Page 1 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) &...
Page 2 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 1: Installing SST (Arms) To Cylinder Block Holes Courtesy of MAZDA MOTORS CORP. 2. Assemble the SSTs (bolts, nuts and plate) to the specified positions.
Page 3 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 2: Assembling SSTs (Bolts, Nuts And Plate) To Positions Courtesy of MAZDA MOTORS CORP. 5. Tighten the SSTs (bolts and nuts) to affix the SSTs firmly.
Page 4: Timing Chain Disassembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Courtesy of MAZDA MOTORS CORP. WARNING: Self-locking brake system of the engine stand may not be  effective when the engine is held in an unbalanced position.
Page 5 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 4: Exploded View Of Timing Chain Components Courtesy of MAZDA MOTORS CORP. Crankshaft Pulley Lock Bolt Disassembly Note...
Page 6 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 5: Installing SST Ring Gear To Lock Crankshaft Against Rotation Courtesy of MAZDA MOTORS CORP. Front Oil Seal Disassembly Note...
Page 7 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 6: Removing Oil Seal Courtesy of MAZDA MOTORS CORP. Chain Tensioner Disassembly Note 1. Unlock the chain tensioner ratchet using a suitable screw driver or equivalent tool.
Page 8 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 7: Disassembling Chain Tensioner Courtesy of MAZDA MOTORS CORP. Oil Pump Sprocket Disassembly Note 1. Hold the oil pump sprocket using the SST .
Page 9: Cylinder Head (I) Disassembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 8: Holding Oil Pump Sprocket Using SST Courtesy of MAZDA MOTORS CORP. CYLINDER HEAD (I) DISASSEMBLY 1. Disassemble in the order indicated in the table.
Page 10 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 9: Exploded View Of Cylinder Head (I) Disassembly Courtesy of MAZDA MOTORS CORP. Camshaft Sprocket Lock Bolt, Variable Valve Timing Actuator Lock Bolt Disassembly Note...
Page 11 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata installation bolt or variable valve timing actuator installation bolt (With variable valve timing mechanism). Without variable valve timing mechanism Fig.
Page 12 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 11: Using Wrench On Cast Hexagon Courtesy of MAZDA MOTORS CORP. Camshaft Cap Disassembly Note 1. Before removing the camshaft caps, inspect the following: Camshaft end play and camshaft journal oil clearance (See CAMSHAFT INSPECTION).
Page 13 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 12: Identifying Loosening Sequence Of Camshaft Cap Bolts Courtesy of MAZDA MOTORS CORP. Tappet Disassembly Note NOTE: The tappets are numbered to make sure they are assembled in their ...
Page 14: Cylinder Head (Ii) Disassembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 13: Loosening Cylinder Head Bolts Courtesy of MAZDA MOTORS CORP. CYLINDER HEAD (II) DISASSEMBLY 1. Disassemble in the order indicated in the table.
Page 15 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 14: Exploded View Of Cylinder Head (II) Disassembly Courtesy of MAZDA MOTORS CORP. Valve Keeper Disassembly Note 1. Remove the valve keeper using the SSTs .
Page 16 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 15: Removing Valve Keeper Courtesy of MAZDA MOTORS CORP. Valve Seal Disassembly Note 1. Remove the valve seal using the SST.
Page 17: Cylinder Block (I) Disassembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 16: Removing Valve Seal Courtesy of MAZDA MOTORS CORP. CYLINDER BLOCK (I) DISASSEMBLY 1. Disassemble in the order indicated in the table.
Page 18 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 17: Exploded View Of Cylinder Block (I) Disassembly Courtesy of MAZDA MOTORS CORP. Drive Plate (ATX), Flywheel (MTX) Disassembly Note 1.
Page 19: Cylinder Block (Ii) Disassembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 18: Removal Sequence Of Drive Plate Or Flywheel Bolts Courtesy of MAZDA MOTORS CORP. CYLINDER BLOCK (II) DISASSEMBLY...
Page 20 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 19: Exploded View Of Cylinder Block (II) Disassembly Courtesy of MAZDA MOTORS CORP. Connecting Rod Cap Disassembly Note 1.
Page 21: Cylinder Head Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata INSPECTION). 2. Loosen the main bearing cap bolts in two or three steps in the order shown in the figure.
Page 22 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 21: Measuring Cylinder Head For Distortion Courtesy of MAZDA MOTORS CORP. 4. Measure the manifold contact surface distortion as shown in the figure.
Page 23: Valve, Valve Guide Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 22: Measuring Manifold Contact Surface Distortion Courtesy of MAZDA MOTORS CORP. If it exceeds the maximum specification, grind the surface or replace the cylinder head.
Page 24 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 23: Measuring Valve Head Margin Thickness Of Each Valve Courtesy of MAZDA MOTORS CORP. 2. Measure the length of each valve. Replace the valve if necessary.
Page 25 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Valve stem diameter (Standard) IN: 5.470-5.485 mm {0.2154-0.2159 in} EX: 5.465-5.480 mm {0.2152-0.2157 in} Valve stem diameter (Minimum) IN: 5.440 mm {0.2142 in} EX: 5.435 mm {0.2140 in}...
Page 26 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 26: Measuring Valve Guise Inner Diameter Courtesy of MAZDA MOTORS CORP. 5. Calculate the valve stem to guide clearance by subtracting the outer diameter of the valve stem from the inner diameter of the corresponding valve guide.
Page 27 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 27: Calculating Valve Stem To Guide Clearance Courtesy of MAZDA MOTORS CORP. Valve stem to guide clearance (Maximum) 0.10 mm {0.004 in} 6.
Page 28: Valve Guide Replacement
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 28: Measuring Protrusion Height (Dimension A) Of Each Valve Guide Courtesy of MAZDA MOTORS CORP. VALVE GUIDE REPLACEMENT Valve Guide Removal 1.
Page 29 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 29: Removing Valve Guide From Combustion Chamber Side Courtesy of MAZDA MOTORS CORP. Valve Guide Installation 1. Assemble the SSTs so that depth L is as specified.
Page 30 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 30: Measuring Valve Guide Protrusion Height Courtesy of MAZDA MOTORS CORP. 2. Tap the valve guide in from the top of the cylinder head until the SSTs contacts the cylinder head.
Page 31 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 31: Installing Valve Guide Courtesy of MAZDA MOTORS CORP. 3. Verify that the valve guide protrusion height (dimension A) is within the specification.
Page 32: Valve Seat Inspection/Repair
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 32: Verifying Valve Guide Height Courtesy of MAZDA MOTORS CORP. VALVE SEAT INSPECTION/REPAIR 1. Measure the seat contact width.
Page 33 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 33: Measuring Seat Contact Width Courtesy of MAZDA MOTORS CORP. 2. Verify that the valve seating position is at the center of the valve face.
Page 34 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 34: Positioning Center Of Valve Face Courtesy of MAZDA MOTORS CORP. 3. Inspect the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem.
Page 35: Valve Spring Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 35: Measuring Protruding Length (Dimension L) Of Valve Stem Courtesy of MAZDA MOTORS CORP. VALVE SPRING INSPECTION 1. Apply pressing force to the pressure spring and inspect the spring height.
Page 36 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 36: Performing Valve Spring Inspection Courtesy of MAZDA MOTORS CORP. 2. Measure the out-of-square of the valve spring, using a square, as shown in the figure.
Page 37: Camshaft Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 37: Measuring Valve Spring Out-Of-Square Courtesy of MAZDA MOTORS CORP. CAMSHAFT INSPECTION 1. Set the No. 1 and No.5 journals on V-blocks.
Page 38 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 38: Measuring Camshaft Runout Courtesy of MAZDA MOTORS CORP. 3. Measure the cam lobe height at the two points as shown in the figure.
Page 39 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata EX: 41.06 {1.616} Without variable valve timing mechanism IN: 42.01 {1.653} EX: 40.96 {1.612} Fig. 39: Measuring Cam Lobe Height At Two Points Courtesy of MAZDA MOTORS CORP.
Page 40 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 40: Measuring Journal Diameters In X And Y Directions At Two Points (A And B) Courtesy of MAZDA MOTORS CORP.
Page 41 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 41: Measuring Oil Clearance Using Plastigauge Courtesy of MAZDA MOTORS CORP. 10. Install the camshaft cap. (See CAMSHAFT ASSEMBLY NOTE).
Page 42: Tappet Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 42: Measuring Camshaft End Play Courtesy of MAZDA MOTORS CORP. TAPPET INSPECTION 1. Measure the tappet hole inner diameter in X and Y directions at the two points (A and B) shown in the figure.
Page 43 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 43: Measuring Tappet Hole Inner Diameter Courtesy of MAZDA MOTORS CORP. 2. Measure the tappet body outer diameter in X and Y directions at the two points (A and B) shown in the figure.
Page 44: Cylinder Block Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 44: Measuring Tappet Body Outer Diameter In X And Y Directions At Two Points (A And B) Courtesy of MAZDA MOTORS CORP.
Page 45 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 45: Measuring Distortion Of Cylinder Block Top Surface In Six Directions Courtesy of MAZDA MOTORS CORP. 2. Measure the cylinder bores in X and Y directions at 42 mm {1.65 in} below the top surface.
Page 46: Oil Jet Valve Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 46: Measuring Cylinder Bores In X And Y Directions At Below Top Surface Courtesy of MAZDA MOTORS CORP.
Page 47: Piston Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 47: Inspecting Oil Jet Valve Courtesy of MAZDA MOTORS CORP. PISTON INSPECTION CAUTION: The piston and connecting rod cannot be disassembled.
Page 48 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 87.465-87.495 mm {3.4435-3.4446 in} 2. Measure the piston-to-cylinder clearance. If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a ...
Page 49 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Top: 0.03-0.08 mm {0.0012-0.0031 in} Second: 0.03-0.07 mm {0.0012-0.0027 in} Oil: 0.03-0.07 mm {0.0012-0.0027 in} Piston ring-to-ring groove clearance (Maximum) Top: 0.17 mm {0.0067 in}...
Page 50: Crankshaft Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Piston end gap (Standard) Top: 0.16-0.31 mm {0.0063-0.0122 in} Second: 0.33-0.48 mm {0.0130-0.0189 in} Oil (rail): 0.20-0.70 mm {0.0079-0.0275 in} Piston end gap (Maximum) 1.0 mm {0.0393 in}...
Page 51 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 0.22-0.45 mm {0.0087-0.0177 in} Crankshaft end play (Maximum) 0.55 mm {0.0216 in} Fig. 51: Measuring Crankshaft End Play Courtesy of MAZDA MOTORS CORP.
Page 52 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 52: Measuring Crankshaft Runout Courtesy of MAZDA MOTORS CORP. Main journal bearing size STD: 51.980-52.000 mm {2.0464-2.0472 in} US0.25: 51.730-51.750 mm {2.0366-2.0373 in}...
Page 53 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Crank pin out of round (Maximum) 0.05 mm {0.0019 in} Fig. 53: Measuring Journal Diameter In X And Y Directions At Two Points (A And B) Courtesy of MAZDA MOTORS CORP.
Page 54: Connecting Rod Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 0.10 mm {0.0039 in} Main bearing size STD: 2.506-2.509 mm {0.0987-0.0988 in} OS0.25: 2.628-2.634 mm {0.1034-0.1037 in} Fig. 54: Measuring Main Journal Oil Clearance Courtesy of MAZDA MOTORS CORP.
Page 55: Assembly Note)
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata single unit. Connecting rod side clearance (Standard) 0.14-0.36 mm {0.0056-0.0141 in} Connecting rod side clearance (Maximum) 0.435 mm {0.0172 in} Fig.
Page 56: Bolt Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 0.026-0.052 mm {0.0011-0.0020 in} Connecting rod bearing oil clearance (Maximum) 0.1 mm {0.0039 in} Connecting rod bearing size [LF] STD: 1.498-1.504 mm {0.0589-0.0592 in}...
Page 57 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 1. Measure the length of each bolt. If it exceeds the specification, replace the bolt.  Bolt length (mm {in}) Cylinder head bolt (With washer) Standard: 149.2-149.8 {5.87-5.90}...
Page 58: Variable Valve Timing Actuator Inspection [With Variable Valve Timing Mechanism]
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 57: Measuring Length Of Each Bolt Courtesy of MAZDA MOTORS CORP. VARIABLE VALVE TIMING ACTUATOR INSPECTION [WITH VARIABLE VALVE TIMING...
Page 59 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 58: Aligning Actuator Rotor Groove & Notch Courtesy of MAZDA MOTORS CORP. OIL CONTROL VALVE (OCV) INSPECTION [WITH VARIABLE VALVE TIMING MECHANISM] Coil Resistance Inspection 1.
Page 60 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 59: Identifying Coil Control Valve Connector Terminals Courtesy of MAZDA MOTORS CORP. Spool Valve Operation Inspection 1. Disconnect the negative battery cable.
Page 61 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 60: Identifying Spool Valve Courtesy of MAZDA MOTORS CORP. 5. Apply battery positive voltage between the oil control valve (OCV) terminals and verify that the spool valve operates and moves to the maximum valve timing advance position.
Page 62: Valve Clearance Inspection
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 61: Positioning Spool Valve Operates And Moves To Maximum Valve Timing Advance Courtesy of MAZDA MOTORS CORP. 6. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing retard position.
Page 63 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 62: Measuring Valve Clearance At Point A Courtesy of MAZDA MOTORS CORP. NOTE: Make sure to note the measured values for choosing the ...
Page 64: Valve Clearance Adjustment
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata EX: 0.27-0.33 mm {0.0106-0.0130 in} VALVE CLEARANCE ADJUSTMENT 1. Remove the engine front cover lower blind plug. 2. Remove the engine front cover upper blind plug.
Page 65 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 64: Locating Cylinder Block SST Courtesy of MAZDA MOTORS CORP. 6. Loosen the timing chain. 1. Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.
Page 66 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 65: Loosening Timing Chain Courtesy of MAZDA MOTORS CORP. 7. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
Page 67 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 66: Holding Camshaft Using Suitable Wrench On Cast Hexagon Courtesy of MAZDA MOTORS CORP. 8. Remove the exhaust camshaft sprocket.
Page 68 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 67: Removing Exhaust Camshaft Sprocket Courtesy of MAZDA MOTORS CORP. 9. Loosen the camshaft cap bolts in several passes in the order shown in the figure.
Page 69 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 68: Identifying Loosening Sequence Of Camshaft Cap Bolts Courtesy of MAZDA MOTORS CORP. 10. Remove the camshaft. 11. Remove the tappet.
Page 70 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata {51.0-91.7 kgf.cm, 44.3-79.5 in.lbf} 2. 14.0-17.0 N.m {1.43-1.73 kgf.m, 10.4-12.5 ft.lbf} Fig. 69: Camshaft Cap Bolt Tightening Sequence Courtesy of MAZDA MOTORS CORP.
Page 71 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 70: Camshaft Sprocket Washer Courtesy of MAZDA MOTORS CORP. 16. Install the exhaust camshaft sprocket. NOTE: Do not tighten the bolt for the camshaft sprocket during this step.
Page 72 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 71: Exhaust Camshaft Sprocket Courtesy of MAZDA MOTORS CORP. 17. Install the SST to the camshaft as shown in the figure.
Page 73 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 72: Installing SST To Camshaft Courtesy of MAZDA MOTORS CORP. 20. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
Page 74 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 73: Holding Camshaft Using Suitable Wrench On Cast Hexagon Courtesy of MAZDA MOTORS CORP. 25. Install the new engine front cover upper blind plug.
Page 75 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 74: Installing Engine Front Cover Upper Blind Plug Courtesy of MAZDA MOTORS CORP. 26. Install the cylinder block lower blind plug.
Page 76 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 75: Installing Cylinder Block Lower Blind Plug Courtesy of MAZDA MOTORS CORP. 27. Install the new engine front cover lower blind plug.
Page 77: Cylinder Block (I) Assembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 76: Identifying Engine Front Cover Lower Blind Plug Courtesy of MAZDA MOTORS CORP. CYLINDER BLOCK (I) ASSEMBLY 1. Assemble in the order indicated in the table.
Page 78 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 77: Exploded View Of Cylinder Block (I) Assembly & Torque Specification Courtesy of MAZDA MOTORS CORP. Main Bearing Cap Assembly Note 1.
Page 79 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Plastic region tightening bolt (Bolt stem length 110 mm) 1. 44-46 N.m {4.5-4.6 kgf.m, 32.5-33.9 ft.lbf} 2. 175°-185° Elastic region tightening bolt (Bolt stem length 104 mm) 1.
Page 80 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 78: Tightening Sequence Of Main Bearing Cap Bolts Courtesy of MAZDA MOTORS CORP. Piston Ring Assembly Note 1. Install the two oil control ring segments and spacer.
Page 81 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 80: Positioning End Gap Of Each Ring Courtesy of MAZDA MOTORS CORP. 2. Insert the piston and connecting rod into the cylinder with the arrow mark to front of the engine.
Page 82 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 81: Inserting Piston And Connecting Rod Into Cylinder Bore Courtesy of MAZDA MOTORS CORP. Connecting Rod Bearing Assembly Note...
Page 83 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 82: Installing Connecting Rod Bearing Courtesy of MAZDA MOTORS CORP. Connecting Rod Cap Assembly Note CAUTION: When assembling the connecting rod caps, align the broken, rough ...
Page 84 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 1. Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly.
Page 85 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 84: Identifying Marks At Exact Top Center Courtesy of MAZDA MOTORS CORP. 6. Set the SST as shown, then measure the gear backlash using a dial gauge.
Page 86 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 85: Measuring Gear Backlash Using Dial Gauge Courtesy of MAZDA MOTORS CORP. NOTE: For an accurate measurement of gear backlash, insert a screwdriver into ...
Page 87 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 86: Measuring Gear Backlash Courtesy of MAZDA MOTORS CORP. If the backlash exceeds the specified range, remeasure the backlash and, ...
Page 88 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata ADJUSTMENT SHIM SELECTION CHART Selection Shim thickness Selection Shim thickness Backlash mm {in} Backlash mm {in} shim (No). mm {in} shim (No).
Page 89: Cylinder Block (Ii) Assembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 0.169-0.175 0.029-0.035 {0.00665- 1.29 {0.507} 1.49 {0.0586} {0.00114-0.00137} 0.00688} 0.162-0.168 0.022-0.028 {0.00637- 1.30 {0.511} 50 (master) 1.50 {0.0590} {0.000866-0.00110} 0.00661}...
Page 90 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 87: Exploded View Of Cylinder Block (II) Assembly & Torque Specification Courtesy of MAZDA MOTORS CORP. Rear Oil Seal Assembly Note 1.
Page 91 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 88: Installing Rear Oil Seal Using SST Courtesy of MAZDA MOTORS CORP. 3. Tighten the rear oil seal bolts in the order as shown in the figure.
Page 92 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 89: Rear Oil Seal Bolt Tightening Sequence Courtesy of MAZDA MOTORS CORP. Drive Plate (ATX), Flywheel (MTX) Assembly Note 1.
Page 93 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 90: Tightening Sequence Of Drive Plate Or Flywheel Bolts (Performed In 3 Steps) Courtesy of MAZDA MOTORS CORP.
Page 94 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 91: Installing Silicone Sealant To Oil Pan Courtesy of MAZDA MOTORS CORP.
Page 95 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 2. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side.
Page 96: Cylinder Head (I) Assembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 93: Rear Oil Pan Bolts Tightening Sequence Courtesy of MAZDA MOTORS CORP. CYLINDER HEAD (I) ASSEMBLY 1. Assemble in the order indicated in the table.
Page 97 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 94: Exploded View Of Cylinder Head (I) Assembly & Torque Specification Courtesy of MAZDA MOTORS CORP. Valve Seal Assembly Note 1.
Page 98 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 95: Pressing Valve Seal Courtesy of MAZDA MOTORS CORP. Valve Keeper Assembly Note 1. Install the valve keeper using the SSTs .
Page 99: Cylinder Head (Ii) Assembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 96: Installing Valve Keeper Courtesy of MAZDA MOTORS CORP. CYLINDER HEAD (II) ASSEMBLY 1. Assemble in the order indicated in the table.
Page 100 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 97: Exploded View Of Cylinder Head (II) Assembly & Torque Specification Courtesy of MAZDA MOTORS CORP. Cylinder Head Bolt Assembly Note 1.
Page 101 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Tightening torque 1. 3-11 N.m {30.6-112 kgf.cm, 26.6-97.3 in.lbf} 2. 13-17 N.m {1.4-1.7 kgf.m, 9.6-12.5 ft.lbf} 3. 43-47 N.m {4.4-4.7 kgf.m, 31.8-34.6 ft.lbf}...
Page 102 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 1. Set the cam position of No. 1 cylinder at the top dead center (TDC) and install the camshaft.
Page 103: Timing Chain Assembly
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata installation. TIMING CHAIN ASSEMBLY 1. Assemble in the order indicated in the table.
Page 104 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 100: Exploded View Of Timing Chain Assembly & Torque Specification Courtesy of MAZDA MOTORS CORP. Oil Pump Sprocket Assembly Note 1.
Page 105 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 102: Installing SST To Camshaft Courtesy of MAZDA MOTORS CORP. 2. Remove the cylinder block lower blind plug.
Page 106 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 103: Installing SST In Place Of Cylinder Block Lower Blind Plug Courtesy of MAZDA MOTORS CORP. 4. Turn the crankshaft clockwise so that the crankshaft is in the No. 1 cylinder TDC position.
Page 107 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 104: Chain Tensioner Retaining Wire Courtesy of MAZDA MOTORS CORP. Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note 1.
Page 108 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 105: Holding Camshaft Using Suitable Wrench On Cast Hexagon Courtesy of MAZDA MOTORS CORP. Front Oil Seal Assembly Note 1.
Page 109 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 106: Installing Front Oil Seal Courtesy of MAZDA MOTORS CORP.
Page 110 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 107: Using SST And Hammer Courtesy of MAZDA MOTORS CORP. Engine Front Cover Assembly Note 1. Apply silicone sealant to the engine front cover as shown in the figure.
Page 111 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 108: Applying Silicone Sealant To Engine Front Cover Courtesy of MAZDA MOTORS CORP. 2. Install the cylinder head cover bolts in the order as shown in the figure.
Page 112 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 8.0-11.5 N.m 1-18 {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf} 19-22 40-55 {4.1-5.6, 29.6-40.5} Fig. 109: Engine Front Cover Bolt Tightening Sequence...
Page 113 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Courtesy of MAZDA MOTORS CORP. Crankshaft Pulley Lock Bolt Assembly Note 1. Install the SST to the camshaft as shown in the figure.
Page 114 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 111: Installing M6 X 1.0 Bolt On Crankshaft Pulley Courtesy of MAZDA MOTORS CORP. 4. Hold the crankshaft pulley using the SST .
Page 115 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf} Fig. 112: Locking Flywheel Using SST Courtesy of MAZDA MOTORS CORP. Cylinder Head Cover Assembly Note 1.
Page 116 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 113: Applying Silicone Sealant To Mating Faces Courtesy of MAZDA MOTORS CORP. 2. Install the cylinder head cover with a new gasket.
Page 117: Engine Technical Data
2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 114: Cylinder Head Cover Bolt Tightening Sequence Courtesy of MAZDA MOTORS CORP. 01-50 TECHNICAL DATA ENGINE TECHNICAL DATA...
Page 118 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata IN: 5.470-5.485 mm {0.2154-0.2159 in} Valve stem diameter (Standard) EX: 5.465-5.480 mm {0.2152-0.2157 in} IN: 5.440 mm {0.2142 in} Valve stem diameter (Minimum) EX: 5.435 mm {0.2140 in}...
Page 119 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Piston diameter (Standard) 87.465-87.495 mm {3.4435-3.4446 in} Piston-to-cylinder clearance (Standard) 0.025-0.045 mm {0.0010-0.0017 in} Piston-to-cylinder clearance (Maximum) 0.11 mm {0.0043 in} Top: 0.03-0.08 mm {0.0012-0.0031 in}...
Page 120 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Maximum: 46.0 {1.81} Main bearing cap bolt (Plastic region tightening bolt only) Standard: 110.0-110.6 {4.33-4.35} Maximum: 111.3 {4.38} IN: 0.22-0.28 mm {0.0087-0.0110 in} Valve clearance [Engine cold] EX: 0.27-0.33 mm {0.0106-0.0130 in}...
Page 121 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata Fig. 115: Identifying Engine SST Holder Courtesy of MAZDA MOTORS CORP. ENGINE SERVICE TOOLS SPECIFICATION 1: 49 UN30 1: 49 E011...
