oil MAZDA MX-5 1994 User Guide

I Brake lines. hoses, and connections Ill Schedule 2 (Unique driving conditions) (AT) (Cont'd) Disc brakes Steering operation and linkage I Front suspension ball joints 111 Page I Drive shaft dust boots I I I CHASSIS AND BODY Service data and inspection point Maintenance Number of months or kilometers {miles}, whichever comes first I Differential oil 111 I Bolts and nuts on chassis and body 111 48 96 60 I Exhaust system heat shield Ill interval Months Kilometers Maintenance (x1,OOO) Miles(x1,OOO) All locks and hinges AIR CONDIVONER SYSTEM 12 24 15 4 8 5 Disc plate thickness Front: 18.0mm (0.71 in)-Minimum Rear: 8.0mm i0.31 in)-Minimum Pad thickness: 1 .Omm (0.04 in)--Minimum Free play: 0-30mm {O-1 .I 8 in} Operation and looseness Fluid leakage or oozing 16 32 20 8 16 10 P--6 I l Oil capacity: I I I I 1 I 1.00 L 11-06 US at. 0.88 lm~ at I M-25 l Proper attachment and connections I I I I I I I I 7, .' , Ill I 1 I I Retighten all loose bolts and nuts I - 20 40 25 l Damage, looseness and grease leakage Cracking and damage Insulator clearance between I I I I I1Iob odv and exhaust svstem 28 56 35 24 48 30 L 1 L I L I L 1 L 1 L 1 Lubricatealllocksandhinges I - Refrigerant 32 64 40 Inspect the refrigerant amount annually 36 72 45 l Refrigerant pressure Low pressure: 0.1 5-0.25 MPa (1.5-2.5 kgf/cm2, 21-36 psi} High pressure: 1.37-1 57 MPa {I 4.0-1 6.0 kgfld, 19%-228 psi] - I 40 80 50 Compressor 44 88 55 Inspect the operation annually Gartner Banana

Schedule interval Maintenance ENGINE Number of months or kilometers {miles), whichever comes first I -. Months 5 10 15 20 25 30 35 40 45 50 55 60 Kilometers 8 16 24 32 40 48 56 64 72 80 88 96 - Service data and inspection point 1~1.000~ Page Spark plugs FUEL SYSTEM -- Plug gap: 1 .GI .l mm {0.04M.043 in) l Recommended spark plugs: D-5 D-6 B-6 F-99 8-1 2 IGNITION SYSTEM R I I Engine oil Engine oil filter Drive belts Air cleaner element Engine timing belt 'l R I R I F-76 F-1 1 3 F-107 F-I30 - Idle speed Fuel filter Fuel lines and hoses PCV valve'2 Emission hoses and tubes R I COOLING SYSTEM I Cooling system Engine coolant R I R I I E4 E-5 E4 I R I R I R I R I*z I l Hoses for cracks or wear l Leaks - Level and strength I R RR I R R R I I R I OilPancapacity: 4.0 L (4.2 US qt, 3.5 Imp qt) 0 Oil filter capacity: 0.15L(0.16USqt,0.13Impqt) 'Cracksordamage 0 Tension - - R I I I I I R I l ldle speed MT: 800-900 rpm (Neutral) AT 750-850 rpm (P range) - l Fittings, connections and components for leaks Operation Fittings and connections I I R I I I I I I I I I R I 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 . ENGINE INDEX ............................. B- 2 OUTLINE .......................... B- 3 SPECIFICATIONS ................ B- 3 TROUBLESHOOTING GUIDE ........ B- 3 ENGINE TUNE-UP .................. 8- 5 PREPARATION ................... B- 5 ENGINE OIL ..................... B- 5 ENGINE COOLANT ............... B- 5 DRIVE BELT ..................... 8- 6 HLA TROUBLESHOOTING GUIDE . 8- 8 IGNITION TIMING. IDLE SPEED .... B- 8 COMPRESSION .................... 8-10 INSPECTION ..................... B-10 ON-VEHICLE MAINTENANCE ....... B-11 PREPARATION ................... B-11 TIMING BELT ..................... 8-12 CYLINDER HEAD GASKET ........ B-16 H LA ............................. 8-20 FRONT OIL SEAL ................. 8-24 REAR OIL SEAL .................. 8-26 REMOVAL ......................... 8-28 PROCEDURE .................... B-28 ENGINE STAND MOUNTING ......... 8-32 PREPARATION ................... 8-32 PROCEDURE .................... B-33 DISASSEMBLY ..................... B-35 PREPARATION ................... 8-35 AUXILIARY PARTS ............... 8-36 TIMING BELT ..................... 8-37 CYLINDER HEAD ................. 8-39 CYLINDER BLOCK (EXTERNAL PARTS) ............. 8-42 CYLINDER BLOCK .............. (INTERNAL PARTS) 8-44 .............. INSPECTION I REPAIR 8-47 ................... PREPARATION 8-47 ................. CYLINDER HEAD 8-47 .............. VALVE MECHANISM 8-48 ...................... CAMSHAFT B-51 HLA ............................. 8-53 ............... CYLINDER BLOCK B-53 .......................... OIL JET B-54 PISTON. PISTON RING. AND ..................... PISTON PIN 8-55 CONNECTING ROD .............. B-56 ................... CRANKSHAFT 8-57 BEARING ........................ 8-57 TIMING BELT ..................... 8-58 TENSIONER. IDLER .............. 8-58 TENSIONER SPRING ............. 8-58 PULLEY ......................... 8-58 ........................ ASSEMBLY 8-59 ................... PREPARATION 8-59 CYLINDER BLOCK (INTERNAL PARTS) .............. B-60 CYLINDER BLOCK (EXTERNAL PARTS) ............. B-65 CYLINDER HEAD ................. B-69 TIMING BELT ..................... 8-73 ............... AUXILIARY PARTS 8-77 ..... ENGINE STAND DISMOUNTING 8-81 .................... PROCEDURE 8-81 INSTALLATION ..................... 8-83 .................... PROCEDURE 843 45UOBX-001 Gartner Banana

