engine MAZDA MX-5 1994 Owner's Guide

ON-VEHICLE MAINTENANCE Installation Note Oil seal 1. Apply a small amount of clean engine oil to w new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a pipe and hammer, tap the oil seal in it is flush with the edge of the rear cover. Note Oil seal outer diameter: 100mm (3.94 in} Oil seal inner diameter: 83mm (3.27 in} 45UOBX-049 Steps After Installation 1. Connect the negative battery cable. 2. Start the engine and perform engine adjustments as necessary. the lip of a evenly until Gartner Banana

B REMOVAL REMOVAL Caution Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death -d and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line safety Procedures" on section F. PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E.) 3. Remove the transmission. 4. Remove in the order shown in the figure, referring to Removal Note. Step 1 1. Air cleaner housing assembly 2. Accelerator cable 3. Radiator hose 4. Oil cooler hose 5. Coolant reservoir hose 6. Fan connector 7. Radiator and fan assembly 8. PIS andlor A/C drive belt ................ Removal 9. Alternator drive belt .................. Removal page B- 6 10. PIS oil pump (If equipped) ............. Removal Note page 529 11. AIC compressor (If equipped) Removal Note ............. page 529 1 page B- 6 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

REMOVAL B Step 4 1. Engine mount nut 2. Engine assembly Removal Note Engine assembly Slowly lift the engine assembly as a unit. Keep the en- gine from swinging or bumping into components in the engine compartment. Gartner Banana

B ENGINE STAND MOUNTING ENGINE STAND MOUNTING PREPARATION SST 49 01 07 680A Engine stand Plate (Part of 49 LO1 0 1 AO) 49 LOlO 103 Hooks (Part of 49 LO1 0 1 AO) 49 LO10 105 Bolts (Part of 49 LO1 0 1 AO) For disassembly and assembly of engine For disassembly and assembly of engine For disassembly and assembly of engine For disassembly and assembly of engine 49 LOlO 1AO - Hanger set, fB engine stand &b A Arms (Part of 49 LO1 0 1 AO) 49 LOlO 104 Nuts (Part of 49 LO1 0 1 AO) 8 Bolts (Part of 49 LO1 0 1 AO) For disassembly and assembly of engine For disassembly and assembly of engine For disassembly and assembly of engine For disassembly and assembly of engine Gartner Banana

ENGINE STAND MOUNTING PROCEDURE Ste~ 1 ~emove in the order shown in the figure. O-RING,, REPLACE 1. Exhaust manifold insulator 5. Water inlet pipe 2. Exhaust manifold 6. PIS oil pump bracket (If equipped) 3. Water bypass pipe 7. Idler pulley (NC) (If equipped) 4. NC compressor bracket (If equipped) 8. Left engine mount Step 2 1. Install the SST (engine hanger) using the holes shown in the figure. Gartner Banana

ENGINE STAND MOUNTING 2. Install the SST (arms) to the holes as shown in the fig- ure, and hand tighten the SST (bolts). 3. Assemble the SST (bolts and plate) in the specified position. 4. Assemble the SST (nuts, hooks, and bolts). 5. Install the SST to the respective arms. 6. Adjust the SST (bolts) so that less than 20mm (0.79 in) of thread is exposed. 7. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts). 8. Tighten the SST (bolts and nuts) to affix the SST firmly. 9. Mount the engine on the SST (engine stand). 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 AUXILIARY PARTS 1. Drain the engine oil. 2. Disassemble in the order shown in the figure. 1. Ignition coil and high-tension lead 2. Crankshaft position sensor 3. Manifold bracket 4. Intake manifold assembly 5. Alternator 6. Alternator bracket 7. Right engine mount 8. Oil filter 9. Oil cooler 10. Oil pressure switch 11. Water outlet pipe 12. Spark plug 13. Dipstick and pipe 14. Engine hanger Gartner Banana

ASSEMBLY 6 ASSEMBLY PREPARATION SST 49 0221 061A Remover & installer, piston pin For removal and installation of piston pin 49 EOll 1AO For prevention of engine rotation Ring gear brake set For prevention of engine rotation For prevention of engine rotation 49 EOll 105 Stopper (Part of 49 EOll 1AO) Shaft (Part of 49 E011 1AO) For prevention of engine rotation For installation of clutch disc 49 SEOl 310A Centering tool, clutch disc Collar (Part of 49 E011 1AO) For installation of valve seal 49 LO1 2 OAO For installation of valve seal nstaller :Part of 49 LO1 2 OAO) Installer set, valve seal & valve guide For nstallation of rralve seal For installation of valve seal Body (Part of 49 LO 1 2 OAO) Spacer 'Part of $9 LOI 2 OAO) - -or 'emoval and nstallation of talve For removal / installation of valves irm, valve ;pring lifter Pivot, valve spring lifter 19 801 2 01 2 3ody Part of .9 80 1 2 0A2) -or emoval I nstallation of ralves For removal 1 nstallation of rralves Foot [Part of 49 801 2 0A2) .or emoval / istallation of 'alves .ocknut Part of 9 8012 0A2) Gartner Banana