Page 122 2007 Mazda MX-5 Miata Sport 2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata 1: 49 B012 0A2 Engine 1: 49 H010 401 hanger set Pivot Oil seal installer 1: 49 T032 1: 49 S120 170...
Page 123: Abs System Wiring Diagram
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata ABS SYSTEM WIRING DIAGRAM Fig. 1: ABS System Wiring Diagram Courtesy of MAZDA MOTORS CORP.
Page 124 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata ON-BOARD DIAGNOSTIC (OBD) TEST DESCRIPTION The OBD test inspects the integrity and function of the ABS and outputs the results when requested by  the specific tests.
Page 125: Clearing Dtcs Procedures
2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Fig. 2: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. CLEARING DTCS PROCEDURES 1. Connect the M-MDS to the DLC-2. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.
Page 126: Pid/Data Monitor And Record Procedure
2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Fig. 3: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. PID/DATA MONITOR AND RECORD PROCEDURE 1. Connect the M-MDS to the DLC-2. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.
Page 127: Active Command Modes Procedure
2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Fig. 4: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. NOTE: The PID data screen function is 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 output part control is necessary.
Page 128: Dtc Table
2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Select "ABS".  Select "DataLogger".  3. Select the active command modes from the PID table. 4. Perform the active command modes, inspect the operations for each parts.
Page 129 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata C1095 Pump motor, motor relay system C1096 Pump motor, motor relay system C1141 LF ABS sensor rotor system C1142 RF ABS sensor rotor system C1143 LR ABS sensor rotor system...
Page 130 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata ABS_VOLT Inspect the power Ignition switch at  (System battery supply circuit. voltage value) (See ABS SYSTEM Approx. 12.2 V  INSPECTION .) Idling: Approx.  14.1 V...
Page 131 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata solenoid valve (See ABS HU/CM Solenoid valve  output state) INSPECTION .) On/Off not activated: ABSRR_O Inspect the ABS Solenoid valve  (Right rear outlet HU/CM. activated: On...
Page 132 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata ACTIVE COMMAND MODES TABLE Command name Output part Operation Operating condition LF_INLET LF inlet solenoid valve LF_OUTLET LF outlet solenoid valve LR_INLET LR inlet solenoid valve LR_OUTLET...
Page 133: Diagnostic Procedure
2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata DIAGNOSTIC PROCEDURE DTC B1317, B1318 DIAGNOSTIC PROCEDURE TABLE STEP INSPECTION ACTION INSPECT BATTERY Make sure that battery terminal VOLTAGE connection is normal. Go to the next step.
Page 134 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata INSPECT ABS HU/CM Go to the next step. POWER SUPPLY FOR Repair or replace the wiring harness for OPEN CIRCUIT open circuit between the ABS HU/CM and ground, then go to Step 6.
Page 135 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata DTC troubleshooting completed. Are any other DTCs  present? DTC B1342 [ABS] DTC B1342 POSSIBLE CAUSE TABLE DTC B1342 ABS HU/CM system DETECTION CONDITION The ABS HU/CM on-board diagnostic ...
Page 136 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata DIAGNOSTIC PROCEDURE DTC B1484 DIAGNOSTIC PROCEDURE TABLE STEP INSPECTION ACTION INSPECT ABS HU/CM Go to the next step. TO BRAKE SWITCH FOR OPEN CIRCUIT Turn the ignition Repair or replace the wiring harness for ...
Page 137 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Go to the next step. Make sure to  reconnect all disconnected connectors. Clear the DTC from  the memory. (See CLEARING  DTCS PROCEDURES .) Are the same DTCs ...
Page 138 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata PROCEDURES .) Go to the next step. Is the same DTC  present? VERIFY AFTER REPAIR Go to the applicable DTC inspection. PROCEDURE (See DTC Table .) Are any other DTCs ...
Page 139 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata DIAGNOSTIC PROCEDURE DTC C1095, C1096 DIAGNOSTIC PROCEDURE TABLE STEP INSPECTION ACTION INSPECT ABS FUSE Go to the next step. CONDITION Replace the fuse, then go to Step 5.
Page 140: Operation
2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata GROUND FOR OPEN Repair or replace the wiring harness for CIRCUIT open circuit between ABS HU/CM terminal A and ground, then go to Step Turn the ignition ...
Page 141 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Is the same DTC  present? VERIFY AFTER REPAIR Go to the applicable DTC inspection. PROCEDURE (See DTC Table .) Are any other DTCs  DTC troubleshooting completed.
Page 142 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Go to the next step. Connect the M-MDS  to the DLC-2. Select the following  PIDs using the M- MDS: LF_WSPD LR_WSPD RF_WSPD RR_WSPD Drive the vehicle.
Page 143 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Clearance Front: 0.3-1.0 mm {0.012- 0.057 in} Rear: 0.8-1.6 mm {0.032-0.062 in} VISUALLY INSPECT Go to the next step. ABS SENSOR ROTOR Replace the front wheel hub component...
Page 144 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata C1155 (open circuit) system RR ABS wheel-speed sensor C1165 (open circuit) system LR ABS wheel-speed sensor C1175 (open circuit) system DETECTION CONDITION Open circuit or short to ...
Page 145 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata ABS HU/CM terminal  H-LR ABS wheel- speed sensor terminal ABS wheel-speed sensor  malfunction Poor connection at  connectors (female terminal) DIAGNOSTIC PROCEDURE DTC C1145, C1155, C1165, C1175 DIAGNOSTIC PROCEDURE TABLE...
Page 146 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Drive the vehicle.  Verify that the wheel  speed-signals are transmitted from each ABS wheel-speed sensor. Are the wheel-speed  signals transmitted? INSPECT FOR OPEN Replace the ABS wheel-speed sensor, CIRCUIT IN WIRING then go to the next step.
Page 147 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata speed sensor (-): Repair or replace the wiring harness, then go to the next step. LR ABS wheel-  speed sensor (+): G-A LR ABS wheel- ...
Page 148 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata wheels indicate abnormal acceleration that exceeds specification. Vehicle wheel speed signals  of any of the four vehicle wheels indicate speed that exceeds specification. POSSIBLE CAUSE ABS wheel-speed sensor ...
Page 149 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata LR_WSPD RF_WSPD RR_WSPD Start the engine and  drive the vehicle. Verify that the PIDs of  the four ABS wheel- speed sensors correspond approximately. Do the vehicle speeds ...
Page 150 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata (See DSC HU/CM Make sure to  REMOVAL/INSTALLATION .) reconnect all disconnected connectors. Clear the DTC from  the memory. (See Clearing DTCs  Procedures .) Start the engine and ...
Page 151 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata DIAGNOSTIC PROCEDURE DTC C1186, C1266 DIAGNOSTIC PROCEDURE TABLE STEP INSPECTION ACTION INSPECT ABS FUSE Go to the next step. CONDITION Replace the fuse, then go to Step 3.
Page 152 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata VERIFY Replace the ABS HU/CM, then go to TROUBLESHOOTING next step. COMPLETED (See ABS HU/CM REMOVAL/INSTALLATION .) Clear the DTC from  the memory. (See CLEARING ...
Page 153 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata (female terminal) DIAGNOSTIC PROCEDURE DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254 DIAGNOSTIC PROCEDURE TABLE STEP INSPECTION ACTION VERIFY SOLENOID Go to the next step. VALVE OPERATION Turn the ignition ...
Page 154 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata DTC C1233, C1234, C1235, C1236 [ABS] DTC C1233, C1234, C1235, C1236 POSSIBLE CAUSE TABLE LF ABS wheel-speed sensor C1233 (short to ground) system RF ABS wheel-speed sensor...
Page 155 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata terminal L-RR ABS wheel-speed sensor terminal B ABS HU/CM  terminal G-LR ABS wheel-speed sensor terminal A ABS HU/CM  terminal H-LR ABS wheel-speed sensor terminal B ABS wheel-speed sensor ...
Page 156 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata Go to the next step. Connect the M-MDS  to the DLC-2. Select the following  PIDs using the M- MDS: LF_WSPD LR_WSPD RF_WSPD RR_WSPD Drive the vehicle.
Page 157 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata speed sensor Repair or replace the wiring harness, (+): M-A then go to the next step. RF ABS wheel-  speed sensor (-): LF ABS wheel- ...
Page 158 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata output? DTC C1805 [ABS] DTC C1805 POSSIBLE CAUSE TABLE DTC C1805 Incorrect ABS HU/CM installed DETECTION CONDITION The programmed vehicle information and the  data received from the CAN do not correspond.
Page 159 2007 Mazda MX-5 Miata Sport 2007 BRAKES On-Board Diagnostic (ABS) - MX-5 Miata VERIFY AFTER REPAIR Go to the applicable DTC inspection. PROCEDURE (See DTC Table .) DTC troubleshooting completed. Are any other DTCs  present?
Page 160 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 2007 ACCESSORIES & BODY, CAB...
Page 161 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 1: Identifying Power Door Lock System And Keyless Entry System Components Location...
Page 162 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Courtesy of MAZDA MOTORS CORP. THEFT-DETERRENT SYSTEM LOCATION INDEX[ADVANCED KEYLESS SYSTEM] Fig. 2: Identifying Hood Latch Courtesy of MAZDA MOTORS CORP.
Page 163 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 3: Identifying Immobilizer System Components Location Courtesy of MAZDA MOTORS CORP. DOOR KEY CYLINDER REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM 1. Remove the following parts: 1.
Page 164 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 4: Turning Door Key Cylinder Courtesy of MAZDA MOTORS CORP. DOOR LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION [ADVANCED KEYLESS SYSTEM] 1. Remove the following parts: 1.
Page 165 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .) 3.
Page 166: Door Lock Actuator
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 8: Door Lock Switch Connector Terminals With Circuit Courtesy of MAZDA MOTORS CORP. DOOR LOCK STRIKER REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] 1. Remove the screws, and then remove the door lock striker.
Page 167 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Actuator operation B+ GNB lock Unlock (): RH Fig. 10: Identifying Door Lock Actuator Connector Terminals With Circuit Courtesy of MAZDA MOTORS CORP.
Page 168 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 12: Identifying Door Lock-Link Switch Connector Terminals With Circuit Courtesy of MAZDA MOTORS CORP. DOOR KEY CYLINDER SWITCH 1. Disconnect the door lock actuator connector.
Page 169 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 1. Remove the following parts: 1. Door trim (See DOOR TRIM REMOVAL/INSTALLATION .) 2. Door glass (See DOOR GLASS REMOVAL/INSTALLATION .) 3.
Page 170 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 1. Remove the door trim. (See DOOR TRIM REMOVAL/INSTALLATION .) 2. Remove the screws, then remove the inner handle. 3. Detach the cables from the inner handle and door lock knob.
Page 171 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 18: Identifying Open Hook Courtesy of MAZDA MOTORS CORP. FUEL-FILLER LID OPENER REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] 1. To remove the fuel-filler lid opener, remove the trunk side trim (LH). (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
Page 172 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 5. Adjust the fuel-filler lid. (See FUEL-FILLER LID ADJUSTMENT .) COIL ANTENNA REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] NOTE: Do not remove the coil antenna unless you are replacing it.
Page 173 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND CLEARING[ADVANCED KEYLESS SYSTEM] FOREWORD When performing the following procedures, the immobilizer resetting procedure using the M-MDS must ...
Page 174 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata key programming The additional key programming using No.  procedure. (Method for 1 cannot be performed after the procedure. programming other keys M-MDS It is possible to restore the setting.
Page 175 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata M-MDS CARD KEY PROGRAMMING   STEERING LOCK UNIT  PROGRAMMING Carry out the following procedure using the  M-MDS, then go to NO.5 RESETTING New instrument ...
Page 176 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata starting the engine using the next key. If the engine cannot be started using a programmed key, repeat the  procedure from the beginning.
Page 177 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata CAUTION: Do not place the following devices in the vehicle while programming,  otherwise programming cannot be performed: Card key ...
Page 178 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 4. Turn the ignition switch to the LOCK position. 5. Using key 1, turn the ignition switch to the ON position.
Page 179 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata not indicate an improper procedure. Continue to perform the procedure as indicated. 7. Select "BODY/SECURITY/PATS functions" from the M-MDS screen menu.
Page 180 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 24: Identifying Key For Resistration Courtesy of MAZDA MOTORS CORP. 1. Prepare two or more keys to be programmed after the key ID number clearing.
Page 181 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 25: Security Light And Keyless Warning Light Blinking Pattern Courtesy of MAZDA MOTORS CORP. 18. After verifying that the keyless warning light goes out, turn the ignition switch to the LOCK position using key 1.
Page 182 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Key Programming Procedure (Using Two Valid Keys)" setting. This procedure is possible when the vehicle is new, and when replacing ...
Page 183 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata When the keyless control module is replaced  Have one or more card keys to be programmed after the replacement. ...
Page 184 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata CAUTION: The M-MDS displays "At least two or more keys must be  programmed", however, do not perform the key programming and proceed to Step 8.
Page 185 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata any additional keys. 21. Start the engine with key 1. 22. Verify that the security light and keyless warning light operate as follows: From the point when the ignition switch is turned to the ON position, the security light illuminates ...
Page 186 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata approx. 3 s, and goes out. The keyless warning light illuminate when the ignition switch is turned to the ON position for ...
Page 187 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 29: Removing Hood Release Lever From Dashboard Courtesy of MAZDA MOTORS CORP. HOOD LATCH SWITCH INSPECTION[ADVANCED KEYLESS SYSTEM] 1. Open the hood.
Page 188 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 6. Inspect for continuity between the hood latch switch terminals A and B If there is continuity, replace the hood latch.
Page 189 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 32: Identifying Open Hook Courtesy of MAZDA MOTORS CORP. HOOD STRIKER REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] 1. Remove the bolt, then remove the hood striker. HOOD STRIKER 2.
Page 190 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 34: Pulling Out Auxiliary Key Courtesy of MAZDA MOTORS CORP. Fig. 35: Removing Cap Courtesy of MAZDA MOTORS CORP. 3. Insert a flathead screwdriver into the crack and press the battery out.
Page 191 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata NOTE: The batteries will last about 1 years when used 10 times a day.  Fig. 37: Positions For Inserting New Battery Courtesy of MAZDA MOTORS CORP.
Page 192 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 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 ...
Page 193 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 40: Removing Bracket & Screw Courtesy of MAZDA MOTORS CORP. 8. Install in the reverse order of removal. KEYLESS CONTROL MODULE INSPECTION[ADVANCED KEYLESS SYSTEM] 1.
Page 194 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Under any Related  condition: Inspect Continuity detected wiring for continuity to harnesses GND. Door lock  Door lock actuator 1.0 or less rarr; B+...
Page 195 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata (exterior, rear) (- antenna condition: Inspect keyless antenna (exterior, for continuity to Continuity detected (exterior, rear) rear) keyless antenna. keyless Under any...
Page 196 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata (interior, front)(- antenna condition: Inspect keyless antenna (interior, for continuity to Continuity detected (interior, front) front) keyless antenna. Ignition switch is at...
Page 197 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Trunk lid open Trunk  (trunk compartment 1.0 or less compartment Trunk light switch on) Trunk open light switch compartment signal...
Page 198 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata position harnesses Request switch (RH) is ON: Inspect for Continuity detected continuity to ground. Request switch Request Request switch input (RH)
Page 199 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata (Door switch off) harnesses Passenger-side door is unlocked: Inspect Continuity detected Door lock- for continuity to Door lock-link Unlock signal link switch ground.
Page 200 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Inspect for  continuity to PCM. HS-CAN- Continuity detected - Inspect for  continuity to instrument cluster. With immobilizer system With exterior open function (Power window system)
Page 201 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 6. Press the UNLOCK button on card key 2. 7. From the ignition switch in the ON position, switch the ignition switch in the order indicated below.
Page 202 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata When using the IDS (laptop PC)  1. Select "BODY" 2. Select "SECURITY" 3. Select "PATS functions" When using the PDS (Pocket PC) ...
Page 203 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 43: Identifying 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.
Page 204 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata lock unit. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .) For this procedure, a programmed card key is necessary. If there is no ...
Page 205 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata KEYLESS CONTROL MODULE CONFIGULATION[ADVANCED KEYLESS SYSTEM] 1. Connect the M-MDS to the DLC-2 connector. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.
Page 206 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 1. Select "Programmable parameters". 2. Select "RKE". 4. Select the item name, and than select either "ON/ OFF". Fig. 46: Identifying DLC-2 Connector Courtesy of MAZDA MOTORS CORP.
Page 207 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 47: Identifying Keyless Receiver Remove/Install Components (Front) Courtesy of MAZDA MOTORS CORP. REAR 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 208 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 48: Identifying Keyless Receiver Remove/Install Components (Rear) Courtesy of MAZDA MOTORS CORP. KEYLESS RECEIVER INSPECTION[ADVANCED KEYLESS SYSTEM] 1. Measure the voltage or inspect for continuity according to the Terminal Voltage Table (Reference).
Page 209: Exterior, Rear
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata name Continuity Keyless  control Keyless Power module control Under any condition supply Related  module wiring harnesses Keyless  Under any condition: Inspect the...
Page 210 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata 2. Remove the nuts. 3. Disconnect the connector, then remove the keyless antenna. 4. Install in the reverse order of removal.
Page 211 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 52: Identifying Keyless Antenna And Foot Support Courtesy of MAZDA MOTORS CORP. 8. Install in the reverse order of removal.
Page 212 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 53: Identifying Keyless Antenna And Fastener Courtesy of MAZDA MOTORS CORP. INTERIOR, REAR 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 213 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 54: Identifying Keyless Antenna And Nut Courtesy of MAZDA MOTORS CORP. INTERIOR, TRUNK 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 214 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 55: Identifying Keyless Antenna And Nut Courtesy of MAZDA MOTORS CORP. KEYLESS BEEPER REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 215 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 56: Identifying Keyless Beeper Remove/Install Components Courtesy of MAZDA MOTORS CORP. REQUEST SWITCH REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] DEIVER-SIDE/PASSENGER-SIDE 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 216: Trunk Lid
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 57: Identifying Request Switch Remove/Install Components (Driver-Side/Passenger-Side) Courtesy of MAZDA MOTORS CORP. TRUNK LID 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 217 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata If not as specified, replace the request switch.  : Continuity Fig. 59: Request Switch Continuity Table Courtesy of MAZDA MOTORS CORP.
Page 218 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 61: Identifying DLC-2 Connector Courtesy of MAZDA MOTORS CORP. NOTE: When "OUT-CODE" is first displayed, turning the ignition switch from ...
Page 219 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata If the trunk lid opener does not operate as indicated in the table, replace the trunk lid opener.  TRUNK LID OPENER OPERATION REFERENCE...
Page 220 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 64: Identifying Trunk Lid Opener Remove/Install Components With Torque Specifications Courtesy of MAZDA MOTORS CORP. TRUNK LID OPENER SWITCH REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] 1.
Page 221 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata TRUNK LID OPEN CANCEL SWITCH REMOVAL/INSTALLATION [ADVANCED KEYLESS SYSTEM] 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .) 3.
Page 222 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 68: Identifying Trunk Lid Open Cancel Switch Connector Terminals With Circuit Courtesy of MAZDA MOTORS CORP. TRUNK KEY CYLINDER REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] 1.
Page 223 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata If not as specified, replace the trunk key cylinder.  : Continuity Fig. 70: Trunk Key Cylinder Switch Continuity Table Courtesy of MAZDA MOTORS CORP.
Page 224 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Security and Locks (Advanced Keyless System) - MX-5 Miata Fig. 73: Identifying Trunk Lid Opener Switch Terminals With Circuit Courtesy of MAZDA MOTORS CORP. TOP LOCK SWITCH INSPECTION[ADVANCED KEYLESS SYSTEM] 1.
Page 225: Location Index
2008 Mazda MX-5 Miata Grand Touring 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 2008 RESTRAINTS Air Bag System - MX-5 Miata 2008 RESTRAINTS Air Bag System - MX-5 Miata LOCATION INDEX Fig. 1: Identifying Location Of Airbag Components Courtesy of MAZDA MOTORS CORP.
Page 226: Restraints
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata AIR BAG MODULE INSPECTION Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may  cause serious injury. Do not use a tester to inspect an air bag module. Always use the on-board diagnostic function to diagnose the air bag module for malfunctions.
Page 227 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 3: Air Bag Module Handling (1 Of 2) Courtesy of MAZDA MOTORS CORP. A live (undeployed) air bag module placed with its deployment surface to ground is dangerous. If ...
Page 228 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 4: Air Bag Module Handling (2 Of 2) Courtesy of MAZDA MOTORS CORP. SIDE AIR BAG MODULE HANDLING When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad, ...
Page 229 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata (deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the SAS control module or disconnecting the SAS control module connector, always turn the...
Page 230 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may  accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a serious accident.
Page 231 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Disassembling the air bag system components could cause it to not operate (deploy) normally.  Never disassemble any air bag system components. Fig. 6: Air Bag System Service Cautions Courtesy of MAZDA MOTORS CORP.
Page 232 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 7: Air Bag Module & Pre-Tensioner Seat Belt Handling Caution Courtesy of MAZDA MOTORS CORP. SEAT WEIGHT SENSOR HANDLING The seat weight sensor has a built-in strain gauge which may operate improperly if the sensor is ...
Page 233 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Incorrectly repairing an air bag wiring harness can accidentally operate (deploy) the air bag  module and pre-tensioner seat belts. If a problem is found in the air bag wiring harness, always replace the wiring harness with a new one.
Page 234 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 9: View Of Passenger Air Bag Deactivation (PAD) Indicator & Components Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal. DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION...
Page 235 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 10: View Of Driver-Side Air Bag Module & Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal.
Page 236: Passenger-Side Air Bag Module Removal/Installation
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 6. Turn the ignition switch to the ON position. 7. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.
Page 237 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata system service warnings and cautions before handling the air bag module. (See AIR BAG SYSTEM SERVICE WARNINGS .) (See AIR BAG SYSTEM SERVICE CAUTIONS .) If the passenger-side air bag module is installed with debris in the ...
Page 238 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata...
Page 239 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 12: View Of Passenger-Side Air Bag Module & Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 6. Install in the reverse order of removal.
Page 240: Cap Installation Note
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 14: Prying Out Connector Stopper Plate Courtesy of MAZDA MOTORS CORP. 2. Disconnect the connector. CAP INSTALLATION NOTE 1. The cap cannot be reused. Replace the cap with a new one when the cap or the passenger-side air bag module has been removed.
Page 241 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata the foreign material may be scattered when the side air bag module operates (deploys), causing injury. Verify that there is no foreign material in the seat back before installing the side air bag module.
Page 242: Crash Zone Sensor Removal/Installation
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 16: View Of Side Air Bag Module & Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 9. Install in the reverse order of removal.
Page 243 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY REMOVAL/INSTALLATION [LF] .) 4. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION .) 5.
Page 244 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata WARNING: Handling the SAS 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 the SAS control module.
Page 245 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 18: View Of SAS Control Module Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 7. Install in the reverse order of removal. 8. Turn the ignition switch to the ON position.
Page 246 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 19: Identifying DLC-2 Location Courtesy of MAZDA MOTORS CORP. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.
Page 247 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 5. Detach the tab as shown in Fig. 20 and remove the connector from the seat connector. Fig. 20: Detaching Seat Connector Tab & Removing Connector From Seat Connector Courtesy of MAZDA MOTORS CORP.
Page 248 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 21: Removing Connector From Seat Connector Courtesy of MAZDA MOTORS CORP. 7. Install in the reverse order of removal. SEAT TRACK POSITION SENSOR INSTALLATION NOTE Verify that the seat track position sensor is not contacting the metal plate.
Page 249 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 22: View Of Seat Track Position Sensor Courtesy of MAZDA MOTORS CORP. SEAT WEIGHT SENSOR CONTROL MODULE REMOVAL/INSTALLATION CAUTION: When the seat weight sensor control module is replaced with a new ...
Page 250 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 23: View Of Seat Weight Sensor Control Module Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal. SEAT WEIGHT SENSOR CALIBRATION...
Page 251 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Or, the vehicle is involved in a collision  1. Have two 20 kg {44 lb} weights ready to use. 2. Connect the WDS or equivalent to the DLC-2 (16-pin).
Page 252 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata sensor inspection using the WDS or equivalent. Removal of the passenger-side seat  Loosening and retightening of passenger's seat fixing bolts  Or, the vehicle is involved in a collision ...