B INDEX INDEX 1. Timing belt Removal / Installation ....... page 8-1 2 2. Cylinder head gasket Replacement .............. page 6-1 6 3. HLA Removal / Installation ....... page 8-20 4. Front oil seal Replacement .............. page 6-24 5. Rear oil seal Replacement .............. page 6-26 INTAKE MANIFOLD COMPRESSION INSPECTION, PAGE B-10 TIGHTENING TORQUE STANDARD: 1,255 kPa (1 2.8 k f/cm2, 182 psi)-300 rpm 19-25 Nm (1.9-2.6 kgfq 14--18 ft4bf) MINIMUM: 883 kPa (9.0 kgflcm 9 , 128 psi}-300 rpm TIGHTENING TORQUE 3946 Nm i3.9--4.7 kgf m, 29-33 ftdbf) DRIVE BELT ADJUSTMENT. PAG ENGINE OIL INSPECTION, SERVICE, SECTION D DEFLECTION mm (in) ENGINE COOLANT INSPECTION, 6. Engine Removal .................. page 8-28 Engine stand mounting ..... page 6-32 Disassembly .............. page 6-35 Inspection / Repair ......... page B-47 Assembly ................. page 559 Engine stand dismounting ... page 8-81 , Installation ................ page B-83 SERVICE, SECTION E DRIVE BELT ALTERNATOR PIS. PIS + AlC AlC NEW 55-7.0 (0.224.27) 8.&9.0{0.324.35] 8.0-9.0{0.324.35) USED 6.0-7.5 (0.24-0.29) 9.0-10.0{0.364.39) 9.0-10.0{0.364.39} LIMIT 8.0 (0.31) 11.5 (0.45) 11.5 (0.453 Gartner Banana

OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS Engine Item Tv~e BP DOHC Gasoline, 4-cvcle . . I -, Dis~lacement ml kc. cu inl I 1.840 (1.840. 11 2) I Cylinder arrangement and number Combustion chamber Valve system Bore x stroke mm {in) I 83.0 x 85.0 (3.27 x 3.35) I In-line, 4-cylinders Pentroof DOHC, belt-driven Com~ression ratio I 9.0 I Compression pressure kPa (kgf/cm2, psi)-rpm .- . 1 open (BTDCO) 1,255 {I 2.8, 182)-300 5 Valve timing TROUBLESHOOTING GUIDE tX Valve clearance Problem .. . -. . Difficult starting ' With System Selector (49 B019 9AO) test switch at SELF TEST. 45uo~x-003 Close (ATDCO) IN mm {in) EX mm {in) Poor idling Close (ABDCO) Open (BBDCO) 14 0: Maintenance-free 0: Maintenance-free Excessive oil consumption 48 56 Possible Cause Malfunction of engine-related components Burned valve Worn piston, piston ring, or cylinder Failed cylinder head gasket Malfunction of fuel system Malfunction of ignition system Malfunction of engine-related components Malfunction of HLA' Poor valve-to-valve seat contact Failed cvlinder head aasket Oil leakage I Refer to section D I I Remedy Malfunction of fuel system Malfunction of ignition system Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder Oil working down Worn valve seal Worn valve stem or guide Page Replace Replace or repair Replace Refer to section F Refer to section G Replace Replace or repair Re~lace 8-48 B-53,55 B-1 6 B-20 B-50 B-1 6 Refer to section F Refer to section G Replace Replace or repair Replace Replace B-55 B-53,55 B-39,70 8-48 Gartner Banana

