gasket MAZDA MX-5 1994 User Guide

INSPECTION I REPAIR INSPECTION 1 REPAIR PREPARATION SST 49 801 2 005 Remover & installer, valve guide Nut (Part of 49 LO1 2 OAO) For removal of valve guide 49 LO1 2 002 Body (Part of 49 LO 1 2 OAO) For installation of valve guide For installation of valve guide 49 LO1 2 OAO Installer set, 4 8 valve seal & valve guide t~@ Installer (Part of 49 LO1 2 OAO) For installation of valve guide For installation of valve guide 1. Clean all parts, being sure to remove all gasket fragments, dirt, oil or grease, carbon, moisture residue, and other foreign materials. 2. Inspection and repairs must be performed in the order specified. L 45UOBX485 CYLINDER HEAD 1. lnspect the cylinder head for damage, cracks, and leak- age of water and oil. Replace the cylinder head if neces- sary. 2. Measure the cylinder head distortion in the six directions shown in the figure. Distortion: 0.lOmm (0.004 in} max. 3. lnspect the following and repair or replace the cylinder head as necessary. (1) Sunken valve seats (2) Damaged intake and exhaust manifold contact sur- faces (3) Excessive camshaft oil clearances and end play 4. If the cylinder head distortion exceeds specification, grind the cylinder head surface. 5. If the cylinder head height is not within specification, re- place it. Height: 133.8-1 34.0mm (5.268-5.275 in) Grinding: O.lOmm (0.004 in} max. Gartner Banana

ASSEMBLY 1. Do not reuse gaskets or oil seals. 2. Clean all parts before reinstallation. 3. Apply new engine oil to all sliding and rotating parts. 4. Replace plain bearings if they are peeled, burned, or otherwise damaged. 5. Tighten all bolts and nuts to the specified torques. CYLINDER BLOCK (INTERNAL PARTS) Torque Specifications CYLINDER WALLS I#- WASHER, NEW JOURNALS AND BEARINGS NEW Connecting Rod and Piston Assembly 1. Install one piston pin clip into the clip groove in the pis- ton. 2. Assemble the piston and the connecting rod. 3. Apply clean engine oil to the piston pin. 4. Install the piston pin from the side opposite the clip. 5. Tap the piston pin in with the SST until the pin contacts the clip. . , If the pin cannot be installed easily, replace the connect- ing rod. 6. Install the second clip into the clip groove in the piston. 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

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 Dipstick, Dipstick Pipe 1. Apply a small amount of clean engine oil to the new 0- ring. 2. Push the dipstick pipe into the oil pan. u 3. Tighten the dipstick pipe bracket nut. Tightening torque: 7.9-10.7 N.m (80-1 10 kgfem, 70-95.4 in4bf) 4. lnstall the dipstick. Spark Plug lnstall the spark plugs. Tightening torque: 15-22 N.m (1 .%2.3 kgf-m, 11-1 6 ft4bf) Water Outlet Pipe 1. Remove all foreign material from the water outlet pipe mounting surface. 2. lnstall a new gasket and the water outlet pipe. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft4bf) Oil Pressure Switch lnstall the oil pressure switch. Tightening torque: 12-17 N.m (1.2-1.8 kgf-m, 9-13 ft4bf) Gartner Banana

B ASSEMBLY BLADE NEW Intake Manifold Assembly 1. Remove all foreign material from the intake manifold contact surface. 2. Install a new gasket and the intake manifold assembly. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft.lbf) Manifold Bracket Install the manifold bracket. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft.lbf) Crankshaft Position Sensor 1. Apply grease to a new O-ring and the blade. 2. Install the crankshaft position sensor to the rear end of exhaust-side camshaft and hand tighten the installation bolt. -J Ignition Coil and High-tension Lead 1. Install the ignition coil. Tightening torque: 19-25 N.m (1 .%--2.6 kgf.m, 14-18 ftdbf) 2. Connect the high-tension leads. 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

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

D OIL PAN OIL PAN REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine oil. (Refer to page D-5.) 3. Remove the undercover. 4. Remove in the order shown in the figure, referring to Removal Note. 5. Install in the reverse order of removal, referring to Installation Note. 94--117 (9.5-11.9,69-86) 57-78 (5.8--8.0,42-57) 69-83 {7.0-8.5,51-61) GASKET, REPLAC 7.9--10.7 Nm {60-110 kgfan, 70-95 O-RING, REPLACE 'If 64-49 (6.!%9.1,4&65) 7.9-10.7 N.m (80-110 kgf.crn, 70-95 indbf] 1. Dipstick and pipe 5. Oil pan ............. 2. Intermediate shaft Removal Note page D- 9 ........... .......... Removal / lnstllation section N Installation Note page D-10 3. Engine mount nut 6. Oil strainer 7. Oil baffle ,' ............. Removal Note page D- 9 ............. 4. Crossmember installation bolt and nut Removal Note page D- 9 ............. ........... Removal Note page D- 9 Installation Note page D- 9 Gartner Banana