing cap bolt Plastic region tightening bolt only Standard 110 0 110 6 4 33...

Page 58: ...ned rotate the rotor toward the valve timing retard position by hand until they are in place If the rotor and cover are not fixed even though their notch and groove are aligned replace the variable va...

Page 59: ...il control valve OCV connector 3 Measure the resistance between terminals A and B using an ohmmeter If not as specified replace the oil control valve OCV Specification 6 9 7 9 ohms 20 C 68 F 4 Connect...

Page 60: ...ol valve OCV is in the maximum valve timing retard position as indicated in the figure If it exceeds the specification replace the oil control valve OCV 4 Verify that the battery is fully charged If i...

Page 61: ...ol valve OCV NOTE When applying battery positive voltage between the oil control valve OCV terminals the connection can be either of the following Positive battery cable to terminal A negative battery...

Page 62: ...CV VALVE CLEARANCE INSPECTION 1 Measure the valve clearance as follows 1 Turn the crankshaft clockwise so that the No 1 piston is at TDC of the compression stroke 2 Measure the valve clearance at A in...

Page 63: ...valve clearance exceeds the standard replace the tappet See VALVE CLEARANCE ADJUSTMENT Valve clearance Engine cold IN 0 22 0 28 mm 0 0087 0 0110 in NOTE Make sure to note the measured values for choo...

Page 64: ...ver Upper Lower Blind Plug Courtesy of MAZDA MOTORS CORP 5 Turn the crankshaft clockwise so that the crankshaft is in the No 1 cylinder TDC position CAUTION Removal of this SST is extremely important...

Page 65: ...ble wrench on the cast hexagon and loosen the timing chain 3 Placing the suitable bolt M6 x 1 0 Length 25 35 mm 0 9 1 3 in at the engine front cover upper blind plug secure the chain guide at the posi...

Page 66: ...aust camshaft using a suitable wrench on the cast hexagon as shown in the figure 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday Jul...

Page 67: ...Courtesy of MAZDA MOTORS CORP 8 Remove the exhaust camshaft sprocket 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009 2...

Page 68: ...d the camshaft caps are numbered to make sure they are reassembled in their original position When removed keep the caps with the cylinder head they were removed from Do not mix the caps 2007 Mazda MX...

Page 69: ...in EX 0 30 mm 0 0118 in Valve clearance Engine cold IN 0 22 0 28 mm 0 0087 0 0110 in EX 0 27 0 33 mm 0 0106 0 0130 in 13 Install the camshaft with No 1 cylinder aligned with the TDC position 14 Tighte...

Page 70: ...ft Cap Bolt Tightening Sequence Courtesy of MAZDA MOTORS CORP 15 Install a new washer except for Mazda6 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata...

Page 71: ...not tighten the bolt for the camshaft sprocket during this step First confirm the valve timing then tighten the bolt 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Maz...

Page 72: ...rom the engine front cover to apply tension to the timing chain 19 Turn the crankshaft clockwise so that the crankshaft is in the No 1 cylinder TDC position 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE...

Page 73: ...kgf m 50 9 55 3 ft lbf 22 Remove the SST from the camshaft 23 Remove the SST from the block lower blind plug 24 Rotate the crankshaft clockwise two turns until the TDC position If not aligned loosen t...

Page 74: ...all the new engine front cover upper blind plug Tightening torque 8 0 11 5 N m 82 117 kgf cm 71 101 in lbf 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Mi...

Page 75: ...all the cylinder block lower blind plug Tightening torque 18 22 N m 1 9 2 2 kgf m 13 3 16 2 ft lbf 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Micr...

Page 76: ...he new engine front cover lower blind plug Tightening torque 10 14 N m 102 142 kgf cm 89 123 in lbf 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Mic...

Page 77: ...TORS CORP CYLINDER BLOCK I ASSEMBLY 1 Assemble in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday J...

Page 78: ...tall the main bearing caps in the order indicated in the figure 2 Tighten the main bearing cap bolts using the SST 49 D032 316 Tightening torque 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical O...

Page 79: ...9 in lbf 3 23 27 N m 2 4 2 7 kgf m 17 19 9 ft lbt 4 38 42 N m 3 9 4 2 kgf m 28 1 30 9 ft lbt 5 Loosen all the bolts no remaining torque 6 3 7 N m 30 6 71 3 kgf cm 26 6 61 9 in lbt 7 18 22 N m 1 9 2 2...

Page 80: ...e downward 3 Verify that the top ring is installed with scraper face side inner of upper Fig 79 Identifying Piston Rings Courtesy of MAZDA MOTORS CORP Piston Assembly Note 1 Position the end gap of ea...

Page 81: ...e piston and connecting rod into the cylinder with the arrow mark to front of the engine 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thur...

Page 82: ...Assembly Note 1 Install the connecting rod bearing to the connecting rod and connecting rod caps as shown in the figure 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3...

Page 83: ...1 26 32 N m 2 7 3 2 kgf m 19 2 23 6 ft lbf 2 80 100 Balancer Unit Assembly Note CAUTION When assembling the connecting rod caps align the broken rough faces of the connecting rods and connecting rod c...

Page 84: ...s in the No 1 cylinder TDC position until the balance weight is attached to the SST 4 Install the adjustment shim to the seat face of the balancer unit 5 With the balancer unit marks at the exact top...

Page 85: ...CORP 6 Set the SST as shown then measure the gear backlash using a dial gauge 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 0...

Page 86: ...o the crankshaft No 1 balance weight area and set both the rotation and the thrust direction with the screwdriver using a prying action as shown in the figure 2007 Mazda MX 5 Miata Sport 2006 08 ENGIN...

Page 87: ...acklash Courtesy of MAZDA MOTORS CORP If the backlash exceeds the specified range remeasure the backlash and using the adjustment shim selection table select the proper shim according to the following...

Page 88: ...231 0 00885 0 00909 21 1 21 0 0476 0 085 0 091 0 00334 0 00358 41 1 41 0 0555 0 218 0 224 0 00858 0 00881 22 1 22 0 0480 0 078 0 084 0 00307 0 00330 42 1 42 0 0559 0 211 0 217 0 00830 0 00854 23 1 23...

Page 89: ...5 0 015 0 021 0 00059 0 000826 51 1 51 0 0594 0 148 0 154 0 00582 0 00606 32 1 32 0 519 0 008 0 014 0 000314 0 000551 52 1 52 0 0598 0 141 0 147 0 00555 0 00578 33 1 33 0 523 0 001 0 007 0 00003 0 000...

Page 90: ...sembly Note 1 Apply clean engine oil to the new oil seal lip 2 Install the rear oil seal using the SST as shown in the figure 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3...

Page 91: ...olts in the order as shown in the figure Tightening torque 8 0 11 5 N m 81 6 117 2 kgf cm 70 9 101 7 in lbf 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 M...

Page 92: ...n the 3 steps in the figure Tightening torque 1 46 54 N m 4 70 5 50 kgf m 34 0 39 8 ft lbf 2 76 84 N m 7 75 8 56 kgf m 56 1 61 9 ft lbf 3 108 116 N m 11 1 11 8 kgf m 79 7 85 5 ft lbf 2007 Mazda MX 5 M...

Page 93: ...t to the oil pan as indicated in the figure CAUTION Install the oil pan within 10min of applying the silicone sealant Make sure that there is no oil or dust on the seal side of oil pan 2007 Mazda MX 5...

Page 94: ...To Oil Pan Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009 2 43 26 PM Page 94 2005 Mitch...

Page 95: ...er Block Courtesy of MAZDA MOTORS CORP 3 Tighten the rear oil pan bolts in the order as shown in the figure Tightening torque 17 23 N m 1 8 2 3 kgf m 12 6 16 9 ft lbf 2007 Mazda MX 5 Miata Sport 2006...

Page 96: ...CORP CYLINDER HEAD I ASSEMBLY 1 Assemble in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 0...

Page 97: ...eal Assembly Note 1 Press the valve seal onto the valve guide by hand 2 Lightly tap the SST using a plastic hammer 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6...

Page 98: ...lve Keeper Assembly Note 1 Install the valve keeper using the SSTs 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009 2 43...

Page 99: ...LINDER HEAD II ASSEMBLY 1 Assemble in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009...

Page 100: ...t Assembly Note 1 Tighten the cylinder head bolts in the order indicated in the figure in 5 steps using the SST 49 D032 316 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L...

Page 101: ...m 31 8 34 6 ft lbf 4 88 92 5 88 92 Fig 98 Cylinder Head Bolt Tightening Sequence Courtesy of MAZDA MOTORS CORP Camshaft Assembly Note 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0...

Page 102: ...Tightening Sequence Courtesy of MAZDA MOTORS CORP Camshaft Sprocket Variable Valve Timing Actuator Assembly Note 1 Temporarily tighten the camshaft sprocket or variable valve timing actuator installat...

Page 103: ...ssemble in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009 2 43 26 PM Page 103 2005 Mi...

Page 104: ...Fig 101 Assembling Oil Pump Sprocket Courtesy of MAZDA MOTORS CORP Timing Chain Assembly Note 1 Install the SST to the camshaft then align the No 1 camshaft position with the TDC 2007 Mazda MX 5 Miata...

Page 105: ...e the cylinder block lower blind plug 3 Install the SST as shown in the figure 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July...

Page 106: ...t the crankshaft is in the No 1 cylinder TDC position 5 Install the timing chain 6 Install the chain tensioner and remove the retaining wire 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overh...

Page 107: ...a suitable wrench on the cast hexagon as shown in the figure 2 Tighten the camshaft sprocket lock bolt Tightening torque 69 75 N m 7 1 7 6 kgf m 50 9 55 3 ft lbf 2007 Mazda MX 5 Miata Sport 2006 08 E...

Page 108: ...Apply clean engine oil to the oil seal 2 Push the oil seal slightly in by hand 3 Compress the oil seal using the SST and a hammer 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF...

Page 109: ...Seal Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009 2 43 26 PM Page 109 2005 Mitchell Re...

Page 110: ...the cylinder head cover within 10 min of applying the silicone sealant Silicone sealant is not need in area C as indicated below due to an existing With variable valve timing mechanism Make sure that...

Page 111: ...bolts in the order as shown in the figure CYLINDER HEAD COVER BOLTS SPECIFICATION Bolt No Tightening torque N m kgf m ft lbf 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3...

Page 112: ...N m 81 6 117 2 kgf cm 70 9 101 7 in lbf 19 22 40 55 4 1 5 6 29 6 40 5 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF 2 3L L3 Mazda6 MX 5 Miata Microsoft Thursday July 09 2009...

Page 113: ...haft Courtesy of MAZDA MOTORS CORP 2 Install the M6 x 1 0 bolt in by hand 3 Turn the crankshaft clockwise so that the crankshaft is in the No 1 cylinder TDC position 2007 Mazda MX 5 Miata Sport 2006 0...

Page 114: ...move the M6 x 1 0 bolt 7 Remove the SST from the camshaft 8 Remove the SST from the block lower blind plug 9 Rotate the crankshaft clockwise two turns until the TDC position If not aligned loosen the...

Page 115: ...t to the mating faces as shown in the figure Dot diameter 4 0 6 0 mm 0 16 0 23 in CAUTION Install the cylinder head cover within 10 min of applying the silicone sealant 2007 Mazda MX 5 Miata Sport 200...

Page 116: ...ew gasket 3 Tighten the bolts in the order shown in the figure Tightening torque 8 0 10 5 N m 81 6 107 1 kgf cm 70 9 92 9 in lbf 2007 Mazda MX 5 Miata Sport 2006 08 ENGINE Mechanical Overhaul 2 0L LF...

Page 117: ...004 in Manifold contact surfaces distortion Maximum grinding 0 15 mm 0 006 in Valve head margin thickness Minimum IN 1 62 mm 0 0637 in EX 1 82 mm 0 0716 in Valve length Standard IN 102 99 103 79 mm 4...

Page 118: ...in With variable valve timing mechanism IN 42 33 1 666 EX 41 06 1 616 Without variable valve timing mechanism IN 42 01 1 653 EX 40 96 1 612 Camshaft journal diameter Standard 24 96 24 98 mm 0 9827 0 9...

Page 119: ...3 STD 49 980 50 000 mm 1 9677 1 9685 in US0 25 49 730 49 750 mm 1 9579 1 9586 in Crank pin out of round Maximum 0 05 mm 0 0019 in Main journal oil clearance Standard 0 019 0 035 mm 0 0007 0 0013 in Ma...

Page 120: ...y Standard 110 0 110 6 4 33 4 35 Maximum 111 3 4 38 Valve clearance Engine cold IN 0 22 0 28 mm 0 0087 0 0110 in EX 0 27 0 33 mm 0 0106 0 0130 in Value range 0 005 0 101 mm 0 00019 0 0039 in 2007 Mazd...

Page 121: ...et 1 49 UN30 3465 2 303 465 Camshaft Alignment timing Tool 1 49 G032 354 2 Adjusting wrench 1 49 B012 015 2 Valve guide installer 1 49 0636 100B 2 Valve spring lifter arm 1 49 L010 2007 Mazda MX 5 Mia...

Page 122: ...seal remover 1 49 L012 0A0B 2 Valve seal and valve guide installer set 1 49 UN30 3328 2 303 328 Rear oil seal replacer 1 49 D032 316 2 Protractor 1 49 G011 201 2 Attachment 2007 Mazda MX 5 Miata Sport...

Page 123: ...OSIS ABS 2007 Mazda MX 5 Miata Sport 2007 BRAKES On Board Diagnostic ABS MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 BRAKES On Board Diagnostic ABS MX 5 Miata Microsoft Thursday July 09 2009 3 17 55 P...

Page 124: ...ata values input signals calculated values and system status information ACTIVE COMMAND MODES This function allows you to control devices through the M MDS READING DTCS PROCEDURE 1 Connect the M MDS t...

Page 125: ...Toolbox tab Select Self Test Select Modules Select ABS When using the PDS Pocket PC Select Modules Tests Select ABS Select Self Test 3 Verify the DTC according to the directions on the screen 4 Press...

Page 126: ...op PC Select the Toolbox tab Select DataLogger Select Modules Select ABS When using the PDS Pocket PC Select Modules Tests Select Optional tab Select ABS Select DataLogger 3 Select the applicable PID...

Page 127: ...used for monitoring the calculated value Therefore if the monitored value of the output parts is not within specification inspection of the monitored value of input parts corresponding to applicable o...

Page 128: ...hort circuit in the wiring harness relay motor or solenoid or sticking and operation malfunction Fig 5 Locating DLC 2 Connector Courtesy of MAZDA MOTORS CORP DTC TABLE DTC TABLE DTC System malfunction...

Page 129: ...ve system C1233 LF ABS wheel speed sensor ABS sensor rotor system C1234 RF ABS wheel speed sensor ABS sensor rotor system C1235 RR ABS wheel speed sensor ABS sensor rotor system C1236 LR ABS wheel spe...

Page 130: ...t rear outlet solenoid valve output state On Off Solenoid valve activated On Solenoid valve not activated Off Inspect the ABS HU CM See ABS HU CM INSPECTION ABSPMPRLY Motor relay output state On Off R...

Page 131: ...nput KPH MPH Vehicle stopped 0 KPH 0 MPH Vehicle running Vehicle speed Inspect the ABS wheel speed sensor E F LR_WSPD Left rear ABS wheel speed sensor input KPH MPH Vehicle stopped 0 KPH 0 MPH Vehicle...

Page 132: ...em DETECTION CONDITION B1317 The voltage at ABS HU CM terminal J is 16 8 V or more B1318 The vehicle speed exceeds 6 km h and the voltage at ABS HU CM terminal J is less than 9 6 V POSSIBLE CAUSE ENGI...

Page 133: ...GRAVITY Is battery specific gravity as specified Yes Go to the next step No Replace the battery then go to Step 6 See BATTERY REMOVAL INSTALLATION LF 3 INSPECT CHARGING SYSTEM Are the generator and d...

Page 134: ...rcuit between the ABS HU CM and ground then go to the next step If the resistance is not within 0 1 ohm Repair or replace harness for poor ground then go to the next step 6 VERIFY TROUBLESHOOTING COMP...

Page 135: ...ent Yes Replace the ABS HU CM then go to the next step See ABS HU CM REMOVAL INSTALLATION No Go to the next step 2 VERIFY AFTER REPAIR PROCEDURE Are any other DTCs present Yes Go to the applicable DTC...

Page 136: ...n circuit between ABS HU CM and brake switch then go to the next step 2 INSPECT BRAKE SWITCH Inspect the brake switch See BRAKE SWITCH INSPECTION Is the brake switch normal Yes Go to the next step No...

Page 137: ...uration setting failure is detected POSSIBLE CAUSE Module configuration procedure was not completed properly STEP INSPECTION ACTION 1 VERIFY CONFIGURATION Has the ABS HU CM configuration been performe...

Page 138: ...attery power supply voltage and pump motor power supply voltage remains at 4 0 V or more for 0 1 s or more while the pump motor is operating POSSIBLE CAUSE ABS 40 A fuse malfunction Open or short to g...

Page 139: ...Turn the ignition switch to the ON position engine off Measure voltage between ABS HU CM terminal B harness side and ground Is the voltage B Yes Go to the next step No Repair or replace the wiring ha...

Page 140: ...the pump motor operate Yes Go to the next step No Replace the ABS HU CM then go to the next step See ABS HU CM REMOVAL INSTALLATION 5 VERIFY TROUBLESHOOTING COMPLETED Make sure to reconnect all discon...

Page 141: ...DETECTION CONDITION Periodic abnormality is detected in the signal wave pattern from the ABS wheel speed sensors POSSIBLE CAUSE ABS wheel speed sensor malfunction ABS sensor rotor malfunction foreign...

Page 142: ...RANCE Inspect the clearance between the ABS wheel speed sensor and the ABS sensor rotor See FRONT ABS WHEEL SPEED SENSOR INSPECTION See REAR ABS WHEEL SPEED SENSOR INSPECTION Is the clearance normal Y...

Page 143: ...the DTCs from the memory See CLEARING DTCS PROCEDURES Start the engine and drive the vehicle at 10 km h 6 2 mph or more Are the same DTCs present Yes Repeat the inspection from Step 1 If the malfunct...

Page 144: ...wheel speed sensor terminal ABS HU CM terminal M RF ABS wheel speed sensor terminal A ABS HU CM terminal O RF ABS wheel speed sensor terminal B ABS HU CM terminal F LF ABS wheel speed sensor terminal...

Page 145: ...ECT PID TO VERIFY THAT WHEEL SPEED SIGNALS ARE TRANSMITTED FROM ABS WHEEL SPEED SENSOR USING M MDS Turn the ignition switch off Connect the M MDS to the DLC 2 Select the following PIDs using the M MDS...

Page 146: ...wheel speed sensor connectors on the vehicle wiring harness side and ABS HU CM connectors RF ABS wheel speed sensor M A RF ABS wheel speed sensor O B LF ABS wheel speed sensor F A LF ABS wheel speed...

Page 147: ...HU CM then go to the next step See ABS HU CM REMOVAL INSTALLATION No Go to the next step 4 VERIFY THAT NO OTHER DTCS ARE PRESENT Are any other DTCs output Yes Go to the applicable DTC inspection See...

Page 148: ...or If the sensor rotor is installed at an angle it may cause output of abnormal wave pattern at high speeds Excessive clearance between the ABS wheel speed sensor and sensor rotor STEP INSPECTION ACTI...

Page 149: ...EL SPEED SENSOR REMOVAL INSTALLATION See REAR ABS WHEEL SPEED SENSOR REMOVAL INSTALLATION 3 VISUALLY INSPECT ABS SENSOR ROTOR FOR FOREIGN MATERIAL ADHERING OR IMPROPER INSTALLATION Is the result norma...

Page 150: ...C1186 C1266 Fail safe relay system DETECTION CONDITION C1186 ABS HU CM internal valve relay remains OFF when valve relay ON is commanded C1266 ABS HU CM internal valve relay remains ON stuck when valv...

Page 151: ...ct ABS HU CM connector Turn the ignition switch to the ON position engine off Measure voltage between ABS HU CM terminal C harness side and ground Is voltage B Yes Go to the next step No Repair or rep...

Page 152: ...outlet solenoid valve system C1198 LF inlet solenoid valve system C1210 RF outlet solenoid valve system C1214 RF inlet solenoid valve system C1242 LR outlet solenoid valve system C1246 RR outlet sole...

Page 153: ...Y DTC TROUBLESHOOTING COMPLETED Clear the DTC from the memory See CLEARING DTCS PROCEDURES Start the engine and drive the vehicle at 10 km h 6 2 mph or more Gradually slow down and stop vehicle Are th...

Page 154: ...ecified vehicle speed or more POSSIBLE CAUSE Short to ground in the wiring harness between the following ABS HU CM terminal and the ABS wheel speed sensor terminal ABS HU CM terminal M RF ABS wheel sp...

Page 155: ...inal B ABS wheel speed sensor malfunction Poor connection at connectors female terminal STEP INSPECTION ACTION 1 INSPECT PID TO VERIFY THAT WHEEL SPEED SIGNALS ARE TRANSMITTED FROM ABS WHEEL SPEED SEN...

Page 156: ...ff Disconnect the ABS HU CM connector and the ABS wheel speed sensor connector Inspect for a short to ground in the wiring harness between the following ABS wheel speed sensor connectors on the vehicl...

Page 157: ...emory See CLEARING DTCS PROCEDURES Start the engine and drive the vehicle at 10 km h 6 2 mph or more Are the same DTCs present Yes Repeat the inspection from Step 1 If the malfunction recurs replace t...

Page 158: ...ee ABS HU CM REMOVAL INSTALLATION 2 PERFORM CONFIGURATION Was configuration performed normally Yes Go to the next step No Replace the ABS HU CM then go to the next step See ABS HU CM REMOVAL INSTALLAT...

Page 159: ...Yes Go to the applicable DTC inspection See DTC Table No DTC troubleshooting completed 2007 Mazda MX 5 Miata Sport 2007 BRAKES On Board Diagnostic ABS MX 5 Miata Microsoft Thursday July 09 2009 3 17...

Page 160: ...ta Sport 2007 ACCESSORIES BODY CAB Security and Locks Advanced Keyless System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Security and Locks Advanced Keyless System MX 5 Miata Mic...

Page 161: ...Keyless Entry System Components Location 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Security and Locks Advanced Keyless System MX 5 Miata Microsoft Thursday July 09 2009 3 36 54 PM Page 2...

Page 162: ...ing Hood Latch Courtesy of MAZDA MOTORS CORP IMMOBILIZER SYSTEM LOCATION INDEX ADVANCED KEYLESS SYSTEM 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Security and Locks Advanced Keyless System...

Page 163: ...nit See DOOR UNIT REMOVAL INSTALLATION 5 Outer handle See OUTER HANDLE REMOVAL INSTALLATION ADVANCED KEYLESS SYSTEM 2 Detach the door key cylinder rod 3 Turn the door key cylinder so that the tab is a...

Page 164: ...h the cables from the inner handle and the door lock knob 3 Detach the rods from the key cylinder and the outer handle 4 Remove the screws then remove the door latch and lock actuator 5 Install in the...

Page 165: ...d Screw Courtesy of MAZDA MOTORS CORP DOOR LOCK SWITCH INSPECTION ADVANCED KEYLESS SYSTEM 1 Inspect for continuity between the door lock switch terminals If not as specified replace the door lock swit...

Page 166: ...MOTORS CORP DOOR LOCK ACTUATOR INSPECTION ADVANCED KEYLESS SYSTEM DOOR LOCK ACTUATOR 1 Disconnect the door lock actuator connector 2 Apply battery positive voltage and connect the ground to the corre...

Page 167: ...ock link switch terminals If not as specified replace the door lock actuator Fig 11 Door Lock Link Switch Continuity Chart Courtesy of MAZDA MOTORS CORP Actuator operation B GNB lock A F B E Unlock B...

Page 168: ...place the door lock actuator Fig 13 Door Key Cylinder Switch Continuity Table Courtesy of MAZDA MOTORS CORP Fig 14 Identifying Door Key Cylinder Switch Terminals With Circuit Courtesy of MAZDA MOTORS...

Page 169: ...of the front outer handle and with the front outer handle lever pulled outward 1 remove the rear part of the front outer handle from the front door 6 Pull out the front part of the front outer handle...

Page 170: ...LLATION 3 Scuff plate See SCUFF PLATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Seat back bar garnish See SEAT BA...

Page 171: ...TION 2 Remove the back trim See BACK TRIM REMOVAL INSTALLATION 3 Remove the seat back bar lower garnish See SEAT BACK BAR LOWER GARNISH REMOVAL INSTALLATION 3 Remove in the order indicated in the tabl...

Page 172: ...NSTALLATION NOTE 1 Install the hole of coil antenna to the tab of steering lock 2 Install the hook of coil antenna to the steering lock Fig 21 Identifying Hole Of Coil Antenna And Tab Of Steering Lock...

Page 173: ...ding clearing keys or performing other functions refer to the following table and perform the applicable procedure No 1 to 5 Verify that the room fuse is equipped IMMOBILIZER SYSTEM COMPONENT REPLACEM...

Page 174: ...it is not replaced Programmed card key Programming keys two or more M MDS 5 Replacing the steering lock unit New steering lock unit Programmed card key New keys two or more M MDS Carry out the followi...

Page 175: ...llowing items close to the key grip or contacting it Spare keys Keys for other vehicles equipped with an immobilizer system Any metallic object Any electronic device or any credit or other card with m...

Page 176: ...s started before completion Do not place the card key in the vehicle or bring it within approx 1 m of the vehicle unless indicated in the procedure Two or more key ID numbers must be programmed for th...

Page 177: ...A maximum of eight keys can be programmed for one vehicle If key programming is not successful and DTC 15 appears even though the procedure was performed properly use the PID data monitor function of...

Page 178: ...nnect the M MDS to the DLC 2 See M MDS CONNECTING PROCEDURE 6 Using key 1 turn the ignition switch to the ON position NOTE A maximum of eight keys can be programmed for one vehicle If key registration...

Page 179: ...he Step 6 13 After verifying that the PATS function menu is displayed again on the M MDS screen select the Exit From This Menu to finish the M MDS procedure 14 After Step 10 wait 5 s or more and then...

Page 180: ...ity light goes out turn the ignition switch to the LOCK position using key 2 and then remove key 2 15 If an additional key needs to be programmed repeat Steps 13 14 with the additional key being key 3...

Page 181: ...x 3 s and goes out The keyless warning light illuminates when the ignition switch is turned to the ON position and after approx 1 s after the engine is started it goes out 22 Turn the ignition switch...

Page 182: ...MODULE INSTRUMENT CLUSTER OR STEERING LOCK UNIT Condition Key Programming Procedure Using Two Valid Keys setting This procedure is possible when the vehicle is new and when replacing the keyless unit...

Page 183: ...rom the M MDS screen menu and perform the procedure according to the M MDS screen 7 Perform the security access according to the directions on the M MDS screen See SECURITY ACCESS PROCEDURE ADVANCED K...

Page 184: ...the ignition switch to the ON position 18 Verify that the security light and keyless warning light illuminate for approx 3 s and then goes out 19 After verifying that the security light goes out turn...

Page 185: ...23 After verifying that the keyless warning light goes out turn the ignition switch to the LOCK position using key 1 and then remove the key 24 Repeat Steps 22 23 using key 2 instead of key 1 25 Start...

Page 186: ...CORP 2 Install in the reverse order of removal 3 Adjust the hood See HOOD ADJUSTMENT HOOD RELEASE LEVER REMOVAL NOTE 1 Pull the lever 2 While pushing the tab in the direction of the arrow using a tap...

Page 187: ...or continuity between the hood latch switch terminals A and B If there is no continuity replace the hood latch switch Fig 30 Identifying Hood Latch Switch Terminals A And B Courtesy of MAZDA MOTORS CO...

Page 188: ...TION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Seat back bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTALLATION 7 Back trim See BACK TRIM REMOVAL INSTALLATION 8 Seat back bar lower garnish...

Page 189: ...cations Courtesy of MAZDA MOTORS CORP CARD KEY BATTERY REPLACEMENT ADVANCED KEYLESS SYSTEM CARD KEY TYPE 1 Pull out the auxiliary key 2 Replace the cap using a flathead screwdriver then rotate and rem...

Page 190: ...ut Fig 36 Removing Battery Courtesy of MAZDA MOTORS CORP 4 Insert the new battery CR2025 with the positive pole facing the mark on the cap Battery specification Lithium CR2025 x 1 2007 Mazda MX 5 Miat...

Page 191: ...mes a day NOTE If the keyless control module is replaced always perform the following procedure Without immobilizer system Card key programming See CARD KEY ID CODE REGISTRATION ADVANCED KEYLESS SYSTE...

Page 192: ...e bracket With immobilizer system Card key programming See CARD KEY ID CODE REGISTRATION ADVANCED KEYLESS SYSTEM Steering lock unit programming See STEERING LOCK UNIT ID CODE REGISTRATION ADVANCED KEY...

Page 193: ...Identifying Keyless Control Module Wiring Harness Side Connector Terminals Courtesy of MAZDA MOTORS CORP KEYLESS CONTROL MODULE TERMINALS VOLTAGE TABLE REFERENCE Terminal Signal name Connected to Meas...

Page 194: ...nuity detected keyless antenna exterior RF 2BB keyless antenna exterior RF keyless antenna exterior RF Under any condition Inspect for continuity to keyless antenna Continuity detected keyless antenna...

Page 195: ...interior middle Under any condition Inspect for continuity to keyless antenna Continuity detected keyless antenna interior middle 2L keyless antenna interior middle keyless antenna interior middle Un...

Page 196: ...ondition Inspect for continuity to instrument cluster Continuity detected Instrument cluster 3S Power supply keyless receiver front Keyless receiver front Under any condition B Keyless receiver front...

Page 197: ...is unlocked 1 0 or less Other 5 4C 1 Rx Instrument cluster Ignition switch is at ON position B Instrument cluster Ignition switch is at LOCK or ACC position 1 0 or less 4E Lock signal input Door lock...

Page 198: ...key cylinder is unlocked 1 0 or less Trunk key cylinder switch Related wiring harnesses At the moment key cylinder is neutral position 5 4L Request switch input trunk lid Request switch trunk lid Tru...

Page 199: ...ng harnesses Door closed LH Door switch off B 4U Horn on off Horn relay Other B Horn relay Related wiring harnesses Transmitter LOCK button is pressed twice within 5 s Brarr 1 0or lessrarr B 4V Hood s...

Page 200: ...g cannot be performed M MDS Personal computer Device that can send receive radio waves Verify that the other transmitter is not being operated around the servicing area during card key programming NOT...

Page 201: ...ifying DLC 2 Connector Courtesy of MAZDA MOTORS CORP 4 After the vehicle is identified select the following items from the initialization screen of the M MDS NOTE After Step 3 is completed and the car...

Page 202: ...DVANCED KEYLESS SYSTEM 1 Fully lower the driver side door glass 2 Connect the M MDS to the DLC 2 3 Pull out the M MDS cable from the door glass opening and set the M MDS outside the vehicle NOTE When...

Page 203: ...screen STEERING LOCK UNIT ID CODE REGISTRATION ADVANCED KEYLESS SYSTEM NOTE When OUT CODE is first displayed turning the ignition switch from the LOCK to the ON position 5 times will change the OUT C...

Page 204: ...screen See SECURITY ACCESS PROCEDURE ADVANCED KEYLESS SYSTEM Fig 44 Identifying DLC 2 Connector Courtesy of MAZDA MOTORS CORP 8 The security access begins and the M MDS displays OUT CODE 9 Input the...

Page 205: ...erform the applicable DTC inspection See DTC TABLE IMMOBILIZER SYSTEM ADVANCED KEYLESS SYSTEM Fig 45 Identifying DLC 2 Connector Courtesy of MAZDA MOTORS CORP CUSTOMIZED FUNCTION SETTING PROCEDURE ADV...

Page 206: ...isconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 2 Remove the glove compartment lid See GLOVE COMPARTMENT REMOVAL INSTALLATION 3 Disconnect the keyless receiver module connecto...

Page 207: ...the trunk side trim See TRUNK SIDE TRIM REMOVAL INSTALLATION 3 Remove the nuts 4 Disconnect the connector 5 Remove the keyless receiver rear 6 Install in the reverse order of removal 2007 Mazda MX 5...

Page 208: ...inspect the parts under Inspection item s and related wiring harnesses TERMINAL VOLTAGE TABLE REFERENCE Fig 49 Identifying Keyless Receiver Connector Terminals Courtesy of MAZDA MOTORS CORP KEYLESS R...

Page 209: ...cable See BATTERY REMOVAL INSTALLATION LF name Continuity A Power supply Keyless control module Under any condition B Keyless control module Related wiring harnesses C Data Keyless control module Unde...

Page 210: ...cuff plate See SCUFF PLATE REMOVAL INSTALLATION 3 Remove the side panel See SIDE PANEL REMOVAL INSTALLATION 4 Partially peel back the floor covering so that the foot support can be removed 5 Remove th...

Page 211: ...STALLATION 3 Remove the side wall See SIDE WALL REMOVAL INSTALLATION 4 Remove the console panel See CONSOLE PANEL REMOVAL INSTALLATION 5 Remove the clips 6 Disconnect the connector then remove the key...

Page 212: ...REMOVAL INSTALLATION 3 Remove the back trim See BACK TRIM REMOVAL INSTALLATION 4 Remove the nuts 5 Disconnect the connector then remove the keyless antenna 6 Install in the reverse order of removal 20...

Page 213: ...runk side trim See TRUNK SIDE TRIM REMOVAL INSTALLATION 3 Remove the nuts 4 Disconnect the connector then remove the keyless antenna 5 Install in the reverse order of removal 2007 Mazda MX 5 Miata Spo...

Page 214: ...LATION LF 2 Remove the trunk side trim See TRUNK SIDE TRIM REMOVAL INSTALLATION 3 Remove the nuts 4 Disconnect the connector 5 Remove the keyless beeper 6 Install in the reverse order of removal 2007...

Page 215: ...See DOOR TRIM REMOVAL INSTALLATION 3 Remove the outer handle See OUTER HANDLE REMOVAL INSTALLATION ADVANCED KEYLESS SYSTEM 4 Remove the screws A then remove the handle seat and plate 5 Remove screw B...

Page 216: ...witch 4 Install in the reverse order of removal Fig 58 Identifying Request Switch And Connector Courtesy of MAZDA MOTORS CORP REQUEST SWITCH INSPECTION ADVANCED KEYLESS SYSTEM 1 Inspect for continuity...

Page 217: ...from the following Program Additional card key Card Key Code Erase Steering Lock Unit Programming Program additional ignition key with immobilizer system Ignition Key Code Erase with immobilizer syst...

Page 218: ...62 Identifying Trunk Lid Striker And Bolt With Torque Specifications Courtesy of MAZDA MOTORS CORP TRUNK LID OPENER INSPECTION ADVANCED KEYLESS SYSTEM 1 Apply battery positive voltage and connect the...

Page 219: ...ATTERY REMOVAL INSTALLATION LF 2 Remove the trunk end trim See TRUNK END TRIM REMOVAL INSTALLATION 3 Detach the rod 4 Disconnect the trunk lid opener connector and the trunk compartment light connecto...

Page 220: ...he tabs of the trunk lid opener switch from the dashboard 3 Push the trunk lid opener switch into the dashboard and remove 4 Disconnect the trunk lid opener switch connector 5 Install in the reverse o...

Page 221: ...of removal Fig 66 Identifying Trunk Lid Opener Cancel Switch And Tab Courtesy of MAZDA MOTORS CORP TRUNK LID OPEN CANCEL SWITCH INSPECTION ADVANCED KEYLESS SYSTEM 1 Remove the trunk lid open cancel s...

Page 222: ...e the trunk key cylinder 5 Install in the reverse order of removal Fig 69 Identifying Trunk Key Cylinder Remove Install Components With Torque Specifications Courtesy of MAZDA MOTORS CORP TRUNK KEY CY...

Page 223: ...ADVANCED KEYLESS SYSTEM 1 Remove the trunk lid open switch 2 Inspect for continuity between the trunk lid open switch terminals If not as specified replace the trunk lid open switch Continuity Fig 72...

Page 224: ...between the striker switch terminals is as indicated in the table If not as indicated in the table replace the striker Continuity Fig 74 Striker Switch Continuity Chart Courtesy of MAZDA MOTORS CORP...

Page 225: ...E WARNINGS 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3...

Page 226: ...n switch to the LOCK position disconnect the negative battery cable and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power Handling a li...

Page 227: ...dangerous If the air bag module were to accidentally operate deploy it could cause serious injury Always place a live undeployed air bag module with its deployment surface up 2008 Mazda MX 5 Miata Gra...

Page 228: ...of the front or side air bag in an accident This may cause the passenger sensing function to operate improperly and result in a serious accident Always replace the passenger seat and seat weight senso...

Page 229: ...may cause serious injury Before removing the crash zone sensor or disconnecting the crash zone sensor connector always turn the ignition switch to the LOCK position disconnect the negative battery cab...

Page 230: ...loy normally which could result in a serious accident Always replace the side air bag sensor with a new one The side air bag sensor cannot be bench checked or self checked PRE TENSIONER SEAT BELT INSP...

Page 231: ...r allow oil grease or water to get on the air bag modules or pre tensioner seat belts Inserting a screwdriver or similar object into the connector of an air bag module or a pre tensioner seat belt may...

Page 232: ...r or tightening any of the nuts and bolts installed to the sensor body may cause it to operate deploy improperly Never disassemble the seat weight sensor or tighten any of the nuts or bolts installed...

Page 233: ...move the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the following parts 1 Side wall See SIDE WALL REMOVAL INSTALLATION 2 Center panel unit See C...

Page 234: ...ee BATTERY REMOVAL INSTALLATION LF 4 Remove in the order indicated in Fig 10 WARNING Handling the air bag module improperly can accidentally deploy the air bag module which may seriously injure you Re...

Page 235: ...e Specifications Courtesy of MAZDA MOTORS CORP 5 Install in the reverse order of removal 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3...

Page 236: ...g a flathead screwdriver pry out the connector stopper plate Fig 11 Prying Out Connector Stopper Plate Courtesy of MAZDA MOTORS CORP 2 Disconnect the connector PASSENGER SIDE AIR BAG MODULE REMOVAL IN...

Page 237: ...re is no debris in the passenger side air bag module before installation If a damaged passenger side air bag module is installed the vehicle may be damaged or the passenger may be injured when the air...

Page 238: ...2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3 43 37 PM Page 14 2005 Mitchell Repair Information Company LLC...

Page 239: ...IR BAG MODULE REMOVAL NOTE 1 Remove the passenger side air bag module in the order indicated below 1 Disengage the tab locks by sliding the passenger side air bag module upward 2 Slide the passenger s...

Page 240: ...r bag module improperly can accidentally operate deploy the air bag module which may seriously injure you Read the air bag system service warnings and cautions before handling the air bag module See A...

Page 241: ...ab Courtesy of MAZDA MOTORS CORP 6 Partially peel back the seat back trim 7 Partially peel back the seat back pad 8 Remove in the order indicated in Fig 16 the foreign material may be scattered when t...

Page 242: ...ection of the system CRASH ZONE SENSOR REMOVAL INSTALLATION 1 Turn the ignition switch to the LOCK position 2 Remove the battery cover WARNING Handling the crash zone sensor improperly can accidentall...

Page 243: ...AZDA MOTORS CORP 7 Install in the reverse order of removal 8 Turn the ignition switch to the ON position 9 Verify that the air bag system warning light illuminates for approx 6 s and goes out If the a...

Page 244: ...ntrol module improperly can accidentally deploy the air bag modules and pre tensioner seat belt which may seriously injure you Read the air bag system service warnings and cautions before handling the...

Page 245: ...AS CONTROL MODULE CONFIGURATION 9 Verify that the air bag system warning light illuminates for approx 6 s and goes out If the air bag system warning light does not operate normally refer to RESTRAINTS...

Page 246: ...o the directions on the screen 5 Retrieve DTCs using the M MDS then verify if DTCs are present If a DTC is present perform the applicable DTC inspection SEAT TRACK POSITION SENSOR REMOVAL INSTALLATION...

Page 247: ...eat Connector Tab Removing Connector From Seat Connector Courtesy of MAZDA MOTORS CORP 6 Remove in the order indicated in Fig 21 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5...

Page 248: ...of removal SEAT TRACK POSITION SENSOR INSTALLATION NOTE Verify that the seat track position sensor is not contacting the metal plate 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System...

Page 249: ...or 1 min or more See BATTERY REMOVAL INSTALLATION LF 4 Remove in the order indicated in Fig 23 CAUTION When the seat weight sensor control module is replaced with a new one perform the seat weight sen...

Page 250: ...w seat weight sensor control module Replacement with new passenger side seat parts Disassembly of the passenger side seat If any of the following work is performed perform the seat weight sensor inspe...

Page 251: ...WEIGHT SENSOR INSPECTION Or the vehicle is involved in a collision NOTE When Lightly pat the passenger seat cushion is displayed on the WDS or equivalent screen lightly pat horizontally approx five ti...

Page 252: ...tening of passenger s seat fixing bolts Or the vehicle is involved in a collision If any of the following work is performed perform the seat weight sensor calibration using the WDS or equivalent See S...

Page 253: ...urn the ignition switch to the ON position 8 Verify that the air bag system warning light illuminates for approx 6 s and goes out If the air bag system warning light does not operate normally refer to...

Page 254: ...27 PAD Switch Continuity Table Courtesy of MAZDA MOTORS CORP Fig 28 Inspecting Passenger Air Bag Deactivation PAD Switch Connector Terminals Courtesy of MAZDA MOTORS CORP 2008 Mazda MX 5 Miata Grand T...

Page 255: ...NSTALLATION 7 Remove in the order indicated in Fig 29 Fig 29 View Of Side Air Bag Sensor Components Courtesy of MAZDA MOTORS CORP WARNING Handling the side air bag sensor improperly can accidentally o...

Page 256: ...ION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the following parts 1 Driver side air bag module See DRIVER SIDE AIR BAG MODULE REMO...

Page 257: ...DJUSTMENT CLOCK SPRING ADJUSTMENT 1 Set the front tires straight ahead 2 Turn the clock spring clockwise until it stops CAUTION If the clock spring is not adjusted the spring wire in the clock spring...

Page 258: ...RS CORP 3 From the stopped position turn the clock spring counterclockwise 2 3 4 turns 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3 4...

Page 259: ...of MAZDA MOTORS CORP 4 Align the mark on the clock spring with the mark on the outer housing 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 20...

Page 260: ...spring See CLOCK SPRING REMOVAL INSTALLATION 4 Verify that the continuity is as indicated in Fig 34 If not as indicated in Fig 34 replace the clock spring NOTE When the vehicle side connector for the...

Page 261: ...ensioner seat belt may accidentally operate deploy when it is disposed of and cause serious injury Do not dispose of a live undeployed air bag module and pre tensioner seat belt If the SSTs Deployment...

Page 262: ...odule See DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 2 Connect the SSTs Adapter harness to the driver side air bag module as shown in Fig 36 3 Install the driver side air bag module See DRIVER SI...

Page 263: ...er supply red clip to the positive battery terminal and the black clip to the negative battery terminal 6 Verify that the red lamp on both SSTs Deployment tool is illuminated 7 Verify that all persons...

Page 264: ...rly This may cause serious injury if the air bag module operates deploy unexpectedly If the two operation explosive sounds are not heard perform Step 8 again If a total of two operation explosive soun...

Page 265: ...flator is forced to operate deploy the other may operate deploy accidentally To prevent injury while disposing of the air bag module make sure to operate deploy both passenger side air bag module infl...

Page 266: ...ons are standing at least 6 m 20 ft away from the vehicle 8 Press the activation switch on the SST Deployment tool connected with 49 L066 002 a yellow connector of the SST Adapter harness and after 3...

Page 267: ...ted deployed properly This may cause serious injury if the air bag module operates deploy unexpectedly If the two operation explosive sounds are not heard perform Step 8 again If a total of two operat...

Page 268: ...y that all persons are standing at least 6 m 20 ft away from the vehicle Fig 43 Connecting SST Deployment Tool To SST Adapter Harness Courtesy of MAZDA MOTORS CORP 7 Press the activation switch on the...

Page 269: ...IM REMOVAL INSTALLATION 2 Remove the pre tensioner seat belt and connect the SST Adapter harness as shown in Fig 45 See SEAT BELT REMOVAL INSTALLATION 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAIN...

Page 270: ...nnect the power supply red clip to the positive battery terminal and the black clip to the negative battery terminal 6 Verify that the red lamp on the SST Deployment tool is illuminated 7 Verify that...

Page 271: ...S CORP 8 Press the activation switch on the SST Deployment tool to operate deploy the pre tensioner seat belt 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Th...

Page 272: ...ensioner seat belt DRIVER SIDE AIR BAG MODULE 1 Remove the driver side air bag module See DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 2 Connect the SSTs Adapter harness to the driver side air bag...

Page 273: ...more through the wheel and the bolt installation holes of the air bag module at least 4 times WARNING If the air bag module is not properly installed to the tire wheel serious injury may occur when th...

Page 274: ...e tires without wheels on top of the tire with the driver side air bag module and then stack another tire with a wheel on the very top 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag Syste...

Page 275: ...river Side Air Bag Module Courtesy of MAZDA MOTORS CORP 5 Secure the tires with wire 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3 43...

Page 276: ...ip to the positive battery terminal and the black clip to the negative battery terminal 8 Verify that the red lamp on both SSTs Deployment tool is illuminated 9 Verify that all persons are standing at...

Page 277: ...inflators would not have operated deployed properly This may cause serious injury if the air bag module operates deploy unexpectedly If the two operation explosive sounds are not heard perform Step 8...

Page 278: ...g module as shown in Fig 54 WARNING The passenger side air bag module is a dual inflator type If one inflator is forced to operate deploy the other may operate deploy accidentally To prevent injury wh...

Page 279: ...r more through the tire and the brackets at least 4 times as shown in Fig 55 WARNING If the air bag module is not properly secured to the tire the tires may fall over by the impact of operation deploy...

Page 280: ...o tires without wheels Stack a tire without a wheel on top of the tire with the passenger side air bag module and then stack another tire with a wheel on the very top 2008 Mazda MX 5 Miata Grand Touri...

Page 281: ...Of Two Tires Without Wheels Courtesy of MAZDA MOTORS CORP 5 Secure the tires with wire 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3...

Page 282: ...ip to the positive battery terminal and the black clip to the negative battery terminal 8 Verify that the red lamp on both SSTs Deployment tool is illuminated 9 Verify that all persons are standing at...

Page 283: ...ith 49 L066 002 a yellow connector of the SST Adapter harness and after 3 s press the activation switch on the other SST Deployment tool to operate deploy the air bag module both inflators 2008 Mazda...

Page 284: ...s would not have operated deployed properly This may cause serious injury if the air bag module operates deploy unexpectedly If the two operation explosive sounds are not heard perform Step 8 again If...

Page 285: ...more through the tire and around the bolts at least 4 times WARNING If the air bag module is not properly secured to the tire the tires may fall over by the impact of operation deployment and cause se...

Page 286: ...tesy of MAZDA MOTORS CORP 4 Connect the SST Adapter harness to the side air bag module as shown in Fig 62 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursd...

Page 287: ...top of two tires without wheels Stack a tire without a wheel on top of the tire with the side air bag module and then stack another tire with a wheel on the very top 2008 Mazda MX 5 Miata Grand Tourin...

Page 288: ...Tires Without Wheels Courtesy of MAZDA MOTORS CORP 6 Secure the tires with wire 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3 43 37 P...

Page 289: ...p to the positive battery terminal and the black clip to the negative battery terminal 9 Verify that the red lamp on the SST Deployment tool is illuminated 10 Verify that all persons are standing at l...

Page 290: ...itch on the SST Deployment tool to operate deploy the side air bag module 12 Disconnect the SSTs Deployment tool from the SSTs Adapter harness 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air B...

Page 291: ...nsioner seat belt See SEAT BELT REMOVAL INSTALLATION 2 Connect the SST Adapter harness to the pre tensioner seat belt as shown in Fig 67 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag Sys...

Page 292: ...stallation holes at least 4 times WARNING If the pre tensioner seat belt is not properly installed to the tire serious injury may occur when the pre tensioner part is operated deployed When installing...

Page 293: ...seat belt on two of tires without wheels Stack a tire without a wheel on top of the tire with the pre tensioner seat belt and then stack another tire with a wheel on the very top 2008 Mazda MX 5 Miata...

Page 294: ...Of Tires Without Wheels Courtesy of MAZDA MOTORS CORP 5 Secure the tires with wire 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3 43 37...

Page 295: ...p to the positive battery terminal and the black clip to the negative battery terminal 8 Verify that the red lamp on the SST Deployment tool is illuminated 9 Verify that all persons are standing at le...

Page 296: ...ch on the SST Deployment tool to operate deploy the pre tensioner seat belt 11 Disconnect the SSTs Deployment tool from the SSTs Adapter harness 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air...

Page 297: ...touch an air bag module and pre tensioner seat belt for at least 15 min after deployment Pouring water on the deployed air bag module and pre tensioner seat belt is dangerous The water will mix with t...

Page 298: ...e and pre tensioner seat belt wear gloves and safety glasses Due to the adoption of 2 step deployment control in both the driver and passenger side air bag modules depending on the impact force it is...

Page 299: ...belt to accidentally operate deploy CAUTION Because the permissible voltage for the SST 49 H066 002 is 12 V do not connect a 24 V power source because it will damage the SST Always connect only a 12...

Page 300: ...urtesy of MAZDA MOTORS CORP 3 Press the activation switch On Off 2008 Mazda MX 5 Miata Grand Touring 2008 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 3 43 38 PM Page 76 2005 M...

Page 301: ...M SERVICE WARNINGS 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12 55 P...

Page 302: ...ition switch to the LOCK position disconnect the negative battery cable and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power Handling...

Page 303: ...is dangerous If the air bag module were to accidentally operate deploy it could cause serious injury Always place a live undeployed air bag module with its deployment surface up 2007 Mazda MX 5 Miata...

Page 304: ...ent of the front or side air bag in an accident This may cause the passenger sensing function to operate improperly and result in a serious accident Always replace the passenger seat and seat weight s...

Page 305: ...ich may cause serious injury Before removing the crash zone sensor or disconnecting the crash zone sensor connector always turn the ignition switch to the LOCK position disconnect the negative battery...

Page 306: ...deploy normally which could result in a serious accident Always replace the side air bag sensor with a new one The side air bag sensor cannot be bench checked or self checked PRE TENSIONER SEAT BELT...

Page 307: ...Never allow oil grease or water to get on the air bag modules or pre tensioner seat belts Inserting a screwdriver or similar object into the connector of an air bag module or a pre tensioner seat belt...

Page 308: ...ensor or tightening any of the nuts and bolts installed to the sensor body may cause it to operate deploy improperly Never disassemble the seat weight sensor or tighten any of the nuts or bolts instal...

Page 309: ...1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the following parts 1 Side wall See SIDE WALL REMOVAL INSTALLATION 2 Center panel unit S...

Page 310: ...ore See BATTERY REMOVAL INSTALLATION LF 4 Remove in the order indicated in Fig 10 WARNING Handling the air bag module improperly can accidentally deploy the air bag module which may seriously injure y...

Page 311: ...Torque Specifications Courtesy of MAZDA MOTORS CORP 5 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12...

Page 312: ...Using a flathead screwdriver pry out the connector stopper plate Fig 11 Prying Out Connector Stopper Plate Courtesy of MAZDA MOTORS CORP 2 Disconnect the connector PASSENGER SIDE AIR BAG MODULE REMOVA...

Page 313: ...there is no debris in the passenger side air bag module before installation If a damaged passenger side air bag module is installed the vehicle may be damaged or the passenger may be injured when the...

Page 314: ...2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12 55 PM Page 14 2005 Mitchell Repair Information Company LLC...

Page 315: ...DE AIR BAG MODULE REMOVAL NOTE 1 Remove the passenger side air bag module in the order indicated below 1 Disengage the tab locks by sliding the passenger side air bag module upward 2 Slide the passeng...

Page 316: ...e air bag module improperly can accidentally operate deploy the air bag module which may seriously injure you Read the air bag system service warnings and cautions before handling the air bag module S...

Page 317: ...ng Tab Courtesy of MAZDA MOTORS CORP 6 Partially peel back the seat back trim 7 Partially peel back the seat back pad 8 Remove in the order indicated in Fig 16 the foreign material may be scattered wh...

Page 318: ...ction of the system CRASH ZONE SENSOR REMOVAL INSTALLATION 1 Turn the ignition switch to the LOCK position 2 Remove the battery cover WARNING Handling the crash zone sensor improperly can accidentally...

Page 319: ...of MAZDA MOTORS CORP 7 Install in the reverse order of removal 8 Turn the ignition switch to the ON position 9 Verify that the air bag system warning light illuminates for approx 6 s and goes out If...

Page 320: ...S control module improperly can accidentally deploy the air bag modules and pre tensioner seat belt which may seriously injure you Read the air bag system service warnings and cautions before handling...

Page 321: ...ee SAS CONTROL MODULE CONFIGURATION 9 Verify that the air bag system warning light illuminates for approx 6 s and goes out If the air bag system warning light does not operate normally refer to RESTRA...

Page 322: ...ng to the directions on the screen 5 Retrieve DTCs using the M MDS then verify if DTCs are present If a DTC is present perform the applicable DTC inspection SEAT TRACK POSITION SENSOR REMOVAL INSTALLA...

Page 323: ...ng Seat Connector Tab Removing Connector From Seat Connector Courtesy of MAZDA MOTORS CORP 6 Remove in the order indicated in Fig 21 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Mia...

Page 324: ...der of removal SEAT TRACK POSITION SENSOR INSTALLATION NOTE Verify that the seat track position sensor is not contacting the metal plate 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5...

