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Mazda MX 5 1989 2009 Gregorys Workshop Service Repair Manual

The MX-5, released as the MX-5 Miata /miˈɑːtə/ in North America, and the Roadster in Japan, is a lightweight two-seater roadster with front-engine, rear-wheel-drive layout. Manufactured by Mazda in Hiroshima, Japan, the model debuted in 1989 at the Chicago Auto Show. The MX-5 was conceived as a small roadster – with light weight and minimal mechanical complexity limited only by legal and safety requirements; technologically modern, but philosophically descending from small British and Italian roadsters of the 1960s such as the Triumph Spitfire, MG MGB, Fiat 124 Sport Spider, Alfa Romeo Spider, and Lotus Elan.

The second generation MX-5 (NB) had been launched in 199an as well as the present (NC) model has been in production since 2005. It continues to be the best-selling two-seat convertible activities car in history and by February 2011 over 900,000 MX-5s had been built and offered all over the world.

Since the launch of the third generation, Mazda consolidated worldwide marketing using the MX-5 title with the exception of North America where it is marketed as the MX-5 Miata. The name Miata derives from Old High German for reward.

The MX5's first generation, the NA, sold over 400,000 units from 1989 to 1997 – with a 1.6 L (98 cu in) straight-4 engine to 1993, a 1.8 L (110 cu in) engine thereafter (with a DE-tuned 1.6 as a budget option in some markets) – recognizable by its pop-up headlights. The second generation (NB) had been introduced in 1999 with a minor increase in engine power; it can be recognized by the fixed headlights and the cup rear window, although first generation owners may opt for the glass window design when replacing the original top. The third generation (NC) was introduced in 2006 with a 2.0 L (120 cu in) engine.

Launched at a time when production of small roadsters had almost come to an end, the Alfa Romeo Spider had been the only comparable amount model in production at the time of the MX-5's launch. Simply a decade earlier, a host of similar models — notably the MG B, Triumph TR7, Triumph Spitfire, and Fiat Spider — had been available.

The body is a conventional, but unibody, light or monocoque construction, with (detachable) front and back subframes. The MX-5 also includes a longitudinal truss, sold as the Powerplant Frame (PPF), providing a rigid connection between the engine and differential, minimizing flex and contributing to responsive handling. Some MX-5s feature limited slip differentials and anti-lock braking system. Traction control is an option available on NC models. The earlier cars weighed just over a ton, with engine power output usually 116 bhp (87 kW). The later cars were heavier, with greater power engines.

With an approximate 50:50 front/rear weight balance, the car has nearly neutral handling. Inducing oversteer is simple and very controllable, thus making the MX-5 a popular choice for amateur and stock racing, including, in the US, the Sports Car Club of America's Solo2 autocross and Spec Miata race series, and in the UK, the Ma5da

The MX-5 has won awards including Wheels Magazine 's Car of the Year for 1989 and 2005; Sports Car International's "best sports car of the 1990s" and "ten best sports cars of all time"; 2005–2006 Car of the Year Japan; and 2005 Australian Car of the Year. The Miata has also made Driver and Car magazine's yearly Ten Best list 14 times. In their December 2009 issue, Grassroots Motorsports mag named the Miata as the many important sports car built during the previous 25 many years.

The fact is that if you want a sports car, the MX-5 is perfect. Absolutely nothing on the road will give you better value. Nothing will provide you with so much fun. The only reason I’m offering it five movie stars is because we can’t give it 14.

In 1981, Hall moved to an item preparing place with Mazda USA and again met Yamamoto, today chairman of Mazda Motors, who remembered their conversation about a roadster and in 1982 gave Hall the go-ahead to research the idea further. At this time Hall hired designer Mark Jordan to join the newly formed Mazda design studio in Southern California. There, Hall and Jordan collaborated on the parameters of the initial proportion, visualization and image of the "light-weight sports" concept. In 1983, the idea switched idea had been approved under the "Offline 55" system, an inner Mazda initiative that sought to change the way new models were developed. Thus, under head of task Masakatsu, the concept development had been turned into a competition between the Mazda design teams in Tokyo and California.

