timing belt MAZDA MX-5 1994 Owner's Manual

ASSEMBLY B I I 35UOBX477 TIMING BELT Torque Specifications 3. Install the camshaft pulley lock bolts. 4. Hold the camshaft with a wrench. 5. Tighten the camshaft pulley lock bolt. Tightening torque: 50-40 N.m (5.0-6.2 kgf.m, 3744 ft-lbf) Gartner Banana

B ASSEMBLY TIMING MARK Timing Belt Pulley 1. lnstall the timing belt pulley. 2. lnstall the pulley woodruff key with the tapered side to- ward the oil pump body. d Idler lnstall the idler. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ftlbf) Tensioner and Tensioner Spring 1. lnstall the tensioner and the tensioner spring. 2. Temporarily secure the tensioner with the spring fully ex- tended. Timing Belt 1, Turn the crankshaft and align the timing belt pulley mark with the timing mark. Do not turn the crankshaft counter- clockwise. 2. Verify that the camshaft pulley marks are aligned with the seal plate marks. E for intake side and I for exhaust side. Do not turn the crankshaft counterclockwise. 3. lnstall the timing belt so that there is no looseness at the idler side or between the two camshaft pulleys. 4. lnstall the pulley boss and pulley lock bolt. 5. Turn the crankshaft two turns clockwise, and align the timing belt pulley mark with the timing mark. Do not turn the crankshaft counterclockwise. 6. Verify that the camshaft pulley marks are aligned with the seal plate marks. J If not aligned, remove the timing belt and repeat from tensioner installation. Gartner Banana

ASSEMBLY B r/ DEFLECTION %HECKING POINT , 7. Reverse the direction of the SST on the flywheel (MT) or drive plate (AT). 8. Tighten the pulley lock bolt. Tightening torque: 157-166 N-m (16-17 kgf.m, 116-122 ft-lbf) 9. Turn the crankshaft 1 and 516 turns clockwise, and align the timing belt pulley mark with the tension set mark. 10. Loosen the tensioner lock bolt to apply tension to the tim- ing belt. 11. Tighten the tensioner lock bolt. Tightening torque: 38-51 N-m (3.8-5.3 kgf-m, 28-38 ft4bf) 12. Turn the crankshaft 2 and 116 turns clockwise and verify that the timing marks are correctly aligned. 13. Measure the timing belt deflection by applying moderate pressure 98 N (10 kgf, 22 Ibf) midway between the two camshaft pulleys. If the deflection is not correct, repeat from step 7 above. Deflection: 9.0-11.5mm (0.36-0.45 in) at 98 N (1 0 kgf, 22 Ibf) Timing Belt Cover Install the lower, middle, and upper covers. Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in4bf) Gartner Banana

B INSTALLATION ALTERNATOR Drive belt 1. lnstall the alternator drive belt. (Refer to page B-5.) 2. lnstall the PIS and/or AIC drive belt. 3. Adjust the drive belt deflection, and tighten the alternator - and PIS mounting bolts and nuts. (Refer to page 8-7.) Radiator and coolant fan assembly 1. lnstall the radiator and coolant fan assembly. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft4bf) 2. lnstall the AIC pipe bracket to the radiator Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in4bf) 3. Connect the upper and lower radiator hoses. 4. Connect the coolant reservoir hose. 5. Connect the coolant fan motor connector. Steps After Installation 1. lhstall the transmission. (Refer to sections J, K.) 2. lnstall the under cover. 3. If the engine oil was drained, fill with the specified amount and type of engine oil. (Refer to section D.) 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E.) 5. If the transmission oil was drained, fill with the specified amount and type of transmission oil. (Refer to sections J, K.) 6. Connect the negative battery cable. 7. Start the engine and check the following. (1) Engine oil, transmission oil, and engine coolant leakage (2) Ignition timing, idle speed (Refer to page 59.) (3) Operation of emission control system 8. Perform a road test. 9. Recheck the engine oil and engine coolant levels. Gartner Banana

WATER PUMP WATER PUMP REMOVAL I INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to page E-5 for WARNING and procedure) 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal. 1. Timing belt 4. Water pump Service . . . . . . . . . . . . . . . . . . . . . Section B Inspect for cracks, damaged mounting sur- 2. PIS oil pump face, bearing condition, and leakage. Removal Note . . . . . . . . . . . . . . page E-1 1 If the water pump is damage, replace it. 3. Water hose Do not repair it. 5. Water inlet pipe Gartner Banana