Page 325: ...ait for 1 min or more See BATTERY REMOVAL INSTALLATION LF 4 Remove in the order indicated in Fig 23 CAUTION When the seat weight sensor control module is replaced with a new one perform the seat weigh...

Page 326: ...with a new seat weight sensor control module Replacement with new passenger side seat parts Disassembly of the passenger side seat If any of the following work is performed perform the seat weight se...

Page 327: ...EAT WEIGHT SENSOR INSPECTION Or the vehicle is involved in a collision NOTE When Lightly pat the passenger seat cushion is displayed on the WDS or equivalent screen lightly pat horizontally approx fiv...

Page 328: ...tightening of passenger s seat fixing bolts Or the vehicle is involved in a collision If any of the following work is performed perform the seat weight sensor calibration using the WDS or equivalent S...

Page 329: ...emoval 7 Turn the ignition switch to the ON position 8 Verify that the air bag system warning light illuminates for approx 6 s and goes out If the air bag system warning light does not operate normall...

Page 330: ...Fig 27 PAD Switch Continuity Table Courtesy of MAZDA MOTORS CORP Fig 28 Inspecting Passenger Air Bag Deactivation PAD Switch Connector Terminals Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Spo...

Page 331: ...L INSTALLATION 7 Remove in the order indicated in Fig 29 Fig 29 Removing Installing Side Air Bag Sensor Courtesy of MAZDA MOTORS CORP WARNING Handling the side air bag sensor improperly can accidental...

Page 332: ...ION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the following parts 1 Driver side air bag module See DRIVER SIDE AIR BAG MODULE REMO...

Page 333: ...NG ADJUSTMENT CLOCK SPRING ADJUSTMENT 1 Set the front tires straight ahead 2 Turn the clock spring clockwise until it stops CAUTION If the clock spring is not adjusted the spring wire in the clock spr...

Page 334: ...MOTORS CORP 3 From the stopped position turn the clock spring counterclockwise 2 3 4 turns 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12 55...

Page 335: ...esy of MAZDA MOTORS CORP 4 Align the mark on the clock spring with the mark on the outer housing 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2...

Page 336: ...lock spring See CLOCK SPRING REMOVAL INSTALLATION 4 Verify that the continuity is as indicated in Fig 34 If not as indicated in Fig 34 replace the clock spring NOTE When the vehicle side connector for...

Page 337: ...re tensioner seat belt may accidentally operate deploy when it is disposed of and cause serious injury Do not dispose of a live undeployed air bag module and pre tensioner seat belt If the SSTs Deploy...

Page 338: ...ag module See DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 2 Connect the SSTs Adapter harness to the driver side air bag module as shown in Fig 36 3 Install the driver side air bag module See DRIVE...

Page 339: ...power supply red clip to the positive battery terminal and the black clip to the negative battery terminal 6 Verify that the red lamp on both SSTs Deployment tool is illuminated 7 Verify that all per...

Page 340: ...roperly This may cause serious injury if the air bag module operates deploy unexpectedly If the two operation explosive sounds are not heard perform Step 8 again If a total of two operation explosive...

Page 341: ...P inflator is forced to operate deploy the other may operate deploy accidentally To prevent injury while disposing of the air bag module make sure to operate deploy both passenger side air bag module...

Page 342: ...persons are standing at least 6 m 20 ft away from the vehicle 8 Press the activation switch on the SST Deployment tool connected with 49 L066 002 a yellow connector of the SST Adapter harness and afte...

Page 343: ...perated deployed properly This may cause serious injury if the air bag module operates deploy unexpectedly If the two operation explosive sounds are not heard perform Step 8 again If a total of two op...

Page 344: ...erify that all persons are standing at least 6 m 20 ft away from the vehicle Fig 43 Connecting SST Deployment Tool To SST Adapter Harness Courtesy of MAZDA MOTORS CORP 7 Press the activation switch on...

Page 345: ...K TRIM REMOVAL INSTALLATION 2 Remove the pre tensioner seat belt and connect the SST Adapter harness as shown in Fig 45 See SEAT BELT REMOVAL INSTALLATION 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS A...

Page 346: ...ttery Connect the power supply red clip to the positive battery terminal and the black clip to the negative battery terminal 6 Verify that the red lamp on the SST Deployment tool is illuminated 7 Veri...

Page 347: ...OTORS CORP 8 Press the activation switch on the SST Deployment tool to operate deploy the pre tensioner seat belt 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursd...

Page 348: ...re tensioner seat belt DRIVER SIDE AIR BAG MODULE 1 Remove the driver side air bag module See DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 2 Connect the SSTs Adapter harness to the driver side air...

Page 349: ...or more through the wheel and the bolt installation holes of the air bag module at least 4 times WARNING If the air bag module is not properly installed to the tire wheel serious injury may occur whe...

Page 350: ...three tires without wheels on top of the tire with the driver side air bag module and then stack another tire with a wheel on the very top 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX...

Page 351: ...th Driver Side Air Bag Module Courtesy of MAZDA MOTORS CORP 5 Secure the tires with wire 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12 56 P...

Page 352: ...d clip to the positive battery terminal and the black clip to the negative battery terminal 8 Verify that the red lamp on both SSTs Deployment tool is illuminated 9 Verify that all persons are standin...

Page 353: ...oth inflators would not have operated deployed properly This may cause serious injury if the air bag module operates deploy unexpectedly If the two operation explosive sounds are not heard perform Ste...

Page 354: ...r bag module as shown in Fig 54 WARNING The passenger side air bag module is a dual inflator type If one inflator is forced to operate deploy the other may operate deploy accidentally To prevent injur...

Page 355: ...n2 or more through the tire and the brackets at least 4 times as shown in Fig 55 WARNING If the air bag module is not properly secured to the tire the tires may fall over by the impact of operation de...

Page 356: ...f two tires without wheels Stack a tire without a wheel on top of the tire with the passenger side air bag module and then stack another tire with a wheel on the very top 2007 Mazda MX 5 Miata Sport 2...

Page 357: ...Top Of Two Tires Without Wheels Courtesy of MAZDA MOTORS CORP 5 Secure the tires with wire 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12 5...

Page 358: ...d clip to the positive battery terminal and the black clip to the negative battery terminal 8 Verify that the red lamp on both SSTs Deployment tool is illuminated 9 Verify that all persons are standin...

Page 359: ...ed with 49 L066 002 a yellow connector of the SST Adapter harness and after 3 s press the activation switch on the other SST Deployment tool to operate deploy the air bag module both inflators 2007 Ma...

Page 360: ...ators would not have operated deployed properly This may cause serious injury if the air bag module operates deploy unexpectedly If the two operation explosive sounds are not heard perform Step 8 agai...

Page 361: ...2 in2 or more through the tire and around the bolts at least 4 times WARNING If the air bag module is not properly secured to the tire the tires may fall over by the impact of operation deployment and...

Page 362: ...Courtesy of MAZDA MOTORS CORP 4 Connect the SST Adapter harness to the side air bag module as shown in Fig 62 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday J...

Page 363: ...on top of two tires without wheels Stack a tire without a wheel on top of the tire with the side air bag module and then stack another tire with a wheel on the very top 2007 Mazda MX 5 Miata Sport 20...

Page 364: ...p Of Tires Without Wheels Courtesy of MAZDA MOTORS CORP 6 Secure the tires with wire 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12 56 PM Pa...

Page 365: ...clip to the positive battery terminal and the black clip to the negative battery terminal 9 Verify that the red lamp on the SST Deployment tool is illuminated 10 Verify that all persons are standing...

Page 366: ...n switch on the SST Deployment tool to operate deploy the side air bag module 12 Disconnect the SSTs Deployment tool from the SSTs Adapter harness 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag S...

Page 367: ...e tensioner seat belt See SEAT BELT REMOVAL INSTALLATION 2 Connect the SST Adapter harness to the pre tensioner seat belt as shown in Fig 67 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System...

Page 368: ...t installation holes at least 4 times WARNING If the pre tensioner seat belt is not properly installed to the tire serious injury may occur when the pre tensioner part is operated deployed When instal...

Page 369: ...ner seat belt on two of tires without wheels Stack a tire without a wheel on top of the tire with the pre tensioner seat belt and then stack another tire with a wheel on the very top 2007 Mazda MX 5 M...

Page 370: ...Two Of Tires Without Wheels Courtesy of MAZDA MOTORS CORP 5 Secure the tires with wire 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12 56 PM...

Page 371: ...clip to the positive battery terminal and the black clip to the negative battery terminal 8 Verify that the red lamp on the SST Deployment tool is illuminated 9 Verify that all persons are standing a...

Page 372: ...switch on the SST Deployment tool to operate deploy the pre tensioner seat belt 11 Disconnect the SSTs Deployment tool from the SSTs Adapter harness 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag...

Page 373: ...not touch an air bag module and pre tensioner seat belt for at least 15 min after deployment Pouring water on the deployed air bag module and pre tensioner seat belt is dangerous The water will mix wi...

Page 374: ...odule and pre tensioner seat belt wear gloves and safety glasses Due to the adoption of 2 step deployment control in both the driver and passenger side air bag modules depending on the impact force it...

Page 375: ...seat belt to accidentally operate deploy CAUTION Because the permissible voltage for the SST 49 H066 002 is 12 V do not connect a 24 V power source because it will damage the SST Always connect only a...

Page 376: ...h Courtesy of MAZDA MOTORS CORP 3 Press the activation switch On Off 2007 Mazda MX 5 Miata Sport 2007 RESTRAINTS Air Bag System MX 5 Miata Microsoft Thursday July 09 2009 2 12 56 PM Page 76 2005 Mitch...

Page 377: ...WIRING DIAGRAM 2007 Mazda MX 5 Miata Sport 2007 BRAKES Antilock Brake System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 BRAKES Antilock Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 16 19...

Page 378: ...Preparation 1 Verify that battery is fully charged 2 Turn the ignition switch to the ON position and verify that the ABS warning light goes out after approx 2007 Mazda MX 5 Miata Sport 2007 BRAKES Ant...

Page 379: ...perform ABS HU CM operation inspection Operation Inspection 1 Perform Preparation 2 Connect the M MDS or equivalent to the DLC 2 3 Set up an active command mode inspection according to the combinatio...

Page 380: ...ONFIGURATION 2 Remove in the order indicated in Fig 4 3 Install in the reverse order of removal condition PMP_MOTOR RF_OUTLET RF_INLET transmission type Brake pressure retention OFF OFF ON Manual Brak...

Page 381: ...NNECTOR REMOVAL NOTE 1 Pull the lock lever up in the direction of the arrow 2 Pull the connector toward the vehicle rear and remove it 2007 Mazda MX 5 Miata Sport 2007 BRAKES Antilock Brake System MX...

Page 382: ...ORS CORP BRAKE PIPE REMOVAL NOTE 1 Place an alignment mark on the brake pipe and ABS HU CM 2007 Mazda MX 5 Miata Sport 2007 BRAKES Antilock Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 16...

Page 383: ...mark made before removing the brake pipe and temporarily install the brake pipe to the ABS HU CM CAUTION If the brake pipe is tightened to the specified torque it may be difficult to install it to th...

Page 384: ...oint referring to Fig 7 2 Tighten the brake pipe to the specified torque using the SST 49 0259 770B ABS HU CM CONNECTOR INSTALLATION NOTE 1 After connecting the connector verify that the lock lever Is...

Page 385: ...sy of MAZDA MOTORS CORP ABS CONFIGURATION 1 Connect the M MDS or equivalent to the DLC 2 2007 Mazda MX 5 Miata Sport 2007 BRAKES Antilock Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 16 1...

Page 386: ...ctions on the screen 5 Retrieve DTCs using the M MDS then verify if DTCs are present If a DTC is present perform the applicable DTC inspection See ON BOARD DIAGNOSTIC ABS MX 5 MIATA ABS HU CM INSPECTI...

Page 387: ...ty detected Wiring harness A ground point B Power supply ABS motor operation Battery Voltage Under any condition B Wiring harness B battery C Power supply solenoid Battery Voltage Under any condition...

Page 388: ...d sensor connector terminal A Continuity detected Wiring harness G LR ABS wheel speed sensor connector terminal A H LR wheel speed sensor ground LR ABS wheel speed sensor Continuity H LR ABS wheel spe...

Page 389: ...eel speed sensor connector terminal A Continuity detected Wiring harness M RF ABS wheel speed sensor connector terminal A N Brake switch Brake switch Voltage N brake switch Brake pedal depressed B Wir...

Page 390: ...U V W X Y CAN_L DLC 2 CAN_L Continuity Y DLC 2 terminal CAN_L Continuity detected Wiring harness Y DLC 2 terminal CAN_L Z CAN_H DLC 2 CAN_H Continuity Z DLC 2 terminal CAN_H Continuity detected Wiring...

Page 391: ...ont ABS wheel speed sensor 2 Measure the distance between the front ABS wheel speed sensor installation surface and the ABS sensor rotor This is dimension A 3 Measure the distance between the front AB...

Page 392: ...g 12 Measuring Distance Between Front ABS Wheel Speed Sensor Installation Surface ABS Wheel Speed Sensor Tip Courtesy of MAZDA MOTORS CORP SENSOR OUTPUT VALUE INSPECTION CAUTION Resistance inspection...

Page 393: ...ine and drive the vehicle 5 Verify that the display of the M MDS or equivalent shows the same value as the speedometer If there is any malfunction replace the front ABS wheel speed sensor ABS wheel sp...

Page 394: ...removal Fig 14 Identifying Rear ABS Wheel Speed Sensor With Torque Specifications Courtesy of MAZDA MOTORS CORP REAR ABS WHEEL SPEED SENSOR INSPECTION INSTALLATION VISUAL INSPECTION 1 Inspect the fol...

Page 395: ...8 1 6 mm 0 032 0 062 in Fig 15 Inspecting ABS Sensor To Rotor Clearance Courtesy of MAZDA MOTORS CORP SENSOR OUTPUT VALUE INSPECTION 1 Turn the ignition switch off 2 Connect the M MDS or equivalent to...

Page 396: ...nsor 4 Start the engine and drive the vehicle 5 Verify that the display of the M MDS or equivalent shows the same value as the speedometer If there is any malfunction replace the rear ABS wheel speed...

Page 397: ...at seams Do not pull the valve forcibly Be careful not to get the wiring harness caught between parts during installation 4 Prevent incorrect or insufficient installation or missing parts Be careful...

Page 398: ...alcohol IPA 6 ATF care If ATF is spilled on the floor wipe it off immediately as it is quite slippery and dangerous Be sure to use JWS3309 type ATF Disassembly Components Fig 1 Disassembled View Of A...

Page 399: ...omatic Transmission Components 2 Of 5 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2009 1 42 23 PM Page 3 2005 Mitchell R...

Page 400: ...omatic Transmission Components 3 Of 5 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2009 1 42 23 PM Page 4 2005 Mitchell R...

Page 401: ...omatic Transmission Components 4 Of 5 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2009 1 42 23 PM Page 5 2005 Mitchell R...

Page 402: ...Remove the drain plug and gasket CAUTION Do not damage the oil seal Do not drop the torque converter 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Mi...

Page 403: ...bine sensor Fig 6 Identifying Drain Plug And Gasket CAUTION Do not damage the turbine sensor Fig 8 Identifying Breather Tube And Pipe 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmi...

Page 404: ...sher Using Flathead Screwdriver 7 Remove the nut and lock washer CAUTION Do not damage the VSS Fig 9 Identifying Turbine Sensor 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission...

Page 405: ...ch Fig 12 Identifying Nut And Lock Washer CAUTION Do not damage the fitting surface of the transmission case and the converter housing 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transm...

Page 406: ...e fitting surface of the extension housing and the extension dust deflector Fig 15 Tapping Converter Housing Using Plastic Hammer CAUTION Do not damage the extension housing Fig 16 Tapping Extension D...

Page 407: ...Extension Housing Shroud Using Flathead Screwdriver CAUTION Do not damage the fitting surface of the transmission case and the extension housing Fig 19 Identifying Bolts 2007 Mazda MX 5 Miata Sport 20...

Page 408: ...mission case and the oil pan Do not deform the oil pan Fig 21 Removing Snap Ring Using Snap Ring Pliers NOTE Inspect the oil pan for foreign material and determine the worn areas of the transmission F...

Page 409: ...onnect the solenoid connectors from the solenoids 22 Disconnect the coupler component from the clamps Fig 22 Identifying Bolts Fig 23 Locating Magnet In Oil Pan 2007 Mazda MX 5 Miata Sport 2006 08 TRA...

Page 410: ...ifying Lock Plate 25 Fix the coupler component with tape to the transmission case as shown in the figure CAUTION When installing the control valve body make sure that it does not interfere with the co...

Page 411: ...ng Bolts 28 Disconnect the manual valve link and remove the control valve body component CAUTION Do not drop the control valve body component Fig 28 Identifying Detent Spring And Bolt 2007 Mazda MX 5...

Page 412: ...from transmission case 31 Blow compressed air from the oil passage shown in the figure and remove accumulator pistons A and B CAUTION Be careful of the accumulator pistons A and B as they pop out Fig...

Page 413: ...ng a flathead screwdriver remove the O ring from accumulator piston A and B CAUTION Do not damage the accumulator pistons Fig 34 Identifying Snap Ring On Accumulator Pistons A And B CAUTION Be careful...

Page 414: ...m accumulator pistons C 37 Remove the accumulator valve and compression springs from the transmission case Fig 36 Locating Oil Passage 38 Remove the bracket Fig 35 Identifying O Ring On Accumulator Pi...

Page 415: ...d spring 41 Using a flathead screwdriver remove the driven plate from shaft parking pawl 42 Remove the parking pawl CAUTION Be careful not to apply too much force to the torsion spring 2007 Mazda MX 5...

Page 416: ...d pin punch remove the pin CAUTION Do not damage the manual valve component Fig 40 Removing Manual Shaft Washer Using Flathead Screwdriver And Hammer 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION A...

Page 417: ...screwdriver remove the oil seal 47 Remove the bolts from the oil pump as shown in the figure CAUTION Do not damage the transmission case component Fig 43 Removing Oil Seal Using Flathead Screwdriver...

Page 418: ...race from oil pump Fig 46 Identifying O Ring Thrust Needle Bearing And Bearing Race On Oil Pump CAUTION Do not damage the oil pump Fig 45 Removing Oil Pump Using Flathead Screwdriver 2007 Mazda MX 5 M...

Page 419: ...asher and F2 one way clutch component from the clutch drum component Fig 49 Identifying Thrust Washer And F2 One Way Clutch Component On Clutch Drum Component 54 Using a flathead screwdriver remove th...

Page 420: ...nt mark is wearing away replace with a new drive plate When replacing inspect the contact surfaces between the retaining plate driven plate and drive plate If they are scratched or have changed color...

Page 421: ...ng B2 Brake Piston Component 59 Remove the bearing race and thrust washer from the F1 one way clutch component 60 Remove the F1 one way clutch component from the B3 brake piston component Fig 52 Ident...

Page 422: ...gear component 63 Remove the bearing race and thrust needle bearing from front and middle ring gear component Fig 57 Identifying Front And Middle Ring Gear Component Thrust Needle Bearing And Bearing...

Page 423: ...late If they are scratched or have changed color replace with new parts 66 Remove the middle planetary gear component and sun gear 67 Remove the bearing race and thrust needle bearing from middle plan...

Page 424: ...69 Remove the piston return spring and B1 brake piston component Fig 62 Identifying Piston Return Spring And B1 Brake Piston Component 70 Using a flathead screwdriver remove the snap ring from transmi...

Page 425: ...ve the retaining plates drive and driven plates Fig 65 Identifying Drive And Driven Plates 73 Remove the piston return spring 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Ov...

Page 426: ...replace with new parts 75 Blow compressed air into the oil passage as shown in the figure while pressing the B2 brake piston component by hand and remove the B2 brake piston component from the transmi...

Page 427: ...ring pliers Fig 70 Removing Snap Ring From Transmission Case Using Snap Ring Pliers 78 Remove the following parts from the transmission case and disassemble in the order indicated below 1 Inner race...

Page 428: ...te Shaft Components Fig 72 Disassembled View Of Transmission Case Components 79 Remove the retaining plates drive and driven plates 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmiss...

Page 429: ...g plate driven plate and drive plate If they are scratched or have changed color replace with new parts 81 Remove the rear planetary gear component and bearing race and thrust needle bearing NOTE Befo...

Page 430: ...ng Fig 77 Identifying SSTs For Compressing Piston Return Spring 84 Remove the piston return spring CAUTION Make sure that the snap ring is not expanded excessively Fig 76 Identifying Brake Tube 2007 M...

Page 431: ...ion case Air pressure 392 kPa 4 kgf cm2 57 psi Fig 79 Blowing Compressed Air Into Oil Passage 86 Remove the inner brake piston and sleeve and B4 brake piston Fig 80 Identifying Inner Brake Piston And...

Page 432: ...entifying O Ring On Sleeve 89 Remove the O ring from B4 brake piston Fig 83 Identifying O Ring On B4 Brake Piston OIL PUMP DISASSEMBLY Components 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Autom...

Page 433: ...pump component Fig 85 Identifying O Ring On Oil Pump 2 Remove the seal ring from the oil pump shaft 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Mic...

Page 434: ...Pump Housing 4 Remove the screw from the oil pump Fig 88 Identifying Screw On Oil Pump 5 Remove the oil pump shaft from the pump housing 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Tran...

Page 435: ...pump housing Fig 91 Identifying Inner And Outer Oil Pump Gear 8 Using a flathead screwdriver remove the oil seal from the pump housing CAUTION Do not damage the bushing on the pump housing 2007 Mazda...

Page 436: ...an average If it exceeds the specification replace the pump housing component with a new one When the pump housing component is replaced inspect the contact surface opposed to the torque converter If...

Page 437: ...e oil pump shaft with a new one When the oil pump shaft is replaced inspect the contact surface opposed to the input shaft If the surface of it is scratched or has changed color replace the input shaf...

Page 438: ...Oil pump gear size mm in OIL PUMP GEAR SIZE REFERENCE Fig 95 Measuring Oil Pump Gear Outer Clearance Using Feeler Gauge CAUTION If it exceeds the specification replace the pump housing with a new one...

Page 439: ...the maximum specification replace the inner oil pump gear and outer oil pump gear with a new one so that the side clearance is within the maximum specification If the side clearance still exceeds the...

Page 440: ...ATF to the new O ring Fig 99 Identifying Alignment Marks On Oil Pump Gear 4 Install the O ring to the pump housing Fig 100 Identifying O Ring On Pump Housing 5 Align the oil pump shaft with the mark o...

Page 441: ...Compress the seal rings as shown in the figure then install the seal rings to the oil pump shaft 10 Apply ATF to the new O rings CAUTION Do not expand the seal ring too much Be careful not to shorten...

Page 442: ...hly Fig 105 Turning Drive Gear Using Flathead Screwdrivers 13 Using a hammer install the new oil seal to the pump housing 14 Apply grease to the oil seal lip CAUTION Do not damage the oil seal 2007 Ma...

Page 443: ...ENT DISASSEMBLY Components Fig 107 Clutch Drum Component And F4 One Way Clutch Component Disassembled View 1 Of 2 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5...

Page 444: ...rewdriver remove the snap ring from the C3 clutch piston component 2 Remove the clutch hub component from the C3 clutch piston component 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Tran...

Page 445: ...te Drive Plate And Driven Plate 4 Remove the retaining plate from the C3 clutch piston component Fig 111 Identifying Retaining Plate On C3 Clutch Piston Component 5 Remove the thrust needle bearing fr...

Page 446: ...he bearing race and the thrust washer from clutch hub Fig 114 Identifying Thrust Bearing Bearing Race And Thrust Washer 8 Remove the C1 C4 clutch component from the C2 C3 clutch drum 2007 Mazda MX 5 M...

Page 447: ...nd F4 one way clutch from the C1 C4 clutch component Fig 117 Identifying Clutch Hub And F4 One Way Clutch 11 Remove the bearing race from the C1 C4 clutch component 2007 Mazda MX 5 Miata Sport 2006 08...

Page 448: ...component Fig 120 Removing Snap Ring From Input Shaft Component Using Flathead Screwdriver 14 Remove the retaining plate C1 and the drive plate C1 and the driven plate C1 from the input shaft compone...

Page 449: ...Ring From Input Shaft Component Using Flathead Screwdriver 16 Remove the retaining plate C4 and the drive plate C4 and the driven plate C4 from the input shaft component 2007 Mazda MX 5 Miata Sport 2...

Page 450: ...4 Removing Installing Snap Ring Using Snap Ring Pliers 19 Remove the C4 clutch seal plate and the piston return spring from the input shaft component CAUTION Be careful not to expand the snap ring too...

Page 451: ...Air pressure 392 kPa 4 02 kgf cm2 57 psi 21 When applying compressed air shut the oil passages of the input shaft component Fig 126 Applying Compressed Air Into Oil Passage 22 Remove the O ring from t...

Page 452: ...al ring from the input shaft component Fig 129 Identifying Seal Ring On Input Shaft Component 25 Using a flathead screwdriver remove the snap ring C3 from the C2 C3 clutch drum 2007 Mazda MX 5 Miata S...

Page 453: ...the driven plate C2 from the input shaft component Fig 132 Identifying Retaining Plate Drive And Driven Plate 28 Install the SST as shown in the figure and compress the C2 clutch piston return spring...

Page 454: ...s 30 Remove the seal plate and the C2 clutch piston return spring from the C3 clutch drum Fig 133 Identifying SST 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5...

Page 455: ...pressure 392 kPa 4 02 kgf cm2 57 psi 32 When applying compressed air shut the oil passage of the input shaft component Fig 136 Identifying Oil Passage For Applying Compressed Air 33 Remove the O ring...

Page 456: ...ngth of 100 mm as shown in the figure to compress the piston return spring 36 Remove the snap ring using snap ring pliers CAUTION Be careful not to expand the snap ring too much Fig 139 Identifying SS...

Page 457: ...Piston Component 38 Remove the C2 C3 clutch drum C3 clutch piston component Fig 142 Identifying C2 C3 Clutch Drum And C3 Clutch Piston Component 39 Remove the O ring from the C3 clutch piston compone...

Page 458: ...worn or the print mark is wearing away replace it with a new drive plate When replacing inspect the contact surfaces between the retaining plate driven plate and drive plate If they are scratched or...

Page 459: ...measure the free length of the piston return spring C1 C4 clutch return spring free length Standard 26 29 mm 1 04 in If it less than the specification replace the piston return spring with a new one...

Page 460: ...ng or has changed color or if it is worn or the print mark is wearing away replace it with a new drive plate When replacing inspect the contact surfaces between the retaining plate driven plate and dr...

Page 461: ...ing 7 Using vernier calipers measure the free length of the piston return spring C3 clutch return spring free length Standard 21 03 mm 0 83 in If it less than the specification replace the piston retu...

Page 462: ...input shaft component with a new one When the input shaft component is replaced inspect the contact surface opposed to the intermediate shaft If the surface of it is scratched or has changed color rep...

Page 463: ...age If it exceeds the specification replace the clutch hub with a new one When the clutch hub is replaced Inspect the contact surface opposed to the input shaft component If the surface of it is scrat...

Page 464: ...ASSEMBLY Components When the clutch hub component is replaced inspect the contact surface opposed to the clutch hub If the surface of it is scratched or has changed color replace the clutch hub with a...

Page 465: ...mponent And F4 One Way Clutch Component 1 Of 2 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2009 1 42 24 PM Page 69 2005...

Page 466: ...ssembly Procedure 1 Apply ATF to the new O ring 2 Install the O rings to the C2 C3 clutch drum 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsof...

Page 467: ...C3 clutch drum to the C3 clutch piston component 7 Apply ATF to the seal plate and the piston return spring CAUTION Do not damage the O ring Fig 159 Identifying O Rings On C3 Clutch Piston Component C...

Page 468: ...s shown in the figure to compress the piston return spring 10 Remove the snap ring using snap ring pliers Fig 160 Identifying C2 C3 Clutch Drum CAUTION Do not expand the snap ring too much Fig 162 Ide...

Page 469: ...h Piston 14 Install the O rings to the C2 clutch seal plate 15 Apply ATF to the C2 clutch piston and the C2 C3 clutch drum CAUTION Do not damage the O ring Fig 165 Identifying O Rings On C2 Clutch Sea...

Page 470: ...pring to the C2 C3 clutch drum Fig 167 Identifying C2 Clutch Seal Plate And C2 Clutch Piston Return Spring 19 Install the SST as shown in the figure and compress the C2 clutch piston return spring CAU...

Page 471: ...Ring Pliers 22 Install the driven plate C2 the drive plate C2 the retaining plate C2 to the C2 C3 clutch drum Fig 168 Identifying SST CAUTION Inspect the number of drive and driven plates 2007 Mazda...

Page 472: ...y Air pressure 200 kPa 2 kgf cm2 28 psi THICKNESS REFERENCE Fig 170 Identifying Driven Drive Plate And Retaining Plate CAUTION When installing the snap ring set the end gap of the snap ring as shown i...

Page 473: ...8 0 132 4 3 35 3 45 0 132 0 136 5 3 45 3 55 0 136 0 140 6 3 55 3 65 0 140 0 144 7 3 65 3 75 0 144 0 148 8 3 75 3 85 0 148 0 152 CAUTION If the C2 clutch pack clearance exceeds the maximum specificatio...

Page 474: ...the C2 C3 clutch drum CAUTION Inspect the number of drive and driven plates CAUTION When installing the snap ring set the end gap of the snap ring as shown in the figure Fig 174 Identifying Retaining...

Page 475: ...the average value Verify that the piston moves smoothly Fig 176 Measuring Driven Plate Travel Distance Using Dial Gauge Air pressure 200 kPa 2 kgf cm2 28 psi Standard travel distance A 1 62 2 68 mm 0...

Page 476: ...6 2 95 3 05 0 116 0 120 7 3 05 3 15 0 120 0 124 8 3 15 3 25 0 124 0 128 9 3 25 3 35 0 128 0 132 A 3 35 3 45 0 132 0 136 B 3 45 3 55 0 136 0 140 CAUTION If the C3 clutch pack clearance exceeds the maxi...

Page 477: ...ponent Fig 179 Identifying O Ring On Input Shaft Component 37 Install the C1 clutch piston and the C4 clutch piston to the input shaft component 38 Apply ATF to the C1 clutch seal plate and the input...

Page 478: ...ap Ring Pliers 42 Apply ATF to the retaining plate C4 the driven plate C4 the drive plate C4 CAUTION Do not damage the D ring CAUTION Do not expand the snap ring too much Fig 181 Identifying C1 Clutch...

Page 479: ...5 Measure the retaining plate travel distance at both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure and calculate the average val...

Page 480: ...15 0 120 0 124 2 3 15 3 25 0 124 0 128 3 3 25 3 35 0 128 0 132 4 3 35 3 45 0 132 0 136 5 3 45 3 55 0 136 0 140 6 3 55 3 65 0 140 0 144 7 3 65 3 75 0 144 0 148 8 3 75 3 85 0 148 0 152 9 3 85 3 95 0 152...

Page 481: ...g plate travel distance at both ends across the diameter using a dial gauge while blowing compressed air into the oil passage as shown in the figure and calculate the average value Verify that the pis...

Page 482: ...ameter Using Dial Gauge 51 Install the F4 one way clutch to the clutch hub 52 Apply ATF to the bearing race CAUTION If the C1 clutch pack clearance exceed the maximum specification select another reta...

Page 483: ...e clutch hub to the C1 C4 clutch component 55 Apply ATF to the bearing race Fig 191 Identifying Clutch Hub 56 Install the bearing race to the C3 clutch piston component 2007 Mazda MX 5 Miata Sport 200...

Page 484: ...Component 59 Install the thrust bearing bearing race and thrust washer Fig 194 Identifying Thrust Bearing Bearing Race And Thrust Washer 60 Install the clutch hub to the C3 clutch piston component 61...

Page 485: ...te to the C3 clutch piston component Fig 197 Identifying Retaining Plate On C3 Clutch Piston Component 65 Install the clutch hub component to the C3 clutch piston component 66 Apply ATF to the retaini...

Page 486: ...Using a flathead screwdriver install the snap ring to the C3 clutch piston component CAUTION Inspect the number of drive and driven plates Fig 198 Identifying Clutch Hub Component 2007 Mazda MX 5 Miat...

Page 487: ...ents Fig 201 B1 B3 Brake And F1 F2 One Way Clutch Component Disassembled View Disassembly Procedure 1 Remove the B3 brake cylinder from the F1 one way clutch 2007 Mazda MX 5 Miata Sport 2006 08 TRANSM...

Page 488: ...screwdriver remove the snap ring from the B3 brake cylinder Fig 204 Removing Snap Ring From B3 Brake Cylinder Using Flathead Screwdriver 4 Remove the piston return spring from the B3 brake piston 2007...

Page 489: ...m the B3 brake cylinder Air pressure 392 kPa 4 0 kgf cm2 57 psi Fig 206 Locating Oil Passage 6 Remove the O ring from the B3 brake piston Fig 207 Identifying O Ring On B3 Brake Piston 2007 Mazda MX 5...

Page 490: ...ng O Ring On B1 Brake Piston B1 B3 BRAKE AND F1 F2 ONE WAY CLUTCH INSPECTION 1 Using vernier calipers measure the free length of the piston return spring B3 brake return spring free length Standard 15...

Page 491: ...or have changed color replace with new parts Fig 211 Identifying Print Mark Location 3 Using vernier calipers measure the free length of the piston return spring B1 brake return spring free length St...

Page 492: ...e scratched or have changed color replace with new parts Fig 213 Identifying Print Mark Location 5 Verify that the F1 one way clutch rotates when the bearing race is secured and rotated clockwise and...

Page 493: ...t rotate when the clutch hub is rotated counterclockwise Fig 215 Identifying F2 One Way Clutch Rotation Positions B1 B3 BRAKE AND F1 F2 ONE WAY CLUTCH COMPONENT ASSEMBLY Components 2007 Mazda MX 5 Mia...

Page 494: ...tall the O rings to the B1 brake piston 3 Apply ATF to the B1 brake piston and the B1 brake cylinder CAUTION Do not damage the O ring 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmi...

Page 495: ...ton 7 Apply ATF to the B3 brake cylinder to the B3 brake piston Fig 217 Identifying O Rings On B1 Brake Piston CAUTION Do not damage the O ring Fig 219 Identifying O Rings On B3 Brake Piston 2007 Mazd...

Page 496: ...the snap ring with a finger install it to the brake cylinder using a flathead screwdriver 11 Apply ATF to the thrust washer 12 Install the bearing race to the thrust washer Fig 222 Installing Brake Cy...

Page 497: ...cylinder to the F1 one way clutch Fig 224 Identifying B3 Brake Cylinder PLANETARY GEAR COMPONENT DISASSEMBLY Components 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhau...

Page 498: ...ing a flathead screwdriver remove the snap ring from the middle planetary ring gear 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday...

Page 499: ...ge 3 Using a flathead screwdriver remove the snap ring from the middle planetary ring gear Fig 228 Removing Snap Ring From Middle Planetary Ring Gear 4 Remove the front planetary ring gear from the mi...

Page 500: ...from the rear planetary ring gear Fig 231 Identifying Rear Planetary Ring Gear Flange PLANETARY GEAR COMPONENT INSPECTION 1 Using a dial gauge measure the inner diameter of the front planetary ring ge...

Page 501: ...f it is scratched or has changed color replace the middle planetary gear component with a new one Fig 232 Measuring Inner Diameter Of Front Planetary Ring Gear Flange Bushings CAUTION Measure at diffe...

Page 502: ...average If it exceeds the specification replace the Rear planetary gear component with a new one When the front planetary gear component is replaced inspect the contact surface opposed to the intermed...

Page 503: ...uring Inner Diameter Of Rear Planetary Gear Component Bushings 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2009 1 42 25...

Page 504: ...e 1 Install the rear planetary gear flange to the rear planetary ring gear 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2...

Page 505: ...all the front planetary ring gear to the middle planetary ring gear Fig 238 Identifying Front Planetary Ring Gear 4 Using a flathead screwdriver install the snap ring to the middle planetary ring gear...

Page 506: ...g a flathead screwdriver install the snap ring to the middle planetary ring gear Fig 241 Installing Snap Ring To Middle Planetary Ring Gear B2 B4 BRAKE AND F3 ONE WAY CLUTCH COMPONENT DISASSEMBLY Comp...

Page 507: ...n in the figure while pressing the B2 brake piston and brake cylinder by hand and remove the B2 brake piston Air pressure 392 kPa 4 0 kgf cm2 57 psi 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Au...

Page 508: ...ce from the F3 one way clutch component Fig 245 Identifying Inner Race On F3 One Way Clutch Component 4 Remove the O ring from the B4 brake piston 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Auto...

Page 509: ...ing O Ring On Inner Brake Piston B2 B4 BRAKE AND F3 ONE WAY CLUTCH INSPECTION 1 Using vernier calipers measure the free length of the piston return spring B2 brake return spring free length 2007 Mazda...

Page 510: ...faces between the retaining plate driven plate and drive plate If they are scratched or have changed color replace with new parts Fig 250 Identifying Print Mark Location 3 Using vernier callpers measu...

Page 511: ...driven plate and drive plate If they are scratched or have changed color replace with new parts Fig 252 Identifying Print Mark Location 5 Verify that the inner race rotates when the F3 one way clutch...

Page 512: ...RAKE AND F3 ONE WAY CLUTCH COMPONENT ASSEMBLY Components 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2009 1 42 25 PM Pag...

Page 513: ...y ATF to the new O rings 2 Install the O rings to the B4 brake piston 3 Apply ATF to the new O rings 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Mi...

Page 514: ...7 Apply ATF to the inner race and the F3 one way clutch component Fig 257 Identifying O Ring On B4 Brake Piston 8 Install the inner race to the F3 one way clutch component 9 Apply ATF to the new O rin...

Page 515: ...o the brake cylinder Fig 260 Identifying B2 Brake Piston On Brake Cylinder CONTROL VALVE BODY DISASSEMBLY ASSEMBLY Components CAUTION Do not damage the O ring Fig 259 Identifying O Ring On B2 Brake Pi...

Page 516: ...C from the control valve body CAUTION Do not damage the solenoid CAUTION Do not damage the solenoid 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Mic...

Page 517: ...e control valve body Fig 262 Identifying Shift Solenoid C CAUTION Do not damage the solenoid Fig 263 Identifying Shift Solenoid B CAUTION Do not damage the solenoid 2007 Mazda MX 5 Miata Sport 2006 08...

Page 518: ...12 0 N m 81 6 122 3 kgf cm 70 9 106 1 in lbf 2 Install the bolt and the wiring harness clip Fig 264 Identifying Shift Solenoid A CAUTION Do not damage the solenoid CAUTION Do not damage the solenoid 2...

Page 519: ...Tightening torque 8 0 12 0 N m 81 6 122 3 kgf cm 70 9 106 1 in lbf Fig 266 Identifying Shift Solenoid E CAUTION Do not damage the solenoid Fig 267 Identifying Shift Solenoid A CAUTION Do not damage t...

Page 520: ...9 Identifying Shift Solenoid C AUTOMATIC TRANSMISSION ASSEMBLY Assembly Bearing and race locations Fig 268 Identifying Shift Solenoid B 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Trans...

Page 521: ...2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2009 1 42 25 PM Page 125 2005 Mitchell Repair Information Company LLC...

Page 522: ...on Assembly With Bearing And Race Locations 1 Of 2 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thursday July 09 2009 1 42 25 PM Page 126...

Page 523: ...20 00 0 79 63 8 2 51 89 3 3 52 76 3 3 00 60 0 2 36 34 9 1 37 29 6 1 06 43 3 1 70 37 0 1 46 Bearing mm Outer diameter 85 6 3 37 41 0 1 61 53 1 2 09 73 5 2 89 43 85 1 73 58 0 2 28 52 5 2 07 Inner diamet...

Page 524: ...edure 1 Apply ATF to the new O ring CAUTION Do not damage the O ring and B4 brake piston 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmission Overhaul MX 5 Miata RX 8 Microsoft Thur...

Page 525: ...g surface of the transmission case CAUTION Do not damage the O ring and sleeve Fig 274 Identifying O Ring And B4 Brake Piston CAUTION Do not damage the O ring and inner brake piston Fig 275 Identifyin...

Page 526: ...nstall the piston return spring Fig 278 Identifying Piston Return Spring 10 Using the SST compress the piston return spring and install the snap ring into the groove CAUTION Do not expand the snap rin...

Page 527: ...essed air into the transmission case Fig 279 Identifying SST For Compressing Piston Return Spring CAUTION Align the tabs of the brake tube with the position shown in the figure Fig 280 Identifying Tab...

Page 528: ...plates and drive plate components 5 and driven plates 4 at the both ends across the diameter using a vernier caliper and calculate the average value Dimension B 21 92 22 72 mm 0 87 0 89 in 15 Calcula...

Page 529: ...s of retaining plates for the pack clearance adjustment Select the one with the most suitable thickness Identification mark Thickness mm in 0 0 2 0 15 0 25 0 006 0 010 4 0 35 0 45 0 014 0 0177 6 0 55...

Page 530: ...ission case Fig 284 Identifying Rear Planetary Gear Components 19 Install the retaining plates drive plates and driven plates to the transmission case as shown in the figure CAUTION Inspect the number...

Page 531: ...the intermediate shaft Fig 287 Identifying Bearing Race And Needle Bearing Race 22 Install the rear ring gear component F3 one way clutch and inner race to the intermediate shaft Fig 285 Identifying R...

Page 532: ...ly positioned 25 Install snap ring to the transmission case using snap ring pliers CAUTION If the snap ring is not installed in the correct direction the automatic transmission may not operate normall...

Page 533: ...all the brake piston and brake cylinder to the transmission case CAUTION Align the opening of the snap ring with the position shown in the figure Fig 293 Positions For Aligning Opening Of Snap Ring 20...

Page 534: ...using a vernier caliper and calculate the average value Dimension A 21 19 21 90 mm 0 84 0 86 in 30 Measure the thickness of all the driven plates and drive plate components 4 and driven plates 3 at t...

Page 535: ...in RETAINING PLATE THICKNESS NOTE There are 8 types of retaining plates for the pack clearance adjustment Select the one with the most suitable thickness Identification mark Thickness mm in 0 1 95 2 0...

Page 536: ...35 Install the retaining plate drive plate component and driven plates in the order indicated in the figure CAUTION Inspect the number and order of the retaining plate drive and driven plates Fig 296...

Page 537: ...flathead screwdriver install the snap ring into the groove CAUTION Align the opening of the snap ring with the position shown in the figure Fig 300 Identifying SST CAUTION Align the hole of the brake...

Page 538: ...ent And Return Spring 40 Install the SST as shown in the figure and compress the piston return spring Fig 303 Identifying SST Fig 301 Position For Installing Snap Ring 2007 Mazda MX 5 Miata Sport 2006...

Page 539: ...ake piston upper surface and retaining plate contact surface at the both ends across the B1 brake piston diameter using a vernier caliper and calculate the average value CAUTION Align the opening of t...

Page 540: ...on B Thickness H 46 If the pack clearance exceeds the maximum specification select the retaining plate with a clearance that is the maximum specification and install it Pack clearance 0 42 0 72 mm 0 0...

Page 541: ...ing Plate 50 Install the middle planetary gear component and sun gear 51 Apply ATF to the bearing race and thrust needle bearing 52 Install the bearing race and thrust needle bearing to the middle pla...

Page 542: ...nstall the thrust washer to the front planetary gear component 56 Apply ATF to the thrust washer and install it to the bearing race Fig 311 Identifying Thrust Washer And Front Planetary Gear Component...

Page 543: ...e piston with the position shown in the figure Fig 313 Position For Aligning Hole Of Brake Piston CAUTION If the snap ring is not installed in the correct direction the automatic transmission may not...

Page 544: ...ning of the snap ring with the position shown in the figure Fig 315 Installing Snap Ring Using Snap Ring Pliers NOTE Inspect the number and order of the retaining plate drive and driven plates 2007 Ma...

Page 545: ...he groove 64 Apply ATF to the thrust washer and install it to the F2 one way clutch component Fig 316 Identifying Retaining Plate Drive And Driven Plates CAUTION Align the opening of the snap ring wit...

Page 546: ...and the F2 one way clutch component Fig 320 Identifying Bearing Race Thrust Needle Bearing And Clutch Drum Component 68 Install the clutch drum component and F2 one way clutch component 69 Apply ATF...

Page 547: ...ig 322 Identifying Thrust Needle Bearing Bearing Race And O Ring 72 Install the oil pump as shown in the figure CAUTION Do not drop the oil pump 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automa...

Page 548: ...the bearing race 75 Install the thrust needle bearing and bearing race to the front planetary gear component 76 Install snap ring using snap ring pliers Fig 323 Identifying Oil Pump 2007 Mazda MX 5 Mi...

Page 549: ...047 in If not within the specification select an appropriate bearing race Fig 326 Measuring Clearance Between Snap Ring And Bearing Race Using Thickness Gauge Retaining plate size 2007 Mazda MX 5 Miat...

Page 550: ...he input shaft end play Input shaft end play 0 35 1 05 mm 0 014 0 041 in Fig 328 Measuring Input Shaft End Play Using Dial Indicator 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Transmis...

Page 551: ...nual valve Fig 330 Identifying Manual Shaft Washer And Manual Valve 83 Tap in a new pin using a hammer CAUTION Do not damage the transmission case Fig 329 Installing Oil Seal Using SST And Hammer 2007...

Page 552: ...late to the parking pawl shaft 88 Install the parking pawl shaft spring 89 Connect the parking rod to the manual valve CAUTION Be careful not to apply too much force to the spring Fig 333 Identifying...

Page 553: ...s 91 Set the manual valve to the P position and verify that the parking pawl shaft is properly engaged with the front planetary gear component Fig 336 Engaging Parking Pawl Shaft 2007 Mazda MX 5 Miata...

Page 554: ...ons C 94 Install the accumulator piston C compression spring to the transmission case CAUTION Do not damage the O ring and accumulator piston Fig 337 Identifying Accumulator Valve And Compression Spri...

Page 555: ...Identifying O Ring On Accumulator Pistons A B 96 Using a flathead screwdriver install the compression spring snap ring to the accumulator pistons A B 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION A...

Page 556: ...transmission case gasket new brake drum gasket and install the transmission case CAUTION Do not damage gasket Fig 342 Identifying Accumulator Pistons A B And Compression Spring 2007 Mazda MX 5 Miata...

Page 557: ...stall the control valve body component CAUTION When installing the control valve body component route the wiring harness correctly to the separate plate depression inside the control valve body compon...

Page 558: ...orque 10 0 12 0 N m 102 122 kgf cm 89 105 in lbf 103 Install the detent spring cover and detent spring to the control valve body component NOTE Aligning the bolt holes temporarily tighten the bolts by...

Page 559: ...ATF to the new O ring and install the oil strainer Fig 348 Identifying Solenoid Connector 108 Install the oil strainer to the control valve body component Tightening torque 8 0 12 0 N m 82 122 kgf cm...

Page 560: ...trol Valve Body NOTE Wash the magnets before installing them CAUTION Do not damage the contact surface of the oil pan and transmission case Do not deform the oil pan Fig 350 Locating Magnet On Oil Pan...

Page 561: ...as shown in the figure 116 Install the extension housing and transmission case Fig 352 Identifying Sealant Application Area On Extension Housing 117 Temporarily tighten the bolts by hand as shown in t...

Page 562: ...e to the oil seal lip Bolt number Bolt size Length measured from below the head mm in A M10 1 5 35 1 38 B M 10 1 5 45 1 77 NOTE Do not apply sealant to the transmission case The characters shown in th...

Page 563: ...shown in the figure CAUTION Do not damage the oil seal Do not damage the extension housing Do not damage the extension housing shroud Fig 355 Position For Installing Extension Housing Shroud To Exten...

Page 564: ...f C 47 0 66 6 N m 4 80 6 79 kgf m 34 7 49 1 ft lbf Fig 356 Position For Installing Extension Dust Deflector Bolt number Bolt size Length measured from below the head mm in A M10 1 5 35 1 38 B M 10 1 5...

Page 565: ...Identifying TR Switch And Manual Shaft Notch Align Position 128 Install the washer lock washer and nut Tightening torque 5 9 7 8 N m 61 79 kgf cm 53 69 in lbf CAUTION If the TR switch is not adjusted...

Page 566: ...1 6 kgf m 7 3 11 6 ft lbf Fig 361 Bending Tab Of Lock Washer Using Flathead Screwdriver 131 Install the VSS Tightening torque 3 9 6 9 N m 40 70 kgf cm 35 61 in lbf CAUTION Do not damage the VSS 2007 M...

Page 567: ...lbf 134 Install the breather pipe Fig 362 Identifying VSS CAUTION Do not damage the turbine sensor Fig 363 Identifying Turbine Sensor CAUTION Do not damage the breather tube 2007 Mazda MX 5 Miata Spo...

Page 568: ...e A between the end of the torque converter and the end of the converter housing Distance A between the end of the torque converter and the end of the converter housing 26 2 mm 1 0 in CAUTION Do not d...

Page 569: ...TECHNICAL DATA TRANSMISSION TECHNICAL DATA CAUTION Install the drain plug being careful of the drain plug gasket direction Item Specification Pump housing bushing inner diameter 38 113 38 138 mm 1 50...

Page 570: ...33 312 33 337 mm 1 31150 1 31248 in B3 brake return spring free length Standard 15 72 mm 0 62 in B1 brake return spring free length Standard 17 05 mm 0 67 in Front planetary ring gear bushing inner d...

Page 571: ...002 Compressor 49 N019 003 Extension 49 N019 004 Attachment 49 N019 005 Attachment 49 T019 014 Body 49 G019 027 Attachment 49 G019 029 Nut 2007 Mazda MX 5 Miata Sport 2006 08 TRANSMISSION Automatic Tr...

Page 572: ...CCESSORIES BODY CAB Body Panels MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday July 09 2009 3 33 45 PM Page 1 2005 Mitchell Repair Informati...

Page 573: ...fying Location Of Body Panel Components 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday July 09 2009 3 33 45 PM Page 2 2005 Mitchell Repair Information...

Page 574: ...OTORS CORP FUEL FILLER LID ADJUSTMENT 1 Measure the gap and height difference between the fuel filler lid and the body 2 Loosen the fuel filler lid installation bolts and adjust the fuel filler lid St...

Page 575: ...ery cable See BATTERY REMOVAL INSTALLATION LF 2 Disconnect the front fog light connectors for vehicles with front fog lights 3 Disconnect the side marker light connectors 4 Remove in the order indicat...

Page 576: ...2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday July 09 2009 3 33 45 PM Page 5 2005 Mitchell Repair Information Company LLC...

Page 577: ...BLY ASSEMBLY 1 To disassemble the front bumper remove the following parts 1 Front fog lights Vehicles with the front fog lights See FRONT FOG LIGHT REMOVAL INSTALLATION 2 Front side marker light See F...

Page 578: ...2 Remove the front bumper See FRONT BUMPER REMOVAL INSTALLATION 3 Remove the front combination light See FRONT COMBINATION LIGHT REMOVAL INSTALLATION 4 Remove the fresh air duct See INTAKE AIR SYSTEM...

Page 579: ...lling Front Bumper Reinforcement With Torque Specifications Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday July 09 2009 3...

Page 580: ...ARD REMOVAL INSTALLATION 4 Remove the trunk side trim See TRUNK SIDE TRIM REMOVAL INSTALLATION 5 Remove the rear combination lights See REAR COMBINATION LIGHT REMOVAL INSTALLATION 6 Remove the screws...

Page 581: ...CORP 8 Remove in the order indicated in the table 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday July 09 2009 3 33 45 PM Page 10 2005 Mitchell Repair...

Page 582: ...ing Rear Bumper Ends Wheel Arch Outward From Bumper Slider Courtesy of MAZDA MOTORS CORP CAUTION When detaching the rear bumper from the bumper slider the rear bumper could fall and be damaged Secure...

Page 583: ...EMOVAL INSTALLATION 1 Remove the following parts 1 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 2 Trunk end trim See TRUNK END TRIM REMOVAL INSTALLATION 3 Partition board...

Page 584: ...ERY REMOVAL INSTALLATION LF 2 Remove the front bumper See FRONT BUMPER REMOVAL INSTALLATION 3 Remove the front combination lights See FRONT COMBINATION LIGHT REMOVAL INSTALLATION 4 Remove the side ste...

Page 585: ...stall in the reverse order of removal HOOD REMOVAL INSTALLATION WARNING Removing the hood without proper support can be dangerous The 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels...

Page 586: ...Side step molding See SIDE STEP MOLDING REMOVAL See SIDE STEP MOLDING INSTALLATION 4 Front fender panel See FRONT FENDER PANEL REMOVAL INSTALLATION 3 Remove in the order indicated in Fig 13 hood may...

Page 587: ...MAZDA MOTORS CORP 4 Install in the reverse order of removal 5 Adjust the hood See HOOD ADJUSTMENT 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday July 0...

Page 588: ...P MOLDING INSTALLATION 4 Front fender panel See FRONT FENDER PANEL REMOVAL INSTALLATION 3 Loosen the hood hinge installation bolts and adjust the hood 4 Tighten the bolts Fig 14 Adjusting Hood Hinge C...

Page 589: ...f MAZDA MOTORS CORP HEIGHT DIFFERENCE ADJUSTMENT 1 Turn the stop rubber to adjust the height of the hood 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday...

Page 590: ...en the hood and the body is within the specification Standard clearance a 1 0 2 0 mm 0 04 0 07 in b 1 5 1 5 mm 0 06 0 05 in c 0 5 1 5 mm 0 02 0 05 in 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY...

Page 591: ...then take the trunk lid harness out from the vehicle WARNING Removing the stay damper without supporting the trunk lid can be dangerous The trunk lid may fall and injure you Be sure to open the trunk...

Page 592: ...rtesy of MAZDA MOTORS CORP 3 Remove the clips that secure the trunk lid wiring harness 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday July 09 2009 3 33...