The Californian team proposed back-wheel-drive, front-engine layout, codenamed Duo 101, in line with the British roadster ancestry, but their Japanese counterparts favored the more common front-engine, front-wheel-drive layout or the rear mid-engine, rear-wheel-drive layout.

The first round of judging the competing designs was held in April 1984, with designs presented on paper only. The mid-engined automobile showed up to offer favorable qualities, although it was known at the time that such a layout would struggle to meet the noise, vibration, and harshness (NVH) requirements of the project. It was only at the 2nd round of the competition in August 1984, when full-scale clay designs had been provided, that the Duo 101 won the competition and was selected as the basis for what would become the MX-5.

The Duo 101, so named as either a soft top or hard top could be used, incorporated many key stylistic cues encouraged by the Lotus Elan, a 1960s roadster, including the door handles and grill opening. International Automotive Design (IAD) in England, Worthing was commissioned to develop a running prototype, codenamed V705. It was built with a fiberglass human body, a 1.4 L (85 cu in) engine from a Mazda Familia and components from a variety of early Mazda models. The V705 was completed in August 1985 and taken to the US where it rolled on the roads around Santa Barbara, California and got positive responses.

The task got final approval on 18 January 1986. The model's codename was changed to P729 as it moved into the production phase, under mind of program Toshihiko Hirai. The task of constructing five engineering mules (much more developed prototypes) had been again allocated to IAD, which also conducted the first front and rear crash tests on the P729. While Tom Matano, After Mark Jordan, Wu Huang Chin, Norman Garrett, and Koichi Hayashi worked on the final design, the project was moved to Japan for engineering and production details.

By 1989, with a definitive model name now chosen, the MX-5 (as in "Mazda Experiment", task number 5) was ready to be introduced to the world as a true lightweight sports car, weighing just 940 kg (2,070 lb).

Although Mazda's concept was for the MX-5 to be an inexpensive sports car, at introduction the design met strong demand, with many dealers putting clients on pre-order lists and several dealers across North America increasing the vehicle markup.

The MX-5 had been unveiled at the Chicago Auto Show on February 10, 1989, with a price tag of US,000 (US,400 in 2011 modified for inflation). The MX-5, with production code NA, was made available for delivery to buyers worldwide in the following dates: May 1989 (as a 1990 model) in the US; Canada and September 1, 1989 in Japan; and 1990 in Europe. An optional hardtop was made available at the same time, in sheet moulding compound (SMC). Demand initially outstripped manufacturing, fueled by enthusiastic press reviews.

In Japan, the vehicle was not badged as a Mazda, as the company was experimenting with the creation of different marques for deluxe models, similar to Nissan's Infiniti and Toyota's Lexus (both brands of which launched at the same time as the Miata). Rather, the Mazda MX-5 was sold as the Eunos Roadster in that market.

The body shell of the NA had been all-steel with a light-weight aluminium hood. Overall dimensions were 3,970 mm (156 in) in length, 1,675 mm (65.9 in) in width, and 1,235 mm (48.6 in) in height. Without options, the NA weighed only 2,150 lb (980 kg). Drag coefficient had been indicated as 0.38. Suspension was an independent double wishbone on all four tires, with an anti-roll bar at the front and rear. Four wheel-disc brakes, ventilated at the front side, were behind alloy tires with 185/60HR14 radial tires. The base model came with stamped steel wheels from the then-current 323/Protege.

1990 Mazda MX5 1,600cc DOHC 4-cylinder engine. This example has been modified with the addition of a GReddy TD04(Mitsubishi) turbocharger kit

The original MX-5 came with a 1.6 L (98 cu in) double overhead cam inline four-cylinder engine, producing 86 kW (115 bhp) at 6,800 rpm, and 136 N���·m (100 lbf���·ft) of torque at 5,500 rpm. The motor employs an electronic gas injection system using a vane-type air flow meter and an electronic ignition system with a crankshaft angle sensor instead of a distributor. This codename, engine B6ZE(RS), was particularly designed for the MX-5 and featured a lightened flywheel, crankshaft, and aluminum sump with cooling fins.

