engine MAZDA MX-5 1994 Repair Manual

ASSEMBLY B Oil Filter 1. Remove all foreign material from the oil filter mounting surface. 2. Apply a small amount of clean engine oil to the rubber seal of the oil filter. 3. Install the oil filter and tighten it by hand until the rubber seal contacts the base. 4. Hand tightening type (Numbers printed on filter) Tighten the filter 314 of a turn by hand after it contacts the cylinder block. If tightening by hand is difficult, use the filter wrench. Example When the oil filter contacts the cylinder block at "l", turn it 314 of a turn further to "4". Filter wrench tightening type (No numbers printed on fil- ter) Tighten the filter 1 and 116 turns with the filter wrench af- ter it contacts the cylinder block. Right Engine Mount Install the right engine mount. Tightening torque: 37-53 N-m (3.7-5.5 kgf.m, 27-39 ft.lbf) Alternator Bracket Install the alternator bracket. Tightening torque: 64-49 N-m (6.5--9.1 kgf-m, 48-45 ft4bf) Alternator Install the alternator and hand tighten the mounting bolts. Gartner Banana

ENGINE STAND DISMOUNTING B ENGINE STAND DISMOUNTING PROCEDURE i_/ 1. Remove the engine from the SST (engine stand). 2. Remove the SST (engine hanger) from the engine. 3. lnstall the parts shown in the figure. Torque Specifications 05UOBX-251 Left Engine Mount Install the left engine mount. Tightening torque: 37-53 N-m (3.7-5.5 kgf.m, 27-39 ftlbf) Gartner Banana

B ENGINE STAND DISMOUNTING PIS Oil Pump Bracket lnstall the PIS oil pump bracket. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) Idler lnstall the A/C idler. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 2U8 ft4bf) Water Inlet Pipe and Bypass Pipe 1. Remove all foreign material from the water inlet pipe mounting surface. 2. lnstall a new gasket and the water inlet pipe. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ftlbf) 3. Apply a small amount of engine coolant to the new 0- ring. 4. lnstall the water bypass pipe. AIC Compressor Bracket lnstall the A/C compressor bracket. Tightening torque @: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ftlbf) 0: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) Exhaust Manifold 1. Remove all foreign material from the exhaust manifold contact surface. 2. lnstall a new gasket and the exhaust manifold. Tightening torque: 3-6 N-m (3.9-4.7 kgf-m, 29--33 ft-lbf) Exhaust Manifold Insulator lnstall the exhaust manifold insulator. Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in4bf) Gartner Banana

INSTALLATION B INSTALLATION PROCEDURE u Tighten all bolts and nuts to the specified torques. Step 1 Torque Specifications I RIGHT I LEFT 05UOBX-258 Engine assembly 1. Suspend the engine assembly. Slowly lower the engine assembly as a unit. Keep the en- gine from swinging or bumping into components in the engine compartment. 2. Install the engine tilting downward. 3. Align the engine mounts with the crossmember mount- ing holes. 4. Install the engine mount nuts and hand tighten them. Engine mount nut Tighten the engine mount nuts. Tightening torque: 57-78 N.m (5.8--8.0 kgf.m, 42-57 ft-lbf) I-, /-b -1 45UOBX-173 Gartner Banana

B INSTALLATION ALTERNATOR Drive belt 1. lnstall the alternator drive belt. (Refer to page B-5.) 2. lnstall the PIS and/or AIC drive belt. 3. Adjust the drive belt deflection, and tighten the alternator - and PIS mounting bolts and nuts. (Refer to page 8-7.) Radiator and coolant fan assembly 1. lnstall the radiator and coolant fan assembly. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft4bf) 2. lnstall the AIC pipe bracket to the radiator Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in4bf) 3. Connect the upper and lower radiator hoses. 4. Connect the coolant reservoir hose. 5. Connect the coolant fan motor connector. Steps After Installation 1. lhstall the transmission. (Refer to sections J, K.) 2. lnstall the under cover. 3. If the engine oil was drained, fill with the specified amount and type of engine oil. (Refer to section D.) 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E.) 5. If the transmission oil was drained, fill with the specified amount and type of transmission oil. (Refer to sections J, K.) 6. Connect the negative battery cable. 7. Start the engine and check the following. (1) Engine oil, transmission oil, and engine coolant leakage (2) Ignition timing, idle speed (Refer to page 59.) (3) Operation of emission control system 8. Perform a road test. 9. Recheck the engine oil and engine coolant levels. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . LUBRICATION SYSTEM INDEX ....................................... D- 2 ..................................... OUTLINE D- 3 ........................... SPECIFICATIONS D- 3 TROUBLESHOOTING GUIDE .................. D- 3 OIL PRESSURE .............................. D- 4 PREPARATION ............................. D- 4 INSPECTION ............................... D- 4 ENGINE OIL .................................. D- 5 INSPECTION ............................... D- 5 REPLACEMENT ............................ D- 5 OIL FILTER ................................... D- 6 REPLACEMENT ............................ D- 6 OIL COOLER ................................. D- 7 REMOVAL / INSTALLATION .................. D- 7 OIL PAN ..................................... D- 8 REMOVAL / INSTALLATION .................. D- 8 OIL PUMP .................................... D-11 DISASSEMBLY / ASSEMBLY ................. D-11 INSPECTION ............................... D-12 45UODX401 Gartner Banana