Page 593: ...amper Fig 20 Prying Out Connecting Part Of Stay Damper Hinge With Flathead Screwdriver Courtesy of MAZDA MOTORS CORP 6 Remove nuts A then remove the trunk lid 7 Remove nuts B then remove the trunk lid...

Page 594: ...ifference between the trunk lid and the body 2 Loosen the trunk lid hinge installation nuts or the trunk lid lock striker installation screws and adjust the trunk lid 2007 Mazda MX 5 Miata Sport 2007...

Page 595: ...actable Hardtop b 5 0 9 0 mm 0 20 0 35 in c 3 0 6 0 mm 0 12 0 23 in Except Power Retractable Hardtop 4 0 8 0 mm 0 16 0 31 in Power Retractable Hardtop d 3 0 5 0 mm 0 12 0 19 in 3 Tighten the nuts 2007...

Page 596: ...DAMPER DISPOSAL 1 Wear protective eye wear NOTE The gas in the stay damper is colorless odorless and non toxic 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Th...

Page 597: ...Remove the console See CONSOLE REMOVAL INSTALLATION 3 Remove the quarter trim See QUARTER TRIM REMOVAL INSTALLATION 4 Remove the scuff plate See SCUFF PLATE REMOVAL INSTALLATION 5 Remove the tire hou...

Page 598: ...R SPEAKER REMOVAL INSTALLATION 12 Remove the seat belt set plate See SEAT BELT REMOVAL INSTALLATION 13 Remove the clips then remove the speaker wiring harness 14 Remove in the order indicated in Fig 2...

Page 599: ...2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Body Panels MX 5 Miata Microsoft Thursday July 09 2009 3 33 45 PM Page 28 2005 Mitchell Repair Information Company LLC...

Page 600: ...OTE 1 After temporarily tightening all of the bolts and nuts tighten them to the specified torque Tightening Torque 20 0 28 0 N m 2 04 2 85 kgf m 14 7 20 6 lb ft CAUTION If the seat back crossmember c...

Page 601: ...urfaces Be careful not to spill any on painted surfaces If it is spilled wipe it off immediately 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata 2007 Mazda MX 5 Miata Spor...

Page 602: ...g torque Front 6 9 9 8 N m 71 99 Kgf cm 62 86 in lbf Rear 6 0 8 0 N m 62 81 Kgf cm 54 70 in lbf 5 Repeat Steps 3 and 4 until no air bubbles are seen 6 Perform air bleeding as described in the above pr...

Page 603: ...e power brake unit side of the vacuum hose towards the intake manifold side and that air cannot be blown in the opposite direction If there is any malfunction of the inner check valve replace it toget...

Page 604: ...the upper surface of the pedal pad to the insulator and verify that it is as specified If not within the specification adjust the pedal height Brake pedal height reference value 167 mm 6 57 in 2007 M...

Page 605: ...2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 18 52 PM Page 5 2005 Mitchell Repair Information Company LLC...

Page 606: ...switch may not operate normally after adjusting the pedal height Whenever adjusting the pedal height replace the brake switch with a new one The interlock cable may not operate normally after adjusti...

Page 607: ...5 0 kgf 33 0 lbf 2 Measure the distance between the pedal pad center and the insulator and verify that it is as specified If the pedal to floor clearance is less than the specification check for air i...

Page 608: ...ot properly installed or the connector is connected before installation the clearance may be incorrect causing a brake light malfunction Therefore always verify that the brake switch is properly insta...

Page 609: ...e that the installation of the interlock cable could become defective Always refer to the interlock cable installation note when replacing the brake pedal See INTERLOCK CABLE INSTALLATION NOTE NOTE Wh...

Page 610: ...BRAKE SWITCH CONNECTOR INSTALLATION NOTE 1 Inspect the brake pedal See BRAKE PEDAL INSPECTION 2 With the brake pedal in its original position install the brake switch to the brake switch connector BR...

Page 611: ...e switch Fig 9 Terminal Continuity Reference Table Courtesy of MAZDA MOTORS CORP the brake switch if it is removed 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsof...

Page 612: ...NDER REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 11 2 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thu...

Page 613: ...2 15 9 ft lbf CAUTION If the master cylinder is installed at an angle the master cylinder piston may push against the push rod retainer of the power brake unit causing poor air bleeding brake drag or...

Page 614: ...of 66 7 kPa 500 mmHg 19 7 inHg to the power brake unit using a vacuum gauge NOTE Use any commercially available vacuum gauge 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Mia...

Page 615: ...S CORP 3 Using calipers measure dimension L as shown in Fig 14 Standard L dimension 30 4 30 6 mm 1 197 1 204 in 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft T...

Page 616: ...001 and while stopping the push rod rotation with the SST 49 E043 003A adjust the push rod length with the SST 49 B043 004 5 Switch the SSTs and remeasure dimension L 2007 Mazda MX 5 Miata Sport 2007...

Page 617: ...uid level sensor connector from the master cylinder 2 Inspect for continuity according to fluid level between the brake fluid level sensor terminals If not as indicated in Fig 16 replace the reserve t...

Page 618: ...erminal Continuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 18 52 PM Page 18 2005 Mitchell Rep...

Page 619: ...se After repairing inspect again Vacuum Loss Function Inspection 1 Start the engine 2 Depress the pedal with normal force 3 With the pedal depressed stop the engine 4 Maintain the pedal depressed for...

Page 620: ...the air from the SSTs through air bleeding valve A Fig 18 Installing SST 49 N043 001 Courtesy of MAZDA MOTORS CORP WITHOUT DSC Flare nut across flat 12 mm 0 47 in 2007 Mazda MX 5 Miata Sport 2007 BRA...

Page 621: ...unction Without DSC Courtesy of MAZDA MOTORS CORP WITH DSC 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 18 52 PM Page 21 2005 Mitchell...

Page 622: ...right after stopping the engine measure the lowest amount of vacuum 5 If the lowest amount is 3 3 kPa 25 mmHg 1 0 inHg or less the system is normal Lack of Hydraulic Pressure Inspection 1 With the eng...

Page 623: ...SSURE SPECIFICATIONS POWER BRAKE UNIT REMOVAL INSTALLATION 1 Remove the master cylinder See MASTER CYLINDER REMOVAL INSTALLATION 2 Remove the clutch pipe MT Vacuum amount at o kPa 0 mmHg 0 inHg Pedal...

Page 624: ...MOTORS CORP 3 Remove the nut shown in Fig 22 then remove the cooler hose LO bracket from the vehicle 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday Jul...

Page 625: ...he order indicated in Fig 23 Fig 23 Identifying Power Brake Unit With Torque Specifications Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata M...

Page 626: ...on See BRAKE PEDAL INSPECTION DUAL PROPORTIONING VALVE REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 24 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Micro...

Page 627: ...rque Specifications Courtesy of MAZDA MOTORS CORP 2 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday July 09 2009...

Page 628: ...ioning Valve Courtesy of MAZDA MOTORS CORP DUAL PROPORTIONING VALVE INSTALLATION NOTE 1 Install the dual proportioning valve so that the R marks faces the upper side of the vehicle 2007 Mazda MX 5 Mia...

Page 629: ...ATION NOTE 1 Align the marks made before removal and install the brake pipe to the dual proportioning valve referring to Fig 27 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 M...

Page 630: ...nect the SSTs to the brake pipes as shown in Fig 28 2 Bleed the air from the brake system and the SSTs Bleed the air from the SSTs through air bleeding valve A 2007 Mazda MX 5 Miata Sport 2007 BRAKES...

Page 631: ...ure of the master cylinder and the rear brake If not within the specification replace the dual proportioning valve 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsof...

Page 632: ...n the rotation direction This characteristic is most noticeable when applying brakes at a vehicle speed of 100 140 km h 62 1 86 8 mph Floor Vibration MASTER CYLINDER PRESSURE kPa kgf cm2 psi REAR BRAK...

Page 633: ...late unevenly 2 If the runout is less than 0 05 mm 0 002 in uneven wear does not occur The Disc Plate Is Deformed By Heat 1 Repeated panic braking may raise the temperature in some portions of disc pl...

Page 634: ...ng all the hub nuts to the same torque put the dial gauge on the friction surface of disc plate 10 mm 0 12 0 28 in from the disc plate edge 3 Rotate the disc plate one time and measure the runout Fron...

Page 635: ...caliper micrometer 3 Subtract the minimum value from the maximum and if the result is not within specification machine the disc plate using a lathe Thickness variation limit 0 015 mm 0 00059 in WARNI...

Page 636: ...20 mm 0 79 in Minimum front disc plate thickness after machining using a brake lathe on vehicle 20 8 mm 0 82 in Disc Pad Thickness Inspection CAUTION Excessive runout may result if the disc plate is r...

Page 637: ...he minimum thickness Fig 33 Inspecting Disc Pad Thickness Courtesy of MAZDA MOTORS CORP FRONT BRAKE DISC REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 34 2 Install in the reverse order o...

Page 638: ...CORP CALIPER INSTALLATION NOTE 1 Clean the exposed area of the piston 2 Install the piston using the SST 3 Install the caliper 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Mi...

Page 639: ...cated in Fig 36 2 Install in the reverse order of removal 3 After installation depress the brake pedal a few times then verify that the brakes do not drag 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conve...

Page 640: ...sy of MAZDA MOTORS CORP CALIPER FRONT DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 37 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursda...

Page 641: ...2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 18 52 PM Page 41 2005 Mitchell Repair Information Company LLC...

Page 642: ...liper body Fig 38 Removing Piston From Caliper Body By Blowing Compressed Air Through Bleeder Screw Hole Courtesy of MAZDA MOTORS CORP REAR BRAKE DISC INSPECTION BRAKE JUDDER REPAIR HINTS Description...

Page 643: ...002 in at the position 10 mm 0 39 in from the disc plate edge uneven wear occurs on the disc plate because the pad contacts the plate unevenly 2 If the runout is less than 0 05 mm 0 002 in uneven wea...

Page 644: ...ening all the hub nuts to the same torque put the dial gauge on the friction surface of disc plate 10 mm 0 39 in from the disc plate edge 3 Rotate the disc plate one time and measure the runout Rear d...

Page 645: ...indicated in Fig 41 using a caliper micrometer 3 Subtract the minimum value from the maximum and if the result is not within specification machine the disc plate using a lathe Thickness variation lim...

Page 646: ...8 mm 0 31 in Minimum rear disc plate thickness after machining using a brake lathe on vehicle 8 8 mm 0 35 in Disc Pad Thickness Inspection CAUTION Excessive runout may result if the disc plate is rem...

Page 647: ...ad Thickness Courtesy of MAZDA MOTORS CORP REAR BRAKE DISC REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 43 2 Install in the reverse order of removal 3 After installation depress the bra...

Page 648: ...y of MAZDA MOTORS CORP DISC PLATE REMOVAL NOTE 1 Mark the wheel hub and disc plate 2 Remove the disc plate 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursd...

Page 649: ...disc plate to the wheel hub CALIPER INSTALLATION NOTE 1 Clean the exposed area of the piston 2 Rotate the piston clockwise slowly using the SST and push the piston completely until the piston grooves...

Page 650: ...After installing the parking brake cable verify that the operating lever returns to the stopper nut with the parking brake lever released 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake Sy...

Page 651: ...der of removal 3 After installation depress the brake pedal a few times and inspect the following The disc pad projection is securely installed to the piston groove Parking brake lever stroke Brake dr...

Page 652: ...osed area of the piston 2 Rotate the piston clockwise slowly using the SST and push in the piston completely until the piston grooves are in the position shown in Fig 48 2007 Mazda MX 5 Miata Sport 20...

Page 653: ...Install the caliper CALIPER REAR DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 49 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday Ju...

Page 654: ...2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 18 52 PM Page 54 2005 Mitchell Repair Information Company LLC...

Page 655: ...ig 50 Rotating Piston Counter Clockwise Using SST Courtesy of MAZDA MOTORS CORP DUST SEAL PISTON ASSEMBLY NOTE 1 Assemble the dust seal to the piston 2 Assemble the lip of the dust seal to the groove...

Page 656: ...SST slowly and push the piston inwards completely 4 Verify that the dust seal is installed into the groove of the piston securely 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX...

Page 657: ...r indicated in FIG 2 Install in the reverse order of removal 3 After installation add brake fluid bleed the air and inspect for fluid leakage See AIR BLEEDING 2007 Mazda MX 5 Miata Sport 2007 BRAKES C...

Page 658: ...in the order indicated in the table 2 Install in the reverse order of removal 3 After installation add brake fluid bleed the air and inspect for fluid leakage See AIR BLEEDING 2007 Mazda MX 5 Miata S...

Page 659: ...ponents With Torque Specifications Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 BRAKES Conventional Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 18 52 PM Page 59 2005 Mi...

Page 660: ...5 0 87 0 ft lbf Fig 1 Wheel Lug Nut Tightening Sequence Courtesy of MAZDA MOTORS CORP BRAKE LINES DISCONNECTION 2007 Mazda MX 5 Miata Sport 2007 GENERAL INFORMATION Brakes General Procedures MX 5 Miat...

Page 661: ...CEDURE 1 When replacing or removing the following parts perform the initialization procedure See COMBINED SENSOR INITIALIZATION PROCEDURE See STEERING ANGLE SENSOR INITIALIZATION PROCEDURE See STEERIN...

Page 662: ...the negative battery cable is disconnected the stored initial position of the steering angle sensor will be cleared and the DSC will not operate properly making the vehicle unsafe to drive Perform the...

Page 663: ...the battery duct NEGATIVE BATTERY CABLE INSTALLATION NOTE 1 When connecting the negative battery cable to the battery connect the negative battery cable and the ground cable as shown in Fig 3 2007 Ma...

Page 664: ...ery as follows WARNING Since battery acid is toxic be careful when handling the battery Since battery acid is highly corrosive be careful not to allow it to contact clothing or the vehicle In case bat...

Page 665: ...positive voltage 12 4 V or more Go to Step 3 Less than 12 4 V Go to the next step 2 Quick charge for 30 min and recheck voltage 12 4 V or more Go to the next step Less than 12 4 V Replace the battery...

Page 666: ...mmobilizer system the system periodically shifts synchronization of the security light flashing Therefore 45 mA 0 1s current is supplied when the security light is illuminated and 25 mA 2s current is...

Page 667: ...arts when the engine is cold otherwise they can cause severe burns or serious injury When the battery cables are connected touching the vehicle body with generator terminal B will generate sparks This...

Page 668: ...Torque Specifications Courtesy of MAZDA MOTORS CORP GENERATOR INSTALLATION NOTE 1 Tighten bolt A temporarily 2 Tighten bolt B C to the specified tightening torque 3 Tighten bolt A to the specified tig...

Page 669: ...ension is correct See DRIVE BELT INSPECTION LF 3 Turn off all electrical loads 4 Start the engine 5 Verify that the generator rotates smoothly without any noise while the engine is running If there is...

Page 670: ...ness 5 Connect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 6 Turn off all electrical loads 7 Start the engine 8 Increase engine speed to 2 500 rpm NOTE Since the charging current de...

Page 671: ...d generator are hot PCM AND GENERATOR SHEARING INSPECTION 1 Connect the M MDS or equivalent to the DLC 2 will not be verified although the generator is normal In this case increase the electrical load...

Page 672: ...2AJ using a tester Is the voltage between 13 and 15 V Yes Go to Step 4 No PCM input error 3 Monitor the ALTT V PID using the M MDS or equivalent or measure the voltage of PCM terminal 2AJ using a test...

Page 673: ...M terminal 2AI using an oscilloscope Is the duty value 0 Yes PCM input error No PCM generator or both are not normal 1 Headlights blower motor rear window defroster and brake light 2 If the generator...

Page 674: ...Verify that there is no continuity between the slip ring and core using a tester If there is continuity replace the rotor 2007 Mazda MX 5 Miata Sport 2007 ELECTRICAL Charging System MX 5 Miata Micros...

Page 675: ...e condition If the slip ring surface is rough use a lathe or fine sandpaper to repair it Stator Coil 1 Verify that the continuity is as indicated in Fig 10 2007 Mazda MX 5 Miata Sport 2007 ELECTRICAL...

Page 676: ...nal Continuity Check Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ELECTRICAL Charging System MX 5 Miata Microsoft Thursday July 09 2009 3 07 38 PM Page 15 2005 Mitchell Repair...

Page 677: ...stator 2 Verify that there is no continuity between the stator coil leads and core using a tester If there is continuity replace the stator coil 2007 Mazda MX 5 Miata Sport 2007 ELECTRICAL Charging Sy...

Page 678: ...wear If any brush is worn almost to or beyond the limit replace all of the brushes Generator brush length Standard 22 5 mm 0 89 in Minimum 5 0 mm 0 20 in 2007 Mazda MX 5 Miata Sport 2007 ELECTRICAL C...

Page 679: ...RS CORP Brush Spring 1 Measure the force of the brush spring using a spring pressure gauge 2007 Mazda MX 5 Miata Sport 2007 ELECTRICAL Charging System MX 5 Miata Microsoft Thursday July 09 2009 3 07 3...

Page 680: ...19 lbf Minimum 1 7 N 0 17 kgf 0 38 lbf Rectifier Using an analog circuit tester 1 Inspect for continuity of the diodes using an analog circuit tester If not as specified replace the rectifier Specifi...

Page 681: ...ied replace the rectifier Specification RECTIFIER SPECIFICATION USING AN DIGITAL CIRCUIT TESTER B No P1 P2 P3 P4 P5 P6 E No B Yes Negative Positive Continuity E P1 P2 P3 P4 P5 P6 No B Yes P1 P2 P3 P4...

Page 682: ...aring 1 Inspect for abnormal noise looseness and sticking Replace the bearing if necessary 2007 Mazda MX 5 Miata Sport 2007 ELECTRICAL Charging System MX 5 Miata Microsoft Thursday July 09 2009 3 07 3...

Page 683: ...e table 2 Assemble in the reverse order of disassembly CAUTION Melt the solder quickly otherwise the diodes rectifier and regulator will be damaged by excessive heat 2007 Mazda MX 5 Miata Sport 2007 E...

Page 684: ...Of Generator With Torque Specifications Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ELECTRICAL Charging System MX 5 Miata Microsoft Thursday July 09 2009 3 07 38 PM Page 23 2005 Mit...

Page 685: ...07 TRANSMISSION Clutch MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thursday July 09 2009 1 44 45 PM Page 1 2005 Mitchell Repair Information Company LLC Microso...

Page 686: ...lutch Components Courtesy of MAZDA MOTORS CORP GENERAL PROCEDURES CLUTCH 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thursday July 09 2009 1 44 45 PM Page 2 2005 Mitchell...

Page 687: ...D REPLACEMENT CAUTION Fluid will damage painted surfaces Be careful not to spill any fluid on painted surfaces If fluid does get on painted surfaces wipe it off immediately NOTE If any hydraulic relat...

Page 688: ...until no air comes from the vinyl hose 6 Tighten the bleeder screw Tightening torque 5 9 8 8 N m 61 89 kgf cm 53 77 in lbf 7 Fill the reserve tank to MAX with the recommended fluid 8 Perform the follo...

Page 689: ...clutch pedal stroke If there is any malfunction loosen locknut A and adjust the pedal stroke by adjusting bolt B Tighten locknut A after adjustment Clutch pedal stroke 130 mm 5 12 in 2007 Mazda MX 5...

Page 690: ...NSPECTION ADJUSTMENT 1 Lightly depress the clutch pedal by hand until clutch resistance is felt and then measure the pedal play Clutch pedal play 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch M...

Page 691: ...6 in 2 If it is not within the specification loosen locknut C and turn push rod D to adjust the pedal play 3 Remeasure the pedal play and if it is within the specification tighten locknut C 2007 Mazda...

Page 692: ...ue Specifications Courtesy of MAZDA MOTORS CORP CLUTCH DISENGAGEMENT POINT INSPECTION 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thursday July 09 2009 1 44 45 PM Page 8...

Page 693: ...istance A from pedal not depressed to clutch disengagement point and verify that it is within the specification Clutch disengagement stroke Reference value A 80 110 mm 3 15 4 33 in Fig 6 Inspecting Cl...

Page 694: ...ector 5 Verify continuity as indicated in Fig 7 Fig 7 Clutch Switch Continuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thursday Ju...

Page 695: ...EDAL REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 9 2 Install in the reverse order of removal 3 Inspect and adjust the clutch pedal See CLUTCH PEDAL ADJUSTMENT 2007 Mazda MX 5 Miata Spo...

Page 696: ...rection A slide it in direction B until it locks securely 3 Move the clutch to a fully open stroke in direction C and securely fit the terminal of the starter interlock switch CAUTION If the rod Is pu...

Page 697: ...Bleed the air from the system See CLUTCH FLUID REPLACEMENT 4 Inspect and adjust the clutch pedal See CLUTCH PEDAL ADJUSTMENT CAUTION Fluid will damage painted surfaces Be careful not to spill any flui...

Page 698: ...CORP CLUTCH MASTER CYLINDER DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 12 2 Assemble in the reverse order of disassembly 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX...

Page 699: ...NG DISASSEMBLY ASSEMBLY NOTE 1 While pressing the piston in with a cloth wrapped pin punch to protect the push rod contacting surface remove install the snap ring 2007 Mazda MX 5 Miata Sport 2007 TRAN...

Page 700: ...m See CLUTCH FLUID REPLACEMENT 4 Inspect and adjust the clutch pedal See CLUTCH PEDAL ADJUSTMENT CAUTION Fluid will damage painted surfaces Be careful not to spill any fluid on painted surfaces If flu...

Page 701: ...SSEMBLY 1 Disassemble in the order indicated in Fig 15 2 Assemble in the reverse order of disassembly Fig 15 Exploded View Of Clutch Release Cylinder Components With Torque Specifications 2007 Mazda M...

Page 702: ...TALLATION 1 Remove in the order indicated in Fig 16 2 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thursday July 09 2009 1 44 46 PM...

Page 703: ...pring tension is released 3 Remove the clutch cover and disc Fig 17 Identifying SSTs Courtesy of MAZDA MOTORS CORP PILOT BEARING REMOVAL NOTE 1 Use the SST to remove the pilot bearing NOTE The pilot b...

Page 704: ...79 side of a Snap on brand millimeter size bushing driver set A160M adapter A160M7 20 22 mm 0 79 0 86 in or substitution tool Substitution tool Outer diameter 21 mm 0 83 in Inner diameter 19 mm 0 75 i...

Page 705: ...g Pilot Bearing Using SSTs Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thursday July 09 2009 1 44 46 PM Page 21 2005 Mitchell Repair Informa...

Page 706: ...RP FLYWHEEL REMOVAL NOTE 1 Hold the flywheel using the SST 2 Remove the bolts evenly and gradually in a crisscross pattern 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thu...

Page 707: ...SEAL REPLACEMENT LF FLYWHEEL INSTALLATION NOTE 1 Clean the crankshaft thread holes 2 Install the flywheel to the crankshaft 3 Hand tighten the flywheel lock bolts 4 Install the SST to the flywheel 5 G...

Page 708: ...htening Sequence Courtesy of MAZDA MOTORS CORP CLUTCH DISC INSTALLATION NOTE 1 Hold the clutch disc position using the SST 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thu...

Page 709: ...1 Install the SSTs 2 Tighten the bolts evenly and gradually in a crisscross pattern Tightening torque 25 0 33 0 N m 2 6 3 4 kgf m 18 5 24 4 ft lbf 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch...

Page 710: ...easure the wear of the diaphragm spring fingers If it exceeds the maximum specification replace the clutch cover Clutch disc maximum depth 0 6 mm 0 024 in 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION...

Page 711: ...plate with a straight edge and a feeler gauge If it exceeds the maximum specification replace the clutch cover Clutch cover maximum clearance 0 5 mm 0 020 in 2007 Mazda MX 5 Miata Sport 2007 TRANSMIS...

Page 712: ...on the cylinder block 4 Rotate the flywheel and check for misaligned diaphragm spring fingers If it exceeds the maximum specification replace the clutch cover Clutch cover maximum height difference 1...

Page 713: ...torsion spring for weakness and the rivet for looseness 4 Using a vernier caliper measure the depth between the lining surface and the rivet head Clutch disc minimum depth 0 3 mm 0 012 in If it is les...

Page 714: ...e clutch disc runout using a dial gauge Clutch disc maximum runout 0 7 mm 0 028 in If it exceeds the maximum specification replace the clutch disc 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch...

Page 715: ...he axial direction and inspect for sticking excessive resistance and an abnormal noise If there is any malfunction replace the clutch release collar CAUTION Do not clean the clutch release collar with...

Page 716: ...NSPECTION 1 Without removing the pilot bearing turn the bearing while applying force in the axial direction If there is any malfunction replace the pilot bearing 2007 Mazda MX 5 Miata Sport 2007 TRANS...

Page 717: ...ight scratches and discoloration using sandpaper Inspect the runout of the surface that contacts the clutch disc with the flywheel installed to the crankshaft 2007 Mazda MX 5 Miata Sport 2007 TRANSMIS...

Page 718: ...teeth for damage and wear 4 Install the flywheel 5 Measure the runout of the surface that contacts the clutch disc using a dial gauge Flywheel maximum runout 0 1 mm 0 004 in If it exceeds the maximum...

Page 719: ...l Maximum Runout Using Dial Gauge Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 TRANSMISSION Clutch MX 5 Miata Microsoft Thursday July 09 2009 1 44 46 PM Page 35 2005 Mitchell Repair...

Page 720: ...rious injury It may also damage the engine and cooling system Turn off the engine and wait until it is cool Even then be very careful when removing the cap Wrap a thick cloth around it and slowly turn...

Page 721: ...amage the engine and cooling system Turn off the engine and wait until it is cool Even then be very careful when removing the cap Wrap a thick cloth around it and slowly turn it counterclockwise to th...

Page 722: ...d freezing Do not use coolants containing Alcohol Methanol Borate or Silicate These coolants could damage the cooling system Use only soft demineralized water in the coolant mixture Water that contain...

Page 723: ...ing to the graph shown in Fig 4 If the coolant protection level is not correct add water or coolant coolant 45 water Use the solution as is when replacing coolant 2007 Mazda MX 5 Miata Sport 2007 ENGI...

Page 724: ...g system cap or loosen the radiator drain plug while the engine is running or when the engine and radiator are hot Scalding engine coolant and steam may shoot out and 2007 Mazda MX 5 Miata Sport 2007...

Page 725: ...by an ethylene glycol based coolant to prevent corrosion and freezing Do not use coolants containing Alcohol Methanol Borate or Silicate These coolants could damage the cooling system Use only soft de...

Page 726: ...S CORP Engine coolant capacity approx quantity 7 5 L 7 9 US qt 6 6 Imp qt 1 Remove the cooling system cap 2007 Mazda MX 5 Miata Sport 2007 ENGINE Cooling System MX 5 Miata Microsoft Thursday July 09 2...

Page 727: ...olor are gone 4 Let the system drain completely 5 Tighten the radiator drain plug Tightening torque 0 8 1 5 N m 8 15 kgf cm 7 13 in lbf 6 Referring to ANTIFREEZE SOLUTION MIXTURE PERCENTAGE TABLE sele...

Page 728: ...6 CAUTION If the water temperature gauge rises too high stop the engine and decrease the water temperature to prevent overheating Then verify the malfunctioning part and repair or replace it If the en...

Page 729: ...nk filler port 5 Apply pressure using the radiator cap tester Pressure 122 6 kPa 1 25 kgf cm2 17 8 psi 1 min WARNING Never remove the cooling system cap or loosen the radiator drain plug while the eng...

Page 730: ...or when the engine and radiator are hot Scalding engine coolant and steam may shoot out and cause serious injury It may also damage the engine and cooling system Turn off the engine and wait until it...

Page 731: ...aching Cooling System Cap To SST Radiator Cap Tester Courtesy of MAZDA MOTORS CORP COOLANT RESERVE TANK REMOVAL INSTALLATION LF WARNING Never remove the cooling system cap or loosen the radiator drain...

Page 732: ...MENT LF 5 Inspect for engine coolant leakage See ENGINE COOLANT LEAKAGE INSPECTION LF slowly turn it counterclockwise to the first stop Step back while the pressure escapes When you are sure all the p...

Page 733: ...COOLANT REPLACEMENT LF 11 Inspect for engine coolant leakage See ENGINE COOLANT LEAKAGE INSPECTION LF 12 Inspect the ATF level AT See AUTOMATIC TRANSMISSION FLUID ATF INSPECTION SJ6A EL WARNING Never...

Page 734: ...ses still connected CONDENSER REMOVAL NOTE 1 Remove the condenser with the cooler pipes still connected THERMOSTAT REMOVAL INSTALLATION LF WARNING Never remove the cooling system cap or loosen the rad...

Page 735: ...hile the engine is running or when the engine and radiator are hot Scalding engine coolant and steam may shoot out and cause serious injury It may also damage the engine and cooling system Turn off th...

Page 736: ...t With Torque Specifications Courtesy of MAZDA MOTORS CORP THERMOSTAT INSPECTION LF 2007 Mazda MX 5 Miata Sport 2007 ENGINE Cooling System MX 5 Miata Microsoft Thursday July 09 2009 3 06 06 PM Page 17...

Page 737: ...T LF WARNING During inspection the thermostat and water are extremely hot and can cause severe burns Do not touch the thermostat and water WARNING Never remove the cooling system cap or loosen the rad...

Page 738: ...the engine coolant See ENGINE COOLANT REPLACEMENT LF 9 Inspect for engine coolant leakage See ENGINE COOLANT LEAKAGE INSPECTION LF 2007 Mazda MX 5 Miata Sport 2007 ENGINE Cooling System MX 5 Miata Mic...

Page 739: ...1 Refill the engine coolant See ENGINE COOLANT REPLACEMENT LF 12 Inspect for engine coolant leakage See ENGINE COOLANT LEAKAGE INSPECTION LF 13 Inspect the ATF level AT See AUTOMATIC TRANSMISSION FLUI...

Page 740: ...N LF PART INSPECTION 1 Verify that the battery is fully charged 2 Install a tester and battery to the cooling fan motor connector 4 terminals as shown in Fig 15 2007 Mazda MX 5 Miata Sport 2007 ENGINE...

Page 741: ...current If there is any malfunction replace the applicable part Cooling fan motor current Fan motor rotation speed Connection terminal Positive Negative High A and C B and D Middle C B and D Low C B 2...

Page 742: ...9 0 12 0 A Middle 6 4 9 4 A Low 4 8 7 8 A 2007 Mazda MX 5 Miata Sport 2007 ENGINE Cooling System MX 5 Miata Microsoft Thursday July 09 2009 3 06 06 PM Page 23 2005 Mitchell Repair Information Company...

Page 743: ...CONTROL SWITCH REMOVAL INSTALLATION Fig 1 Identifying Cruise Control Switch Terminals B C Courtesy of MAZDA MOTORS CORP CRUISE CONTROL SWITCH RESISTANCE SPECIFICATION Switch condition Resistance ohm O...

Page 744: ...on pressed No continuity 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES EQUIPMENT Cruise Control System MX 5 Miata Microsoft Thursday July 09 2009 3 37 42 PM Page 2 2005 Mitchell Repair Information Comp...

Page 745: ...for approx 5min to stabilize the differential oil 2 Remove the oil fill plug and the washer 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 D...

Page 746: ...oil leakage and add the specified oil NOTE Each vehicle is filled with a specified amount of oil 0 7 0 1 L when it is delivered therefore the oil level is lower than the lower end of the plug hole as...

Page 747: ...with a new washer and tighten Tightening torque 39 2 53 9 N m 4 00 5 49 kgf m 29 0 39 7 ft lbf DIFFERENTIAL OIL REPLACEMENT 1 Park the vehicle on level ground 2 Remove the oil fill plug 3 Remove the d...

Page 748: ...h the oil fill plug hole until the oil level reaches the lower end of the plug hole Differential oil Grade API service GL 5 Viscosity SAE 90 SAE 80W 90 SAE 75W 90 Not available from Mazda Capacity app...

Page 749: ...Remove the drain plug and drain the oil 2 Install the drain plug with a new washer and tighten Tightening torque 39 2 53 9 N m 4 00 5 49 kgf m 29 0 39 7 ft lbf 3 Disconnect the rear drive shaft on the...

Page 750: ...w clip to the rear drive shaft insert it into the rear differential See REAR DRIVE SHAFT REAR KNUCKLE COMPONENT INSTALLATION NOTE 9 Verify that the rear drive shaft is held securely by the clip by pul...

Page 751: ...NSTALLATION 2 Replace the oil seal companion flange referring to the rear differential disassembly assembly procedure See REAR DIFFERENTIAL DISASSEMBLY See REAR DIFFERENTIAL ASSEMBLY 3 Install the rea...

Page 752: ...E See POWER PLANT FRAME INSTALLATION NOTE 5 Remove in the order indicated in Fig 8 6 Install in the reverse order of removal 7 Add rear differential oil See DIFFERENTIAL OIL REPLACEMENT harness if it...

Page 753: ...AZDA MOTORS CORP BRAKE CALIPER COMPONENT REMOVAL NOTE 1 Suspend the brake caliper component using a cable or equivalent 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microso...

Page 754: ...etween the rear differential and differential side outer ring and remove the rear drive shaft CAUTION The sharp edges of the drive shaft can slice or puncture the oil seal Be careful not to damage the...

Page 755: ...ecting the rear drive shaft REAR DIFFERENTIAL REMOVAL INSTALLATION NOTE 1 Remove or install the rear differential while supporting it securely with a jack and moving the jack gradually WARNING If the...

Page 756: ...p opening facing upward and the clip width within the specification Standard 31 2 mm 1 23 in 2 After installing the clip measure the outer diametric if it exceeds the specification reinstall a new cli...

Page 757: ...r drive shaft can slice or puncture the oil seal Be careful not to damage the oil seal when installing the rear drive shaft from the rear differential WARNING The engine stand is equipped with a self...

Page 758: ...MOTORS CORP DIFFERENTIAL COMPONENT DISASSEMBLY NOTE 1 Install the differential component to the SSTs 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursday July 0...

Page 759: ...CORP BEARING CAP DISASSEMBLY NOTE 1 Mark the bearing cap and differential carrier for proper installation 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursday Ju...

Page 760: ...CORP ADJUSTMENT SHIM SIDE BEARING OUTER RACE DISASSEMBLY NOTE 1 Remove the adjustment shim using a flathead screwdriver 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Micros...

Page 761: ...ORS CORP 2 Put left and right identification marks on the removed adjustment shims and side bearing outer races 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thurs...

Page 762: ...CORP SIDE BEARING DISASSEMBLY NOTE 1 Remove the side bearing using the SST 2 Put left and right identification marks on the removed side bearings 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Diff...

Page 763: ...OLL PIN DISASSEMBLY NOTE 1 Tap the roll pin out from the direction shown in Fig 19 using a pin punch 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursday July 09...

Page 764: ...CORP LOCKNUT DISASSEMBLY NOTE 1 Remove the locknut while fixing the companion flange using the SST 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursday July 09...

Page 765: ...sy of MAZDA MOTORS CORP COMPANION FLANGE DISASSEMBLY NOTE 1 Remove the companion flange using the SST 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursday July 0...

Page 766: ...drive pinion top to prevent damage to the thread 2 Remove the drive pinion component by tapping the locknut lightly using a plastic hammer 3 Remove the locknut installed in Step 1 2007 Mazda MX 5 Mia...

Page 767: ...ove the rear bearing using the SST and a press CAUTION The drive pinion could be damaged if it falls off Support the drive pinion with your hand when removing the rear bearing 2007 Mazda MX 5 Miata Sp...

Page 768: ...OUTER RACE DISASSEMBLY NOTE 1 Remove the bearing outer race by lightly tapping the edge of the bearing outer race using a flathead screwdriver 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differe...

Page 769: ...y rotates it could cause injury therefore do not maintain the rear differential tilted When turning the rear differential grasp the rotation handle firmly NOTE Clean away the old silicone sealant befo...

Page 770: ...side gear thrust washer pinion gear and the pinion shaft to the gear case 2 Install the dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of 2007 Mazda MX 5 Mia...

Page 771: ...oper washer Backlash of pinion gear and side gear 0 1 mm 0 004 in or less WASHER TABLE ROLL PIN ASSEMBLY NOTE Identification mark Part name Thickness mm in 9 MA29 27 252 0 90 0 0354 95 MA29 27 253 0 9...

Page 772: ...pprox 0 04 cm3 0 04 cc 0 0024 cu in Ring gear bolt thread points B Approx 0 4 cm3 0 4 cc 0 024 cu in 1 location approx 0 04 cm3 0 04 cc 0 0024 cu in CAUTION The gear case and ring gear could be damage...

Page 773: ...RING ASSEMBLY NOTE 1 Press the side bearing in using the SST and a press Fig 28 Pressing Side Bearing In Using SST Press Courtesy of MAZDA MOTORS CORP NOTE When assembling the side bearings do not mix...

Page 774: ...l Seal Using SSTs Courtesy of MAZDA MOTORS CORP REAR BEARING OUTER RACE ASSEMBLY NOTE 1 Press the rear bearing outer race into the differential carrier using the SST and a press 2007 Mazda MX 5 Miata...

Page 775: ...CORP FRONT BEARING OUTER RACE ASSEMBLY NOTE 1 Press the front bearing outer race into the differential carrier using the SST and a press 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential...

Page 776: ...e the spacer bearing inner race rear side and the SST O ring to the SST 49 8531 565 as shown in Fig 32 NOTE Use the installed spacer when adjusting Install the spacer with the chamfer on the SST side...

Page 777: ...tep 1 from the rear side of the differential carrier 3 Assemble the SST 49 8531 567 front bearing companion flange and a washer from the front side of the differential carrier 2007 Mazda MX 5 Miata Sp...

Page 778: ...hat the SST 49 8531 565 can be turned by hand 5 Place the SST 49 N027 001 on top of the SST 49 8531 565 6 Place the SST on the surface plate and set the dial gauge to zero 2007 Mazda MX 5 Miata Sport...

Page 779: ...uring probe of the dial gauge at the point where the side bearing is installed in the differential carrier and measure at the lowest position Measure the left and right sides 2007 Mazda MX 5 Miata Spo...

Page 780: ...Side Bearing Is Installed In Differential Carrier Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursday July 09 2009 3 11 17 PM Pag...

Page 781: ...Height Adjustment Value Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursday July 09 2009 3 11 17 PM Page 37 2005 Mitchell Repair...

Page 782: ...100 0 03 Therefore assemble a spacer 0 03 mm 0 0012 thicker than the currently assembled one The thickness settings are in increments of 0 015 mm 0 0006 so choose one closest in thickness and install...

Page 783: ...e serrated part of the drive pinion by hand to seat the bearing 3 Tighten the locknut temporarily tightened in Step 1 from the lower limit of the specified tightening torque using the SST and obtain t...

Page 784: ...ied tightening torque replace with a new collapsible spacer and adjust again 4 Remove the locknut washer and companion flange OIL SEAL COMPANION FLANGE ASSEMBLY NOTE 1 Apply differential oil to the li...

Page 785: ...BLY NOTE 1 Tighten a new locknut with the torque recorded at the drive pinion preload adjustment using the SST 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursd...

Page 786: ...the specification If not within the specification perform the preload adjustment again Drive pinion preload 1 3 1 8 N m 14 18 kgf cm 12 15 in lbf 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Diffe...

Page 787: ...nd differential gear case component on the surface plate as shown in Fig 42 and measure the height using a caliper and a ruler This is value A Standard Height A 151 4 152 6 mm 5 961 6 007 in 2007 Mazd...

Page 788: ...ection of the differential gear case component installed in the differential carrier This is value B Standard width B 171 mm 6 73 in 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5...

Page 789: ...assembled adjustment shims is not equal to the calculated thickness or if the adjustment shims have to be replaced select two appropriate adjustment shims from the table below ADJUSTMENT SHIM TABLE Id...

Page 790: ...emporarily tighten the bolts 7 Install the dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of one of the ring gear teeth 590 5 90 0 232 640 6 40 0 252 595 5 9...

Page 791: ...0 05 mm 0 0020 in or more Variance 0 07 mm 0 0028 in or less NOTE Measure the backlash at 4 locations around the ring gear Make sure all of the 4 locations are within specification and the minimum va...

Page 792: ...46 Measuring Backlash At 4 Locations Around Ring Gear Courtesy of MAZDA MOTORS CORP NOTE When moving the gear case component in the axial direction replace the adjustment shims If the adjustment shim...

Page 793: ...k and forth for several times 3 Inspect the tooth contact pattern in 4 locations around the ring gear and verify that the tooth contact points exhibit the pattern shown in Fig 48 If the tooth contact...

Page 794: ...ints appear as shown in Fig 49 after the drive pinion and ring gear teeth contact inspection replace the spacer with a thinner one and move the drive pinion outward 2007 Mazda MX 5 Miata Sport 2007 DR...

Page 795: ...ar as shown in Fig 50 after the drive pinion and ring gear teeth contact inspection replace the spacer with a thicker one and move the drive pinion inward 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AX...

Page 796: ...el Face Contact Points Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Differential MX 5 Miata Microsoft Thursday July 09 2009 3 11 17 PM Page 52 2005 Mitchell Repair In...

Page 797: ...ON 2 Front combination lights See FRONT COMBINATION LIGHT REMOVAL INSTALLATION 3 Side step molding See SIDE STEP MOLDING REMOVAL See SIDE STEP MOLDING INSTALLATION 4 Mad guard 5 Front fender panel See...

Page 798: ...CONNECTOR REMOVAL NOTE 1 Pull down the lever in the direction indicated by the arrow and disconnect the connector 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Doors Liftgate MX 5 Miata Micros...

Page 799: ...or hinge installation bolts or the door lock striker installation screws and adjust the door 3 Tighten the bolts or screws Fig 4 Identifying Gap Height Difference Between Door Body 2007 Mazda MX 5 Mia...

Page 800: ...EMOVAL INSTALLATION LF 2 Remove the following parts 1 Door trim See DOOR TRIM REMOVAL INSTALLATION 2 Door speaker See DOOR SPEAKER REMOVAL INSTALLATION 3 Disconnect the power outer mirror harness conn...

Page 801: ...lling Door Unit Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Doors Liftgate MX 5 Miata Microsoft Thursday July 09 2009 3 33 00 PM Page 5 2005 Mitchell Repair Inf...

Page 802: ...s If there is any malfunction replace the applicable part 3 Move the spline and joint up and down left and right by hand and verify that there is no roughness If there is any malfunction replace the a...

Page 803: ...oving the ABS wheel speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake Before performing the following procedures remove the ABS wheel speed sensor axle s...

Page 804: ...MOVAL NOTE 1 Lock the disc plate by applying the brakes 2 Knock the crimped portion of the locknut outward using a chisel and a hammer 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Drive Shaft MX 5...

Page 805: ...RP 3 Remove the locknut BRAKE CALIPER COMPONENT REMOVAL NOTE 1 Suspend the brake caliper component using a cable or equivalent 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Drive Shaft MX 5 Miata M...

Page 806: ...DRIVE SHAFT REMOVAL NOTE 1 Temporarily install a spare nut to the end of the rear drive shaft 2 Knock the nut with copper hammer lightly and remove the rear drive shaft from the wheel hub 2007 Mazda M...

Page 807: ...r side of the vehicle and disconnect it from the rear differential 6 To hold the rear knuckle component install the rear lateral link upper to the rear knuckle temporarily after disconnecting the rear...

Page 808: ...the rear drive shaft with the installation width within the specification Standard 31 2 mm 1 23 in 2 After installing the clip measure the outer diameter If it exceeds the specification reinstall the...

Page 809: ...drive shaft is securely held by the clip by pulling the outer ring on the differential side towards the axle LOCKNUT INSTALLATION NOTE 1 Tighten a new locknut CAUTION The sharp edges of the rear driv...

Page 810: ...mp the locknut using a chisel and hammer REAR DRIVE SHAFT DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 9 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Drive Shaft MX 5 Miata Mic...

Page 811: ...ssembly BOOT BAND AXLE SIDE DISASSEMBLY NOTE 1 Remove the boot band using end clamp pliers NOTE Remove the boot band only if there is an abnormality 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Dr...

Page 812: ...RP BOOT BAND DIFFERENTIAL SIDE DISASSEMBLY NOTE 1 Remove the crimp of the clip using a flathead screwdriver 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Drive Shaft MX 5 Miata Microsoft Thursday J...

Page 813: ...ORS CORP TRIPOD JOINT SOCKET DISASSEMBLY NOTE 1 Place an alignment mark on the drive shaft and the outer ring 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Drive Shaft MX 5 Miata Microsoft Thursday...

Page 814: ...SNAP RING TRIPOD JOINT DISASSEMBLY NOTE 1 Place an alignment mark on the shaft and tripod joint 2 Remove the snap ring using a snap ring plier 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Drive Sh...

Page 815: ...p the shaft spline with vinyl tape CAUTION To prevent damage to the component do not use a hammer when removing it NOTE Remove the axle side boot only if there is an abnormality 2007 Mazda MX 5 Miata...

Page 816: ...d with vinyl tape 3 Remove the vinyl tape TRIPOD JOINT SNAP RING ASSEMBLY NOTE NOTE The boot shapes on the axle side and the differential side are different so do not miss install them NOTE Do not tou...

Page 817: ...rease amount 135 155 g 4 77 5 46 oz 2 Assemble the outer ring 3 Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver CAUTION To pr...

Page 818: ...ge BOOT BAND DIFFERENTIAL SIDE ASSEMBLY NOTE 1 Using pliers pull the boot band around the boot slot in opposite direction of drive shaft forward rotation direction and tighten 2 Insert the end of the...

Page 819: ...is installed to the boot slot securely BOOT BAND AXLE SIDE ASSEMBLY NOTE 1 Turn the adjusting bolt of the SST and adjust the opening size to the specification A Specification A 2 9 mm 0 11 in 2007 Ma...

Page 820: ...lue B is less than the specification increase opening length A of the SST and crimp the new boot band Specification B 2 4 2 8 mm 0 095 0 110 in 4 Verify that the boot band does not protrude from the b...

Page 821: ...thin the specification If crimp value B exceeds the specification reduce opening length A of the SST and recrimp the boot band If the crimp value B is less than the specification replace the boot band...

Page 822: ...area If the boot band protrudes from the installation area replace it with a new band and repeat Step 7 thru 9 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Drive Shaft MX 5 Miata Microsoft Thursda...

Page 823: ...or less Differential pinion height 0 038 mm 0 0015 in or less Differential drive pinion preload 1 3 1 8 N m 14 18 kgf cm 12 1 15 6 in lbf Backlash of drive pinion and ring gear Standard 0 09 0 11 mm 0...

Page 824: ...MOTORS CORP DSC SYSTEM WIRING DIAGRAM 2007 Mazda MX 5 Miata Sport 2007 BRAKES Dynamic Stability Control MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 BRAKES Dynamic Stability Control MX 5 Miata Microso...

Page 825: ...hat battery is fully charged 2 Turn the ignition switch to the ON position and verify that the ABS warning light goes out after approx 2007 Mazda MX 5 Miata Sport 2007 BRAKES Dynamic Stability Control...

Page 826: ...drag perform DSC HU CM operation inspection ABS CONTROL INSPECTION 1 Perform Preparation 2 Connect the M MDS to the DLC 2 3 Set up an active command mode inspection according to the combination of com...

Page 827: ...R V_TRC_L OFF V_TRC_R V_STB_L V_STB_R LF_INLET ON OFF OFF OFF LF_OUTLET LR_INLET OFF ON LR_OUTLET RF_INLET ON OFF RF_OUTLET RR_INLET OFF ON RR_OUTLET PMP_MOTOR ON CAUTION To protect the DSC HU CM the...

Page 828: ...ems cannot be verified Malfunction with intermittent occurrence of the above items Malfunction of DSC HU CM input system wiring harnesses and parts Extremely small leaks in the DSC HU CM internal hydr...

Page 829: ...eer control inhibited Oversteer control inhibited LF RF LR RR V_TRC_L ON OFF ON V_TRC_R OFF ON OFF V_STB_L OFF V_STB_R LF_INLET OFF OFF OFF ON LF_OUTLET OFF LR_INLET ON LR_OUTLET OFF RF_INLET ON RF_OU...

Page 830: ...ION PROCEDURE 5 After installation perform the steering angle sensor initialization procedure See STEERING ANGLE SENSOR INITIALIZATION PROCEDURE 6 After installation perform the steering angle signal...

Page 831: ...OR REMOVAL NOTE 1 Pull the lock lever up in the direction of the arrow 2 Pull the connector toward the vehicle rear and remove it 2007 Mazda MX 5 Miata Sport 2007 BRAKES Dynamic Stability Control MX 5...

Page 832: ...mark on the brake pipe and DSC HU CM 2 Apply protective tape to the connector to prevent brake fluid from entering 3 Remove the brake pipe 2007 Mazda MX 5 Miata Sport 2007 BRAKES Dynamic Stability Co...

Page 833: ...brake pipe to the DSC HU CM and brake pipe joint referring to the figure 2 Tighten the brake pipe to the specified torque using the SST 49 0259 770B CAUTION If the brake pipe is tightened to the speci...

Page 834: ...R INSTALLATION NOTE 1 After connecting the connector verify that the lock lever is completely pushed in 2007 Mazda MX 5 Miata Sport 2007 BRAKES Dynamic Stability Control MX 5 Miata Microsoft Thursday...

Page 835: ...ing 2 Select Module Programming 3 Then select the Programmable Module Installation and ABS from the screen menu 4 Perform the configuration according to the directions on the screen 5 Retrieve DTCs us...

Page 836: ...F 3 Attach the tester lead to the DSC HU CM harness side connector then inspect voltage continuity or resistance according to the standard reference value on REFERENCE VALUE TABLE STANDARD REFERENCE V...

Page 837: ...ound DSC system Ground point Continuity D ground point Continuity detected Wiring harness D ground point E LF wheel speed sensor ground LF ABS wheel speed sensor Continuity E LF ABS wheel speed sensor...

Page 838: ...ntinuity I RR ABS wheel speed sensor connector terminal A Continuity detected Wiring harness I RR ABS wheel speed sensor connector terminal A J Power supply system Ignition switch Voltage Ignition swi...

Page 839: ...essed 1 V or less O RF wheel speed sensor ground RF ABS wheel speed sensor Continuity O RF ABS wheel speed sensor connector terminal B Continuity detected Wiring harness O RF ABS wheel speed sensor co...

Page 840: ...ontinuity AA combined sensor connector terminal B Continuity detected Wiring harness AA combined sensor connector terminal B AB Yaw rate test signal Combined sensor Continuity AB combined sensor conne...

Page 841: ...erminal D Continuity detected Wiring harness AI combined sensor connector terminal D AJ AK AL AM AN AO AP AQ AR AS AT WARNING If the initialization procedure of the steering angle signal is not comple...

Page 842: ...driving verify that the DSC system is normal Fig 12 Locating DLC 2 Connector Courtesy of MAZDA MOTORS CORP FRONT ABS WHEEL SPEED SENSOR REMOVAL INSTALLATION 1 Remove or install the front ABS wheel sp...

Page 843: ...th ABS See REAR ABS WHEEL SPEED SENSOR INSPECTION COMBINED SENSOR REMOVAL INSTALLATION 1 Remove the console See CONSOLE REMOVAL INSTALLATION 2 Remove in the order indicated in Fig 13 CAUTION The inter...

Page 844: ...lation perform the combined sensor initialization procedure See COMBINED SENSOR INITIALIZATION PROCEDURE COMBINED SENSOR INSPECTION 1 Turn the ignition switch off 2007 Mazda MX 5 Miata Sport 2007 BRAK...

Page 845: ...ORS CORP 1 Verify the LAT_ACCL change when the combined sensor is tilted to the left and right If there is any malfunction replace the combined sensor Standard When the sensor is tilted to the right A...

Page 846: ...ght If there is any malfunction replace the combined sensor Standard When the sensor is rotated to the right A YAW_RATE changes negatively When the sensor is rotated to the left B YAW RATE changes pos...

Page 847: ...f 4 Connect the M MDS to the DLC 2 WARNING Unless the initialization procedure of the combined sensor is completed the DSC will not operate causing an unexpected accident Therefore always perform the...

Page 848: ...ions 2 Select Sensor Initialization 6 Drive the vehicle forward 7 After 5 min of driving verify that the DSC system is normal BRAKE FLUID PRESSURE SENSOR INSPECTION 1 Turn the ignition switch off 2 In...

Page 849: ...LI P PID 6 Start the engine 7 Depress the brake pedal and confirm that the fluid pressure value of the SST Gauge and the value shown on the M MDS are equal If the fluid pressures are different replace...

Page 850: ...wiring harness between steering angle sensor terminal B and battery then repair or replace if necessary Standard voltage B NOTE The steering angle sensor is integrated into the combination switch to e...

Page 851: ...inal A and ignition switch then repair or replace if necessary Standard voltage B 4 Measure the voltage between steering angle sensor terminal H and the ground If there is any malfunction inspect the...

Page 852: ...ned to the right SWA_POS changes positively When the steering wheel is turned to the left SWA_POS changes negatively Fig 21 Locating DLC 2 Connector Courtesy of MAZDA MOTORS CORP STEERING ANGLE SENSOR...

Page 853: ...VAL INSTALLATION 1 Remove the side panel See SIDE PANEL REMOVAL INSTALLATION 2 Remove in the order indicated in Fig 22 completed the DSC will not operate causing an unexpected accident Therefore alway...

Page 854: ...t the DSC OFF switch connector from the DSC OFF switch DSC OFF SWITCH REMOVAL NOTE 1 Access the DSC OFF switch from behind of the dashboard and squeeze the tabs of the switch 2 Pull the DSC OFF switch...

Page 855: ...DSC OFF Switch Continuity Table Courtesy of MAZDA MOTORS CORP Fig 24 Identifying DSC OFF Switch Connector Terminals Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 BRAKES Dynamic Stabil...

