The 1991 Mazda MX-5, a celebrated icon of the roadster revival, embodies pure driving pleasure. As the first generation (NA) model, it captures the spirit of classic lightweight sports cars, offering agile handling and direct driver engagement. Powered by a 1.6L DOHC engine (B6ZE) producing approximately 114-116 horsepower, this rear-wheel-drive vehicle is renowned for its balanced chassis and responsive steering, making it a joy on winding roads and a consistent favorite among automotive enthusiasts. Its compact dimensions and simple, yet effective, design have cemented its status as a beloved automotive legend. This comprehensive repair service manual provides detailed instructions and technical specifications for the 1991 Mazda MX-5. It covers all essential maintenance procedures, from routine oil changes and fluid checks to complex engine overhauls, transmission service, brake system repairs, and suspension adjustments. The manual includes in-depth information on the electrical system, body and chassis components, and troubleshooting guidance for common issues. Its extensive coverage, including detailed wiring diagrams and torque specifications, is designed to assist both professional technicians and dedicated DIY enthusiasts in maintaining and restoring the vehicle to optimal condition. 🏷️ Basic Information Identification Make: Mazda Model: MX-5 Year: 1991 Generation Platform: NA (First Generation) 👋 Introduction Market Position Target Audience: Professional technicians and experienced DIY enthusiasts seeking detailed repair and maintenance information for the 1991 Mazda MX-5. Competitive Analysis Value Proposition: Provides factory-level technical data and procedures, enabling owners to perform complex repairs and maintenance accurately, saving on dealership service costs. Key Features Instant Access: Available for instant download, allowing immediate access to repair information. Completeness: Designed to be a comprehensive reference, covering topics typically found in both factory service manuals and owner's manuals. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair and service for the 1991 Mazda MX-5. Page Count Estimated Page Count: Difficult to determine precise page count for PDF download without opening, but typical factory service manuals of this era for a single model are often 500-1000+ pages. Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed procedures for engine overhaul, disassembly, assembly, diagnostics, timing belt, cooling system, lubrication system, fuel system, ignition system, emissions control. Transmission: Service and repair for manual transmission (e.g., 5-speed), clutch system, drivetrain components (driveshafts, differential). Brakes: Front and rear brake system service, including disc brake overhaul, hydraulic system bleeding, parking brake adjustment. Suspension And Steering: Front and rear suspension component inspection and replacement, wheel alignment specifications, steering system diagnosis and repair. Electrical System: Comprehensive wiring diagrams, starter, alternator, battery service, lighting system, ignition system, instrument cluster, power windows, power locks (if equipped). Body And Chassis: Body panel repair, door mechanisms, convertible top operation and repair, chassis components, frame specifications. Fuel Injection System: In-depth coverage of the fuel pump, injectors, fuel pressure regulator, throttle body, and associated sensors for diagnosis and repair. Procedures Included Routine Maintenance: Oil and filter changes, fluid level checks and top-offs, spark plug replacement, air filter replacement, tire rotation, brake pad inspection. Diagnostics: Troubleshooting common problems, diagnostic charts, fault code interpretation (if applicable to the era). Repair And Overhaul: Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for most major vehicle systems. Technical Specifications: Detailed specifications for engine, transmission, brakes, suspension, electrical components, torque values, clearances, and fluid capacities. Wiring Diagrams: Includes comprehensive electrical wiring diagrams crucial for diagnosing and repairing electrical faults. Torque Specifications: Provides precise torque values for all critical fasteners to ensure proper assembly and prevent component damage. Technical Depth Depth: Aimed at professional technicians but accessible to DIY mechanics with basic knowledge. Covers everything from routine maintenance to major component overhauls and diagnostics. Engine Rebuild: Detailed instructions for complete engine teardown, component measurement, and reassembly, including piston ring installation, bearing clearance checks, and valve seat grinding. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Printability: Full Printable. Users can print individual pages or the entire manual. Binding Type Binding: Digital download; no physical binding. Paper Type Paper Equivalent: Digital; replicates content typically found in a professionally printed paper manual. Features Zoom Capability: YES Searchability: Likely searchable if the PDF is text-based (OCR applied), common for factory manuals. Not explicitly stated, but implied by PDF format. ⚙️ Engine Specifications Primary Engine Engine Code: B6ZE (1.6L DOHC) Displacement: 1598 cc (1.6 Liters) Configuration: Inline 4-cylinder, DOHC (Double Overhead Camshaft) Performance Horsepower: Approx. 114-116 hp @ 6500 rpm (varies slightly by market/emission controls) Torque: Approx. 100-103 lb-ft @ 5000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPFI) Fuel Type: Unleaded Gasoline Cooling System Coolant Capacity: Approx. 5.5 Liters (5.8 US Quarts) Lubrication System Oil Capacity: Approx. 3.7 Liters (3.9 US Quarts) with filter Recommended Oil Viscosity: 10W-30 API SG or SH (refer to manual for specific...