length MAZDA MX-5 1994 Workshop Manual

IDENTIFICATION NUMBER LOCATIONS/UNITS IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER (VIN) AUTOMATIC TRANSMISSION MODEL AND NUMBER ENGINE MODEL AND NUMBER UNITS Electrical current ............ A (ampere) Electric potential ............ V (volt) Electric power. .............. W (watt) Length ..................... mm (millimeter) in (inches) Negative pressure ........... kPa (kilo Pascal) mmHg (millimeter of mercury) inHg (inches of mercury) Positive pressure ............ kPa (kilo Pascal) kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) Resistance ................. SZ (ohm) Torque ..................... N-m (Newton meter) kgfm (kilogram force per meter) kgfzm (kilogram force per centimeter) ft-lbf (foot pounds) in-lbf (inch pounds) Volume .................... L (liter) US qt (U.S. quart) Imp qt (Imperial quart) Gartner Banana

FUNDAMENTAL PROCEDURES GI ADJUSTMENTS Use suitable gauges and testers when making adjust- ments. RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tubing. HOSE CLAMPS When reinstalling, position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. VISE When using a vise, put protective plates in the jaws of the vise to prevent damage to parkGI-1 3 TORQUE FORMULAS When using a torque wrench-SST combination, the writ- ten torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the for- mula that applies to you. GI-I 3 L&A Unit centimeter centimeter centimeter inch inch Torque Unit N.m kgfm kgfcm ft.lbf in-lbf A = The length of the SST past the torque wrench drive. L = The length of the torque wrench. Formula N,m x [U(L+A)] kgf.m x [U(L+A)] kgfcrn x [U(L+A)] ft4bf x [U(L+A)] in.lbf x [U(L+A)] Gartner Banana

B INSPECTION / REPAIR 8' STEM TIP VALVE FACE MARGIN 1 ANGLE THICKNESST 450 6. Measure the manifold contact surface distortion in the four directions shown in the figure. Distortion: 0.15mm (0,006 in) max. u 7. If distortion exceeds specification, grind the surface or replace the cylinder head. Grinding: 0.20mm (0.008 in) max. VALVE MECHANISM Valve and Valve Guide 1. Inspect each valve for the following. Replace or resur- face the valve if necessary. (1) Damaged or bent stem (2) Rough or damaged face (3) Damaged or unevenly worn stem tip 2. Measure the valve head margin thickness of each valve. Replace the valve if necessary. Margin thickness IN: 0.9mm (0.035 in) EX: 1 .Omm (0.039 in) 3. Measure the length of each valve. Length Standard IN: lOl.89mm (4.0114 in) EX: 101.99mm (4.01 53 in) Minimum IN: 100.39mm (3.9524 in) EX: 100.49mm (3.9563 in) 4. Measure the stem diameter of each valve at the points shown. Diameter IN: 5.970-5.985mm (0.23514.2356 in) EX: 5.965-5.980mm (0,23494.2354 in) Minimum IN: 5.920mm (0.2331 in) EX: 5.9515mm (0.2329 in) 5. Measure the inner diameter of each valve guide at the points shown. Inner diameter IN: 5.99-6.03mm (0.2359-0.2374 in) EX: 5.99--6.03mm (0.23594.2374 in} 6. Calculate the valve stem-to-guide clearance. Subtract the outer diameter of the valve stem from the inner diameter of the corresponding valve guide. Clearance IN: 0.005-0.060mm (0.00024.0023 in) EX: 0.01 O-O.065mm (0.0004--0.0025 in) Maximum: 0.20mm (0.008 in) Gartner Banana

INSPECTION / REPAIR OUT-OF-SQUARE I 9. Measure the valve stem protruding length (dimension L). Dimension L: 45.0mm (1.772 in) (1) If L is 45.0-E.5mm (l.772-l.79l in), no correc- tion is needed. (2) If L is 45.5-46.5mm (1.792-1.830 in), adjust with washer on spring seat area of cylinder head. (3) If L is 46.5mm (1.831 in) or more, replace cylinder head. Valve Spring 1. lnspect each valve spring for cracks or damage. 2. Measure the free length and out-of-square. Replace the valve spring if necessary. Free length Standard: 46.26mm (1.821 in) Minimum length: 39.5mm (1.56 in) with a set load of 224--253 N (22.G25.8 kgf, 50.2-56.7 Ibf) Out-of-square: 1.62mm (0.0638 in) max. CAMSHAFT 1. Set the front and rear journals on V-blocks. 2. Measure the camshaft runout. Replace the camshaft if necessary. Runout: 0.03mm (0.0012 in) max. 3. lnspect the camshaft for wear or damage. Replace the camshaft if necessary. 4. Measure the cam lobe heights at the two points as shown. Height Standard IN: 44.094mm (1,7360 in) EX: 44.600mm (1.7560 in) Minimum IN: 43.894mm (1,7281 in) EX: 44.400mm (1.7480 in) Gartner Banana