Page 856: ...ain fuse block See Fig 1 Keyless Buzzer Front of luggage compartment See Fig 35 Main Relay EGI In relay main fuse block See Fig 1 Rear Window Defroster Relay DEFOG In relay main fuse block See Fig 1 S...

Page 857: ...tuator Left Right In respective front door See Fig 36 Fuel Pump Unit Under rear center of vehicle See Fig 6 Mix Air Actuator Behind right side of dash See Fig 22 Power Outer Mirror Left Right On front...

Page 858: ...driver s seat See Fig 26 Seat Weight Sensor Left Right Under respective side of passenger seat See Fig 27 Steering Angle Sensor In steering column See Fig 17 Throttle Position Sensor Left front of eng...

Page 859: ...ion Range Switch On transmission See Fig 8 Trunk Compartment Light Switch Right rear of luggage compartment See Fig 39 Trunk Lid Opener Cancel Switch Lower center rear of luggage compartment See Fig 3...

Page 860: ...or Field Effect Transistor Power MOS FET Behind right end of dash See Fig 21 Seat Warmer Left Right In respective seat cushion See Fig 31 Selector Lever Component Under center console See Fig 19 Trans...

Page 861: ...e Fig 3 G9 Behind left side of dash See Fig 3 G10 Behind center of dash See Fig 3 G11 Behind right kick panel See Fig 3 G12 Under passenger s seat See Fig 3 G13 Under front of center console See Fig 3...

Page 862: ...ig 1 Relay Main Fuse Block Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 7 2005 Mitchell Repair Information Company LL...

Page 863: ...Fig 2 Ground System Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 8 2005 Mitchell Repair Information Company LLC...

Page 864: ...Fig 3 Ground System Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 9 2005 Mitchell Repair Information Company LLC...

Page 865: ...Fig 4 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 10 2005 Mitchell Repair Information Company LLC...

Page 866: ...Fig 5 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 11 2005 Mitchell Repair Information Company LLC...

Page 867: ...Fig 6 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 12 2005 Mitchell Repair Information Company LLC...

Page 868: ...Fig 7 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 13 2005 Mitchell Repair Information Company LLC...

Page 869: ...8 Dash Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 14 2005 Mitchell Repair Information Company L...

Page 870: ...g 9 Engine Control System Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 15 2005 Mitchell Repair Information Company LL...

Page 871: ...ig 10 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 16 2005 Mitchell Repair Information Company LLC...

Page 872: ...11 Dash Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 17 2005 Mitchell Repair Information Company...

Page 873: ...ig 12 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 18 2005 Mitchell Repair Information Company LLC...

Page 874: ...ig 13 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 19 2005 Mitchell Repair Information Company LLC...

Page 875: ...g 14 Engine Control System Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 20 2005 Mitchell Repair Information Company L...

Page 876: ...g 15 Dash Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 21 2005 Mitchell Repair Information Company L...

Page 877: ...gine Compartment Rear Of Vehicle Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 22 2005 Mitchell Repair Information Com...

Page 878: ...17 Dash Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 23 2005 Mitchell Repair Information Company...

Page 879: ...Fig 18 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 24 2005 Mitchell Repair Information Company LLC...

Page 880: ...omatic Transmission Control System Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 25 2005 Mitchell Repair Information C...

Page 881: ...ig 20 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 26 2005 Mitchell Repair Information Company LLC...

Page 882: ...21 Dash Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 27 2005 Mitchell Repair Information Company...

Page 883: ...Fig 22 Dash Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 28 2005 Mitchell Repair Information Company LLC...

Page 884: ...ig 23 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 29 2005 Mitchell Repair Information Company LLC...

Page 885: ...Fig 24 Air Bag System Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 30 2005 Mitchell Repair Information Company LLC...

Page 886: ...Fig 25 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 31 2005 Mitchell Repair Information Company LLC...

Page 887: ...Fig 26 Seats Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 32 2005 Mitchell Repair Information Company LLC...

Page 888: ...Fig 27 Passenger Seat Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 33 2005 Mitchell Repair Information Company LLC...

Page 889: ...Fig 28 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 34 2005 Mitchell Repair Information Company LLC...

Page 890: ...Fig 29 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 35 2005 Mitchell Repair Information Company LLC...

Page 891: ...Fig 30 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 36 2005 Mitchell Repair Information Company LLC...

Page 892: ...Fig 31 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 37 2005 Mitchell Repair Information Company LLC...

Page 893: ...Fig 32 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 38 2005 Mitchell Repair Information Company LLC...

Page 894: ...Fig 33 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 39 2005 Mitchell Repair Information Company LLC...

Page 895: ...esy of MAZDA MOTORS CORP Fig 35 Dash Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 40 2005 Mitchell R...

Page 896: ...gine Compartment Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 41 2005 Mitchell Repair Information Co...

Page 897: ...Fig 37 Dash Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 42 2005 Mitchell Repair Information Company LLC...

Page 898: ...Fig 38 Rear Of Vehicle Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 43 2005 Mitchell Repair Information Company LLC...

Page 899: ...Fig 39 Rear Of Vehicle Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 44 2005 Mitchell Repair Information Company LLC...

Page 900: ...Fig 40 Dash Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 45 2005 Mitchell Repair Information Company LLC...

Page 901: ...Fig 41 Dash Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 46 2005 Mitchell Repair Information Company LLC...

Page 902: ...ig 42 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 47 2005 Mitchell Repair Information Company LLC...

Page 903: ...ig 43 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 48 2005 Mitchell Repair Information Company LLC...

Page 904: ...g 44 Dash Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 49 2005 Mitchell Repair Information Company L...

Page 905: ...Fig 45 Dash Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 50 2005 Mitchell Repair Information Company LLC...

Page 906: ...ig 46 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 51 2005 Mitchell Repair Information Company LLC...

Page 907: ...gine Compartment Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 52 2005 Mitchell Repair Information Co...

Page 908: ...Fig 48 Vehicle Overview Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 53 2005 Mitchell Repair Information Company LLC...

Page 909: ...ig 49 Engine Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 08 59 PM Page 54 2005 Mitchell Repair Information Company LLC...

Page 910: ...tractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP Fig 52 Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thu...

Page 911: ...rtesy of MAZDA MOTORS CORP Fig 54 Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 09 00 PM Page 56...

Page 912: ...tractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 09 00 PM Page 57 2005 Mitchell Repair Information Co...

Page 913: ...rtesy of MAZDA MOTORS CORP Fig 57 Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 09 00 PM Page 58...

Page 914: ...rtesy of MAZDA MOTORS CORP Fig 59 Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 MAZDA MX 5 Miata Microsoft Thursday July 09 2009 3 09 00 PM Page 59...

Page 915: ...ourtesy of MAZDA MOTORS CORP EXHAUST SYSTEM 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miat...

Page 916: ...3 Identifying Location Of Fuel Tank Side Components Courtesy of MAZDA MOTORS CORP FUEL FILLER CAP INSPECTION LF LEAKAGE INSPECTION 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System M...

Page 917: ...ctory If not refer to the tester operators manual to contact tester manufacturer 5 Press the ON OFF switch to turn on the SST and make sure the left display reads 0 0 6 Turn the control valve on the t...

Page 918: ...eplace it Fig 5 Connecting Fuel Cap Receiver Assembly Courtesy of MAZDA MOTORS CORP 4 Turn the control valve to the FILL position 5 Wait maximum 20s until the left display reads 13 9 to 14 in of water...

Page 919: ...AIR FILTER REMOVAL INSTALLATION LF 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Disconnect the evaporative hose from the air filter 4 Cover...

Page 920: ...f MAZDA MOTORS CORP 5 Remove the air filter 6 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miata Microsoft Thursday July 09 2009 2 3...

Page 921: ...y that there is airflow from port B If not as specified replace the air filter 3 Blow from port B and verify that there is airflow from port A If not as specified replace the air filter See AIR FILTER...

Page 922: ...isconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove in the order indicated in Fig 10 4 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ENGINE PER...

Page 923: ...ve hose onto the respective fittings and install clamps as shown in Fig 11 1 Insert the evaporative hose securely to the nipple 2 Inspect the evaporative hose for damage and deformation 2007 Mazda MX...

Page 924: ...etection pump side and purge solenoid valve side of the charcoal canister 3 Inspect for air leakage when blowing air by mouth from the fuel tank side If air leaks replace the charcoal canister See CHA...

Page 925: ...leak detection pump connector 4 Disconnect the evaporative hose from the EVAP system leak detection pump 5 Cover the evaporative hose with vinyl sheets or the like to prevent them from being scratched...

Page 926: ...h Torque Specifications Courtesy of MAZDA MOTORS CORP 7 Remove the bracket from the EVAP system leak detection pump 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miata Micro...

Page 927: ...the evaporative hose onto the respective fittings and install clamps as shown in Fig 15 1 Insert the evaporative hose securely to the nipple 2 Inspect the evaporative hose for damage and deformation 2...

Page 928: ...LF 4 Blow air into port A and verify that there is airflow from port B If not as specified replace the EVAP system leak detection pump See EVAPORATIVE EMISSION EVAP SYSTEM LEAK DETECTION PUMP REMOVAL...

Page 929: ...If not as specified replace the EVAP system leak detection pump See EVAPORATIVE EMISSION EVAP SYSTEM LEAK DETECTION PUMP REMOVAL INSTALLATION LF If as specified carry out the CIRCUIT OPEN SHORT INSPE...

Page 930: ...en or short circuit continuity check Open Circuit If there is no continuity there is an open circuit Repair or replace the wiring harness EVAP system leak detection pump terminal C and PCM terminal 1V...

Page 931: ...d EVAP system leak detection pump terminal D and body ground EVAP system leak detection pump terminal C and power supply EVAP system leak detection pump terminal D and power supply EVAP system leak de...

Page 932: ...attery cable See BATTERY REMOVAL INSTALLATION LF 3 Disconnect the purge solenoid valve connector 4 Disconnect the vacuum hose from the purge solenoid valve 5 Remove the purge solenoid valve from the a...

Page 933: ...VALVE AIRFLOW REFERENCE TABLE If as specified in PURGE SOLENOID VALVE AIRFLOW REFERENCE TABLE perform the CIRCUIT OPEN SHORT INSPECTION If not as specified in PURGE SOLENOID VALVE AIRFLOW REFERENCE T...

Page 934: ...or open or short circuit continuity check Measured condition Continuity between A B When voltage is not applied between terminals A and B No airflow When voltage is applied between terminals A and B A...

Page 935: ...e the wiring harness Purge solenoid valve terminal A and power supply Purge solenoid valve terminal A and body ground Purge solenoid valve terminal B and body ground EGR VALVE REMOVAL INSTALLATION LF...

Page 936: ...TION 3 Remove the cowl grille See COWL GRILLE REMOVAL INSTALLATION 4 Remove the side cowl grille See SIDE COWL GRILLE REMOVAL INSTALLATION 5 Move the cooler pipe No 3 and heater pipe slightly out of t...

Page 937: ...pecifications Courtesy of MAZDA MOTORS CORP 6 Remove the harness bracket 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miata Microsoft Thursday July 09 2009 2 38 04 PM Page...

Page 938: ...CORP 7 Disconnect the heater hose and move the heater pipe slightly out of the way 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miata Microsoft Thursday July 09 2009 2 38 0...

Page 939: ...CORP 8 Disconnect the EGR valve connector 9 Set the SST to the EGR valve installation bolt 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miata Microsoft Thursday July 09 20...

Page 940: ...TORS CORP 10 Remove both EGR valve installation bolts 11 Remove the EGR valve with the engine coolant hose 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miata Microsoft Thur...

Page 941: ...ard from the EGR valve when engine cranking If the buzzing sound is not heard perform the resistance inspection RESISTANCE INSPECTION 1 Remove the plug hole plate See PLUG HOLE PLATE REMOVAL INSTALLAT...

Page 942: ...hin the specification replace the EGR valve See EGR VALVE REMOVAL INSTALLATION LF STANDARD RESISTANCE SPECIFICATIONS Fig 28 Identifying EGR Valve Connector Terminals Courtesy of MAZDA MOTORS CORP Term...

Page 943: ...valve terminal D and main relay Short Circuit If there is continuity there is a short circuit Repair or replace the wiring harness EGR valve terminal A and body ground EGR valve terminal A and power...

Page 944: ...REMOVAL INSTALLATION LF 2 Remove the PCV valve 3 Verify that there is no airflow when pressure is applied to port A If there is airflow replace the PCV valve 4 Verify that there is airflow when vacuu...

Page 945: ...itor PIDs as following Monitor the WU TWC using O2S11 PID for upstream HO2S and O2S12 PID for downstream HO2S NOTE Make sure that no HO2S DTCs have been detected If detected this inspection is not app...

Page 946: ...y crosses the 0 5 V line Fig 31 Identifying HO2S Graph Line 5 Inversions Courtesy of MAZDA MOTORS CORP 9 Count the number of times inversions that the downstream HO2S graph line actually crosses the 0...

Page 947: ...ine Example Fig 32 Upstream HO2S Graph Line Example Courtesy of MAZDA MOTORS CORP Downstream HO2S Graph Line Example 1 Equation RATIO 30 inversions upstream HO2S inversions divided by 5 inversions dow...

Page 948: ...ORS CORP Downstream HO2S Graph Line Example 2 Fig 34 Downstream HO2S Graph Line Example 2 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 Miata Microsoft Thursday July 09 2009...

Page 949: ...ALLATION LF ROLLOVER VALVE INSPECTION LF 1 Perform the fuel tank inspection See FUEL TANK INSPECTION LF FUEL SHUT OFF VALVE REMOVAL INSTALLATION LF NOTE The rollover valve cannot be removed as it is b...

Page 950: ...like to prevent them from being scratched or contaminated with foreign material 6 Install in the reverse order of removal Fig 36 Identifying Evaporative Chamber And Evaporative Hose Courtesy of MAZDA...

Page 951: ...r Ports Courtesy of MAZDA MOTORS CORP QUICK RELEASE CONNECTOR EMISSION SYSTEM REMOVAL INSTALLATION LF QUICK RELEASE CONNECTOR TYPE CAUTION There are four types of quick release connectors Verify the t...

Page 952: ...aged if the release tab is bent excessively Do not expand the release tab over the stopper NOTE The evaporative hose can be removed by pushing it to the joint port side to release the lock NOTE The re...

Page 953: ...necting Evaporative Hose Straight From Joint Port Courtesy of MAZDA MOTORS CORP 3 Cover the disconnected quick release connector and joint port with vinyl sheeting or a similar material to prevent it...

Page 954: ...has two internal locking tabs which retain the joint port Be sure that the squeezing place on the retainer is squeezed until it can be released from the joint port NOTE The retainer is attached to th...

Page 955: ...et the SST parallel to the quick release connector CAUTION Be careful not to damage the pipe when unlocking the retainer NOTE If the quick release connector is removed replace the retainer with a new...

Page 956: ...s and press the retainer 4 Pull the connector side and disconnect the quick release connector 5 Raise a retainer tab using the SST and remove the retainer 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFO...

Page 957: ...D REMOVAL 1 Release the locks between the retainer and joint port by pressing each retainer lock one by one using a flathead screwdriver or a similar tool CAUTION When releasing the retainer locks ta...

Page 958: ...is attached to the pipe even after the connector is disconnected NOTE If the quick release connector O ring is damaged or has slipped replace the evaporative hose A checker tab is integrated with the...

Page 959: ...INSTALLATION Fig 46 Removing Checker Tab From Quick Release Connector Completely Engaged With Joint Port Courtesy of MAZDA MOTORS CORP NOTE If the quick release connector does not move at all disconne...

Page 960: ...sing a flathead screwdriver then pull out the release tab from the joint A checker tab is integrated with the quick release connector for new evaporative hoses Remove the checker tab from the quick re...

Page 961: ...is connected securely TYPE C INSTALLATION NOTE If the quick release connector does not move at all disconnect it verify that the O ring is not damaged or has not slipped and then reconnect the quick...

Page 962: ...se Connector Courtesy of MAZDA MOTORS CORP pipe CAUTION Be sure to replace the retainer with a new one to prevent gas leakage 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Emission System MX 5 M...

Page 963: ...vaporative hose When replacing with a new evaporative hose disengage the release tabs from the join port A checker tab is integrated with the quick release connector for new evaporative hoses Remove t...

Page 964: ...out the release tab from the joint port and remove it Fig 50 Removing Checker Tab From Quick Release Connector After Connector Completely Engaged With Joint Port Courtesy of MAZDA MOTORS CORP 2007 Ma...

Page 965: ...connector straight to the joint port until a click is heard 5 Lightly pull and push the quick release connector a few times by hand and then verify that it is connected securely NOTE If the quick rel...

Page 966: ...GINE PERFORMANCE Engine Control System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 09 PM Page 1 2005 Mitchell R...

Page 967: ...2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 09 PM Page 2 2005 Mitchell Repair Information Company LLC...

Page 968: ...M DIAGRAM LF Fig 2 Engine Control System System Diagram Courtesy of MAZDA MOTORS CORP CONTROL SYSTEM WIRING DIAGRAM LF 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Mi...

Page 969: ...ring Diagram 1 Of 2 Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 09 PM Page 4 2005 Mitchell R...

Page 970: ...ntrol System Wiring Diagram 2 Of 2 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 09 PM Page 5 2005 Mitchell Repair Informati...

Page 971: ...YSTEM REMOVAL INSTALLATION LF 5 Move the water hose from the PCM cover slightly out of the way 6 Remove in the order indicated in Fig 5 Fig 5 Removing PCM With Torque Specifications Courtesy of MAZDA...

Page 972: ...RP PCM INSPECTION LF NOT USING THE M MDS OR EQUIVALENT NOTE The PCM terminal voltage can vary with the conditions when measuring and changes due to aged deterioration on the vehicle causing false diag...

Page 973: ...tch pedal released B 1E 1F 1G 1H Fuel pump control Fuel pump relay Ignition switch is turned to the ON position Engine off and a certain period has elapsed B Fuel pump relay Related wiring harness Cra...

Page 974: ...ow 1 0 1O 1P MAF sensor ground MAF sensor Under any condition Below 1 0 Related wiring harness 1Q Main relay control Main relay Ignition switch is turned to the ON position Below 1 0 Main relay Relate...

Page 975: ...harness Except above B 1Y 1Z 1AA 1AB Brake switch No 1 Brake switch Brake pedal depressed B Brake switch Related wiring harness Brake pedal released Below 1 0 1AC 1AD 1AE 1AF Brake switch No 2 Brake...

Page 976: ...1AP APP sensor No 2 APP sensor Ignition switch is turned to the ON position Accelerator pedal depressed Approx 3 4 APP sensor Related wiring harness Accelerator pedal released Approx 1 0 1AQ Cruise c...

Page 977: ...harness Ignition switch is turned to the ON position B 1AX Drive by wire relay control Drive by wire relay Under any condition Below 1 0 Drive by wire relay Related wiring harness 1AY Ignition switch...

Page 978: ...g the wave profile See INSPECTION USING AN OSCILLOSCOPE REFERENCE Throttle valve actuator Related wiring harness 2B Throttle control Throttle body Throttle valve actuator Inspect using the wave profil...

Page 979: ...EGR valve terminal E Idle EGR control not operating Below 1 0 EGR valve Related wiring harness 2L EGR valve 3 coil control EGR valve terminal B Idle EGR control not operating B EGR valve Related wiri...

Page 980: ...gital type voltmeter because measurement voltage will be detected less than true voltage when using analog type voltmeter Below 1 0 KS Related wiring harness 2W CKP CKP sensor Inspect using the wave p...

Page 981: ...nspect using the wave profile See INSPECTION USING AN OSCILLOSCOPE REFERENCE Generator Related wiring harness 2AK Throttle valve opening angle No 1 Throttle body TP sensor Ignition switch is turned to...

Page 982: ...nsor ground MAP sensor Under any condition Below 1 0 Related wiring harness 2AW IGT2 Ignition coil No 2 cylinders Inspect using the wave profile See INSPECTION USING AN OSCILLOSCOPE REFERENCE Ignition...

Page 983: ...jector No 3 Inspect using the wave profile See INSPECTION USING AN OSCILLOSCOPE REFERENCE Fuel injector No 3 Related wiring harness 2BE Rear HO2S heater control Rear HO2S heater Heavy load Heater cont...

Page 984: ...or pedal released Fig 8 Waveform Graph Throttle Control Signal Courtesy of MAZDA MOTORS CORP Throttle Control Signal PCM Terminals 3 Turn the test mode on using the M MDS simulation function 4 MT with...

Page 985: ...ignal Courtesy of MAZDA MOTORS CORP Purge Control Signal PCM Terminals 2C Negative battery terminal Oscilloscope Setting 2 V DIV Y 0 1 s DIV X DC range Vehicle Condition Idle after warm up 2007 Mazda...

Page 986: ...ls 2E Negative battery terminal Oscilloscope Setting 2 5 V DIV Y 1 ms DIV X DC range Vehicle Condition Idle after warm up 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5...

Page 987: ...Negative battery terminal Oscilloscope Setting 1 V DIV Y 10 ms DIV X DC range Vehicle Condition Vehicle speed is 10 km h 6 2 mph 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control Syst...

Page 988: ...2S Negative battery terminal Oscilloscope Setting 2 V DIV Y 50 ms DIV X DC range Vehicle Condition Idle after warm up 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Mia...

Page 989: ...gative battery terminal Oscilloscope Setting 2 V DIV Y 10 ms DIV X DC range Vehicle Condition Idle after warm up 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Mi...

Page 990: ...inals 2AI Negative battery terminal Oscilloscope Setting 0 5 V DIV Y 1 ms DIV X DC range Vehicle Condition Idle after warm up 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System...

Page 991: ...nal PCM Terminals 2AJ Negative battery terminal Oscilloscope Setting 2 V DIV Y 1 ms DIV X DC range Vehicle Condition Idle after warm up 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Contr...

Page 992: ...Negative battery terminal IGT3 No 3 2AX Negative battery terminal IGT4 No 4 2AT Negative battery terminal Oscilloscope Setting 2 V DIV Y 50 ms DIV X DC range Vehicle Condition Idle after warm up 2007...

Page 993: ...ive battery terminal Fuel Injection No 3 2BD Negative battery terminal Fuel Injection No 4 2AZ Negative battery terminal Oscilloscope Setting 10 V DIV Y 10 ms DIV X DC range Vehicle Condition Idle aft...

Page 994: ...minals 2BG Negative battery terminal Oscilloscope Setting 5 V DIV Y 50 ms DIV X DC range Vehicle Condition Idle after warm up no load 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control...

Page 995: ...equivalent to the DLC 2 NOTE PIDs for the following parts are not available on this model Go to the appropriate part inspection reference CMP sensor Main relay 2007 Mazda MX 5 Miata Sport 2007 ENGINE...

Page 996: ...e If a monitored value of an output device is out of specification inspect the monitored value of the input device related to the output control For input output signals except those of the monitoring...

Page 997: ...pressure switch high low A C amplifier 1AU ACCS A C relay On Off A C relay is ON On A C relay is OFF Off The following PIDs CPP 1 CPP PNP 1 ECT RPM TP TR 2 AC_REQ COLP 1I AFR Air fuel ratio Idle afte...

Page 998: ...ed Approx 1 6 V Accelerator pedal depressed Approx 3 9 V APP2 APP sensor No 2 Accelerator pedal released Approx 21 Accelerator pedal depressed Approx 67 APP sensor 1AP V Accelerator pedal released App...

Page 999: ...light On Off Idle Generator warning light illuminate On Idle Generator warning light not illuminate Off Generator warning light COLP Refrigerant pressure switch middle On Off Refrigerant pressure is m...

Page 1000: ...lambda Target lambda Excess air factor supplied air amount theoretical air fuel ratio Front HO2S ETC_ACT Throttle control Accelerator pedal released Approx 0 Accelerator pedal depressed Approx 94 5 TP...

Page 1001: ...ring test mode CTP Off WOT On The following PIDs ECT test TP 1R FLI Fuel level Indicate the fuel level FP Fuel pump relay On Off Ignition switch is turned to the ON position and a certain period has e...

Page 1002: ...ALTT V VPWR Generator HTR11 Front HO2S heater control On Off Ignition switch is turned to the ON position Off Idle On The following PIDs ECT IAT RPM TP MAF MAP VPWR 2BG HTR12 Rear HO2S heater control...

Page 1003: ...pedal released Except above Off CPP switch Neutral switch 1D 1X AT Driving range On Except above Off TR switch IVS CTP condition Idle Off Idle Idle Idle Other than idle Off Idle The following PIDs TP...

Page 1004: ...small leak detection fail value mA s Indicate EVAP system very small leak detection fail value LDP_VSL_SV EVAP system very small leak detection safe value mA s Indicate EVAP system very small leak det...

Page 1005: ...itch is turned to the ON position Indicate the MAP MAP sensor 2AG V Ignition switch is turned to the ON position at sea level 4 1 V Idle after warm up Approx 1 2 V MIL Malfunction indicator lamp On Of...

Page 1006: ...ttery cable is disconnected before running PCM adaptive memory procedure drive mode Not Learnt Verify after repair procedure RO2FT1 Rear HO2S fuel trim Idle after warm up Approx 0 The following PIDs O...

Page 1007: ...lowing PIDs MAF TP ECT RPM VSS SELTESTDTC Diagnostic trouble codes Indicate the diagnostic trouble codes SHRTFT1 Short term fuel trim front Idle after warm up 25 25 The following PIDs CPP 1 CPP PNP 1...

Page 1008: ...e Indicate the tire revolution per a mile TP REL Throttle position signal relative value Accelerator pedal released Approx 10 Accelerator pedal depressed Approx 81 The following PIDs TP1 TP2 TP1 TP se...

Page 1009: ...V Indicate the battery voltage Battery 1BA VSS Vehicle speed Km h Mph Vehicle running Indicate the vehicle speed ABS DSC HU CM 3 VSS 4 TCM 5 2O 4 1AM 3 5 1AI 3 5 VT ACT1 Actual valve timing Idle Appro...

Page 1010: ...Select Module Programming 4 Select Programmable Module Installation OCV control PIDs ECT RPM TP MAF 1 MT 2 California emission regulation applicable model 3 With ABS DSC HU CM 4 MT without ABS DSC 5 A...

Page 1011: ...RAL SWITCH REMOVAL INSTALLATION P66M D Fig 22 Neutral Switch Continuity Reference Table Courtesy of MAZDA MOTORS CORP If the monitor item condition specification reference is not within the specificat...

Page 1012: ...CM Harness Side Connectors Courtesy of MAZDA MOTORS CORP Open Circuit If there is no continuity there is an open circuit Repair or replace the wiring harness Neutral switch terminal 2A and PCM termina...

Page 1013: ...h Continuity Table Courtesy of MAZDA MOTORS CORP If the monitor item condition specification reference is not within the specification even though there is no malfunction perform the CIRCUIT OPEN SHOR...

Page 1014: ...is an open circuit Repair or replace the wiring harness CPP switch terminal B and PCM terminal 1D CPP switch terminal D and body ground Short Circuit 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMAN...

Page 1015: ...PP switch See POWER STEERING OIL PUMP DISASSEMBLY ASSEMBLY Fig 26 Power Steering Pressure Switch Continuity Reference Table Courtesy of MAZDA MOTORS CORP If the monitor item condition specification re...

Page 1016: ...MAZDA MOTORS CORP Open Circuit If there is no continuity there is an open circuit Repair or replace the wiring harness PSP switch terminal A and PCM terminal 2T Short Circuit 2007 Mazda MX 5 Miata Sp...

Page 1017: ...t side See FRONT SUSPENSION TOWER BAR REMOVAL INSTALLATION 2 Remove the wiper arm See WIPER ARM AND BLADE REMOVAL INSTALLATION 3 Remove the cowl grille See COWL GRILLE REMOVAL INSTALLATION 4 Remove th...

Page 1018: ...ter Hose Heater Pipe Courtesy of MAZDA MOTORS CORP 7 Remove the ECT sensor NOTE Put the double nut together and install the torque wrench See TORQUE FORMULAS 2007 Mazda MX 5 Miata Sport 2007 ENGINE PE...

Page 1019: ...reverse order of removal ECT sensor tightening torque 10 14 N m 1 1 1 4 kgf m 7 4 10 3 ft lbf 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday J...

Page 1020: ...MOTORS CORP ENGINE COOLANT TEMPERATURE ECT SENSOR INSPECTION LF 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 10 PM Page 55...

Page 1021: ...PECTION If not within the specification replace the ECT sensor See ENGINE COOLANT TEMPERATURE ECT SENSOR REMOVAL INSTALLATION LF STANDARD ECT SENSOR RESISTANCE SPECIFICATION CIRCUIT OPEN SHORT INSPECT...

Page 1022: ...rness Side Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 10 PM Page 57 2005 Mitchell...

Page 1023: ...ng harness ECT sensor terminal A and power supply ECT sensor terminal A and body ground ECT sensor terminal B and power supply MASS AIR FLOW MAF INTAKE AIR TEMPERATURE IAT SENSOR REMOVAL INSTALLATION...

Page 1024: ...acks Rusted sensor terminal Bent sensor terminal If there is any malfunction replace the MAF IAT sensor See MASS AIR FLOW MAF INTAKE AIR TEMPERATURE IAT SENSOR NOTE Before performing the following ins...

Page 1025: ...LATION LF 2 Inspect the following wiring harness for open or short circuit continuity Inspection Open Circuit If there is no continuity there is an open circuit Repair or replace the wiring harness MA...

Page 1026: ...IR TEMPERATURE IAT SENSOR INSPECTION LF Condition Intake MAF g s Engine load calculated value MT AT Idle 2 1 2 6 2 3 2 8 13 5 24 0 Engine Speed 2 500 rpm 6 1 7 5 6 7 8 3 11 5 21 5 2007 Mazda MX 5 Miat...

Page 1027: ...not within the specification replace the MAF IAT sensor See MASS AIR FLOW MAF INTAKE AIR TEMPERATURE IAT SENSOR REMOVAL INSTALLATION Fig 36 Identifying MAF IAT Sensor Connectors Courtesy of MAZDA MOT...

Page 1028: ...r an open or short circuit Continuity inspection Fig 37 Identifying MAF IAT Sensor Harness Side Connectors Courtesy of MAZDA MOTORS CORP 60 140 0 493 0 667 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERF...

Page 1029: ...MAF IAT sensor terminal E and power supply MAF IAT sensor terminal D and power supply MAF IAT sensor terminal D and body ground MANIFOLD ABSOLUTE PRESSURE MAP SENSOR REMOVAL INSTALLATION LF 1 Remove t...

Page 1030: ...MAP SENSOR INSPECTION LF 1 Connect the M MDS or equivalent to the DLC 2 NOTE Before performing the following inspection make sure to follow the procedure as indicated in the troubleshooting flow diag...

Page 1031: ...25 0 kPa 187 mmHg 7 38 inHg to the MAP sensor and verify that the MAP variation from that of Step 4 is approx 25 0 kPa 187 mmHg 7 38 inHg If not as verified perform the CIRCUIT OPEN SHORT INSPECTION...

Page 1032: ...rness Side Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 10 PM Page 67 2005 Mitchell...

Page 1033: ...ess MAP boost air temperature sensor terminal A and power supply MAP boost air temperature sensor terminal C and body ground MAP boost air temperature sensor terminal D and power supply MAP boost air...

Page 1034: ...cation when the accelerator pedal not depressed See PCM INSPECTION LF 6 Operate the accelerator pedal and verify that the TP1 or TP2 PID percentage changes as shown in Fig 44 If not verified perform t...

Page 1035: ...EN SHORT INSPECTION 1 Disconnect the PCM connector See PCM REMOVAL INSTALLATION LF 2 Disconnect the throttle body connector 3 Inspect the following wiring harnesses for an open or short circuit Contin...

Page 1036: ...Harness Side Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 10 PM Page 71 2005 Mitche...

Page 1037: ...the wiring harness Throttle body terminal C and power supply Throttle body terminal D and body ground Throttle body terminal D and power supply Throttle body terminal E and body ground Throttle body t...

Page 1038: ...pedal not depressed See PCM INSPECTION LF CIRCUIT OPEN SHORT INSPECTION 1 Disconnect the PCM connector See PCM REMOVAL INSTALLATION LF 2 Disconnect the APP sensor connector 3 Inspect the following wi...

Page 1039: ...rness Side Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 10 PM Page 74 2005 Mitchell...

Page 1040: ...C and power supply APP sensor terminal D and body ground APP sensor terminal E and power supply APP sensor terminal F and body ground APP sensor terminal F and power supply CRANKSHAFT POSITION CKP SE...

Page 1041: ...connect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the CKP sensor See CRANKSHAFT POSITION CKP SENSOR REMOVAL INSTALLATION LF 4 Verify that there are no metal shavings on t...

Page 1042: ...51 Identifying CKP Sensor Harness Side Connector Courtesy of MAZDA MOTORS CORP CKP SENSOR VOLTAGE SPECIFICATION CAUTION Water penetrating the connector will cause sensor malfunction To prevent this b...

Page 1043: ...t Continuity Inspection Fig 52 Identifying CKP Sensor Harness Side Connector Courtesy of MAZDA MOTORS CORP A 0 Under any condition 1 Output voltage varies with crankshaft rotation 2007 Mazda MX 5 Miat...

Page 1044: ...ty the circuit is shorted Repair or replace the wiring harness CKP sensor terminal A and power supply CKP sensor terminal B and power supply CKP sensor terminal B and body ground CKP sensor terminal C...

Page 1045: ...ATF hose slightly out of the way AT Fig 54 Identifying ATF Hose Courtesy of MAZDA MOTORS CORP 2 Remove the cylinder block lower blind plug and install the SST CAUTION When foreign material such as an...

Page 1046: ...space 3 Align the center line of the CKP sensor and the line drawn in Step 2 then install the CKP sensor CAUTION If the line is not accurately drawn ignition timing fuel injection and other engine con...

Page 1047: ...14 16 ft lbf 6 Install in the reverse order of removal CAMSHAFT POSITION CMP SENSOR REMOVAL INSTALLATION LF 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INST...

Page 1048: ...ng as they can cause the sensor output signal to malfunction from fluctuation in magnetic flux resulting in a deterioration in engine control Cover a removed CMP sensor in plastic to protect it from f...

Page 1049: ...utput voltage using an oscilloscope If not within the specification replace the CMP sensor See CAMSHAFT POSITION CMP SENSOR REMOVAL INSTALLATION LF If the monitor item condition specification referenc...

Page 1050: ...ollowing wiring harnesses for an open or short circuit Continuity Inspection Terminal Voltage V Condition C B Under any condition B 4 8 or more High output 1 0 8 or less Low output 1 A 0 Under any con...

Page 1051: ...rness Side Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 10 PM Page 86 2005 Mitchell...

Page 1052: ...r or replace the wiring harness I CMP sensor terminal A and power supply CMP sensor terminal B and power supply CMP sensor terminal B and body ground CMP sensor terminal C and body ground FRONT HEATED...

Page 1053: ...CURRENT INSPECTION 1 Warm up the engine to normal operating temperature 2 Using the M MDS or equivalent monitor the following NOTE Before performing the following inspection make sure to follow the pr...

Page 1054: ...within the specification inspect the front HO2S for an open or short circuit See FRONT HO2S CIRCUIT OPEN SHORT INSPECTION Then if there is no malfunction in the wiring harness replace the front HO2S...

Page 1055: ...ohms FRONT HO2S CIRCUIT OPEN SHORT INSPECTION 1 Disconnect the PCM connector See PCM REMOVAL INSTALLATION LF 2 Disconnect the front HO2S connector 3 Inspect the following wiring harnesses for an open...

Page 1056: ...HO2S Terminals Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday July 09 2009 2 41 10 PM Page 91 2005 Mitchell Repai...

Page 1057: ...rt Circuit If there is continuity in the following wiring harnesses there is a short circuit Repair or replace the wiring harness Front HO2S terminal A and power supply Front HO2S terminal A and body...

Page 1058: ...5 Install in the reverse order of removal Rear HO2S tightening torque 29 49 N m 3 0 4 9 kg fm 22 35 ft lbf REAR HEATED OXYGEN SENSOR HO2S INSPECTION LF NOTE Before performing the following inspection...

Page 1059: ...that the rear HO2S voltage PID O2S12 is 0 3 V or less while decelerating as shown in Fig 67 Fig 67 Rear HO2S Voltage Graph Courtesy of MAZDA MOTORS CORP If not within the specification inspect the rea...

Page 1060: ...LF Rear HO2S heater resistance 2 50 ohms Fig 68 Identifying Rear HO2S Connector Terminals Courtesy of MAZDA MOTORS CORP REAR HO2S CIRCUIT OPEN SHORT INSPECTION 1 Disconnect the PCM connector 2 Disconn...

Page 1061: ...ity Inspection Fig 69 Identifying Rear HO2S Harness Side Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System MX 5 Miata Microsoft Thursday...

Page 1062: ...there is continuity in the following wiring harnesses there is a short circuit Repair or replace the wiring harness Rear HO2S terminal A and power supply Rear HO2S terminal A and body ground Rear HO2S...

Page 1063: ...allation bolt then remove the KS 6 Install in the reverse order of removal KS tightening torque 16 24 N m 1 7 2 4 kgf m 12 17 ft lbf KNOCK SENSOR KS INSPECTION LF RESISTANCE INSPECTION NOTE Before per...

Page 1064: ...specification even though the KS resistance is within the specification perform the CIRCUIT OPEN SHORT INSPECTION KS resistance Approx 4 87 megohms CIRCUIT OPEN SHORT INSPECTION 1 Disconnect the PCM...

Page 1065: ...KS terminal A and body ground KS terminal B and power supply KS terminal B and body ground BAROMETRIC PRESSURE BARO SENSOR INSPECTION LF 1 Connect the M MDS or equivalent to the DLC 2 NOTE Before per...

Page 1066: ...equivalent 4 Verify that the BARO PID pressure and barometric pressure are practically equal If not as verified replace the PCM See PCM REMOVAL INSTALLATION LF 2007 Mazda MX 5 Miata Sport 2007 ENGINE...

Page 1067: ...Sport 2007 ENGINE Mechanical MX 5 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 50 PM Page 1 2005 Mitchell Repair Information Company LLC Microsoft Thurs...

Page 1068: ...2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 50 PM Page 2 2005 Mitchell Repair Information Company LLC...

Page 1069: ...g Plug Hole Plate From Installation Areas Rubber Clips Courtesy of MAZDA MOTORS CORP 2 Install the plug hole plate NOTE Lift off and remove the plug hole plate from the installation areas rubber and c...

Page 1070: ...hole plate grasp rubber 1 and 2 as shown in Fig 4 with your hands and press them in 2 Grasp clips 3 with your hands and press them in 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft...

Page 1071: ...LATION LF NOTE Drive belt deflection tension inspection is not necessary because of the use of the auto tensioner NOTE Use a mirror to see the position of the drive belt auto tensioner indicator mark...

Page 1072: ...ve belt auto tensioner indicator mark does not exceed the limit If it exceeds the limit replace the drive belt See DRIVE BELT REPLACEMENT LF AT 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5...

Page 1073: ...Belt Auto Tensioner Indicator Mark AT Courtesy of MAZDA MOTORS CORP MT 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 50 PM Page 7 2005 Mitchell Repair In...

Page 1074: ...ATION LF DRIVE BELT REPLACEMENT LF 1 Remove the battery and battery tray See BATTERY REMOVAL INSTALLATION LF 2 Rotate the drive belt auto tensioner in the direction shown in Fig 8 and remove the drive...

Page 1075: ...e limit See DRIVE BELT INSPECTION LF If it exceeds the limit replace the drive belt 5 Install the battery and battery tray See BATTERY REMOVAL INSTALLATION LF NOTE Use a mirror to see the position of...

Page 1076: ...lt See DRIVE BELT REPLACEMENT LF 3 Verify that the drive belt auto tensioner moves smoothly in the operational direction Replace the drive belt auto tensioner if necessary NOTE Use a mirror to see the...

Page 1077: ...he drive belt auto tensioner pulley by hand and verify that it rotates smoothly Replace the drive belt auto tensioner if necessary 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thu...

Page 1078: ...AL INSTALLATION LF 5 Remove the front suspension tower bar joint See FRONT SUSPENSION TOWER BAR REMOVAL INSTALLATION 6 Remove the CMP sensor See CAMSHAFT POSITION CMP SENSOR REMOVAL INSTALLATION LF 7...

Page 1079: ...TDC of the compression stroke 4 Measure the valve clearance at B in Fig 12 If the valve clearance is out of the specification adjust it See VALVE CLEARANCE ADJUSTMENT LF Fig 12 Identifying Where To M...

Page 1080: ...tray See BATTERY REMOVAL INSTALLATION LF 2 Remove the plug hole plate See PLUG HOLE PLATE REMOVAL INSTALLATION LF 3 Remove the air cleaner See INTAKE AIR SYSTEM REMOVAL INSTALLATION LF 4 Disconnect t...

Page 1081: ...lind Plug Courtesy of MAZDA MOTORS CORP 13 Remove the engine front cover upper blind plug 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 50 PM Page 15 200...

Page 1082: ...y of MAZDA MOTORS CORP 14 Remove the cylinder block lower blind plug 15 Install the SST as shown in Fig 15 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21...

Page 1083: ...chet 2 Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain 3 Placing the suitable bolt M6 X 1 0 length 25 mm 35 mm 0 99 in 1 37 in at the engine...

Page 1084: ...Loosening Timing Chain Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 50 PM Page 18 2005 Mitchell Repair Information Compan...

Page 1085: ...g 17 Fig 17 Holding Exhaust Camshaft Using Wrench On Cast Hexagon Courtesy of MAZDA MOTORS CORP 19 Remove the exhaust camshaft sprocket 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsof...

Page 1086: ...s in the order shown in Fig 19 NOTE The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position Do not mix the caps 2007 Mazda MX 5 Miata Sport 20...

Page 1087: ...ve clearance Engine cold IN 0 22 0 28 mm 0 0087 0 0110 in EX 0 27 0 33 mm 0 0107 0 0129 in 24 Install the camshaft with No 1 cylinder camshaft lobes aligned with the TDC position 25 Tighten the camsha...

Page 1088: ...Tightening Sequence Courtesy of MAZDA MOTORS CORP 26 Install a new washer 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 50 PM Page 22 2005 Mitchell Repai...

Page 1089: ...ft sprocket NOTE Do not tighten the bolt for the camshaft sprocket during this step First confirm the valve timing then tighten the bolt 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microso...

Page 1090: ...ket Courtesy of MAZDA MOTORS CORP 28 Install the SST to the camshaft as shown in Fig 23 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 50 PM Page 24 2005...

Page 1091: ...tension to the timing chain 30 Turn the crankshaft clockwise until the crankshaft is in the No 1 cylinder TDC position 31 Hold the exhaust camshaft using a suitable wrench on the cast hexagon as show...

Page 1092: ...plug 35 Rotate the crankshaft clockwise two turns until the TDC position If not aligned loosen the crankshaft pulley lock bolt and repeat from Step 16 36 Apply silicone sealant to the engine front cov...

Page 1093: ...MOTORS CORP 38 Install the cylinder block lower blind plug Tightening torque 18 22 N m 1 9 2 2 kgf m 13 3 16 2 ft lbf 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 0...

Page 1094: ...RS CORP 39 Install the new engine front cover lower blind plug Tightening torque 10 14 N m 102 142 kgf cm 89 123 in lbf 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July...

Page 1095: ...rn the crankshaft clockwise so that the No 1 piston is at TDC of the compression stroke 2 Measure the valve clearance at A in Fig 28 If the valve clearance is out of the specification adjust it See VA...

Page 1096: ...e clearance at B in Fig 28 If the valve clearance is out of the specification adjust it See VALVE CLEARANCE ADJUSTMENT LF Valve clearance Engine cold NOTE Make sure to note down the measured values fo...

Page 1097: ...f necessary See BATTERY INSPECTION LF 2 Warm up the engine to the normal operating temperature 3 Stop the engine and allow it to cool down for about 10 min 4 Perform Fuel Line Safety Procedures Leave...

Page 1098: ...head distorted and overhaul is required Compression Standard 1 720 kPa 17 5391 kgf cm2 249 465 psi 300 rpm Minimum 1 204 kPa 12 277 kgf cm2 174 58 psi 300 rpm Maximum difference between cylinders 196...

Page 1099: ...t the OCV connector 8 Remove the ignition coils See IGNITION COIL REMOVAL INSTALLATION LF 9 Remove the drive belt See DRIVE BELT REPLACEMENT LF 10 Remove the under cover See TRANSVERSE MEMBER REMOVAL...

Page 1100: ...se order of removal 16 Start the engine and Verify the ignition timing idle speed and idle mixture See ENGINE TUNE UP LF 17 Perform a road test 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5...

Page 1101: ...2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 51 PM Page 35 2005 Mitchell Repair Information Company LLC...

Page 1102: ...tall the SST Fig 31 Installing SST Courtesy of MAZDA MOTORS CORP 3 Turn the crankshaft clockwise until the crankshaft is in the No 1 cylinder TDC position until the balance weight contacts the SST 4 H...

Page 1103: ...emove the crankshaft pulley lock bolt FRONT OIL SEAL REMOVAL NOTE 1 Remove the oil seal using a screwdriver as shown in Fig 33 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursda...

Page 1104: ...the chain tensioner ratchet lock mechanism away from the ratchet stem 2 Slowly compress the tensioner piston 3 Hold the tensioner piston using a 1 5 mm 0 059 in wire or paper clip 2007 Mazda MX 5 Mia...

Page 1105: ...ft pulley and crankshaft pulley lock bolt to the crankshaft and lock the oil pump against rotation as shown in figure 2 Remove the oil pump sprocket and then remove the crankshaft pulley and crankshaf...

Page 1106: ...TALLATION NOTE 1 Temporarily install the crankshaft pulley and crankshaft pulley lock bolt to the crankshaft and lock the oil pump against rotation as shown in Fig 36 2007 Mazda MX 5 Miata Sport 2007...

Page 1107: ...pulley and crankshaft pulley lock bolt Tightening torque 20 30 N m 2 1 3 0 kgf m 14 8 22 1 ft lbf TIMING CHAIN INSTALLATION NOTE 1 Install the SST to the camshaft as shown in Fig 37 2 Install the timi...

Page 1108: ...Fig 38 Thickness A 2 0 3 0 mm 0 079 0 118 in B 1 5 2 5 mm 0 059 0 098 in NOTE Install the front oil seal before performing the following procedure CAUTION Install the engine front cover within 10 min...

Page 1109: ...shown in Fig 39 ENGINE FRONT COVER BOLTS TIGHTENING TORQUE Bolt No Tightening torque 1 18 8 0 11 5 N m 81 6 117 2 kgf cm 70 9 101 7 in lbf 19 22 40 55 N m 4 1 5 6 kgf m 29 7 40 5 ft lbf 2007 Mazda MX...

Page 1110: ...ATION NOTE 1 Apply clean engine oil to a new oil seal 2 Push the front oil seal in the engine front cover by hand 3 Compress the oil seal using the SST and a hammer 2007 Mazda MX 5 Miata Sport 2007 EN...

Page 1111: ...Hammer Courtesy of MAZDA MOTORS CORP CRANKSHAFT PULLEY LOCK BOLT INSTALLATION NOTE 1 Install the SST to the camshaft as shown in Fig 41 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microso...

Page 1112: ...ght contacts SST 3 To position the crankshaft pulley temporarily tighten it and using a suitable bolt M6 X 1 0 length 25 mm 35 mm 0 99 in 1 37 in fix the crankshaft pulley to the engine front cover 20...

Page 1113: ...Ts to the crankshaft pulley lock the crankshaft against rotation 5 Tighten the crankshaft pulley lock bolt using the following two steps 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microso...

Page 1114: ...lind plug 9 Remove the SST from the crankshaft pulley 10 Rotate the crankshaft clockwise two turns until the TDC position If not aligned loosen the crankshaft pulley lock bolt and repeat from Step 1 1...

Page 1115: ...cone sealant to the mating surfaces as shown in Fig 45 Thickness 4 0 6 0 mm 0 16 0 23 in CAUTION Install the cylinder head cover within 10 minutes of applying the silicone sealant 2007 Mazda MX 5 Miat...

Page 1116: ...nder head cover with a new gasket 3 Tighten the bolts in the order shown in Fig 46 Tightening torque 8 0 10 5 N m 81 6 107 1 kgf cm 70 8 92 9 in lbf 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical...

Page 1117: ...PENSION TOWER BAR REMOVAL INSTALLATION 5 Remove the air cleaner See INTAKE AIR SYSTEM REMOVAL INSTALLATION LF WARNING Fuel vapor is hazardous It can very easily ignite causing serious injury and damag...

Page 1118: ...E REMOVAL INSTALLATION 14 Remove the side cowl grille See SIDE COWL GRILLE REMOVAL INSTALLATION 15 Remove the service hole cover See EGR VALVE REMOVAL INSTALLATION LF 16 Disconnect the generator but d...

Page 1119: ...tesy of MAZDA MOTORS CORP CAMSHAFT REMOVAL NOTE NOTE The cylinder head and the camshaft caps are numbered to make sure they 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday J...

Page 1120: ...ZDA MOTORS CORP CYLINDER HEAD REMOVAL NOTE 1 Loosen the cylinder head bolts in two or three steps in the order shown in Fig 49 are reassembled in their original position Do not mix the caps 2007 Mazda...

Page 1121: ...ngth of each cylinder head bolt Replace any that exceed the maximum length Cylinder Head Bolt Length L 145 2 145 8 mm 5 72 5 74 in Cylinder Head Bolt Maximum 146 5 mm 5 77 in 2007 Mazda MX 5 Miata Spo...

Page 1122: ...teps using the SST 49 D032 316 1 Tighten to 5 0 N m 51 0 kgf cm 44 3 in lbf 2 Tighten 13 17 N m 1 4 1 7 kgf m 10 0 12 5 ft lbf 3 Tighten 44 46 N m 4 5 4 6 kgf m 32 5 33 9 ft lbf 4 Tighten 88 92 5 Tigh...

Page 1123: ...the camshaft bearing caps evenly in two or three steps 3 Tighten the camshaft cap bolts in the order shown in Fig 52 with the following two steps 1 Tighten to 5 0 9 0 N m 51 0 91 7 kgf cm 44 3 79 6 i...

Page 1124: ...L INSTALLATION 5 Remove the front suspension tower bar joint 6 Remove the ignition coil See IGNITION COIL REMOVAL INSTALLATION LF 7 Remove the OCV connector 8 Remove the cylinder head cover See TIMING...

Page 1125: ...y of MAZDA MOTORS CORP CRANKSHAFT PULLEY LOCK BOLT REMOVAL NOTE 1 Remove the cylinder block lower blind plug 2 Install the SST 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursda...

Page 1126: ...the crankshaft is in the No 1 cylinder TDC position until the balance weight contacts the SST 4 Hold the crankshaft pulley using the SSTs 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Micros...

Page 1127: ...lley lock bolt FRONT OIL SEAL REMOVAL NOTE 1 Cut the oil seal lip using a razor knife 2 Remove the oil seal using a screwdriver wrapped with a rag 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX...

Page 1128: ...gine oil to a new oil seal 2 Push the front oil seal in the engine front cover by hand 3 Tap the oil seal in evenly using the SST and a hammer Front oil seal press in amount 0 1 0 mm 0 0 039 in 2007 M...

Page 1129: ...LLATION NOTE 1 Install the SST on the camshaft as shown in Fig 58 2 Verify that cylinder No 1 is at TDC of the compression stroke Crankshaft balance weight contacts SST 2007 Mazda MX 5 Miata Sport 200...

Page 1130: ...y temporarily tighten it and using a suitable bolt M6 X 1 0 length 25 mm 35 mm 0 99 in 1 37 in fix the crankshaft pulley to the engine front cover 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX...

Page 1131: ...inst rotation 5 Tighten the crankshaft pulley lock bolt in the order shown in Fig 60 using the following two steps 1 Tighten to 96 104 N m 9 8 10 6 kgf m 70 9 76 7 ft lbf 2 Tighten 87 93 2007 Mazda MX...

Page 1132: ...crankshaft pulley 10 Rotate the crankshaft clockwise two turns until the TDC position If not aligned loosen the crankshaft pulley lock bolt and repeat from Step 4 11 Install the cylinder block lower b...

Page 1133: ...ove the drive plate AT See CLUTCH UNIT REMOVAL INSTALLATION See DRIVE PLATE REMOVAL INSTALLATION SJ6A EL 2 Remove in the order indicated in Fig 62 3 Install in the reverse order of removal 2007 Mazda...

Page 1134: ...OIL SEAL INSTALLATION NOTE 1 Apply silicone sealant to the mating faces as shown in Fig 63 Thickness 4 0 6 0 mm 0 16 0 23 in 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday...

Page 1135: ...CORP 2 Apply clean engine oil to the new oil seal lip 3 Install the SST to the non woven fabric side of the rear oil seal 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday Jul...

Page 1136: ...ORS CORP 4 From the back side of the rear oil seal verify that there is no damage or separation in the lip area of the rear oil seal 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft T...

Page 1137: ...ip Area Courtesy of MAZDA MOTORS CORP 5 Install the rear oil seal to the engine as shown in Fig 66 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 51 PM Pa...

Page 1138: ...rtesy of MAZDA MOTORS CORP 6 Tighten the rear oil seal bolts in the order as shown 2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 51 PM Page 72 2005 Mitch...

Page 1139: ...e liquid If fuel spills or leaks from the pressurized fuel system it will cause serious injury or death and facility breakage Fuel can also irritate skin and eyes To prevent this always complete the F...

Page 1140: ...A EL 8 Disconnect the brake vacuum hose 9 Disconnect the quick release connector from the dynamic chamber See QUICK RELEASE CONNECTOR EMISSION SYSTEM REMOVAL INSTALLATION LF 10 Disconnect the quick re...

Page 1141: ...transmission and crossmember component using an engine lifter in the order indicated in Fig 68 WARNING Remove the engine transmission and crossmember carefully holding it steady If the transmission fa...