Page 253 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH REMOVAL/INSTALLATION 1. Remove the battery cover. 2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 3. Remove the side panel. (See SIDE PANEL REMOVAL/INSTALLATION .) 4.
Page 254 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 2. Verify that the continuity between the PAD switch terminals is as indicated in Fig. 27 . If not as indicated in Fig. 27 , replace the PAD switch.
Page 255: Side Air Bag Sensor Removal/Installation
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata SIDE AIR BAG SENSOR REMOVAL/INSTALLATION WARNING: Handling the side air bag sensor improperly can accidentally  operate (deploy) the air bag module, which may seriously injure you.
Page 256 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 8. Install in the reverse order of removal. 9. Turn the ignition switch to the ON position and hold for 5 s or more . 10. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.
Page 257: Clock Spring Adjustment
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal. 6. Turn the ignition switch to the ON position. 7. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.
Page 258 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 31: Turning Clock Spring Clockwise Courtesy of MAZDA MOTORS CORP. 3. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns .
Page 259 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 32: Turning Clock Spring Counterclockwise 2 3/4 Turns Courtesy of MAZDA MOTORS CORP. 4. Align the mark on the clock spring with the mark on the outer housing.
Page 260: Clock Spring Inspection
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 33: Aligning Mark On Clock Spring With Mark On Outer Housing Courtesy of MAZDA MOTORS CORP. CLOCK SPRING INSPECTION 1. Remove the driver-side air bag module. (See DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION .)
Page 261 (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 tool and Adapter harness) are not available, consult the nearest Mazda representative for assistance.
Page 262 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata CAUTION: Deploying the air bag modules and pre-tensioner seat belts inside  the vehicle may cause damage to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules and pre-tensioner seat belts outside the vehicle.
Page 263 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 36: Connecting SSTs (Adapter Harness) To Driver-Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).
Page 264: Passenger-Side Air Bag Module
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 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).
Page 265 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 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 inflators simultaneously, following the procedure below.
Page 266 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 40: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 267: Side Air Bag Module
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata WARNING: Verify that air bag module operation (explosive) sound occurs  twice. If no operation (explosive) sound was heard or a single operation (explosive) sound was heard, both inflators would not have operated (deployed) properly.
Page 268 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata 3. Connect the SST (Deployment tool) to the SST (Adapter harness). 4. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 269: Pre-Tensioner Seat Belt
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 44: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. PRE-TENSIONER SEAT BELT 1. Remove the back trim. (See BACK TRIM REMOVAL/INSTALLATION .) 2. Remove the pre-tensioner seat belt and connect the SST (Adapter harness) as shown in Fig. 45 . (See...
Page 270 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 45: View Of Pre-Tensioner Seat Belt & SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 3. Install the pre-tensioner seat belt. 4. Connect the SST (Deployment tool) to the SST (Adapter harness).
Page 271 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 46: Connecting SST (Deployment Tool) To SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 8. Press the activation switch on the SST (Deployment tool) to operate (deploy) the pre-tensioner seat belt.
Page 272: Driver-Side Air Bag Module
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 47: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. 9. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness). DEPLOYMENT PROCEDURE FOR OUTSIDE OF VEHICLE 1.
Page 273 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 48: Connecting SSTs (Adapter Harness) To Driver-Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 3. Place the driver-side air bag module on the center of the tire wheel with the padded surface facing up. To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm...
Page 274 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 49: Placing Driver-Side Air Bag Module On Center Of Tire Wheel Courtesy of MAZDA MOTORS CORP. 4. Stack three tires without wheels on top of the tire with the driver-side air bag module, and then stack...
Page 275 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 50: Stacking Tires Without Wheels On Top Of Tire With Driver-Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 5. Secure the tires with wire.
Page 276 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 51: Tying Tires Together With Wire Courtesy of MAZDA MOTORS CORP. 6. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness). 7. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 277 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 52: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 10. 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 s , press the activation switch on the other SST (Deployment tool) to operate (deploy) the air bag module (both inflators).
Page 278: Passenger-Side Air Bag Module
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 53: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. 11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness). PASSENGER-SIDE AIR BAG MODULE WARNING: The passenger-side air bag module is a dual inflator type.
Page 279 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 54: Connecting SSTs (Adapter Harness) To Passenger-Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 3. Place the padded surface of the passenger-side air bag module facing the center of the tire as shown in Fig.
Page 280 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 55: Wrapping Wire Through Tire & Brackets Courtesy of MAZDA MOTORS CORP. 4. Stack the tire with the passenger-side air bag module on top of 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.
Page 281 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 56: Stacking Tire With Passenger-Side Air Bag Module On Top Of Two Tires Without Wheels Courtesy of MAZDA MOTORS CORP. 5. Secure the tires with wire.
Page 282 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 57: Tying Tires Together With Wire Courtesy of MAZDA MOTORS CORP. 6. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness). 7. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 283 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 58: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 10. 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 s , press the activation switch on the other SST (Deployment tool) to operate (deploy) the air bag module (both inflators).
Page 284: Side Air Bag Module
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 59: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. WARNING: Verify that air bag module operation (explosive) sound occurs  twice. If no operation (explosive) sound was heard or a single operation (explosive) sound was heard, both inflators would not have operated (deployed) properly.
Page 285 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 60: View Of Nuts On Side Air Bag Module & SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 3. Place the padded surface of the side air bag module facing the center of the tire as shown in Fig. 61 . To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm...
Page 286 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 61: Placing Padded Surface Of Side Air Bag Module Facing Center Of Tire Courtesy of MAZDA MOTORS CORP. 4. Connect the SST (Adapter harness) to the side air bag module as shown in Fig. 62 .
Page 287 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 62: Connecting SST (Adapter Harness) To Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 5. Stack the tire with the side air bag module on top of two tires without wheels. Stack a tire without a wheel...
Page 288 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 63: Stacking Tire With Side Air Bag Module On Top Of Tires Without Wheels Courtesy of MAZDA MOTORS CORP. 6. Secure the tires with wire.
Page 289 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 64: Tying Tires Together With Wire Courtesy of MAZDA MOTORS CORP. 7. Connect the SST (Deployment tool) to the SST (Adapter harness). 8. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 290 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 65: Connecting SST (Deployment Tool) To SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 11. Press the activation switch on the SST (Deployment tool) to operate (deploy) the side air bag module.
Page 291: Pre-Tensioner Seat Belt
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 66: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. PRE-TENSIONER SEAT BELT 1. Remove the pre-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 .
Page 292 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 67: Connecting SST (Adapter Harness) To Pre-Tensioner Seat Belt Courtesy of MAZDA MOTORS CORP. 3. Put the pre-tensioner seat belt inside the tire and secure it to the tire by wrapping a wire (cross section of 1.25 mm...
Page 293 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 68: Putting Pre-Tensioner Seat Belt Inside Tire & Secure To Tire By Wrapping Wire Courtesy of MAZDA MOTORS CORP. 4. Stack the tire with the pre-tensioner seat belt on two of tires without wheels. Stack a tire without a wheel...
Page 294 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 69: Stacking Tire With Pre-Tensioner Seat Belt On Two Of Tires Without Wheels Courtesy of MAZDA MOTORS CORP. 5. Secure the tires with wire.
Page 295 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 70: Tying Tires Together With Wire Courtesy of MAZDA MOTORS CORP. 6. Connect the SST (Deployment tool) to the SST (Adapter harness). 7. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 296 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 71: Connecting SST (Deployment Tool) To SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 10. Press the activation switch on the SST (Deployment tool) to operate (deploy) the pre-tensioner seat belt.
Page 297 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 72: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES WARNING: A live (undeployed) air bag module or pre-tensioner seat belt may ...
Page 298 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata deployed air bag module and pre-tensioner seat belt, wear gloves and safety glasses. Due to the adoption of 2-step deployment control in both the driver ...
Page 299: Inspection Procedure
2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Fig. 74: Inspecting SST (Deployment Tool) Courtesy of MAZDA MOTORS CORP. INSPECTION PROCEDURE 1. Follow the steps below to inspect the SST (49 H066 002). If not as indicated in SST INSPECTION REFERENCE TABLE , replace the SST (49 H066 ...
Page 300 2008 Mazda MX-5 Miata Grand Touring 2008 RESTRAINTS Air Bag System - MX-5 Miata Press the activation switch. Fig. 75: Inspecting Activation Switch Courtesy of MAZDA MOTORS CORP.
Page 301 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 2007 RESTRAINTS Air Bag System - MX-5 Miata 2007 RESTRAINTS Air Bag System - MX-5 Miata LOCATION INDEX Fig. 1: Identifying Location Of Airbag Components Courtesy of MAZDA MOTORS CORP.
Page 302 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata AIR BAG MODULE INSPECTION Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may  cause serious injury. Do not use a tester to inspect an air bag module. Always use the on-board diagnostic function to diagnose the air bag module for malfunctions.
Page 303 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 3: Air Bag Module Handling (1 Of 2) Courtesy of MAZDA MOTORS CORP. A live (undeployed) air bag module placed with its deployment surface to ground is dangerous. If ...
Page 304 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 4: Air Bag Module Handling (2 Of 2) Courtesy of MAZDA MOTORS CORP. SIDE AIR BAG MODULE HANDLING When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad, ...
Page 305 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata (deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the SAS control module or disconnecting the SAS control module connector, always turn the...
Page 306 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may  accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a serious accident.
Page 307 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Disassembling the air bag system components could cause it to not operate (deploy) normally.  Never disassemble any air bag system components. Fig. 6: Air Bag System Service Cautions Courtesy of MAZDA MOTORS CORP.
Page 308 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 7: Air Bag Module & Pre-Tensioner Seat Belt Handling Caution Courtesy of MAZDA MOTORS CORP. SEAT WEIGHT SENSOR HANDLING The seat weight sensor has a built-in strain gauge which may operate improperly if the sensor is ...
Page 309 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Incorrectly repairing an air bag wiring harness can accidentally operate (deploy) the air bag  module and pre-tensioner seat belts. If a problem is found in the air bag wiring harness, always replace the wiring harness with a new one.
Page 310 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 9: Removing/Installing Passenger Air Bag Deactivation (PAD) Indicator Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal. DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION...
Page 311 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 10: Removing/Installing Driver-Side Air Bag Module (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal.
Page 312 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 6. Turn the ignition switch to the ON position. 7. 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 -- ON- ...
Page 313 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata system service warnings and cautions before handling the air bag module. (See AIR BAG SYSTEM SERVICE WARNINGS .) (See AIR BAG SYSTEM SERVICE CAUTIONS .) If the passenger-side air bag module is installed with debris in the ...
Page 314 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata...
Page 315 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 12: Removing/Installing Passenger-Side Air Bag Module (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 6. Install in the reverse order of removal. 7. Turn the ignition switch to the ON position.
Page 316 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 14: Prying Out Connector Stopper Plate Courtesy of MAZDA MOTORS CORP. 2. Disconnect the connector. CAP INSTALLATION NOTE 1. The cap cannot be reused. Replace the cap with a new one when the cap or the passenger-side air bag module has been removed.
Page 317 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata the foreign material may be scattered when the side air bag module operates (deploys), causing injury. Verify that there is no foreign material in the seat back before installing the side air bag module.
Page 318 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 16: Removing Side Air Bag Module (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 9. Install in the reverse order of removal. 10. Turn the ignition switch to the ON position.
Page 319 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 3. Disconnect the negative battery cable and wait for 1 min or more . (See BATTERY REMOVAL/INSTALLATION [LF] .) 4. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION .) 5.
Page 320 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata WARNING: Handling the SAS 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 the SAS control module.
Page 321 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 18: Removing/Installing SAS Control Module (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 7. Install in the reverse order of removal. 8. Turn the ignition switch to the ON position.
Page 322 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 19: Identifying DLC-2 Location Courtesy of MAZDA MOTORS CORP. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.
Page 323 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 5. Detach the tab as shown in Fig. 20 and remove the connector from the seat connector. Fig. 20: Detaching Seat Connector Tab & Removing Connector From Seat Connector Courtesy of MAZDA MOTORS CORP.
Page 324 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 21: Removing Connector From Seat Connector Courtesy of MAZDA MOTORS CORP. 7. Install in the reverse order of removal. SEAT TRACK POSITION SENSOR INSTALLATION NOTE Verify that the seat track position sensor is not contacting the metal plate.
Page 325 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 22: Installing Seat Track Position Sensor Courtesy of MAZDA MOTORS CORP. SEAT WEIGHT SENSOR CONTROL MODULE REMOVAL/INSTALLATION CAUTION: When the seat weight sensor control module is replaced with a new ...
Page 326 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 23: Removing/Installing Seat Weight Sensor Control Module Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal. SEAT WEIGHT SENSOR CALIBRATION CAUTION: If any of the following work is performed, perform the seat weight ...
Page 327 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Or, the vehicle is involved in a collision  1. Have two 20 kg {44 lb} weights ready to use. 2. Connect the WDS or equivalent to the DLC-2 (16-pin).
Page 328 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata sensor inspection using the WDS or equivalent. Removal of the passenger-side seat  Loosening and retightening of passenger's seat fixing bolts  Or, the vehicle is involved in a collision ...
Page 329 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH REMOVAL/INSTALLATION 1. Remove the battery cover. 2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 3. Remove the side panel. (See SIDE PANEL REMOVAL/INSTALLATION .) 4.
Page 330 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 2. Verify that the continuity between the PAD switch terminals is as indicated in Fig. 27 . If not as indicated in Fig. 27 , replace the PAD switch.
Page 331 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata SIDE AIR BAG SENSOR REMOVAL/INSTALLATION WARNING: Handling the side air bag sensor improperly can accidentally  operate (deploy) the air bag module, which may seriously injure you.
Page 332 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 8. Install in the reverse order of removal. 9. Turn the ignition switch to the ON position and hold for 5 s or more . 10. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.
Page 333 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal. 6. Turn the ignition switch to the ON position. 7. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.
Page 334 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 31: Turning Clock Spring Clockwise Courtesy of MAZDA MOTORS CORP. 3. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns .
Page 335 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 32: Turning Clock Spring Counterclockwise 2 3/4 Turns Courtesy of MAZDA MOTORS CORP. 4. Align the mark on the clock spring with the mark on the outer housing.
Page 336 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 33: Aligning Mark On Clock Spring With Mark On Outer Housing Courtesy of MAZDA MOTORS CORP. CLOCK SPRING INSPECTION 1. Remove the driver-side air bag module. (See DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION .)
Page 337 (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 tool and Adapter harness) are not available, consult the nearest Mazda representative for assistance.
Page 338 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata CAUTION: Deploying the air bag modules and pre-tensioner seat belts inside  the vehicle may cause damage to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules and pre-tensioner seat belts outside the vehicle.
Page 339 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 36: Connecting SSTs (Adapter Harness) To Driver-Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).
Page 340: Passenger-Side Air Bag Module
2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 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).
Page 341 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 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 inflators simultaneously, following the procedure below.
Page 342 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 40: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 343: Side Air Bag Module
2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata WARNING: Verify that air bag module operation (explosive) sound occurs  twice. If no operation (explosive) sound was heard or a single operation (explosive) sound was heard, both inflators would not have operated (deployed) properly.
Page 344 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 3. Connect the SST (Deployment tool) to the SST (Adapter harness). 4. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 345: Pre-Tensioner Seat Belt
2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 44: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. PRE-TENSIONER SEAT BELT 1. Remove the back trim. (See BACK TRIM REMOVAL/INSTALLATION .) 2. Remove the pre-tensioner seat belt and connect the SST (Adapter harness) as shown in Fig. 45 . (See...
Page 346 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 45: Removing Pre-Tensioner Seat Belt & Connect SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 3. Install the pre-tensioner seat belt. 4. Connect the SST (Deployment tool) to the SST (Adapter harness).
Page 347 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 46: Connecting SST (Deployment Tool) To SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 8. Press the activation switch on the SST (Deployment tool) to operate (deploy) the pre-tensioner seat belt.
Page 348 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 47: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. 9. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness). DEPLOYMENT PROCEDURE FOR OUTSIDE OF VEHICLE 1.
Page 349 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 48: Connecting SSTs (Adapter Harness) To Driver-Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 3. Place the driver-side air bag module on the center of the tire wheel with the padded surface facing up. To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm...
Page 350 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 49: Placing Driver-Side Air Bag Module On Center Of Tire Wheel Courtesy of MAZDA MOTORS CORP. 4. Stack three tires without wheels on top of the tire with the driver-side air bag module, and then stack...
Page 351 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 50: Stacking Tires Without Wheels On Top Of Tire With Driver-Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 5. Secure the tires with wire.
Page 352 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 51: Tying Tires Together With Wire Courtesy of MAZDA MOTORS CORP. 6. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness). 7. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 353 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 52: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 10. 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 s , press the activation switch on the other SST (Deployment tool) to operate (deploy) the air bag module (both inflators).
Page 354 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 53: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. 11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness). PASSENGER-SIDE AIR BAG MODULE WARNING: The passenger-side air bag module is a dual inflator type. If one ...
Page 355 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 54: Connecting SSTs (Adapter Harness) To Passenger-Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 3. Place the padded surface of the passenger-side air bag module facing the center of the tire as shown in Fig.
Page 356 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 55: Wrapping Wire Through Tire & Brackets Courtesy of MAZDA MOTORS CORP. 4. Stack the tire with the passenger-side air bag module on top of 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.
Page 357 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 56: Stacking Tire With Passenger-Side Air Bag Module On Top Of Two Tires Without Wheels Courtesy of MAZDA MOTORS CORP. 5. Secure the tires with wire.
Page 358 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 57: Tying Tires Together With Wire Courtesy of MAZDA MOTORS CORP. 6. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness). 7. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 359 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 58: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 10. 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 s , press the activation switch on the other SST (Deployment tool) to operate (deploy) the air bag module (both inflators).
Page 360 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 59: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. WARNING: Verify that air bag module operation (explosive) sound occurs  twice. If no operation (explosive) sound was heard or a single operation (explosive) sound was heard, both inflators would not have operated (deployed) properly.
Page 361 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 60: Installing Nuts To Side Air Bag Module & Connect SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 3. Place the padded surface of the side air bag module facing the center of the tire as shown in Fig. 61 . To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm...
Page 362 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 61: Placing Padded Surface Of Side Air Bag Module Facing Center Of Tire Courtesy of MAZDA MOTORS CORP. 4. Connect the SST (Adapter harness) to the side air bag module as shown in Fig. 62 .
Page 363 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 62: Connecting SST (Adapter Harness) To Side Air Bag Module Courtesy of MAZDA MOTORS CORP. 5. Stack the tire with the side air bag module on top of two tires without wheels. Stack a tire without a wheel...
Page 364 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 63: Stacking Tire With Side Air Bag Module On Top Of Tires Without Wheels Courtesy of MAZDA MOTORS CORP. 6. Secure the tires with wire.
Page 365 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 64: Tying Tires Together With Wire Courtesy of MAZDA MOTORS CORP. 7. Connect the SST (Deployment tool) to the SST (Adapter harness). 8. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 366 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 65: Connecting SST (Deployment Tool) To SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 11. Press the activation switch on the SST (Deployment tool) to operate (deploy) the side air bag module.
Page 367 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 66: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. PRE-TENSIONER SEAT BELT 1. Remove the pre-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 .
Page 368 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 67: Connecting SST (Adapter Harness) To Pre-Tensioner Seat Belt Courtesy of MAZDA MOTORS CORP. 3. Put the pre-tensioner seat belt inside the tire and secure it to the tire by wrapping a wire (cross section of 1.25 mm...
Page 369 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 68: Putting Pre-Tensioner Seat Belt Inside Tire & Secure To Tire By Wrapping Wire Courtesy of MAZDA MOTORS CORP. 4. Stack the tire with the pre-tensioner seat belt on two of tires without wheels. Stack a tire without a wheel...
Page 370 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 69: Stacking Tire With Pre-Tensioner Seat Belt On Two Of Tires Without Wheels Courtesy of MAZDA MOTORS CORP. 5. Secure the tires with wire.
Page 371 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 70: Tying Tires Together With Wire Courtesy of MAZDA MOTORS CORP. 6. Connect the SST (Deployment tool) to the SST (Adapter harness). 7. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive battery terminal, and the black clip to the negative battery terminal.
Page 372 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 71: Connecting SST (Deployment Tool) To SST (Adapter Harness) Courtesy of MAZDA MOTORS CORP. 10. Press the activation switch on the SST (Deployment tool) to operate (deploy) the pre-tensioner seat belt.
Page 373 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 72: Identifying Activation Switch Courtesy of MAZDA MOTORS CORP. AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES WARNING: A live (undeployed) air bag module or pre-tensioner seat belt may ...
Page 374 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata deployed air bag module 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 possible that inflator No.
Page 375 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata Fig. 74: Inspecting SST (Deployment Tool) Courtesy of MAZDA MOTORS CORP. INSPECTION PROCEDURE 1. Follow the steps below to inspect the SST (49 H066 002). If not as indicated in SST INSPECTION REFERENCE TABLE , replace the SST (49 H066 ...
Page 376 2007 Mazda MX-5 Miata Sport 2007 RESTRAINTS Air Bag System - MX-5 Miata 3 Press the activation switch. Fig. 75: Inspecting Activation Switch Courtesy of MAZDA MOTORS CORP.
Page 377 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata 2007 BRAKES Antilock Brake System - MX-5 Miata 2007 BRAKES Antilock Brake System - MX-5 Miata ABS LOCATION INDEX Fig. 1: Identifying Location Of ABS Components Courtesy of MAZDA MOTORS CORP.
Page 378 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 2: ABS System Wiring Diagram Courtesy of MAZDA MOTORS CORP. ABS SYSTEM INSPECTION ABS HYDRAULIC UNIT ON-VEHICLE INSPECTION Preparation 1. Verify that battery is fully charged.
Page 379 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata 3s . 3. Turn the ignition switch off. 4. Jack up the vehicle and support it evenly on safety stands. 5. Shift to neutral. 6. Release the parking brake.
Page 380 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata condition PMP_MOTOR RF_OUTLET RF_INLET transmission type Brake pressure retention Manual Brake pressure reduction The ACTIVE COMMAND MODE INSPECTION REFERENCE TABLE above shows an example of a right front wheel inspection.
Page 381 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 4: Identifying ABS HU/CM Steps (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. ABS HU/CM CONNECTOR REMOVAL NOTE 1. Pull the lock lever up in the direction of the arrow.
Page 382 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 5: Identifying Lock Lever Position Courtesy of MAZDA MOTORS CORP. BRAKE PIPE REMOVAL NOTE 1. Place an alignment mark on the brake pipe and ABS HU/CM.
Page 383 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 6: Placing Alignment Mark On Brake Pipe & ABS HU/CM Courtesy of MAZDA MOTORS CORP. 2. Apply protective tape to the connector to prevent brake fluid from entering.
Page 384: Brake Pipe Installation Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 7: Identifying Aligning Marks Courtesy of MAZDA MOTORS CORP. BRAKE PIPE INSTALLATION NOTE 1. Align the marks made before removal and install the brake pipe to the ABS HU/CM and brake pipe joint referring to Fig.
Page 385 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 8: Verifying Lock Lever Is Completely Pushed In Courtesy of MAZDA MOTORS CORP. ABS CONFIGURATION 1. Connect the M-MDS or equivalent to the DLC-2.
Page 386 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 9: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. 2. After the Vehicle is identified, select the following items from the initial screen of the M-MDS.
Page 387 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata TABLE . STANDARD (REFERENCE VALUE) Fig. 10: Identifying ABS HU/CM Connector Terminals Courtesy of MAZDA MOTORS CORP. STANDARD (REFERENCE VALUE) TABLE Measured Measured terminal Inspection Terminal Signal name Connected to...
Page 388 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata (E-LF E-LF ABS wheel- LF wheel- LF ABS wheel-speed Continuity speed speed sensor wheel-speed Continuity sensor detected sensor (ground) sensor connector connector terminal B terminal Wiring ...
Page 389 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata terminal Ignition Wiring  switch at ON harness Power supply Ignition Voltage ignition (system) switch switch) Ignition 1 V or less switch is off. Wiring  harness...
