ignition MAZDA MX-5 1994 User Guide

ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION SST I 49 9200 020 Tension gauge, V-ribbed belt For inspection of ignition timing and idle speed For inspection of drive belt tension ENGINE OIL 49 801 9 9AO System selector Warning Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water im- mediately after this work. 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 if 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}. ENGINE COOLANT Inspection Coolant level (engine cold) Warning Removing 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 can shoot out and cause serious in- jury. It can 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, and remove it. 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. 3. Add coolant if necessary. Gartner Banana

ENGINE TUNE-UP HLA TROUBLESHOOTING GUIDE Problem 1. Noise when engine is started immediately af- ter oil is changed 2. Noise when engine is started after setting approx. one day 3. Noise when engine is started after cranking for 3 seconds or more 4. Noise when engine is started after new HLA is installed 5. Noise continues more than 10 minutes 5. Noise occurs during idle after high speed run- ning Possible Cause Oil leakage in oil passage Oil leakage in HLA Faulty HLA Action Run engine 2000-3000 rpm. If noise stops after 2 second-10 minutes(') HLA is normal. If not, replace HLA. Time required for engine oil to circulate withir engine, includes tolerance for engine oi condition and ambient temperature. Insufficient oil pressure (Refer to page 8-53) Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. Check oil pressure. If lower than specification, check for cause. Oil pressure; 295-392 kPa I3.0-4.0 kgf/cm2, 43-56 psil-3000 rpm Deteriorated oil Check oil quality. If deteriorated, replace with specified type and amount of oil. Incorrect oil amount IGNITION TIMING, IDLE SPEED Preparation 1. Check the condition of the engine (spark plugs, leaks in hoses, etc.). 2. Make sure all accessories are OFF. 3. Warm up the engine to normal operating temperature. 4. Connect a timing light and a tachometer to the data link connector terminal IG-. When using an externally pow- ered timing light and/or tachometer, connect it to the power connector (Blue: 1 -pin). Measure valve clearance. If more than Omm {0 in}, replace HLA. Check oil level. Drain or add oil as necessary. Caution Grounding the power connector terminal (Blue: 1-pin) will burn out the 20A wiper fuse. 5. Make sure coolant fan does not operate. Gartner Banana

ENGINE TUNE-UP B lgnition Timing 1. Connect the SST and set the TEST SW to "SELF TEST or connect data link connector terminals TEN and GND with a ium~er wire. ~ 4 2. Check the'idle speed, and set it to specification if neces- sary. (Refer to section F.) ldle speed (Neutral): 800-900 (850 + 50) rpm [MT] (P range): 750-450 (800 + 50) rpm [AT] 3. Verify that the timing mark (White) on the crankshaft pulley and the timing belt cover are aligned. lgnition timing: BTDC 9"-11" (1 0" + 1 ") 4. If the marks are not aligned, loosen the crankshaft posi- tion sensor lock bolt, and turn the crankshaft position sensor to make the adjustment 5. Tighten the crankshaft position sensor lock bolt to the specified torque. Tightening torque: 19-25 N.m {I .9--2.6 kgf.m, 1 &-I8 ft-lbf) 6. Disconnect the SST. 7. Verify that the ignition timing is within the specification. Ignition timing: BTDC 6-18" ldle Speed 1. Connect the SST and set the TEST SW to "SELF-TEST or connect data link connector terminals TEN and GND with a jumper wire. 2. Verify that the idle speed is within specification. ldle speed (Neutral): 800-900 (850 + 50) rpm [MT] (P range): 75-50 (800 -e 50) rpm [AT] 3. If the idle speed is not within specification, remove the blind cap from the air adjusting screw and adjust it. 4. After adjusting the idle speed, install the blind cap and disconnect the SST or jumper wire from the data link connector. Gartner Banana

COMPRESSION COMPRESSION If the engine exhibits low power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to section G.) 2. Compression (Refer to page B-10.) 3. Fuel system (Refer to section F.) INSPECTION 1. Check that the battery is fully charged. Recharge it if necessary. (Refer to section G.) 2. Warm up the engine to the normal operating tempera- ture. 3. Turn the engine OFF. 4. Remove all spark plugs. 5. Disconnect the ignition coil connector. 6. Connect a compression gauge to the No.1 spark plug hole. 7. Fully depress the accelerator pedal and crank the en- gine. 8. Record the maximum gauge reading. 9. Check each cylinder, as above. Compression: 1,255 kPa (1 2.8 kgf/cm2, 182 psi)-300 rpm Minimum: 883 kPa (9.0 kgf/cm2, 128 psiF300 rpm Differential limit between cylinders: 196 kPa (2.0 kgf/cm2, 28 psi} 10. If the compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder and re- check the compression. (1) If the compression increases, the piston, piston rings, or cylinder wall may be worn. (2) If the compression stays low, the valve may be stuck or seated improperly. (3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be defective or the cyl- inder head distorted. 11 . Connect the ignition coil connector. 12. Install the spark plugs. Tightening torque: 15--22 N.m (1.5-2.3 kgf.m, 11-16 ftlbf) Gartner Banana