Page 1142: ...2007 Mazda MX 5 Miata Sport 2007 ENGINE Mechanical MX 5 Microsoft Thursday July 09 2009 3 21 51 PM Page 76 2005 Mitchell Repair Information Company LLC...

Page 1143: ...them with a crane Fig 69 Identifying Engine Transmission From Crossmember Components With Torque Specifications Courtesy of MAZDA MOTORS CORP 21 Install in the reverse order of removal 22 Start the e...

Page 1144: ...SJ6A EL 2 Remove the following parts 1 The clutch unit MT See CLUTCH UNIT REMOVAL INSTALLATION 2 The ignition coil See IGNITION COIL REMOVAL INSTALLATION LF 3 The CMP sensor See CAMSHAFT POSITION CMP...

Page 1145: ...se See QUICK RELEASE CONNECTOR EMISSION SYSTEM REMOVAL INSTALLATION LF 5 Remove the front suspension tower bar joint See FRONT SUSPENSION TOWER BAR REMOVAL INSTALLATION 6 Remove the CMP sensor See CAM...

Page 1146: ...ting noise from the variable valve timing actuator each time the cam passes the fully lifted position it means that the actuator is not secured Replace the actuator 12 Install the cylinder head cover...

Page 1147: ...as a single unit See VALVE CLEARANCE ADJUSTMENT LF 2 Remove the variable valve timing actuator 1 Mark the camshaft and variable valve timing actuator as shown in Fig 72 to make sure they are installe...

Page 1148: ...g actuator 1 Secure the camshaft in a vise 2 Align the marks of the camshaft and variable valve timing actuator 3 Tighten the variable valve timing actuator tightening bolt Tightening torque 69 75 N m...

Page 1149: ...AL INSTALLATION LF 5 Remove the CMP sensor See CAMSHAFT POSITION CMP SENSOR REMOVAL INSTALLATION LF 6 Remove the OCV connector Fig 74 Identifying Oil Control Valve OCV LF With Torque Specifications Co...

Page 1150: ...tance between terminals A and B using an ohmmeter If not as specified replace the oil control valve See OIL CONTROL VALVE OCV REMOVAL INSTALLATION LF Oil control valve resistance 6 9 7 9 ohms 20 C 68...

Page 1151: ...NTROL VALVE OCV REMOVAL INSTALLATION LF Fig 76 Identifying Spool Valve Courtesy of MAZDA MOTORS CORP 5 Verify that the battery is fully charged If not as specified recharge the battery See BATTERY INS...

Page 1152: ...or N position MT Shift lever is in neutral position 2 Verify that no DTCs are available 3 Warm up the engine ECT is approx 80 C 176 F or more as follows NOTE When applying battery positive voltage be...

Page 1153: ...A MOTORS CORP 7 Verify that the idling speed M MDS RPM PID is within the specification using the M MDS or equivalent function Standard AT 700 800 rpm MT 670 770 rpm IGNITION TIMING INSPECTION NOTE Ign...

Page 1154: ...more than 48 A 800 900 rpm P S ON 700 800 rpm MT 750 850 rpm AT A C ON 825 925 rpm MT 775 875 rpm AT IDLE MIXTURE INSPECTION 1 Verify that the idle speed and ignition timing are within the specificati...

Page 1155: ...Within the regulation Oil pressure reference value oil temperature 100 C 212 F 337 591 kPa 3 44 6 03 kgf cm2 49 0 85 8 psi min 3 000 rpm Engine oil capacity approx quantity AT 5MT Oil replacement 3 9...

Page 1156: ...harge current 46B24L 36 3 5 4 5 A Battery quick charge current 30 min 46B24L 36 25 A Generator standard voltage IG ON Terminal B B Terminal P Approx 1 V or less Terminal D Approx 0 V Generator standar...

Page 1157: ...in Minimum 28 8 mm 1 13 in Segment groove depth of starter commutator Standard 0 5 mm 0 02 in Minimum 0 2 mm 0 008 in Starter brush length Standard 12 3 mm 0 48 in Minimum 5 5 mm 0 22 in Starter brush...

Page 1158: ...NC25F 7 130614 JM1NC26F 7 130614 Applied VIN Assumed Item U S A and CANADA Except U S A and CANADA Engine oil grade API SL or ILSAC Engine oil viscosity 5W 20 2007 Mazda MX 5 Miata Sport 2007 ENGINE T...

Page 1159: ...CCESSORIES BODY CAB Entertainment MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 2009 3 34 33 PM Page 1 2005 Mitchell Repair Infor...

Page 1160: ...nents Courtesy of MAZDA MOTORS CORP CENTER PANEL UNIT REMOVAL INSTALLATION 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 2009 3 34 33 PM Pag...

Page 1161: ...rom the underside of the driver seat If the installation bolt is equipped remove it Fig 2 Identifying Installation Bolt With Torque Specifications Courtesy of MAZDA MOTORS CORP 7 Remove in the order i...

Page 1162: ...unit make sure that the wiring harness and antenna feeder are not caught between the unit and dashboard If the wiring harness or the antenna feeder is caught between the unit and dashboard it may caus...

Page 1163: ...d in Fig 5 CAUTION Verify that bolt has been removed when pulling the center panel unit outward If the center panel unit is pulled with bolt installed stress will be applied to the connectors inside t...

Page 1164: ...emble in the reverse order of disassembly SCREW A ASSEMBLE NOTE 1 Tighten screws A at the position shown in Fig 6 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microso...

Page 1165: ...P AUDIO UNIT DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 7 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 2009 3 34 33 P...

Page 1166: ...udio Unit Components Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 2009 3 34 33 PM Page 8 2005 Mitchell Repair...

Page 1167: ...Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front seat back bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTALLATION 7 Back trim See BACK TRIM REMOVAL INSTALLATION 8 Seat belt set plate See SEAT...

Page 1168: ...over 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the following parts 1 Console See CONSOLE REMOVAL INSTALLATION 2 Quarter trim See QUARTER TRIM REMOVAL INSTALL...

Page 1169: ...ble Fig 9 Identifying Audio Amplifier Courtesy of MAZDA MOTORS CORP 5 Install in the reverse order of removal DOOR SPEAKER REMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative bat...

Page 1170: ...S CORP 5 Install in the reverse order of removal DOOR SPEAKER INSTALLATION NOTE 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 2009 3 34 33 P...

Page 1171: ...pecification replace the door speaker Resistance Standard 4 ohms BOSE 1 ohm 2 Connect a 1 5 V battery to the door speaker and verify that noise is heard from the door speaker If no noise is heard repl...

Page 1172: ...e door upper speaker terminals using an ohmmeter If the resistance is not within the specification replace the door upper speaker Fig 13 Door Upper Speaker Continuity Table 2007 Mazda MX 5 Miata Sport...

Page 1173: ...e QUARTER TRIM REMOVAL INSTALLATION 3 Scuff plate See SCUFF PLATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front...

Page 1174: ...ER INSPECTION 1 Inspect for resistance between the rear speaker terminals using an ohmmeter If the resistance is not within the specification replace the rear speaker 2007 Mazda MX 5 Miata Sport 2007...

Page 1175: ...ontinuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 2009 3 34 33 PM Page 17 2005 Mitchell Repair Inf...

Page 1176: ...ve the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove in the order indicated in Fig 18 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Enterta...

Page 1177: ...1 Insert a tape wrapped flathead screwdriver into the service hole 2 Pry with the screwdriver in the direction shown by the arrow to remove the center speaker cover 2007 Mazda MX 5 Miata Sport 2007 AC...

Page 1178: ...not within the specification replace the center speaker Resistance 3 6 ohms 2 Connect a 1 5 V battery to the center speaker and verify that noise is heard from the center speaker If no noise is heard...

Page 1179: ...RY REMOVAL INSTALLATION LF 3 Remove the door trim See DOOR TRIM REMOVAL INSTALLATION 4 Disconnect the connector 5 Remove the screws 6 Remove the tweeter door upper speaker 7 Install in the reverse ord...

Page 1180: ...tween the tweeter terminals using an ohmmeter If the resistance is not within the specification replace the tweeter Fig 22 Tweeter Continuity Table 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CA...

Page 1181: ...e See SCUFF PLATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front seat back bar garnish See SEAT BACK BAR GARNISH...

Page 1182: ...P 5 Install in the reverse order of removal AUDIOPILOT MICROPHONE REMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove i...

Page 1183: ...ATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the jack 4 Remove in the order indicated in Fig 26 2007 Mazda MX 5 Miata Sport 200...

Page 1184: ...Install in the reverse order of removal MOUNTING NUT REMOVAL NOTE 1 Use snap ring pliers to remove the mounting nut 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Micr...

Page 1185: ...ltage at manual antenna connector terminal C If the voltage is B go to the next step If the voltage is not B inspect the audio unit or the antenna feeder NOTE A amplifier is built into the manual ante...

Page 1186: ...REMOVAL INSTALLATION LF 3 Disconnect the manual antenna connector 4 Inspect for continuity between the manual antenna terminals using an ohmmeter If not as specified replace the manual antenna 2007 M...

Page 1187: ...Identifying Manual Antenna Terminals Courtesy of MAZDA MOTORS CORP ANTENNA FEEDER LOCATION 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 20...

Page 1188: ...ated in Fig 32 If not as indicated in the table replace the AM FM antenna feeder No 1 Fig 32 AM FM Antenna Feeder No 1 Continuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 A...

Page 1189: ...NO 2 INSPECTION 1 Verify that the continuity is as indicated in the table If not as indicated in Fig 34 replace the AM FM antenna feeder No 2 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Ente...

Page 1190: ...ver side air bag module See DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 4 Remove the steering wheel See STEERING WHEEL AND COLUMN REMOVAL INSTALLATION 5 Remove in the order indicated in Fig 36 NOT...

Page 1191: ...een the audio control switch terminals If the resistance and continuity are not as indicated in the tables replace the audio control switch Fig 37 Audio Control Switch Continuity Table Courtesy of MAZ...

Page 1192: ...tive battery cable See BATTERY REMOVAL INSTALLATION LF Switch position Resistance ohm VOL switch ON 51 56 VOL switch ON 140 154 SEEK switch ON 286 315 SEEK switch ON 534 589 MODE switch ON 985 1 080 M...

Page 1193: ...nstall in the reverse order of removal Fig 39 Identifying Accessory Socket Courtesy of MAZDA MOTORS CORP ACCESSORY SOCKET REMOVAL NOTE 1 While pressing a tape wrapped flathead screwdriver against the...

Page 1194: ...MOTORS CORP CAP REMOVAL NOTE 1 While pressing the tabs pull the cap outwards 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 2009 3 34 33 PM P...

Page 1195: ...nect a tester as shown in Fig 42 and verify that there is continuity If the continuity cannot be verified replace the accessory socket 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainme...

Page 1196: ...ocket Terminals Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Entertainment MX 5 Miata Microsoft Thursday July 09 2009 3 34 33 PM Page 38 2005 Mitchell...

Page 1197: ...3 Remove in the order indicated in the table 4 Install in the reverse order of removal WARNING A hot engine and exhaust system can cause severe burns Turn off the engine and wait until they are cool...

Page 1198: ...E BELT REPLACEMENT LF 3 Remove the under cover See TRANSVERSE MEMBER REMOVAL INSTALLATION 4 Remove the suspension tower bar joint and right side See FRONT SUSPENSION TOWER BAR REMOVAL INSTALLATION 5 R...

Page 1199: ...2 Move the water pipe and heater hose slightly out of the way 3 Disconnect the ventilation hose from the cylinder head See QUICK RELEASE CONNECTOR EMISSION SYSTEM REMOVAL INSTALLATION LF 2007 Mazda MX...

Page 1200: ...g Heater Hose Water Pipe Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Exhaust System MX 5 Miata Microsoft Thursday July 09 2009 3 05 24 PM Page 4 2005 Mitchell Repair Informat...

Page 1201: ...CCESSORIES BODY CAB Exterior Trim MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Exterior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 32 12 PM Page 1 2005 Mitchell Repair Infor...

Page 1202: ...ior Trim Components Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Exterior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 32 12 PM Page 2 2005 Mitchell Repair...

Page 1203: ...f MAZDA MOTORS CORP FRONT BELTLINE MOLDING REMOVAL INSTALLATION 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Exterior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 32 12 PM Page 3 2005 Mi...

Page 1204: ...verse order of removal Fig 3 Removing Installing Front Beltline Molding Courtesy of MAZDA MOTORS CORP COWL GRILLE REMOVAL INSTALLATION 1 Remove the windshield wiper arm and blade See WIPER ARM AND BLA...

Page 1205: ...s 7 Remove the cowl grille 8 Install in the reverse order of removal SIDE COWL GRILLE REMOVAL INSTALLATION 1 Remove the windshield wiper arm and blade See WIPER ARM AND BLADE REMOVAL INSTALLATION 2 Re...

Page 1206: ...ee BACK TRIM REMOVAL INSTALLATION 8 Seat belt set plate See SEAT BELT REMOVAL INSTALLATION 9 Seat back crossmember assembly See SEAT BACK CROSSMEMBER ASSEMBLY REMOVAL INSTALLATION 10 Rear side trim Se...

Page 1207: ...molding 6 Install in the reverse order of removal DRIP MOLDING REMOVAL INSTALLATION 1 Partially peel back the seaming welt 2 Remove the screws 3 Remove the drip molding 4 Install in the reverse order...

Page 1208: ...BAR GARNISH REMOVAL INSTALLATION 7 Back trim See BACK TRIM REMOVAL INSTALLATION 8 Seat belt set plate See SEAT BELT REMOVAL INSTALLATION 9 Seat back crossmember assembly See SEAT BACK CROSSMEMBER ASSE...

Page 1209: ...VAL NOTE 1 Unlock the top lock CONVERTIBLE TOP INSTALLATION NOTE 1 Insert the rain rail into the beltline molding lip and install it over the studs 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CA...

Page 1210: ...ASSEMBLY 1 Disassemble in the order indicated in the table 2 To remove the striker remove the following parts 1 Female wedge See CONVERTIBLE TOP DISASSEMBLY ASSEMBLY 2 Map light See MAP LIGHT REMOVAL...

Page 1211: ...DA MOTORS CORP RETAINER DISASSEMBLY NOTE 1 Mark around the retainer installation screws with paint before removing them 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Exterior Trim MX 5 Miata M...

Page 1212: ...Removing Top Fabric From Front Bow Retainer Courtesy of MAZDA MOTORS CORP 2 Pull out the top fabric from the front header Fig 14 Pulling Out Top Fabric From Front Header Courtesy of MAZDA MOTORS CORP...

Page 1213: ...ove the cables from the cable guide Fig 16 Identifying Rivet And Cable Guide Courtesy of MAZDA MOTORS CORP 6 Remove the band installation rivet using a drill 2007 Mazda MX 5 Miata Sport 2007 ACCESSORI...

Page 1214: ...a drill SPRING A DISASSEMBLY NOTE 1 Remove the bolt 2 Remove the spacers spring and collars from the link Fig 19 Identifying Spacers Spring Collars Courtesy of MAZDA MOTORS CORP SPRING B DISASSEMBLY...

Page 1215: ...Flatten the stem using hammer Fig 21 Securing Top Fabric Rain Rail With Rivet Courtesy of MAZDA MOTORS CORP TOP FABRIC ASSEMBLY NOTE 1 Place the link onto the top fabric 2 Align the link with the set...

Page 1216: ...tifying Cable Guide And Rivet Courtesy of MAZDA MOTORS CORP RETAINER ASSEMBLY NOTE 1 Install the retainers to the link aligning the retainer marks with the retainer installation screws Fig 24 Identify...

Page 1217: ...otating the adjustment nut Fig 25 Identifying Convertible Top Adjustment Components Courtesy of MAZDA MOTORS CORP Clearance A 4 8 mm 0 16 0 31 in 7 Install in the reverse order of removal NOTE Turn th...

Page 1218: ...ve the snap ring by prying along the perimeter so as not to damage the snap ring CAUTION Remove the snap ring such that the dimension is maintained as indicated in the figure Because the snap ring is...

Page 1219: ...End Using Snap Ring Pliers Courtesy of MAZDA MOTORS CORP WINDSHIELD GARNISH REMOVAL 1 Cut the double sided adhesive tape on the windshield garnish using a flathead screwdriver or razor while warming i...

Page 1220: ...e of the windshield garnish and body 3 Apply primer to the bonding area of the windshield garnish 4 Attach double sided adhesive tape to the windshield garnish as shown in the figure Clearance a 16 mm...

Page 1221: ...the double sided adhesive tape 4 and 5 and attach it to the position shown in the figure 6 Peel off the tape backing from the double sided adhesive tape 4 and 5 and then adhere the windshield garnish...

Page 1222: ...pplying pressure 10 Peel off the tape backing from the double sided adhesive tape 8 and 9 and then adhere the windshield garnish center Fig 33 Position For Attaching Double Sided Adhesive Tape On Wind...

Page 1223: ...rews Courtesy of MAZDA MOTORS CORP DETACHABLE HARDTOP ADJUSTMENT TOP LOCK 1 Remove the spring 2 Remove the snap ring See SNAP RING REMOVAL NOTE See SNAP RING INSTALLATION NOTE 3 Remove the pin 4 Remov...

Page 1224: ...t the snap ring to the pin while slightly expanding the snap ring end using snap ring pliers 2 After securing the snap ring verify that there is no excessive play between the snap ring and pin NOTE Tu...

Page 1225: ...ring and remove the snap ring by prying along the perimeter so as not to damage the snap ring CAUTION Remove the snap ring such that the dimension is maintained as indicated in the figure Because the...

Page 1226: ...ing Rear Deck Lock Cover And Screw Courtesy of MAZDA MOTORS CORP 5 Move the plate right left fore or aft until it is tight 6 Tighten the plate installation bolts Tightening torque 17 7 26 4 N m 1 8 2...

Page 1227: ...BACK CROSSMEMBER ASSEMBLY REMOVAL INSTALLATION 10 Rear side trim See REAR SIDE TRIM REMOVAL INSTALLATION 11 Rear package trim See REAR PACKAGE TRIM REMOVAL INSTALLATION 12 Side shelf See SIDE SHELF RE...

Page 1228: ...LATION 8 Seat belt upper anchor installation bolt See SEAT BELT REMOVAL INSTALLATION 9 Seat belt set plate See SEAT BELT REMOVAL INSTALLATION 10 Rear side trim See REAR SIDE TRIM REMOVAL INSTALLATION...

Page 1229: ...EMOVAL INSTALLATION LF 3 Remove the rear combination light See REAR COMBINATION LIGHT REMOVAL INSTALLATION 4 Remove clip A using a fastener remover and then remove the extractor chamber from the vehic...

Page 1230: ...dy then install it to the side step molding Fig 46 Identifying Side Step Molding Components Courtesy of MAZDA MOTORS CORP SIDE STEP MOLDING INSTALLATION 1 Install clips A and then C to the vehicle fro...

Page 1231: ...olts A at section A shown in the figure 3 Remove the bolts B at section B shown in the figure 4 Remove the fasteners C at section C shown in the figure 5 Remove the front under cover 6 Install in the...

Page 1232: ...move the fasteners at section A shown in the figure 3 Install in the reverse order of removal Fig 49 Identifying Fasteners Section With Torque Specifications Courtesy of MAZDA MOTORS CORP SPLASH SHIEL...

Page 1233: ...panel 3 Cover both sides of the rear window glass with thick cloth to protect the window 4 Remove the battery cover 5 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 6 Remov...

Page 1234: ...INSTALLATION 11 Cab side weatherstrip See CONVERTIBLE TOP DISASSEMBLY ASSEMBLY 7 Disconnect the roof motor connectors 8 Disconnect the rear window defroster connector 9 Disconnect the roof motor limit...

Page 1235: ...RP BOLT B REMOVAL INSTALLATION NOTE 1 Remove or install bolt B shown in the figure by inserting a hand from the deck panel opening 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Exterior Trim M...

Page 1236: ...lock is locked 2 Install the power retractable hardtop without any gap a between the positioning surface of the main bracket and stud bolt and tighten the bolt and nut Tightening torque 19 25 N m 1 9...

Page 1237: ...p ring See SNAP RING REMOVAL NOTE See SNAP RING INSTALLATION NOTE 3 Remove the pin 4 Remove the screws 5 Remove the cover Fig 54 Identifying Power Retractable Hardtop Adjustment Components Courtesy of...

Page 1238: ...1 Insert the snap ring to the pin while slightly expanding the snap ring end using snap ring pliers 2 After securing the snap ring verify that there is no excessive play between the snap ring and pin...

Page 1239: ...tions Courtesy of MAZDA MOTORS CORP 2 Adjust the gap and height difference between the front roof panel and rear window glass within the specification by moving them back and forth left and right and...

Page 1240: ...ER RETRACTABLE HARDTOP SWITCH INSPECTION 1 Verify that the continuity between the power retractable hardtop switch terminals is as indicated in the table If not as indicated in the table replace the h...

Page 1241: ...is any malfunction replace the hazard warning switch POWER RETRACTABLE HARDTOP CONTROL MODULE REMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVA...

Page 1242: ...y of MAZDA MOTORS CORP 7 Install in the reverse order of removal POWER RETRACTABLE HARDTOP CONTROL MODULE INSPECTION 1 Remove the following parts 1 Console See CONSOLE REMOVAL INSTALLATION 2 Quarter t...

Page 1243: ...REFERENCE Terminal Signal Connected to Test condition Standard Inspection item 1A Trunk lid opener relay output signal Trunk lid opener relay The deck panel is in the fully closed position B Deck pan...

Page 1244: ...nel open close switch Power retractable hardtop switch hazard warning switch Ignition switch is turned to the ON position Opening switch on approx 2 5 Power retractable hardtop switch Related wiring h...

Page 1245: ...s When the roof panel is not fully closed B 1S CAN H Because this terminal is for communication good no good judgment by terminal voltage is not possible Related wiring harnesses 1T Roof open position...

Page 1246: ...arness 2F Power GND GND Under any condition Inspect for continuity to GND Continuity detected Related wiring harness 3A Roof motor control open Roof motor RH Ignition switch is turned to the ON positi...

Page 1247: ...r LH Related wiring harness Roof panel close operation 1 0 or less 1 Other approx 2 3M Deck panel motor control open Deck panel motor RH Ignition switch is turned to the ON position Deck panel open op...

Page 1248: ...CORP DECK PANEL MOTOR HALL SENSOR Terminal connected power retractable hardtop control module 1K RH 1O LH Negative battery terminal Oscilloscope setting 2 V DIV Y 5 ms DIV X DC range Measurement condi...

Page 1249: ...ATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front seat back bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTA...

Page 1250: ...INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the following parts 1 Console See CONSOLE PANEL REMOVAL INSTALLATION 2 Quar...

Page 1251: ...C 8 Remove the roof motor 9 Install in the reverse order of removal Fig 70 Identifying Roof Motor Components With Torque Specifications Courtesy of MAZDA MOTORS CORP ROOF MOTOR INSPECTION 1 Apply batt...

Page 1252: ...ides of the rear window glass with thick cloth to protect the window 3 Remove the battery cover 4 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 5 Remove the following parts...

Page 1253: ...AL INSTALLATION 10 Cab side weatherstrip See CONVERTIBLE TOP DISASSEMBLY ASSEMBLY 6 Disconnect the roof motor limit switch connector 7 Disconnect the power retractable hardtop drain hose See POWER RET...

Page 1254: ...HARDTOP LIMIT SWITCH INSPECTION 1 Verify that the continuity between the power retractable hardtop limit switch terminals is as indicated in the table If not as indicated in the table replace the roof...

Page 1255: ...rt a Phillips screwdriver with no wear securely into each screw groove and remove the screws Fig 76 Identifying Wire Guide Plate Wire Guide And Screw Courtesy of MAZDA MOTORS CORP CAUTION If the deck...

Page 1256: ...en the nut then pull the roof hook cable in the direction shown by the arrow and remove it Fig 77 Removing Tabs A Courtesy of MAZDA MOTORS CORP 9 Remove the bolts 2007 Mazda MX 5 Miata Sport 2007 ACCE...

Page 1257: ...See DECK PANEL MOTOR REMOVAL INSTALLATION 2 Remove the high mount brake light See HIGH MOUNT BRAKE LIGHT REMOVAL INSTALLATION 3 Disassemble in the order indicated in the table 4 Assemble in the rever...

Page 1258: ...eck panel trunk lid and back window glass are within the specifications Adjust the power retractable hardtop if necessary DECK PANEL ADJUSTMENT 1 Loosen the installation nuts for deck panel 2 Adjust t...

Page 1259: ...f out of the way See SIDE SHELF REMOVAL INSTALLATION 5 Remove the deck panel See DECK PANEL REMOVAL INSTALLATION 6 Remove the screws indicated in the figure 7 Remove the deck panel motor 8 Install in...

Page 1260: ...s indicated in the table replace it Fig 83 Identifying Deck Panel Motor Terminals With Circuit Diagram Courtesy of MAZDA MOTORS CORP CAUTION If the deck panel motor temperature is high the motor may n...

Page 1261: ...L INSTALLATION 5 Remove the deck panel See DECK PANEL REMOVAL INSTALLATION 6 Remove the deck panel motor RH See DECK PANEL MOTOR REMOVAL INSTALLATION 7 Remove the screws A and B 8 Remove the deck pane...

Page 1262: ...limit switch terminals is as indicated in the table If not as indicated in the table replace the deck panel link RH Fig 85 Deck Panel Limit Switch Continuity Chart Courtesy of MAZDA MOTORS CORP 2007...

Page 1263: ...ZDA MOTORS CORP REAR DECK WEATHERSTRIP INSTALLATION 1 Align the deck flange with the weatherstrip marking and insert 1 2 Peel off the tape backing of the butylene tape align it to the molded part at t...

Page 1264: ...INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front seat back bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTALLATION 7 Back trim See BACK TRIM REMOVAL INSTALLATION 3 Open the cabl...

Page 1265: ...k 8 Remove the cover 9 Install in the reverse order of removal Fig 91 Identifying Roof Hook Screw And Cover Courtesy of MAZDA MOTORS CORP ROOF HOOK INSTALL NOTE 1 Securely fix the 3 grooves to the cab...

Page 1266: ...ck bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTALLATION 7 Back trim See BACK TRIM REMOVAL INSTALLATION 3 Open the cable case cover and disconnect the cable while pressing the cable in the direct...

Page 1267: ...osen the nut then pull the roof hook cable in the direction shown by the arrow and remove it 9 Remove the nut 10 Remove the cable case CAUTION The screws are engaged firmly because thread locking comp...

Page 1268: ...2 Install in the reverse order of removal CAUTION If the roof hook cable is installed to the installation groove on the drain cover it may become a source of noise during deck panel operation Do not i...

Page 1269: ...e QUARTER TRIM REMOVAL INSTALLATION 3 Scuff plate See SCUFF PLATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front...

Page 1270: ...Link Bracket And Bolts With Torque Specifications Courtesy of MAZDA MOTORS CORP 5 Rotate the power retractable hardtop link bracket in the direction shown by the arrow at the pivot fulcrum of pin A a...

Page 1271: ...UARTER TRIM REMOVAL INSTALLATION 3 Scuff plate See SCUFF PLATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front se...

Page 1272: ...hook B 8 Remove the cover 9 Remove the bolts and washers 10 Remove the sims 11 Remove the front roof panel 12 Install in the reverse order of removal NOTE Verify the number of shims because it differs...

Page 1273: ...ABLE HARDTOP ADJUSTMENT and verify that the gap and height difference between the front roof panel and middle roof panel are within the specifications Adjust the power retractable hardtop if necessary...

Page 1274: ...emoving them Fig 106 Identifying Mark Around Retainer Installation Screws Courtesy of MAZDA MOTORS CORP RETAINER ASSEMBLY NOTE 1 Install the retainers to the link aligning the retainer marks with the...

Page 1275: ...Back trim See BACK TRIM REMOVAL INSTALLATION 8 Seat belt upper anchor installation bolt See SEAT BELT REMOVAL INSTALLATION 9 Power retractable hardtop link bracket See POWER RETRACTABLE HARDTOP LINK...

Page 1276: ...ssemble View Of Middle Roof Panel Courtesy of MAZDA MOTORS CORP RETAINER DISASSEMBLY NOTE 1 Mark around the retainer installation screws with paint before removing them Fig 109 Identifying Mark Around...

Page 1277: ...EMOVAL INSTALLATION REMOVAL 1 Remove the fasteners Fig 111 Identifying Middle Roof Panel Weatherstrip Components Courtesy of MAZDA MOTORS CORP 2 Peel off the double sided adhesive tape 3 Remove the mi...

Page 1278: ...e deck panel 2 Remove the rear defroster harness from the roof link lock LH See REAR WINDOW GLASS REMOVAL INSTALLATION POWER RETRACTABLE HARDTOP 3 Remove the bolt 4 Remove the pin A 5 Remove the roof...

Page 1279: ...ff plate See SCUFF PLATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front seat back bar garnish See SEAT BACK BAR...

Page 1280: ...val Fig 116 Identifying Power Retractable Hardtop Control Module Bracket And Nut Courtesy of MAZDA MOTORS CORP BLACK OUT FILM REMOVAL FRONT 1 Partially peel back the middle roof weatherstrip 2 Peel of...

Page 1281: ...roof panel Fig 118 Moving Power Retractable Hardtop Courtesy of MAZDA MOTORS CORP 2 Peel off the black out film by pulling it outward from one end NOTE Slowly remove the black out film since it may t...

Page 1282: ...hin 2 mm from the line shown in the figure adhere the surface of the black out film 4 Peel off the transparent protective film on the black out film 5 Apply pressure to the black out film in the order...

Page 1283: ...the positioning point shown in the figure Clearance a 0 3 0 mm 0 0 118 in 3 Peel off the tape backing and adhere the black out film surface 4 Peel off the transparent protective film on the black out...

Page 1284: ...NSTALLATION 1 Fully close the power retractable hardtop 2 Fully open the deck panel 3 Remove clip A and remove the power retractable hardtop drain hose from the rear window glass CAUTION Adhere so tha...

Page 1285: ...pair It is necessary to perform the recovery procedure to engage the pinion gear deck panel motor and sector gear See RECOVERY PROCEDURE NOTE The temporary measure is for releasing the lock using a ro...

Page 1286: ...To perform the following procedure use the tools that comes with the vehicle To free the deck panel both the motors need to be unlocked The following procedure is only for the left side Perform the sa...

Page 1287: ...Courtesy of MAZDA MOTORS CORP 5 Insert the eye bolt into the guide pipe shown in the figure NOTE When the deck panel motor bracket is pressed the deck panel motor bracket rotates and the pinion gear d...

Page 1288: ...d Lock Pin Of Deck Panel Base Link Courtesy of MAZDA MOTORS CORP Close the deck panel Temporary measure 1 Double tie the rope to the deck panel link screw as shown in the figure NOTE If the deck panel...

Page 1289: ...of MAZDA MOTORS CORP 3 Route the rope on the vehicle s rear side to the outside of the vehicle passing it between the deck panel links 4 After doing the same procedure on the right side close the dec...

Page 1290: ...Hinge Courtesy of MAZDA MOTORS CORP DECK PANEL MANUAL OPEN CLOSE PROCEDURE AFTER TEMPORARILY MEASURE CAUTION Tie the rope on the trunk lid hinge to prevent the lock from releasing while driving Tie t...

Page 1291: ...rope on the vehicle s rear rope is outside of vehicle along the trunk lid to engage and lock the sector gear and the lock pin of the deck panel base link Fig 136 Pulling Rope From Vehicle Rear Side o...

Page 1292: ...deck panel motor bracket in the direction of the arrow to engage the pinion gear deck panel motor and the sector gear 3 Install the bolt CAUTION Tie the rope on the trunk lid hinge to prevent the loc...

Page 1293: ...sconnect the high mount brake light connector on the left side by pulling it in the direction of 2 while pressing it in the direction of 1 6 Remove the deck panel Nut Removal Note 1 Insert a spanner i...

Page 1294: ...TRACTABLE HARDTOP ADJUSTMENT POWER RETRACTABLE HARDTOP OPEN CLOSE WARNING BEEP ON OFF SWITCHING 1 Connect the M MDS to the DLC 2 2 After the vehicle is identified select the following items from the i...

Page 1295: ...Warning Lamps Chimes 4 Select the RHT buzzer IC on the M MDS to set on off Item RHT Buzzer IC Fig 142 Identifying DLC 2 Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSO...

Page 1296: ...wheel bearing for axial looseness If it exceeds the maximum specification replace the wheel hub component Maximum front wheel bearing play 0 05 mm 0 002 in 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE A...

Page 1297: ...BOLT REPLACEMENT 1 Remove the brake caliper component and disc plate 2 Remove the wheel hub bolt using the SST as shown in Fig 3 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Front Axle MX 5 Miata...

Page 1298: ...in the wheel hub 4 Install the wheel hub bolt by placing a proper sized washer on the hub and tightening the nut as shown in Fig 4 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Front Axle MX 5 Mia...

Page 1299: ...he following procedures without first removing the ABS wheel speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake Before performing the following procedures...

Page 1300: ...of MAZDA MOTORS CORP BRAKE CALIPER COMPONENT REMOVAL NOTE 1 Suspend the brake caliper component using a cable or equivalent 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Front Axle MX 5 Miata Micr...

Page 1301: ...Remove the wheel hub bolts from the wheel hub using a press NOTE Remove the wheel hub bolt only if there is an abnormality 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Front Axle MX 5 Miata Micro...

Page 1302: ...MOTORS CORP WHEEL HUB BOLT INSTALLATION NOTE 1 Press in new wheel hub bolts into the wheel hub using a press 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Front Axle MX 5 Miata Microsoft Thursday...

Page 1303: ...b Bolts Into Wheel Hub Using Press Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Front Axle MX 5 Miata Microsoft Thursday July 09 2009 3 14 56 PM Page 8 2005 Mitchell...

Page 1304: ...r may possibly cause an open circuit in the wiring harness if it is pulled by mistake Before performing the following procedures remove the ABS wheel speed sensor axle side and fix it to an appropriat...

Page 1305: ...MBLY 1 Remove the front shock absorber and coil spring See FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL INSTALLATION 2 Remove in the order indicated in Fig 3 3 Install in the reverse order of removal...

Page 1306: ...spring using the SSTs and remove the piston rod nut WARNING Before removing the piston rod nut secure the shock absorber and spring in the SSTs Otherwise the shock absorber and spring could fly off un...

Page 1307: ...sing a piece of cloth and install the SSTs 2 Compress the coil spring using the SSTs 3 Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring sea...

Page 1308: ...PER SPRING SEAT INSTALLATION NOTE 1 Align the mark on the upper spring seat with the dust boot projection 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday Jul...

Page 1309: ...stall the upper spring seat so that the upper spring seat stud is at a 27 33 angle to the shock absorber installation shaft lower side 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5...

Page 1310: ...ck absorber on a flat surface 2 Drill a 2 3 mm 0 08 0 12 in hole at a point 25 mm 0 98 in from the bottom of the tube so that the gas can escape 3 Turn the hole downwards 4 The oil can be collected by...

Page 1311: ...owing procedures without first removing the ABS wheel speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake Before performing the following procedures remove...

Page 1312: ...suspend it with a cable in a location out of the way FRONT LOWER ARM BALL JOINT REMOVAL NOTE 1 Disconnect the front lower arm ball joint from the steering knuckle using the SST NOTE When removing the...

Page 1313: ...OVAL NOTE 1 Loosen the bolts on the vehicle side 2 Disconnect the upper arm ball joint using the SST bushing may also come off If it comes off replace the steering knuckle 2007 Mazda MX 5 Miata Sport...

Page 1314: ...EMOVAL NOTE 1 Mark the front upper arm as shown in Fig 12 CAUTION Be careful not to damage the front lower arm If it is damaged replace it 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension...

Page 1315: ...Arm Courtesy of MAZDA MOTORS CORP 2 Remove the bushing using the SSTs 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 49 57 PM Page 12 2005 M...

Page 1316: ...1 Cut off the stopper plate rubber using a razor CAUTION Be careful not to damage the front lower arm If it is damaged replace it 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miat...

Page 1317: ...OTORS CORP 2 Cut off 5 6 mm 0 20 0 23 in from each side of the knob end of the bushing using a hacksaw 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 0...

Page 1318: ...hing Using Hacksaw Courtesy of MAZDA MOTORS CORP 3 Remove the bushing using the SSTs 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 49 57 PM...

Page 1319: ...ING PART REMOVAL NOTE 1 Remove the bushing using the SSTs CAUTION Be careful not to damage the front lower arm If it is damaged replace it 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension...

Page 1320: ...ING SHOCK ABSORBER LOWER SIDE CONNECTING PART INSTALLATION NOTE 1 Compress the bushing using the SSTs 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 09...

Page 1321: ...MOTORS CORP BUSHING FRONT SIDE INSTALLATION NOTE 1 Press the bushing in using the SSTs 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 49 57...

Page 1322: ...TORS CORP 2 Insert the stopper plate rubber into the inner pipe of the bushing front side 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 49 5...

Page 1323: ...MAZDA MOTORS CORP BUSHING REAR SIDE INSTALLATION NOTE 1 Align the marks placed during removal and install the bushing 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft...

Page 1324: ...tesy of MAZDA MOTORS CORP 2 Press the bushing in using the SSTs 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 49 57 PM Page 21 2005 Mitchell...

Page 1325: ...Fig 23 Installing Dust Boot To Ball Joint Courtesy of MAZDA MOTORS CORP 6 Wipe off any excess grease FRONT LOWER ARM INSTALLATION NOTE 1 Install the front lower arm rear side bushing part horizontall...

Page 1326: ...e the front lower arm See FRONT LOWER ARM REMOVAL INSTALLATION Fig 24 Measuring Ball Joint Rotational Torque Courtesy of MAZDA MOTORS CORP FRONT UPPER ARM INSPECTION 1 Remove the front upper arm from...

Page 1327: ...stall in the reverse order of removal 3 Inspect the front wheel alignment and adjust it if necessary See FRONT WHEEL ALIGNMENT CAUTION Performing the following procedures without first removing the AB...

Page 1328: ...RS CORP FRONT UPPER ARM BALL JOINT REMOVAL NOTE 1 Remove the front upper arm ball joint from the steering knuckle using the SST 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata...

Page 1329: ...nd and the front lower arm FRONT STABILIZER REMOVAL INSTALLATION 1 Remove in the order indicated in the table CAUTION Performing the following procedures without first removing the ABS wheel speed sen...

Page 1330: ...ILIZER BRACKET INSTALLATION NOTE 1 Apply rubber grease to the inner side of the stabilizer bushing 2 Align the outer side of the stabilizer slide stopper with the stabilizer bushing 2007 Mazda MX 5 Mi...

Page 1331: ...y malfunction replace it 3 Rotate the ball joint stud 10 times and then rock it side to side 10 times 4 Measure the ball joint rotational torque using an Allen wrench and a torque wrench Stabilizer co...

Page 1332: ...ted in Fig 31 6 Install in the reverse order of removal 7 Inspect the front wheel alignment See FRONT WHEEL ALIGNMENT CAUTION Performing the following procedures without first removing the ABS wheel s...

Page 1333: ...HUB COMPONENT REMOVAL NOTE 1 Loosen the front upper arm inner bolts 2 Remove the axle and hub component FRONT CROSSMEMBER COMPONENT REMOVAL NOTE 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Susp...

Page 1334: ...10 x 1 5 length 30 mm 1 18 in Fig 32 Identifying Chain Bolt Location Courtesy of MAZDA MOTORS CORP 2 Suspend the engine 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsof...

Page 1335: ...to the front crossmember 6 Remove the front crossmember component WARNING Verify that the crossmember component is securely supported by a jack If the crossmember component falls it could cause seriou...

Page 1336: ...RSE MEMBER REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 35 2 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Th...

Page 1337: ...he crossmember using a jack 2 Remove the transverse member UNDER COVER INSTALLATION NOTE 1 Align projection A with the transverse member opening to temporarily support the under cover 2007 Mazda MX 5...

Page 1338: ...ber Courtesy of MAZDA MOTORS CORP 2 Tighten the bolts in the order of A B and C 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 49 58 PM Page...

Page 1339: ...SPENSION TOWER BAR REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 38 2 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Micr...

Page 1340: ...ourtesy of MAZDA MOTORS CORP PLATE INSTALLATION NOTE 1 Install the plates with the identification marks facing upward 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft...

Page 1341: ...te Identification Marks Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Front Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 49 58 PM Page 38 2005 Mitchell Repair In...

Page 1342: ...DEX LF ENGINE COMPARTMENT SIDE 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 11 PM...

Page 1343: ...Fuel System Components LF Courtesy of MAZDA MOTORS CORP FUEL TANK SIDE 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 11 PM Page 2 2005 Mitchell R...

Page 1344: ...th and damage Fuel can also irritate skin and eyes To prevent this always complete the Fuel Line Safety Procedure A person charged with static electricity could cause a fire or explosion resulting in...

Page 1345: ...tem it will cause serious injury or death and facility breakage Fuel can also irritate skin and eyes To prevent this always complete the Fuel Leakage Inspection WARNING Fuel is very flammable liquid I...

Page 1346: ...fuel pipe side replace the fuel pipe Standard There shall be no leakage after 5 min 4 After reinstallation repeat step 2 3 in the fuel leakage inspection Not Using SST M MDS or Equivalent 1 Remove the...

Page 1347: ...nector Terminal F P To Ground Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 12 PM Page 6 2005 Mitchell Repair Inform...

Page 1348: ...side replace the fuel pipe Standard There shall be no leakage after 5 min 7 After reinstallation repeat step 5 thru 6 in the fuel leakage inspection FUEL LINE PRESSURE INSPECTION LF WARNING Fuel line...

Page 1349: ...ne compartment See QUICK RELEASE CONNECTOR FUEL SYSTEM REMOVAL INSTALLATION LF 5 Turn the lever of the SST parallel to the hose as shown in Fig 8 6 Insert the SST quick release connector into the fuel...

Page 1350: ...he M MDS or equivalent to the DLC 2 Fig 9 Locating DLC 2 Connector Courtesy of MAZDA MOTORS CORP 3 Start the fuel pump using the FP simulation function Not using M MDS or equivalent 1 Short the check...

Page 1351: ...rminal F P To Ground Using Jumper Wire Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 12 PM Page 10 2005 Mitchell Rep...

Page 1352: ...ssure If not within the specification inspect the following If it less than the specification Fuel pump unit Fuel line leakage If it exceeds the specification Fuel line clogging Fuel pressure Referenc...

Page 1353: ...Park the vehicle on a level surface WARNING Fuel is very flammable liquid If fuel spills or leaks from the pressurized fuel system it will cause serious injury or death and facility breakage Fuel can...

Page 1354: ...l See REAR DIFFERENTIAL REMOVAL INSTALLATION 6 Rear crossmember component See REAR CROSSMEMBER REMOVAL INSTALLATION 6 Perform the following procedure to remove the service hole cover 1 To remove the b...

Page 1355: ...e the fuel pump unit See FUEL PUMP UNIT REMOVAL INSTALLATION LF 9 Siphon the fuel from the fuel tank 10 Remove in the order indicated in Fig 13 11 Install in the reverse order of removal 12 Complete t...

Page 1356: ...sy of MAZDA MOTORS CORP PROTECTOR REMOVAL NOTE 1 Remove the trunk side trim See TRUNK SIDE TRIM REMOVAL INSTALLATION 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday J...

Page 1357: ...unch 2 2 8 mm 0 08 0 11 in diameter CAUTION Be careful not to damage the fuel tank when removing the rivet If the fuel tank is damaged it may cause fuel leakage NOTE The insulator is installed using r...

Page 1358: ...Courtesy of MAZDA MOTORS CORP 2 Remove the flange using a drill 5 mm 0 20 in drill bit 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 12 PM Page 17...

Page 1359: ...mp as shown in Fig 16 Fig 16 Installing Breather Hose Clamp Courtesy of MAZDA MOTORS CORP JOINT HOSE INSTALLATION NOTE 1 Install the joint hose and clamp as shown in Fig 17 2007 Mazda MX 5 Miata Sport...

Page 1360: ...rforming any work operations to prevent fuel from spilling from the fuel system See BEFORE SERVICE PRECAUTION LF NOTE The two rollover valves built into the fuel tank and check valves two way built in...

Page 1361: ...it pipe port B and port C Fig 18 Identifying Plug Fuel Pump Unit Pipe Ports Courtesy of MAZDA MOTORS CORP 2 Apply a pressure of 3 kPa 23 mmHg 0 9 inHg to port A and wait for a while 3 Verify that ther...

Page 1362: ...that there is airflow from port A and the pressure is 0 5 0 kPa 3 8 0 mmHg 0 2 0 inHg If there is no airflow replace the fuel tank If there is airflow place the fuel tank upside down 12 Apply a press...

Page 1363: ...INSTALLATION 2 Quarter trim See QUARTER TRIM REMOVAL INSTALLATION pressurized fuel system it will cause serious injury or death and facility breakage Fuel can also irritate skin and eyes To prevent th...

Page 1364: ...TALLATION 3 Remove the service hole cover Fig 20 Identifying Service Hole Cover Courtesy of MAZDA MOTORS CORP 5 Disconnect the quick release connector from the fuel pump unit See QUICK RELEASE CONNECT...

Page 1365: ...tall the fuel tank See FUEL TANK REMOVAL INSTALLATION LF 3 Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed 4 Stop the vehicle and verify from outside t...

Page 1366: ...isassembly skin and eyes To prevent this do not damage the sealing surface of the fuel pump unit when removing or installing 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Th...

Page 1367: ...emble Assemble Order Fuel Pump Unit Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 12 PM Page 26 2005 Mitchell Repair...

Page 1368: ...FUEL LINE SAFETY PROCEDURE while referring to BEFORE SERVICE PRECAUTION LF Fuel is very flammable liquid If fuel spills or leaks from the pressurized fuel system it will cause serious injury or death...

Page 1369: ...g the FP simulation function Not using M MDS or equivalent 1 Short the check connector terminal F P to ground using a jumper wire 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microso...

Page 1370: ...rminal F P To Ground Using Jumper Wire Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 12 PM Page 29 2005 Mitchell Rep...

Page 1371: ...following Fuel pump unit continuity If not within the specification inspect the following Fuel pump unit relay Wiring harnesses and connectors between main relay and fuel pump relay Wiring harnesses...

Page 1372: ...move the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Disconnect the fuel pump unit connector See FUEL PUMP UNIT REMOVAL INSTALLATION LF 2007 Mazda MX 5...

Page 1373: ...p See FUEL PUMP UNIT DISASSEMBLY ASSEMBLY LF1 CIRCUIT OPEN SHORT INSPECTION 1 Inspect the following wiring harnesses for an open or short circuit continuity check Open circuit If there is no continuit...

Page 1374: ...ble liquid If fuel spills or leaks from the pressurized fuel system it will cause serious injury or death and facility breakage Fuel can also irritate skin and eyes To prevent this always complete the...

Page 1375: ...Rotate the release tab on the quick release connector to the stopper position CAUTION The quick release connector may be damaged if the release tab is bent excessively Do not expand the release tab ov...

Page 1376: ...ng Out Fuel Hose Straight From Fuel Pipe Courtesy of MAZDA MOTORS CORP 4 Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from becom...

Page 1377: ...onnector CAUTION Be careful not to damage the pipe when unlocking the retainer NOTE If the quick release connector is removed replace the retainer with a new one NOTE The retainer is attached to the p...

Page 1378: ...h the SST ends and press the retainer 4 Pull the connector side and disconnect the quick release connector 5 Raise a retainer tab using the SST and remove the retainer 2007 Mazda MX 5 Miata Sport 2007...

Page 1379: ...e quick release connector O ring is damaged or has slipped replace the fuel hose A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses Remove the checke...

Page 1380: ...d is connected securely 5 Complete the AFTER SERVICE PRECAUTION See AFTER SERVICE PRECAUTION LF TYPE B INSTALLATION Fig 35 Identifying Checker Tab Courtesy of MAZDA MOTORS CORP NOTE If the quick relea...

Page 1381: ...OTE If the quick release connector O ring is damaged or has slipped replace the piping component A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses R...

Page 1382: ...the quick release connector a few times by hand and then verify that it is connected securely 6 Complete the AFTER SERVICE PRECAUTION See AFTER SERVICE PRECAUTION LF FUEL INJECTOR REMOVAL INSTALLATION...

Page 1383: ...connector and move the harness slightly out of the way 6 Remove in the order indicated in Fig 37 WARNING Fuel is very flammable liquid If fuel spills or leaks from the pressurized fuel system it will...

Page 1384: ...ON LF FUEL INJECTOR REMOVAL NOTE CAUTION Use of a deformed injector clip will cause the fuel injector to be connected incorrectly and could result in fuel leakage It will also cause the injector to ro...

Page 1385: ...screwdriver 3 Remove the injector with the clip 4 Remove the clip from the fuel injector using the following procedure NOTE When pushing the clip finger outward deform the finger until it is removed...

Page 1386: ...P 1 Hold the clip using pliers 2 Pull the clip parallel to the injector groove and remove it from the injector 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09...

Page 1387: ...the injector into the injector cup Continue pressing until the clip contacts the lower surface of the injector cup 6 Verify that the injector and clip are correctly installed with the clip locked ont...

Page 1388: ...tester If within the specification perform the CIRCUIT OPEN SHORT INSPECTION If not within the specification replace the fuel injector See FUEL INJECTOR REMOVAL INSTALLATION LF Fuel injector resistan...

Page 1389: ...MOVAL INSTALLATION LF 2 Inspect the following wiring harnesses for open or short circuit continuity check Fig 43 Identifying Fuel Injector Connector PCM Connector Terminal Courtesy of MAZDA MOTORS COR...

Page 1390: ...nal B and power supply Fuel injector No 4 terminal B and body ground Fuel injector No 4 terminal B and power supply Fuel injector No 1 terminal A and body ground Fuel injector No 2 terminal A and body...

Page 1391: ...h Wire Courtesy of MAZDA MOTORS CORP 6 Connect the fuel hose 7 Start the fuel pump using the following procedure Using M MDS 1 Connect the negative battery cable 2 Connect the M MDS to the DLC 2 2007...

Page 1392: ...mp using the FP simulation function Not using M MDS 1 Short the check connector terminal F P to ground using a jumper wire 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thur...

Page 1393: ...rminal F P To Ground Using Jumper Wire Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 12 PM Page 52 2005 Mitchell Rep...

Page 1394: ...injector at an angle of 24 to inspect for leakage If not within the specification replace the fuel injector See FUEL INJECTOR REMOVAL INSTALLATION LF NOTE Prepare a container to collect the gasoline...

Page 1395: ...p 10 Remove the battery cover 11 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 12 Remove the wire or equivalent securing the fuel injector 13 Install the fuel injector See...

Page 1396: ...he following procedure Using M MDS 1 Connect the negative battery cable 2 Connect the M MDS or equivalent to the DLC 2 Fig 49 Locating DLC 2 Connector Courtesy of MAZDA MOTORS CORP 3 Start the fuel pu...

Page 1397: ...g a jumper wire Fig 50 Checking Connector Terminal F P To Ground Using Jumper Wire Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July...

Page 1398: ...ml 204 216 cc 12 5 13 1 cu in min 8 Turn the ignition switch to off to stop the fuel pump 9 Install the fuel injector See FUEL INJECTOR REMOVAL INSTALLATION LF 10 Complete the AFTER SERVICE PRECAUTION...

Page 1399: ...ecting Atomization Status Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Fuel System MX 5 Miata Microsoft Thursday July 09 2009 2 37 12 PM Page 58 2005 Mitchell Repair Informati...

Page 1400: ...ATION LF 3 Discharge the refrigerant from the system See REFRIGERANT RECOVERY See REFRIGERANT CHARGING 4 Drain the engine coolant See ENGINE COOLANT REPLACEMENT LF 2007 Mazda MX 5 Miata Sport 2007 HVA...

Page 1401: ...PANEL REMOVAL INSTALLATION 5 Center panel unit See CENTER PANEL UNIT REMOVAL INSTALLATION 6 Lower panel See LOWER PANEL REMOVAL INSTALLATION 7 Knee bolster CAUTION If moisture or foreign material ent...

Page 1402: ...ION 15 Side panel See SIDE PANEL REMOVAL INSTALLATION 16 Hood release lever See HOOD LATCH AND RELEASE LEVER REMOVAL INSTALLATION ADVANCED KEYLESS SYSTEM 17 Female bracket See CONVERTIBLE TOP DISASSEM...

Page 1403: ...nit as shown in Fig 4 9 Install in the reverse order of removal 10 Perform the refrigerant system performance test See REFRIGERANT SYSTEM PERFORMANCE TEST 2007 Mazda MX 5 Miata Sport 2007 HVAC Basic S...

Page 1404: ...rder indicated in Fig 5 CAUTION If a non specified grease is used it may result in abnormal noise or improper operation of the links Apply only the specified grease to each link 2007 Mazda MX 5 Miata...

Page 1405: ...See REFRIGERANT CHARGING 4 Drain the engine coolant See ENGINE COOLANT REPLACEMENT LF 5 Disconnect from A C unit in the order in Fig 6 CAUTION If moisture or foreign material enters the refrigeration...

Page 1406: ...UTION UNIT REMOVAL INSTALLATION 7 Disassembly the A C unit as shown in Fig 7 8 Install in the reverse order of removal 9 Perform the refrigerant system performance test See REFRIGERANT SYSTEM PERFORMA...

Page 1407: ...pecified grease to each link If the air mix damper is removed and reinstalled improperly because the original installation position cannot be specified the air mix damper and air mix actuator may be d...

Page 1408: ...MAZDA MOTORS CORP EVAPORATOR TEMPERATURE SENSOR ASSEMBLY NOTE 1 Assemble the evaporator temperature sensor as shown in Fig 9 2007 Mazda MX 5 Miata Sport 2007 HVAC Basic System MX 5 Miata Microsoft Thu...