Page 390: Front Abs Wheel-Speed Sensor Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata terminal B connector terminal CAN_L DLC-2 Continuity Y-DLC-2 Continuity Wiring  (CAN_L) terminal detected harness CAN_L. (Y-DLC- terminal CAN_L) CAN_H DLC-2 Continuity Z-DLC-2 Continuity Wiring  (CAN_H)
Page 391: Front Abs Wheel-Speed Sensor Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 11: Identifying Front ABS Wheel-Speed Sensor (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. FRONT ABS WHEEL-SPEED SENSOR INSPECTION INSTALLATION VISUAL INSPECTION 1. Inspect the following items: If there is any malfunction, replace the applicable part.
Page 392: Sensor Output Value Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Clearance (mm {in}) = A - B 5. Verify that the clearance between the ABS sensor rotor and the front ABS wheel-speed sensor is as indicated below.
Page 393 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata ABS wheel-speed sensor internal circuit. Be sure to use the M-MDS or equivalent to inspect the ABS wheel-speed sensor. 1. Turn the ignition switch off. 2. Connect the M-MDS or equivalent to the DLC-2.
Page 394: Rear Abs Wheel-Speed Sensor Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION 1. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .) 2. Remove the partition board. (See PARTITION BOARD REMOVAL/INSTALLATION .) 3.
Page 395 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata 1. Verify the clearance between the ABS sensor rotor and the ABS wheel-speed sensor. If there is any malfunction, check for improper installation, and replace if necessary.
Page 396 2007 Mazda MX-5 Miata Sport 2007 BRAKES Antilock Brake System - MX-5 Miata Fig. 16: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. 3. Select the following PIDs using the M-MDS or equivalent: LR_WSPD  (LR wheel-speed sensor) RR_WSPD ...
Page 397: Automatic Transmission
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8...
Page 398 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Do not apply oil or drive the vehicle immediately after installing a part applied with sealant. Leave  it for one hour or more. Do not wash aluminum parts or rubber parts with alkaline chemicals.
Page 399 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 2: Disassembled View Of Automatic Transmission Components (2 Of 5)
Page 400 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 3: Disassembled View Of Automatic Transmission Components (3 Of 5)
Page 401 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 4: Disassembled View Of Automatic Transmission Components (4 Of 5)
Page 402 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 5: Disassembled View Of Automatic Transmission Components (5 Of 5) Disassembly procedure 1. Remove the drain plug and gasket. CAUTION: Do not damage the oil seal.
Page 403 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 6: Identifying Drain Plug And Gasket 2. Remove the torque converter. Fig. 7: Identifying Torque Converter 3. Remove the breather hose and breather pipe.
Page 404 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 CAUTION: Do not damage the VSS.  Fig. 9: Identifying Turbine Sensor 5. Remove the VSS. Fig. 10: Identifying VSS 6. Lift up the lock washer using a flathead screwdriver.
Page 405 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 CAUTION: Do not damage the TR switch.  Fig. 12: Identifying Nut And Lock Washer 8. Remove the TR switch. Fig. 13: Identifying TR Switch 9.
Page 406 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 14: Identifying Bolts 10. Using a plastic hammer, tap the converter housing to remove it. CAUTION: Do not damage the fitting surface of the extension housing and ...
Page 407 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 17: Removing Extension Housing Shroud Using Flathead Screwdriver 13. Using a flathead screwdriver, remove the oil seal. Fig. 18: Removing Oil Seal Using Flathead Screwdriver 14.
Page 408 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 15. Using a plastic hammer, tap the extension housing to remove it. Fig. 20: Tapping Extension Housing Using Plastic Hammer 16. Remove the snap ring using snap ring pliers.
Page 409 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 22: Identifying Bolts Fig. 23: Locating Magnet In Oil Pan 19. Remove the oil strainer from the control valve body component. 20. Remove the O-ring from the oil strainer.
Page 410 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 25: Identifying Solenoid Connectors 23. Remove the lock plate from the control valve body component. CAUTION: When installing the control valve body, make sure that it does ...
Page 411 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 27: Identifying Tape 26. Disconnect the detent spring cover and detent spring from the control valve body component. CAUTION: Do not drop the control valve body component.
Page 412: Brakes
2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 30: Identifying Manual Valve Link 29. Remove the check valve subcomponent and compression spring from transmission case. Fig. 31: Identifying Check Valve Subcomponent And Compression Spring 30.
Page 413 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 and the compression spring from the transmission case. Fig. 33: Locating Oil Passage 32. Using a flathead screwdriver, remove the snap ring from accumulator pistons A and B.
Page 414 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 35: Identifying O-Ring On Accumulator Piston A And B 35. Blow compressed air from the oil passage shown in the figure and remove accumulator pistons C and the compression springs from the transmission case.
Page 415 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 37: Identifying Bracket Bolts 39. Remove the parking rod from the manual valve lever. Fig. 38: Identifying Parking Rod On Manual Valve Lever 40. Pull out the shaft parking pawl and spring.
Page 416 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 39: Identifying Shaft Parking Pawl And Spring 43. Using a flathead screwdriver and hammer, remove the manual shaft washer. CAUTION: Do not damage the manual valve component.
Page 417 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 41: Removing Pin Using Hammer And Pin Punch 45. Pull out the manual shaft and remove the manual valve component. Fig. 42: Identifying Manual Shaft And Manual Valve Component 46.
Page 418 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 44: Identifying Bolts On Oil Pump 48. Using a flathead screwdriver, remove the oil pump. CAUTION: Do not damage the oil pump.  Fig. 45: Removing Oil Pump Using Flathead Screwdriver 49.
Page 419 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 51. Remove the clutch drum component. Fig. 47: Identifying Clutch Drum Component 52. Remove the thrust needle bearing and bearing race from the clutch drum component.
Page 420 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 50: Removing Snap Ring From Transmission Case Using Flathead Screwdriver 55. Remove the retaining plates, drive and driven plates. Fig. 51: Identifying Drive And Driven Plates 56.
Page 421 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 52: Identifying Print Mark Location 57. Remove the snap ring from transmission case using snap ring pliers. Fig. 53: Removing Snap Ring From Transmission Case Using Snap Ring Pliers 58.
Page 422 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 55: Identifying F1 One-Way Clutch, B3 Brake Piston Component, Bearing Race And Thrust Washer 61. Remove the front planetary gear component and thrust washer.
Page 423 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 58: Identifying Retaining Plates, Drive And Driven Plates 65. Inspect the lining of all drive plates. If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, ...
Page 424 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 60: Identifying Middle Planetary Gear Component And Sun Gear 68. Using a flathead screwdriver, remove the snap ring from transmission case component. Fig. 61: Removing Snap Ring Using Flathead Screwdriver 69.
Page 425 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 63: Removing Snap Ring Using Flathead Screwdriver 71. Remove the driven plate. Fig. 64: Identifying Driven Plate 72. Remove the retaining plates, drive and driven plates.
Page 426 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 66: Identifying Piston Return Spring 74. Inspect the lining of all drive plates If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, ...
Page 427 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 68: Identifying Oil Passage Location 76. Remove the stopper spring from the transmission case. Fig. 69: Identifying Stopper Spring On Transmission Case 77. Remove the snap ring from the transmission case using snap ring pliers.
Page 428 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 3. Rear ring gear component 4. Bearing race 5. Needle bearing 6. Bearing race 7. Intermediate shaft Fig. 71: Identifying Intermediate Shaft Components Fig. 72: Disassembled View Of Transmission Case Components...
Page 429 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 73: Identifying Retaining Plates, Drive And Driven Plates 80. Inspect the lining of all drive plates. If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, ...
Page 430 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 75: Identifying Rear Planetary Gear Component, Bearing Race And Thrust Needle Bearing 82. Remove the brake tube. CAUTION: Make sure that the snap ring is not expanded excessively.
Page 431 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 78: Identifying Piston Return Spring 85. Blow compressed air into the oil passage as shown in the figure while pressing the B4 brake piston component by hand and remove the B4 brake piston component from the transmission case.
Page 432: Oil Pump Disassembly
2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 87. Remove the O-ring from the inner brake piston. Fig. 81: Identifying O-Ring On Inner Brake Piston 88. Remove the O-ring from sleeve. Fig. 82: Identifying O-Ring On Sleeve 89.
Page 433 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 84: Disassembled View Of Oil Pump Components Disassembly 1. Remove the O-ring from the oil pump component. Fig. 85: Identifying O-Ring On Oil Pump...
Page 434 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 86: Identifying Seal Ring 3. Put an installation mark on the pump housing and oil pump shaft. Fig. 87: Identifying Fitting Mark On Pump Housing 4.
Page 435 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 89: Identifying Oil Pump Shaft 6. Remove the O-ring from the pump housing. Fig. 90: Identifying O-Ring On Pump Housing 7. Remove the inner oil pump gear and outer oil pump gear from the pump housing.
Page 436: Oil Pump Inspection
2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 92: Removing Oil Seal From Pump Housing Using Flathead Screwdriver OIL PUMP INSPECTION 1. Using a dial gauge, measure the inner diameter of the pump housing component bushings.
Page 437 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Oil pump shaft bushing inner diameter 21.501-21.527 mm {0.846496-0.847520 in} CAUTION: Measure at different places and take an average. If it exceeds  the specification, replace the oil pump shaft with a new one.
Page 438 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 95: Measuring Oil Pump Gear Outer Clearance Using Feeler Gauge 4. Measure the clearance between the inner and outer oil pump gears using a feeler gauge.
Page 439: Oil Pump Assembly
2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 9.967-9.973 9.974-9.980 9.981-9.987 9.988-9.994 Fig. 97: Measuring Side Clearance Of Both Gears Using Steel Straight Edge And Feeler Gauge CAUTION: If the measurement exceeds the maximum specification, replace ...
Page 440 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Assembly Procedure 1. Apply ATF to the inner oil pump gear, outer oil pump gear and sliding surface of the pump housing. 2. Install the inner oil pump gear and outer oil pump gear to the pump housing as shown in the figure.
Page 441 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 101: Identifying Fitting Mark On Pump Housing 6. Align the oil pump shaft with bolt hole on the pump housing, and temporarily tighten. 7. Tighten the bolts.
Page 442 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 103: Identifying Seal Rings 11. Install the O-rings to the oil pump component. Fig. 104: Identifying O-Rings 12. Turn the drive gear with flathead screwdrivers and verify it rotates smoothly.
Page 443 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 106: Installing Oil Seal To Pump Housing Using Hammer CLUTCH DRUM COMPONENT AND F4 ONE-WAY CLUTCH COMPONENT DISASSEMBLY Components Fig. 107: Clutch Drum Component And F4 One-Way Clutch Component Disassembled View (1 Of 2)
Page 444 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 108: Clutch Drum Component And F4 One-Way Clutch Component Disassembled View (2 Of 2) Disassembly Procedure 1. Using a flathead screwdriver, remove the snap ring from the C3 clutch piston component.
Page 445 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 109: Removing Snap Ring From C3 Clutch Piston Component Using Screwdriver 3. Remove the retaining plate and the drive plate and the driven plate from the clutch hub component.
Page 446 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 112: Identifying Thrust Needle Bearing On Clutch Hub 6. Remove the clutch hub from the C3 clutch piston component. Fig. 113: Identifying Clutch Hub 7.
Page 447 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 115: Identifying Clutch Component 9. Remove the bearing race from the C3 clutch piston component. Fig. 116: Identifying Bearing Race 10. Remove the clutch hub and F4 one-way clutch from the C1, C4 clutch component.
Page 448 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 118: Identifying Bearing Race 12. Remove the F4 one-way clutch from the clutch hub. Fig. 119: Identifying F4 One-Way Clutch 13. Using a flathead screwdriver, remove the snap ring from the input shaft component.
Page 449 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 121: Identifying Retaining Plate, Drive And Driven Plate 15. Using a flathead screwdriver, remove the snap ring from the input shaft component. Fig. 122: Removing Snap Ring From Input Shaft Component Using Flathead Screwdriver 16.
Page 450 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 123: Identifying Retaining Plate, Drive And Driven Plate 17. Place the SST on the seal plate and compress the piston return spring with a press.
Page 451 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 125: Identifying C4 Clutch Seal Plate And Piston Return Spring 20. Apply compressed air into the oil passage as shown in the figure and remove the C4 clutch piston and C1 clutch piston from the input shaft component.
Page 452 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 127: Identifying O-Ring On Input Shaft Component 23. Remove the D-ring from the C1 clutch seal plate. Fig. 128: Identifying D-Ring On C1 Clutch Seal Plate 24.
Page 453 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 130: Removing Snap Ring (C3) From C2, C3 Clutch Drum 26. Using a flathead screwdriver, remove the snap ring (C2) from the C2, C3 clutch drum.
Page 454 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 133: Identifying SST 29. Remove the snap ring using snap ring pliers. Fig. 134: Removing/Installing Snap Ring Using Snap Ring Pliers 30. Remove the seal plate and the C2 clutch piston return spring from the C3 clutch drum.
Page 455 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 135: Identifying Seal Plate And C2 Clutch Piston Return Spring 31. Apply compressed air into the oil passage as shown in the figure and remove the C2 clutch piston and C3 clutch piston from the input shaft component.
Page 456 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 137: Identifying O-Ring On C2 Clutch Seal Plate 34. Remove the O-ring from the C2 clutch piston. Fig. 138: Identifying O-Ring On C2 Clutch Piston 35.
Page 457 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 140: Removing Snap Ring Using Snap Ring Pliers 37. Remove the seal plate piston return spring from the C3 clutch piston component. Fig. 141: Identifying Seal Plate Piston Return Spring On C3 Clutch Piston Component 38.
Page 458 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 143: Identifying O-Ring On C3 Clutch Piston Component 40. Remove the O-ring from the C2, C3 clutch drum. Fig. 144: Identifying O-Ring On C2, C3 Clutch Drum CLUTCH DRUM COMPONENT AND F4 ONE-WAY CLUTCH INSPECTION 1.
Page 459 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 145: Identifying Print Mark On Drive Plates (C1) 2. Inspect the lining of all drive plates. (C4) If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, ...
Page 460 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 147: Measuring Free Length Of Piston Return Spring 4. Inspect the lining of all drive plates. (C2) If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, ...
Page 461 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 ATF. Fig. 149: Identifying Print Mark On Drive Plates (C3) 6. Using vernier calipers, measure the free length of the piston return spring. C2 clutch return spring free length Standard: 20.02 mm {0.79 in}...
Page 462 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 151: Measuring Free Length Of Piston Return Spring 8. Using a dial gauge, measure the inner diameter of the input shaft component bushings. Input shaft component bushing inner diameter 18.000-18.025 mm {0.7087-0.7096 in}...
Page 463 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 9. Using a dial gauge, measure the inner diameter of the clutch hub bushings. Clutch hub bushing inner diameter Front side: 23.037-23.062 mm {0.90697-0.90795 in} Rear side: 23.037-23.062 mm {0.90697-0.90795 in}...
Page 464 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 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 ...
Page 465 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 156: Exploded View Of Clutch Drum Component And F4 One-Way Clutch Component (1 Of 2)
Page 466 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 157: Exploded View Of Clutch Drum Component And F4 One-Way Clutch Component (2 Of 2) Assembly Procedure 1. Apply ATF to the new O-ring...
Page 467 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 3. Apply ATF to the new O-rings. Fig. 158: Identifying O-Ring On C2, C3 Clutch Drum 4. Install the O-rings to the C3 clutch piston component.
Page 468 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 160: Identifying C2, C3 Clutch Drum 8. Install the seal plate and the piston return spring to the C3 clutch hub component. Fig. 161: Identifying Seal Plate And Piston Return Spring 9.
Page 469 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 163: Removing Snap Ring Using Snap Ring Pliers 11. Apply ATF to the new O-rings. 12. Install the O-rings to the C2 clutch piston.
Page 470 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 16. Install the C2 clutch piston and the C2, C3 clutch drum. 17. Apply ATF to the C2 clutch seal plate and the C2, C3 clutch drum.
Page 471 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 168: Identifying SST 20. Install the snap ring using snap ring pliers. 21. Apply ATF to the driven plate (C2) and the drive plate (C2) and the retaining plate (C2).
Page 472 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 170: Identifying Driven, Drive Plate And Retaining Plate 23. Using a flathead screwdriver, install the snap ring (C2) to the C2, C3 clutch drum.
Page 473 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 3.05-3.15{0.120-0.124} 3.15-3.25{0.124-0.128} 3.25-3.35{0.128-0.132} 3.35-3.45{0.132-0.136} 3.45-3.55{0.136-0.140} 3.55-3.65{0.140-0.144} 3.65-3.75{0.144-0.148} 3.75-3.85{0.148-0.152} Fig. 172: Measuring Retaining Plate Travel Distance At Both Ends Across Diameter Using Dial Gauge CAUTION: If the C2 clutch pack clearance exceeds the maximum ...
Page 474 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 173: Installing Snap Ring Using Flathead Screwdriver CAUTION: Inspect the number of drive and driven plates.  27. Install the retaining plate (C3) and the driven plate (C3) and the drive plate (C3) and the sleeve to the C2, C3 clutch drum.
Page 475 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 175: Installing Snap Ring Using Flathead Screwdriver 29. Measure the driven plate travel distance of the reverse piston travel distance and driven plate at the 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.
Page 476 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 THICKNESS REFERENCE Identification mark Thickness (mm {in}) 2.35-2.45 {0.093-0.096} 2.45-2.55 {0.096-0.100} 2.55-2.65 {0.100-0.104} 2.65-2.75 {0.104-0.108} 2.75-2.85 {0.108-0.112} 2.85-2.95 {0.112-0.116} 2.95-3.05 {0.116-0.120} 3.05-3.15 {0.120-0.124} 3.15-3.25 {0.124-0.128} 3.25-3.35 {0.128-0.132}...
Page 477 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 33. Install the D-ring to the C4 clutch seal plate. 34. Apply ATF to the new O-ring. Fig. 178: Identifying D-Ring On C4 Clutch Seal Plate 35.
Page 478 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 39. Install the C1 clutch seal plate and the piston return spring to the input shaft component. CAUTION: Do not damage the D-ring.  40. Place the SST on the C1 clutch seal plate and compress the piston return spring with a press.
Page 479 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 183: Identifying Retaining Plate, Driven And Drive Plate 43. Install the retaining plate (C4), the driven plate (C4), the drive plate (C4) to the input shaft component.
Page 480 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Standard gap 0.4-0.7 mm {0.0158-0.0275 in} THICKNESS REFERENCE Identification mark Thickness (mm {in}) 2.95-3.05{0.116-0.120} 3.05-3.15{0.120-0.124} 3.15-3.25{0.124-0.128} 3.25-3.35{0.128-0.132} 3.35-3.45{0.132-0.136} 3.45-3.55{0.136-0.140} 3.55-3.65{0.140-0.144} 3.65-3.75{0.144-0.148} 3.75-3.85{0.148-0.152} 3.85-3.95{0.152-0.156} Fig. 185: Measuring Retaining Plate Travel Distance At Both Ends Across Diameter Using Dial...
Page 481 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 CAUTION: Inspect the number of drive and driven plates.  47. Install the retaining plate (C1), the driven plate (C1), the drive plate (C1) to the input shaft component.
Page 482 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 0.14-0.17 mm {0.0056-0.0066 in} Standard gap 0.56-0.86 mm {0.0221-0.0338 in} CAUTION: If the C1 clutch pack clearance exceed the maximum  specification, select another retaining plate.
Page 483 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 189: Identifying F4 One-Way Clutch And Thrust Washer 53. Install the bearing race to the C1, C4 clutch component. Fig. 190: Identifying Bearing Races 54.
Page 484 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 192: Identifying Bearing Race On C3 Clutch Piston Component 57. Install the C1, C4 clutch component to the C2, C3 clutch drum. 58. Apply ATF to the thrust bearing, the bearing race and the thrust washer.
Page 485 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 195: Identifying Clutch Hub On C3 Clutch Piston Component 62. Install the thrust needle spring to the clutch hub. 63. Apply ATF to the retaining plate.
Page 486 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 CAUTION: Inspect the number of drive and driven plates.  Fig. 198: Identifying Clutch Hub Component 67. Install the retaining plate (C3), the drive plate (C3), and the driven plate (C3) to the clutch hub component.
Page 487 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 200: Installing Snap Ring To C3 Clutch Piston Component Using Flathead Screwdriver B1, B3 BRAKE AND F1, F2 ONE-WAY CLUTCH COMPONENT DISASSEMBLY Components Fig. 201: B1, B3 Brake And F1, F2 One-Way Clutch Component Disassembled View Disassembly Procedure 1.
Page 488 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 202: Identifying B3 Brake Cylinder 2. Remove the F1 one-way clutch and the thrust washer from the bearing race. Fig. 203: Identifying F1 One-Way Clutch And Thrust Washer 3.
Page 489 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 205: Identifying Piston Return Spring 5. While pushing the B3 brake piston, apply compressed air into the oil passage as shown in the figure and remove the B3 brake piston from the B3 brake cylinder.
Page 490 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 7. While pushing the B1 brake piston, apply compressed airinto the oil passage as shown in the figure and remove the B1 brake piston from the B1 brake cylinder.
Page 491 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 210: Measuring Free Length Of Piston Return Spring Using Vernier Caliper 2. Inspect the lining of all drive plates. (B3) If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, ...
Page 492 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 212: Measuring Free Length Of Piston Return Spring 4. Inspect the lining of all drive plates. (B1) If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, ...
Page 493 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 214: Identifying F1 One-Way Clutch Rotation Positions 6. Verify that the F2 one-way clutch rotates when the clutch hub is secured and rotated clockwise, and that it does not rotate when the clutch hub is rotated counterclockwise.
Page 494 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 216: Exploded View Of B1, B3 Brake And F1, F2 One-Way Clutch Component Assembly Procedure 1. Apply ATF to the new O-ring. 2. Install the O-rings to the B1 brake piston.
Page 495 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 217: Identifying O-Rings On B1 Brake Piston 4. Install the B1 brake piston to the B1 brake cylinder. 5. Apply ATF to the new O-rings.
Page 496 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 8. Install the B3 brake piston to the B3 brake cylinder. Fig. 220: Identifying B3 Brake Piston On B3 Brake Cylinder 9. Install the piston return spring to the B3 brake piston.
Page 497 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 13. Install the F1 one-way clutch to the bearing race. Fig. 223: Identifying F1 One-Way Clutch 14. Install the B3 brake cylinder to the F1 one-way clutch.
Page 498 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 225: Planetary Gear Component Disassembled View Disassembly Procedure 1. Using a flathead screwdriver, remove the snap ring from the middle planetary ring gear.
Page 499 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 226: Removing Snap Ring From Middle Planetary Ring Gear Using Flathead Screwdriver 2. Remove the front planetary ring gear flange from the middle planetary ring gear.
Page 500 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 229: Identifying Front Planetary Ring Gear 5. Using a flathead screwdriver, remove the snap ring from the rear planetary ring gear. Fig. 230: Removing Snap Ring From Rear Planetary Ring Gear Using Flathead Screwdriver 6.
Page 501 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 46.038-46.063 mm {1.81252-1.81350 in} CAUTION: Measure at different places and take an average. If it exceeds  the specification, replace the front planetary ring gear flange with a new one.
Page 502 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 233: Measuring Inner Diameter Of Front Planetary Gear Component Bushings 3. Using a dial gauge, measure the inner diameter of the rear planetary gear component bushings.
Page 503 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 234: Measuring Inner Diameter Of Rear Planetary Gear Component Bushings PLANETARY GEAR COMPONENT ASSEMBLY Components...
Page 504 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 235: Exploded View Of Planetary Gear Components Assembly Procedure 1. Install the rear planetary gear flange to the rear planetary ring gear.
Page 505 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 236: Identifying Rear Planetary Gear Flange 2. Using a flathead screwdriver, install the snap ring to the rear planetary ring gear. Fig. 237: Installing Snap Ring To Rear Planetary Ring Gear 3.
Page 506 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 239: Installing Snap Ring To Middle Planetary Ring Gear 5. Install the middle planetary ring gear flange to the middle planetary ring gear. Fig. 240: Identifying Middle Planetary Ring Gear Flange 6.
Page 507 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 242: B2, B4 Brake And F3 One-Way Clutch Component Disassembled View Disassembly Procedure 1. Blow compressed air into the oil passage as shown in the figure while pressing the B2 brake piston and brake cylinder by hand and remove the B2 brake piston.
Page 508 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 243: Locating Oil Passage 2. Remove the O-ring from the B2 brake piston. Fig. 244: Identifying O-Ring On B2 Brake Piston 3. Remove the inner race from the F3 one-way clutch component.
Page 509 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 246: Identifying O-Ring On B4 Brake Piston 5. Remove the O-ring from the sleeve. Fig. 247: Identifying O-Ring On Sleeve 6. Remove the O-ring from the inner brake piston.
