torque MAZDA MX-5 1994 Service Manual

INSTALLATION B Step 4 Torque Specifications AIC compressor (If equipped) Install the AIC compressor. Tightening torque: 15-21 N-m (1.5-2.2 kgf-m, 11-15 ft-lbf) PIS oil pump Install the PIS oil pump and hand tighten the mounting bolts. 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

D OIL PRESSURE OIL PRESSURE PREPARATION SST 05UODX-008 INSPECTION 1. Remove the oil pressure switch. pressure 2. Screw the SST into the oil pressure switch installation hole. 3. Warm up the engine to normal operating temperature. 4. Run the engine at 1,000 rpm and 3,000 rpm, and note the gauge reading. For inspection of oil pressure Oil pressure: 9kl96 kPa (1.0-2.0 kgf/cm2,15-28 psik1,000 rpm 295492 kPa (3.0-4.0 kgf/cm2, 43-66 psi)-3,000 rpm 5. If the pressure is not as specified, check for the cause and repair. (Refer to Troubleshooting Guide.) 6. Remove the SST and install the oil pressure switch. Tightening torque: 12-17 N-m (1.2-1.8 kgf-m, 9-13 ft-lbf) 45UODX-007 Gartner Banana

ENGINE OIL D ENGINE OIL 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 as 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}. REPLACEMENT Warning When the engine and the oil are hot, they can badly burn. Don't burn yourself with either. 1. Warm up the engine to normal operating temperature and stop it. 2. Remove the oil filler cap and the oil drain plug. 3. Drain the oil into a container. 4. Install a new gasket and the drain plug. Tightening torque: 3041 N-m 13.0-4.2 kgf.m, 22-30 ft-lbf) 5. Refill the engine with the specified type and amount of engine oil. Oil replacement: 3.6 L 13.8 US qt, 3.2 Imp qt) 6. Refit the oil filler cap. 7. Run the engine and check for leaks. 8. Check the oil level and add oil if necessary. Gartner Banana

OIL PAN NOTCH NOTCH I 05UODX-209 Steps After Installation 1. Install the undercover. Oil pan 1. Remove all foreign material from the contact surfaces. 2. Apply silicone sealant to the shaded areas shown in the figure. 3. Install new gaskets onto the oil pump body and the rear cover with the projections in the notches shown in the fig- ure. 4. Apply a continuous bead of silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends. 5. Install the oil pan with five minutes. Tightening torque 0: 7.9-10.7 N.m (80-110 kgf-cm, 70-95 in4bf) @: 64-49 N.m (6.5-9.1 kgf-m, 48-45 ft-lbf) 2. Connect the negative battery cable. 3. Fill with the specified amount and type of engine oil. (Refer to page D-5.) 4. Start the engine and check for leaks. 5. Check the oil level and add oil if necessary. Gartner Banana

Neutral swltch (MT) 7 PCV valve Powertrain control mod- ule (engine) (PCME) Purge solenoid valve Resonance chamber Steering pressure sen- Stoplight swltch I Throttle posltion sensor r [Two-way check valve Function jetects amount of intake air; sends signal to powertrain :ontrol module (engine) Li~ht illuminates when input device malfunctions - Light flashes to indicate trouble code number of input and output devices Detects in-gear condition; sends signal to powertrain :ontrol module (engine) - Controls blow by aas amount introduced into engine Detects the followlng: 1. A/C operation 2. Airlfuel ratio (Oxygen concentration) 3. Barometric absolute pressure 4. Braking signal 5. Cranking signal 6. EIL operation 7. Engine coolant temperature 8. Engine speed 9. In-gear condition 10. lntake air amount 11, lntake air temperature 12. No.1 piston TDC 13. PIS operation 14. Initial set signal 15. Throttle valve opening angle Controls operatlon of the followlng: 1. AIC (Cut off) 2. Fail-safe function 3. Fuel injection system 4. ldle speed control 5. Ignition timing control system 6. Monitor function 7. Purge control system 8. Lockup control svstem Controls vacuum to pressure regulator -- Adjusts fuel pressure supplied to fuel injectors Controls evaporative fumes from canister to intake man- ifold -- lm~roves mid-ranae torque characteristics -. Detects PIS operation; sends signal to powertrain con- trol module (engine) -- Detects braking operation (deceleration); sends signal to powertrain control module (engine) Reduces HC, CO, and NOx by chemical reaction Controls pressurein fuel tank Controls intake air quantity Detects position of the throttle valve closed throttle posi- tion; sends signal to powertrain control module (engine) Detects the throttle valve opening at a preset angle; sends si~nal to powertrain control module (engine) controls pressure in fuel tank Remark lntake air temperature sensor and fuel pump switch included Use Vref (5 volt) as power source ' Data link connector terminal TEN ' Data link connector terminal TEN Switch ON when in neutral 1, Air conditioning sesnor 2. Heated oxygen sensor 3. Barometric absolute pressure sensor 4. Stoplight switch 5. Ignition switch (START position) 6. Coolant fan relay Light and turn relay Blower switch 7. Engine coolant temperature sensor 8. Crankshaft position sensor (SGT-signal) 9. Neutral and dutch switches (MT) Parklneutral switch (AT) 10. Mass airflow sensor 11, lntake air temperature sensor 12. Crankshaft position sensor (SGC-signal) 13. Steering pressure switch 14. Data link connector 15. Throttle position sensor 1. NC relay 2. Self-diagnosis checker and MIL 3. Fuel injector 4. IAC valve 5. Igniter 6. Monitor lamp (Self-diagnosis checker) 7. Purge solenoid valve 8. Powertrain control module (transmission) (AT) D Controlled by duty signal from powertrain control module (engine) D PIS: ON when steering wheel turned Monolith type D Integrated throttle position sensor, Idle air control valve, and dashpol Gartner Banana