INDEX INDEX HYDRAULIC LASH ADJUSTER (HLA) REMOVAL / INSPECTION I INSTALLATION, SECTION B ENGINE OIL SPECIFICATION API SERVICE SG, SH (ECII) ILSAC TOTAL CAPACITY 4.0 L (4.2 US qt, 3.5 Imp qt) 1. Oil pressure 4. Oil cooler Inspection ................. page D- 4 Removal I Installation ....... page D- 7 2. Engine oil 5. Oil pan Inspection ................. page D- 5 Removal / Installation ....... page D- 8 Replacement .............. page D- 5 6. Oil pump _-' 3. Oil filter Disassembly I Assembly .... page D-11 .............. Replacement page D- 6 Inspection ................. page D-12 Gartner Banana

OUTLINE, TROUBLESHOOTING GUIDE D OUTLINE SPECIFICATIONS Engine BP DOHC Lubrication system Oil capacity Engine oil Force-fed type Trochoid gear 344--441 {3.5-4.5,50--63) Full-flow, paper element 79--117 {0.&1.2, 12-1 7) Oil pump Oil filter Oil and oil filter replacement L {US qt, Imp qt) API service SG, SH (ECII) l LSAC TY pe Relief pressure kPa {kgf/cm2, psi) Type Relief pressure differential kPa {kgf/cm2, psi) Total (dry engine) L (US qt, Imp qt} Oil replacement L {US qt, Imp qt} 3.75 (4.0, 3.3) 4.0 f4.2, 3.5) 3.6 (3.8,3.2) I TROUBLESHOOTING GUIDE Problem SAE 1 OW-30 SAE 5W-30 Viscosity number Engine hard starting 45UODX-003 Above -25°C (-1 3°F) Below 0°C {32"F} Excessive oil consumption Oil pressure drop Oil pressure gauge (meter) does not operate Warning Possible Cause Improper engine oil Insufficient engine oil Oil working up or down Oil leakage Insufficient oil Oil leakage Worn and/or damaged oil pump inner and outer rotor Worn plunger (inside oil pump) or weak spring Clogged oil strainer Excessive main bearing or connecting rod bearing clearance Oil pressure drop Malfunction of oil pressure gauge Malfunction of electrical system Remedy Replace Add oil Refer to section 6 Repair Add oil Repair Replace Replace Clean Refer to section B As described above Refer to section T Refer to section T Page D-5 D-5 - 0-5 - D-11,12 D-ll,12 - - 45UODX-004 Conthuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. Gartner Banana

D OIL PRESSURE OIL PRESSURE PREPARATION SST 05UODX-008 INSPECTION 1. Remove the oil pressure switch. pressure 2. Screw the SST into the oil pressure switch installation hole. 3. Warm up the engine to normal operating temperature. 4. Run the engine at 1,000 rpm and 3,000 rpm, and note the gauge reading. For inspection of oil pressure Oil pressure: 9kl96 kPa (1.0-2.0 kgf/cm2,15-28 psik1,000 rpm 295492 kPa (3.0-4.0 kgf/cm2, 43-66 psi)-3,000 rpm 5. If the pressure is not as specified, check for the cause and repair. (Refer to Troubleshooting Guide.) 6. Remove the SST and install the oil pressure switch. Tightening torque: 12-17 N-m (1.2-1.8 kgf-m, 9-13 ft-lbf) 45UODX-007 Gartner Banana

ENGINE OIL D ENGINE OIL INSPECTION 1. Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and check the oil level and condi- tion. 5. Add or replace oil as necessary. Note The distance between the L and F marks on the dip- stick represents 0.8 L (0.85 US qt, 0.70 Imp qt}. REPLACEMENT Warning When the engine and the oil are hot, they can badly burn. Don't burn yourself with either. 1. Warm up the engine to normal operating temperature and stop it. 2. Remove the oil filler cap and the oil drain plug. 3. Drain the oil into a container. 4. Install a new gasket and the drain plug. Tightening torque: 3041 N-m 13.0-4.2 kgf.m, 22-30 ft-lbf) 5. Refill the engine with the specified type and amount of engine oil. Oil replacement: 3.6 L 13.8 US qt, 3.2 Imp qt) 6. Refit the oil filler cap. 7. Run the engine and check for leaks. 8. Check the oil level and add oil if necessary. Gartner Banana