Page 510 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Standard: 22.66 mm {0.89 in} If it less than the specification, replace the piston return spring with a new one.  Fig. 249: Measuring Free Length Of Piston Return Spring 2.
Page 511 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 If it less than the specification, replace the piston return spring with a new one.  Fig. 251: Measuring Free Length Of Piston Return Spring 4.
Page 512 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 253: F3 One-Way Clutch Rotation Position B2, B4 BRAKE AND F3 ONE-WAY CLUTCH COMPONENT ASSEMBLY Components...
Page 513 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 254: Exploded View Of B2, B4 Brake And F3 One-Way Clutch Components Assembly Procedure 1. Apply ATF to the new O-rings. 2. Install the O-rings to the B4 brake piston.
Page 514 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 255: Identifying O-Rings On B4 Brake Piston 4. Install the O-rings to the sleeve. 5. Apply ATF to the new O-ring. Fig. 256: Identifying O-Ring On Sleeve 6.
Page 515 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 258: Identifying Inner Race On F3 One-Way Clutch Component 10. install the O-ring to the B2 brake piston. 11. Apply ATF to the brake cylinder and the B2 brake piston.
Page 516 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 261: Exploded View Of Control Valve Body Disassembly Procedure CAUTION: Do not damage the solenoid.  1. Remove the shift solenoid C from the control valve body.
Page 517 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 262: Identifying Shift Solenoid C 2. Remove the shift solenoid B shift solenoid D from the control valve body. 3. Remove the bolt and the wiring harness clip.
Page 518 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 264: Identifying Shift Solenoid A 5. Remove the shift solenoid E from the control valve body. Fig. 265: Identifying Shift Solenoid E Assembly Procedure CAUTION: Do not damage the solenoid.
Page 519 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 266: Identifying Shift Solenoid E 3. Install the shift solenoid A to the control valve body. Tightening torque 8.0-12.0 N.m {81.6-122.3 kgf.cm, 70.9-106.1 in.lbf} CAUTION: Do not damage the solenoid.
Page 520: Automatic Transmission Assembly
2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 268: Identifying Shift Solenoid B 5. Install the shift solenoid C to the control valve body. Tightening torque 8.0-12.0 N.m {81.6-122.3 kgf.cm, 70.9-106.1 in.lbf} Fig.
Page 521 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8...
Page 522 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 270: Exploded View Of Automatic Transmission Assembly With Bearing And Race Locations (1 Of...
Page 523: Bearing Reference
2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 271: Exploded View Of Automatic Transmission Assembly With Bearing And Race Locations (2 Of BEARING REFERENCE Outer 87.74 35.6 92.6 102.7 96.7 83.6 50.8 44.9...
Page 524 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 273: Exploded View Of Automatic Transmission Components (2 Of 2) Disassembly Procedure 1. Apply ATF to the new O-ring. CAUTION: Do not damage the O-ring and B4 brake piston.
Page 525 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 2. Install the O-ring to the B4 brake piston. 3. Apply ATF to the new O-rings. CAUTION: Do not damage the O-ring and sleeve. ...
Page 526 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 276: Identifying O-Ring And Inner Brake Piston 8. Install the inner brake piston, sleeve and B4 brake piston to the transmission case. Fig. 277: Identifying Inner Brake Piston, Sleeve And B4 Brake Piston 9.
Page 527 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 279: Identifying SST For Compressing Piston Return Spring 11. Install the brake tube to the transmission case as shown in the figure. CAUTION: Align the tabs of the brake tube with the position shown in the ...
Page 528 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 281: Blowing Compressed Air Into Transmission Case 13. Measure the level difference (length A) between the brake tube upper surface and the retaining plate contact surface at the both ends across the B4 brake piston diameter using a vernier caliper, and calculate the average value.
Page 529 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 282: Identifying Dimension A And B 16. If the pack clearance exceeds the maximum specification, select the retaining plate with a clearance that is the maximum specification and install it.
Page 530 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 17. Apply ATF to the bearing race, thrust needle bearing and install to the rear planetary gear component. Fig. 283: Identifying Bearing Race, Thrust Needle Bearing And Rear Planetary Gear Component 18.
Page 531 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 285: Identifying Retaining Plates, Drive And Driven Plates 20. Install the retaining plate, drive plates and driven plates in the order indicated in the figure.
Page 532 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 288: Identifying Rear Ring Gear Component, F3 One-Way Clutch And Inner Race 23. Install the intermediate shaft component to the transmission case. Fig. 289: Identifying Intermediate Shaft Component 24.
Page 533 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 291: Installing Snap Ring To Transmission Case Using Snap Ring Pliers 26. Install the stopper spring to the transmission case. Fig. 292: Identifying Stopper Spring On Transmission Case 27.
Page 534 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 28. Verify that B2 brake piston moves smoothly when the compressed air atomization equipment lever is pulled/released while blowing compressed air into the transmission case.
Page 535 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 295: Identifying Dimension A, B And H 31. Calculate the pack clearance using the following formula. Dimension A-Dimension B-1.6 mm {0.063 in}-Thickness H 32. If the pack clearance exceeds the maximum specification, select the retaining plate with a clearance that is the maximum specification and install it.
Page 536 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 33. Install the return spring to the transmission case. CAUTION: Inspect the number and order of the retaining plate, drive and  driven plates. Fig. 296: Identifying Piston Return Spring 34.
Page 537 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 298: Identifying Retaining Plate, Drive Plate Component And Driven Plates 36. Install the retaining plate to the transmission case. Fig. 299: Identifying Retaining Plate 37.
Page 538 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 301: Position For Installing Snap Ring 39. Install the B1 brake piston component and return spring to the transmission case as shown in the figure.
Page 539 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 41. Using a flathead screwdriver, install the snap ring to the transmission case. CAUTION: Align the opening of the snap ring with the position shown in ...
Page 540 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Dimension A 15.27-15.92 mm {0.61-0.62 in} 44. Measure the thickness of all the driven plates and drive plate components (3), and driven plates (3) at the both ends across the diameter using a vernier caliper, and calculate the average value.
Page 541 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Identification mark Thickness (mm {in}) 1.95-2.05 {0.077-0.081} 2.15-2.25 {0.085-0.089} 2.35-2.45 {0.093-0.096} 2.55-2.65 {0.100-0.104} CAUTION: Inspect the number and order of the retaining plate, drive and ...
Page 542 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 309: Identifying Middle Planetary Gear Component And Sun Gear 53. Install the front and middle planetary gear ring component. 54. Apply ATF to the thrust washer.
Page 543 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 312: Identifying F1 One-Way Clutch Component 58. Install the brake piston to the transmission case as shown in the figure. CAUTION: Align the hole of the brake piston with the position shown in the ...
Page 544 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 314: Position For Installing Snap Ring 60. Using snap ring pliers, install snap ring into the groove. NOTE: Align the opening of the snap ring with the position shown in the ...
Page 545 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 316: Identifying Retaining Plate, Drive And Driven Plates 62. Install the driven plates, drive plate and the retaining plate in the order indicated in the figure.
Page 546 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 318: Installing Snap Ring Using Flathead Screwdriver 65. Install the F2 one-way clutch component to the clutch drum component. 66. Apply ATF to the bearing race and thrust needle bearing.
Page 547 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 321: Identifying Clutch Drum Component 71. Apply ATF to the thrust needle bearing, bearing race and install it to the oil pump component. Fig. 322: Identifying Thrust Needle Bearing, Bearing Race And O-Ring 72.
Page 548 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 323: Identifying Oil Pump 73. Install the bolt as shown in the figure. Tightening torque 17.6-24.5 N.m {1.8-2.4 kgf.m, 13.0-18.0 ft.lb} Fig. 324: Identifying Bolt 74.
Page 549 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 325: Installing Thrust Needle Bearing And Bearing Race 77. Measure the clearance between snap ring and bearing race using a thickness gauge. Standard 0.02-0.12 mm {0.0008-0.0047 in} If not within the specification, select an appropriate bearing race.
Page 550 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 327: Retaining Plate Size Reference Chart 78. Verify that the input shaft turns smoothly. 79. Using a dial indicator, measure the input shaft end play.
Page 551 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 80. Using the SST and a hammer, install a new oil seal. CAUTION: Do not damage the transmission case.  Fig. 329: Installing Oil Seal Using SST And Hammer 81.
Page 552 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 331: Tapping Pin Using Hammer 84. Align the manual shaft groove with the spacer hole and crimp them using a punch. 85. Verify that the manual shaft turns smoothly.
Page 553 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 334: Identifying Parking Rod On Manual Valve Lever 90. Install the bracket. Tightening torque 5.9-8.8 N.m {60.2-89.7 kgf.cm, 52.3-77.8 in.lbf} Fig. 335: Identifying Bracket Bolts 91.
Page 554 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 92. Install the accumulator valve and compression spring to the transmission case. CAUTION: Do not damage the O-ring and accumulator piston.  Fig. 337: Identifying Accumulator Valve And Compression Spring 93.
Page 555 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 339: Identifying Accumulator Piston C And Compression Spring 95. Apply ATF to the new O-ring and install the accumulator pistons A, B. Fig. 340: Identifying O-Ring On Accumulator Pistons A, B...
Page 556 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 341: Identifying Snap Ring On Accumulator Pistons A, B 97. Install the accumulator pistons A, B and the compression spring to the transmission case.
Page 557 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 343: Identifying Transmission Case And Brake Drum Gasket 99. Install the check valve subcomponent and compression spring to the transmission case. Fig. 344: Identifying Check Valve Subcomponent And Compression Spring 100.
Page 558 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 346: Position For Installing Control Valve Body Component 101. Temporarily tighten the bolts to the transmission case as shown in the figure. Bolt length (measured from below the head) A.
Page 559 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Tightening torque 8.0-12.0 N.m {82-122 kgf.cm, 72-105 in.lbf} 104. Install the TFT sensor, lock plate to control valve body component. Tightening torque 8.0-12.0 N.m {82-122 kgf.cm, 72-105 in.lbf} 105.
Page 560 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 349: Identifying Bolts On Control Valve Body 109. Clean the contact surface of the oil pan and transmission case. NOTE: Wash the magnets before installing them.
Page 561 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 351: Identifying Transmission Case Bolts 113. Remove the silicons sealant and be careful not to spill any oil on the contact surface of the transmission case and extension housing.
Page 562 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 353: Locating Bolts On Transmission Case TRANSMISSION CASE BOLTS REFERENCE Bolt number Bolt size Length (measured from below the head) (mm {in}} M10-1.5 35 {1.38} M 10-1.5...
Page 563 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 354: Position For Installing Oil Seal To Extension Housing 121. Using the SST and a hammer, install the new extension housing shroud to the extension housing as shown in the figure.
Page 564 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 356: Position For Installing Extension Dust Deflector 123. Temporarily tighten the bolts A and new bolts B, C by hand as shown in the figure.
Page 565 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 125. Turn the manual shaft fully to the extension housing side and turn it back two steps so that the N position is selected. 126. Install the TR switch and temporarily tighten the new TR switch installation bolt.
Page 566 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 360: Identifying Washer, Lock Washer And Nut 129. Using a flathead screwdriver, bend the tab of lock washer. 130. Tighten the TR switch installation bolt.
Page 567 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 362: Identifying VSS 132. Install the turbine sensor. Tightening torque 3.9-6.9 N.m {40-70 kgf.cm, 35-61 in.lbf} CAUTION: Do not damage the turbine sensor. ...
Page 568 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 364: Identifying Breather Tube And Pipe 135. Using a flathead screwdriver, position the drive gear on the oil pump component in the center. Then install the torque converter component to the transmission.
Page 569 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Fig. 366: Identifying Distance A 137. Clean the drain plug. CAUTION: Install the drain plug being careful of the drain plug gasket  direction. 138. Install the new drain plug gasket and drain plug to the oil pan.
Page 570: Service Tools
2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 Oil pump gear outer standard clearance 0.10-0.17 mm {0.004-0.006 in} Oil pump gear inner standard clearance 0.07-0.15 mm {0.0028-0.0059 in} Oil pump gear side standard clearance 0.02-0.04 mm {0.0008-0.0015 in}...
Page 571 2007 Mazda MX-5 Miata Sport 2006-08 TRANSMISSION Automatic Transmission Overhaul - MX-5 Miata & RX-8 49 W027 003 49 H019 001 49 T019 003 Support block Attachment Body 49 HD64 377 49 HD64 376 49 G033 102 Attachment Body Handle...
Page 572 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata...
Page 573 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 1: Identifying Location Of Body Panel Components...
Page 574: Fuel-Filler Lid Adjustment
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Courtesy of MAZDA MOTORS CORP. FUEL-FILLER LID REMOVAL/INSTALLATION 1. Remove the bolts. 2. Remove the fuel-filler lid. 3. Install in the reverse order of removal.
Page 575: Front Bumper Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata 3. Tighten the bolts. Fig. 3: Identifying Gap & Height Difference Between Fuel-Filler Lid & Body Courtesy of MAZDA MOTORS CORP. FRONT BUMPER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 576 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata...
Page 577: Front Bumper Disassembly/Assembly
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 4: Removing/Installing Front Bumper (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 5. Install in the reverse order of removal. 6. Adjust the front fog light aiming for vehicles with the front fog lights. (See FRONT FOG LIGHT AIMING .)
Page 578 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 5: Disassembling/Assembling Front Bumper Courtesy of MAZDA MOTORS CORP. 3. Assemble in the reverse order of disassembly. FRONT BUMPER REINFORCEMENT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 579 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata 6. Remove in the order indicated in Fig. 6. Fig. 6: Removing/Installing Front Bumper Reinforcement (With Torque Specifications) Courtesy of MAZDA MOTORS CORP.
Page 580: Rear Bumper Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata 7. Install in the reverse order of removal. REAR BUMPER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .) 3.
Page 581 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Courtesy of MAZDA MOTORS CORP. 8. Remove in the order indicated in the table.
Page 582 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 8: Removing Rear Bumper Courtesy of MAZDA MOTORS CORP. 9. Install in the reverse order of removal. REAR BUMPER REMOVAL NOTE 1. Pull the rear bumper ends (wheel arch) outward to detach from the bumper slider.
Page 583 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata REAR BUMPER INSTALLATION NOTE 1. Spread the rear bumper ends (wheel arches) apart. 2. Attach the rear bumper to the body. 3. Press the rear bumper connecting area into the body to engage with the bumper slider.
Page 584: Front Fender Panel Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata 2. Remove the nuts, then remove the rear bumper reinforcement. 3. Install in the reverse order of removal. Fig. 11: Removing Rear Bumper Reinforcement (With Torque Specifications) Courtesy of MAZDA MOTORS CORP.
Page 585: Hood Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 12: Removing/Installing Front Fender Panel (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 6. Install in the reverse order of removal. HOOD REMOVAL/INSTALLATION WARNING: Removing the hood without proper support can be dangerous.
Page 586 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata hood may fall and injure you. Always perform the following procedure with at least another person. 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2.
Page 587 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 13: Removing/Installing Hood (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 4. Install in the reverse order of removal. 5. Adjust the hood. (See HOOD ADJUSTMENT .)
Page 588: Hood Adjustment
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata HOOD ADJUSTMENT GAP ADJUSTMENT 1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2. Remove the following parts: 1. Front bumper (See FRONT BUMPER REMOVAL/INSTALLATION .) 2.
Page 589 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata b. 3.0-5.0 mm {0.12-0.19 in} Fig. 15: Identifying Gap Between Hood & Body Courtesy of MAZDA MOTORS CORP. HEIGHT DIFFERENCE ADJUSTMENT 1. Turn the stop rubber to adjust the height of the hood.
Page 590 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 16: Turning Stop Rubber To Adjust Height Of Hood Courtesy of MAZDA MOTORS CORP. 2. Verify that the height difference between the hood and the body is within the specification.
Page 591: Trunk Lid Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 17: Identifying Height Difference Between Hood & Body Courtesy of MAZDA MOTORS CORP. TRUNK LID REMOVAL/INSTALLATION WARNING: Removing the stay damper without supporting the trunk lid can be ...
Page 592 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 18: Disconnecting Trunk Lid Wiring Harness Connector Courtesy of MAZDA MOTORS CORP. 3. Remove the clips that secure the trunk lid wiring harness.
Page 593 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 19: Removing Trunk Lid Wiring Harness Clips Courtesy of MAZDA MOTORS CORP. 4. Pry off the stay damper band using a flathead screwdriver. 5. Pry out the connecting part of the stay damper and the hinge with a flathead screwdriver to disconnect them, then remove the stay damper.
Page 594: Trunk Lid Adjustment
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 21: Removing Trunk Lid Hinge (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. TRUNK LID ADJUSTMENT 1. Measure the gap and height difference between the trunk lid and the body.
Page 595 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 22: Adjusting Trunk Lid Courtesy of MAZDA MOTORS CORP. Standard clearance a. 4.5-7.5 mm {0.18-0.29 in} (Except Power Retractable Hardtop) 5.5-8.5 mm {0.22-0.33 in} (Power Retractable Hardtop) b.
Page 596: Stay Damper Disposal
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 23: Identifying Trunk Lid Standard Clearance Courtesy of MAZDA MOTORS CORP. STAY DAMPER DISPOSAL NOTE: The gas in the stay damper is colorless, odorless, and non-toxic.
Page 597 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata 2. Lay the stay damper flat. 3. Saw 2-3 mm {0.08-0.11 in} into the stay damper using a hacksaw, and allow the gas to escape from the stay damper.
Page 598 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata 9. Remove the back trim. (See BACK TRIM REMOVAL/INSTALLATION .) 10. Remove the open hook. (See OPEN HOOK REMOVAL/INSTALLATION[ADVANCED KEYLESS SYSTEM] .) 11. Remove the rear speaker. (See REAR SPEAKER REMOVAL/INSTALLATION .) 12.
Page 599 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata...
Page 600 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Body Panels - MX-5 Miata Fig. 25: Removing/Installing Seat Back Crossmember Assembly (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 15. Half open the power retractable hardtop CAUTION: If the seat back crossmember component is removed with the power retractable hardtop fully opened, it may contact the middle roof and damage the roof.
Page 601: Air Bleeding
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata 2007 BRAKES Conventional Brake System - MX-5 Miata 2007 BRAKES Conventional Brake System - MX-5 Miata CONVENTIONAL BRAKE SYSTEM LOCATION INDEX Fig. 1: Identifying Location Of Conventional Brake System Components Courtesy of MAZDA MOTORS CORP.
Page 602 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata NOTE: Keep the fluid level in the reserve tank at 3/4 full or more during the air  bleeding. Begin air bleeding with the master cylinder and then continue with the ...
Page 603 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 2: Brake Bleeding Procedure Courtesy of MAZDA MOTORS CORP. VACUUM LINE INSPECTION 1. Remove the vacuum hose between the power brake unit and the intake manifold using pliers.
Page 604: Brake Pedal Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 3: Inspecting Vacuum Line Check Valve Courtesy of MAZDA MOTORS CORP. BRAKE PEDAL INSPECTION BRAKE PEDAL HEIGHT INSPECTION 1. Measure the distance from the center of the upper surface of the pedal pad to the insulator and verify that it is as specified.
Page 605 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata...
Page 606: Brake Pedal Height Adjustment
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 4: Inspecting Brake Pedal Height Courtesy of MAZDA MOTORS CORP. BRAKE PEDAL HEIGHT ADJUSTMENT CAUTION: The brake switch may not operate normally after adjusting the pedal ...
Page 607: Brake Pedal Play Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 5: Adjusting Brake Pedal Height Courtesy of MAZDA MOTORS CORP. BRAKE PEDAL PLAY INSPECTION 1. Depress the pedal several times to release the vacuum in the power brake unit.
Page 608: Brake Pedal Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 6: Inspecting Pedal-To-Floor Clearance Courtesy of MAZDA MOTORS CORP. BRAKE PEDAL REMOVAL/INSTALLATION CAUTION: The clearance between the brake switch and the brake pedal is  automatically adjusted to the correct amount when the brake switch connector is connected after the brake switch has been properly installed.
Page 609 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata one when replacing the power brake unit or the pedal, or performing any procedure that changes the pedal stroke. When replacing the brake pedal (AT), it is possible that the ...
Page 610: Brake Switch Connector Installation Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata 1. Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm. 2. Remove the brake pedal.
Page 611 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata the brake switch if it is removed. 1. Verify continuity as indicated in Fig. 9 . If not as indicated in Fig. 9 replace the brake switch.
Page 612: Master Cylinder Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 10: Identifying Brake Switch Connector Courtesy of MAZDA MOTORS CORP. MASTER CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in Fig. 11 . 2. Install in the reverse order of removal.
Page 613 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 11: Identifying Master Cylinder Removing/Installing Steps (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. MASTER CYLINDER INSTALLATION NOTE CAUTION: If the master cylinder is installed at an angle, the master cylinder ...
Page 614 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 12: Identifying Special Tool To Power Brake Unit Courtesy of MAZDA MOTORS CORP. 2. Apply a vacuum of 66.7 kPa {500 mmHg, 19.7 inHg} to the power brake unit using a vacuum gauge.
Page 615 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 13: Applying Vacuum To Power Brake Unit Using Vacuum Gauge Courtesy of MAZDA MOTORS CORP. 3. Using calipers, measure dimension L as shown in Fig. 14 .
Page 616 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 14: Measuring Dimension L Using Calipers Courtesy of MAZDA MOTORS CORP. 4. If dimension L is not within the standard, remove the SST (49 G043 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).
Page 617: Brake Fluid Level Sensor Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 15: Adjusting Pushrod Length Courtesy of MAZDA MOTORS CORP. 6. Install the master cylinder to the power brake unit. BRAKE FLUID LEVEL SENSOR INSPECTION 1. Disconnect the brake fluid level sensor connector from the master cylinder.
Page 618 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 16: Brake Fluid Sensor Terminal Continuity Table Courtesy of MAZDA MOTORS CORP.
Page 619: Power Brake Unit Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 17: Identifying Brake Fluid Level Sensor Connector Courtesy of MAZDA MOTORS CORP. POWER BRAKE UNIT INSPECTION NOTE: The following inspection methods are simple inspection methods to judge ...
Page 620 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Flare nut across flat: 12 mm {0.47 in}  2. Connect the SSTs , a vacuum gauge and a pedal force gauge to the master cylinder and bleed the air from the SSTs and the brake line.
Page 621 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 19: Inspecting Vacuum Loss Function - Without DSC Courtesy of MAZDA MOTORS CORP. WITH DSC...
Page 622 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 20: Inspecting Vacuum Loss Function - With DSC Courtesy of MAZDA MOTORS CORP. Checking For Vacuum Loss (Loaded Condition) 1. Start the engine. 2. Depress the brake pedal with a force of 200 N {20.4 kgf, 44.9 lbf} .
Page 623: Power Brake Unit Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Power Brake Unit Fluid Pressure POWER BRAKE UNIT FLUID PRESSURE SPECIFICATIONS Vacuum amount at o kPa {0 mmHg, 0 inHg} Pedal force (N {kgf, lbf}) Fluid pressure (kPa {kgf/cm , psi}) 200 {20.4, 44.9}...
Page 624 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 21: Removing Clutch Pipe (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 3. Remove the nut shown in Fig. 22 , then remove the cooler hose (LO) bracket from the vehicle.
Page 625 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 22: Removing Cooler Hose (LO) Bracket From Vehicle Courtesy of MAZDA MOTORS CORP. 4. Remove in the order indicated in Fig. 23 . Fig. 23: Identifying Power Brake Unit (With Torque Specifications)
Page 626 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata 5. Install in the reverse order of removal. 6. After installation, perform brake pedal inspection. (See BRAKE PEDAL INSPECTION .) DUAL PROPORTIONING VALVE REMOVAL/INSTALLATION 1. Remove in the order indicated in Fig. 24 .
Page 627 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 24: Dual Proportioning Valve Removing/Installing Steps (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 2. Install in the reverse order of removal.
Page 628: Brake Pipe Removal Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata BRAKE PIPE REMOVAL NOTE 1. Place an alignment mark on the brake pipe and dual proportioning valve. Fig. 25: Placing Alignment Mark On Brake Pipe & Dual Proportioning Valve Courtesy of MAZDA MOTORS CORP.
Page 629 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 26: Identifying Dual Proportioning Valve R Marks Courtesy of MAZDA MOTORS CORP. BRAKE PIPE INSTALLATION NOTE 1. Align the marks made before removal and install the brake pipe to the dual proportioning valve referring...