Page 1409: ...ECTION 1 Inspect the heater core for damage cracks and water leakage If there is any malfunction replace the heater core 2 Visually inspect the fins for bending If there is any bending use the end of...

Page 1410: ...1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Discharge the refrigerant from the system See REFRIGERANT CHARGING 4 Remove the air cleaner Se...

Page 1411: ...EM PERFORMANCE TEST CAUTION If moisture or foreign material enters the refrigeration cycle cooling ability will be lowered and abnormal noise or other malfunction could occur Always plug open fittings...

Page 1412: ...A C compressor should be greater than the old one 4 Pour the same amount oil of drained from the old A C compressor back into the new A C compressor A C compressor oil type DH PR A C compressor oil s...

Page 1413: ...ver 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Discharge the refrigerant from the system See REFRIGERANT CHARGING 4 Remove the splash shields 5 Remove the under cove...

Page 1414: ...ture or foreign material enters the refrigeration cycle cooling ability will be lowered and abnormal noise or other malfunction could occur Always plug open fittings immediately after removing any ref...

Page 1415: ...ecifications Courtesy of MAZDA MOTORS CORP 8 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 HVAC Basic System MX 5 Miata Microsoft Thursday July 09 2009 2 22 45 PM Page 16 20...

Page 1416: ...EMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Discharge the refrigerant from the system See REFRIGERANT CHARGING 4 Remove...

Page 1417: ...e REFRIGERANT SYSTEM PERFORMANCE TEST REFRIGERANT LINE REMOVAL NOTE 1 Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly and...

Page 1418: ...nd 2 Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly and then tighten the connection bolt or nut with a torque wrench 2007 Ma...

Page 1419: ...ing Block Joint Type Pipes Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 HVAC Basic System MX 5 Miata Microsoft Thursday July 09 2009 2 22 45 PM Page 20 2005 Mitchell Repair Informati...

Page 1420: ...ssed air Some mixtures of air and R 134a have been shown to be combustible at elevated pressures These mixtures if ignited may cause injury or property damage Additional health and safety information...

Page 1421: ...Therefore install caps immediately after using the compressor oil or removing refrigerant system parts to prevent moisture absorption Fig 1 Moisture Absorption Efficiency Graph Courtesy of MAZDA MOTOR...

Page 1422: ...e and throat Also due to environmental concerns use service equipment certified to meet the requirements of SAE J2210 R 134a recycling equipment when draining R 134a from the air conditioning system I...

Page 1423: ...hose to the vacuum pump 5 Connect the charging hose to the refrigerant tank 6 Place the refrigerant tank on the scale Fig 3 Connecting Vacuum Pump Hose To Center Joint Of Manifold Gauge Courtesy of M...

Page 1424: ...nged inspect for leakage and then repeat from Step 7 If the reading has not changed go to next step 12 Open the valve of the refrigerant tank 13 Weigh the refrigerant tank to charge the suitable amoun...

Page 1425: ...which can destroy the ozone layer in the stratosphere follow the proper procedures and charge with only a small amount of refrigerant when checking for gas leakage If charging the system with refriger...

Page 1426: ...ep 18 If leakage is found at a loose joint tighten the joint go to next step 17 Inspect for leakage again If there is no leakage after tightening the joint go to next step If there is still a leakage...

Page 1427: ...nt by service cans or refrigerant tank running the engine with the high pressure side valve open is dangerous Pressure within the service cans or refrigerant tank will increase and they could explode...

Page 1428: ...sure side valve open is dangerous Pressure within the service cans or refrigerant tank will increase and they could explode scattering metal fragments and liquid refrigerant that can seriously injure...

Page 1429: ...oz from the amount in Step 13 22 Close the low pressure side valve of the manifold gauge and the valve of the refrigerant tank 23 Stop the engine and A C compressor 24 Inspect for leakage using a gas...

Page 1430: ...re is still leakage at the same joint discharge the refrigerant and then repair the joint Repeat the charging procedure from Step 7 26 Remove the manifold gauge set 27 Install the caps to the charging...

Page 1431: ...t 1 500 rpm 4 Set the fan speed MAX HI WARNING Avoid breathing air conditioning refrigerant or lubricant vapor Exposure may irritate eyes nose and throat Also due to environmental concerns use service...

Page 1432: ...and ambient temperature 11 Verify that the high and low pressure readings are within each shaded zone If there is any malfunction inspect the refrigerant system according to the troubleshooting chart...

Page 1433: ...frigerant pressure See REFRIGERANT PRESSURE CHECK 2 Place a dry bulb thermometer in the driver side center ventilator outlet 3 Start the engine and arrow it to reach operating temperature 2007 Mazda M...

Page 1434: ...and off at regular intervals 12 After the blower air is stabilized read the dry bulb thermometer 13 Verify the ambient temperature 14 Verify that the temperature reading is in the shaded zone If the...

Page 1435: ...AL INSTALLATION LF 3 Remove the following parts 1 Console See CONSOLE REMOVAL INSTALLATION 2 Glove compartment See GLOVE COMPARTMENT REMOVAL INSTALLATION 2007 Mazda MX 5 Miata Sport 2007 HVAC Control...

Page 1436: ...ATION 13 Meter hood See METER HOOD REMOVAL INSTALLATION 14 Instrument cluster See INSTRUMENT CLUSTER REMOVAL INSTALLATION 15 Side panel See SIDE PANEL REMOVAL INSTALLATION 16 Hood release lever See HO...

Page 1437: ...GLOVE COMPARTMENT REMOVAL INSTALLATION 3 Side wall See SIDE WALL REMOVAL INSTALLATION 4 Console panel See CONSOLE PANEL REMOVAL INSTALLATION 5 Center panel unit See CENTER PANEL UNIT REMOVAL INSTALLA...

Page 1438: ...AND RELEASE LEVER REMOVAL INSTALLATION ADVANCED KEYLESS SYSTEM 17 Female bracket See CONVERTIBLE TOP DISASSEMBLY ASSEMBLY 18 A pillar trim See A PILLAR TRIM REMOVAL INSTALLATION 19 Scuff plate See SC...

Page 1439: ...ION 2 Knee bolster 4 Remove in the order indicated in Fig 4 Fig 4 Removing Airflow Mode Actuator Courtesy of MAZDA MOTORS CORP 5 Install in the reverse order of removal BLOWER MOTOR REMOVAL INSTALLATI...

Page 1440: ...SPECTION 1 Connect battery positive voltage to blower motor terminal A ground to terminal B and then verify that the blower motor operates smoothly If the operation condition is not normal replace the...

Page 1441: ...y cable See BATTERY REMOVAL INSTALLATION LF 3 Disconnect the power MOS FET connector 4 Remove the power MOS FET as shown in Fig 7 5 Install in the reverse order of removal 6 Perform the refrigerant sy...

Page 1442: ...ECTION 1 Verify that the resistance between the terminals of the power MOS FET is as shown in TERMINALS RESISTANCE TABLE If there is any malfunction replace the power MOS FET 2007 Mazda MX 5 Miata Spo...

Page 1443: ...the order indicated in Fig 9 Tester lead Resistance kilohm approx quantity A B 1 300 A C 1 300 A D 2 2 B A infinity B C 0 12 B D infinity C A infinity C B 0 12 C D infinity D A 2 2 D B 190 D C 1 300...

Page 1444: ...ue Specifications Courtesy of MAZDA MOTORS CORP 2 Assemble in the reverse order of disassembly 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX 5 Miata Microsoft Thursday July 09 2009 2 27 32 P...

Page 1445: ...the pressure plate as shown in Fig 10 Fig 10 Removing Installing Bolt Courtesy of MAZDA MOTORS CORP SNAP RING REMOVAL INSTALLATION NOTE 1 Remove the snap ring using a snap ring pliers 2007 Mazda MX 5...

Page 1446: ...NOTE 1 Remove the A C compressor pulley using the SST 49 0839 425C CAUTION Be careful that the SST 49 0839 425C tabs do not hang over the stator 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX...

Page 1447: ...C Compressor Pulley 1 Of 2 Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX 5 Miata Microsoft Thursday July 09 2009 2 27 32 PM Page 13 2005 Mitchell Repair Inform...

Page 1448: ...S CORP STATOR INSTALLATION NOTE 1 Align the positioning pin with the hole of A C compressor body and insert 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX 5 Miata Microsoft Thursday July 09 2...

Page 1449: ...or CAUTION If the SST is not properly positioned when the A C compressor pulley is press fit the A C compressor axle will interfere with the SST possibly damaging component parts Verify that the SST a...

Page 1450: ...sor Courtesy of MAZDA MOTORS CORP SHIM INSTALLATION NOTE 1 First insert the 1 mm 0 039 in thick shim into the shaft 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX 5 Miata Microsoft Thursday J...

Page 1451: ...and A C compressor pulley using a thickness gauge 2 Inspect the clearance If not within the specification adjust the clearance by changing the shim or the number of shims Magnetic clutch clearance 0...

Page 1452: ...hickness Gauge Courtesy of MAZDA MOTORS CORP MAGNETIC CLUTCH INSPECTION 1 Connect battery positive voltage to magnetic clutch terminal A and ground 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System...

Page 1453: ...f MAZDA MOTORS CORP 2 Verify that the magnetic clutch turns on If the magnetic clutch does not turn on replace the A C compressor 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX 5 Miata Micros...

Page 1454: ...r intake mode to RECIRCULATE 4 Turn the A C switch off 5 Close all of the doors and roll up all the windows 6 Wait for 5 min 7 Disconnect the evaporator temperature sensor connector 8 Measure the temp...

Page 1455: ...ator temperature sensor Fig 20 Evaporator Temperature Sensor Graph Courtesy of MAZDA MOTORS CORP REFRIGERANT PRESSURE SWITCH REMOVAL INSTALLATION 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System M...

Page 1456: ...l in the reverse order of removal REFRIGERANT PRESSURE SWITCH INSTALLATION NOTE 1 Apply compressor oil to the O ring joints REFRIGERANT PRESSURE SWITCH INSPECTION 1 Connect the manifold gauge 2 Verify...

Page 1457: ...pressure switch Fig 22 Refrigerant Pressure Switch Specification Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX 5 Miata Microsoft Thursday July 09 2009 2 27 32...

Page 1458: ...TALLATION LF 3 Remove the side wall See SIDE WALL REMOVAL INSTALLATION 4 Remove the center panel unit See CENTER PANEL UNIT REMOVAL INSTALLATION 5 Remove the climate control unit from the center panel...

Page 1459: ...of MAZDA MOTORS CORP CLIMATE CONTROL UNIT DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 25 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX 5 Miata Microsoft Thursday July 09...

Page 1460: ...tive lead of the tester into each climate control unit terminal measure the voltage according to TERMINAL VOLTAGE REFERENCE TABLE If there is any malfunction inspect the parts under Inspection item s...

Page 1461: ...der any condition B Wiring harness continuity short circuit Climate control unit fuse B ROOM 15 A ROOM 15 A fuse C Blower fan speed control Power MOS FET Fan stopped 1 0 or less Wiring harness continu...

Page 1462: ...t terminal voltage D Headlight switch ON 2 7 Wiring harness short circuit Climate control unit instrument cluster F 1F G Actuator power Air intake actuator Air mix actuator Airflow mode actuator IG SW...

Page 1463: ...ontrol unit evaporator temperature sensor M B S A Wiring harness short circuit Climate control unit evaporator temperature sensor M B Evaporator temperature sensor N Rear window defroster operation Re...

Page 1464: ...Sensor Voltage Vs Temperature Graph 1 Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 HVAC Control System MX 5 Miata Microsoft Thursday July 09 2009 2 27 32 PM Page 30 2005 Mitchell Re...

Page 1465: ...HOLE PLATE REMOVAL INSTALLATION LF 4 Remove the front suspension tower bar joint See FRONT SUSPENSION TOWER BAR REMOVAL INSTALLATION 5 Remove in the order indicated in Fig 2 6 Install in the reverse o...

Page 1466: ...a normal cylinder and re perform the spark test If the spark is not normal due to a malfunctioning ignition coil replace that ignition coil It is unlikely that all four ignition coils fail to operate...

Page 1467: ...nds to the table replace the ignition coil TESTER CONNECTION POSITION Item Tester Connection Position Condition Positive Negative Terminal C A 0 ohm is not normal Infinity ohm is normal A C C B B C A...

Page 1468: ...or Terminals Courtesy of MAZDA MOTORS CORP SPARK PLUG REMOVAL INSTALLATION LF 2007 Mazda MX 5 Miata Sport 2007 ENGINE Ignition System MX 5 Miata Microsoft Thursday July 09 2009 2 39 35 PM Page 4 2005...

Page 1469: ...1 Measure the spark plug gap using a wire type plug gap gauge If it exceeds the specification replace the spark plug Spark plug gap 1 25 1 35 mm 0 050 0 053 in CLEANING CAUTION If a spark plug that is...

Page 1470: ...hift lever to neutral MT or the selector lever to P position AT to prevent an accident and serious injury To avoid possible damage to the spark plug tip do not use a wire brush for cleaning NOTE To av...

Page 1471: ...e spark plug using a tester as shown in Fig 5 If not within the specification replace the spark plug Spark plug resistance 25 C 77 F 3 0 7 5 kilohms 2007 Mazda MX 5 Miata Sport 2007 ENGINE Ignition Sy...

Page 1472: ...Resistance Of Spark Plug Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Ignition System MX 5 Miata Microsoft Thursday July 09 2009 2 39 36 PM Page 8 2005 Mitchell Repair Informa...

Page 1473: ...TE 7 Speedometer indication is defective See NO 7 SPEEDOMETER INDICATION IS DEFECTIVE 8 Tachometer indication is defective See NO 8 TACHOMETER INDICATION IS DEFECTIVE 9 Water temperature gauge indicat...

Page 1474: ...POSSIBLE CAUSE TABLE 1 Fuel gauge needle position incorrect Fuel gauge sender unit malfunction Instrument cluster malfunction Connector or pin malfunction 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES...

Page 1475: ...the check code 23 inspection Is there any malfunction Yes Replace the instrument cluster No Go to the next step 4 Perform the check code 22 inspection Is there any malfunction Yes Go to the next step...

Page 1476: ...ring harness between the instrument cluster and the fuel gauge sender unit 9 Turn the ignition switch off Is the fuel gauge sender unit installed properly Yes Inspect the fuel gauge sender unit No Rei...

Page 1477: ...ge B Yes Go to the next step No Inspect the suspect wiring harness then repair or replace 4 Turn the ignition switch off Inspect the instrument cluster connector terminals for poor connection such as...

Page 1478: ...als F and E for short to power supply or GND Is there any malfunction Yes Inspect the wiring harness and CAN system related module Repair or replace the malfunctioning part No Replace the instrument c...

Page 1479: ...th a check code other than 26 Yes Inspect the PCM No Replace the instrument cluster 4 Disconnect the negative battery cable Measure the resistance between the DLC 2 terminals F and E Is the resistance...

Page 1480: ...malfunction Connector or pin malfunction Short circuit in wiring harness between CAN L CAN H and GND Open circuit in CAN wiring harness CAN L CAN H CAN wiring harness CAN L CAN H short each other STEP...

Page 1481: ...o Replace the instrument cluster 7 Turn the ignition switch off Inspect the instrument cluster connector terminals for poor connection such as damaged pulled out pins and corrosion Are the terminals n...

Page 1482: ...wiring harness then replace the fuse 4 Turn the ignition switch off Inspect the instrument cluster connector terminals for poor connection such as damaged pulled out pins and corrosion Are the termin...

Page 1483: ...the instrument cluster 5 Disconnect the negative battery cable Measure the resistance between the DLC 2 terminals F and E Is the resistance 54 66 ohms Yes Go to the next step No Go to Step 7 6 Disconn...

Page 1484: ...N H and GND Open circuit in CAN wiring harness CAN L CAN H CAN wiring harness CAN L CAN H short each other STEP INSPECTION ACTION 1 Start the engine Does the tachometer needle move smoothly Does the t...

Page 1485: ...e ignition switch off Inspect the instrument cluster connector terminals for poor connection such as damaged pulled out pins and corrosion Are the terminals normal Yes Go to the next step No Repair or...

Page 1486: ...e PCM or connectors No Replace the instrument cluster 5 Disconnect the negative battery cable Measure the resistance between the DLC 2 terminals F and E Is the resistance 54 66 ohms Yes Go to the next...

Page 1487: ...USE PCM malfunction Instrument cluster malfunction Oil pressure switch malfunction Connector or pin malfunction Short circuit in wiring harness between CAN L CAN H and GND Open circuit in CAN wiring h...

Page 1488: ...ct the wiring harness and CAN system related module Repair or replace the malfunctioning part No Replace the instrument cluster 8 Turn the ignition switch off Inspect the instrument cluster connector...

Page 1489: ...LLATION 5 Remove the column cover See COLUMN COVER REMOVAL INSTALLATION 6 Remove in the order indicated in Fig 2 CAUTION When replacing the instrument cluster the configuration procedure must be perfo...

Page 1490: ...ACEMENT KEY ADDITION AND CLEARING ADVANCED KEYLESS SYSTEM and IMMOBILIZER SYSTEM COMPONENT REPLACEMENT KEY ADDITION AND CLEARING KEYLESS ENTRY SYSTEM CAUTION The removed instrument cluster should be p...

Page 1491: ...EMOVAL NOTE 1 Rotate the instrument cluster in the direction of the arrow and remove the instrument cluster 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Instrumentation Driver Info MX 5 Miata...

Page 1492: ...MOVAL NOTE 1 Rotate the clip B 90 then remove the clip B from the instrument cluster 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Instrumentation Driver Info MX 5 Miata Microsoft Thursday Jul...

Page 1493: ...ZDA MOTORS CORP INSTRUMENT CLUSTER CONFIGURATION 1 Connect the M MDS to the DLC 2 connector 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Instrumentation Driver Info MX 5 Miata Microsoft Thurs...

Page 1494: ...cluster perform the following procedure 1 Select Programmable Parameters from the menu 2 Select Odometer Write and perform the procedure following the screen 5 Retrieve DTCs using the M MDS and verif...

Page 1495: ...emble in the reverse order of disassembly INSTRUMENT CLUSTER INSPECTION SPEEDOMETER CAUTION Do not drop the instrument cluster or damage the printed board This will lead to a system malfunction 2007 M...

Page 1496: ...or the indication is not within the allowable range inspect the PCM and the related wiring harnesses If the PCM and the related wiring harnesses are normal replace the instrument cluster TACHOMETER U...

Page 1497: ...lect Module Select IC When using the PDS Pocket PC Select Module Tests Select IC Select DataLogger CAUTION If the engine speed exceeds the allowable range the engine could be damaged Therefore when in...

Page 1498: ...to check code 28 of the input output check mode See INSTRUMENT CLUSTER INPUT OUTPUT CHECK MODE INSTRUMENT CLUSTER INPUT OUTPUT CHECK MODE CHECK CODE TABLE INSTRUMENT CLUSTER INPUT OUTPUT CHECK CODE TA...

Page 1499: ...inspected The check codes are displayed in numerical order While performing the inspection if you want to inspect a check code with a number smaller than the code number you are currently inspecting...

Page 1500: ...RS CORP Checking Order NOTE When inspecting more than two check codes begin with the code with the 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Instrumentation Driver Info MX 5 Miata Microsof...

Page 1501: ...ver side SAS control module Wiring harness Buckle switch driver side SAS control module Using the DTC and PID of SAS control module inspect the SAS control module buckle switch and the related wiring...

Page 1502: ...the following parts Buckle switch passenger side Seat weight sensor control module Seat weight sensor SAS control module Wiring harness Buckle switch passenger side SAS control module seat weight sens...

Page 1503: ...e Using the DTC and PID of SAS control module inspect the SAS control module buckle switch driver side passenger side seat weight sensor control module seat weight sensor and the related wiring harnes...

Page 1504: ...rmal Check code 08 TNS relay ON OFF signal STEP INSPECTION CONDITION DISPLAY ACTION 1 Turn the headlight switch to the TNS position TNS relay ON Go to the next step Verify that the voltage of instrume...

Page 1505: ...check code 12 wait for approx 2 s The speedometer needle moves full scale then returns to approx 60 km h or approx 60 mph The speedometer is normal Except above Replace the instrument cluster Check c...

Page 1506: ...instrument cluster Check code 18 Ignition key illumination control signal INSPECTION CONDITION DISPLAY ACTION After selecting check code 18 wait approx 2 s Ignition key illumination flashes three tim...

Page 1507: ...t above Go to the Step 6 4 Using the SST Fuel and thermometer checker or resistor input 60 ohms between instrument cluster terminals 2R and 2T Go to the next step Except above Go to the Step 6 5 Using...

Page 1508: ...ove Replace the instrument cluster Replace the instrument cluster Check code 25 Water temperature gauge operation signal INSPECTION CONDITION DISPLAY ACTION After selecting check code 25 wait approx 2...

Page 1509: ...t Keyless indicator light The odometer tripmeter is normal Warning and indicator is normal Except above Replace the instrument cluster Check code 28 Oil pressure gauge operation signal INSPECTION COND...

Page 1510: ...is not as specified inspect the following parts Key reminder switch Wiring harness Battery key reminder switch instrument cluster 2 Remove the key from the steering lock The key reminder switch is of...

Page 1511: ...ule etc flashes three times The panel light control signal is normal Except above Verify that the voltage of instrument cluster terminal 1F is B If the voltage is as specified replace the instrument c...

Page 1512: ...right The wiring harnesses between the fuel gauge sender unit and instrument cluster are normal Go to next step Inspect following parts Fuel gauge sender unit Wiring harness Fuel gauge sender unit in...

Page 1513: ...ect the Toolbox tab Select DataLogger Select Modules Select IC When using the PDS Pocket PC Select Module Tests Select IC Select DataLogger Fig 10 Locating DLC 2 Connector If the PCM is normal replace...

Page 1514: ...within the specification inspection of the monitored value of input parts corresponding to applicable output part control is necessary In addition because the system does not display output part malfu...

Page 1515: ...iring harness If the related wiring harness is normal inspect the oil pressure See OIL PRESSURE INSPECTION LF If the oil pressure is normal replace the oil pressure switch HORN REMOVAL INSTALLATION 1...

Page 1516: ...of MAZDA MOTORS CORP 4 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Instrumentation Driver Info MX 5 Miata Microsoft Thursday July 09 2009 3 30 27 PM P...

Page 1517: ...AKE AIR SYSTEM LOCATION INDEX LF 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Intake Air System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Intake Air System MX 5 Miata Micro...

Page 1518: ...nents Courtesy of MAZDA MOTORS CORP INTAKE AIR SYSTEM DIAGRAM LF 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Intake Air System MX 5 Miata Microsoft Thursday July 09 2009 2 40 18 PM Page 2 2005...

Page 1519: ...ication perform the following inspections Compression pressure See COMPRESSION INSPECTION LF Air intake Each hose installation part Throttle body installation part Fuel injector installation part PCV...

Page 1520: ...t until they are cool before removing the intake air system Fuel line spills and leakage from the pressurized fuel system are dangerous Fuel can ignite and cause serious injury or death and damage Fue...

Page 1521: ...the purge solenoid valve slightly out of the way See PURGE SOLENOID VALVE REMOVAL INSTALLATION LF FRESH AIR DUCT REMOVAL NOTE 1 Remove the front bumper See FRONT BUMPER REMOVAL INSTALLATION THROTTLE...

Page 1522: ...BLADE REMOVAL INSTALLATION 3 Remove the cowl grille See COWL GRILLE REMOVAL INSTALLATION 4 Remove the side cowl grille See SIDE COWL GRILLE REMOVAL INSTALLATION 5 Move the cooler pipe No 3 and heater...

Page 1523: ...ORP 5 Disconnect the heater hose and move the heater pipe slightly out of the way 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Intake Air System MX 5 Miata Microsoft Thursday July 09 2009 2 40...

Page 1524: ...esy of MAZDA MOTORS CORP 6 Remove the harness bracket 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Intake Air System MX 5 Miata Microsoft Thursday July 09 2009 2 40 18 PM Page 8 2005 Mitchell R...

Page 1525: ...See QUICK RELEASE CONNECTOR FUEL SYSTEM REMOVAL INSTALLATION LF 11 Remove the fuel distributor See FUEL INJECTOR REMOVAL INSTALLATION LF 12 Disconnect the water hose from the EGR valve 13 Disconnect t...

Page 1526: ...Dynamic Chamber Courtesy of MAZDA MOTORS CORP 17 Remove the EGR pipe 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Intake Air System MX 5 Miata Microsoft Thursday July 09 2009 2 40 18 PM Page 10...

Page 1527: ...solenoid valve and the charcoal canister slightly out of the way 21 Move the clutch release cylinder slightly out of the way MT See CLUTCH RELEASE CYLINDER REMOVAL INSTALLATION 22 Disconnect the evapo...

Page 1528: ...25 Remove the MAP sensor See MANIFOLD ABSOLUTE PRESSURE MAP SENSOR REMOVAL INSTALLATION LF THROTTLE BODY INSTALLATION NOTE 1 Tighten the bolts in the order as shown in Fig 13 Throttle body tightening...

Page 1529: ...er element Has the replacement interval come Is the air cleaner element soiled damaged or bent Are the air cleaner case and the air cleaner element correctly sealed Is the correct air cleaner element...

Page 1530: ...Inspection Specification AMBIENT TEMPERATURE SPECIFICATION Fig 14 Identifying Throttle Actuator Connector Terminals Courtesy of MAZDA MOTORS CORP CIRCUIT OPEN SHORT INSPECTION 1 Disconnect the PCM co...

Page 1531: ...is open Repair or replace the wiring harness Throttle valve actuator terminal A and PCM terminal 2B Throttle valve actuator terminal B and PCM terminal 2A Short Circuit 2007 Mazda MX 5 Miata Sport 20...

Page 1532: ...HOLE PLATE REMOVAL INSTALLATION LF 2 Remove the battery cover 3 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 4 Remove in the order indicated in Fig 16 5 Install in the re...

Page 1533: ...following conditions If not as specified replace the variable intake air solenoid valve If as specified carry out the Circuit Open Short Inspection Fig 17 Variable Intake Air Solenoid Valve Continuit...

Page 1534: ...ON 1 Disconnect the PCM connector See PCM REMOVAL INSTALLATION LF 2 Inspect the following wiring harness for open or short continuity check 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Intake A...

Page 1535: ...uit is open Repair or replace the wiring harness Variable intake air solenoid valve terminal B and PCM terminal 2J Variable intake air solenoid valve terminal A and main relay Short Circuit 2007 Mazda...

Page 1536: ...air solenoid valve 3 Connect a vacuum pump to the vacuum hose 4 Apply vacuum and verify that the rod moves If the rod does not move replace the variable intake air shutter valve actuator See VARIABLE...

Page 1537: ...Remove the wiper arm See WIPER ARM AND BLADE REMOVAL INSTALLATION 3 Remove the cowl grille See COWL GRILLE REMOVAL INSTALLATION 4 Remove the side cowl grille See SIDE COWL GRILLE REMOVAL INSTALLATION...

Page 1538: ...e the fuel distributor See FUEL INJECTOR REMOVAL INSTALLATION LF 12 Move the clutch release cylinder slightly out of the way MT See CLUTCH RELEASE CYLINDER REMOVAL INSTALLATION 13 Remove the dynamic c...

Page 1539: ...r on the opposite side using a suitable screwdriver or equivalent tool as shown in Fig 23 CAUTION Do not remove the lever otherwise the variable intake air shutter valve opening angle will deviate To...

Page 1540: ...the dynamic chamber on the opposite side until a click is heard and install it ACCELERATOR PEDAL REMOVAL INSTALLATION LF 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY...

Page 1541: ...Specifications Courtesy of MAZDA MOTORS CORP 4 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Intake Air System MX 5 Miata Microsoft Thursday July 09 2009...

Page 1542: ...MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 200...

Page 1543: ...MOTORS CORP Fig 3 Identifying Location Of Interior Trim Components 3 Of 3 Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursd...

Page 1544: ...ATION 6 Lower panel See LOWER PANEL REMOVAL INSTALLATION 7 Knee bolster See KNEE BOLSTER REMOVAL INSTALLATION 8 Column cover See COLUMN COVER REMOVAL INSTALLATION 9 Driver side air bag module See DRIV...

Page 1545: ...SCUFF PLATE REMOVAL INSTALLATION 20 Front side trim See FRONT SIDE TRIM REMOVAL INSTALLATION 21 Fuse box No 1 Fig 5 Identifying Fuse Box No 1 Courtesy of MAZDA MOTORS CORP 4 Disconnect the dashboard...

Page 1546: ...RD WARNING SWITCH REMOVAL INSTALLATION 3 Center speaker cover See CENTER SPEAKER REMOVAL INSTALLATION 4 Center speaker vehicles with BOSE See CENTER SPEAKER REMOVAL INSTALLATION 5 Passenger side air b...

Page 1547: ...ted in Fig 7 3 Assemble in the reverse order of disassembly 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 29 26 PM Page 6 2005 Mitche...

Page 1548: ...e the ignition key illumination See IGNITION KEY ILLUMINATION BULB REMOVAL INSTALLATION 4 Install in the reverse order of removal Fig 8 Removing Upper Lower Column Cover Courtesy of MAZDA MOTORS CORP...

Page 1549: ...ent Courtesy of MAZDA MOTORS CORP LOWER PANEL REMOVAL INSTALLATION 1 Pull the lower panel outward and detach clips A and tab B 2 Turn the lower panel downward and remove the tabs C 3 Remove the lower...

Page 1550: ...1 Pull the meter hood upward and detach clips A 2 Remove the meter hood 3 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Micros...

Page 1551: ...e decoration panel driver s side See DRIVER S SIDE 2 Remove the screws 3 Remove the ventilator grille 4 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB In...

Page 1552: ...anel unit See CENTER PANEL UNIT REMOVAL INSTALLATION 5 Remove the glove compartment See GLOVE COMPARTMENT REMOVAL INSTALLATION 6 Remove the decoration panel passenger s side See PASSENGER S SIDE 7 Rem...

Page 1553: ...r panel unit See CENTER PANEL UNIT REMOVAL INSTALLATION 5 Remove the glove compartment See GLOVE COMPARTMENT REMOVAL INSTALLATION 6 Remove the decoration panel passenger s side See PASSENGER S SIDE 7...

Page 1554: ...rd and detach clips A 2 Pull the side panel rearward and detach tab B from the dashboard 3 Remove the side panel 4 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES...

Page 1555: ...e lower panel See LOWER PANEL REMOVAL INSTALLATION 2 Remove the screws 3 Remove the knee bolster 4 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interio...

Page 1556: ...the direction shown by the arrow 2 Remove the side wall 3 Install in the reverse order of removal CAUTION Do not pull the side wall ends outward to remove the side wall The side wall and clips could...

Page 1557: ...egative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the selector lever knob AT shift lever knob MT 4 Remove in the order indicated in Fig 18 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES...

Page 1558: ...2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 29 26 PM Page 17 2005 Mitchell Repair Information Company LLC...

Page 1559: ...e clips using a fastener remover inserted in the position indicated by the arrow Fig 19 Identifying Front Cover Clips Protective Tape Courtesy of MAZDA MOTORS CORP 2 Remove the front cover in the dire...

Page 1560: ...ORP CONSOLE DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 21 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 29 26 P...

Page 1561: ...ION LF 3 Remove the console See CONSOLE REMOVAL INSTALLATION 4 Remove the side wall See SIDE WALL REMOVAL INSTALLATION 5 Remove the screws 6 Pull the console panel outward and detach tabs A and pins B...

Page 1562: ...female wedge See CONVERTIBLE TOP DISASSEMBLY ASSEMBLY 2 Pull the A pillar trim then disengage clips A and B 3 Pull the A pillar trim upward then disengage tabs C from the body 4 Remove the A pillar t...

Page 1563: ...LIGHT REMOVAL INSTALLATION 5 Remove the A pillar trim See A PILLAR TRIM REMOVAL INSTALLATION 6 Remove the screws 7 Pull the front header trim toward you then disengage the clips A and pin B from the...

Page 1564: ...light See MAP LIGHT REMOVAL INSTALLATION 7 Install the female wedge See CONVERTIBLE TOP DISASSEMBLY ASSEMBLY CAUTION Do not twist or drop the front header trim otherwise the vanity mirror could be da...

Page 1565: ...le bale hardtop 2 Remove the fastener 3 Remove the clips A 4 Pull the quarter trim upward and detach clips B 5 Remove the seat belt from the quarter trim through the slit in the quarter trim and remov...

Page 1566: ...move the covers 4 Remove the screws 5 Detach clips A from the door trim using fastener remover 6 Pull the door trim upward and detach tabs B from the door 7 Disconnect the power outer mirror switch co...

Page 1567: ...the inner handle cover 9 Remove the door trim 10 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 2009...

Page 1568: ...CORP DOOR TRIM DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 29 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 29...

Page 1569: ...LLATION 1 Insert a tape wrapped flathead screwdriver into the service hole 2 Twist the flathead screwdriver as indicated by the arrow to remove the clips A and tab B 2007 Mazda MX 5 Miata Sport 2007 A...

Page 1570: ...rts 1 Console See CONSOLE REMOVAL INSTALLATION 2 Quarter trim See QUARTER TRIM REMOVAL INSTALLATION 3 Scuff plate See SCUFF PLATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INS...

Page 1571: ...llowing parts a Console See CONSOLE REMOVAL INSTALLATION b Quarter trim See QUARTER TRIM REMOVAL INSTALLATION c Scuff plate SCUFF PLATE REMOVAL INSTALLATION d Tire house trim See TIRE HOUSE TRIM REMOV...

Page 1572: ...ZDA MOTORS CORP 4 Remove the fasteners 5 Slide the seat back bar lower garnish to the vehicle rear and detach clips B and pin C 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5...

Page 1573: ...INSTALLATION 3 Scuff plate See SCUFF PLATE REMOVAL INSTALLATION 4 Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION 5 Aeroboard See AEROBOARD REMOVAL INSTALLATION 6 Front seat back bar garnish...

Page 1574: ...of MAZDA MOTORS CORP 3 Remove the fasteners Fig 35 Identifying Seat Back Trim 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 29 26 PM...

Page 1575: ...ns B 2 Remove the front seat back bar garnish Fig 36 Identifying Front Seat Back Bar Garnish Courtesy of MAZDA MOTORS CORP 3 Remove the screws 4 Pull the rear seat back bar garnish upward and detach c...

Page 1576: ...VAL INSTALLATION 6 Front seat back bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTALLATION 7 Back trim See BACK TRIM REMOVAL INSTALLATION 8 Seat belt set plate See SEAT BELT REMOVAL INSTALLATION 9...

Page 1577: ...e See SCUFF PLATE REMOVAL INSTALLATION d Tire house trim See TIRE HOUSE TRIM REMOVAL INSTALLATION e Aeroboard See AEROBOARD REMOVAL INSTALLATION f Seat back bar garnish See SEAT BACK BAR GARNISH REMOV...

Page 1578: ...e the side lock 4 Disengage the B pillar upper trim clips A using a fastener remover 5 While cutting the double sided adhesive tape using a screwdriver or a razor separate the B pillar upper trim from...

Page 1579: ...ve the adhesive remaining on the B pillar upper trim and the body using a razor 2 Remove any grease or dirt from the adhesion surface of the B pillar upper trim and the body 3 Apply primer to the bond...

Page 1580: ...IRE HOUSE TRIM REMOVAL INSTALLATION 1 Remove the quarter trim See QUARTER TRIM REMOVAL INSTALLATION 2 Remove the scuff plate See SCUFF PLATE REMOVAL INSTALLATION 3 Remove the fasteners 4 Pull the tire...

Page 1581: ...d See AEROBOARD REMOVAL INSTALLATION 6 Front seat back bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTALLATION 7 Back trim See BACK TRIM REMOVAL INSTALLATION 8 Seat belt set plate See SEAT BELT REM...

Page 1582: ...ON PANEL REMOVAL INSTALLATION DRIVER S SIDE 1 Pull the decoration panel outward and detach clips A 2 Remove the decoration panel 3 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2...

Page 1583: ...Remove the center panel unit See CENTER PANEL UNIT REMOVAL INSTALLATION 5 Remove the glove compartment See GLOVE COMPARTMENT REMOVAL INSTALLATION 6 Remove the three screws 7 Pull the decoration panel...

Page 1584: ...ION 2 Remove the seaming welt 3 Remove the fastener 4 Pull the front side trim toward you then disengage clip A and pin B from the body 5 Remove the front side trim 6 Install in the reverse order of r...

Page 1585: ...hile detaching tabs C and then detach clips A and D and pins B 4 E 1 from the body and remove the scuff plate 2 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BOD...

Page 1586: ...ded adhesive tape using a flathead screwdriver or razor 3 Remove the rear trim WARNING Using a razor with bare hands can cause injury Always wear gloves when using a razor 2007 Mazda MX 5 Miata Sport...

Page 1587: ...grease or dirt from the adhesion surface of the rear trim and the detachable hardtop 3 Attach double sided adhesive tape to the rear trim as shown in Fig 49 3 Peel off the ends of the double sided ad...

Page 1588: ...ard See AEROBOARD REMOVAL INSTALLATION 6 Front seat back bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTALLATION 7 Back trim See BACK TRIM REMOVAL INSTALLATION 8 Seat belt set plate See SEAT BELT R...

Page 1589: ...OBOARD REMOVAL INSTALLATION f Seat back bar garnish See SEAT BACK BAR GARNISH REMOVAL INSTALLATION g Back trim See BACK TRIM REMOVAL INSTALLATION 2 Disconnect the power retractable hardtop drain hose...

Page 1590: ...EMOVAL INSTALLATION 2 Remove the partition board See PARTITION BOARD REMOVAL INSTALLATION 3 Remove the fasteners 4 Remove the trunk side trim 5 Install in the reverse order of removal 2007 Mazda MX 5...

Page 1591: ...PARTITION BOARD REMOVAL INSTALLATION 1 Remove the fasteners 2 Remove the partition board 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 2009...

Page 1592: ...fasteners 2 Disconnect the trunk compartment light connector 3 Disconnect the trunk rid cancel switch connector 4 Remove the trunk end trim 5 Install in the reverse order of removal 2007 Mazda MX 5 Mi...

Page 1593: ...N 1 Remove the fasteners 2 Remove the trunk mat 3 Remove the seal fasteners 4 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Mic...

Page 1594: ...lock 3 B pillar upper trim See B PILLAR UPPER TRIM REMOVAL DETACHABLE HARDTOP B PILLAR UPPER TRIM INSTALLATION DETACHABLE HARDTOP 4 Male wedge cover 5 Top lock cover 6 Headliner See HEADLINER REMOVAL...

Page 1595: ...tachable hardtop 2 Remove the following parts 1 B pillar garnish 2 Side lock 3 B pillar upper trim See B PILLAR UPPER TRIM REMOVAL DETACHABLE HARDTOP 4 Male wedge cover 5 Top lock cover 3 Remove the f...

Page 1596: ...le panel See CONSOLE PANEL REMOVAL INSTALLATION 5 Foot rest 6 Quarter trim See QUARTER TRIM REMOVAL INSTALLATION 7 Scuff plate See SCUFF PLATE REMOVAL INSTALLATION 8 Front side trim See FRONT SIDE TRI...

Page 1597: ...urtesy of MAZDA MOTORS CORP 5 Remove the fasteners 6 Remove the floor covering 7 Install in the reverse order of removal NOTE The cut part needs to match up when installing the floor covering 2007 Maz...

Page 1598: ...ove the side shelf See SIDE SHELF REMOVAL INSTALLATION 3 Remove the stoppers 4 Remove the fasteners 5 Remove the rear floor covering 6 Install in the reverse order of removal 2007 Mazda MX 5 Miata Spo...

Page 1599: ...r Floor Covering Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Interior Trim MX 5 Miata Microsoft Thursday July 09 2009 3 29 27 PM Page 58 2005 Mitchell Repair In...

Page 1600: ...ta Sport 2007 ACCESSORIES BODY CAB Security and Locks Keyless Entry System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Security and Locks Keyless Entry System MX 5 Miata Microsoft...

Page 1601: ...ION INDEX KEYLESS ENTRY SYSTEM Fig 2 Identifying Hood Latch Courtesy of MAZDA MOTORS CORP IMMOBILIZER SYSTEM LOCATION INDEX KEYLESS ENTRY SYSTEM 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB S...

Page 1602: ...side trim Driver s side See FRONT SIDE TRIM REMOVAL INSTALLATION 4 Lower panel See LOWER PANEL REMOVAL INSTALLATION 5 Column cover See COLUMN COVER REMOVAL INSTALLATION 3 Disconnect the coil antenna...

Page 1603: ...s adding erasing keys or performing other functions refer to the following table and perform the applicable procedure No 1 to 5 IMMOBILIZER SYSTEM COMPONENT REPLACEMENT KEY ADDITION AND CLEARING PROCE...

Page 1604: ...er replacement the engine cannot be started The keys two or more keys readied before beginning the procedure do not have to be new keys Any key that is capable of starting the engine before beginning...

Page 1605: ...e steering lock the engine cannot be started Before beginning the procedure verify that the customer has turned in all of the keys for the vehicle Unless two or more keys are registered after replacem...

Page 1606: ...y affected resulting in the engine not starting or the key registration failure Do not perform the procedure if any of the following items are touching or near the key head Any metallic object Spare k...

Page 1607: ...can be used to verify the number of key ID numbers registered to a single vehicle Do not select screen menus of the M MDS that are not indicated within the procedures Fig 5 Caution For Key Registrati...

Page 1608: ...IONS Customer has only one valid key Or customer has no valid keys Can also be performed even if there are two or more valid keys To clear the key ID numbers refer to NO 3 KEY REPLACEMENT PROCEDURE CL...

Page 1609: ...the clearing the key ID numbers 2 Using key 1 turn the ignition switch to the ON position other keys the previously registered key ID numbers must first be cleared To clear the key ID numbers refer to...

Page 1610: ...TRATION METHOD NOTE This procedure is for changing the enable disable setting of the No 1 Additional Key Registration Procedure Using Two Valid Keys The default setting for new vehicles and new instru...

Page 1611: ...Using key 1 turn the ignition switch to the ON position x Procedure is possible Procedure is not possible CAUTION When replacing the PCM and the instrument cluster at the same time follow the same ins...

Page 1612: ...ng security access Program Additional Ignition Key Ignition key ID number Erase or Customer Spare Key Programming Enable Disable is displayed on the M MDS screen When performing Parameter Reset securi...

Page 1613: ...A MOTORS CORP 2 Insert a small screwdriver into the slot and gently pry open the transmitter Fig 10 Opening Transmitter Courtesy of MAZDA MOTORS CORP 3 Remove the battery 2007 Mazda MX 5 Miata Sport 2...

Page 1614: ...rogrammed At this time the same transmitter programmed transmitter can be programmed two or three times NOTE Always program three ID codes because all the ID codes programmed prior to activation are c...

Page 1615: ...VAL INSTALLATION 3 Remove the bolt and nut 4 While inclining the keyless control module along the body panel in the direction indicated by the arrow disengage the bracket tab from the hole in the body...

Page 1616: ...ECTION KEYLESS ENTRY SYSTEM 1 Measure the voltage or inspect for continuity according to the Terminal Voltage Table Reference NOTE The screw which fixes the keyless control module and bracket is for a...

Page 1617: ...D Under any condition Inspect for continuity to GND Continuity detected Related wiring harnesses 1C Door lock control Door lock actuator Door lock actuator locking 1 0 or less B 1 0 or less Door lock...

Page 1618: ...tion Inspect for continuity to keyless receiver Continuity detected Keyless receiver 3Z Trunk open signal Trunk compartment light switch Trunk lid open trunk compartment light switch on 1 0 or less Tr...

Page 1619: ...e UNLOCK button transmitter B 1 0 or less B 1 0 or less B Other B 4P Trunk open output Trunk opener relay Press the trunk open switch 1 0 or less Trunk opener relay Related wiring harnesses Other B 4Q...

Page 1620: ...Door closed LH Door switch off B 4U Horn on off Horn relay Transmitter LOCK button is pressed twice within 5 s B 1 0 or less B Horn relay Related wiring harnesses Other B 4V Hood switch signal Hood s...

Page 1621: ...ntinuity detected Keyless control module Related wiring harnesses E GND Body ground Under any condition Inspect for continuity to ground Continuity detected GND 2007 Mazda MX 5 Miata Sport 2007 ACCESS...

Page 1622: ...CCESSORIES BODY CAB Lighting Systems MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 2009 3 27 42 PM Page 1 2005 Mitchell Repair...

Page 1623: ...Location Of Lighting Systems Components 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 2009 3 27 42 PM Page 2 2005 Mitchell Repair Inform...

Page 1624: ...cket Because of the danger of electrical shock do not insert fingers or a tester When the headlights are on high voltage flows around the socket and bulb When turning on the discharge headlights while...

Page 1625: ...with a new one to prevent electrical shock and improper operation Although the control module may temporarily operate normally even though it has received an impact it is possible that the interior ma...

Page 1626: ...e between the right and left and that illumination is consistent FRONT COMBINATION LIGHT REMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INS...

Page 1627: ...6 Adjust the headlight aiming See HEADLIGHT AIMING HEADLIGHT AIMING 1 Point the headlight beams to a wall and verify that the headlight beams are as shown in Fig 5 2007 Mazda MX 5 Miata Sport 2007 ACC...

Page 1628: ...e pressure to the specification 4 Position the unloaded vehicle on a flat level surface 5 Seat one person in the driver s seat 6 Position the vehicle straight ahead and perpendicular to the white scre...

Page 1629: ...object in front of the headlight not being adjusted to block its light beam 9 Start the engine so that the battery remains charged 10 Turn on the low beam headlight 2007 Mazda MX 5 Miata Sport 2007 AC...

Page 1630: ...sy of MAZDA MOTORS CORP HEADLIGHT BULB REMOVAL INSTALLATION LOW BEAM Halogen Type 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the wa...

Page 1631: ...ulb generates extremely high heat when it is illuminated If the surface of the bulb is soiled excessive heat will build up and the life of the bulb will be shortened When replacing the bulb hold the m...

Page 1632: ...TALLATION 4 Remove the fasteners LH WARNING Incorrect servicing of the discharge headlights could result in electrical shock Before servicing the discharge headlights always refer to the discharge hea...

Page 1633: ...at when it is illuminated If the surface of the bulb is soiled excessive heat will build up and the life of the bulb will be shortened When replacing the bulb hold the metal flange not the glass Wipe...

Page 1634: ...Install in the reverse order of removal CAUTION A halogen bulb generates extremely high heat when it is illuminated If the surface of the bulb is soiled excessive heat will build up and the life of th...

Page 1635: ...5 Disconnect the connector 6 Remove the discharge headlight control module 7 Install in the reverse order of removal WARNING Incorrect servicing of the discharge headlights could result in electrical...

Page 1636: ...g of the discharge headlights could result in electrical shock Before servicing the discharge headlights always refer to the discharge headlight service warnings See DISCHARGE HEADLIGHT SERVICE WARNIN...

Page 1637: ...e voltage at discharge headlight control module terminal C wiring harness side Is the voltage approx 12 V Yes Go to Step 6 No Go to the next step 2 INSPECT FUSE Turn the headlight switch to the OFF po...

Page 1638: ...tween the following terminals Battery positive terminal and headlight relay main fuse block terminal A Headlight relay terminal 2C and HEAD LOW R 15 A fuse RH terminal U Headlight relay terminal 2C an...

Page 1639: ...UNCTION IS IN DISCHARGE HEADLIGHT BULB OR DISCHARGE HEADLIGHT CONTROL MODULE Install the discharge headlight low bulb previously verified as illuminating normally See HEADLIGHT BULB REMOVAL INSTALLATI...

Page 1640: ...t in the direction of the arrow 1 and detach the tab 4 Pull area A of the front side marker light in the defection of arrow 2 and remove the front side marker light 5 Detach the socket and remove the...

Page 1641: ...he battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the fasteners 4 Slightly bent back the mudguard 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY...

Page 1642: ...tor 6 Remove the socket then remove the front turn light bulb 7 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thur...

Page 1643: ...ttery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the fasteners 4 Slightly bent back the mudguard 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB L...

Page 1644: ...lt then remove the front fog light 7 Install in the reverse order of removal 8 Adjust the front fog light aiming See FRONT FOG LIGHT AIMING 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighti...

Page 1645: ...AIMING 1 Point the headlight beams to a wall and verify that the headlight beams are as shown in Fig 22 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thur...

Page 1646: ...ORS CORP 2 Make a headlight adjustment screen as shown in Fig 23 using double weight white paper 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday Ju...

Page 1647: ...Fog Light Hole Cover Courtesy of MAZDA MOTORS CORP 6 Seat one person in the driver s seat 7 Line up the headlights with the white screen at a distance of 3 m 9 8 ft apart 8 Place an object in front o...

Page 1648: ...ifying Bolt B Courtesy of MAZDA MOTORS CORP 12 Install the bolt A and tighten the bolt B FRONT FOG LIGHT BULB REMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable Se...

Page 1649: ...bulb generates extremely high heat when it is illuminated If the surface of the bulb is soiled excessive heat will build up and the life of the bulb will be shortened When handling the bulb hold the...

Page 1650: ...battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the trunk end trim See TRUNK END TRIM REMOVAL INSTALLATION 4 Remove the trunk side trim See TRUNK SIDE TRIM REMOVAL INSTALLATION 5 Remove in...

Page 1651: ...LE TOP 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the partition board See PARTITION BOARD REMOVAL INSTALLATION 4 Disconnect the hig...

Page 1652: ...1 Fully open the deck panel 2 Partially peel back the seal cover 3 Disconnect the high mount brake light connector 4 Remove the wiring harness and connector of the high mount brake light from the dec...

Page 1653: ...Courtesy of MAZDA MOTORS CORP 5 remove the nuts 6 Remove the high mount brake light 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 2009 3...

Page 1654: ...nse plate light in the direction of the arrow 1 and detach the tab 4 Pull area A of the license plate light in the direction of the arrow 2 and remove the license plate light 5 Disconnect the connecto...

Page 1655: ...VAL INSTALLATION LF 3 Loosen the starter installation bolts only enough that the starter is loose but not removed P66M D See STARTER REMOVAL INSTALLATION LF 4 Remove the transmission P66M D See TRANSM...

Page 1656: ...ch With Torque Specifications Courtesy of MAZDA MOTORS CORP 6 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursd...

Page 1657: ...rminals using an ohmmeter If there is any malfunction replace the back up light switch Fig 35 Back Up Light Switch Continuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCES...

Page 1658: ...rse order of removal 8 Perform the steering angle sensor initialization procedure Vehicles with DSC See STEERING ANGLE SENSOR INITIALIZATION PROCEDURE 9 If the steering angle sensor combination switch...

Page 1659: ...eformed or has foreign material adhering to it performance of the steering angle sensor may be reduced causing abnormal operation When handling the combination switch be careful not to deform the disc...

Page 1660: ...y cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the column cover See COLUMN COVER REMOVAL INSTALLATION 4 Disconnect the connector 5 Remove the screws and then remove the light switch 6 Install in...

Page 1661: ...y between the light switch terminals is as indicated in Fig 40 If not as indicated in Fig 40 replace the light switch Headlight Switch 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Sy...

Page 1662: ...Continuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 2009 3 27 42 PM Page 41 2005 Mitchell Repair...

Page 1663: ...nnector Terminals Courtesy of MAZDA MOTORS CORP Turn Switch 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 2009 3 27 42 PM Page 42 2005 Mi...

Page 1664: ...tinuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 2009 3 27 42 PM Page 43 2005 Mitchell Repair In...

Page 1665: ...that the continuity between the front fog light switch terminals is as indicated in Fig 44 If not as indicated in Fig 44 replace the light switch 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB...

Page 1666: ...Front Fog Light Switch Connector Terminals Courtesy of MAZDA MOTORS CORP HAZARD WARNING SWITCH REMOVAL INSTALLATION 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata M...

Page 1667: ...DECORATION PANEL REMOVAL INSTALLATION 7 Remove in the order indicated in Fig 46 Fig 46 Identifying Hazard Warning Switch Courtesy of MAZDA MOTORS CORP 8 Install in the reverse order of removal HAZARD...

Page 1668: ...ORP Fig 48 Identifying Hazard Warning Switch Connector Terminals Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July...

Page 1669: ...Disconnect the connector 4 Remove the screw and then remove the flasher control module 5 Install in the reverse order of removal Fig 49 Identifying Flasher Control Module 2007 Mazda MX 5 Miata Sport 2...

Page 1670: ...l module connector 4 Verify that continuity at terminal F is as indicated in TERMINAL VOLTAGE TABLE If there is any malfunction inspect the parts under Inspection item s If the system does not work pr...

Page 1671: ...item s A Power supply HAZARD 10 A fuse Under any condition B HAZARD 10 A fuse Related wiring harnesses D Flasher control Turn light Turn light switch LH is on Turn light LH Alternates between 1 0 or...

Page 1672: ...harnesses Hazard warning switch is on Except above 1 0 or less H Hazard warning switch input Hazard warning switch Hazard warning switch is on 1 0 or less Hazard warning switch See HAZARD WARNING SWI...

Page 1673: ...e Courtesy of MAZDA MOTORS CORP DRL SYSTEM WIRING DIAGRAM 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 2009 3 27 42 PM Page 52 2005 Mitc...

Page 1674: ...l module connector 4 If the value are not as specified in TERMINAL VOLTAGE TABLE REFERENCE inspect the parts under Inspection item s and related wiring harnesses 5 If the system does not work properly...

Page 1675: ...ty Parking brake switch See PARKING BRAKE SWITCH INSPECTION Related wiring harness Parking brake lever released Check for continuity to ground No 1I IG1 Ignition switch Turn the ignition switch to the...

Page 1676: ...Front fog light relay See RELAY INSPECTION Related wiring harness Front fog light switch is off B 2A Headlight RH operation high beam Headlight high beam Light switch at 2nd position Dimmer switch at...

