Mazda MX5 MIATA Replacement Parts Manual 1991-1992
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🏷️ Basic Information Identification Make: Mazda Model: MX-5 Miata Chassis Code: NA Generation: First Generation (NA) Platform: Mazda M-Platform Codes Engine Code Primary: B6 (1.6L) 👋 Introduction Market Position Market Niche: Essential for owners and independent repair shops specializing in the iconic Mazda MX-5 Miata (NA). Value Proposition: Provides critical OEM part identification and numbers, crucial for sourcing correct replacement parts and ensuring authenticity and proper fitment. Competitive Analysis Comparison To Service Manuals: Complements service manuals by focusing solely on parts identification and numbers, rather than repair procedures. Key Features Illustrations: Detailed exploded view diagrams for accurate part visualization. Part Number Listing: Comprehensive catalog of OEM part numbers, vital for ordering. Utility: Indispensable for DIY enthusiasts undertaking restoration or repair projects. 📋 Manual Details Coverage Areas Covered Years: 1991, 1992 Covered Models: Mazda MX-5 Miata (NA) Covered Trim Levels: All trims Page Count Estimated Page Count: Approx. 200-400 pages (typical for OEM parts manuals of this era) Manual Type Type: OEM Replacement Parts Manual / Parts Catalog Description: Illustrated with exploded parts diagrams, listing all part numbers for disassembly, repair, and assembly. Language Language: English Format Format: Printed (Original Equipment Manufacturer) 📖 Manual Coverage Systems Covered Engine Components: Engine block, cylinder head, pistons, crankshaft, camshafts, valves, timing components, oil system, cooling system, fuel system (injectors, pump, lines), intake and exhaust manifolds. Transmission Drivetrain: Manual transmission (gearbox), clutch assembly, driveshafts, differential, hubs, axles. Suspension Steering: Front suspension (control arms, springs, dampers, anti-roll bar), rear suspension (multi-link, springs, dampers, anti-roll bar), steering rack, steering column, power steering components (if applicable). Brake System: Front and rear brake calipers, rotors, pads, master cylinder, brake lines, parking brake mechanism. Electrical System: Starter motor, alternator, battery, ignition system, lighting (headlights, taillights, interior), wiring harnesses, fuses, relays, ECUs (Engine Control Unit), sensors. Body Exterior: Body panels (fenders, hood, doors, trunk lid), bumpers, grille, headlights, taillights, mirrors, soft top frame and mechanism, hardtop components (if applicable), emblems, trim. Interior Components: Dashboard, seats, seat belts, interior trim panels, steering wheel, shift knob, pedals, HVAC (Heating, Ventilation, Air Conditioning) components (blower motor, vents, heater core, evaporator core). Wheels Tires: Wheels (rims), lug nuts, tire specifications. Procedures Included Disassembly Identification: Identification of all individual parts and their placement within assemblies through exploded diagrams. Part Identification: Comprehensive listing of OEM part numbers for every component. Assembly Guidance: Visual reference for correct assembly order and orientation of parts. Technical Depth Depth: Component-level detail for parts replacement and identification. Does not include detailed repair procedures or diagnostic steps typically found in a service manual. 📊 Manual Specifications File Format Digital Format If Applicable: N/A (Original is printed) Print Quality Print Quality: OEM Standard (typically black and white line drawings and text) Binding Type Binding Type: Typically bound (stapled or perfect bound) for durability in a workshop environment. Paper Type Paper Type: Durable paper stock suitable for workshop use. ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-4 (DOHC) Displacement: 1.6 Liters (1598 cc) Bore X Stroke: 78.0 mm x 83.6 mm Compression Ratio: 9.4:1 Valve Configuration: Dual Overhead Camshafts (DOHC), 16 Valves Performance Horsepower 1991: 115 hp @ 6500 rpm (US Market) Torque 1991: 100 lb-ft @ 5000 rpm (US Market) Horsepower 1992: 116 hp @ 6500 rpm (US Market) Torque 1992: 100 lb-ft @ 5000 rpm (US Market) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Cooling System Cooling Type: Water-Cooled Coolant Capacity: 5.4 Quarts (5.1 Liters) Lubrication System Oil Capacity W Filter: 3.7 US Quarts (3.5 Liters) Recommended Oil Viscosity: SAE 10W-30 (API SG or higher) 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission (Less Common) Features Clutch Type: Hydraulic, Dry Single Plate Transmission Fluid Type: API GL-4 SAE 75W-90 Gear Oil Transmission Fluid Capacity: Approx. 2.0 Liters (Manual) 📐 Dimensions Exterior Length: 3915 mm (154.1 in) Width: 1675 mm (65.9 in) Height Soft Top Up: 1235 mm (48.6 in) Wheelbase: 2265 mm (89.2 in) Front Track: 1430 mm (56.3 in) Rear Track: 1435 mm (56.5 in) Ground Clearance: 135 mm (5.3 in) Weights Curb Weight: Approx. 1000-1050 kg (2200-2315 lbs) Gross Vehicle Weight Rating: Not explicitly specified, but designed for driver + passenger + light cargo. Towing Capacity: Not Recommended Wheels Tires Standard Wheel Size: 14 x 5.5 inches Optional Wheel Size: 15 x 6.0 inches (Later models/options) Standard Tire Size: 185/60R14 Optional Tire Size: 195/50R15 Bolt Pattern: 4x100 mm Center Bore: 54.1 mm Lug Nut Size: M12 x 1.5 Recommended Tire Pressure Front: 200 kPa (29 psi) Recommended Tire Pressure Rear: 200 kPa (29 psi) 🛡️ Safety Features Ratings NHTSA Rollover Rating: Not rated in the same manner as modern vehicles; designed with a low center of gravity. Roll bar is a standard safety feature. Active Features Brakes: Front: Ventilated Disc, Rear: Solid Disc (ABS optional on later...