Standard transmission was 5-speed manual. In the US, Japan and an, an optional automated transmission was also offered but proved to be unpopular. The American and Japanese markets also received an optional viscous limited slip rear differential, although it had been only readily available for cars with a manual transmission. To achieve the low introductory price, the base model was stripped. It had steel tires, manual steering, roll-up windows, and no stereo or air-conditioning. Power steering, air-conditioning, and stereo were added as standard equipment in later years.

The NA could reach 60 mph (97 km/h) in 8.1 seconds and had a top speed of 126 mph (203 km/h) although Japanese market Eunos models were limited to 112 mph (180 km/h). This first generation of Miata (often referred to as the NA) included a special Limited Edition of 250 examples in 1991, created in British Racing Green with the first usage of tan interior, to commemorate the highly successful launch of the MX-5 in the UK. These have a numbered metal plaque on the dash above the glovebox and on the front of the Owners Book, and are fitted with alloy wheels from MSW (Mazda Sports Workshop) that are often mistaken for BBS's, but are entirely unique to this model.

1990 Mazda MX-5 right hand drive interior.

1500 LE (Limited Edition) automobiles had been produced in 1993. This model showcased red leather interior, upgraded stereo, Nardi shift knob, leather-wrapped steering wheel, cruise, limited slip differential, energy house windows, energy mirrors, energy steering, air conditioning, BBS tires, Bilstein shocks, front and rear ABS, spoilers brakes, stainless sill plates, and Harley style peanut tank door speaker trim. All 1993 LE cars came in black colored.

For the 1994 model 12 months, the first-generation MX-5 had been freshened with the introduction of the much more powerful 1.8 L (110 cu in) BP-ZE engine, dual airbags and a limited slip differential in some markets. The chassis was substantially braced to meet new side-impact standards, most visibly by adding a "track bar" between the seatbelt towers inside the car, but also to the front and rear subframes. Also, 1994 and 1995 had been the only years where Mazda offered a light metallic blue paint (Laguna Blue Mica), making these cars unusual collectors cars to some. 1994 also saw the introduction of the "R" package, a sport-themed package with Bilstein shocks and subtle underbody spoilers, in addition to the removal of unnecessary items such as power steering. No body style changes were made, however.

The new 1.8 L (110 cu in) engine produced 98 kW (131 bhp), which was then increased to 99 kW (133 bhp) for the 1996 model year. The base weight increased to 990 kg (2,180 lb). Performance was enhanced somewhat, the additional power being partly offset by the extra weight. In some markets such as Europe, the 1.6 L (98 cu in) engine continued to be available as a lower-cost option, but was detuned to 66 kW (89 bhp). This lower-powered model did not receive all the extra chassis bracing of the new 1.8 L (110 cu in). US and Japanese cars were fitted with an optional Torsen LSD, which was far much more durable than the earlier viscous differential.

The retractable headlamps of the NA (front car) were replaced by fixed headlamps on the NB (rear car).

There were an amount of trim levels and unique editions available, determined by local Mazda marketing departments. In the US, the base model was offered for US,995 at launch and was very basic, with handbook windows, steel wheels, and without A/C or power steering. The "A Package" provided power steering, a leather-wrapped steering wheel, aluminum alloy wheels and cassette stereo. The "B Package" added power windows, along with cruise control and headrest speakers, while the "C Package" included a tan interior and leather and top seats. The "R Package" was for racing, as well as the annual special editions were formalized as "M Editions". These included all of the luxury options from the "C Package" because well as special paint and, sometimes, special wheels. In the UK, to celebrate Mazda's 24 hours of Le Mans win, Mazda broughan away a special edition of the MX-5, with the winner's color scheme (see Mazda 787B) and came equipped with BBR (Brodie Brittain Racing) turbo conversion; the vehicle is one of the most looked for after special edition cars of the MX-5s.