Page 630 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 27: Aligning Brake Pipe To Dual Proportioning Valve Marks Courtesy of MAZDA MOTORS CORP. DUAL PROPORTIONING VALVE INSPECTION 1. Connect the SSTs to the brake pipes as shown in Fig. 28 .
Page 631 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 28: Identifying Special Tools Courtesy of MAZDA MOTORS CORP. 3. Measure the fluid pressure of the master cylinder and the rear brake. If not within the specification, replace the dual proportioning valve.
Page 632: Front Brake (Disc) Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 29: Dual Proportioning Valve Fluid Pressure Graph Courtesy of MAZDA MOTORS CORP. DUAL PROPORTIONING VALVE FLUID PRESSURE SPECIFICATIONS MASTER CYLINDER PRESSURE (kPa REAR BRAKE PRESSURE (kPa {kgf/cm...
Page 633 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata 1. When applying the brakes, the vehicle body shakes back and forth. The seriousness of the shaking is not influenced by vehicle speed. Brake Pedal Vibration 1. When applying brakes, a pulsating force tries to push the brake pad back. The pulsation is transmitted to the brake pedal.
Page 634 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 30: Front Brake Inspection & Repair Flow Procedure Courtesy of MAZDA MOTORS CORP. Lateral Runout Inspection 1. To secure the disc plate and the hub, insert the washer (thickness 10 mm {0.39 in} , inner diameter more than 12 mm {0.47 in} ) between each hub bolt and the hub nut, then tighten all the hub nuts.
Page 635 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 31: Measuring Front Disc Plate Runout Courtesy of MAZDA MOTORS CORP. Thickness Variation Inspection 1. Clean the disc plate-to-pad friction surface using a brake cleaner. 2. Measure the points indicated in Fig. 32 using a caliper (micrometer).
Page 636 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 32: Inspecting Disc Plate-To-Pad Friction Surface Courtesy of MAZDA MOTORS CORP. Disc Plate Thickness Inspection CAUTION: Excessive runout may result if the disc plate is removed from the ...
Page 637 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata 1. Jack up the front of the vehicle and support it with safety stands. 2. Remove the wheel and tires. 3. Verify the remaining thickness of the pads.
Page 638 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 34: Identifying Front Brake (Disc) Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CALIPER INSTALLATION NOTE 1. Clean the exposed area of the piston. 2. Install the piston using the SST .
Page 639: Disc Pad (Front) Replacement
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 35: Installing Piston Using Special Tool Courtesy of MAZDA MOTORS CORP. DISC PAD (FRONT) REPLACEMENT 1. Remove in the order indicated in Fig. 36 . 2. Install in the reverse order of removal.
Page 640: Caliper (Front) Disassembly/Assembly
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 36: Identifying Disc Pad Components (Front) (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CALIPER (FRONT) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in Fig. 37 .
Page 641 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata...
Page 642: Rear Brake (Disc) Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 37: Exploded View Of Caliper (Front) (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 2. Assemble in the reverse order of disassembly. PISTON DISASSEMBLY NOTE CAUTION: The piston could be damaged if blown out with great force.
Page 643 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata 1. Brake judder concern has the following 3 characteristics: Steering Wheel Vibration 1. Steering wheel vibrates in 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} .
Page 644 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 39: Rear Brake Inspection & Repair Flow Procedure Courtesy of MAZDA MOTORS CORP. Lateral Runout Inspection 1. To secure the disc plate and the hub, insert the washer (thickness 10 mm {0.39 in} , inner diameter more than 12 mm {0.47 in} ) between each hub bolt and the hub nut, then tighten all the hub nuts.
Page 645 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 40: Measuring Rear Disc Plate Runout By Putting Dial Gauge On Friction Surface Of Disc Plate Courtesy of MAZDA MOTORS CORP. Thickness Variation Inspection 1. Clean the disc plate-to-pad friction surface using a brake cleaner.
Page 646 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 41: Inspecting Disc Plate-To-Pad Friction Surface Courtesy of MAZDA MOTORS CORP. Disc Plate Thickness Inspection CAUTION: Excessive runout may result if the disc plate is removed from the ...
Page 647: Rear Brake (Disc) Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata 1. Jack up the front of the vehicle and support it with safety stands. 2. Remove the wheel and tires. 3. Verify the remaining thickness of the pads.
Page 648: Disc Plate Removal Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 43: Identifying Rear Brake (Disc) Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. DISC PLATE REMOVAL NOTE 1. Mark the wheel hub and disc plate.
Page 649: Caliper Installation Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 44: Identifying Wheel Hub & Disc Plate Mark Courtesy of MAZDA MOTORS CORP. DISC PLATE INSTALLATION NOTE 1. Remove any rust or foreign material from the wheel hub and disc plate.
Page 650 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 45: Rotating Piston Clockwise Using SST Courtesy of MAZDA MOTORS CORP. PARKING BRAKE CABLE INSTALLATION NOTE 1. After installing the parking brake cable, verify that the operating lever returns to the stopper nut with the...
Page 651: Disc Pad (Rear) Replacement
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 46: Identifying Stopper Nut And Operating Lever Courtesy of MAZDA MOTORS CORP. DISC PAD (REAR) REPLACEMENT 1. Remove in the order indicated in Fig. 47 .
Page 652 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 47: Identifying Disc Pad (Rear) Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CALIPER INSTALLATION NOTE 1. Clean the exposed area of the piston. 2. Rotate the piston clockwise slowly using the SST and push in the piston completely until the piston...
Page 653: Caliper (Rear) Disassembly/Assembly
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 48: Rotating Piston Clockwise Using SST Courtesy of MAZDA MOTORS CORP. 3. Install the caliper. CALIPER (REAR) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in Fig. 49 .
Page 654 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata...
Page 655: Piston Disassembly Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 49: Exploded View Of Caliper (Rear) (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 2. Assemble in the reverse order of disassembly. PISTON DISASSEMBLY NOTE 1. Rotate the piston counter-clockwise using the SST , remove the piston from the caliper body.
Page 656 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 51: Assembling Lip Of Dust Seal Courtesy of MAZDA MOTORS CORP. 3. Rotate the piston clockwise using the SST slowly and push the piston inwards completely.
Page 657 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 52: Rotating Piston Clockwise Using SST Courtesy of MAZDA MOTORS CORP. BRAKE HOSE (FRONT) REMOVAL/INSTALLATION 1. Remove in the order indicated in FIG..2. Install in the reverse order of removal.
Page 658 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 53: Identifying Brake Hose (Front) Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. BRAKE HOSE (REAR) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table.
Page 659 2007 Mazda MX-5 Miata Sport 2007 BRAKES Conventional Brake System - MX-5 Miata Fig. 54: Identifying Brake Hose (Rear) Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP.
Page 660: General Information
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 GENERAL INFORMATION Brakes General Procedures - MX-5 Miata 2007 GENERAL INFORMATION Brakes General Procedures - MX-5 Miata 2007 GENERAL INFORMATION Brakes General Procedures - MX-5 Miata GENERAL PROCEDURES (BRAKE) WHEEL AND TIRE INSTALLATION 1.
Page 661 2007 Mazda MX-5 Miata Sport 2007 GENERAL INFORMATION Brakes General Procedures - MX-5 Miata 1. If any brake line has been disconnected anytime during the procedures, add brake fluid, bleed the brakes, and inspect for leakage after the procedure has been completed.
Page 662 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata 2007 ELECTRICAL Charging System - MX-5 Miata 2007 ELECTRICAL Charging System - MX-5 Miata CHARGING SYSTEM LOCATION INDEX [LF] Fig. 1: Identifying Location Of Charging System Components Courtesy of MAZDA MOTORS CORP.
Page 663 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 2: Identifying Removal Order Of Battery (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. BATTERY DUCT REMOVAL NOTE 1. Remove the under cover. 2. Remove the battery duct.
Page 664: Electrolyte Specific Gravity
2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 3: Connecting Negative Battery Cable Courtesy of MAZDA MOTORS CORP. BATTERY INSPECTION [LF] 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 ...
Page 665: Standard Specification
2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata BATTERY INSPECTION TABLE Step Inspection Action 12.4 V or Go to Step 3. more 1 Measure the battery positive voltage. Less than Go to the 12.4 V next step.
Page 666 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata CAUTION: Operating electrical loads while the back-up current is being  measured can damage the tester. NOTE: For vehicles with the immobilizer 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...
Page 667 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 4: Connecting Battery Charger To Battery Courtesy of MAZDA MOTORS CORP. 3. After the battery is recharged, verify that the voltage is within the specification and remains at the same value for 1 h or more after the recharging was completed.
Page 668: Generator Installation Note
2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata manifold. Make sure the generator duct is installed securely. 1. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [LF] .) 2. Remove the drive belt. (See DRIVE BELT REPLACEMENT [LF] .) 3.
Page 669: Generator Warning Light
2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata CAUTION: Do not apply direct battery positive voltage to the generator terminal  D, otherwise it could cause damage to the internal parts (power transistor) of the generator.
Page 670 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 6: Identifying Ignition Switch Connector Terminals Courtesy of MAZDA MOTORS CORP. Current NOTE: Since the charging current decreases rapidly after starting the engine,  carry out the following procedure quickly, and read the maximum current value.
Page 671 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata will not be verified although the generator is normal. In this case, increase the electrical load (by turning on the headlight and leave it for a while, then discharge the battery or by similar methods) and recheck.
Page 672 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 7: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. 2. Inspect as follows: PCM AND GENERATOR SHEARING INSPECTION TABLE Step Inspection Action 15 V Go to Step 2.
Page 673: Generator Inner Parts
2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata PCM, generator, or both are not normal. value 100%? Monitor the ALTF PID using the M-MDS or equivalent, or calculate the PCM input error. duty value of the PCM terminal 2AI using an oscilloscope. Is the duty...
Page 674 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 8: Measuring Resistance Between Slip Rings Using Tester Courtesy of MAZDA MOTORS CORP. 2. Verify that there is no continuity between the slip ring and core using a tester.
Page 675 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 9: Verifying There Is No Continuity Between Slip Ring & Core Courtesy of MAZDA MOTORS CORP. 3. Inspect the slip ring surface condition. If the slip ring surface is rough, use a lathe or fine sandpaper to repair it.
Page 676 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 10: Stator Coil Terminal Continuity Check Table Courtesy of MAZDA MOTORS CORP.
Page 677 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 11: Identifying Stator Coil Terminals Courtesy of MAZDA MOTORS CORP. If there is any malfunction, replace the stator.  2. Verify that there is no continuity between the stator coil leads and core using a tester.
Page 678 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 12: Inspecting Continuity Between Stator Coil Leads And Core Courtesy of MAZDA MOTORS CORP. Brush 1. Inspect brushes for wear. If any brush is worn almost to or beyond the limit, replace all of the brushes.
Page 679 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 13: Inspecting Brushes For Wear Courtesy of MAZDA MOTORS CORP. Brush Spring 1. Measure the force of the brush spring using a spring pressure gauge.
Page 680 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 14: Measuring Force Of Brush Spring Using Spring Pressure Gauge Courtesy of MAZDA MOTORS CORP. 2. Read the spring pressure gauge at the brush tip projection of 2 mm {0.079 in}.
Page 681 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata P1, P2, P3, P4, P5, P6 Fig. 15: Identifying Diodes Courtesy of MAZDA MOTORS CORP. Rectifier (Using a digital circuit tester) 1. Inspect for continuity of the diodes using a digital circuit tester.
Page 682 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 16: Identifying Diodes Courtesy of MAZDA MOTORS CORP. Bearing 1. Inspect for abnormal noise, looseness, and sticking. Replace the bearing if necessary. ...
Page 683 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 17: Inspecting Bearing Courtesy of MAZDA MOTORS CORP. GENERATOR DISASSEMBLY/ASSEMBLY [LF] CAUTION: Melt the solder quickly, otherwise the diodes (rectifier) and regulator  will be damaged by excessive heat.
Page 684 2007 Mazda MX-5 Miata Sport 2007 ELECTRICAL Charging System - MX-5 Miata Fig. 18: Identifying Disassemble Order Of Generator (With Torque Specifications) Courtesy of MAZDA MOTORS CORP.
Page 685: Clutch Location Index
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata 2007 TRANSMISSION Clutch - MX-5 Miata 2007 TRANSMISSION Clutch - MX-5 Miata CLUTCH LOCATION INDEX...
Page 686 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 1: Identifying Location Of Clutch Components Courtesy of MAZDA MOTORS CORP. GENERAL PROCEDURES (CLUTCH)
Page 687: Clutch Fluid Inspection
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata 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 related parts of the clutch system are removed during the ...
Page 688 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata 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. Keep the fluid level in the reserve tank at 3/4 full or more during air ...
Page 689: Clutch Pedal Adjustment
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 3: Identifying Clutch Bleeding Courtesy of MAZDA MOTORS CORP. CLUTCH PEDAL ADJUSTMENT CLUTCH PEDAL STROKE INSPECTION/ADJUSTMENT 1. Measure the clutch pedal stroke. If there is any malfunction, loosen locknut A and adjust the pedal stroke by adjusting bolt B.
Page 690 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 4: Adjusting Clutch Pedal (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CLUTCH PEDAL PLAY INSPECTION/ADJUSTMENT 1. Lightly depress the clutch pedal by hand until clutch resistance is felt and then measure the pedal play.
Page 691 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata 5-15 mm {0.20-0.59 in} Clutch pedal push rod play At push rod setting line: 0.1-0.5 mm {0.004-0.020 in} (Reference value) At pedal pad: 0.5-2.7 mm {0.020-0.106 in} 2. If it is not within the specification, loosen locknut C and turn push rod D to adjust the pedal play.
Page 692 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 5: Inspecting Clutch Pedal Play (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CLUTCH DISENGAGEMENT POINT INSPECTION...
Page 693: Clutch Switch Inspection
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata 1. Start the engine. 2. Without depressing the clutch pedal, move the shift lever slowly to the reverse position until gear noise is heard and hold the lever in that position.
Page 694 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata 3. Disconnect the negative battery cable. 4. Disconnect the clutch switch connector. 5. Verify continuity as indicated in Fig. 7 . Fig. 7: Clutch Switch Continuity Table Courtesy of MAZDA MOTORS CORP.
Page 695: Clutch Pedal Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 8: Identifying Clutch Switch Connector Courtesy of MAZDA MOTORS CORP. If there is any malfunction, replace the clutch switch.  CLUTCH PEDAL REMOVAL/INSTALLATION 1. Remove in the order indicated in Fig. 9 .
Page 696 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 9: Identifying Clutch Pedal Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. STARTER INTERLOCK SWITCH INSTALLATION NOTE CAUTION: If the rod Is pushed in, it may not operate properly. Be careful not to ...
Page 697: Clutch Master Cylinder Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 10: Identifying Starter Interlock Switch And Pedal Bracket Courtesy of MAZDA MOTORS CORP. CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION CAUTION: Fluid will damage painted surfaces. Be careful not to spill any fluid ...
Page 698: Clutch Master Cylinder Disassembly/Assembly
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 11: Identifying Clutch Master Cylinder Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in Fig. 12 .
Page 699 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 12: Exploded View Of Clutch Master Cylinder Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. SNAP RING DISASSEMBLY/ASSEMBLY NOTE 1. While pressing the piston in with a cloth-wrapped pin punch to protect the push rod contacting surface,...
Page 700: Clutch Release Cylinder Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 13: Removing Snap Ring Courtesy of MAZDA MOTORS CORP. CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION 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.
Page 701: Clutch Release Cylinder Disassembly/Assembly
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 14: Identifying Clutch Release Cylinder Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in Fig. 15 .
Page 702: Clutch Unit Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Courtesy of MAZDA MOTORS CORP. CLUTCH UNIT REMOVAL/INSTALLATION 1. Remove in the order indicated in Fig. 16 . 2. Install in the reverse order of removal.
Page 703 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 16: Identifying Clutch Unit Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CLUTCH COVER AND DISC REMOVAL NOTE 1. Install the SSTs. 2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
Page 704 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 18: Removing Pilot Bearing Using SST Courtesy of MAZDA MOTORS CORP. PILOT BEARING INSTALLATION NOTE 1. Install the pilot bearing using the corresponding 20mm {0.79} 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.
Page 705 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 19: Installing Pilot Bearing Using SSTs Courtesy of MAZDA MOTORS CORP.
Page 706 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 20: Identifying Pilot Bearing Installation Dimension Courtesy of MAZDA MOTORS CORP. FLYWHEEL REMOVAL NOTE 1. Hold the flywheel using the SST. 2. Remove the bolts evenly and gradually in a crisscross pattern.
Page 707 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 21: Identifying Flywheel Bolts Removing Sequence Courtesy of MAZDA MOTORS CORP. 3. Remove the flywheel. 4. Inspect for oil leakage from the crankshaft rear oil seal. If there is any malfunction, replace the crankshaft rear oil seal. (See REAR OIL SEAL ...
Page 708 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata 108-116 N.m {11.1-11.8 kgf.m, 79.7-85.5 ft.lbf} Fig. 22: Identifying Flywheel Bolts Tightening Sequence Courtesy of MAZDA MOTORS CORP. CLUTCH DISC INSTALLATION NOTE 1. Hold the clutch disc position using the SST.
Page 709 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 23: Holding Clutch Disc Position Using SST Courtesy of MAZDA MOTORS CORP. CLUTCH COVER INSTALLATION NOTE 1. Install the SSTs. 2. Tighten the bolts evenly and gradually in a crisscross pattern.
Page 710: Clutch Cover Inspection
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 24: Identifying Clutch Cover Bolts Tightening Sequence Courtesy of MAZDA MOTORS CORP. CLUTCH COVER INSPECTION 1. Measure the wear of the diaphragm spring fingers. If it exceeds the maximum specification, replace the clutch cover.
Page 711 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 25: Measuring Wear Of Diaphragm Spring Fingers Courtesy of MAZDA MOTORS CORP. 2. Measure the flatness of the pressure plate with a straight edge and a feeler gauge.
Page 712 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 26: Measuring Flatness Of Pressure Plate With Straight Edge & Feeler Gauge Courtesy of MAZDA MOTORS CORP. 3. When checking the diaphragm spring fingers, mount a dial indicator on the cylinder block.
Page 713: Clutch Disc Inspection
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 27: Measuring Clutch Cover Height Difference Courtesy of MAZDA MOTORS CORP. CLUTCH DISC INSPECTION 1. Remove the clutch disc. 2. Inspect the lining surface for discoloration and grease/oil contamination.
Page 714 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 28: Measuring Clutch Disc Minimum Depth Using Vernier Caliper Courtesy of MAZDA MOTORS CORP. 5. Measure the clutch disc runout using a dial gauge. Clutch disc maximum runout 0.7 mm {0.028 in}...
Page 715: Clutch Release Collar Inspection
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 29: Measuring Clutch Disc Maximum Runout Using Dial Gauge Courtesy of MAZDA MOTORS CORP. 6. Install the clutch disc. CLUTCH RELEASE COLLAR INSPECTION CAUTION: Do not clean the clutch release collar with cleaning fluids or a steam ...
Page 716 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 30: Inspecting Clutch Release Collar Courtesy of MAZDA MOTORS CORP. 3. Install the clutch release collar. PILOT BEARING INSPECTION 1. Without removing the pilot bearing, turn the bearing while applying force in the axial direction.
Page 717: Flywheel Inspection
2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 31: Inspecting Pilot Bearing Courtesy of MAZDA MOTORS CORP. FLYWHEEL INSPECTION 1. Remove the flywheel. NOTE: Correct slight scratches and discoloration using sandpaper.  Inspect the runout of the surface that contacts the clutch disc with ...
Page 718 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 32: Correcting Slight Scratches Using Sandpaper Courtesy of MAZDA MOTORS CORP. 2. Inspect the surface that contacts the clutch disc for scratches, nicks, and discoloration. 3. Inspect the ring gear teeth for damage and wear.
Page 719 2007 Mazda MX-5 Miata Sport 2007 TRANSMISSION Clutch - MX-5 Miata Fig. 33: Measuring Flywheel Maximum Runout Using Dial Gauge Courtesy of MAZDA MOTORS CORP.
Page 720 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata 2007 ENGINE Cooling System - MX-5 Miata 2007 ENGINE Cooling System - MX-5 Miata COOLING SYSTEM LOCATION INDEX [LF] Fig. 1: Identifying Location Of Cooling System Components Courtesy of MAZDA MOTORS CORP.
Page 721 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata When you are sure all the pressure is gone, press down on the cap  using the cloth, turn it, and remove it. ENGINE COOLANT LEVEL INSPECTION [LF]...
Page 722 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 2: Identifying Proper Cooling System Cap Courtesy of MAZDA MOTORS CORP. ENGINE COOLANT PROTECTION INSPECTION [LF] 1. Measure the coolant temperature and specific gravity using a thermometer and a hydrometer.
Page 723 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata coolant, 45% water). Use the solution as is when replacing coolant. Fig. 3: Identifying Proper Cooling System Cap Courtesy of MAZDA MOTORS CORP. 2. Determine the coolant protection level by referring to the graph shown in Fig. 4.
Page 724 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 4: Coolant Protection Level Graph Courtesy of MAZDA MOTORS CORP. ENGINE COOLANT REPLACEMENT [LF] WARNING: Never remove the cooling system cap or loosen the radiator drain ...
Page 725 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata cause serious 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 it counterclockwise to the first stop.
Page 726 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 5: Identifying Proper Cooling System Cap Courtesy of MAZDA MOTORS CORP. Engine coolant capacity (approx. quantity) 7.5 L {7.9 US qt, 6.6 Imp qt} 1. Remove the cooling system cap.
Page 727 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 6: Identifying Cooling System Cap & Reserve Tank Courtesy of MAZDA MOTORS CORP. 2. Remove the radiator drain plug and drain the engine coolant into a container.
Page 728 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 7: Identifying Radiator Drain Plug Courtesy of MAZDA MOTORS CORP. ANTIFREEZE SOLUTION MIXTURE PERCENTAGE (EXCEPT FL22 TYPE ENGINE COOLANT) Volume percentage (%) Engine coolant protection Gravity at 20°C {68°F}...
Page 729 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata 9. Start the engine and warm up the engine by idling. 10. After the engine warms up, perform the following steps. At this time, be careful of the coolant temperature to prevent overheating.
Page 730 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 8: Applying Pressure Using Radiator Cap Tester Courtesy of MAZDA MOTORS CORP. 6. When pressurizing the cooling system, verify that the pressure is maintained. If the gauge needle drops, it may indicate water leakage. Repair or replace the applicable part.
Page 731 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata 2. Inspect for cracks or roll up on the sealed part of the cooling system cap. If there is any malfunction, replace the cooling system cap.  3. Attach the cooling system cap to the SST and a radiator cap tester.
Page 732 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you are sure all the pressure is gone, press down on the cap ...
Page 733 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 10: Identifying Removal Order Of Coolant Reserve Tank (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. RADIATOR REMOVAL/INSTALLATION [LF] WARNING: Never remove the cooling system cap or loosen the radiator drain ...
Page 734 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 11: Identifying Removal Order Of Radiator (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. P/S COOLING PIPE REMOVAL NOTE 1. Remove the P/S cooling pipe with the hoses still connected.
Page 735 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata plug while 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.
Page 736 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 12: Identifying Removal Order Of Thermostat (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. THERMOSTAT INSPECTION [LF]...
Page 737 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata 1. Inspect the thermostat for the following. WARNING: During inspection, the thermostat and water are extremely hot  and can cause severe burns. Do not touch the thermostat and water.
Page 738 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata 6. Remove in the order indicated in Fig. 13 . 7. Install in the reverse order of removal. 8. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)
Page 739 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 13: Identifying Removal Order Of Water Pump (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. FAN MOTOR REMOVAL/INSTALLATION [LF] WARNING: Never remove the cooling system cap or loosen the radiator drain ...
Page 740: Part Inspection
2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 14: Identifying Removal Order Of Fan Motor (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. FAN MOTOR INSPECTION [LF] PART INSPECTION 1. Verify that the battery is fully charged.
Page 741 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata Fig. 15: Identifying Cooling Fan Motor Connector Courtesy of MAZDA MOTORS CORP. FAN MOTOR OPERATION TABLE Connection terminal Fan motor rotation speed Positive Negative High A and C...
Page 742 2007 Mazda MX-5 Miata Sport 2007 ENGINE Cooling System - MX-5 Miata High: 9.0-12.0 A Middle: 6.4-9.4 A Low: 4.8-7.8 A...