Page 1677: ...onnect the connector 7 Install in the reverse order of removal MAP LIGHT REMOVAL NOTE 1 Insert a tape wrapped flathead screwdriver into the gap between the headliner and the map light 2 Press the tab...

Page 1678: ...fy that the continuity between the map light terminals is as indicated in Fig 56 If not as indicated in Fig 56 replace the map light Fig 56 Map Light Continuity Table 2007 Mazda MX 5 Miata Sport 2007...

Page 1679: ...or Terminals Courtesy of MAZDA MOTORS CORP TRUNK COMPARTMENT LIGHT REMOVAL INSTALLATION 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 200...

Page 1680: ...f removal Fig 58 Removing Trunk Compartment Light Bulb Courtesy of MAZDA MOTORS CORP TRUNK COMPARTMENT LIGHT INSPECTION 1 Verify that the continuity between the trunk compartment light terminals is as...

Page 1681: ...MAZDA MOTORS CORP IGNITION KEY ILLUMINATION BULB REMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 2007 Mazda MX 5 Miata Spor...

Page 1682: ...Bulb Courtesy of MAZDA MOTORS CORP DOOR SWITCH REMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Disassemble in the order in...

Page 1683: ...ITCH REMOVAL INSTALLATION 2 Verify that the continuity between door switch terminal and the body ground is as indicated in Fig 63 If not as indicated in Fig 63 replace the door switch 2007 Mazda MX 5...

Page 1684: ...ORP Fig 64 Identifying Door Switch Connector Terminals Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Lighting Systems MX 5 Miata Microsoft Thursday July 09 2009 3...

Page 1685: ...min before continuing 4 Remove the dipstick and verify that the oil level is between the F and L marks on the dipstick If the oil level is below the L mark add engine oil 2007 Mazda MX 5 Miata Sport 2...

Page 1686: ...y stands is dangerous It can slip or fall causing death or serious injury Never work around or under a lifted vehicle if it is not securely supported on safety stands Continuous exposure to USED engin...

Page 1687: ...4 28 US qt 3 56 Imp qt NOTE The amount of residual oil in the engine can vary according to factors such as the replacement method and oil temperature Verify the oil level after engine oil replacement...

Page 1688: ...stall the oil filler cap 8 Start the engine and confirm that there is no oil leakage If there is oil leakage repair or replace the applicable part 9 Inspect the oil level See ENGINE OIL LEVEL INSPECTI...

Page 1689: ...f necessary Fig 3 Screwing SST Into Oil Pressure Switch Installation Hole Courtesy of MAZDA MOTORS CORP Oil pressure reference value oil temperature 100 C 212 F 337 591 kPa 3 44 6 03 kgf cm2 49 0 85 8...

Page 1690: ...N LF 14 Install the battery cover 15 Start the engine and confirm that there is no oil leakage If there is oil leakage repair or replace the applicable part Fig 4 Applying Silicone Sealant To Oil Pres...

Page 1691: ...t until it and the engine oil have cooled A vehicle that is lifted but not securely supported on safety stands is dangerous It can slip or fall causing death or serious injury Never work around or und...

Page 1692: ...ve belt See DRIVE BELT REPLACEMENT WARNING Hot engine and engine oil can cause severe burns Turn off the engine and wait until it and the engine oil have cooled A vehicle that is lifted but not secure...

Page 1693: ...member See TRANSVERSE MEMBER REMOVAL INSTALLATION 12 Remove the member bracket MT See TRANSMISSION REMOVAL INSTALLATION M15M D See TRANSMISSION REMOVAL INSTALLATION P66M D 13 Remove in the order indi...

Page 1694: ...ce hole cover See EGR VALVE REMOVAL INSTALLATION LF 5 Remove the front tires 6 Support the engine using the SST Fig 7 Supporting Engine Using SST Courtesy of MAZDA MOTORS CORP 7 Remove the engine moun...

Page 1695: ...ORP 8 Lift up the engine approx 25 mm 0 98 in using the SST 9 Remove the oil pan installation bolts 10 Remove the oil pan using the separator tool 2007 Mazda MX 5 Miata Sport 2007 ENGINE Lubrication L...

Page 1696: ...housing and oil pan 2 When reusing the oil pan installation bolts clean any old sealant from the bolts CAUTION Apply the silicon sealant in a single unbroken line around the whole perimeter Using bol...

Page 1697: ...RP 3 Use a square ruler to align the oil pan and the cylinder block junction side on the engine front cover side 2007 Mazda MX 5 Miata Sport 2007 ENGINE Lubrication LF MX 5 Miata Microsoft Thursday Ju...

Page 1698: ...MAZDA MOTORS CORP 4 Apply silicone sealant to the oil pan along the inside of the bolt holes as shown in Fig 12 Thickness 2 2 3 2 mm 0 087 0 126 in 2007 Mazda MX 5 Miata Sport 2007 ENGINE Lubrication...

Page 1699: ...P 5 Tighten the bolts in the order shown in Fig 13 Tightening torque 17 23 N m 1 8 2 3 kgf m 12 6 16 9 ft lbf 2007 Mazda MX 5 Miata Sport 2007 ENGINE Lubrication LF MX 5 Miata Microsoft Thursday July...

Page 1700: ...RS CORP 6 Tighten the oil pan transmission installation bolts Tightening torque 37 52 N m 3 8 5 3 kgf m 28 38 ft lbf 2007 Mazda MX 5 Miata Sport 2007 ENGINE Lubrication LF MX 5 Miata Microsoft Thursda...

Page 1701: ...AR REMOVAL INSTALLATION WARNING Hot engine and engine oil can cause severe burns Turn off the engine and wait until it and the engine oil have cooled A vehicle that is lifted but not securely supporte...

Page 1702: ...See TRANSMISSION REMOVAL INSTALLATION P66M D 13 Remove the oil pan See OIL PAN REMOVAL INSTALLATION LF 14 Remove in the order indicated in Fig 15 15 Install in the reverse order of removal 16 Refill...

Page 1703: ...install the oil pump sprocket and then remove the crankshaft pulley lock bolt Tightening torque 20 30 N m 2 1 3 0 kgf m 14 8 22 1 ft lbf OIL PUMP INSTALLATION NOTE 1 Tighten the oil pump bolts in two...

Page 1704: ...nd the engine oil have cooled A vehicle that is lifted but not securely supported on safety stands is dangerous It can slip or fall causing death or serious injury Never work around or under a lifted...

Page 1705: ...e on the oil filter adapter and the oil cooler 10 Install in the reverse order of the removal 11 Refill the engine coolant See ENGINE COOLANT REPLACEMENT LF 12 Start the engine and confirm that there...

Page 1706: ...TION OIL COOLER REMOVAL NOTE 1 Water hose 2 Oil pressure switch connector 3 Oil cooler and oil filter adapter component 4 Oil cooler 2007 Mazda MX 5 Miata Sport 2007 ENGINE Lubrication LF MX 5 Miata M...

Page 1707: ...r component in a vise 2 Loosen the oil cooler fitting bolt 3 Remove the oil cooler 2007 Mazda MX 5 Miata Sport 2007 ENGINE Lubrication LF MX 5 Miata Microsoft Thursday July 09 2009 3 04 27 PM Page 23...

Page 1708: ...of the parking brake lever with a force of 98 N 10 kgf 22 lbf and counting the number of notches clicking sound If not within the specification adjust the parking brake lever Parking brake lever strok...

Page 1709: ...n the adjusting nut and adjust the parking brake lever 4 After adjustment pull the parking brake lever one notch and verify that the parking brake warning light illuminates 5 Verify that the rear brak...

Page 1710: ...PROPELLER SHAFT REMOVAL INSTALLATION 3 Remove the console See CONSOLE REMOVAL INSTALLATION 4 Remove in the order indicated in the table 5 Install in the reverse order of removal 6 After installation...

Page 1711: ...KING BRAKE LEVER REMOVAL NOTE 1 Partially peel back the floor mat and remove the bolt shown in Fig 5 2 Remove the two bolts 3 Remove the parking brake lever 2007 Mazda MX 5 Miata Sport 2007 BRAKES Par...

Page 1712: ...brake switch connector 2 Verify that the continuity is as indicated in Fig 6 If not as indicated in Fig 6 replace the parking brake switch 2007 Mazda MX 5 Miata Sport 2007 BRAKES Parking Brake System...

Page 1713: ...h Continuity Reference Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 BRAKES Parking Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 20 34 PM Page 6 2005 Mitchell Repai...

Page 1714: ...ng Brake Switch Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 BRAKES Parking Brake System MX 5 Miata Microsoft Thursday July 09 2009 3 20 34 PM Page 7 2005 Mitchell Repair I...

Page 1715: ...retractable hardtop stops while operating Power retractable hardtop stops while power retractable hardtop is opening closing 1 Power retractable hardtop warning buzzer sounds continuously DESCRIPTION...

Page 1716: ...perform the appropriate troubleshooting procedure Then go to the next step No Go to the next step 2 VERIFY THAT POWER RETRACTABLE HARDTOP INDICATOR LIGHT ILLUMINATES Turn the ignition switch to ON po...

Page 1717: ...STRUMENT CLUSTER BUZZER OR POWER RETRACTABLE HARDTOP CONTROL MODULE Perform the INSTRUMENT CLUSTER INPUT OUTPUT CHECK MODE See INSTRUMENT CLUSTER INPUT OUTPUT CHECK MODE Does the buzzer sound with che...

Page 1718: ...lock switch and the power retractable hardtop control module Power retractable hardtop control module cannot control thepower retractable hardtop indicator light operation Power retractable hardtop c...

Page 1719: ...power retractable hardtop control module terminal 2C and ground Is there continuity Yes Replace for a short to the ground circuit No Go to the next step 5 INSPECT TO SEE WHETHER MALFUNCTION IS IN POWE...

Page 1720: ...ion switch malfunction Deck panel open position switch improper installation Open or short circuit in the wiring harness Deck panel close position switch signal malfunction Deck panel close position s...

Page 1721: ...e power retractable hardtop open switch Top lock is locked with the power retractable hardtop fully closed Power retractable hardtop the fully open STEP INSPECTION ACTION 1 INSPECT TO SEE WHETHER MALF...

Page 1722: ...e hardtop switch component side connector terminals A and F without the power retractable hardtop close switch pressed Is the resistance 2 18 2 22 kohms Yes Replace the power retractable hardtop switc...

Page 1723: ...released See DTC INSPECTION POWER RETRACTABLE HARDTOP Is the monitor value OFF Yes Go to step 8 No Go to the next step 7 INSPECT TOP LOCK SWITCH Inspect the top lock switch See TOP LOCK SWITCH INSPECT...

Page 1724: ...Remove the power retractable hardtop switch Measure the resistance between power retractable hardtop switch connector component side terminal A and F while the power retractable hardtop open switch is...

Page 1725: ...open position switch malfunction Deck panel open position switch improper installation Open or short circuit in the wiring harness Deck panel close position switch signal improper Deck panel close pos...

Page 1726: ...TION PERMISSION CONDITION SIGNAL OR ELSEWHERE Connect the M MDS to the DLC 2 Monitor the following PIDs See PCM INSPECTION LF See PID DATA MONITOR INSPECTION SJ6A EL See POWER RETRACTABLE HARDTOP CONT...

Page 1727: ...rdtop control module terminal 1H and power retractable hardtop switch terminal F at wiring harness side connectors 4 VERIFY THAT POWER RETRACTABLE HARDTOP INDICATOR LIGHT ILLUMINATES Turn the ignition...

Page 1728: ...LOSE SWITCH SIGNAL OR ELSEWHERE Monitor the power retractable hardtop control module PID SW_CL using the M MDS while the power retractable hardtop close switch is pressed Is the monitor value ON Yes G...

Page 1729: ...lfunction Deck panel link mechanics malfunction excessive restriction or hesitation Deck panel position cannot be detected Deck panel open position switch malfunction Deck panel close position switch...

Page 1730: ...e power retractable hardtop control module Foreign material caught in mechanism Power retractable hardtop switch signal is interrupted while the power retractable hardtop is operating Power retractabl...

Page 1731: ...sing the M MDS at the position where the deck panel does not operate Is the monitor value ON deck panel fully open Yes Go to the next step No Go to step 10 5 INSPECT DECK PANEL OPEN POSITION SWITCH In...

Page 1732: ...SWITCH REMOVAL INSTALLATION 9 INSPECT DECK PANEL CLOSE POSITION SWITCH WIRING HARNESS Turn the ignition switch to the LOCK position Disconnect the power retractable hardtop control module 16 pin and...

Page 1733: ...dtop control module terminal 1O deck panel motor left terminal F Is there an open or short circuit or a poor connection No Go to the next step 11 INSPECT DECK PANEL MOTOR Inspect the deck panel motors...

Page 1734: ...Stops during the roof open operation Go to the next step Stops during the roof close operation Go to step 18 No Go to step 25 15 INSPECT TO SEE WHETHER MALFUNCTION IS IN POWER RETRACTABLE HARDTOP OPE...

Page 1735: ...tor the power retractable hardtop control module PID RHT_CL using the M MDS at the position where the roof could not operate See POWER RETRACTABLE HARDTOP CONTROL MODULE REMOVAL INSTALLATION Is the mo...

Page 1736: ...rcuit and poor connection at the following terminals Power retractable hardtop control module terminal 3I roof motor right terminal A Power retractable hardtop control module terminal 3A roof motor ri...

Page 1737: ...STALLATION 24 INSPECT POWER RETRACTABLE HARDTOP LINK MECHANICS Inspect the roof link mechanics Does the roof operation stop during open or close operation Yes Repair or replace the malfunctioning part...

Page 1738: ...le hardtop control module terminal 1H and the power retractable hardtop switch terminal F Is there any open or short circuit or poor connection Yes Repair or replace the malfunctioning part No Replace...

Page 1739: ...RP AIR BLEEDING 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday July 09 2009 2 11 38 PM Page...

Page 1740: ...g fluid level Add fluid to the specified level as necessary Power steering fluid type ATF M III or equivalent e g Dexron RII Power steering fluid capacity approximate quantity 1 19 L 1 25 US qt 1 04 I...

Page 1741: ...NSPECTION 1 Assemble the SSTs as shown in Fig 3 NOTE The points where fluid leakage may occur are indicated in the figure 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft...

Page 1742: ...re pipe from the oil pump and connect the SSTs Tightening torque 29 4 44 1 N m 3 00 4 49 kgf m 21 7 32 5 ft lbf 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday J...

Page 1743: ...500 rpm and measure the fluid pressure generated by the oil pump If the pressure is not within the specification repair or replace the oil pump component Oil pump fluid pressure 7 55 8 05 MPa 77 0 82...

Page 1744: ...is not within the specification repair or replace the steering gear component Gear housing fluid pressure 7 55 8 05 MPa 77 0 82 0 kgf cm2 1095 1167 psi CAUTION If the steering wheel is kept in the fu...

Page 1745: ...he wheels in the straight ahead position gently turn the steering wheel to the left and right and verify that the play is within the specification If the play exceeds the specification either the stee...

Page 1746: ...ire size and tire pressure Fluid level Drive belt deflection 2 With the vehicle on a hard level surface put the wheels in the straight ahead position 3 Remove the air bag module WARNING Handling the a...

Page 1747: ...8 in lbf max Fig 8 Measuring Steering Wheel Effort Using Torque Wrench Courtesy of MAZDA MOTORS CORP bag module See AIR BAG SYSTEM SERVICE WARNINGS See AIR BAG SYSTEM SERVICE CAUTIONS NOTE To determin...

Page 1748: ...oves smoothly from unlock position to lock position 2 Verify that the steering shaft is fixed firmly when the adjusting lever is locked Replace the steering shaft component as necessary The steering w...

Page 1749: ...LOCK UNIT ID CODE REGISTRATION ADVANCED KEYLESS SYSTEM With immobilizer system Immobilizer system resetting See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT KEY ADDITION AND CLEARING ADVANCED KEYLESS WARN...

Page 1750: ...S CORP STEERING WHEEL REMOVAL NOTE CAUTION Do not try to remove the steering wheel by hitting the shaft with a hammer The column will collapse 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering...

Page 1751: ...eering lock component Fig 12 Removing Bolts Using Screwdriver Courtesy of MAZDA MOTORS CORP STEERING LOCK MOUNTING BOLTS INSTALLATION NOTE 1 Assemble the steering lock component to the steering shaft...

Page 1752: ...NOTE 1 Lock the tilt lever 2 Tighten nut A 3 Tighten nut B 4 Tighten bolt C CAUTION Do not apply a shock in the axial direction of the shaft 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX...

Page 1753: ...st removing the ABS wheel speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake Before performing the following procedures remove the ABS wheel speed sensor axle si...

Page 1754: ...l 5 After installation adjust the total toe in See FRONT WHEEL ALIGNMENT Fig 15 Removing Installing Steering Gear Linkage With Torque Specifications Courtesy of MAZDA MOTORS CORP BOLT INTERMEDIATE SHA...

Page 1755: ...D END BALL JOINT REMOVAL NOTE 1 Remove the tie rod nut 2 Separate the tie rod end from the steering knuckle using the SSTs 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft...

Page 1756: ...d linkage by pulling it from the right side STEERING GEAR AND LINKAGE INSTALLATION NOTE 1 Tighten bolts loosely 2 Assemble the mounting bracket with the mark on the bracket facing the vehicle rear 200...

Page 1757: ...cket bolts to the specified torque in the order shown Tightening torque 74 4 104 8 N m 7 587 10 68 kgf m 54 88 77 29 ft lbf 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsof...

Page 1758: ...lt STEERING GEAR AND LINKAGE DISASSEMBLY 1 Disassemble in the order indicated in Fig 20 CAUTION Place copper plates rag or similar material in a vise when securing the mounting bracket portion of the...

Page 1759: ...y of MAZDA MOTORS CORP TIE ROD DISASSEMBLY NOTE 1 Unclamp the washer 2 Remove the tie rod 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday July 09 2009 2 11 38 PM...

Page 1760: ...HAFT COMPONENT DISASSEMBLY NOTE 1 Remove the clip and the dust cover then remove the pinion plug using the SST 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday Ju...

Page 1761: ...y of MAZDA MOTORS CORP 2 Remove the pinion shaft component from the gear housing 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday July 09 2009 2 11 38 PM Page 23...

Page 1762: ...DA MOTORS CORP HOLDER DISASSEMBLY NOTE 1 Remove the crimp from the holder and cylinder ends using a hacksaw 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday July...

Page 1763: ...ds Using Hacksaw Courtesy of MAZDA MOTORS CORP 2 Remove the holder using the SST 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday July 09 2009 2 11 38 PM Page 25...

Page 1764: ...tall the SST to the gear housing 2 Remove the steering rack and oil seal holder side using a press 3 Remove the oil seal holder side from the steering rack 2007 Mazda MX 5 Miata Sport 2007 STEERING Po...

Page 1765: ...IDE DISASSEMBLY NOTE 1 Set the SSTs as shown 2 Install the SST to the gear housing 3 Remove the oil seal gear housing side and inner guide using a press 2007 Mazda MX 5 Miata Sport 2007 STEERING Power...

Page 1766: ...MOUNTING RUBBER DISASSEMBLY NOTE Press the mounting rubber out from the gear housing using the SSTs and a press 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday...

Page 1767: ...h wear Replace it if necessary 2 Measure the runout of the rack Steering rack runout Near point A 0 08 mm 0 003 in max Near point B 0 15 mm 0 006 in max 3 If not within the specification replace the r...

Page 1768: ...ll joint five times 4 Measure the rotation torque of the ball joint using the SST and a pull scale Tie rod end rotational torque 0 4 3 0 N m 3 5 30 5 kgf cm 3 1 26 5 in lbf Pull scale reading 3 5 29 9...

Page 1769: ...necessary 3 Swing the tie rod five times 4 Measure the swinging torque using a pull scale Tie rod swing torque 0 1 4 1 N m 1 1 41 8 kgf cm 1 0 36 2 in lbf Pull scale reading 0 6 24 4 N 0 06 2 49 kgf 0...

Page 1770: ...order indicated in Fig 32 CAUTION Place copper plates rag or similar material in a vise when securing the mounting bracket portion of the steering gear 2007 Mazda MX 5 Miata Sport 2007 STEERING Power...

Page 1771: ...MOUNTING RUBBER ASSEMBLY NOTE 1 Install the mounting rubber so that two notches of mounting rubber are aligned to the steering rack 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata...

Page 1772: ...of MAZDA MOTORS CORP 3 Press the mounting rubber until the mounting rubber end comes out completely from the gear housing using the SSTs and a press 2007 Mazda MX 5 Miata Sport 2007 STEERING Power St...

Page 1773: ...ting rubber until the mounting rubber end comes out completely from the other side At this time the mounting rubber end and steel pipe are aligned 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steer...

Page 1774: ...eeth so as not to damage the oil seal gear housing side and the inner guide and install the oil seal gear housing side and the inner guide to the seal Move the oil seal gear housing side and the inner...

Page 1775: ...Teeth Courtesy of MAZDA MOTORS CORP 3 Put the steering rack into the gear housing 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday July 09 2009 2 11 38 PM Page 3...

Page 1776: ...e plastic bag to the steering rack end so as not to damage the oil seal holder side and install the oil seal holder side to the seal Move the oil seal holder side together with the plastic bag so that...

Page 1777: ...RP 4 Tighten the holder to the specified torque using the SST Tightening torque 58 9 73 5 N m 6 00 7 49 kgf m 43 4 54 2 ft lbf 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Micro...

Page 1778: ...tening the holder crimp the cylinder end as shown in Fig 40 using a flathead screwdriver so that the holder does not loosen 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsof...

Page 1779: ...ON PLUG ASSEMBLY NOTE 1 Tighten the pinion plug using the SST Tightening torque 39 2 44 1 N m 4 00 4 49 kgf m 29 0 32 5 ft lbf 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Micro...

Page 1780: ...the pinion shaft thoroughly three times to make sure that the pinion shaft and the rack engage smoothly then loosen the adjusting cover 4 Retighten the adjusting cover to 4 9 N m 0 5 kgf m 3 6 ft lbf...

Page 1781: ...enter of rack 90 0 98 1 38 N m 10 0 14 0 kgf cm 8 7 12 2 in lbf Pull scale reading 9 8 13 8 N 1 00 1 40 kgf 2 21 3 10 lbf Except center of rack 90 Less than 1 87 N m 19 1 kgf cm 16 6 in lbf Pull scale...

Page 1782: ...adjusting cover so as not to rotate and tighten the locknut Tightening torque 40 0 58 0 N m 4 08 5 91 kgf m 29 5 42 7 ft lbf 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Micros...

Page 1783: ...gear housing 2 Apply 53 3 kPa 400 mmHg 15 7 inHg vacuum with a vacuum pump and verify that it is held for at least 30 seconds 3 If the vacuum is not held replace the oil seal 2007 Mazda MX 5 Miata Sp...

Page 1784: ...ION 1 Remove the drive belt See DRIVE BELT REPLACEMENT LF 2 Remove in the order indicated in Fig 46 3 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering M...

Page 1785: ...order indicated in Fig 47 2 Assemble in the reverse order of disassembly NOTE The following procedure is for replacement of the O ring and oil seal only Replace the pump component if other repairs are...

Page 1786: ...PUMP COMPONENT DISASSEMBLY NOTE 1 Secure the power pressure oil pump using the SST CAUTION Use the SST to prevent damage to the pump when securing it in a vise 2007 Mazda MX 5 Miata Sport 2007 STEERIN...

Page 1787: ...S CORP OIL SEAL ASSEMBLY NOTE 1 Install the oil seal in the front pump body using the SST and plastic hammer 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday July...

Page 1788: ...MAZDA MOTORS CORP VANE ASSEMBLY NOTE 1 Place the vanes in the rotor with the rounded edges contacting the cam 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday Ju...

Page 1789: ...AZDA MOTORS CORP CAM RING ASSEMBLY NOTE 1 Install the cam ring in the front pump body with the mark facing upward 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thursday...

Page 1790: ...PUMP BODY ASSEMBLY NOTE 1 After installing the rear body manually turn the shaft to verify that it rotates smoothly 2007 Mazda MX 5 Miata Sport 2007 STEERING Power Steering MX 5 Miata Microsoft Thurs...

Page 1791: ...e to drive Perform the steering angle sensor initialization procedure after connecting the room fuse See STEERING ANGLE SENSOR INITIALIZATION PROCEDURE CAUTION Determine and correct the cause of the b...

Page 1792: ...al Fig 2 Removing Installing Upper Block With Torque Specifications Courtesy of MAZDA MOTORS CORP UPPER BLOCK REMOVAL NOTE 1 Press and remove the tabs on upper block at the positions indicated by the...

Page 1793: ...gative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the upper block See UPPER BLOCK REMOVAL INSTALLATION 4 Remove in the order indicated in Fig 4 2007 Mazda MX 5 Miata Sport 2007 ACCESSO...

Page 1794: ...ove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the column cover See COLUMN COVER REMOVAL INSTALLATION 4 Remove in the order indicated in Fig...

Page 1795: ...SPECTION 1 Verify that the continuity between the ignition switch terminals is as indicated in Fig 6 If not as indicated in Fig 6 replace the ignition switch 2007 Mazda MX 5 Miata Sport 2007 ACCESSORI...

Page 1796: ...7 Inspecting Ignition Switch Courtesy of MAZDA MOTORS CORP KEY REMINDER SWITCH REMOVAL INSTALLATION EXCEPT ADVANCED 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Power Systems MX 5 Miata Micr...

Page 1797: ...order of removal Fig 8 Removing Installing Key Reminder Switch Courtesy of MAZDA MOTORS CORP KEY REMINDER SWITCH INSPECTION EXCEPT ADVANCED KEYLESS SYSTEM 1 Verify that the continuity between the key...

Page 1798: ...STEERING LOCK UNIT INSPECTION ADVANCED KEYLESS SYSTEM 1 Remove the column cover See COLUMN COVER REMOVAL INSTALLATION 2 Measure the voltage at each terminal other than terminals G and H 2007 Mazda MX...

Page 1799: ...g 11 Inspecting Steering Lock Unit Connector Courtesy of MAZDA MOTORS CORP TERMINAL VOLTAGE TABLE Terminal Signal name Connected to Measured condition Voltage V Continuity Inspection item s A Push swi...

Page 1800: ...ated wiring harnesses 30s or more after driver side door closed B G Serial communication Keyless control module Under any condition Inspect for continuity to keyless control module Continuity detected...

Page 1801: ...ery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the trunk end trim See TRUNK END TRIM REMOVAL INSTALLATION 4 Remove the trunk lid opener relay 5 Install in the reverse order of removal 2007 Maz...

Page 1802: ...name Type A Main relay Starter relay Drive by wire relay Blower relay Fuel pump relay Front fog light relay A C relay TNS relay Rear window defroster relay Horn relay 2007 Mazda MX 5 Miata Sport 2007...

Page 1803: ...e Courtesy of MAZDA MOTORS CORP Cooling fan relay No 1 Cooling fan relay No 2 Cooling fan relay No 3 Trunk lid opener relay Type B Headlight relay Ignition relay 2007 Mazda MX 5 Miata Sport 2007 ACCES...

Page 1804: ...he relay terminals If not as indicated in Fig 16 replace the relay Fig 16 Type B Continuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Power Systems MX 5...

Page 1805: ...uit Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Power Systems MX 5 Miata Microsoft Thursday July 09 2009 3 28 36 PM Page 15 2005 Mitchell Repair Infor...

Page 1806: ...urtesy of MAZDA MOTORS CORP POWER RETRACTABLE HARDTOP MODEL WITHOUT EXTERIOR OPEN FUNCTION 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Symptom Troubleshooting Power Window System MX 5 Miata...

Page 1807: ...hout Exterior Open Function Courtesy of MAZDA MOTORS CORP SOFT TOP MODEL 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Symptom Troubleshooting Power Window System MX 5 Miata Microsoft Thursday...

Page 1808: ...A MOTORS CORP FOREWORD POWER WINDOW SYSTEM TROUBLESHOOTING PROCEDURE 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Symptom Troubleshooting Power Window System MX 5 Miata Microsoft Thursday Jul...

Page 1809: ...ction to discover whether poor contact points are the cause of any intermittent malfunctions POWER WINDOW SYSTEM TROUBLESHOOTING QUESTIONNAIRE POWER WINDOW SYSTEM 2007 Mazda MX 5 Miata Sport 2007 ACCE...

Page 1810: ...OUBLESHOOTING CHART POWER WINDOW SYSTEM SYMPTOM TROUBLESHOOTING CHART POWER WINDOW SYSTEM No Malfunction symptom 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Symptom Troubleshooting Power Win...

Page 1811: ...window operate properly Yes Go to the next step No Inspect the following items Power window main switch power supply fuse Power window main switch ground wiring harness Power window main switch power...

Page 1812: ...iver side and passenger side power window using the auto open function on the driver side and passenger side power window main switch Do each power window operate properly Yes Go to the next step No G...

Page 1813: ...ext step Automatic open function does not operate one side Go to step 4 2 Turn the ignition switch to ON position Measure the voltage between power window main switch following terminal and ground Ter...

Page 1814: ...out pins corrosion etc Is there any malfunction Yes Go to the next step No Repair or replace malfunctioning part 6 Inspect for open or short circuit in wiring harness between suspected side power win...

Page 1815: ...N SWITCH REMOVAL INSTALLATION No Replace the power window motor See POWER WINDOW REGULATOR REMOVAL INSTALLATION 2 The driver s side power window is inoperative POSSIBLE CAUSE Power supply circuit or g...

Page 1816: ...ain switch terminal 1G power retractable hardtop model terminal J soft top model ground Repair or replace if necessary 3 Is the P WIND 20 A fuse normal Yes Go to step 5 power retractable hardtop model...

Page 1817: ...main switch See POWER WINDOW MAIN SWITCH REMOVAL INSTALLATION 7 Measure the voltage at the power window motor battery power supply terminal while operating the power window using the power window main...

Page 1818: ...ower window is inoperative POSSIBLE CAUSE Power supply circuit malfunction Open or short circuit in wiring harness between power window main switch and passenger s side power window motor Power window...

Page 1819: ...or replace as necessary 4 Operate the passenger s side power window using the power window main switch Does the power window motor operate rotate CAUTION If the power window motor temperature is high...

Page 1820: ...de power window using the power window main switch Does any power window operate Yes Go to step 5 No Go to the next step 2 Operate the driver s side power window using the power window main switch Doe...

Page 1821: ...to the motor internal bimetal function Leave it untouched for about 3 min to cool it down then reinspect Yes Go to the next step No Replace the power window motor See POWER WINDOW REGULATOR REMOVAL I...

Page 1822: ...er window main switch See POWER WINDOW MAIN SWITCH REMOVAL INSTALLATION 5 Abnormal noise while the door glass is opening or closing POSSIBLE CAUSE Installation screw is loose between the door glass an...

Page 1823: ...regulator resin part Power window regulator Replace the power window regulator See POWER WINDOW REGULATOR REMOVAL INSTALLATION Whining noise Gear inside power window motor is deformed due to use Gear...

Page 1824: ...INSTALLATION LF 2 Remove in the order indicated in the table 3 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Propeller Shaft MX 5 Miata 2007 Mazda MX 5 Miat...

Page 1825: ...make alignment marks on the yoke and differential companion flange CAUTION When replacing with a new propeller shaft mark the companion flange to match the position of the tag on the propeller shaft 2...

Page 1826: ...sy of MAZDA MOTORS CORP 2 Install the SST to the extension housing 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Propeller Shaft MX 5 Miata Microsoft Thursday July 09 2009 3 14 12 PM Page 3 2005 Mi...

Page 1827: ...d assemble Fig 5 Identifying Differential Companion Flange Mark And Tag Courtesy of MAZDA MOTORS CORP PROPELLER SHAFT INSPECTION 1 Use a dial gauge to measure the runout of the propeller shaft at each...

Page 1828: ...the direction shown by the arrow Initial torque Reference value 0 29 0 98 N m 3 0 10 kgf cm 2 7 8 6 in lbf If there is excessive play or initial torque replace the propeller shaft 2007 Mazda MX 5 Miat...

Page 1829: ...By Turning Universal Joint In Direction Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Propeller Shaft MX 5 Miata Microsoft Thursday July 09 2009 3 14 12 PM Page 6 2005...

Page 1830: ...l bearing for axial looseness If it exceeds the maximum specification replace the wheel hub component Maximum rear wheel bearing play 0 05 mm 0 002 in 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES...

Page 1831: ...orming the following procedures without first removing the ABS wheel speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake Before performing the following pr...

Page 1832: ...OTE 1 Lock the disc plate by applying the brakes 2 Knock the crimped portion of the locknut outward using a chisel and a hammer 3 Remove the locknut 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Re...

Page 1833: ...MAZDA MOTORS CORP BRAKE CALIPER COMPONENT REMOVAL NOTE 1 Suspend the brake caliper component using a cable or equivalent 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft...

Page 1834: ...onto the end of the rear drive shaft 2 Tap the nut with a copper hammer to loosen the drive shaft from the wheel hub 3 Separate the rear drive shaft from the wheel hub 2007 Mazda MX 5 Miata Sport 200...

Page 1835: ...REMOVAL NOTE 1 Wind the SST and backing plate contact area with packing tape two times 2 Remove the wheel hub component using the SSTs 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 M...

Page 1836: ...ns on the wheel hub component use a chisel to secure a sufficient space for installing the SST between wheel hub component and bearing inner race 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear...

Page 1837: ...CORP 4 Remove the bearing inner race using the SST 5 After removing the bearing repair any backing plate deformation 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thu...

Page 1838: ...ontact area with packing tape two times 2 Remove the wheel bearing from the rear knuckle using the SSTs 3 After removing the bearing repair any backing plate deformation 2007 Mazda MX 5 Miata Sport 20...

Page 1839: ...E 1 Place an alignment mark on the dust cover and rear knuckle for proper installation NOTE Remove the dust cover only if there is an abnormality 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear...

Page 1840: ...ar Knuckle Courtesy of MAZDA MOTORS CORP 2 Remove the dust cover using a chisel 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thursday July 09 2009 3 15 37 PM Page 11...

Page 1841: ...MOTORS CORP BUSHING REMOVAL NOTE 1 Remove the bushing from the rear knuckle using the SSTs 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thursday July 09 2009 3 15 3...

Page 1842: ...MOVAL NOTE 1 Remove the wheel hub bolts from the wheel hub using a press NOTE Remove the wheel hub bolt only if there is an abnormality 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5...

Page 1843: ...MOTORS CORP WHEEL HUB BOLT INSTALLATION NOTE 1 Press in new wheel hub bolts into the wheel hub using a press 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thursday J...

Page 1844: ...of MAZDA MOTORS CORP BUSHING INSTALLATION NOTE 1 Press the new bushing into the rear knuckle using the SSTs 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thursday Ju...

Page 1845: ...N NOTE 1 Align the new and old dust covers and place alignment marks on the new dust cover 2 Align the marks on the new dust cover and rear knuckle 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rea...

Page 1846: ...rtesy of MAZDA MOTORS CORP 3 Press the new dust cover onto the rear knuckle using the SSTs 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thursday July 09 2009 3 15 37...

Page 1847: ...sy of MAZDA MOTORS CORP WHEEL BEARING INSTALLATION NOTE 1 Install a new wheel bearing using the SSTs 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thursday July 09 20...

Page 1848: ...MOTORS CORP WHEEL HUB COMPONENT INSTALLATION NOTE 1 Install the wheel hub component using the SSTs 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thursday July 09 200...

Page 1849: ...LLATION NOTE 1 Tighten a new locknut 2 Install a new locknut and indent as shown to crimp the locknut using a chisel and hammer 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Mi...

Page 1850: ...ling New Locknut Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 DRIVELINE AXLES Rear Axle MX 5 Miata Microsoft Thursday July 09 2009 3 15 37 PM Page 21 2005 Mitchell Repair Information...

Page 1851: ...Performing the following procedures without first removing the ABS wheel speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake Before operations remove the...

Page 1852: ...ng See REAR SHOCK ABSORBER AND COIL SPRING REMOVAL INSTALLATION 2 Remove in the order indicated in Fig 3 3 Install in the reverse order of removal WARNING Removing installing the shock absorber and co...

Page 1853: ...he coil spring and remove the piston rod nut WARNING Before removing the piston rod nut secure the shock absorber and spring in the SSTs Otherwise the shock absorber and spring could fly off under tre...

Page 1854: ...cloth 2 Using the SSTs compress the coil spring 3 Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat 2007 Mazda MX 5 Miata Sport 2007 SU...

Page 1855: ...OLLAR INSTALLATION NOTE 1 Install the collar so that the tapered side is facing downward as shown in Fig 6 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 Miata Microsoft Thursday Jul...

Page 1856: ...ING SEAT RUBBER INSTALLATION NOTE 1 Install the spring seat rubber to the upper spring seat as shown in Fig 7 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 Miata Microsoft Thursday...

Page 1857: ...SEAT INSTALLATION NOTE 1 Install the coil spring with the lead lower end of the lower spring seat facing the direction shown in Fig 8 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 M...

Page 1858: ...TION 1 Inspect the rear shock absorber in the same way as the front shock absorber See FRONT SHOCK ABSORBER INSPECTION 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 Miata Microsoft...

Page 1859: ...wheel alignment See REAR WHEEL ALIGNMENT CAUTION Performing the following procedures without first removing the ABS wheel speed sensor may possibly cause an open circuit in the wiring harness if it is...

Page 1860: ...the SST disconnect the rear lateral link upper ball joint NOTE When removing the rear lateral link upper ball joint the rear knuckle bushing may also come off If it comes off replace the rear knuckle...

Page 1861: ...grease off the ball joint stud 2 Fill the inside of the new dust boot with grease 3 Using the SST install the dust boot to the ball joint 4 Wipe off the excess grease 2007 Mazda MX 5 Miata Sport 2007...

Page 1862: ...s If there is any malfunction replace the ball joint 4 Rotate the ball joint 5 times 5 Measure the ball joint rotational torque using an Allen wrench and a torque wrench Rear lateral link upper ball j...

Page 1863: ...REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 13 2 Install in the reverse order of removal 3 Inspect the rear wheel alignment See REAR WHEEL ALIGNMENT 2007 Mazda MX 5 Miata Sport 2007 S...

Page 1864: ...OTE 1 Using the SST disconnect the ball joint NOTE When removing the rear lateral link lower ball joint the rear knuckle bushing may also come off If it comes off replace the rear knuckle 2007 Mazda M...

Page 1865: ...the ball joint stud 2 Fill the inside of the new dust boot with grease 3 Using the SST install the dust boot to the ball joint 4 Wipe off the excess grease 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION...

Page 1866: ...s If there is any malfunction replace the ball joint 4 Rotate the ball joint 5 times 5 Measure the ball joint rotational torque using an Allen wrench and a torque wrench Rear lateral link lower ball j...

Page 1867: ...OVAL INSTALLATION 1 Remove in the order indicated in Fig 17 2 Install in the reverse order of removal 3 Inspect the rear wheel alignment See REAR WHEEL ALIGNMENT 2007 Mazda MX 5 Miata Sport 2007 SUSPE...

Page 1868: ...Link With Torque Specifications Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 52 15 PM Page 18 2005 Mitchell R...

Page 1869: ...Fig 18 Installing Dust Boot To Ball Joint Using SST Courtesy of MAZDA MOTORS CORP TOE CONTROL LINK BALL JOINT INSTALLATION NOTE 1 Install the toe control link ball joint so that the ball joint stud pr...

Page 1870: ...on replace the ball joint 4 Rotate the ball joint 5 times 5 Install the SST to the ball stud and measure the ball joint rotational torque using a pull scale Toe control link ball joint rotational torq...

Page 1871: ...INSTALLATION 1 Remove in the order indicated in Fig 21 2 Install in the reverse order of removal 3 Inspect the rear wheel alignment See REAR WHEEL ALIGNMENT 2007 Mazda MX 5 Miata Sport 2007 SUSPENSIO...

Page 1872: ...Using the SST disconnect the ball joint NOTE When removing the rear trailing link upper ball joint the rear knuckle bushing may also come off If it comes off replace the rear knuckle 2007 Mazda MX 5...

Page 1873: ...the ball joint stud 2 Fill the inside of the new dust boot with grease 3 Using the SST install the dust boot to the ball joint 4 Wipe off the excess grease 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION...

Page 1874: ...r looseness If there is any malfunction replace the ball joint 4 Rotate the ball joint 5 times 5 Measure the ball joint rotational torque using an Allen wrench and a torque wrench Rear trailing link u...

Page 1875: ...REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 25 2 Install in the reverse order of removal 3 Inspect the rear wheel alignment See REAR WHEEL ALIGNMENT 2007 Mazda MX 5 Miata Sport 2007 S...

Page 1876: ...S CORP REAR STABILIZER REMOVAL INSTALLATION 1 Remove in the order indicated in Fig 26 2 Install in the reverse order of removal 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 Miata M...

Page 1877: ...R STABILIZER INSTALLATION NOTE 1 Install the rear stabilizer so that the identification mark is on the right side of the vehicle 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 Miata...

Page 1878: ...CAUTION Be sure to install the stabilizer control link in the proper position If it is not installed properly the stabilizer control link may interfere with peripheral components when driving causing...

Page 1879: ...Place the vehicle on the ground and verify that the stabilizer control link is installed in the angle shown in Fig 29 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 Miata Microsoft T...

Page 1880: ...joint 10 times and rock the ball joint 10 times 4 Measure the ball joint rotational torque using an Allen wrench and a torque wrench Stabilizer control link ball joint rotational torque 0 23 0 47 N m...

Page 1881: ...he rear drive shaft See REAR DRIVE SHAFT REMOVAL INSTALLATION 5 Remove the rear differential See REAR DIFFERENTIAL REMOVAL INSTALLATION 6 Remove in the order indicated in the table 7 Install in the re...

Page 1882: ...of MAZDA MOTORS CORP REAR AXLE COMPONENT REMOVAL NOTE NOTE When removing the ball joints the rear knuckle bushings may also come off If they come off replace the rear knuckle 2007 Mazda MX 5 Miata Sp...

Page 1883: ...outer bolt Fig 32 Disconnecting Rear Trailing Link Upper Ball Joint Using SST Courtesy of MAZDA MOTORS CORP 4 Using the SST disconnect the rear lateral link upper ball joint 2007 Mazda MX 5 Miata Spor...

Page 1884: ...t the rear lateral link lower ball joint 6 Remove the toe control link outer bolt 7 Remove the shock absorber lower bolt 8 Remove the rear axle component 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Re...

Page 1885: ...move the bolt WARNING Be sure that the crossmember component is securely supported by the jack If not securely supported the crossmember component could fall resulting in serious injury or death and d...

Page 1886: ...ack Courtesy of MAZDA MOTORS CORP 2 Remove the rear crossmember component 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Rear Suspension MX 5 Miata Microsoft Thursday July 09 2009 1 52 15 PM Page 36 2005...

Page 1887: ...passenger s seat is removed perform the seat weight sensor inspection using the WDS or equivalent after installing the passenger s seat See SEAT WEIGHT SENSOR INSPECTION When the passenger s seat is...

Page 1888: ...LF 4 Press connector tab A in the direction of the arrow Fig 2 Pressing Connector Tab A Courtesy of MAZDA MOTORS CORP 5 Pull out the connector lock in the direction of the arrow and disconnect the co...

Page 1889: ...etach the clip tabs and slide the anchor cover to the vehicle front and remove it passenger s seat 8 Remove the lower anchor installation bolt of the seat belt passenger s seat See SEAT BELT REMOVAL I...

Page 1890: ...eat 10 Install in the reverse order of removal 11 Perform the weight sensor initialization procedure See SEAT WEIGHT SENSOR CALIBRATION 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Seats MX 5...

Page 1891: ...g the seat See AIR BAG SYSTEM SERVICE WARNINGS See AIR BAG SYSTEM SERVICE CAUTIONS CAUTION If any of the following work is performed perform the seat weight sensor calibration using the WDS or equival...

Page 1892: ...e seat parts Disassembly of the passenger side seat If any of the following work is performed perform the seat weight sensor inspection using the WDS or equivalent See SEAT WEIGHT SENSOR INSPECTION Re...

Page 1893: ...e the console See CONSOLE REMOVAL INSTALLATION 4 Remove the side wall See SIDE WALL REMOVAL INSTALLATION 5 Remove the console panel See CONSOLE PANEL REMOVAL INSTALLATION 6 Squeeze the tabs of seat wa...

Page 1894: ...E 1 Verify that the continuity between the seat warmer switch terminals is as indicated in Fig 9 If not as indicated in Fig 9 replace the seat warmer switch 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIE...

Page 1895: ...ORS CORP PASSENGER S SIDE 1 Verify that the continuity between the seat warmer switch terminals is as indicated in Fig 11 If not as indicated in Fig 11 replace the seat warmer switch 2007 Mazda MX 5 M...

Page 1896: ...s Side Courtesy of MAZDA MOTORS CORP SEAT WARMER UNIT INSPECTION 1 Remove the seat See SEAT REMOVAL INSTALLATION 2 Remove the seat cushion trim See SEAT DISASSEMBLY ASSEMBLY 2007 Mazda MX 5 Miata Spo...

Page 1897: ...mostat Of Seat Warmer Unit On Seat Cushion Courtesy of MAZDA MOTORS CORP 4 Verify that the continuity between the seat warmer terminals is as indicated in Fig 14 If not as indicated in Fig 14 replace...

Page 1898: ...AZDA MOTORS CORP Fig 15 Identifying Seat Warmer Connector Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Seats MX 5 Miata Microsoft Thursday July 09 2009 3 26 44 P...

Page 1899: ...rns or serious injury When the battery cables are connected touching the vehicle body with starter terminal B will generate sparks This can cause personal injury fire and damage to the electrical comp...

Page 1900: ...icated in Fig 2 7 Install in the reverse order of removal Fig 2 Identifying Removal Order Of Starter With Torque Specifications Courtesy of MAZDA MOTORS CORP STARTER INSTALLATION NOTE 1 Peel off the i...

Page 1901: ...tarter Insulator 2 Degrease the insulator attachment area 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Microsoft Thursday July 09 2009 3 06 51 PM Page 3 2005 Mitchell Repair Info...

Page 1902: ...3 Attach a new insulator to the starter Fig 5 Identifying New Starter Insulator 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Microsoft Thursday July 09 2009 3 06 51 PM Page 4 20...

Page 1903: ...TEST 1 Verify that the battery is fully charged 2 Connect the starter battery and a tester as shown in Fig 6 3 Operate the starter and verify that it rotates smoothly If the starter does not rotate sm...

Page 1904: ...motor pinion is not extended repair or replace the starter NOTE Depending on the battery charge condition the starter motor pinion may rotate while in an extended state This is due to current flowing...

Page 1905: ...Disconnect the motor wire from terminal M 2 Connect battery positive voltage to terminal M and ground the starter body 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Microsoft Thur...

Page 1906: ...turn repair or replace the starter PINION GAP INSPECTION 1 Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body grounded CAUTION Applying power for...

Page 1907: ...tended If not as specified adjust with an adjustment washer between drive housing front cover and magnetic switch Starter pinion gap 0 5 2 0 mm 0 02 0 07 in 2007 Mazda MX 5 Miata Sport 2007 ENGINE Sta...

Page 1908: ...Armature 1 Verify that there is no continuity between the commutator and the core at each segment using a tester If there is continuity replace the armature 2007 Mazda MX 5 Miata Sport 2007 ENGINE Sta...

Page 1909: ...2 Verify that there is no continuity between the commutator and the shaft using a tester If there is continuity replace the armature 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata...

Page 1910: ...CORP 3 Place the armature on V blocks and measure the runout using a dial indicator Starter armature runout 0 1 mm 0 004 in max 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Micro...

Page 1911: ...diameter If not within the minimum specification replace the armature Starter commutator diameter Standard 29 4 mm 1 16 in Minimum 28 8 mm 1 13 in 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting Syst...

Page 1912: ...ithin the minimum specification undercut the grooves to the standard depth Segment groove depth of starter commutator Standard 0 5 mm 0 02 in Minimum 0 2 mm 0 008 in 2007 Mazda MX 5 Miata Sport 2007 E...

Page 1913: ...Switch 1 Inspect for continuity between terminals S and M using a tester If there is no continuity replace the magnetic switch 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Micro...

Page 1914: ...P 2 Inspect for continuity between terminal S and the body using a tester If there is no continuity replace the magnetic switch 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Micro...

Page 1915: ...3 Verify that there is no continuity between terminals M and B using a tester If there is continuity replace the magnetic switch 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Mic...

Page 1916: ...Holder 1 Verify that there is no continuity between each insulated brush and plate using a tester If there is continuity replace the brush holder 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting Syst...

Page 1917: ...h If any brush is worn almost to or beyond the minimum specification replace all of the brushes Starter brush length Standard 12 3 mm 0 48 in Minimum 5 5 mm 0 22 in 2007 Mazda MX 5 Miata Sport 2007 EN...

Page 1918: ...nimum specification replace the brush and brush holder component Starter brush spring force Standard 15 0 20 4 N 1 53 2 08 kgf 3 38 4 58 lbf Minimum 2 75 N 0 28 kgf 0 62 lbf 2007 Mazda MX 5 Miata Spor...

Page 1919: ...TARTER DISASSEMBLY ASSEMBLY LF 1 Disassemble in the order indicated in Fig 22 2 Assemble in the reverse order of disassembly 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Microsof...

Page 1920: ...tch connector 4 Verify that the continuity is as indicated in Fig 23 using a tester If the continuity is not as indicated in Fig 23 replace the starter interlock switch CAUTION Do not reuse the starte...

Page 1921: ...A MOTORS CORP Fig 24 Identifying Starter Interlock Switch Connector Terminals Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE Starting System MX 5 Miata Microsoft Thursday July 0...

Page 1922: ...ss Entry System Courtesy of MAZDA MOTORS CORP WITHOUT ADVANCED KEYLESS SYSTEM AND KEYLESS ENTRY SYSTEM 2007 Mazda MX 5 Miata Sport 2007 SUSPENSION Symptom Troubleshooting MX 5 Miata 2007 Mazda MX 5 Mi...

Page 1923: ...riving on a rough road or when the engine is vibrating perform the steps below An improperly routed improperly clamped or loose harness can cause wiring to become pinched NOTE There are several reason...

Page 1924: ...on manually 5 Shake each connector or wire harness a bit vertically and horizontally while monitoring the PID If PID value is unstable check for poor connection Fig 3 Shaking Connector Or Wire Harness...

Page 1925: ...he malfunction is in the female terminal or not Fig 4 Checking Connection Condition Of Female Terminal Courtesy of MAZDA MOTORS CORP SYMPTOM TROUBLESHOOTING SYMPTOM TROUBLESHOOTING CHART NOTE If engin...

Page 1926: ...INSPECT THE TIRE Is there any foreign object adhering to the tire Yes Remove any foreign object Replace the tire if necessary and then go to the next step No Go to the next step 2 INSPECT THE TIRE PRE...

Page 1927: ...ight low pressure warning illuminates after engine start and turns off after driving for a period of time TROUBLESHOOTING HINTS The tire pressure decreases approaches value to illuminate TPMS warning...

Page 1928: ...flat tire and then go tot the next step No Go to the next step 2 DOES THE FLAT TIRE WARNING LIGHT TURN OFF Adjust the tire pressure and then drive the vehicle at 25 km h 15 5 mph or more for 10 min o...

Page 1929: ...ON CONDITIONS ID AND TIRE PRESSURE TABLE USING THE M MDS OR EQUIVALENT Refer to M MDS display example to specify wheel unit for which the ID could not be registered See Display Of M MDS Example Is the...

Page 1930: ...a 0 kPa Tire Pressure Candidate 0 kPa 0 kPa 0 kPa 0 kPa WU_1 WU_2 WU_3 WU_4 ID Number Stored 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD ID Number Candidate 0xEEEEEEEE 0x00000000 0x00000000 0x00000000...

Page 1931: ...00000 Tire Pressure Stored aaa kPa bbb kPa 0 kPa 0 kPa Tire Pressure Candidate eee kPa 0 kPa 0 kPa 0 kPa WU_1 WU_2 WU_3 WU_4 ID Number Stored 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD ID Number Cand...

Page 1932: ...kPa 0 kPa 0 kPa 0 kPa WU_1 WU_2 WU_3 WU_4 ID Number Stored 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD ID Number Candidate 0xEEEEEEEE 0x00000000 0x00000000 0x00000000 Tire Pressure Stored 0 kPa 0 kPa...

Page 1933: ...a 0 kPa 0 kPa 0 kPa WU_1 WU_2 WU_3 WU_4 ID Number Stored 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD ID Number Candidate 0xEEEEEEEE 0x00000000 0x00000000 0x00000000 Tire Pressure Stored 0 kPa 0 kPa 0...

Page 1934: ...7 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata Microsoft Thursday July 09 2009 2 42 09 PM Page 1 2005 Mi...

Page 1935: ...ing Diagram LF 1 Of 2 Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata Microsoft Thursday July 09 2009 2 42 09 PM Page 2 2005 Mitche...

Page 1936: ...bleshooting Wiring Diagram LF 2 Of 2 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata Microsoft Thursday July 09 2009 2 42 09 PM Page 3 2005 Mitchell Repair Infor...

Page 1937: ...tom troubleshooting See QUICK DIAGNOSTIC TABLE LF Fig 3 Malfunction Flow Diagram Courtesy of MAZDA MOTORS CORP ENGINE SYMPTOM TROUBLESHOOTING LF Confirm trouble symptom using the following diagnostic...

Page 1938: ...e time than normal to return to idle speed See NO 7 SLOW RE TO IDLE LF 8 Engine runs rough rolling idle The engine speed fluctuates between the specified idle speed and lower speed and the engine shak...

Page 1939: ...cceleration cruise Sound is produced when the air fuel mixture is ignited by something other than the spark plug such as hot spot in combustion chamber See NO 13 KNOCKING PINGI ACCELERATION C LF 14 Po...