ENGINE TUNE-UP - TIMING LIGHT - 45UOFX422 GND Irnr Air Cleaner Element Inspection 1. Check the air cleaner element for excessive dirt and for oil and damage. Caution Cleaning the element with compressed air will re- duce the element's ability to filter the air. Don't use compressed air to clean the element. 2. Replace the element if necessary. ADJUSTMENT Preparation 1. Warm up the engine to normal operating temperature. 2. Turn all electric loads OFF. Headlight switch Blower switch Rear window defroster switch 3. Connect the SST to the data link connector. 4. Connect a timing light to the engine. 5. Connect a tachometer to the data link connector terminal IG- as shown. Ignition Timing 1. Perform Preparation. (Refer to above.) 2. Verify that the idle speed is within the specification; if not, adjust it. Idle speed 4 (Neutral): 800-900 (850 + 50) rpm [MT] (P range): 750-850 (800 & 50) rpm [AT] 3. Set switch A to position 1. 4. Set test switch to SELF TEST. 5. If the SST is not used, connect a jumper wire between the TEN terminal and the GND terminal of the data link connector. 6. Verify that the idle speed is within the specification. ldle speed (Ground the terminal TEN): 650-975 rpm 7. Verify that the timing mark (white) on the crankshaft pulley and the mark on the timing belt cover are aligned. lgnition timing: BTDC 9"-11" (10" & lo) 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 ELECTRICAL SYSTEM INDEX ....................................... G- 2 OUTLINE ..................................... G- 3 SPECIFICATIONS ........................... G- 3 TROUBLESHOOTING GUIDE .................. G- 4 CHARGING SYSTEM .......................... G- 6 PREPARATION ............................. G- 6 CIRCUIT DIAGRAM ......................... G- 6 TROUBLESHOOTING ....................... G- 7 BATTERY .................................. G- 8 ALTERNATOR .............................. G-10 DRIVE BELT ................................ G-13 IGNITION SYSTEM ............................ G-15 PREPARATION ............................. G-15 CIRCUIT DIAGRAM ......................... G-15 TROUBLESHOOTING ....................... G-16 IGNITION TIMING ........................... G-17 SPARK PLUG ............................... G-18 IGNITION COIL ............................. G-19 IGNITER ................................... G-19 HIGH-TENSION LEAD ....................... G-20 STARTING SYSTEM ........................... G-21 CIRCUIT DIAGRAM ......................... G-21 TROUBLESHOOTING ....................... G-21 STARTER .................................. G-22 STARTER INTERLOCK SWITCH (MT) ......... G-28 45UOGX401 Gartner Banana

OUTLINE OUTLINE SPECIFICATIONS (i.e. powertrain control module (engine), audio, etc.) *2 With System Selector (49 B019 9AO) test switch at SELF TEST. - Engine Item Starter Ignition system Cylinder Arrangement Battery BP DOHC MT I AT 12, Negative ground S46A24L(S) (32 Ah) Maintenance-free 20.0 A.C. I REAR Voltage V Type and capacity (5-hour rate) 12-65 -. 1 2-70 Drive belt deflection mm {in} Dark current" m A Transistorized (built-in voltage regulator) 14.3-1 4.9 21.5 I0.846) 8 (0.31 1 Ignition timing** BTDC ("CA)lrpm U Alternator 'I Dark current is the constant flow of current while the ignition switch is OFF. 45UoGX-003 New Used 101850 Ignition coil Spark plug FRONT 55-7.0 (0.22-0.27) 6.0-7.5 (0.2H.29) 101800 TY pe Primary coil winding n Secondary coil winding kR Type Plug gap mm {in) Firing order Type Output V-A Regulator type Regulated voltage V TY pe Output V-kW Molded (with igniter) - 8.7-1 2.9 (20°C (68°F)) NGK : BKR5E-11 BKR6E-11 (Standard ... MT) NIPPONDENSO : K16PR-U11 K20PR-U11 (Standard ... MT, AT) 1 .O-1.1 IO.040-0.043) 1-3-4--2 Brush length mm {in) Direct 124.95 17.0 i0.67) 11.5 I0.45) Brush length mm {in} Standard Minimum Coaxial reduction 12-1.4 17.5 i0.69) 12.0 i0.47) Standard Minimum Electronic spark advance (ESA) Powertrain control module (engine) controls spark advance Type Spark advance control Gartner Banana