Page 743 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata 2007 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata 2007 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata CRUISE CONTROL SWITCH INSPECTION [LF] 1.
Page 744 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & EQUIPMENT Cruise Control System - MX-5 Miata No button pressed No continuity...
Page 745: Differential Oil Inspection
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata 2007 DRIVELINE/AXLES Differential - MX-5 Miata 2007 DRIVELINE/AXLES Differential - MX-5 Miata REAR DIFFERENTIAL LOCATION INDEX Fig. 1: Identifying Location Of Rear Differential Components Courtesy of MAZDA MOTORS CORP.
Page 746 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 2: Identifying Oil-Fill Plug Courtesy of MAZDA MOTORS CORP. 3. Inspect if the oil level is close to the rim of the oil-fill plug hole. NOTE: Each vehicle is filled with a specified amount of oil (0.7 +/- 0.1 L) ...
Page 747 Courtesy of MAZDA MOTORS CORP. Differential oil Grade: API service GL-5 Viscosity: SAE 90, SAE 80W-90, SAE 75W-90 (Not available from Mazda) 5. Install the oil-fill 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} DIFFERENTIAL OIL REPLACEMENT 1.
Page 748 5. Add the specified oil through 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 (approx. quantity): 0.6-0.8 L {0.63-0.85 US qt, 0.53-0.70 Imp qt}...
Page 749 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 5: Identifying Oil-Fill Plug Hole And Differential Oil Courtesy of MAZDA MOTORS CORP. 6. Install the oil-fill 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}...
Page 750 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata 4. Remove the clip from the rear drive shaft. CAUTION: To prevent damaging the inside of the differential casing, wrap  cloth on the end of the flathead screwdriver.
Page 751 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata 10. Add differential oil. 11. After adding the oil, perform the oil level inspection. (See DIFFERENTIAL OIL INSPECTION .) 12. Install the oil-fill plug with a new washer and tighten.
Page 752 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata 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 appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
Page 753 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 8: Identifying Rear Differential Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. BRAKE CALIPER COMPONENT REMOVAL NOTE 1. Suspend the brake caliper component using a cable or equivalent.
Page 754 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 9: Suspending Brake Caliper Courtesy of MAZDA MOTORS CORP. 2. Temporarily tighten the wheel nut to prevent the disc plate from falling off. REAR DRIVE SHAFT, REAR KNUCKLE COMPONENT REMOVAL NOTE 1.
Page 755 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 10: Removing Rear Drive Shaft & Rear Knuckle Components Courtesy of MAZDA MOTORS CORP. 2. Pull the rear drive shaft and rear knuckle component to the outer side, and detach the rear drive shaft from the rear differential.
Page 756 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 11: Supporting Differential With Jack Courtesy of MAZDA MOTORS CORP. REAR DRIVE SHAFT, REAR KNUCKLE COMPONENT INSTALLATION NOTE 1. Install a new drive shaft clip to the clip groove at the top of the rear drive shaft with the clip opening facing upward and the clip width within the specification.
Page 757 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 12: Installing New Drive Shaft Clip To Clip Groove At Top Of Rear Drive Shaft Courtesy of MAZDA MOTORS CORP. CAUTION: The sharp edges of the rear drive shaft can slice or puncture the ...
Page 758 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 13: Exploded View Of Rear Differential Components Courtesy of MAZDA MOTORS CORP. DIFFERENTIAL COMPONENT DISASSEMBLY NOTE 1. Install the differential component to the SSTs .
Page 759 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 14: Installing Differential Component To SSTs Courtesy of MAZDA MOTORS CORP. BEARING CAP DISASSEMBLY NOTE 1. Mark the bearing cap and differential carrier for proper installation.
Page 760 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 15: Marking Bearing Cap & Differential Carrier For Installation Courtesy of MAZDA MOTORS CORP. ADJUSTMENT SHIM, SIDE BEARING OUTER RACE DISASSEMBLY NOTE 1. Remove the adjustment shim using a flathead screwdriver.
Page 761 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 16: Removing Adjustment Shim Using Flathead Screwdriver Courtesy of MAZDA MOTORS CORP. 2. Put left and right identification marks on the removed adjustment shims and side bearing outer races.
Page 762 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 17: Putting Left & Right Identification Marks On Adjustment Shims & Side Bearing Outer Races Courtesy of MAZDA MOTORS CORP. SIDE BEARING DISASSEMBLY NOTE 1. Remove the side bearing using the SST .
Page 763 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 18: Removing Side Bearing Using SST Courtesy of MAZDA MOTORS CORP. ROLL PIN DISASSEMBLY NOTE 1. Tap the roll pin out from the direction shown in Fig. 19 using a pin punch.
Page 764 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 19: Tapping Roll Pin Out Using Pin Punch Courtesy of MAZDA MOTORS CORP. LOCKNUT DISASSEMBLY NOTE 1. Remove the locknut while fixing the companion flange using the SST .
Page 765 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 20: Removing Locknut While Fixing Companion Flange Using SST Courtesy of MAZDA MOTORS CORP. COMPANION FLANGE DISASSEMBLY NOTE 1. Remove the companion flange using the SST .
Page 766 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 21: Removing Companion Flange Using SST Courtesy of MAZDA MOTORS CORP. DRIVE PINION COMPONENT DISASSEMBLY NOTE 1. Install the removed locknut to the drive pinion top to prevent damage to the thread.
Page 767 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 22: Removing Drive Pinion Component By Tapping Locknut Using Plastic Hammer Courtesy of MAZDA MOTORS CORP. REAR BEARING DISASSEMBLY NOTE CAUTION: The drive pinion could be damaged if it falls off. Support the drive ...
Page 768 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 23: Removing Rear Bearing Using SST & Press Courtesy of MAZDA MOTORS CORP. FRONT BEARING OUTER RACE, REAR BEARING OUTER RACE DISASSEMBLY NOTE 1. Remove the bearing outer race by lightly tapping the edge of the bearing outer race using a flathead...
Page 769: Rear Differential Assembly
2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 24: Removing Bearing Outer Race By Lightly Tapping Edge Of Bearing Outer Race Using Flathead Screwdriver Courtesy of MAZDA MOTORS CORP. REAR DIFFERENTIAL ASSEMBLY WARNING: The engine stand is equipped with a self-lock mechanism, however, ...
Page 770 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 25: Identifying Rear Differential Assembly Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. WASHER ASSEMBLY NOTE 1. Assemble the side gear, thrust washer, pinion gear, and the pinion shaft to the gear case.
Page 771 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata one of the pinion gear teeth. Fig. 26: Installing Dial Gauge Courtesy of MAZDA MOTORS CORP. 3. Fix either one of the side gears. 4. Move the pinion gear and measure the backlash at the pinion gear top.
Page 772 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata 1. Align the differential gear case and pinion shaft pin holes. 2. Tap the roll pin in using a pin punch. RING GEAR ASSEMBLY NOTE CAUTION: The gear case and ring gear could be damaged if the ring gear is ...
Page 773 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 27: Identifying Ring Gear Assembly Courtesy of MAZDA MOTORS CORP. 2. Install the ring gear to the differential gear case and tighten the bolts in a criss-cross pattern.
Page 774 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata OIL SEAL (SIDE GEAR) ASSEMBLY NOTE 1. Apply differential oil to the lip of a new oil seal. 2. Assemble the oil seal using the SSTs . Fig. 29: Assembling Oil Seal Using SSTs Courtesy of MAZDA MOTORS CORP.
Page 775 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 30: Pressing Rear Bearing Outer Race Into Differential Carrier Using SST & Press Courtesy of MAZDA MOTORS CORP. FRONT BEARING OUTER RACE ASSEMBLY NOTE 1. Press the front bearing outer race into the differential carrier using the SST and a press.
Page 776 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 31: Pressing Front Bearing Outer Race Into Differential Carrier Using SST & Press Courtesy of MAZDA MOTORS CORP. SPACER ASSEMBLY NOTE Pinion Height Adjustment NOTE: Use the installed spacer when adjusting.
Page 777 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 32: Assembling Spacer, Bearing Inner Race (Rear Side) & SST (O-Ring) To SST (49 8531 565) Courtesy of MAZDA MOTORS CORP. 2. Insert the set assembled in Step 1 from the rear side of the differential carrier.
Page 778 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 33: Inserting Assembled Set In From Rear Side Of Differential Carrier Courtesy of MAZDA MOTORS CORP. 4. Tighten the locknut to the extent that the SST (49 8531 565) can be turned by hand.
Page 779 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 34: Placing SST On Surface Plate & Setting Dial Gauge To Zero Courtesy of MAZDA MOTORS CORP. 7. Set the SSTs as shown in Fig. 35 . 8. Place the measuring probe of the dial gauge at the point where the side bearing is installed in the...
Page 780 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 35: Placing Measuring Probe Of Dial Gauge Where Side Bearing Is Installed In Differential Carrier Courtesy of MAZDA MOTORS CORP.
Page 781 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 36: Measuring Pinion Height Adjustment Value Courtesy of MAZDA MOTORS CORP.
Page 782 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata 9. Add the two (left and right) values obtained by the measurements taken in Step 8 and then divide the total by 2 . From this sum, subtract the sum of the number inscribed on the end of the drive pinion divided by 100 .
Page 783 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 37: Pressing Drive Pinion Into Rear Bearing Using SSTs & Press Courtesy of MAZDA MOTORS CORP. DRIVE PINION COMPONENT ASSEMBLY NOTE Drive Pinion Preload Adjustment NOTE: Perform preload adjustment with the oil seal uninstalled.
Page 784 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata 150-380 N.m {15.3-38.7 kgf.m, 111-280 ft.lbf} Drive pinion preload 1.3-1.8 N.m {14-18 kgf.cm, 12-15 in.lbf} Fig. 38: Tighten Locknut Using SST Courtesy of MAZDA MOTORS CORP. If the specified preload cannot be obtained within the specified tightening torque, replace with a ...
Page 785 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 39: Assembling Oil Seal Using SST Courtesy of MAZDA MOTORS CORP. LOCKNUT ASSEMBLY NOTE 1. Tighten a new locknut with the torque recorded at the drive pinion preload adjustment using the SST .
Page 786 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 40: Tightening Locknut Using SST Courtesy of MAZDA MOTORS CORP. 2. Verify that the drive pinion preload is within the specification. If not within the specification, perform the preload adjustment again.
Page 787 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 41: Measuring Drive Pinion Preload Courtesy of MAZDA MOTORS CORP. ADJUSTMENT SHIM ASSEMBLY NOTE Ring Gear Backlash Adjustment 1. Stack the side bearing race and differential gear case component on the surface plate as shown in Fig. 42 and measure the height using a caliper and a ruler.
Page 788 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 42: Measuring Height Using Caliper & Ruler Courtesy of MAZDA MOTORS CORP. 2. Measure the width of the section of the differential gear case component installed in the differential carrier.
Page 789: Adjustment Shim Table
2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 43: Measuring Width Of Differential Gear Case Component In Differential Carrier Courtesy of MAZDA MOTORS CORP. 1. The combined thickness of the left and right adjustment shims is obtained by the following formula.
Page 790 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata 5.90 {0.232} 6.40 {0.252} 5.95 {0.234} 6.50 {0.256} 6.00 {0.236} NOTE: If the adjustment shims are to be reused, assemble the left and right  shims that were identified during disassembly.
Page 791 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 45: Measuring Probe Of Dial Gauge Attached To End Of One Of Ring Gear Teeth Courtesy of MAZDA MOTORS CORP. 8. Secure the drive pinion and measure the backlash of the ring gear.
Page 792 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 46: Measuring Backlash At 4 Locations Around Ring Gear Courtesy of MAZDA MOTORS CORP. 9. If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.
Page 793 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 47: Aligning Bearing Cap Alignment Marks & Assembling Bearing Cap Courtesy of MAZDA MOTORS CORP. 2. Perform the drive pinion and ring gear tooth contact inspection. DRIVE PINION, RING GEAR TOOTH CONTACT INSPECTION 1.
Page 794 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 48: Inspecting Tooth Contact Pattern In Locations Around Ring Gear Courtesy of MAZDA MOTORS CORP. 4. If the toe and flank contact points appear as shown in Fig. 49 after the drive pinion and ring gear teeth...
Page 795 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 49: Identifying Toe Contact & Flank Contact Points Courtesy of MAZDA MOTORS CORP. 5. If the heel and face contact points appear as shown in Fig. 50 after the drive pinion and ring gear teeth...
Page 796 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Differential - MX-5 Miata Fig. 50: Identifying Heel & Face Contact Points Courtesy of MAZDA MOTORS CORP.
Page 797: Door Removal / Installation
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata 2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata 2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata DOORS LOCATION INDEX Fig.
Page 798 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata Fig. 2: Removing/Installing Door (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. CONNECTOR REMOVAL NOTE 1. Pull down the lever in the direction indicated by the arrow and disconnect the connector.
Page 799: Door Adjustment
2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata Fig. 3: Pulling Down Lever Courtesy of MAZDA MOTORS CORP. DOOR ADJUSTMENT 1. Measure the gap and height difference between the door and the body.
Page 800 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata Courtesy of MAZDA MOTORS CORP. Standard clearance A-A top and bottom (a): 3.1-5.0 mm {0.13-0.19 in} A-A middle (a): 3.3-5.2 mm {0.13-0.20 in} B-B top (b): -1.0-1.0 mm {-0.040-0.039 in} B-B bottom (b): -0.5-1.5 mm {-0.020-0.059 in}...
Page 801 2007 Mazda MX-5 Miata Sport 2007 ACCESSORIES & BODY, CAB Doors & Liftgate - MX-5 Miata Fig. 5: Removing/Installing Door Unit Courtesy of MAZDA MOTORS CORP.
Page 802 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata REAR DRIVE SHAFT LOCATION INDEX Fig. 1: Identifying Location Of Rear Drive Shaft Components Courtesy of MAZDA MOTORS CORP.
Page 803 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata REAR DRIVE SHAFT REMOVAL/INSTALLATION 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 pulled by mistake. Before performing the following...
Page 804 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 2: Identifying Rear Drive Shaft (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. LOCKNUT REMOVAL NOTE 1. Lock the disc plate by applying the brakes.
Page 805: Brake Caliper Component Removal Note
2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 3: Knocking Out Crimped Portion Of Locknut Using Chisel & Hammer Courtesy of MAZDA MOTORS CORP. 3. Remove the locknut. BRAKE CALIPER COMPONENT REMOVAL NOTE 1. Suspend the brake caliper component using a cable or equivalent.
Page 806 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 4: Suspending Brake Caliper Component Courtesy of MAZDA MOTORS CORP. 2. Temporarily tighten the wheel nut to prevent the disc plate from falling off. REAR DRIVE SHAFT REMOVAL NOTE 1.
Page 807 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 5: Knocking Out Nut With Copper Hammer Lightly & Removing Rear Drive Shaft From Wheel Hub Courtesy of MAZDA MOTORS CORP. 3. Separate the rear drive shaft from the wheel hub.
Page 808 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 6: Removing Rear Shaft Courtesy of MAZDA MOTORS CORP. CLIP INSTALLATION NOTE 1. Point the opening of the new drive shaft clip upward, install it to the clip groove at the end of the rear drive shaft with the installation width within the specification.
Page 809 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 7: Identifying Clip Groove End Of Rear Drive Shaft Courtesy of MAZDA MOTORS CORP. REAR DRIVE SHAFT INSTALLATION NOTE 1. Apply differential oil to the differential oil seal lip.
Page 810 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 8: Tightening New Locknut (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 2. Crimp the locknut, using a chisel and hammer. REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in Fig. 9 .
Page 811 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 9: Disassembling/Assembling Rear Drive Shaft Courtesy of MAZDA MOTORS CORP. 2. Assemble in the reverse order of disassembly. BOOT BAND (AXLE SIDE) DISASSEMBLY NOTE NOTE: Remove the boot band only if there is an abnormality.
Page 812 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 10: Removing Boot Band Using End Clamp Pliers Courtesy of MAZDA MOTORS CORP. BOOT BAND (DIFFERENTIAL SIDE) DISASSEMBLY NOTE 1. Remove the crimp of the clip using a flathead screwdriver.
Page 813 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 11: Removing Crimp Of Clip Using Flathead Screwdriver Courtesy of MAZDA MOTORS CORP. TRIPOD JOINT SOCKET DISASSEMBLY NOTE 1. Place an alignment mark on the drive shaft and the outer ring.
Page 814 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 12: Placing Alignment Mark On Drive Shaft & Outer Ring Courtesy of MAZDA MOTORS CORP. 2. Remove the outer ring. SNAP RING, TRIPOD JOINT DISASSEMBLY NOTE 1. Place an alignment mark on the shaft and tripod joint.
Page 815 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 13: Removing Snap Ring Using Snap Ring Plier Courtesy of MAZDA MOTORS CORP. 3. Remove the tripod joint from the shaft. CAUTION: To prevent damage to the component, do not use a hammer ...
Page 816 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 14: Wrapping Shaft Spline With Vinyl Tape Courtesy of MAZDA MOTORS CORP. 2. Remove the boot. BOOT ASSEMBLY NOTE NOTE: The boot shapes on the axle side and the differential side are different so ...
Page 817 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata 1. Align the tripod joint with the shaft mark and insert it using a brass bar. CAUTION: To prevent damage to the component, do not tap the roller part ...
Page 818 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata CAUTION: Do not let the grease leak.  Do not damage the boot.  Fig. 16: Releasing Trapped Air From Boot Courtesy of MAZDA MOTORS CORP. 4. Set the drive shaft length to the specification when the inside of the boots is at ambient pressure.
Page 819 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 17: Inserting End Of Boot Band Between Boot Band Clip & Fold Back Clip Tabs Using Flathead Screwdriver Courtesy of MAZDA MOTORS CORP. 3. Verify that the boot band is installed to the boot slot securely.
Page 820 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 18: Identifying Adjusting Bolt Of SST Courtesy of MAZDA MOTORS CORP. 2. Crimp the boot band (small-size) using the SST. 3. Verify that the crimp value B is within the specification.
Page 821 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata Fig. 19: Crimping Boot Band Courtesy of MAZDA MOTORS CORP. 5. Fill the boot with the repair kit grease. 6. Adjust opening length A of the SST to the specification.
Page 822 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Drive Shaft - MX-5 Miata 9. Verify that the boot band does not protrude from the boot band installation area. If the boot band protrudes from the installation area, replace it with a new band and repeat Step 7 ...
Page 823 2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 DRIVELINE/AXLES Technical Data - MX-5 Miata 2007 DRIVELINE/AXLES Technical Data - MX-5 Miata 2007 DRIVELINE/AXLES Technical Data - MX-5 Miata DRIVELINE/AXLE TECHNICAL DATA DRIVELINE/AXLE TECHNICAL DATA Item Specification Maximum front wheel bearing play 0.05 mm {0.002 in}...
Page 824: Dynamic Stability Control Location Index
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata 2007 BRAKES Dynamic Stability Control - MX-5 Miata 2007 BRAKES Dynamic Stability Control - MX-5 Miata DYNAMIC STABILITY CONTROL LOCATION INDEX Fig. 1: Identifying Location Of Dynamic Stability Control Connector Terminals Courtesy of MAZDA MOTORS CORP.
Page 825: Dsc System Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 2: DSC System Wiring Diagram Courtesy of MAZDA MOTORS CORP. DSC SYSTEM INSPECTION 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.
Page 826: Abs Control Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata 3 s . 3. Turn the ignition switch off. 4. Jack up the vehicle and support it evenly on safety stands. 5. Shift to the N position.
Page 827 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata V_TRC_L V_TRC_R V_STB_L V_STB_R LF_INLET LF_OUTLET LR_INLET LR_OUTLET RF_INLET RF_OUTLET RR_INLET RR_OUTLET PMP_MOTOR BRAKE PRESSURE REDUCTION Inspected wheels Command name LF RF LR RR V_TRC_L V_TRC_R V_STB_L...
Page 828: Dsc Control Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata wheel does not rotate. While brake pressure is being reduced and an DSC HU/CM operation click sound is heard, confirm that the wheel rotates. Performing the inspection above determines the following: ...
Page 829 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 4: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. ACTIVE COMMAND MODE INSPECTION Inspected wheels Command name Understeer control inhibited Oversteer control inhibited V_TRC_L V_TRC_R V_STB_L...
Page 830: Dsc Hu/Cm Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata 5. Confirm that the wheel does not rotate easily while a DSC HU/CM operation click sound is heard. Performing the inspection above determines the following:  The DSC HU/CM brake lines are normal.
Page 831: Dsc Hu/Cm Connector Removal Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 5: Identifying DSC HU/CM With Torque Specifications Courtesy of MAZDA MOTORS CORP. DSC HU/CM CONNECTOR REMOVAL NOTE 1. Pull the lock lever up in the direction of the arrow.
Page 832 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 6: Identifying Lock Lever Position Courtesy of MAZDA MOTORS CORP. BRAKE PIPE REMOVAL NOTE 1. Place an alignment mark on the brake pipe and DSC HU/CM.
Page 833: Brake Pipe Installation Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 7: Brake Pipe At DSC HU/CM Courtesy of MAZDA MOTORS CORP. BRAKE PIPE (DSC HU/CM-BRAKE PIPE JOINT) INSTALLATION NOTE 1. Align with the mark made before removing the brake pipe and temporarily install the brake pipe to the DSC HU/CM.
Page 834: Dsc Hu/Cm Connector Installation Note
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 8: Identifying DSC HU/CM Courtesy of MAZDA MOTORS CORP. DSC HU/CM CONNECTOR INSTALLATION NOTE 1. After connecting the connector, verify that the lock lever is completely pushed in.
Page 835 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 9: Identifying Lock Lever Position Courtesy of MAZDA MOTORS CORP. DSC CONFIGURATION 1. Connect the M-MDS to the DLC-2 connector. 2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.
Page 836: Dsc Hu/Cm Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 10: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. DSC HU/CM INSPECTION 1. Disconnect the DSC HU/CM connector. (See DSC HU/CM REMOVAL/INSTALLATION .) 2. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 3.
Page 837 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Courtesy of MAZDA MOTORS CORP. STANDARD REFERENCE VALUE TABLE Measured terminal Measured (measured Inspection item Terminal Signal name Connected to item condition) Standard Wiring  harness Ground (ABS...
Page 838 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Wiring  harness (G-LR G-LR ABS LR wheel- LR ABS wheel-speed Continuity wheel- speed sensor wheel-speed Continuity sensor detected speed (signal) sensor connector sensor terminal A connector...
Page 839 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Wiring  harness (M-RF M-RF ABS RF wheel- RF ABS wheel-speed Continuity wheel- speed sensor wheel-speed Continuity sensor detected speed (signal) sensor connector sensor terminal A connector...
Page 840 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Wiring  W-DLC-2 harness DLC-2 Continuity CAN_L Continuity terminal (W-DLC- (CAN_L) detected CAN_L 2 terminal CAN_L) Wiring  X-DLC-2 harness DLC-2 Continuity CAN_H Continuity terminal (X-DLC-2 (CAN_H)
Page 841 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata terminal Wiring  harness AI-combined (AI- Lateral-G Combined sensor Continuity combined Continuity (signal) sensor connector detected sensor terminal D connector terminal STEERING ANGLE SIGNAL INITIALIZATION PROCEDURE WARNING: If the initialization procedure of the steering angle signal is not ...
Page 842 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata When using the IDS (laptop PC)  1. Select "Chassis". 2. Select "ABS/DSC". 3. Select "Sensor Initialization". When using the PDS (Pocket PC)  1. Select "All Tests and Calibrations".
Page 843 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata 1. Inspect the front ABS wheel-speed sensor in the same order of vehicles with ABS. (See FRONT ABS WHEEL-SPEED SENSOR INSPECTION .) REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION 1.
Page 844: Combined Sensor Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 13: Combined Sensor (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 3. Install in the reverse order of removal. 4. After installation, perform the combined sensor initialization procedure. (See COMBINED SENSOR INITIALIZATION PROCEDURE .)
Page 845 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata 2. Connect the M-MDS to the DLC-2. 3. Select the following PIDs, then inspect the lateral acceleration speed and the yaw rate. LAT_ACCL: (lateral acceleration speed) ...
Page 846 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 15: Tilting Combined Sensor Left And Right Courtesy of MAZDA MOTORS CORP. 2. Yaw rate inspection 1. Verify the YAW_RATE change when the combined sensor is rotated to the left and right.