The first generation MX-5 had been phased out with the 1997 model year (with the exception of 400 limited edition Berkeley models sold only in the UK in 1999 to mark the end of the NA), with the final 1500 NAs produced for the US market being the "STO" ("Special Touring Option") variations.

A small range of Miata units were assembled by the M2 Incorporated. Founded in November 1991, M2, also known as "Mazda Too", had been Mazda's brand new off-line planning / niche-house / Research & Development company back in the early '90s. The M2 Corp. employees had noble intentions — creating niche-mobiles derived from Mazda's volume products. Although M2's fundamental mission involved focusing on the "soft" aspects of vehicle design in an attempt to create more specifically targeted niche variants, the changes to the off-line cars would go well beyond mere beauty products.

Heading the M2 operation was Mr. Masakatsu Kato, original father of the Miata (Eunos Roadster) in Japan, in addition to creator of several Mazda concept vehicles. Kato-san was assisted by Hirotaka Tachibana, development engineer responsible for the superb dynamics of the FC (second-generation RX-7an as well as the NA Roadster (Miata MX-5). M2 Corp. was based out of Japan, Tokyo. M2-Corp was a 100% had subsidiary of Mazda, and it was closed by Mazda in 1995. Mazda kept a similar program going with the Mazdaspeed vehicles, and then in the late '90s Mazdaspeed had been consumed into Mazda as a subsidiary company in Mazda Auto Tokyo. There were many types of M2 branded vehicles between 1991 and 1995, beginning with the 1001 up to the 1031 Cafe Racer (Dec-91).

M2-1001 Cafe Roadster (Dec-91) Limited 1/300 M2 Corp. released the M2-1001 Roadster in December 1991. It was a special "Limited Production" Roadster variant that was a short manufacturing run of only 300 units, in a special Blue/Black Mica Paint, with a sticker price of ,000. Prospective buyers were required to show up in person at M2's Tokyo headquarters to register for a lottery to place an order for this extremely limited Roadster.

This upscale Eunos Roadster was M2's very first turn-key, race-ready offering. Here is a list of a few of the goodies that made it so popular: useful front airdam with integrated fog lamps, vintage aero mirrors, 4-point roll bar, vintage measure cluster, fixed back bucket seats, polished 3-spoke steering wheel, stiffer suspension package with M2 specific rates, refined aluminum strut brace, upgraded exhaust by HKS, intake system, 1.6L motor with new aggressive pistons, upgraded camshaft, lightweight LSD, flywheel cooling intake, handbook steering, manual windows (A/C was optional), racing pedals, centerless console with matching shortened radio bezel, aluminum gas filler cap, a far more aggressive wheel & tire package (15" x 6" Panasport rims), and a rear spoiler (which became standard for the R package). The performance changes made to the Roadster would bump the power to 132 bhp (98 kW) @ 7,000 rpm, and 109 lbf���·ft (148 N���·m) of torque @ 5,500 rpm. When released, it proved therefore popular that individuals were paying up to ,000 for one.

M2-1002 Vintage Roadster (Nov-92) Limited 1/300 M2-CORP released its second Roadster in late 1992, with a sightly different front bumper but all the exact same products as the previous 1001 Roadster. This one did not do as well as the 1001.

