MAZDA MX-5 1994 Workshop Manual

ASSEMBLY , MATCHINGMARKS A SIDE CLEARANCE 1 2. Apply a liberal amount of clean engine oil to the cylinder walls, pistons, and piston rings. 3. Check the piston rings for correct end gap alignment. 4. Insert each piston assembly into the cylinder block with ..-, the F mark facing the front of the engine. Use a piston ring compressor (commercially available). Connecting Rod Cap 1. Align the matching marks on the cap and the connecting rod and install the connecting rod cap. 2. Measure the connecting rod bearing oil clearances us- ing the same procedure as for the main bearing oil clear- ance. Tightening torque: 48-50 N.m (4.8-5.1 kgf.m, 35--36 ftlbf} Oil clearance: 0.020-0.044mm (0.0008-0.0017 in) Maximum: 0.lOmm (0.004 in) 3. If the oil clearance exceeds the maximum, grind the crankshaft and use undersize bearings. (Refer to page 8-57.) U' 4. Measure the connecting rod side clearances. Side clearance: 0.11 O4.262rnm (O.OO44-O.OIO3 in) Maximum: 0.30mm (0.01 2 in) 5. If the clearance exceeds the maximum, replace the con- necting rod and cap. Apply a liberal amount of clean engine oil to the crank pin journals and connecting rod bearings. Install the connecting rod caps with the matching marks aligned. 8. Tighten the connecting rod cap nuts in two or three steps. Tightening torque: 48-50 N-m (4.8-5.1 kgf-m, 35--36 ftdbf) Gartner Banana

ASSEMBLY B CYLINDER BLOCK (EXTERNAL PARTS) Torque Specifications 7.9-10.7 Nm (80-110 kgfwn, 70--95.4 in4bf) OIL SEAL. NEW 7.9-10.7 Nm (80-110 kgfcm, 7045.4 Indbf) Nm (kgf m, ftlbf) 05UOBX-198 Rear Cover 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a pipe, press the oil seal in evenly until it is flush with the edge of the rear cover. L Note Oil seal outer diameter: 100mm (3.94 in} Oil seal inner diameter: 83mm (3.27 in} Gartner Banana

ASSEMBLY 4. Apply silicone sealant to the shaded area shown in the figure. 5. Install the rear cover Tightening torque: 7.9-1 0.7 N.m (80-1 10 kgfem, 70-95.4 in-lbf) Oil Pump 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a pipe, press the oil seal in evenly until it is flush with the edge of the oil pump body. U' Note Oil seal outer diameter: 50.5mm (1.99 in} Oil seal inner diameter: 36.5mm (1.44 in) 4. Install the oil pump and a new gasket. Tightening torque: 19-25 N.m (1 -9-2.6 kgf-m, 14--18 ft-lbf) 5. Cut away the portion of the gasket that projects from the body toward the oil pan side. Gartner Banana

ASSEMBLY B Water Pump 1. Remove all foreign material from the water pump mount- ing surface. 2. Install the water pump and a new gasket. Tightening torque: 19-25 N.m {I .9--2.6 kgf.m, 14--18 ft-lbf) Oil Pan Baffle 1. Remove all foreign material from the contact surfaces. 2. Apply a continuous bead of silicone sealant to the baffle along the inside of the bolt holes, and install within five minutes. Oil Strainer Install the oil strainer and a new gasket. NOTCH NOTCH 05UOBX-20 Tightening torque: 7.9-1 0.7 N.m (80-1 10 kgf.cm, 70-95.4 in4bf) Oil Pan 1. Remove all foreign material from the contact surfaces. 2. Apply silicone sealant to the areas indicated in the figure. 3. Install new gaskets onto the oil pump body and the rear cover with the projections of the notches shown in the figure. Gartner Banana

