maintenance MAZDA MX-5 1994 Owner's Manual

ON-VEHICLE MAINTENANCE -- 1. Air cleaner housing assembly 2. Accelerator cable Installation Note ............. section E ,, 3. Hoses Removal / Installation Note ....... below 4. Harnesses Removal / lnstallation Note . . page El 8 5. Exhaust manifold insulator 6. Water bypass pipe nut Removal Note ............. page El8 7. Timina belt ~&moval/ Installation ....... page 51 2 Removal / lnstallation Note Hoses Disconnect the hoses shown in the figure. 8. Front exhaust pipe 9. Manifold bracket 10. Cylinder head bolt Removal Note ............. page 518 Installation Note ........... page 519 11. Cylinder head Disassembly .............. page 539 Inspection ................. page B-47 ................. Assembly page 6-69 12. Cylinder head gasket 45UOBX-035 Gartner Banana

ON-VEHICLE MAINTENANCE Harnesses Disconnect the harness connectors shown in the figure. Removal Note Water bypass pipe 1. Remove the exhaust manifold nut as shown in the figure. 2. Remove the water bypass pipe from the cylinder head assembly. 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. 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 HLA Removal / lnstallation 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E.) 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to lnstallation Note. 1. Timing belt Removal / Installation ....... page 51 2 2. Crankshaft position sensor Installation Note ............. section G 3. Camshaft pulley Removal Note ............. page 521 Installation Note ........... page 522 4. Camshaft Removal Note ............. page B-21 Installation Note ........... page B-21 5. HLA 1 Removal Note ............. page B-21 Installation Note ........... page B-21 Inspection ................. page B-53 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

B ON-VEHICLE MAINTENANCE I - DOWEL PINS I 3. Apply silicone sealant to the shaded areas shown in the figure. Do not let any sealant get on the sealant surfaces. 4. Install the camshaft caps according to the cap number and arrow mark. 5. Install the camshaft cap bolts and tighten them in two or three steps in the order shown in the figure. Tightening torque: 11.3-1 4.2 N.m (115--145 kgf.cm, 100-125 in-lbf} ii 6. Apply a small amount of clean engine oil to the lip of a new camshaft oil seal. 7. Push the oil seal slightly in by hand. 8. Using a pipe and hammer, tap the oil seal in evenly until it is flush with the edge of the camshaft cap. Note Oil seal outer diameter: 48mm {I .89 in) Oil seal inner diameter: 34mm {I .34 in} Camshaft pulley 1. Turn the camshafts until the camshaft dowel pins face straight up. 2. Install the camshaft pulleys with the I mark (intake side) or the E mark (exhaust side) straight up. 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

B ON-VEHICLE MAINTENANCE FRONT OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove the under cover. 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to lnstallation Note. 1. Timing belt 3. Oil seal i Removal / Installation ....... page B-12 Removal Note ............. page 525 2. Timing belt pulley Installation Note ........... page B-25 Installation Note ........... page 8-25 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

B ON-VEHICLE MAINTENANCE REAR OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove the transmission. (MT Refer to section J. AT: Refer to section K.) 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to lnstallation Note. Nm (kgfm, ft-lbf) I 1. Clutch cover, clutch disc (MT) 4. Oil seal Removal / Installation ......... section H Removal Note .................. below 2. Flywheel (MT) Installation Note ........... page 6-27 ......... Removal / Installation section J 3. Drive plate (AT) ......... Removal / Installation section K Removal Note Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. 05UOBX-063 Gartner Banana