INSPECTION I REPAIR 5. Measure each piston ring end gap with a feeler gauge. Replace the piston ring if necessary. End gap \-.l Top: 0.15--0.30mm (0.006--0.011 in) Second: 0.1 54.3Omm (0.006--0.011 in) Oil rail: 0.204.70mm (0.008--0.027 in) Maximum: 1 .Omm (0.039 in) Piston and Piston Pin 1. Measure each piston pin hole diameter in X and Y direc- tions at four points. Diameter: 19.988-20.000mm (0.7870-4.7874 in) 2. Measure each piston pin diameter in X and Y directions at four points. Diameter: 19.987-1 9.993mm (0.7869-4.7871 in) 3. Calculate the piston pin-to-piston clearance. 1 Clearance: -0.005-0.01 3mm (-0.0002--0.0005 in) 4. If the clearance exceeds specification, replace the pis- ton and/or piston pin. CONNECTING ROD 1. Measure each connecting rod bushing inner diameter. Diameter: 20.003-20.014mm (0.7876-0.7879 in) 2. Calculate the clearance between the connecting rod bushing and piston pin. Clearance: 0.01 U.027mrn {O.OOO4--O.OOlO in) 3. Measure each connecting rod for bending. Repair or re- place the connecting rod if necessary. If the connecting rod is replaced, the connecting rod cap, bolts and nuts must also be replaced because they are a matched set. Bending: 0.030mm (0.0012 in) max./100mm (3.94 in) Length (Center to center): 132.85-1 32.9Smm (5.231-5.234 in) Gartner Banana

INSPECTION I REPAIR ee x 25rnrn (1.0 in) min DAMAGE WEAR TIMING BELT Caution The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bending it, or allowing oil or grease on it. 1. Replace the timing belt if there is any oil or grease on it. 2. Check the timing belt for damage, wear, peeling, cracks, and hardening. Replace the timing belt if necessary. TENSIONER, IDLER Caution Using cleaning fluids or a steam cleaner to clean the tensioner can dissolve the grease in its sealed bearing. \.-' Check the tensioner and idler for smooth rotation and abnormal noise. Replace the tensioner or idler if neces- sary. TENSIONER SPRING Measure the free length of the tensioner spring. Replace the tensioner spring if necessary. Free length: 59.2mm (2.331 in) PULLEY Timing Belt Pulley, Camshaft Pulley Inspect the pulley teeth for wear, deformation, and other damage. Replace the pulley if necessary. Gartner Banana

D OIL PUMP PROTECT PUMP BODY WITH RAG OSUODX. Disassembly Note Oil seal Remove the oil seal with a screwdriver protected with a rag. 4 INSPECTION Oil Pressure Spring 1. Inspect the spring for weakness or breakage. 2. Measure the free length. Replace the spring if neces- sary. Free length: 45.94mm (1.809 in) Rotor Clearance Measure the following clearances. Replace the rotor if necessary. Tooth tip clearance: Standard: 0.02-0.18mm (0,0008--0.0070 in) . J Maximum: 0.2mm (0.0079 in) Outer rotor to pump body clearance: Standard: 0.09-0.18mm (0.0036--0.007 in} Maximum: 0.2mm {0.0079 in) Side clearance: Standard: O.O3--O.l2mm (0.001 2-0.0047 in) Maximum: 0.14mm (0,0055 in) 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

TRANSMISSION J Bearing Inspect for damage and rough rotation. Reverse Idler Gear and Shaft 1. Inspect gear teeth for wear and cracks. 2. Measure the clearance between the reverse idler gear b~~shing and shaft. Standard clearance: 0.02-0.05mm {0.000&-0.0020 in) Maximum: 0.15mm (0.006 in) Springs Measure the free length of the springs. Standard free length Shift rod (Sth/Reverse) spring: 75mm (2.953 in) Detent ball spring (lst/2nd, 3rdI4th): 22.5mm (0.886 in) Detent ball spring (Sth/Reverse): 17.0mm (0.669 in) Intermediate housing Measure the intermediate housing pin height. Standard height: 9.0-10.0mm (0.354-0.394 in) Gartner Banana

Bolt length (measured from below the head) @ : 28mm @I : 35mm Adjustment shim Measure the clearance between the countershaft center bearing and the bearing housing. If not within specification, adjust the clearance by instal- i, ling the correct adjustment shim(s). Standard clearance: 04.1 mm (0-4.004 in) Adjustment shim: O.lmm (0.004 in), 0.3mm (0.012 in) Mainshaft front bearing Press the mainshaft front bearing into the bearing hous- ing with a suitable pipe. Outer diameter of pipe: 70.0mm (2.76 in) Adjustment shim Measure the clearance between the mainshaft front bearing and the bearing housing. If not within specification, adjust the clearance by instal- ling the correct adjustment shim(s). Standard clearance: 0-4.1 mm (0--0.004 in) Adjustment shim: O.lmm (0.004 in), 0.15mm (0.006 in), 0.3mm (0.012 in) Reverse idler gear shaft 1. Press the reverse idler gear shaft into the bearing hous- ing. 2. Install and tighten the reverse idler gear shaft installation bolt. Tightening torque: 8.9-12.7 N.m (90-130 kgf.cm, 79-112 in4bf) Reverse idler gear 1. Install the reverse idler gear, end washer, and bearing cover. 2. Tighten the bearing cover installation bolts. Tightening torque @: 18-26 N.m (1.8-2.7 kgf-m, 14--19 ftlbf) @I: 37-53 N.m f3.7-5.5 kgf-m, 27-39 ft4bf) Gartner Banana