lock MAZDA MX-5 1994 Owner's Manual

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 CRANKSHAFT POSITION SENSOR DRIVE GROOVE 45UOBX-04 Removal Note Camshaft pulley 1. Hold the camshaft with a wrench at the cast hexagon. 2. Remove the camshaft pulley lock bolts. 3. Remove the camshaft pulleys. Camshaft 1. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure. 2. Remove the camshaft caps. 3. Remove the camshafts. 4. Remove the camshaft oil seals from the camshafts. HLA Caution The HLA must be reinstalled in the same posi- tions from which they were removed. If they are not, it can cause premature and uneven wear. Note Mark the HLA to show their original positions. Remove the HLA from the cylinder head. Installation Note 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. Camshaft Note The exhaust camshaft has a groove for the crank- shaft position sensor drive. 1. Apply clean engine oil to the camshaft journals and bear- ings. 2. Install the camshaft in position. 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

DISASSEMBLY B DISASSEMBLY PREPARATION SST 49 EOll 1AO For prevention of engine rotation 49 EOll 103 For prevention of engine rotation Ring gear brake set Shaft (Part of 49 EOl 1 1 AO) 49 E011 105 Stopper (Part of 49 EOll lAO) a For prevention of engine rotation 49 EOll 104 For prevention of engine rotation Collar (Part of 49 E011 1 AO) For removal / installation of valves 49 8012 012 Body (Part of 49 801 2 0A2) For removal I installation of valves Pivot, valve spring lifter For removal / installation of valves For removal / installation of valves Foot (Part of 49 80 1 2 0A2) Locknut (Part of 49 B012 0A2) For removal / installation of valves 49 S120 170 Remover, valve seal For removal of valve seals Arm, valve spring lifter 49 0221 061 A Remover & installer, piston pin For removal / installation of piston pins 1. Code all identical parts (such as piston, piston rings, connecting rods, and valve springs) so that they can be reinstalled in the cylinder from which they were removed. 2. Clean the parts with a steam cleaner. Blow off any remaining water with compressed air. 45UOBX-065 Gartner Banana

DISASSEMBLY B TIMING BELT Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Water pump pulley 2. Crankshaft pulley, plate 3. Cylinder head cover 4. Upper timing belt cover 5. Middle timing belt cover 6. Lower timing belt cover 7. Pulley lock bolt Disassembly Note ... 8. Pulley boss 9. Timing belt .......... Disassembly Note page 538 ................. Inspection page 558 10. Tensioner, tensioner spring ................. Inspection page B-58 11. Idler ................. Inspection page B-58 page 8-38 12. Timing belt pulley ................. Inspection page 558 Gartner Banana

DISASSEMBLY ROTATION ARROW - Disassembly Note Pulley lock bolt 1. Hold the flywheel (MT) or drive plate (AT 2. Loosen the pulley lock bolt. 3. Remove the pulley lock bolt. ') with the SST. Timing belt 1. ~rGect the tensioner with a rag. 2. Loosen the tensioner lock bolt. Ply the tensioner out- ward with a bar. 3. Tighten the lock bolt with the tensioner spring fully ex- tended. 4. Mark the timing belt rotation for proper reinstallation. 5. Remove the timing belt. Gartner Banana

DISASSEMBLY Disassembly Note Camshaft pulley 1. Hold the camshaft with a wrench at the cast hexagon. 2. Remove the camshaft pulley lock bolts. 3. Remove the camshaft pulleys. Camshaft 1. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure. 2. Remove the camshaft caps. 3. Remove the camshafts. 4. Remove the camshaft oil seals from the camshafts. HLA Caution The HLA must be reinstalled in the same position from which they were removed. If they are not, it can cause premature and uneven wear. L Note Mark the HLA to show their original positions. Remove the HLA from the cylinder head. Cylinder head bolt 1. Loosen the cylinder head bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head bolts. Valve keeper 1. Set the SST against the upper valve spring seat as shown in the figure. 2. Compress the spring and remove the valve keepers. Gartner Banana

B DISASSEMBLY CYLINDER BLOCK (EXTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note. GASKET, REPLACE - L 1. Clutch cover, clutch disc (MT) Removal 1 Installation ......... section H 2. Flywheel (MT), drive plate (AT) Disassembly Note .......... page 8-43 3. End plate 4. Oil pan Disassembly Note .......... page B43 5. Oil strainer 6. Oil pan baffle Disassembly Note .......... page B-44 7. Water pump 8. Oil pump ...... Disassembly 1 Assembly section D 9. Front oil seal Disassembly Note .......... page B-43 10. Rear cover 11. Rear oil seal Disassembly Note .......... page 6-43 Gartner Banana

DISASSEMBLY B PROTECT PUMP BODY WlTH RAG 05UOBX-10; I PROTECT REAR COYER WITH RAG I Disassembly Note Flywheel (MT) or drive plate (AT) 1. Hold the flywheel with the SST. 2. Remove the flywheel lock bolts. 3. Remove the flywheel. Oil pan 1. Remove the oil pan mounting bolts. Caution Pry tools can easily scratch the cylinder block and oil pan contact surfaces. 2. Insert a screwdriver only at the points shown in the fig- ure. 3. Remove the oil pan. Oil pan baffle 1. Insert a screwdriver between the cylinder block and the baffle to separate them. 2. Remove the baffle. Front oil seal Remove the oil seal with a screwdriver protected with a rag. Rear oil seal Remove the oil seal with a screwdriver protected with a rag. Gartner Banana

B DISASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Connecting rod cap Inspection ................. page B-45 2. Lower connecting rod bearing Inspection ................. page 8-45 3. Connecting rod and piston assembly Disassembly Note .......... page 545 4. Upper connecting rod bearing Inspection ................. page 8-57 5. Piston ring Disassembly Note .......... page 545 Inspection ................. page 555 6. Piston pin clip 7. Piston pin Disassembly Note Inspection ................. page 6-45 8. Piston Inspection ................. page 555 9. Connecting rod Inspection ................. page I345 10. Main bearing cap Disassembly Note .......... page 8-46 11. Lower main bearing Inspection ................. page B-46 12. Crankshaft Inspection ................. page 8-46 13. Upper main bearing Inspection ................. page 8-46 14. Thrust bearing Inspection ................. page 6-63 15. Oil jet Inspection ................. page B-53 16. Cylinder block Inspection ................. page 553 Gartner Banana