Engine Controls - Removal, Overhaul & Installation: Other Mazda MX-5 NB

IGNITION SYSTEM

Note. All models except Millenia 2.5L are equipped with distributorless ignition system.

CAMSHAFT POSITION (CMP) SENSOR

Note. On Millenia 2.5L, CMP sensor is integrated with distributor and is not serviced separately. If faulty, distributor assembly must be replaced. See DISTRIBUTOR (MILLENIA 2.5L) .

CMP SYNCHRONIZER

IGNITION CONTROL MODULE

Note. On Millenia 2.5L, ignition control module is integrated with distributor and is not serviced separately, replace complete distributor assembly.

FUEL SYSTEM

Except B2500, B3000 & B4000

Disconnect fuel pump relay. See FUEL PUMP RELAY LOCATION table. Start engine. Allow engine to run until it stalls. Turn ignition off. Reinstall relay.

FUEL PUMP RELAY LOCATION

Disconnect & Connect (Tab-less Design)

Clean quick release connector. Press tool (49N013103) into quick release connector and pull connector apart. Inspect sealing area and clean as necessary. To connect, push connector together until a click is heard. Pull connector to ensure connector is locked together.

Disconnect & Connect (Tab Design)

Clean quick release connector. Squeeze tabs to release connector and pull connector apart. Inspect retainer and replace as necessary. To connect, push connector together until a click is heard. Pull connector to ensure connector is locked together.

Disconnect (Spring Lock Coupler)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-91109-S01487239142001030200000). Remove locking (safety) clip (if equipped). Place Spring Lock Coupler Releaser (49-UN01-051 for 3/8" line, 49-UN01-052 for 1/2" line) over fuel line coupler. (Scheme 16)
2. Push spring lock coupler releaser to release female fitting from garter spring. Pull spring lock coupler apart. Remove releaser.

Connect

1. Check for damaged garter spring. If garter spring is damaged, remove using small hooked wire, and replace spring. Wipe end of lines using clean cloth. Place NEW "O" rings onto tube. Lubricate ends of lines with clean refrigerant oil.
2. Push fitting together using a slight twisting motion. Ensure garter spring is over flared end of female fitting. Attempt to pull lines apart to ensure coupler is fully engaged. Install locking clip (if equipped).

Scheme 16

Disconnect (Fuel Line Coupler)

Disengage locking tabs on connector retainer. Separate retainer halves. Disengage fitting from regulator by pushing fitting toward regulator and inserting Fuel Line Coupling Key (49 UN01 006). (Scheme 17)

To reconnect fuel line coupling, push coupler tube assembly firmly into coupler body recess until fully engaged. Pull gently on both ends of coupler to ensure engagement. See FUEL RAILS & INJECTORS .

Scheme 17

Disconnect - Quick Release Coupling With "R" Clip

Note. Quick release coupling with "R" clip may also be referred to as hairpin clip fitting.

Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove shipping tab by bending downward. (Scheme 18) Spread "R" clip legs and push into coupling. (Scheme 19) Separate fuel line from coupling. (Scheme 20)

Scheme 18

Scheme 19

Scheme 20

Wipe end of fuel line using clean cloth. Install NEW "R" clip into coupling. Align fuel line and coupling and push together until click is heard. (Scheme 21) Pull gently on both fuel lines to ensure engagement.

Scheme 21

FUEL SYSTEM PRIMING

Connect jumper wire between GND and F/P terminals of data link connector. (Scheme 22) Turn ignition on for about 10 seconds and then off. Disconnect jumper wire.

Scheme 22

FUEL PUMP

FUEL PRESSURE REGULATOR

FUEL RAILS & INJECTORS

LYSHOLM COMPRESSOR (MILLENIA 2.3L)

1. Remove dynamic chamber cover. Remove charge air cooler air duct and air cleaner assembly. Remove fresh air duct and connecting air duct. Remove mass airflow sensor and air intake hose.
2. Remove air resonator. Remove right and left air charge air coolers with connecting hoses (if needed) from air intake pipe assembly. Disconnect accelerator cable. Remove EGR valve. Disconnect vacuum lines and harness connector from air intake pipe assembly. Remove air intake pipe assembly.
3. Remove charge air cooler pipe from intake manifold. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-91109-S01487239142001030200000) . Disconnect negative battery cable. Disconnect fuel line. Remove fuel rail assemblies. See «FUEL RAILS & INJECTORS»(ref-91109-S32560369342001030200000) . Disconnect coolant hose. Remove intake manifolds. Remove throttle body from compressor. Loosen and remove drive belt. Remove Lysholm compressor.

Install components in reverse order of removal. Ensure intake manifold bolts are tighten in crisscross pattern to specification. See TORQUE SPECIFICATIONS . Ensure hose clamps are positioned correctly to prevent interference with other hoses or electrical harnesses. Partially tighten air intake pipe bolts in crisscross order and loosen. Retighten bolts to specification.

THROTTLE BODY

UPPER INTAKE MANIFOLD

Note. Models not listed do not require upper intake manifold to be removed to access fuel system or engine control components.

Miata

TORQUE SPECIFICATIONS (Miata)

Millenia 2.3L

TORQUE SPECIFICATIONS (Millenia 2.3L)

Millenia 2.5L & 626 2.5L

TORQUE SPECIFICATIONS (Millenia 2.5L & 626 2.5L)

Protege & 626 2.0L

TORQUE SPECIFICATIONS (Protege & 626 2.0L)