Identification of all individual parts and their placement within assemblies through exploded diagrams.
Part Identification:
Comprehensive listing of OEM part numbers for every component.
Assembly Guidance:
Visual reference for correct assembly order and orientation of parts.
Technical Depth
Depth:
Component-level detail for parts replacement and identification. Does not include detailed repair procedures or diagnostic steps typically found in a service manual.
📊 Manual Specifications
File Format
Digital Format If Applicable:
N/A (Original is printed)
Print Quality
Print Quality:
OEM Standard (typically black and white line drawings and text)
Binding Type
Binding Type:
Typically bound (stapled or perfect bound) for durability in a workshop environment.
Paper Type
Paper Type:
Durable paper stock suitable for workshop use.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-4 (DOHC)
Displacement:
1.6 Liters (1598 cc)
Bore X Stroke:
78.0 mm x 83.6 mm
Compression Ratio:
9.4:1
Valve Configuration:
Dual Overhead Camshafts (DOHC), 16 Valves
Performance
Horsepower 1991:
115 hp @ 6500 rpm (US Market)
Torque 1991:
100 lb-ft @ 5000 rpm (US Market)
Horsepower 1992:
116 hp @ 6500 rpm (US Market)
Torque 1992:
100 lb-ft @ 5000 rpm (US Market)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Cooling System
Cooling Type:
Water-Cooled
Coolant Capacity:
5.4 Quarts (5.1 Liters)
Lubrication System
Oil Capacity W Filter:
3.7 US Quarts (3.5 Liters)
Recommended Oil Viscosity:
SAE 10W-30 (API SG or higher)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission (Less Common)
Features
Clutch Type:
Hydraulic, Dry Single Plate
Transmission Fluid Type:
API GL-4 SAE 75W-90 Gear Oil
Transmission Fluid Capacity:
Approx. 2.0 Liters (Manual)
📐 Dimensions
Exterior
Length:
3915 mm (154.1 in)
Width:
1675 mm (65.9 in)
Height Soft Top Up:
1235 mm (48.6 in)
Wheelbase:
2265 mm (89.2 in)
Front Track:
1430 mm (56.3 in)
Rear Track:
1435 mm (56.5 in)
Ground Clearance:
135 mm (5.3 in)
Weights
Curb Weight:
Approx. 1000-1050 kg (2200-2315 lbs)
Gross Vehicle Weight Rating:
Not explicitly specified, but designed for driver + passenger + light cargo.
Towing Capacity:
Not Recommended
Wheels Tires
Standard Wheel Size:
14 x 5.5 inches
Optional Wheel Size:
15 x 6.0 inches (Later models/options)
Standard Tire Size:
185/60R14
Optional Tire Size:
195/50R15
Bolt Pattern:
4x100 mm
Center Bore:
54.1 mm
Lug Nut Size:
M12 x 1.5
Recommended Tire Pressure Front:
200 kPa (29 psi)
Recommended Tire Pressure Rear:
200 kPa (29 psi)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
Not rated in the same manner as modern vehicles; designed with a low center of gravity. Roll bar is a standard safety feature.
Active Features
Brakes:
Front: Ventilated Disc, Rear: Solid Disc (ABS optional on later models, rare for '91-'92).
Traction Control:
N/A
Passive Features
Airbags:
Driver's airbag standard (from 1990 MY in many markets).
Seat Belts:
Three-point inertia reel seatbelts.
Rollover Protection:
Reinforced windshield frame and standard behind-seat roll bar.
💡 Technology Features
Infotainment
Head Unit:
Factory fitted AM/FM stereo with cassette player. Optional CD player in later models.
Speakers:
Typically 4 speakers (dashboard and door mounted).
Driver Assistance
ABS:
Optional on select models, not standard for '91-'92.
Connectivity
Bluetooth:
N/A (Requires aftermarket head unit installation)
Usb:
N/A (Requires aftermarket head unit installation)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first.
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed (typically 30,000 miles).
Spark Plug Replacement:
Every 30,000 miles (NGK BKR5E-11 or equivalent).
Timing Belt Replacement:
Crucial: Every 60,000 miles or 5 years due to interference engine design. Includes idler pulley and tensioner.
Brake Fluid Flush:
Every 2 years (DOT 3 or DOT 4 recommended).
Coolant Flush:
Every 2 years or 30,000 miles.
Fluid Specifications
Engine Oil:
API SG, SAE 10W-30
Transmission Fluid Manual:
API GL-4 SAE 75W-90 Gear Oil
Brake Fluid:
DOT 3 or DOT 4
Coolant:
50/50 mix of ethylene glycol antifreeze and distilled water
Power Steering Fluid If Equipped:
Dexron II or equivalent ATF
Known Issues
Common Wear Items:
Clutch, throw-out bearing, radiator, water pump, alternator, starter motor, cam angle sensor, crankshaft position sensor, fuel injectors, window regulators, soft top canvas.
Oil leaks from valve cover gasket and oil pan gasket. Timing belt failure can cause catastrophic engine damage. Coil on plug (COP) conversion is a popular upgrade.
Electrical Specific:
Corrosion in wiring harnesses, intermittent issues with pop-up headlights, HVAC blower resistor failure.
📚 Vehicle History
Brand Heritage
Heritage Connection:
Direct descendant of the Lotus Elan and classic British roadsters. Embodiment of Mazda's Jinba-Ittai ('horse and rider as one') philosophy.