check engine MAZDA MX-5 1994 User Guide

ON-VEHICLE MAINTENANCE B Steps After Installation 1. Connect the neaative batterv cable. Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. Installation Note Oil seal 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. Tap the oil seal in evenly with a pipe and a hammer until it is flush with the edge of the oil pump body. Note Oil seal outer diameter: 50.5mm (1.99 in} Oil seal inner diameter: 36.5mm (1.44 in} Timing belt pulley 1. Install the timing belt pulley. 2. Install the pulley woodruff key with the tapered side to- ward the oil pump body. 2. Start the enginsand check, and if necessary, adjust the ignition timing. 3. Connect the negative battery cable. 4. Start the engine and check follows: (1) Engine coolant leakage (2) Ignition timing (Refer to page B-9.) 5. Recheck the engine coolant levels. Gartner Banana

ASSEMBLY B SPACER TANG UPPER RAIL ...-.. OIL RlNG SPACER ENDS LOWER RAlL PISTON OIL RlNG UPPER RAIL TOP RING OIL RING + PISTOI PIN OIL RING. SECOND LOWER RAIL RING 7. Check the oscillation torque of the connecting rod. If the large end does not drop by its own weight, replace the piston and/or piston pin. Piston Ring 1. Install the three-piece oil rings on the pistons. (1) Apply clean engine oil to the oil ring spacer and rails. (2) lnstall the oil ring spacer with the ends upward. Note The upper and lower rails are the same. They can be installed with either face upward (3) Install the upper and lower rails. 2. Verify that the spacer tang separates the rails, and that the rails turn smoothly in both directions. 3. lnstall the rings with the R marks upward. 4. Using a piston ring expander, install the second ring with the scraper face downward. 5. Using a piston ring expander, install the top ring. 6. Apply clean engine oil to the top and second piston rings. 7. Position the end gaps of the rings as shown in the figure. Gartner Banana

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

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

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

OIL COOLER D OIL COOLER REMOVAL I INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine oil and engine coolant. (Refer to page D-5, Section E.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. INSTALL OIL COOLER WITH IDENTIFICATION MARK (BLACK) FACING UP A OIL FILTER^ RUBBER I 3049 (3.0--4.0,22-28) REPLACE Nm {kgtm, ft4bf) 1. Oil filter 3. Oil cooler Replacement . . . . . . . . . . . . . . . Page D-6 4. O-ring 2. Water hose Steps After Installation 1. Connect the negative battery cable. 2. Fill with the specified amount and type of engine oil and engine coolant. (Refer to page D-5, Section E.) 3. Start the engine and check for leaks. 4. Check the oil level and add oil if necessary. 5. Recheck the engine coolant levels. Gartner Banana

OIL PAN NOTCH NOTCH I 05UODX-209 Steps After Installation 1. Install the undercover. Oil pan 1. Remove all foreign material from the contact surfaces. 2. Apply silicone sealant to the shaded areas shown in the figure. 3. Install new gaskets onto the oil pump body and the rear cover with the projections in the notches shown in the fig- ure. 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 with five minutes. Tightening torque 0: 7.9-10.7 N.m (80-110 kgf-cm, 70-95 in4bf) @: 64-49 N.m (6.5-9.1 kgf-m, 48-45 ft-lbf) 2. Connect the negative battery cable. 3. Fill with the specified amount and type of engine oil. (Refer to page D-5.) 4. Start the engine and check for leaks. 5. Check the oil level and add oil if necessary. Gartner Banana

ENGINE COOLANT ENGINE COOLANT PREPARATION SST INSPECTION 49 9200 145 Adapter set, radiator cap tester Warning Removing the radiator cap or the coolant drain plug while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press down on the cap - still using a cloth -turn it, andremove it. For inspection of cooling system pressure Coolant Level (Engine Cold) 1. Verify that the coolant level is near the radiator filler neck. 2. Verify that the coolant level in the coolant reservoir is be- tween the FULL and LOW marks. Add coolant if neces- sary. u Note The distance between the LOW and FULL marks on the coolant reservoir represents 4.5 L (4.8 US qt, 4.0 Imp qt). Coolant Quality 1. Verify that there is no buildup of rust or scale around the radiator cap or radiator filler neck. 2. Verify that coolant is free of oil. Replace the coolant if necessary. 49 9200 146 Adapter A (Part of 49 9200 145) Coolant Leakage 1. Connect a radiator tester (commercially available) and the SST to the radiator filler neck. 2. Apply 103 kPa (1.05 kgf/cm2, 14.9 psi} pressure to the system. 3. Verify that the pressure is held. If not, check for coolant leakage. For inspection of cooling system pressure / V Caution Apply more than 103 kPa (1.05 kgf/cm2, 14.9 psi) can damage the hoses, fittings, and other compo- nents, and cause leaks. Gartner Banana

E ENGINE COOLANT REFILLING Use the proper amount and mixture of ethylene-glycol based coolant. (Refer to Coolant Protection, page E-5.) 1. Slowly pour the coolant into the radiator up to the coolant filler port. Filling pace: 1.0 L (1.1 US qt, 0.9 Imp qt}/min. max 2. Fill the coolant reservoir up to the FULL level. 3. Fully install the radiator cap. 4. Start the engine and let it idle until it warms up. 5. If the temperature increases beyond normal, there is ex- cessive air in the system. Stop the engine and allow it to cool; then repeat step 1-3. 6. Run the engine at 2,200-2,800 rpm for five seconds; re- peat several times. 7. Stop the engine and allow it to cool. Warning Remove the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding cool- ant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press ii down on the cap -still using a cloth - turn it, and remove it. 8. Remove the radiator cap and check the coolant level. If the coolant level has dropped, repeat the procedure from step 1. Gartner Banana