1999 Mazda Miata MX-5 Workshop Manual (P/N 9999-95-042B-99)

This 1999 Mazda Miata MX-5 workshop manual covers on-vehicle service, repair, and diagnosis for BP-engine models with manual or automatic transmission. The printed workshop volume is identified by Mazda P/N 9999-95-042B-99.

• Engine mechanical repair: Timing belt replacement, valve-clearance inspection and shim adjustment, cylinder-head gasket replacement, camshaft service, oil-seal replacement, and engine removal.

• Engine management: OBD-II trouble-code diagnosis, symptom troubleshooting, freeze-frame interpretation, PID recording, simulation tests, and sensor and actuator inspections.

• Clutch and transmission: Clutch hydraulic repair, transmission removal and installation, automatic-transmission pressure and stall tests, solenoid checks, and shift-mechanism service.

• Chassis and steering: Wheel alignment, suspension and wheel-hub service, drive-shaft repair, differential setup, and manual or power steering inspection and repair.

• Brakes and ABS: Hydraulic bleeding, master-cylinder and caliper disassembly, parking-brake adjustment, ABS fault diagnosis, and wheel-speed sensor inspection.

• Body and accessories: Convertible-top and detachable-hardtop work, window-regulator repair, glass adjustment, door-lock diagnosis, lighting checks, and instrument-cluster testing.

This manual is suited to technicians and experienced owners familiar with automotive electrical testing and workshop equipment; advanced diagnostic procedures use Mazda’s NGS tester and system-specific service tools.

Engine Repair and Scheduled Maintenance

Timing-belt procedures include pulley alignment, tensioner-spring inspection, and belt-tension verification. Valve service explains adjustment-shim selection and the use of dedicated tools.

The camshaft installation notes address cylinder-head thrust-surface damage caused by uneven loading. Engine coverage includes removal and external attachment disassembly; full internal engine rebuilding is outside this volume.

Scheduled maintenance accompanies tune-up, ignition-timing, lubrication, and cooling-system procedures. Radiator, thermostat, water-pump, and cooling-fan work includes component inspection and replacement information.

Overview illustrations identify tightening torques, replacement parts, sealant locations, and special-tool requirements. General information also explains cleaning and reassembly conventions, wiring color codes, abbreviations, and SI unit conversions.

Engine Controls, Fuel Delivery, and Electrical Diagnosis

Section 01-01A pairs DTC inspection with the Quick Diagnosis Chart and symptom-based troubleshooting. Freeze-frame data, PID traces, and circuit checks help distinguish wiring faults from sensor or actuator problems before components are replaced.

Fuel-system coverage includes fuel-pump testing, injector inspection, fuel-line pressure checks, and leak testing. EVAP procedures address the charcoal canister, purge solenoid valve, canister drain cut valve, and fuel-tank pressure sensor.

EGR valve and EGR boost sensor inspections accompany intake-air and VICS testing. The Vacuum Hose Routing Diagram, Control System Component Location, and Fuel Tank Pressure Graph support hose identification and drivability diagnosis.

Ignition-coil, mass air flow sensor, charging-system, starter, and cruise-control checks include electrical measurements and connector illustrations. Electrical coverage centers on component tests and terminal views; full-vehicle wiring schematics are outside this volume.

Transmission Testing and Driveline Repair

Manual-transmission procedures cover lubricant service, rear oil-seal replacement, speedometer-sensor testing, and Power Plant Frame alignment. Removal cautions identify crankshaft position sensor damage that can result from excessive transmission movement.

Automatic-transmission diagnosis includes line-pressure, stall, time-lag, and road tests. The Shift Diagram and TCM Terminal Voltage Chart accompany range-switch, speed-sensor, and solenoid inspections.

Control valve body, torque converter, and oil-cooler removal are covered. Full manual and automatic transmission bench overhaul is outside this volume.

Differential procedures extend to bearing preload, backlash, and tooth-contact assessment, with illustrated disassembly and assembly information.

Brakes, Steering, Climate Control, and Body Systems

Brake coverage distinguishes ABS and non-ABS components and includes caliper and master-cylinder repair. Steering sections cover manual gear service, power steering pressure testing, pump disassembly, and steering-gear inspection.

HVAC material includes refrigerant-system performance tests, charging procedures, compressor service, and heater-control adjustment. Restraint sections address airbag diagnosis, clock-spring adjustment, and seat-belt inspection.

Body procedures include convertible-top fabric and rain-rail work, detachable-hardtop adjustment, window regulators, mirrors, locks, wipers, audio equipment, and instruments.

Always ensure the vehicle is safely supported on approved stands and the battery is disconnected prior to major service or repair. Follow the system-specific precautions for airbag and refrigerant work.

Examples of Valve-Clearance and Transmission Sensor Data

For the BP engine, the valve-clearance inspection specifies 0.18–0.24 mm at the intake valves and 0.28–0.34 mm at the exhaust valves with the engine cold. Shim-selection information accompanies the adjustment procedure.

For SB4A-EL diagnosis, input/turbine speed sensor resistance is 560–680 Ω at an ATF temperature of 20 °C (68 °F). Output speed sensor resistance is 387–473 Ω at the same temperature.

Bookmarked PDF and Diagram Detail

Text search and connector detail: PDF text search is unavailable. Embedded bookmarks cover the main systems and many subsections. Small connector letters and terminal labels require zooming for comfortable reading.

One printable PDF in English contains 736 pages total, including the eight-page alphabetical index.