TD TECHNICAL DATA A. MEASUREMENTS I Item I Measurements I B. ENGINE Overall length mm {in) Overall width mm (in) Overall height mm {in) Wheelbase mm {in) 3,948 (1 55.4) 1,676 i65.9) 1,224 I48.2) 2,266 I89.2) 1,410 (55.5) 1,428 (56.2) Tread - ltem Tvoe u Front mm (in) Rear mm {in) BP DOHC Gasoline. 4-cvcle . In-line, 4-cylinders Pentroof DOHC, belt-driven 16 valves 83.0 x 85.0 {3.27 x 3.35) 1,840 (1,840, 11 2) 9.0 1,255 {I 2.8, 1823-300 883 (9.0, 1281-300 196 {2.0, 28) s. Cylinder arrangement and number Combustion chamber Valve system Bore x Stroke mm {in] Total piston displacement ml {cc, cu in) Compression ratio Valve timing Compression pressure kPa (kgflcm2. psil-r~m I Valve and valve auide I Standard Minimum Maximum difference between each cvlinder - - IN openz (BTDCO) Close (ABDCO) Open (BBDCO) EX close (ATDC") Valve clearance mm {in) Cylinder head 5 48 56 14 IN 133.8-1 34.0 i5.268-5.275) 0.1 0 {0.004) max. 0.10 {0.004) max. 0.02G0.066 {0.0010-0,0025) 0.18 {0.0071) Height mm (in) Distortion mm {in) Grinding mm {in) - 0: Maintenance-free Cylinder head-to-HLA clearance mm (in} Valve head diameter mm Iin) Valve head margin thickness mm {in} Valve face angle I Valve seat 1 u Standard Maximum Valve length mm {in) EX IN EX IN EX IN EX Standard Minimum Standard Minimum IN EX IN EX 5.99--6.03 iO.2359--0.2374) 0.005--0.060 (0.0002-0.0023) 0.01 b0.065 (0.0004-0,0025) 0.20 {0.008} 18.3-1 8.9 {0.7214.744) 18.3-1 8.9 (0.721-0.744) Guide inner diameter mm (in) 0: Maintenance-free 32.9-33.1 {I .296--1.303) 27.85-28.15 {I .097-1 .I 08) 0.9 {0.035) 1 .O (0.039) 45" 45" 101.89 {4.0114} 100.39 {3.9524) 101.99 (4.0153) 100.49 (3,9563) 5.970-5.985 {0.2351-0.2356) 5.96G5.980 l0.2349-0.2354) Valve stem diameter mm {in) Valve stem-to-guide clearance mm (in) Guide projection (Height "A) mm {in) Seat angle IN EX Maximum IN EX IN 45" EX 45" Gartner Banana

TECHNICAL DATA TI) G. ENGINE ELECTRICAL SYSTEM )ark current*' - Engine tem Voltage V 3attery Type and capacity (5-hour rate) Starter -. . BP DOHC MT mA 1 20.0 AT Tvm Ignition system 12, Negative ground S46A24L(S) (32 Ah) Maintenance-free A.C. ST- Output V-A Regulator type Regulated voltage V 12-65 Brush length mm {in) Drive belt deflection mm {in) 17.5 (0.69) 12.0 (0.471 - -- r-- I I hPe Spark plug 1 2-70 Standard Minimum New Used Brush length mm {in) BKR6E-11 (Standard ... MT) NIPPONDENSO : K16PR-U11 K20PR-U11 (Standard ... MT, AT) TYW OU~DU~ V-kW Standard 1 17.0 I0.67) Minimum 1 11.5 10.451 1 Type Spark advance control Ignition timing*2 BTDC ("CA)/rpm Transistorized (built-in voltage regulator) 14.3-1 4.9 21.5 (0.85) 8 I0.31) 5.5-7.0 {0.22--0.27) 6.0-7.5 {0.24--0.29) . . I . . Electronic spark advance (ESA) Powertrain control module (engine) controls spark advance Ignition coil H. CLUTCH Direct lot850 TY ~e Primary coil winding a Secondary coil winding ks2 . .- - Engine Item BP DOHC 1 Coaxial reduction 10/800 Molded (with igniter) - 8.7-1 2.9 NGK : BKR5E-11 *I Dark current is the.constant flow of current while the ignition switch is OFF. (i.e. powertrain control module (engine), audio, etc.) '2 With System Selector (49 B019 9AO) test switch at SELF TEST. , Plug gap mm (in) Firing order 124.95 1 .O-1.1 {0.040--0.043) 1-342 Clutch control Runout limit mm {in) 1 0.2 (0.008) I 12-1.4 Hydraulic Clutch pedal TYP Suspended A .- 6.13 120 (4.72) 175--185 {6.89--7.28) 0.G3.1 (0.02-0.12) 68 I2.68) Pedal ratio Full stroke mm {in) Height (with carpet) mm (in} Free play mm {in} Distance to carpet when clutch fully disengaged rnm [in Minimum Gartner Banana