B TROUBLESHOOTING GUIDE Problem nsufficlent power 4bnormal combustion Engine noise Possible Cause Insufficient compression Malfunction of HLA' Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Stuck, damaged, or worn piston ring Cracked or worn piston Malfunction of fuel system Malfunction of ignition system Others Slipping clutch Dragging brakes Wrong size tires Malfunction of engine-related components Malfunction of HLA* Stuck or burned valve Weak or broken valve spring Carbon accumulation in combustion chamber Malfunction of fuel system Malfunction of ignition system Crankshaft- or bearing-related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged Piston-related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod Valves or timing-related parts Malfunction of HLA' Broken valve spring Excessive valve auide clearance Malfunction of cooling system Malfunction of fuel system Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage Malfunction of timina belt tensioner Remedy Replace Repair Replace Replace Replace Replace Replace Replace Refer to section F Refer to section G Refer to section H Refer to section P Refer to section Q Replace Replace Replace Eliminate carbon Refer to section F Refer to section G Replace or repair Replace Replace or repair Replace or repair Replace Replace or repair Replace Replace Replace Replace Replace Replace Replace Refer to section E Refer to section F Refer to section E Adjust Refer to section G Refer to section F Replace Page Tappet noise may occur if the engine has set idle for an extended period. The noise should dissipate after the engine has reached normal operating temperature. (HLA troubleshooting: Refer to page 6-8) Gartner Banana

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 V-RIBBED BELT PIS or PIS + A/C EQUIPPED AIC EQUIPPED IDLER Coolant quality 1. Verify that there is no buildup of rust or scale around the radiator cap or radiator filler neck. 2. Verify that the coolant is free of oil. d 3. Replace the coolant if necessary. DRIVE BELT Inspection 1. Remove the air intake pipe. 2. Check the drive belts for wear, cracks, and fraying. Re- place if necessary. 3. Verify that the drive belts are correctly mounted on the pulleys. 4. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Ap- ply moderate pressure 98 N (10 kgf, 22 Ibf) midway be- tween the specified pulleys. Deflection rnrn {in) Drive belt New' Used Limit Alternator 5.5-7.0 6.0-7.5 m.22-0.27) (0.24-0.29) 8.0 (0.31) t" NC 8.0-9.0 9'0-'0.0 11.5 {0.45} {0.32-0.35) {0.36-0.39) A belt that has been on a running engine for less than five minutes. 5. If the deflection is not within specification, adjust it. 6. Install the air intake pipe. Drive belt tension check Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys. Gartner Banana

ENGINE TUNE-UP B 2 ADJUSTING BOLT LOCKNUT Tension N {kgf, lbfl I Drive belt New* Used I Limit I A belt that has been on a running engine for less than five minutes. 45UOBX-011 Alternator PIS, PIS + A/C AIC Adjustment (1) Alternator belt Loosen the alternator bolts @J and @ and adjust the belt deflection by turning the adjusting bolt 0. Tightening torque @: 19-25 N-m {I .9-2.6 kgf.m, 14-18 ft4bf) @: 38-51 N-m (3.8-5.3 kgf.m, 28-38 ft4bf) 491 -745 (50-76, 11 0-1 67) 491-588 (50-60, 11C-132) 49 1-588 (50-60, 11 0-1 32) (2) PIS belt, PIS + A/C belt Loosen the PIS oil pump bolt @ and nuts @ and @ and adjust the belt deflection by turning the adjusting bolt @. Tightening torque @: 3246 N.m (3.24.7 kgf.m, 24-33 ftlbf) @: 37-53 N-m I3.7-5.5 kgf.m, 27-39 ft4bf) 0: 19-25 N-m {I .9-2.6 kgf.m, 14-18 ft4bf) 491 -706 (50-72, 11 0-1 58) 422-490 (43-50, 95-1 10) 422490 {43-50, 95-1 lo} (3) AIC belt If necessary, loosen the lock nut and adjust the belt deflection by turning the adjusting bolt. 343 (35,771 245 {25, 55) 245 {25,55) Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbf) 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