Page 847: Combined Sensor Initialization Procedure
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 16: Tilting Combined Sensor Left And Right Courtesy of MAZDA MOTORS CORP. COMBINED SENSOR INITIALIZATION PROCEDURE WARNING: Unless the initialization procedure of the combined sensor is ...
Page 848: Brake Fluid Pressure Sensor Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 17: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. 5. After the vehicle is identified, select the following items from the initial screen of the M-MDS.
Page 849 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Flare nut across flat: 12 mm {0.47 in}  3. Bleed the air from the SSTs and the brake line. (Bleed air from the SSTs through air bleeding valve A.) Fig.
Page 850: Steering Angle Sensor Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 19: Locating DLC-2 Connector Courtesy of MAZDA MOTORS CORP. STEERING ANGLE SENSOR REMOVAL/INSTALLATION NOTE: The steering angle sensor is integrated into the combination switch to ...
Page 851 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 20: Identifying Steering Angle Sensor Connector Terminals Courtesy of MAZDA MOTORS CORP. 3. Turn the ignition switch to the ON position, then measure the voltage between steering angle sensor terminal A and ground.
Page 852 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata 5. Turn the ignition switch off. 6. Connect the M-MDS to the DLC-2. 7. Select the SWA_POS PID. 8. Verify the SWA_POS changes when the steering wheel is turned to the left and right.
Page 853: Dsc Off Switch Removal/Installation
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata completed, the DSC will not operate, causing an unexpected accident. Therefore, always perform the initialization procedure to ensure DSC operation if the power supply to the steering angle sensor has been cut off due to disconnection of the steering angle sensor connector or negative battery cable, or any other cause.
Page 854: Dsc Off Switch Inspection
2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata Fig. 22: Identifying DSC OFF Switch Courtesy of MAZDA MOTORS CORP. 3. Install in the reverse order of removal. DSC OFF SWITCH CONNECTOR REMOVAL NOTE 1. Access the DSC OFF switch connector from behind of the dashboard, and squeeze the tabs of the switch connector.
Page 855 2007 Mazda MX-5 Miata Sport 2007 BRAKES Dynamic Stability Control - MX-5 Miata 2. Verify that the continuity is as indicated in Fig. 23 . If not as indicated in Fig. 23 replace the DSC OFF switch.  Fig. 23: DSC OFF Switch Continuity Table Courtesy of MAZDA MOTORS CORP.
Page 856: Control Units
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata 2007 MAZDA MX-5 Miata 2007 MAZDA MX-5 Miata BUZZERS, RELAYS & TIMERS BUZZERS, RELAYS & TIMERS LOCATION Component Location A/C Relay (AIR COND) In relay & main fuse block. See Fig. 1.
Page 857 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Keyless Control Module Behind left end of dash. See Fig. 32. Left front corner of engine compartment. See Fig. 9. Power Retractable Hardtop Control Module Left side of retractable top storage compartment. See Fig. 57.
Page 858 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Brake Fluid Level Sensor In brake fluid reservoir. See Fig. 46. Camshaft Position Sensor Right rear of engine. See Fig. 12. Combined Sensor Under rear of center console. See Fig. 18.
Page 859 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Brake Switch Top of brake pedal assembly. See Fig. 14. Buckle Switch (Left/Right) On respective seat belt buckle. See Fig. 26. Clutch Pedal Position Switch Top of clutch pedal assembly. See Fig. 14.
Page 860: Connectors Location
2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Joint Connector (C-20) Behind center of dash. See Fig. 15. Right front of luggage compartment. See Fig. Joint Connector (C-21) Left side of retractable top storage Joint Connector (C-22) compartment. See Fig. 56.
Page 861 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata C-15 (32 Pin) Behind right kick panel. See Fig. 29. C-16 (32 Pin) Behind left kick panel. See Fig. 29. C-17 (4 Pin) Left side of luggage compartment. See Fig. 34.
Page 862 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 1: Relay & Main Fuse Block Courtesy of MAZDA MOTORS CORP.
Page 863 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 2: Ground System Courtesy of MAZDA MOTORS CORP.
Page 864 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 3: Ground System Courtesy of MAZDA MOTORS CORP.
Page 865 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 4: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 866 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 5: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 867 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 6: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 868 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 7: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 869 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 8: Dash & Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 870 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 9: Engine Control System Courtesy of MAZDA MOTORS CORP.
Page 871 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 10: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 872 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 11: Dash & Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 873 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 12: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 874 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 13: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 875 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 14: Engine Control System Courtesy of MAZDA MOTORS CORP.
Page 876 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 15: Dash & Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 877 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 16: Engine Compartment & Rear Of Vehicle Courtesy of MAZDA MOTORS CORP.
Page 878 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 17: Dash & Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 879 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 18: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 880 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 19: Automatic Transmission Control System Courtesy of MAZDA MOTORS CORP.
Page 881 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 20: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 882 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 21: Dash & Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 883 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 22: Dash Courtesy of MAZDA MOTORS CORP.
Page 884 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 23: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 885 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 24: Air Bag System Courtesy of MAZDA MOTORS CORP.
Page 886 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 25: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 887 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 26: Seats Courtesy of MAZDA MOTORS CORP.
Page 888 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 27: Passenger Seat Courtesy of MAZDA MOTORS CORP.
Page 889 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 28: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 890 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 29: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 891 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 30: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 892 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 31: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 893 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 32: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 894 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 33: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 895 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 34: Vehicle Overview Courtesy of MAZDA MOTORS CORP. Fig. 35: Dash & Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 896 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 36: Engine Compartment & Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 897 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 37: Dash Courtesy of MAZDA MOTORS CORP.
Page 898 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 38: Rear Of Vehicle Courtesy of MAZDA MOTORS CORP.
Page 899 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 39: Rear Of Vehicle Courtesy of MAZDA MOTORS CORP.
Page 900 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 40: Dash Courtesy of MAZDA MOTORS CORP.
Page 901 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 41: Dash Courtesy of MAZDA MOTORS CORP.
Page 902 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 42: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 903 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 43: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 904 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 44: Dash & Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 905 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 45: Dash Courtesy of MAZDA MOTORS CORP.
Page 906 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 46: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 907 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 47: Engine Compartment & Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 908 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 48: Vehicle Overview Courtesy of MAZDA MOTORS CORP.
Page 909 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 49: Engine Compartment Courtesy of MAZDA MOTORS CORP.
Page 910 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 50: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP. Fig. 51: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP. Fig. 52: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP.
Page 911 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 53: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP. Fig. 54: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP.
Page 912 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 55: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP.
Page 913 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 56: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP. Fig. 57: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP.
Page 914 2007 Mazda MX-5 Miata Sport 2007 MAZDA MX-5 Miata Fig. 58: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP. Fig. 59: Retractable Top Storage Compartment Courtesy of MAZDA MOTORS CORP.
Page 915: Engine Performance
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata EMISSION SYSTEM LOCATION INDEX [LF] ENGINE COMPARTMENT SIDE Fig.
Page 916: Fuel Tank Side
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 2: Identifying Location Of Exhaust System Components Courtesy of MAZDA MOTORS CORP. FUEL TANK SIDE Fig. 3: Identifying Location Of Fuel Tank Side Components Courtesy of MAZDA MOTORS CORP.
Page 917 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata 1. Perform the following SST (Evaporative Emission System Tester 134-01049) self-test: NOTE: If the tester does not work correctly during self-test, refer to the  tester operators manual for more detailed procedures.
Page 918 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata 9. After the 2-min countdown (left display) is completed, the right display shows the total pressure loss for that period. A 0.5 in of water loss is acceptable on the self-test.
Page 919 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata If the red light turns on, the fuel-filler cap has leakage. Replace it.  8. Close the gas cylinder valve. 9. Turn the control valve to the FILL position.
Page 920 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 7: Identifying Evaporative Hose And Air Filter Courtesy of MAZDA MOTORS CORP. 5. Remove the air filter. 6. Install in the reverse order of removal.
Page 921 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 8: Removing Air Filter (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. AIR FILTER INSPECTION [LF] 1. Remove the air filter. (See AIR FILTER REMOVAL/INSTALLATION [LF] ).
Page 922 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 9: Identifying Air Filter Courtesy of MAZDA MOTORS CORP. CHARCOAL CANISTER REMOVAL/INSTALLATION [LF] 1. Remove the battery cover. 2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 3.
Page 923 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 10: Identifying Charcoal Canister Components (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. EVAPORATIVE HOSE INSTALLATION NOTE 1. Fit the evaporative hose onto the respective fittings, and install clamps as shown in Fig. 11.
Page 924 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 11: Inserting Evaporative Hose Securely To Nipple Courtesy of MAZDA MOTORS CORP. CHARCOAL CANISTER INSPECTION [LF] 1. Remove the charcoal canister. (See CHARCOAL CANISTER REMOVAL/INSTALLATION [LF] ).
Page 925 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 12: Identifying Charcoal Canister Courtesy of MAZDA MOTORS CORP. EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP REMOVAL/INSTALLATION [LF] 1. Remove the battery cover. 2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 3.
Page 926 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 13: Identifying Evaporative Emission System Leak Detection Pump And Evaporative Hose (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 7. Remove the bracket from the EVAP system leak detection pump.
Page 927 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 14: Removing Bracket From EVAP System Leak Detection Pump Courtesy of MAZDA MOTORS CORP. 8. Install in the reverse order of removal. EVAPORATIVE HOSE INSTALLATION NOTE 1.
Page 928: Airflow Inspection
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 15: Inserting Evaporative Hose Securely To Nipple Courtesy of MAZDA MOTORS CORP. EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP INSPECTION [LF] NOTE: Perform the following procedure only when directed.
Page 929 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP REMOVAL/INSTALLATION [LF] ). If as specified, perform the following "RESISTANCE INSPECTION".  Fig. 16: Identifying Evaporative Emission System Leak Detection Pump Ports Courtesy of MAZDA MOTORS CORP.
Page 930: Circuit Open/Short Inspection
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 17: Identifying EVAP System Leak Detection Pump Connector Terminals Courtesy of MAZDA MOTORS CORP. CIRCUIT OPEN/SHORT INSPECTION 1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .) 2.
Page 931 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata EVAP system leak detection pump terminal A and main relay  EVAP system leak detection pump terminal B and body ground  Short Circuit If there is continuity, there is a short circuit. Repair or replace the wiring harness.
Page 932 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 18: Identifying PCM Wiring Harness-Side Connector Courtesy of MAZDA MOTORS CORP. PURGE SOLENOID VALVE REMOVAL/INSTALLATION [LF] 1. Remove the battery cover. 2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .) 3.
Page 933 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 19: Removing Purge Solenoid Valve From Air Hose Courtesy of MAZDA MOTORS CORP. 6. Install in the reverse order of removal. PURGE SOLENOID VALVE INSPECTION [LF] NOTE: Perform the following procedure only when directed.
Page 934 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Measured condition Continuity between A-B When voltage is not applied between terminals A No airflow and B When voltage is applied between terminals A Airflow detected and B Fig.
Page 935 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 21: Purge Solenoid Valve & PCM Connector Courtesy of MAZDA MOTORS CORP. Open Circuit If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
Page 936 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata 4. Drain the engine coolant from the radiator. (See ENGINE COOLANT REPLACEMENT [LF] .) 5. Remove the service hole cover. 1. Remove the suspension tower bar (joint), (right side) and (left side). (See FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION .)
Page 937 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 23: Removing Service Hole Cover (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 6. Remove the harness bracket.
Page 938 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 24: Removing Harness Bracket Courtesy of MAZDA MOTORS CORP. 7. Disconnect the heater hose and move the heater pipe slightly out of the way.
Page 939 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 25: Identifying Heater Hose & Heater Pipe Courtesy of MAZDA MOTORS CORP. 8. Disconnect the EGR valve connector. 9. Set the SST to the EGR valve installation bolt.
Page 940 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 26: Setting SST (49 N013 001) To EGR Valve Installation Bolt Courtesy of MAZDA MOTORS CORP. 10. Remove both EGR valve installation bolts. 11. Remove the EGR valve with the engine coolant hose.
Page 941: On-Vehicle Inspection
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 27: Removing EGR Valve With Engine Coolant Hose (With Torque Specifications) Courtesy of MAZDA MOTORS CORP. 12. Disconnect the engine coolant hose from the EGR valve.
Page 942 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata 4. Disconnect the EGR valve connector. (See EGR VALVE REMOVAL/INSTALLATION [LF] ). 5. Measure the resistance between the EGR valve terminals. If within the specification, perform out the CIRCUIT OPEN/SHORT INSPECTION .
Page 943 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata CIRCUIT OPEN/SHORT INSPECTION 1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .) 2. Inspect the following wiring harnesses for open or short circuit (continuity check). Open Circuit If there is no continuity, there is an open circuit.
Page 944 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 29: Identifying EGR Valve & PCM Wiring Harness-Side Connector Courtesy of MAZDA MOTORS CORP. POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [LF] 1. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .) 2.
Page 945 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata If there is no airflow, replace the PCV valve.  Fig. 30: Identifying PCV Valve Courtesy of MAZDA MOTORS CORP. WARM-UP THREE-WAY CATALYTIC CONVERTER (WU-TWC) INSPECTION [LF] NOTE: Make sure that no HO2S DTCs have been detected.
Page 946 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata 2. Monitor the appropriate PIDs. 3. Drive the vehicle for 10 min at 65-96 km/h {40-60 mph} to allow the front catalytic converter to reach operating temperature.
Page 947 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata If the ratio is 1.5 or more or there is no downstream HO2S inversion, the WU-TWC is functioning  properly. If the ratio is less than 1.5 , the WU-TWC is not functioning properly. Replace the WU-TWC.
Page 948 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 33: Downstream HO2S Graph Line Example 1 Courtesy of MAZDA MOTORS CORP. Downstream HO2S Graph Line Example 2 Fig. 34: Downstream HO2S Graph Line Example 2...
Page 949 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Courtesy of MAZDA MOTORS CORP. Downstream HO2S Graph Line Example 3 Equation RATIO = 30 inversions (upstream HO2S inversions) divided by 27 inversions (downstream HO2S inversions) = 1.1 (bad WU-TWC) Fig.
Page 950 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata NOTE: The fuel shut-off valve cannot be removed as it is built into the fuel tank.  FUEL SHUT-OFF VALVE INSPECTION [LF] NOTE: The fuel shut-off valve cannot be removed and inspected as it is built into ...
Page 951: Quick Release Connector Type
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata EVAPORATIVE CHAMBER INSPECTION [LF] 1. Remove the evaporative chamber. 2. Blow from port A and verify that there is airflow from port B. If not as specified, replace the evaporative chamber.
Page 952: Type A Removal
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 38: Identifying Location Of Different Types Of Quick Release Connectors Courtesy of MAZDA MOTORS CORP. TYPE A REMOVAL CAUTION: The quick release connector may be damaged if the release tab is ...
Page 953 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 39: Rotating Release Tab On Quick Release Connector To Stopper Position Courtesy of MAZDA MOTORS CORP. 2. Pull out the evaporative hose straight from the joint port and disconnect it.
Page 954: Type B Removal
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 41: Covering Disconnected Quick Release Connector Courtesy of MAZDA MOTORS CORP. TYPE B REMOVAL 1. Squeeze the release tab until the locks are released. NOTE: The retainer has two internal locking tabs which retain the joint port.
Page 955: Type C Removal
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 42: Removing Type B Components 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 from becoming scratched or dirty.
Page 956 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 43: Disconnecting Quick Release Connector Courtesy of MAZDA MOTORS CORP. 3. Hold the center of the retainer tabs with the SST ends and press the retainer.
Page 957 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 44: Raising Retainer Tab Using SST Courtesy of MAZDA MOTORS CORP. 6. Cover the disconnected quick release connector and joint port with vinyl sheeting or a similar material to prevent it from becoming scratched or dirty.
Page 958: Type A Installation
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 45: Releasing Locks Between Retainer And Joint Port Courtesy of MAZDA MOTORS CORP. 2. Pull out the hose straight from the joint port and disconnect it.
Page 959: Type B Installation
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 46: Removing Checker Tab From Quick Release Connector Completely Engaged With Joint Port Courtesy of MAZDA MOTORS CORP. 1. Inspect the evaporative hose and joint port sealing surface for damage and deformation.
Page 960 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata A checker tab is integrated with the quick release connector for new  evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the joint port.
Page 961: Type C Installation
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata port and remove it. 2. Inspect the quick release connector and joint port sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
Page 962 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata pipe. CAUTION: Be sure to replace the retainer with a new one to prevent gas  leakage. 1. Install a new retainer to the quick release connector.
Page 963: Type D Installation
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata 2. Reconnect the hose straight to the pipe until a click is heard. 3. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.
Page 964 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 50: Removing Checker Tab From Quick Release Connector After Connector Completely Engaged With Joint Port Courtesy of MAZDA MOTORS CORP. 1. When newly replacing the quick release connector, remove the release tab using the following procedure.
Page 965 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Emission System - MX-5 Miata Fig. 51: Removing Tab From Joint Port Courtesy of MAZDA MOTORS CORP. 2. Inspect the quick release connector and joint port sealing surface for damage and deformation.
Page 966: Engine Performance
2007 Mazda MX-5 Miata Sport 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata CONTROL SYSTEM LOCATION INDEX [LF]...
Page 967 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata...
Page 968 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 1: Identifying Location Of Control System Components Courtesy of MAZDA MOTORS CORP. CONTROL SYSTEM DIAGRAM [LF] Fig. 2: Engine Control System - System Diagram Courtesy of MAZDA MOTORS CORP.
Page 969 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 3: Engine Control System - Wiring Diagram (1 Of 2) Courtesy of MAZDA MOTORS CORP.
Page 970 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 4: Engine Control System - Wiring Diagram (2 Of 2)
Page 971 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Courtesy of MAZDA MOTORS CORP. PCM REMOVAL/INSTALLATION [LF] 1. When replacing the PCM, perform the following: PCM configuration (See PCM CONFIGURATION [LF] .)  2. Remove the battery cover.
Page 972 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata PCM parameter reset (See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY  ADDITION AND CLEARING[ADVANCED KEYLESS SYSTEM] .) PCM CONNECTOR CONNECTED NOTE 1. Connect the PCM connector fully into the PCM and push the lever until a click is heard.
Page 973 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 7: Identifying PCM Harness Side Connectors Courtesy of MAZDA MOTORS CORP. PCM TERMINALS VOLTAGE SPECIFICATION TABLE Terminal Signal Connected to Test condition Voltage (V) Inspection item Starter ...
Page 974 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata (Refrigerant pressure switch switch (middle) is on.) (middle) Refrigerant Refrigerant pressure pressure Refrigerant pressure is less Related  switch switch than the specification. wiring (middle) (middle)
Page 975 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata wiring harness Ignition switch is turned to EVAP  the ON position system EVAP system leak EVAP system leak detection detection leak detection pump pump pump...
Page 976 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata No.2 power the ON position Related  supply wiring harness Ignition switch is turned to Approx. 0.7  the ON position sensor MAF sensor Related ...
Page 977 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata harness IAT is 20°C Approx. 2.4 Ignition IAT sensor  {68°F} MAF/IAT switch is Related  sensor turned to the IAT is 60°C Approx. 0.9 wiring ON position {140°F}...
Page 978 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Ground Ground Under any condition Below 1.0 Related  wiring harness Ignition switch off Below 1.0 Main relay  Related Ignition switch is turned to ...
Page 979 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata EGR valve #2 EGR valve Idle (EGR control not EGR valve  coil control (terminal A) operating) Related  wiring harness EGR valve #4 EGR valve...
Page 980 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Inspect using the wave profile.   sensor CMP sensor (See INSPECTION USING AN Related  OSCILLOSCOPE wiring (REFERENCE) .) harness Steering PSP switch  wheel at Related ...
Page 981 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Front HO2S Front HO2S Idle after warm-up Approx. 2.8 Front  HO2S Related  wiring harness Ignition switch is turned to Approx. 4.1  the ON position (at sea...
Page 982 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Constant Throttle body Ignition switch is turned to Approx. 5.0 Related  voltage (Vref) (TP sensor) the ON position wiring harness Sensor Throttle body Under any condition Below 1.0...
Page 983 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata IGT1 Ignition coil Inspect using the wave profile. Ignition   (No.1 coil No.1 cylinders) (See INSPECTION USING AN Related  OSCILLOSCOPE wiring (REFERENCE) .) harness...
Page 984 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Turn the test mode on using the M-MDS simulation function. MT without ABS/DSC INSPECTION USING AN OSCILLOSCOPE (REFERENCE) Throttle Control (+) Signal PCM Terminals 2A (+)-Negative battery terminal (-) ...
Page 985 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata 2B (+) - Negative battery terminal (-)  Oscilloscope Setting 5 V/DIV (Y), 1 ms/DIV (X), DC range  Vehicle Condition Idle (Accelerator pedal released) ...
Page 986 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 10: Waveform Graph (Purge Control Signal) Courtesy of MAZDA MOTORS CORP. OCV Control Signal PCM Terminals 2E (+)-Negative battery terminal (-)  Oscilloscope Setting 2.5 V/DIV (Y), 1 ms/DIV (X), DC range ...
Page 987 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 11: Waveform Graph (OCV Control Signal) Courtesy of MAZDA MOTORS CORP. Vehicle Speed Signal PCM Terminals 2O (+)-Negative battery terminal (-)  Oscilloscope Setting 1 V/DIV (Y), 10 ms/DIV (X), DC range ...
Page 988 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 12: Waveform Graph (Vehicle Speed Signal) Courtesy of MAZDA MOTORS CORP. CMP Signal PCM Terminals 2S (+) - Negative battery terminal (-)  Oscilloscope Setting 2 V/DIV (Y), 50 ms/DIV (X), DC range ...
Page 989 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 13: Waveform Graph (CMP Signal) Courtesy of MAZDA MOTORS CORP. CKP Signal PCM Terminals 2W (+) - Negative battery terminal (-)  Oscilloscope Setting 2 V/DIV (Y), 10 ms/DIV (X), DC range ...
Page 990 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 14: Waveform Graph (CKP Signal) Courtesy of MAZDA MOTORS CORP. Generator Field Coil Control Signal PCM Terminals 2AI (+) - Negative battery terminal (-) ...
Page 991 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 15: Waveform Graph (Generator Field Coil Control Signal) Courtesy of MAZDA MOTORS CORP. Generator Output Voltage Signal PCM Terminals 2AJ (+) - Negative battery terminal (-) ...
Page 992 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 16: Waveform Graph (Generator Output Voltage Signal) Courtesy of MAZDA MOTORS CORP. Ignition Timing Signals PCM Terminals IGT1 (No.1): 2BA (+) - Negative battery terminal (-) ...
Page 993 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 17: Waveform Graph (Ignition Timing Signals) Courtesy of MAZDA MOTORS CORP. Fuel Injection Signals PCM Terminals Fuel Injection No.1: 2BB (+) - Negative battery terminal (-) ...
Page 994 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 18: Waveform Graph (Fuel Injection Signals) Courtesy of MAZDA MOTORS CORP. Front HO2S Heater Control Signal PCM Terminals 2BG (+) - Negative battery terminal (-) ...
Page 995 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 19: Waveform Graph (Front HO2S Heater Control Signal) Courtesy of MAZDA MOTORS CORP. USING THE M-MDS OR EQUIVALENT NOTE: PIDs for the following parts are not available on this model. Go to the ...
Page 996 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata Fig. 20: Locating Connector DLC-2 Courtesy of MAZDA MOTORS CORP. 2. Turn the ignition switch to ON position. 3. Measure the PID value. If PID value is not within the specification, follow the instructions in "Inspection item (s)" column.
Page 997: Pid/Data Monitor Table
2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata PID/DATA Monitor Table (Reference) PID/DATA MONITOR TABLE Item Condition/Specification (definition) Unit/Condition (Reference) Inspection item(s) terminal Ignition switch is The following   (Ambient air turned to the ON...
Page 998 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata output voltage) (This is an internal calculation value and differs from the terminal voltage.) 1AO, 1AP Accelerator pedal The following   (Accelerator released: 0% PIDs...
Page 999 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata AC_REQ, COLP Ignition switch is  turned to the ON position: Indicate the barometric BARO pressure (Barometric pressure) Ignition switch is  turned to the ON position (at sea level): 4.1 V...
Page 1000 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Engine Control System - MX-5 Miata pedal position) depressed: On On/Off Clutch pedal  released: Off. Drive/Neutral CPP/PNP Neutral: Neutral Neutral switch   (Shift lever Other than neutral:  position) Drive...

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