M2-1028 Street Competition Roadster (Feb-94) Limited 1/300 M2-CORP released its third Roadster in early 1994, based on the initial "Jinba Ittai" concept made by Toshihiko Hirai. This was billed as a track-ready Roadster. (The US saw a cheaper version known as the R-Package.) Offered in Chaste White or Brilliant Black only, this Roadster used the new 1.8L powerplant with upgraded pistons, camshafts, and other similar goodies as the previous 1001 and 1002. This Roadster had an production of close to 150 bhp (110 kW), and included 14" Eunos Factory Rims with a unique gunmetal paint with polished lip. The only real modifications had been a new set of lightweight side mirrors, MOMO Steering Wheel, Centerless console, racing seats, racing tow hook, a set of lower lip spoilers (R-Package), and a newly created "Duck-Tail" trunk lid with integrated spoiler. The M2-1028 trunk lid was made from aluminum and weighed only 7.7 lb (3.5 kg), a really light fat from the original top of 15.5 lb (7.0 kg). It also came with a 6-point roll cage, but no soft-top, as an alternative featuring a tarp that stretched over the cage. With optional FRP Hardtop with plexiglass rear window for more weight cost savings coming in at only 19 lb (8.6 kg).

In 1998, Mazda released the second-generation MX-5, production code NB, for the 1999 model 12 months. The NB featured a more powerful engine and external styling cues lent from the third generation Mazda RX-7 model. Prices in the United States, the main market for the MX-5, started at US,770 (US,700 in 2011 modified for inflation).

Although many parts of the interior and body were various, the many notable changes were the headlamps: the first generation's retractable headlamps no longer passed pedestrian safety tests and were replaced by fixed ones. The new car grew slightly in width compared to the earlier model; its dimensions were: size 3,945 mm (155.3 in), width 1,678 mm (66.1 in), height 1,228 mm (48.3 in) and wheelbase 2,265 mm (89.2 in). Without options, the NB weighed 1000 kg (2300 lb). The new generation was somewhat more aerodynamic than the original, with a Cd figure of 0.36.

The NB continued to employ four-wheel independent suspension, with enlarged anti-roll bars at the front and rear, but the tires, wheels and brakes were considerably upgraded: anti-lock braking system was offered as an option; alloy tires were now 14 in (360 mm) or 15 in (380 mm) in diameter and 6 in (150 mm) in width, depending on the trim recreations; package models were equipped with the larger tires and 195/50VR15 tires.

The BP-4W engine remained at 1.8 L (110 cu in) but got several minor updates. The engine compression ratio was raised from 9.0:1 to 9.5:1 by adding slightly domed pistons; the intake cam was changed to a solid lifter design with a stronger cam; the intake runners in the head were straightened and the intake manifold was mounted higher up. Mazda's Variable Intake Control System had been introduced, which effectively gave a long narrow intake manifold at low rpm for better swirl, changing to short, free-flowing manifold at high rpm for maximum breathing. Power output of the new engine was quoted at 104.4 kW (140.0 bhp) with 116 lbf���·ft (157 N���·m) of torque.

The 1.6 L (98 cu in) B6 engine remained available in Europe and Japan. The base-model 1.8 L (110 cu in) NB could reach 62 mph (100 km/h) in 7.8 s and had a top speed of 130 mph (210 km/h).

In 1999, Mazda celebrated the 10th anniversary of the MX-5 with the 10th Anniversary Model, a limited version featuring some until-then exclusive features, namely a six-rate Bilstein and transmission shock absorbers; performance figures were slightly different, with slower acceleration but greater top speed compared to standard 5-speed model. The model's nickname among owners and enthusiasts had been 10AM or 10AE (as in "10th Anniversary Edition"). The car had a unique sapphire blue mica (called innocent blue in Japan) paint colour with two-toned black leather and blue alcantara seats. The addition of the sixth gear resulted in different performance results, with 0–100 km/h (62 mph) in 7.5 moments, a tenth of a second slower than the standard 5-speed model, because of the heavier weight. Nevertheless, in spite of the 10AM's greater weight, its top rated speed was higher, at 214 km/h (133 mph) instead of 210 km/h (130 mph). Combined consumption was 8.0 instead of 8.5 l/100 km (29 instead of 28 mpg).