Page 1940: ...under wide open throttle conditions The A C compressor magnetic clutch does not disengage under wide open throttle See NO 25 A C DOE CUT OFF UNDER W OPEN THROTTLE CONDITIONS LF 26 Exhaust sulphur smel...

Page 1941: ...able 1 Of 4 Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata Microsoft Thursday July 09 2009 2 42 09 PM Page 8 2005 Mitchell Repair...

Page 1942: ...able 2 Of 4 Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata Microsoft Thursday July 09 2009 2 42 09 PM Page 9 2005 Mitchell Repair...

Page 1943: ...able 3 Of 4 Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata Microsoft Thursday July 09 2009 2 42 09 PM Page 10 2005 Mitchell Repair...

Page 1944: ...OF MAIN OR OTHER FUSES LF MELTING OF MAIN OR OTHER FUSES POSSIBLE CAUSE 1 Related wiring harness 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata Microsoft Thursd...

Page 1945: ...Generator ROOM ROOM fuse DLC 2 PCM IG KEY2 IG KEY2 fuse Ignition switch ST ST fuse Starter relay FAN 1 FAN fuse Cooling fan relay No 1 Cooling fan motor Cooling fan relay No 2 Cooling fan motor 2007 M...

Page 1946: ...COMP1 fuse Oil control valve Purge solenoid valve Variable intake air control solenoid valve EGR valve EGI COMP2 EGI COMP2 fuse Drive by wire relay PCM Evaporative leak detection pump MAF sensor VSS M...

Page 1947: ...ossibly exist STEP INSPECTION RESULTS ACTION 1 Connect the M MDS or equivalent to the DLC 2 Turn the ignition switch to the ON position Engine off Retrieve any DTCs Are there any DTCs displayed Yes DT...

Page 1948: ...etween ignition switch and starter TR switch malfunction AT TR switch misadjustment AT Low or dead battery Charging system malfunction Starter interlock switch malfunction MT Starter malfunction Seize...

Page 1949: ...is not completely started DTC P1260 is displayed Yes Both conditions appear Go to Step 4 No Either or other condition appears Go to the next step 4 Turn the ignition switch to the ON position Is the c...

Page 1950: ...7 Inspect for the following wiring harnesses and connectors With advanced keyless entry system Between coil terminal A and keyless control module terminal 2S Between coil terminal B and keyless contr...

Page 1951: ...n PCM terminal 1B and starter relay with clutch pedal depressed MT with starter interlock system P or N position AT Yes Go to the next step No Repair or replace wiring harness 10 Is clicking sound hea...

Page 1952: ...and PCM terminal 1B or starter 14 Connect the M MDS or equivalent to the DLC 2 Turn the ignition switch to the ON position Engine off Retrieve any DTCs Are there any DTCs displayed Yes DTC is display...

Page 1953: ...rvice any additional symptoms See ENGINE SYMPTOM TROUBLESHOOTING LF If malfunction remains inspect related Service Bulletins and or On line Repair Information and perform repair or diagnosis If vehicl...

Page 1954: ...on Pressure regulator malfunction built in fuel pump unit WARNING The following DIAGNOSTIC PROCEDURE TABLE contains the fuel system diagnosis and repair procedures Read the following warnings before s...

Page 1955: ...PECTION RESULTS ACTION 1 Inspect for the following Vacuum leakage Proper fuel quality such as proper octane contamination winter summer blend Loose bands on intake air system Cracks on intake air syst...

Page 1956: ...covered with carbon Inspect for fuel leakage from fuel injector Spark plug is grayish white Inspect the fuel injector for clogging No Install the spark plugs on original cylinders Go to the next step...

Page 1957: ...er ignition switch is turned off See FUEL LINE PRESSURE INSPECTION LF Yes Go to the next step No Inspect the fuel injector See FUEL INJECTOR INSPECTION LF If the fuel injector is normal replace the fu...

Page 1958: ...ts as required 16 Verify test results If normal return to diagnostic index to service any additional symptoms See ENGINE SYMPTOM TROUBLESHOOTING LF If malfunction remains inspect related Service Bulle...

Page 1959: ...Improper air fuel mixture ratio control Improper valve timing Improper operation variable valve timing control system Immobilizer system and or circuit malfunction Immobilizer system operating propert...

Page 1960: ...a before disconnecting connecting and make sure that it is free of foreign material STEP INSPECTION RESULTS ACTION 1 Connect the M MDS or equivalent to the DLC 2 Do the following conditions appear The...

Page 1961: ...he following DTCs displayed DTC PCM B1342 U0073 U0155 Instrument cluster B1213 B1600 B1601 B1602 B1681 B2103 2139 B2431 U0110 U0214 Keyless control module with advanced keyless entry system B1681 B210...

Page 1962: ...terminal A and instrument cluster terminal 2S Between coil terminal B and instrument cluster terminal 2Q Is there any malfunction No Go to the next step 7 Inspect for the following wiring harnesses an...

Page 1963: ...ion winter summer blend Electrical connections Smooth operation of throttle valve Are all items normal Yes Go to the next step No Service if necessary Repeat Step 9 9 Connect the M MDS or equivalent t...

Page 1964: ...step No Inspect for the following TP sensor Wiring harnesses and connectors for following PCM terminal 2AK TP sensor terminal F PCM terminal 2AO TP sensor terminal E PCM terminal 2AP TP sensor termin...

Page 1965: ...o Go to the next step 13 Connect the M MDS or equivalent to the DLC 2 Access RPM PID Is RPM PID indicating engine speed during engine cranking Yes Go to the next step No Inspect for the following Open...

Page 1966: ...spark plug condition Is spark plug wet covered with carbon or grayish white Yes Spark plug is wet or covered with carbon Inspect for fuel leakage from injector Spark plug is grayish white Inspect the...

Page 1967: ...pressure gauges to A C low and high pressure side lines Turn A C on and measure low side and high side pressures Are pressures within specifications See REFRIGERANT PRESSURE CHECK NOTE The following...

Page 1968: ...g control function properly Yes Go to the next step No Repair or replace the malfunctioning parts according to variable valve timing control system operation inspection results 27 Is the engine compre...

Page 1969: ...or due to sensor related wire or incorrect installation Low engine compression Engine overheating Vacuum leakage Erratic signal to ignition coil Improper air fuel mixture ratio control Poor fuel quali...

Page 1970: ...el Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE SERVICE PRECAUT...

Page 1971: ...he coil connector securely Return to Step 2 4 Does the security light flush Yes Go to the next step No Inspect and repair or replace the following Wiring harnesses and connectors from keyless control...

Page 1972: ...B and keyless control module terminal 3AA Between keyless control module terminal 4A and instrument cluster terminal 2Q Between keyless control module terminal 4C and instrument cluster terminal 2S Wi...

Page 1973: ...nector No Go to the next step 8 Verify the following Vacuum connection External fuel shut off or accessory such as kill switch alarm Fuel quality proper octane contamination winter summer blend No air...

Page 1974: ...ed Inspect for the following Open circuit in wiring harness between main relay and PCM terminal 1AW or 1BE Open main relay GND circuit Open or short circuit in wiring harness between DLC and PCM termi...

Page 1975: ...s the TP PID Crank the engine with accelerator pedal released Are the TP PID indicates the closed throttle position Yes Go to the next step No Inspect for the following TP sensor Wiring harnesses and...

Page 1976: ...C and PCM terminal 2AQ Open or short circuit in CKP sensor wiring harnesses If CKP sensor and wiring harness are normal go to the next step 15 Visually inspect the CKP sensor and teeth of crankshaft p...

Page 1977: ...umper wiring Turn the ignition switch to the ON position Is fuel line pressure correct when ignition switch is turned on off five times See FUEL LINE PRESSURE INSPECTION LF Yes Go to the next step No...

Page 1978: ...he variable valve timing control system operation See VARIABLE VALVE TIMING CONTROL SYSTEM OPERATION INSPECTION Does variable valve timing control function properly Yes Go to the next step No Repair o...

Page 1979: ...isplayed Yes DTC is displayed Go to the appropriate DTC inspection See DTC TABLE LF No No DTC is displayed Go to the next step 2 Remove thermostat and inspect operation See THERMOSTAT REMOVAL INSTALLA...

Page 1980: ...orm repair or diagnosis If vehicle is repaired troubleshooting completed If vehicle is not repaired or additional diagnostic information is not available replace the PCM See PCM REMOVAL INSTALLATION L...

Page 1981: ...chanical malfunction Improper load signal input Fuel line restriction or clogging Improper fuel injection control operation Fuel leakage from fuel injector Fuel injector clogging Engine overheating Va...

Page 1982: ...ng and make sure that it is free of foreign material STEP INSPECTION RESULTS ACTION 1 Warm up the engine Idle the engine for 5 min Is the symptom disappeared Yes Troubleshooting completed Cause of thi...

Page 1983: ...o symptom troubleshooting NO 17 COOLING SYSTEM CONCERNS OVERHEATING LF No Go to the next step 5 Connect the M MDS or equivalent to the DLC 2 Access MAF PID Drive vehicle with monitoring PID Is MAF PID...

Page 1984: ...h P S on If other symptoms exist go to the next step Yes Go to appropriate the DTC inspection See DTC TABLE LF No Go to the next step 8 Visually inspect the CKP sensor and teeth of crankshaft pulley A...

Page 1985: ...during idle Is fuel line pressure correct during idle See FUEL LINE PRESSURE INSPECTION LF Yes Go to the next step No Low Inspect the fuel line for clogging If there is no malfunction replace fuel pu...

Page 1986: ...nically Inspect EVAP control system No Go to the next step 16 Remove and shake the PCV valve Does the PCV valve rattle Yes Go to the next step No Replace the PCV valve 17 Visually inspect the exhaust...

Page 1987: ...TING LF If malfunction remains inspect related Service Bulletins and or On line Repair Information and perform repair or diagnosis If vehicle is repaired troubleshooting completed If vehicle is not re...

Page 1988: ...OLING SYSTEM CONCERNS RUNS COLD LF 2 Connect the M MDS or equivalent to the DLC 2 Turn the ignition switch to the ON position Engine off Retrieve any DTCs Are there any DTCs displayed Yes DTC is displ...

Page 1989: ...rcuit 4 Connect the M MDS or equivalent to the DLC 2 Start the engine and idle it Retrieve any DTCs for EHPAS Is there any EHPAS DTC displayed Yes DTC is displayed Go to appropriate DTC inspection No...

Page 1990: ...10 LOW IDLE STALLS DURING DECELERATION DESCRIPTION Engine stops unexpectedly at the beginning of deceleration or recovery from deceleration POSSIBLE CAUSE Vacuum leakage Improper operation of electro...

Page 1991: ...is always on or A C compressor runs continuously See NO 24 A C IS ALWAYS ON OR A C COMPRESSOR RUNS CONTINUOUSLY LF No Go to the next step 3 Verify the following Proper routing of and no damage to vac...

Page 1992: ...ssion control system No Go to the next step 7 Connect the M MDS or equivalent to the DLC 2 Access APP1 APP2 TP MAF and VSS PIDs Monitor each PID while driving vehicle See PCM INSPECTION LF Are PIDs no...

Page 1993: ...circuit 9 Verify test results If normal return to diagnostic index to service any additional symptoms See ENGINE SYMPTOM TROUBLESHOOTING LF If malfunction remains inspect related Service Bulletins and...

Page 1994: ...jerks during acceleration cruising or deceleration Momentary pause at beginning of acceleration or during acceleration Momentary minor irregularity in engine output Improper A C system operation Erra...

Page 1995: ...ntermittent open or short circuit of MAF sensor TP sensor Accelerator pedal position sensor and VSS AT malfunction AT Clutch slippage MT Improper variable intake air control operation Loose attaching...

Page 1996: ...nnector joint area before disconnecting connecting and make sure that it is free of foreign material STEP INSPECTION RESULTS ACTION 1 Verify the following Vacuum connection Air cleaner element No air...

Page 1997: ...ehicle with monitoring PIDs Are PIDs within specifications See PCM INSPECTION LF Yes Go to the next step No APP1 APP2 PIDs Inspect if output signal from accelerator pedal position sensor changes smoot...

Page 1998: ...c throttle control system function properly Yes Go to the next step No Repair or replace the malfunctioning part according to electronic throttle system operation inspection results 9 Visually inspect...

Page 1999: ...in specifications See REFRIGERANT PRESSURE CHECK NOTE The following test is for engine stall with the A C on If other symptom exists go to the next step Yes Go to the next step No If the A C is always...

Page 2000: ...ehicle Does the engine condition improve Yes Go to the next step Inspect if the purge solenoid valve is stuck open mechanically Inspect the evaporative emission control system No Go to the next step 1...

Page 2001: ...place the PCM See PCM REMOVAL INSTALLATION LF 12 LACK LOSS OF POWER ACCELERATION CRUISE DESCRIPTION Performance is poor under load such as power down when climbing hills Improper A C system operation...

Page 2002: ...ittent open or short circuit in MAF sensor Accelerator pedal position sensor TP sensor IAT sensor and VSS AT malfunction AT Clutch slippage MT WARNING The following DIAGNOSTIC PROCEDURE TABLE contains...

Page 2003: ...ng and make sure that it is free of foreign material STEP INSPECTION RESULTS ACTION 1 Verify the following Vacuum connection Restriction in intake air system such as air cleaner element fresh air duct...

Page 2004: ...the next step No APP1 APP2 PIDs Inspect if output signal accelerator pedal position sensor changes smoothly RPM PID Inspect CKP sensor and related wiring harness for vibration or intermittent open sho...

Page 2005: ...tion properly Yes Go to the next step No Repair or replace the malfunctioning part according to electronic throttle control system operation inspection results 9 Visually inspect deformed exhaust syst...

Page 2006: ...C is always on go to symptom troubleshooting No 24 A C is always on or A C compressor runs continuously See NO 24 A C IS ALWAYS ON OR A C COMPRESSOR RUNS CONTINUOUSLY LF For other symptoms inspect the...

Page 2007: ...CTION Does the variable valve timing control system function properly Yes Go to the next step No Repair or replace the malfunctioning part according to variable valve timing control system inspection...

Page 2008: ...ic signal from CMP sensor Inadequate engine compression Inadequate fuel pressure WARNING The following DIAGNOSTIC PROCEDURE TABLE contains the fuel system diagnosis and repair procedures Read the foll...

Page 2009: ...cation Yes Go to the next step No Inspect the cooling system for cause of overheating 2 Connect the M MDS or equivalent to the DLC 2 Access IAT and MAF PIDs Monitor each PID See PCM INSPECTION LF Are...

Page 2010: ...nsor normal Yes Inspect ignition timing No Replace the knock sensor 7 Verify test results If normal return to diagnostic index to service any additional symptoms See ENGINE SYMPTOM TROUBLESHOOTING LF...

Page 2011: ...d repair procedures Read following warnings before servicing fuel system Fuel vapor is hazardous It can easily ignite causing serious injury and damage Always keep sparks and flames away from fuel Fue...

Page 2012: ...o to the next step No Service if necessary Repeat Step 1 2 Connect the M MDS or equivalent to the DLC 2 Turn the ignition switch to the ON position Engine off Retrieve any DTCs Are there any DTCs disp...

Page 2013: ...the fuel pump unit See FUEL PUMP UNIT REMOVAL INSTALLATION LF 6 Inspect for variable valve timing control system operation See VARIABLE VALVE TIMING CONTROL SYSTEM OPERATION INSPECTION Does the varia...

Page 2014: ...toms See ENGINE SYMPTOM TROUBLESHOOTING LF If malfunction remains inspect related Service Bulletins and or On line Repair Information and perform repair or diagnosis If vehicle is repaired troubleshoo...

Page 2015: ...ROCEDURE TABLE contains fuel system diagnosis and repair procedures Read following warnings before servicing fuel system Fuel vapor is hazardous It can easily ignite causing serious injury and damage...

Page 2016: ...followed Intake air system and air cleaner element concerns obstructions leakage or dirtiness Are all items normal Yes Go to the next step No Service if necessary Repeat Step 1 2 Connect the M MDS or...

Page 2017: ...st See SPARK TEST Is strong blue spark visible at each cylinder Yes Go to the next step No Repair or replace the malfunctioning part according to spark test result 8 Install the fuel pressure gauge be...

Page 2018: ...eplace the three way catalytic converter 13 Verify test results If normal return to diagnostic index to service any additional symptoms See ENGINE SYMPTOM TROUBLESHOOTING LF If malfunction remains ins...

Page 2019: ...Verify test results If normal return to diagnostic index to service any additional symptoms See ENGINE SYMPTOM TROUBLESHOOTING LF If malfunction remains inspect related Service Bulletins and or On lin...

Page 2020: ...on Collapsed or restricted radiator hoses Radiator pressure cap Overflow system Fan rotational direction Fuses Are all items normal Yes Go to the next step No Service if necessary Repeat Step 1 2 Conn...

Page 2021: ...witch on Does AC_REQ PID read on Yes Go to the next step No Inspect the following Refrigerant pressure switch operation The A C switch is stuck open Open or short circuit between refrigerant pressure...

Page 2022: ...inspect engine block for leakage or blockage No Access ECT PID Inspect for both ECT PID and temperature gauge readings If temperature gauge on instrument cluster indicates normal range but ECT PID is...

Page 2023: ...stem No Go to the next step 2 Does the engine speed continue at fast idle Yes Go to symptom troubleshooting No 9 Fast idle runs on See NO 9 FAST IDLE RUNS ON LF No Go to the next step 3 Remove the the...

Page 2024: ...LF If malfunction remains inspect related Service Bulletins and or On line Repair Information and perform repair or diagnosis If vehicle is repaired troubleshooting completed If vehicle is not repair...

Page 2025: ...away from fuel Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE SER...

Page 2026: ...s not seated seized or worn Damaged cylinder bore If other driveability symptoms are present return to diagnostic index to service any additional symptoms No Replace the PCV valve 3 Does the cooling s...

Page 2027: ...l line pressure correct during idle See FUEL LINE PRESSURE INSPECTION LF Yes Go to the next step No Low Inspect the fuel line for clogging If there is no malfunction replace the fuel pump unit See FUE...

Page 2028: ...id valve malfunction Fuel tank vent system blockage Charcoal canister malfunction Fuel leakage from fuel system WARNING The following DIAGNOSTIC PROCEDURE TABLE contains fuel system diagnosis and repa...

Page 2029: ...een the fuel pipe and the fuel distributor Start engine and idle it Measure fuel line pressure during idle Is fuel line pressure correct during idle See FUEL LINE PRESSURE INSPECTION LF Yes Go to the...

Page 2030: ...rmal return to diagnostic index to service any additional symptoms See ENGINE SYMPTOM TROUBLESHOOTING LF If malfunction remains inspect related Service Bulletins and or On line Repair Information and...

Page 2031: ...ystem looseness Intake air system looseness Other noise Camshaft friction gear noise or MLA noise Timing chain noise STEP INSPECTION RESULTS ACTION 1 Is a squealing click or chirping sound present Yes...

Page 2032: ...next step 6 Is a knocking noise present Yes Go to symptom troubleshooting No 13 Knocking pinging See NO 13 KNOCKING PINGING ACCELERATION CRUISE LF No If the noise comes from the engine internal inspec...

Page 2033: ...ve belt and pulleys Generator Engine mounts Exhaust system mounts All items normal Yes Inspect the following systems Wheels AT Driveline Suspension No Readjust or retighten engine mount installation p...

Page 2034: ...A C switch and PCM through both refrigerant pressure switch and A C amplifier STEP INSPECTION RESULTS ACTION 1 Connect the M MDS or equivalent to the DLC 2 Turn the ignition switch to the ON position...

Page 2035: ...ensor and A C amplifier 4 Remove jumper wiring from the switch connector Reconnect connector to refrigerant pressure switch Start the engine and turn the A C switch on Does the fan operate Yes Inspect...

Page 2036: ...A C switch and PCM Short to GND in wiring harness between A C relay and PCM Short circuit to battery power in A C relay to magnetic clutch STEP INSPECTION RESULTS ACTION 1 Connect the M MDS or equival...

Page 2037: ...ircuit may be present Yes Inspect for short to GND in wiring harness between refrigerant pressure switch and PCM terminal 1AU No Go to the next step 4 Reconnect refrigerant pressure switch connector T...

Page 2038: ...repaired troubleshooting completed If vehicle is not repaired or additional diagnostic information is not available replace the PCM See PCM REMOVAL INSTALLATION LF 25 A C DOES NOT CUT OFF UNDER WOT CO...

Page 2039: ...or On line Repair Information and perform repair or diagnosis If vehicle is repaired troubleshooting completed If vehicle is not repaired or additional diagnostic information is not available replace...

Page 2040: ...ICE PRECAUTION LF CAUTION Disconnecting connecting quick release connector without cleaning it may cause damage to fuel pipe and quick release connector Always clean quick release connector joint area...

Page 2041: ...ace the fuel pump unit See FUEL PUMP UNIT REMOVAL INSTALLATION LF 5 Inspect the charcoal canister for fuel saturation Is excess amount of liquid fuel present in canister Yes Replace the charcoal canis...

Page 2042: ...iagnosis and repair procedures Read the following warnings before servicing the fuel system Fuel vapor is hazardous It can easily ignite causing serious injury and damage Always keep sparks and flames...

Page 2043: ...DTC inspection See DTC TABLE LF No No DTC is displayed Go to the next step 2 Remove the fuel filler pipe Make sure the non return valve is installed properly Inspect non return valve operation Is the...

Page 2044: ...uel nozzle malfunction Fuel nozzle is not inserted correctly WARNING The following DIAGNOSTIC PROCEDURE TABLE contains the fuel system diagnosis and repair procedures Read the following warnings befor...

Page 2045: ...Are there any DTCs displayed Yes DTC is displayed Go to the appropriate DTC inspection See DTC TABLE LF No No DTC is displayed Go to the next step 2 Remove the fuel filler pipe Make sure the non retur...

Page 2046: ...REMOVAL INSTALLATION LF 29 SPARK PLUG CONDITION DESCRIPTION Incorrect spark plug condition Wet carbon stuck on specific plug Spark Weak not visible Air fuel mixture Excessive fuel injection volume Com...

Page 2047: ...cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE SERVICE PRECAUTION and AFTER SERVICE PRECAUTION described in this article See BE...

Page 2048: ...place the spark plug See SPARK PLUG REMOVAL INSTALLATION LF 4 Inspect compression pressure at suspected malfunctioning cylinder Is compression pressure correct See COMPRESSION INSPECTION LF Yes Go to...

Page 2049: ...VAL INSTALLATION LF 7 Inspect the spark plug for the following Heat range Air gap Is the spark plug normal Yes Go to the next step No Replace the spark plug See SPARK PLUG REMOVAL INSTALLATION LF 8 Re...

Page 2050: ...PRESSURE INSPECTION LF Yes Go to the next step No Zero or low Inspect the fuel pump relay and fuel pump circuit Inspect the fuel line for clogging If there is no malfunction replace the fuel pump unit...

Page 2051: ...he fuel filter and the fuel distributor Short check connector terminal F P to body GND using a jumper wiring Turn the ignition switch to the ON position Engine off Is fuel line pressure correct with t...

Page 2052: ...red or additional diagnostic information is not available replace the PCM See PCM REMOVAL INSTALLATION LF NOTE There are several reasons vehicle or engine vibration could cause an electrical malfuncti...

Page 2053: ...alent to the DLC 2 2 Turn the ignition switch to the ON position Engine off 3 Access PIDs for the switch you are inspecting 4 Slightly shake each connector or wiring harness vertically and horizontall...

Page 2054: ...s check for poor connection or poorly mounted sensor or both Inspection Method for Actuators or Relays 1 Connect the M MDS or equivalent to the DLC 2 2 Turn the ignition switch to the ON position Engi...

Page 2055: ...ction occurs only under high humidity or rainy snowy weather perform the following steps NOTE Vibrating relays too strongly may result in open relays CAUTION Indirectly change the temperature and humi...

Page 2056: ...Identifying Water Sprinkling Method Courtesy of MAZDA MOTORS CORP ENGINE CONTROL SYSTEM OPERATION INSPECTION LF INPUT SIGNAL SYSTEM INSPECTION PROCEDURE 1 Find an irregular signal See FINDING IRREGUL...

Page 2057: ...e with the measurement voltage using the digital measurement system function If you use another tester misreading may occur When measuring voltage attach the tester GND to the GND of the PCM that is b...

Page 2058: ...ening is loose Coupler pin holder damage Pin discoloration blackness Harness pin crimp is loose or disconnected 2 Measure the 2 sensor terminal voltage If there is a 0 5 V or more difference between t...

Page 2059: ...or short circuit in wiring harness Harness pin crimp is loose or disconnected GND System Inspection For Variable Resistance Type 1 Confirm that terminal sensor 5 is at 0 V If it is at 0 V inspect the...

Page 2060: ...oration blackness Harness pin crimp is loose or disconnected Input Signal System Inspection For Variable Resistance Type 2 1 When an irregular signal is detected measure the 1 PCM terminal voltage If...

Page 2061: ...ted If there are no problems proceed to next investigation below Electrical Supply System Inspection For Variable Resistance Type 2 Confirm that the sensor 3 terminal is B If the measured voltage on t...

Page 2062: ...pin holder damage Pin discoloration blackness Harness pin crimp is loose or disconnected 2 Measure the 2 sensor terminal voltage If there is a 0 5 V or more difference between the sensor and the M MDS...

Page 2063: ...Harness and connector between PCM terminal 1Q and main relay terminal E INTAKE MANIFOLD VACUUM INSPECTION 1 Verify that the intake air hoses are installed securely 2 Disconnect the vacuum hose connec...

Page 2064: ...Inspection 1 Start the engine and idle it 2 Connect the M MDS or equivalent to the DLC 2 3 Verify that P0506 P0507 or P0511 is not displayed If P0506 P0507 or P0511 are displayed perform DTC inspecti...

Page 2065: ...dal and verify that the PID reading increases accordingly If the PID reading drops momentarily inspect the following Throttle position sensor 7 Fully depress the throttle pedal and verify that the PID...

Page 2066: ...L INJECTOR OPERATION INSPECTION If simulation function of M MDS is used FUEL INJECTOR OPERATION INSPECTION TABLE STEP INSPECTION RESULTS ACTION 1 Start the engine and warm it up until normal operating...

Page 2067: ...te DTC test See DTC TABLE LF No Go to the next step 5 Inspect the fuel injector for suspected cylinder See FUEL INJECTOR INSPECTION LF Is the fuel injector okay Yes Inspect the following for suspected...

Page 2068: ...main relay operation normal Yes Inspect the following Fuel injector power system related wiring harness and connectors PCM connectors Fuel injector GND and related wiring harness and connectors No Rep...

Page 2069: ...not as specified inspect the following ECT sensor and related harness See ENGINE COOLANT TEMPERATURE ECT SENSOR INSPECTION LF Neutral switch and related harness MT See NEUTRAL SWITCH INSPECTION LF Cl...

Page 2070: ...el pump relay PCM terminal 1H SPARK TEST 1 Disconnect the fuel pump relay 2 Verify that each ignition coil and connector is connected properly 3 Inspect the ignition system in the following procedure...

Page 2071: ...ition system is normal No Some cylinders do not spark Go to the next step All cylinders do not spark Go to Step 5 4 Inspect the following wiring harnesses for open or short Ignition coil No 1 terminal...

Page 2072: ...s normal 5 Measure the voltage at terminal A in each ignition coils Is the voltage B Yes Go to the next step No Inspect power supply circuit of ignition coils 6 Verify continuity between each ignition...

Page 2073: ...and verify that EGR valve operation initial operation sound is heard If the operation sound is not heard connect the M MDS or equivalent to the DLC 2 and verify that the DTC P0403 is shown Perform DT...

Page 2074: ...solenoid valve inspection See PURGE SOLENOID VALVE INSPECTION LF 7 Warm up the engine to normal operating temperature 8 Monitor the EVAPCP PID using the M MDS or equivalent and drive the vehicle appr...

Page 2075: ...SUFFICIENTLY LF 4 Fully open the throttle valve and verify that the A C compressor magnetic clutch does not actuate for 2 5 s If it actuates inspect as follows A C relay Open or short to GND circuit i...

Page 2076: ...M MDS or equivalent to DLC 2 2 Start the engine and warm it up to normal operating temperature 3 Perform the KOER self test See KOEO KOER SELF TEST LF 4 Verify that the DTC P0480 P0481 or P0482 is not...

Page 2077: ...OCV operation Harness and connectors for open or short Oil control valve OCV PCM terminal 2E 10 If they are okay replace the intake camshaft pulley with a built in variable valve timing actuator If s...

Page 2078: ...stem Test Description The EVAP system test finds gas leaks in the system using the PCM to monitor changes in the air pump load current of the EVAP system leak detection pump This test starts after sen...

Page 2079: ...You can confirm whether any evaporative gas leak occurred or not by reading the test results 2007 Mazda MX 5 Miata Sport 2007 ENGINE PERFORMANCE Symptom Troubleshooting MX 5 Miata Microsoft Thursday...

Page 2080: ...urrent value and send the results to the M MDS as DTCs DTC CONDITION TABLE DTC No Condition P0442 Evaporative emission control system leak detected small leak 2007 Mazda MX 5 Miata Sport 2007 ENGINE P...

Page 2081: ...porative emission control system leak detected gross leak P0456 Evaporative emission system leak detected very small leak P2401 EVAP system leak detection pump motor circuit low P2402 EVAP system leak...

Page 2082: ...13 15 in of water If the gauge is not reading in this range adjust the pressure by turning the black knob on the low pressure regulator at the nitrogen bottle 5 Turn the control valve to the HOLD pos...

Page 2083: ...not a MAZDA part or equivalent replace it 3 Connect the receiver assembly SST AKS441130 to the vehicle cap test hose assembly part of the SST and the fuel filler cap from the vehicle 4 Connect the ca...

Page 2084: ...TORS CORP 6 Make sure the control valve on the 134 01049 is in the HOLD position and that the valve on the cylinder of nitrogen gas is open 7 Turn the control valve to the open position and let the sy...

Page 2085: ...ATIVE LEAK The flow meter registers zero flow and the pressure gauge returns to the pre set pressure of 356 mm 14 in of water H2O EVAPORATIVE LEAK The pressure does not return to the preset level of 3...

Page 2086: ...CCESSORIES BODY CAB Glass Windows Mirrors MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Glass Windows Mirrors MX 5 Miata Microsoft Thursday July 09 2009 3 24 31 PM Page 1 2005 Mitch...

Page 2087: ...2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Glass Windows Mirrors MX 5 Miata Microsoft Thursday July 09 2009 3 24 31 PM Page 2 2005 Mitchell Repair Information Company LLC...

Page 2088: ...e DOOR UNIT REMOVAL INSTALLATION Fig 2 Identifying Distance Between Top Of Front Door Glass Top Of Front Belt Line Molding Courtesy of MAZDA MOTORS CORP 6 Remove the glass stopper Fig 3 Identifying Gl...

Page 2089: ...nuts 7 Align the door glass with the rear edge of the front beltline molding Fig 5 Identifying Glass Stopper Power Window Regulator With Bolt And Nut NOTE The standard position for the rear edge of th...

Page 2090: ...and the door glass guide DOOR GLASS CLEARANCE SPECIFICATIONS Fig 7 Identifying Door Glass Door Glass Guide With Clearance Courtesy of MAZDA MOTORS CORP 10 Adjust the door glass position Clearance Stan...

Page 2091: ...on of the arrows 13 Verify that the door glass opens and closes smoothly 14 Install the door unit See DOOR UNIT REMOVAL INSTALLATION 15 Install the door trim See DOOR TRIM REMOVAL INSTALLATION 16 Clos...

Page 2092: ...REMOVAL INSTALLATION 5 Remove the door unit See DOOR UNIT REMOVAL INSTALLATION 6 Remove the door glass See DOOR GLASS REMOVAL INSTALLATION 7 Remove the power window regulator See POWER WINDOW REGULATO...

Page 2093: ...oor Quarter Glass Remove Install Components With Torque Specifications Courtesy of MAZDA MOTORS CORP DOOR GLASS GUIDE INSTALLATION NOTE 1 Adjust the adjustment bolt as shown in the figure Fig 14 Ident...

Page 2094: ...NSTALLATION 6 Remove the nuts Fig 15 Identifying Regulator Nuts With Torque Specifications Courtesy of MAZDA MOTORS CORP 7 Remove the power window regulator 8 Install in the reverse order of removal F...

Page 2095: ...of the cover using long nose pliers Fig 18 Crimping Cover Using Long Nose Pliers 1 Cover See Cover Disassembly Note 2 Power window motor 3 Frame NOTE When installing the power window motor be careful...

Page 2096: ...RATION REFERENCE POWER WINDOW MAIN SWITCH REMOVAL INSTALLATION 1 Remove the battery cover 2 Disconnect the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the console See CONSOLE R...

Page 2097: ...ntinuity at terminal J 5 If the system does not work properly even though the inspection items or related wiring harnesses do not have any malfunction replace the power window main switch Fig 21 Ident...

Page 2098: ...n switch output motor While door glass is closing 1 0 or less MOTOR INSPECTION Related wiring harnesses G Close output Power window motor While door glass is opening 1 0 or less Power window motor See...

Page 2099: ...wiring harnesses do not have any malfunction replace the power window main switch POWER WINDOW MAIN SWITCH INSPECTION CHART WITH EXTERIOR OPEN FUNCTION Terminal Signal name Connected to Measured condi...

Page 2100: ...OTOR INSPECTION Related wiring harnesses While door glass is closing B 1J Open output Power window motor While door glass is opening B Power window motor See POWER WINDOW MOTOR INSPECTION Related wiri...

Page 2101: ...spect the power window main switch connector for continuity at terminal G 4 If the system does not work properly even though the inspection items or related wiring harnesses do not have any malfunctio...

Page 2102: ...oor glass is opening 1 0 or less Power window motor See POWER WINDOW MOTOR INSPECTION Related wiring harnesses While door glass is closing B J Open output Power window motor While door glass is openin...

Page 2103: ...ION 3 Side cowl grille See SIDE COWL GRILLE REMOVAL INSTALLATION 4 Windshield garnish See WINDSHIELD GARNISH REMOVAL 5 Rearview mirror See REARVIEW MIRROR REMOVAL INSTALLATION 6 Front header trim See...

Page 2104: ...ifficult to remove warm the windshield molding using a hot air blower The windshield molding is a replacement part NOTE For the areas of the sealant that are difficult to cut use the SST piano wire an...

Page 2105: ...bare hands can cause injury Always wear gloves when using the SST piano wire NOTE Before removing the windshield from the body mark the position of the windshield by affixing tape to the windshield a...

Page 2106: ...from the windshield glass place an alignment mark on the windshield WARNING Using a razor with bare hands can cause injury Always wear gloves when using a razor CAUTION If a door is opened or closed...

Page 2107: ...nstalling Pin To Windshield Courtesy of MAZDA MOTORS CORP 5 Install the windshield molding 6 Use glass primer on the glass then allow it to dry for approx 30 min Fig 32 Identifying Windshield Molding...

Page 2108: ...s of new sealant Fig 34 Cutting Old Sealant Using Razor Or Scraper Courtesy of MAZDA MOTORS CORP 9 Clean and degrease along the perimeter of the bonding area on the body 10 Apply body primer on the bo...

Page 2109: ...imeter of the glass 14 Install the following parts 1 A pillar trim See A PILLAR TRIM REMOVAL INSTALLATION 2 Map light See MAP LIGHT REMOVAL INSTALLATION 3 Front header trim See FRONT HEADER TRIM REMOV...

Page 2110: ...Remove the battery cover 2 Remove the negative battery cable See BATTERY REMOVAL INSTALLATION LF 3 Remove the detachable hardtop 4 Remove the B pillar garnish 5 Remove the side lock 6 Remove the B pi...

Page 2111: ...verlap and adhere the protective tape to the corners to prevent damage WARNING Using the SST piano wire with bare hands can cause injury Always wear gloves when using the SST piano wire NOTE Before re...

Page 2112: ...ins out 15 Remove the rear window glass 16 Mark the seating positions of the pins and remove the pins from the rear window glass 17 Remove the rear window molding from the rear window glass NOTE Use a...

Page 2113: ...and the bonding area on the body 4 Apply glass primer on the rear window glass and body primer as shown in the figure Allow it to dry for approx 30 min CAUTION Proper installation of the rear window...

Page 2114: ...45 Identifying Sealant Applying Area On Glass Surface Courtesy of MAZDA MOTORS CORP 7 Press the rear window pins to engage the tabs to the body CAUTION Keep the area free of dirt and grease and do no...

Page 2115: ...TALLATION DETACHABLE HARDTOP 3 B pillar upper trim See B PILLAR UPPER TRIM INSTALLATION DETACHABLE HARDTOP 4 Side lock 5 B pillar garnish 6 Detachable hardtop 11 Allow the sealant to harden completely...

Page 2116: ...POWER RETRACTABLE HARDTOP REMOVAL INSTALLATION 4 Disconnect the filament connector 5 If the rear window glass or the middle roof panel is to be reused remove it using the following procedure 1 Affix m...

Page 2117: ...uts Fig 49 Identifying Marks Courtesy of MAZDA MOTORS CORP 6 Move the power retractable hardtop in the open direction as shown in the figure until it is separated from the middle roof panel 2007 Mazda...

Page 2118: ...roster 12 Install in the reverse order of removal See REAR WINDOW GLASS INSTALLATION NOTE Fig 51 Identifying Rear Window Defroster Remove Install Components With Torque Specifications Courtesy of MAZD...

Page 2119: ...ing Harness Clips Courtesy of MAZDA MOTORS CORP 4 Remove the wiring harness from the roof link lock groove Fig 53 Identifying Harness Groove And Roof Link Lock Courtesy of MAZDA MOTORS CORP 5 Remove c...

Page 2120: ...ABLE HARDTOP ADJUSTMENT and verify that the gap and height difference between the rear window glass and middle roof panel are within the specifications Adjust the power retractable hardtop if necessar...

Page 2121: ...ar window defroster filament VOLTAGE REFERENCE Fig 56 Checking Voltage Drop In Filament Courtesy of MAZDA MOTORS CORP REAR WINDOW DEFROSTER FILAMENT REPAIR 1 Clean the rear window defroster filament u...

Page 2122: ...EMOVAL INSTALLATION LF 3 Remove the door trim See DOOR TRIM REMOVAL INSTALLATION 4 Remove the door speaker See DOOR SPEAKER REMOVAL INSTALLATION 5 Remove the door unit See DOOR UNIT REMOVAL INSTALLATI...

Page 2123: ...Bolt With Torque Specifications Courtesy of MAZDA MOTORS CORP 9 Rotate the power outer mirror in the direction shown by the arrow Fig 61 Rotating Power Outer Mirror Courtesy of MAZDA MOTORS CORP 2007...

Page 2124: ...R MIRROR GLASS DISASSEMBLY NOTE See OUTER MIRROR GLASS ASSEMBLY NOTE 2 Assemble in the reverse order of disassembly Fig 63 Identifying Outer Mirror Glass Courtesy of MAZDA MOTORS CORP OUTER MIRROR GLA...

Page 2125: ...glass as a single unit Fig 65 Identifying Outer Mirror Glass Holder Pins Courtesy of MAZDA MOTORS CORP OUTER MIRROR GLASS ASSEMBLY NOTE 1 Press area A of the mirror glass into the base to attach pin A...

Page 2126: ...the operation of the power outer mirror If not as specified replace the power outer mirror POWER OUTER MIRROR OPERATION REFERENCE Fig 67 Identifying Power Outer Mirror Connector Terminals Operation T...

Page 2127: ...e door trim by depressing the tab 7 Remove the screws and the power outer mirror switch 8 Install in the reverse order of removal Fig 68 Power Outer Mirror Switch Remove Install Components Courtesy of...

Page 2128: ...d each end of a wire around a bar WARNING Using the SST piano wire with bare hands can cause injury Always wear gloves when using the SST piano wire NOTE Use a long sawing action to spread the work ov...

Page 2129: ...approx 30 min 5 Apply 3 0 mm 0 12 in layer of sealant to the base the SST piano wire to prevent it from breaking Do not pull too hard to prevent damage to windshield WARNING Using a razor with bare h...

Page 2130: ...rearview mirror REARVIEW MIRROR REMOVAL INSTALLATION 1 Insert a flathead screwdriver between the rearview mirror and base 2 Press the base pin downward and remove the rearview mirror Temperature Surf...

Page 2131: ...earview Mirror Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Glass Windows Mirrors MX 5 Miata Microsoft Thursday July 09 2009 3 24 32 PM Page 46 2005 Mitchell Rep...

Page 2132: ...MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Wiper Washer System MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Wiper Washer System MX 5 Miata Microsoft Thursday...

Page 2133: ...he reverse order of removal 3 Adjust the wiper arm and blade See WIPER ARM AND BLADE ADJUSTMENT WIPER ARM INSTALLATION NOTE 1 Clean the wiper arm connector shafts using a wire brush before installing...

Page 2134: ...he wiper arm and blade so that its end is aligned with the clear dot in the black ceramic coating on the inside of the windshield NOTE If the hollowed mark in the ceramic coating cannot be located mea...

Page 2135: ...e the wiper arm and blade See WIPER ARM AND BLADE REMOVAL INSTALLATION 4 Remove the cowl grille See COWL GRILLE REMOVAL INSTALLATION 5 Disconnect the connector 6 Remove the bolts 7 Remove the nut 8 In...

Page 2136: ...MAZDA MOTORS CORP WIPER MOTOR DISASSEMBLY ASSEMBLY 1 Disassemble in the order indicated in Fig 6 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Wiper Washer System MX 5 Miata Microsoft Thursday...

Page 2137: ...ble in the reverse order of disassembly BALL JOINT ASSEMBLY NOTE 1 Use a clean rag to protect the link and squeeze using pliers 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Wiper Washer Syste...

Page 2138: ...the wipers and then stop them at the auto stop position 2 Adjust the motor crank wiper link No 1 and wiper link No 2 so that they are parallel as shown in Fig 8 3 Assemble the wiper motor 2007 Mazda M...

Page 2139: ...nnector 2 Connect battery positive voltage to wiper motor terminal A or C and ground to terminal F then verify that the wipers operate as shown in Fig 9 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BO...

Page 2140: ...rify that the wipers stop 4 Connect wiper motor terminals E and A and apply battery positive voltage to terminal B 5 Operate the wipers at low speed and verify that they stop in the park position If t...

Page 2141: ...OVAL INSTALLATION LF 3 Disconnect the washer hose from joint pipe A 4 Remove the bolt and nut then remove the washer tank 5 Disconnect the washer motor connector 6 Install in the reverse order of remo...

Page 2142: ...le See BATTERY REMOVAL INSTALLATION LF 3 Remove the washer tank See WASHER TANK REMOVAL INSTALLATION 4 Remove the washer motor then remove the grommet 5 Install in the reverse order of removal 2007 Ma...

Page 2143: ...motor terminal A and terminal B to ground 2 Verify that the washer motor operates normally If there is any malfunction replace the washer motor 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB W...

Page 2144: ...LLATION 2 Remove the washer hose from the washer nozzle 3 Squeeze the tabs of the washer nozzle 4 Pull the washer nozzle out to remove it 5 Install in the reverse order of removal 2007 Mazda MX 5 Miat...

Page 2145: ...ip 5 Disconnect joint pipe B then remove washer hose A 6 Disconnect washer hose B from the washer nozzle then remove washer hose B 7 Disconnect joint pipe C then remove washer hose C 8 Remove washer h...

Page 2146: ...LATION LF 3 Remove the column cover See COLUMN COVER REMOVAL INSTALLATION 4 Disconnect the wiper and washer switch connector 5 Remove the screws then remove the wiper and washer switch 6 Install in th...

Page 2147: ...continuity between the wiper and washer switch is as indicated in Fig 17 If not as indicated in Fig 17 replace the wiper and washer switch 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Wiper W...

Page 2148: ...Continuity Table Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Wiper Washer System MX 5 Miata Microsoft Thursday July 09 2009 3 23 47 PM Page 17 2005 Mitchell Rep...

Page 2149: ...er Switch Circuit Courtesy of MAZDA MOTORS CORP 2007 Mazda MX 5 Miata Sport 2007 ACCESSORIES BODY CAB Wiper Washer System MX 5 Miata Microsoft Thursday July 09 2009 3 23 47 PM Page 18 2005 Mitchell Re...

Page 2150: ...RAMS article AIR CONDITIONING 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July...

Page 2151: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 2 2005 Mitchell Repair Information Company LLC...

Page 2152: ...Fig 1 Heater Circuit 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 3 2005 Mitchell Repair Information Company LLC...

Page 2153: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 4 2005 Mitchell Repair Information Company LLC...

Page 2154: ...Fig 2 Manual A C Circuit 1 of 2 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 5 2005 Mitchell Repair Information Company LLC...

Page 2155: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 6 2005 Mitchell Repair Information Company LLC...

Page 2156: ...nual A C Circuit 2 of 2 ANTI LOCK BRAKES 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 7 2005 Mitchell Repair Information Com...

Page 2157: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 8 2005 Mitchell Repair Information Company LLC...

Page 2158: ...ck Brakes Circuit W Dynamic Stability Control 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 9 2005 Mitchell Repair Informatio...

Page 2159: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 10 2005 Mitchell Repair Information Company LLC...

Page 2160: ...es Circuit W O Dynamic Stability Control ANTI THEFT 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 11 2005 Mitchell Repair Inf...

Page 2161: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 12 2005 Mitchell Repair Information Company LLC...

Page 2162: ...Fig 6 Anti theft Circuit 1 of 2 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 13 2005 Mitchell Repair Information Company LLC...

Page 2163: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 14 2005 Mitchell Repair Information Company LLC...

Page 2164: ...theft Circuit 2 of 2 COMPUTER DATA LINES 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 15 2005 Mitchell Repair Information C...

Page 2165: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 16 2005 Mitchell Repair Information Company LLC...

Page 2166: ...omputer Data Lines Circuit COOLING FAN 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 17 2005 Mitchell Repair Information Comp...

Page 2167: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 18 2005 Mitchell Repair Information Company LLC...

Page 2168: ...Cooling Fan Circuit CRUISE CONTROL 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 19 2005 Mitchell Repair Information Company...

Page 2169: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 20 2005 Mitchell Repair Information Company LLC...

Page 2170: ...10 Cruise Control Circuit DEFOGGERS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 21 2005 Mitchell Repair Information Company...

Page 2171: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 22 2005 Mitchell Repair Information Company LLC...

Page 2172: ...foggers Circuit ENGINE PERFORMANCE 2 0L 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 30 PM Page 23 2005 Mitchell Repair Information Com...

Page 2173: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 24 2005 Mitchell Repair Information Company LLC...

Page 2174: ...2 0L Engine Performance Circuit 1 of 4 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 25 2005 Mitchell Repair Information Comp...

Page 2175: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 26 2005 Mitchell Repair Information Company LLC...

Page 2176: ...2 0L Engine Performance Circuit 2 of 4 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 27 2005 Mitchell Repair Information Comp...

Page 2177: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 28 2005 Mitchell Repair Information Company LLC...

Page 2178: ...2 0L Engine Performance Circuit 3 of 4 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 29 2005 Mitchell Repair Information Comp...

Page 2179: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 30 2005 Mitchell Repair Information Company LLC...

Page 2180: ...ine Performance Circuit 4 of 4 EXTERIOR LIGHTS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 31 2005 Mitchell Repair Informat...

Page 2181: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 32 2005 Mitchell Repair Information Company LLC...

Page 2182: ...Fig 16 Back up Lamps Circuit 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 33 2005 Mitchell Repair Information Company LLC...

Page 2183: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 34 2005 Mitchell Repair Information Company LLC...

Page 2184: ...terior Lamps Circuit GROUND DISTRIBUTION 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 35 2005 Mitchell Repair Information Co...

Page 2185: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 36 2005 Mitchell Repair Information Company LLC...

Page 2186: ...Ground Distribution Circuit HEADLIGHTS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 37 2005 Mitchell Repair Information Comp...

Page 2187: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 38 2005 Mitchell Repair Information Company LLC...

Page 2188: ...19 Headlights Circuit W HID W DRL 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 39 2005 Mitchell Repair Information Company...

Page 2189: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 40 2005 Mitchell Repair Information Company LLC...

Page 2190: ...0 Headlights Circuit W Halogen W DRL 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 41 2005 Mitchell Repair Information Compan...

Page 2191: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 42 2005 Mitchell Repair Information Company LLC...

Page 2192: ...21 Headlights Circuit W O DRL W HID 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 43 2005 Mitchell Repair Information Company...

Page 2193: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 44 2005 Mitchell Repair Information Company LLC...

Page 2194: ...ights Circuit W O DRL W Halogen Lamps HORN 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 45 2005 Mitchell Repair Information...

Page 2195: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 46 2005 Mitchell Repair Information Company LLC...

Page 2196: ...23 Horn Circuit INSTRUMENT CLUSTER 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 47 2005 Mitchell Repair Information Company...

Page 2197: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 48 2005 Mitchell Repair Information Company LLC...

Page 2198: ...strument Cluster Circuit INTERIOR LIGHTS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 49 2005 Mitchell Repair Information Co...

Page 2199: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 50 2005 Mitchell Repair Information Company LLC...

Page 2200: ...terior Lights Circuit POWER DISTRIBUTION 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 51 2005 Mitchell Repair Information Co...

Page 2201: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 52 2005 Mitchell Repair Information Company LLC...

Page 2202: ...6 Power Distribution Circuit 1 of 2 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 53 2005 Mitchell Repair Information Company...

Page 2203: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 54 2005 Mitchell Repair Information Company LLC...

Page 2204: ...Distribution Circuit 2 of 2 POWER DOOR LOCKS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 55 2005 Mitchell Repair Informatio...

Page 2205: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 56 2005 Mitchell Repair Information Company LLC...

Page 2206: ...28 Power Door Locks Circuit 1 of 2 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 57 2005 Mitchell Repair Information Company...

Page 2207: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 58 2005 Mitchell Repair Information Company LLC...

Page 2208: ...r Door Locks Circuit 2 of 2 POWER MIRRORS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 59 2005 Mitchell Repair Information C...

Page 2209: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 60 2005 Mitchell Repair Information Company LLC...

Page 2210: ...0 Power Mirrors Circuit POWER SEATS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 61 2005 Mitchell Repair Information Company...

Page 2211: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 62 2005 Mitchell Repair Information Company LLC...

Page 2212: ...Heated Seats Circuit POWER TOP SUNROOF 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 63 2005 Mitchell Repair Information Comp...

Page 2213: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 64 2005 Mitchell Repair Information Company LLC...

Page 2214: ...ower Top Sunroof Circuit POWER WINDOWS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 65 2005 Mitchell Repair Information Comp...

Page 2215: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 66 2005 Mitchell Repair Information Company LLC...

Page 2216: ...ircuit W Power Retractable Hardtop W Power Door Locks 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 67 2005 Mitchell Repair I...

Page 2217: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 68 2005 Mitchell Repair Information Company LLC...

Page 2218: ...rcuit W Power Retractable Hardtop W O Power Door Locks 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 69 2005 Mitchell Repair...

Page 2219: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 70 2005 Mitchell Repair Information Company LLC...

Page 2220: ...ows Circuit W O Power Retractable Hardtop RADIO 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 71 2005 Mitchell Repair Informa...

Page 2221: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 72 2005 Mitchell Repair Information Company LLC...

Page 2222: ...ig 36 Radio Circuit W Base Radio 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 73 2005 Mitchell Repair Information Company LL...

Page 2223: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 74 2005 Mitchell Repair Information Company LLC...

Page 2224: ...Radio Circuit W Bose SHIFT INTERLOCK 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 75 2005 Mitchell Repair Information Compa...

Page 2225: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 76 2005 Mitchell Repair Information Company LLC...

Page 2226: ...ift Interlock Circuit STARTING CHARGING 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 77 2005 Mitchell Repair Information Com...

Page 2227: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 78 2005 Mitchell Repair Information Company LLC...

Page 2228: ...Fig 39 Charging Circuit 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 79 2005 Mitchell Repair Information Company LLC...

Page 2229: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 80 2005 Mitchell Repair Information Company LLC...

Page 2230: ...tarting Circuit SUPPLEMENTAL RESTRAINTS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 81 2005 Mitchell Repair Information Com...

Page 2231: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 82 2005 Mitchell Repair Information Company LLC...

Page 2232: ...Supplemental Restraints Circuit 1 of 2 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 83 2005 Mitchell Repair Information Comp...

Page 2233: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 84 2005 Mitchell Repair Information Company LLC...

Page 2234: ...ental Restraints Circuit 2 of 2 TRANSMISSION 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 85 2005 Mitchell Repair Informatio...

Page 2235: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 86 2005 Mitchell Repair Information Company LLC...

Page 2236: ...Fig 43 A T Circuit 1 of 2 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 87 2005 Mitchell Repair Information Company LLC...

Page 2237: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 88 2005 Mitchell Repair Information Company LLC...

Page 2238: ...Circuit 2 of 2 TRUNK TAILGATE FUEL DOOR 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 89 2005 Mitchell Repair Information Co...

Page 2239: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 90 2005 Mitchell Repair Information Company LLC...

Page 2240: ...Trunk Release Circuit WARNING SYSTEMS 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 91 2005 Mitchell Repair Information Compa...

Page 2241: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 92 2005 Mitchell Repair Information Company LLC...

Page 2242: ...Warning Systems Circuit WIPER WASHER 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 93 2005 Mitchell Repair Information Compa...

Page 2243: ...2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 31 PM Page 94 2005 Mitchell Repair Information Company LLC...

Page 2244: ...Fig 47 Wiper Washer Circuit 2007 Mazda MX 5 Miata Sport 2007 SYSTEM WIRING DIAGRAMS Mazda MX 5 Miata Microsoft Thursday July 09 2009 1 39 32 PM Page 95 2005 Mitchell Repair Information Company LLC...

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