B ON-VEHICLE MAINTENANCE TIMING BELT Removal / lnstallation 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove the under cover. 4. Remove in the order shown in the figure, referring to Removal Note. 5. Install in the reverse order of removal, referring to lnstallation Note. (80-110 kgfmn, 7.9-10.7 Nm 13-17 Nm (125-175 kgfcm, 109-151 In4bf) Nm (kgfm, ft4bf) 45UOBX425 1. Air intake pipe 12. Spark plug 2. Upper radiator hose Removal / Installation ......... section G 3. Water hoses (Connected to thermostat 13. PCV valve housing) 14. Cylinder head cover 4. PIS andlor A/C drive belt 15. Upper timing belt cover Removal 1 Installation ....... page B- 6 16. Middle timing belt cover 5. Alternator drive belt 17. Lower timing belt cover Removal / Installation ....... page 5 6 18. Timing belt 6. Water pump pulley Removal Note ............. page B-13 7. Plate Installation Note ........... page B-14 8. Crankshaft pulley Inspection ................. page 8-58 9. Pulley lock bolt 19. Tensioner, tensioner spring Removal Note ............. page B-13 Installation Note ........... page B-14 /' Installation Note ........... page 51 5 Inspection ................. page 558 10. Pulley boss 20. Idler 11. Ignition coil and high-tension lead Inspection ................. page 8-58 Gartner Banana

ON-VEHICLE MAINTENANCE B Stem After Installation 10. Loosen the tensioner lock bolt to apply spring tension to the timing belt. 11. Tighten the tensioner lock bolt. Tightening torque: 38-51 N-m (3.8-5.3 kgf.m, 28--38 ftlbf) 12. Install the pulley boss and pulley lock bolt. 13. Turn the crankshaft 2 and 116 turns clockwise and verify that the timing marks are correctly aligned. 14. Measure the timing belt deflection by applying moderate pressure 98 N (10 kgf, 22 Ibf) midway between the cam- shaft pulleys. If the deflection is not correct, repeat from Step 10 above. Deflection: 9.0-11.5mm (0.36-4.45 in) at 98 N (10 kgf, 22 Ibf) Pulley lock bolt Hold the crankshaft with the SST and tighten the pulley lock bolt. Tightening torque: 157-166 N.m (16-17 kgf.m, 116-122 ftlbf) 1. till the radiator with specified amount and type of engine coolant. (Refer to section E.) 2. Connect the negative battery cable. 3. Start the engine and check, and if necessary, adjust the ignition timing. Gartner Banana

ON-VEHICLE MAINTENANCE B Installation Note Cylinder head bolt I I 05UOBX-043 Stem After Installation Apply clean engine oil to the bolt threads and seat faces. Install the cylinder head bolts. Tighten the cylinder head bolts in two or three steps in the order shown in the figure. Tightening torque: 76-81 N.m (7.7-8.3 kgf-m, 56-60 ft4bf) 1. pill the radiator with the specified amount and type of engine coolant. (Refer to Section E.) 2. Connect the negative battery cable. 3. Start the engine and check follows: (1) Engine oil and engine coolant leakage (2) Ignition timing, idle speed (Refer to page B-9.) (3) Operation of emission control system 4. Recheck the engine coolant level. Gartner Banana

ON-VEHICLE MAINTENANCE B I I 35UOBX-020 Stem After Installation 3. Install the camshaft pulley lock bolts. 4. Hold the camshaft with a wrench at the cast hexagon. 5. Tighten the camshaft pulley lock bolt. Tightening torque: 50-60 Nm C5.0-6.2 kgfm, 3744 ft4bf) 1. pill the radiator with the specified amount and type of engine coolant. (Refer 2. Connect the negative battery cable. 3. Start the engine and check follows: (1) Engine coolant leakage (2) Ignition timing (Refer to page 59.) 4. Recheck the engine coolant levels. to section E.) Gartner Banana

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

REMOVAL 6 Removal Note PIS oil pump 1. Remove the PIS oil pump with the hoses still connected. 2. Position the pump away from the engine and affix it with wire. 45UOBX-051 AIC compressor (If equipped) 1. Remove the NC compressor with the hoses still con- nected. 2. Position the compressor away from the engine and affix it with wire. I I 45UOBX-052 Step 2 Disconnect the harness connectors shown in the figure. 6 1. Steering pressure sensor 2. Throttle position sensor 3. Idle air control valve 4. Heated oxygen sensor 5. Ignition coil 6. Crankshaft position sensor 7. Ground 8. Fuel injector 9. Alternator 10. Oil pressure switch 11. Starter Gartner Banana