Each car was sequentially numbered on a badge on the driver-side front quarter panel. A "Certificate of Authenticity" with the same number came with each car, signed by Mazda President James E. Miller and dated 10 February 1999. On certain markets, a gift set was additionally included, consisting of a 1/24 scale diecast model, two Seiko-branded wristwatches (his and hers) with matching blue Miata and faceplate logo, and steel keychain in the form of the Miata logo, all encased in a luxury blue velvet box. Despite the publicity that Mazda gave to this model, it took more than a year to sell all units, drawing criticism that too many devices had been produced (another element was the large price with an MSRP of ,875, about 00 more than a base model). For comparison, there were 3,500 units of the NC's third Generation Limited launch model in 2005, and regular limited editions produced each 12 months don't usually go beyond 1,500 units per region. The polished wheels are notorious for corroding once the thin lacquer coating is damaged. Mazda replaced thousands of sets under warranty. There were minor distinctions in specification according to the market, these types of as no sports appearance package (front/side/back skirts, rear wing) or atmosphere training for Europe.

7,500 units of the tenth Anniversary were produced, with 3,700 distributed to Europe (of which: 600 - UK, 20 - Portugal), 3,150 to North America (of which 3,000 to US and 150 to Canada), 500 to Japan and 150 to Australia. Car number 7,500 was sold in the UK.

For the 2001 model year, a facelift to the second-generation MX-5 was released. There had been some minor exterior changes, with a press-release of July 18, 2000, announcing the changes as "resulting in an even sportier and more forceful look". Fog lamps, previously an option, had been made standard. Some cockpit elements were changed, with the instrument panel gauges getting a white face and red numbers. The seats were additionally incorporating, upgraded more support in the part bolsters and taller headrests. Added for top models (designated 'Sport' in the U.K) had been 16-inch (410 mm) wheels with 205/45VR16 low-profile tires, larger brake system at the front and back, additional chassis stiffening braces, a limited slip differential, a 6-speed manual gearbox, Bilstein suspension system and leather seats. The upgraded tires and suspension allowed the new model to pull 0.91 g in lateral grip in tests by Car and Driver magazine. The human body had been strengthened, gaining 16% in bending rigidity and 22% in torsional rigidity. With the bare minimum of options, the 2001 model weighed 1,065 kg (2,348 lb).

2002 Mazda MX5 1,840cc DOHC 4-cylinder engine, with variable valve timing on the intake camshaft

The 1.8 L (110 cu in) BP-Z3 engine was slightly modified and now featured variable valve timing on the intake camshaft. The intake and exhaust system also received a minor upgrade. These adjustments resulted in a power production of 113 kW (152 bhp) (Japan, Australia and UK) or 107 kW (143 bhp) (US only). In the United States, Mazda erroneously quoted the power figure for the Japanese and Australian model in early catalogues. Car and Driver magazine and many owners confirmed the missing energy, and Mazda offered to purchase back the 2001 cars due to those misleading power claims. Owners who did not take up the buy back offer were offered an apology and free servicing for the guarantee period.

2002 saw the launch of the MX5 SP. The MX-5 SP was developed and sold in Australia and its turbocharged motor produced 157 kW (211 bhp) at 6800 rpm. Only 100 of those cars were built. The SP had been very expensive in contrast to a standard MX5 at the time but offered blistering performance. It's fast become a cult classic and sought after model in Australia.

In 2003 Mazda established a campaign to target a younger team of drivers with the introduction of the Shinsen Version (SV) Miata. The Shinsen (Japanese for "Fresh and New") provided an intermediate action between the base model and the pricier LS. Prepared with most standard features on the LS, such as cruise control and aluminum brush trim. This limited production model also shared an inverted color scheme of the exact same 12 months Special Edition with a titanium silver outside and dark blue interior and top.

Also in 2003, a division of Mazda in Japan released the Roadster Coup���©, with an fixed hardtop roof. The body structure was reworked to integrate the roof and gave a substantial increase in framework rigidity with a fat increase of 10 kg (22 lb). Production was restricted to 179 units for Japan only. This was to become one of the rarest forms of the MX-5.

 

Mazda MX-5 1989 - 2009 Gregorys Owners Service & Repair Manual covers Coupe Series - NA, NB, NC

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