TROUBLESHOOTING GUIDE F 18 ENGINE STALLS DURING START-UP DESCRIPTKlN I Engine unexpectedly stops running while starting VROUBLESHOOTING HINTS] @ Misfire occurs when depressing accelerator Q Lack of engine torque for start-up AirIFuel mixture too rich or too lean AirIFuel mixture too rich or too lean Incorrect ignition timing Weak ignition INSPECTION Check if brakes are dragging Section P Check if "00 is displayed on Self-Diagnosis Check- er with ignition switch ON * page F-79 SELECT SW A Check switches for correct operation with Self- Diagnosis Checker Monitor Lamp and ignition switch ON @ page F-95 Disconnect heated oxygen sensor connector and :heck if condition improves SENSOR CONNECTOR -3 I I - Yes - No Yes Yes No - Yes Low intake air amount Low en~ine com~ression ACTION Repair us Section P Go to next step Go to next step -- Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) page F-81 "88" flashes Check PCME terminal 1 E voltage us page F-145 Specification : Battery positive voltage (Ignition switch ON) If OK, replace PCME rc+r page F-143 6 If not OK, check wiring between PCME and Self-Diagno- sis Checker e page F-7 Go to next step Lamp not ONIOFF with specified switch Check for cause (Refer to specified check sequence) uw page F-96 Lamp always ON Check wiring between PCME terminal 1 D and Self-Diag- nosis Checker page F-7 Check heated oxygen sensor @s page F-156 Go to next step Gartner Banana

ENGINE TUNE-UP 8. If the marks are not aligned, remove the ignition coil bracket and push the ignition coil aside for easy access and then loosen the crankshaft position sensor lock bolts, and turn the crankshaft position sensor to make the adjustment. 9. Tighten the distributor lock bolts to the specified torque. Tightening torque: 19-25 N-m (1.9-2.6 kgfem, 14--18 ftqlbf) 10. After adjusting the ignition timing, disconnect the jumper wire or SST from the data link connector. 11. Increase the engine speed and verify that the ignition timing advances. 12. Verify that the ignition timing is within the specification. Ignition timing: BTDC 6-18' ldle Speed 1. Perform Preparation. (Refer to page F-76.) 2. Set switch A to position 1. 3. Set test switch to SELF TEST. 4. With the coolant fan off, verify that the idle speed is within specification. ldle speed (Neutral): 800-900(850 + 50) rpm [MT] (P range): 750--850(800 -c 50) rpm [AT] 5. If not within the specification, adjust the idle by turning the air adjusting screw. 6. Disconnect the SST. Gartner Banana

INTAKE AIR SYSTEM THROTTLE VALVE 45UOFX442 THROTTLE BODY Removal 1. Remove the negative battery terminal. 2. Remove the air pipe. 3. Remove the accelerator cable from the throttle lever. Note Before disconnecting the water hoses, drain the en- gine coolant. 4. Disconnect the water hoses. 5. Disconnect the connectors for the idle air control valve and the throttle position sensor. 6. Remove the throttle body. Inspection Do not remove the thin sealing coating from the throttle valve or bore. 1. Verify that the throttle valve is closed throttle position. 2. Verify that the throttle valve moves smoothly when the throttle lever is moved from closed throttle position to wide open throttle. 3. Replace the throttle body if necessary. Installation Install in the reverse order of removal, using a new mounting gasket. Tightening torque: 19-25 N.m (1.G2.6 kgf.m, 14--18 ftlbf) Gartner Banana

INTAKE AIR SYSTEM INTAKE MANIFOLD Removal Warning e Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures" on page F-108. 1. Remove the throttle body. (Refer to above.) 2. Disconnect the vacuum hoses. 3. Remove the accelerator cable. 4. Disconnect the fuel hoses. 5. Disconnect the connectors from the fuel injectors. 6. Remove the fuel distributor and fuel injectors. 7. Remove the injector harness. 8. Remove the intake manifold bracket. 9. Remove the intake manifold. Installation Install in the reverse order of removal, using a new mounting gasket. 4 Tightening torque Intake manifold and fuel distributor: 19-25 N.m (1.9--2.6 kgf-m, 14--18 ft4bf) Injector harness and bracket: 7.9-1 0.7 N-m 180-110 kgf,cm, 70-95.4 in4bf) Gartner Banana