B ASSEMBLY 4. Apply a continuous bead of silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends. 5. Install the oil pan. ij Tightening torque: 7.9-10.7 N.m (80-110 kgf-cm, 70-95.4 in4bf) End Plate Install the end plate. Tightening torque: 7.9--10.7 N.m (80-110 kgf.cm, 70-95.4 in-lbf) Flywheel (MT) or drive plate (AT) 1. Remove the sealant from the bolt holes in the crankshaft and from the bolts. Caution If all of the old thread locking sealant cannot be re- moved from the bolt, it will not torque properly. - Replace the bolt. Note If a new bolt is used, do not apply thread locking seal- ant. New Mazda bolts have sealant on them. 2. Set the flywheel onto the crankshaft. 3. Apply sealant to the flywheel bolts and install them. 4. Hold the flywheel with the SST. 5. Tighten the bolts in two or three steps in the order shown. Tightening torque: 97-102 N.m (9.8-10.5 kgf+m, 71-75.9 ft.lbf) Clutch Disc and Clutch Cover (MT) Install the clutch disc and clutch cover using the SST. (Refer to section H.) Tightening torque: 18-26 N.m (1.8-2.7 kgf.m, 14--19 ftlbf) Gartner Banana

ASSEMBLY CYLINDER HEAD Torque Specifications Valve Seal Note The intake and exhaust valve seals are different as shown. The exhaust valve seal has ridges on the top for iden- tification. Gartner Banana

B ASSEMBLY @ @ GREATER THAN @ @ 1. Assemble the SST so that depth L is as specified. Depth L: 18.3-18.9mm (0.721-0.744in) 2. Slide the valve seal onto the valve guide. 3. Set the SST against the valve seal. 4. Press the valve seal in until the SST contacts the cylin- der head. Valve and Valve Spring 1. lnstall the lower spring seat. 2. Install the valve. 3. lnstall the valve spring with the closer pitch toward the cylinder head. 4. lnstall the upper spring seat. 5. Compress the valve spring with the SST, and install the valve keepers. 6. Remove the SST. 7. Tap the end of the valve stem lightly two or three times with a plastic hammer to verify that the keepers are all fully seated. Gartner Banana

ASSEMBLY Cylinder Head Gasket 1. Remove all foreign material from the top of the cylinder block. 2. Place the new cylinder head gasket in position. Cylinder Head 1. Install the cylinder head. 2. Apply clean engine oil to the bolt threads and seat faces. 3. Tighten the cylinder head bolts in two or three steps in the order shown. Tightening torque: 76-81 N-m (7.7--8.3 kgf.m, 56-60 ft4bf) Thermostat Housing 1. Remove all foreign material from the thermostat housing mounting surface. 2. Install a new O-ring and the thermostat housing. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft-lbf) Seal Plate Install the seal plate on the cylinder head. Tightening torque: 7.9-10.7 N-m (80-110 kgfem, 70-95.4 in4bf) HLA 1. Apply clean engine oil to the friction surfaces. 2. If the HLA are being reused, install them in the position from which they were removed. 3. Verify that the HLA move smoothly in their bores. Gartner Banana

ASSEMBLY Camshaft Note The rear end of exhaust camshaft is grooved for the L/ crankshaft position sensor drive. 1. Apply clean engine oil to the camshaft journals and bear- ings. 2. Install the camshaft in position. CRANKSHAFT POSITION SENSOR DRIVE GROOVE 45UOBX-151 3. Apply silicone sealant to the shaded areas shown in the figure. Do not let any sealant get on the journal surfaces. 4. Install the camshaft caps according to the cap number and arrow mark. 5. Install the camshaft cap bolts, and tighten them in two or three steps in the order shown. Tightening torque: Il.3--14.2 N.m {ll5-l4S kgfem, 100-125 in4bf) ij 6. Apply a small amount of clean engine oil to the lip of a new camshaft oil seal. 7. Push the oil seal slightly in by hand. 8. Using a pipe and hammer, tap the oil seal in evenly until it is flush with the edge of the camshaft cap. Note Oil seal outer diameter: 48mm (1.89 in) Oil seal inner diameter: 34mm (1.34 in) Camshaft Pulley 1. Turn the camshafts until the camshaft dowel pins face straight up. 2. lnstall the camshaft pulleys with the I mark (intake side) or the E mark (exhaust side) straight up. Gartner Banana

ASSEMBLY B I I 35UOBX477 TIMING BELT Torque Specifications 3. Install the camshaft pulley lock bolts. 4. Hold the camshaft with a wrench. 5. Tighten the camshaft pulley lock bolt. Tightening torque: 50-40 N.m (5.0-6.2 kgf.m, 3744 ft-lbf) Gartner Banana