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1991 mazda miata Service Repair Workshop Manual Download PDF
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🏷️ Basic Information Identification Make: Mazda Model: Miata Year: 1991 Chassis Code: NA Codes OBD System Coverage: OBD-I (On-Board Diagnostics I) 👋 Introduction Market Position Vehicle Class: Lightweight, rear-wheel-drive, two-seater...
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🏷️ Basic Information
Identification
Make:
Mazda
Model:
Miata
Year:
1991
Chassis Code:
NA
Codes
OBD System Coverage:
OBD-I (On-Board Diagnostics I)
👋 Introduction
Market Position
Vehicle Class:
Lightweight, rear-wheel-drive, two-seater sports convertible.
Philosophy:
Embodied the spirit of the classic British roadster, offering pure driving enjoyment at an accessible price point.
Competitive Analysis
Competitors 1991:
Ford Capri, Toyota MR2, Fiat Spider, Alfa Romeo Spider.
Key Features
Design:
Lightweight construction, excellent weight distribution (near 50/50), pop-up headlights, agile handling.
Value Proposition:
Affordable entry into sports car ownership, renowned for reliability and driving fun.
📋 Manual Details
Coverage Areas
General Coverage:
Complete factory service and repair
Mechanical Systems:
Engine overhaul, brakes, timing belt, suspension, transmission, air conditioning, U-joints, CV-joints, front end alignment
Electrical Systems:
Wiring diagrams, trouble codes, computer diagnostic trouble tree charts
Body And Chassis:
Sunroof
Maintenance:
Factory maintenance schedules and charts, driving concerns, serpentine belt routings
Page Count
Estimated Pages:
Estimated 1000+ pages (typical for a comprehensive factory service manual of this era)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul and rebuilding procedures for the 1.6L DOHC inline-4 engine.
Engine Performance:
Detailed analysis of engine performance, including tuning and diagnostics.
Fuel System:
Coverage of fuel injection system components, diagnostics, and repair.
Cooling System:
Radiator, fan, thermostat, coolant flow, and associated components.
Lubrication System:
Oil pump, oil filter, oil pan, and lubrication passages.
Ignition System:
Ignition coils, spark plugs, ignition control module, and timing.
Exhaust System:
Manifold, catalytic converter, mufflers, and piping.
Transmission Manual:
Removal, installation, in-car servicing, and complete overhaul procedures for the 5-speed manual transmission.
Transmission Automatic:
Coverage for automatic transmission models if equipped, including removal, installation, and servicing.
Drivetrain:
Propeller shaft, differential, axle shafts, U-joints, and CV-joints.
Suspension Front:
Double wishbone, shock absorbers, springs, anti-roll bar, ball joints, and alignment specifications.
Suspension Rear:
Multi-link independent suspension, shock absorbers, springs, and trailing arms.
Steering System:
Steering rack, tie rods, steering column, and power steering system (if applicable).
Brake System:
Front disc brakes, rear disc brakes (typical for Miata), calipers, rotors, pads, master cylinder, brake lines, and bleeding procedures.
Wheel And Tires:
Tire specifications, wheel bolt patterns, and mounting procedures.
Body Exterior:
Body panel removal and installation, bumper components, fenders, hood, trunk lid.
Body Interior:
Dashboard, seats, door panels, carpeting, and trim.
Sunroof:
Specific service and repair procedures for the manual or power sunroof.
Climate Control:
Air conditioning system service, capacities, refrigerant types, and component testing.
Electrical Power Distribution:
Battery, alternator, starter motor, and charging system.
Lighting System:
Headlights, taillights, interior lighting, and signal lights.
Instrumentation:
Gauges, warning lights, and instrument cluster diagnostics.
Chassis Electrical:
Horn, wipers, washer system, power windows (if equipped).
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, belt inspections.
Engine Repair:
Complete engine rebuild, head gasket replacement, piston ring replacement, valve service.
Timing Belt Service:
Specific step-by-step procedures for timing belt replacement, including tensioner and water pump recommendations.
Brake Repair:
Pad replacement, rotor resurfacing/replacement, caliper overhaul, brake line repair.
Suspension Service:
Component replacement (shocks, struts, bushings, ball joints), alignment procedures.
Transmission Service:
Fluid changes, clutch replacement, transmission overhaul.
Electrical Troubleshooting:
Diagnostic procedures for electrical faults using wiring diagrams and trouble codes.
Ac Service:
Recharging, leak detection, component replacement, evacuation.
Drivetrain Service:
U-joint replacement, CV-joint boot replacement and repair.
Diagnostic Charts:
Computer diagnostic trouble tree charts for systematic fault finding.
Torque Specifications:
Comprehensive list of all critical torque specifications for engine, chassis, and suspension components.
Wiring Diagrams:
Detailed, high-quality wiring diagrams for all electrical systems.
Vacuum Diagrams:
Detailed vacuum routing diagrams for engine and emissions control.
Technical Depth
Depth:
In-depth, comprehensive coverage from basic maintenance to complete engine and transmission overhauls, suitable for both DIYers and professional mechanics.
Detail Level:
High detail with step-by-step instructions, exploded views, and clear diagrams.
📊 Manual Specifications
File Format
Format:
PDF
Readability:
Easy-to-read text sections.
Searchability:
Likely searchable text within the PDF for efficient information retrieval.
Print Quality
Diagram Quality:
Top quality diagrams and illustrations.
Overall Quality:
High-resolution, professional quality suitable for printing.
Binding Type
Binding:
Digital Download (Printable)
Paper Type
Paper Type:
N/A (Digital PDF)
Compatibility
Operating Systems:
Compatible with all versions of Windows & Mac
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Delivery
Delivery Method:
Instant Download
Features
Printability:
All pages are printable.
⚙️ Engine Specifications
Primary Engine
Engine Code:
B6ZE
Engine Type:
Naturally aspirated, DOHC, Inline-4 (I4)
Displacement:
1597 cc (1.6 Liters)
Performance
Horsepower:
115 hp @ 6500 rpm (US/Canada models)
Torque:
100 lb-ft @ 5500 rpm (US/Canada models)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Other
Bore X Stroke:
78.0 mm x 83.6 mm
Compression Ratio:
9.0:1
Firing Order:
1-3-4-2
🔧 Transmission
Standard
Type:
Mazda Type-B 5-speed Manual Transmission
Optional
Type:
Optional 4-speed Automatic Transmission
Features
Manual Gear Ratios Approx:
1st: 3.133, 2nd: 1.800, 3rd: 1.310, 4th: 1.000, 5th: 0.786, Reverse: 3.117
Manual Fluid Type:
API GL-4, SAE 75W-90 (or 80W-90)
Automatic Fluid Type:
Dexron II (or equivalent)
📐 Dimensions
Exterior
Length:
3955 mm (155.7 in)
Width:
1675 mm (66.0 in)
Height:
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)
Weights
Curb Weight Manual:
Approx. 958 kg (2112 lbs)
Curb Weight Automatic:
Approx. 980 kg (2160 lbs)
Gross Vehicle Weight Rating:
Approx. 1200 kg (2646 lbs)
Towing Capacity:
Not Recommended
🛡️ Safety Features
Ratings
NHTSA Ratings:
Information for 1991 models is limited; later models generally performed acceptably for their era but not to modern standards.
Active Features
Brakes:
Front ventilated discs, Rear solid discs (standard on most trims).
ABS:
Anti-lock Braking System (ABS) available as an option on some models.
Passive Features
Airbags:
Driver's side airbag standard for 1991.
Rollover Protection:
Reinforced A-pillars and optional factory or aftermarket roll bar.
Seatbelts:
Three-point inertia reel seatbelts.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM stereo with cassette player, optional CD player (rare).
Speakers:
Typically 2 or 4 speakers, located in doors and dashboard.
Driver Assistance
Cruise Control:
Available as an option on most trims.
Connectivity
Connectivity Features:
None (analog era vehicle).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (typical).
Timing Belt Replacement:
Every 60,000 miles or 5 years, whichever comes first (critical interval).
Spark Plug Replacement:
Every 30,000 miles (typical for NGK plugs).
Coolant Flush:
Every 30,000 miles or 2 years, whichever comes first.
Fluid Specifications
Engine Oil Capacity:
3.5 Liters (3.7 US Quarts) with filter, using SAE 5W-30 or 10W-30 API SG or SH.
Coolant Capacity:
Approx. 5.0 Liters (5.3 US Quarts) of 50/50 ethylene glycol coolant and distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Wear Items:
Radiator hoses, clutch master/slave cylinders, throwout bearing, window regulators, wiper motor, seatbelt mechanisms.
Engine Specific:
Oil leaks from valve cover gasket, crankshaft seals. Possible throttle body issues.
Electrical Common:
Corroded grounds, failing ECU capacitor (though less prevalent in '91 than later years), dim dashboard lights.
Body Related:
Rust in common areas like rocker panels, sills, and rear wheel arches. Leaking soft top seals.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Mazda's long history of producing driver-focused vehicles, including sports cars like the Cosmo Sport and RX series.
Model Evolution
Launch Year:
1989 (global launch), 1990 (US market launch)
Generation:
First Generation (NA) - 1989-1997.
Design Inspiration:
Inspired by the classic Lotus Elan and Triumph Spitfire.
Production
Manufacturing Location:
Hiroshima, Japan
Production Volume Impact:
The Miata was an immediate sales success, revitalizing the small sports car market.
🏆 Awards & Recognition
Recognitions
Automotive Journalism:
Car and Driver '10Best' list for multiple years, including 1990-1992.
Overall Impact:
Widely credited with reviving the affordable sports car segment and becoming an instant automotive icon.
Design Awards:
Recognized for its classic, timeless design that has aged exceptionally well.