torque MAZDA MX-5 1994 Workshop Manual

GENERAL INFORMATION SAFETY INFORMATION ...................... GI- 2 LUBRICANTS .............................. GI- 2 JACKING POSITIONS ...................... GI- 2 SAFETY STAND POSITIONS ................ GI- 2 VEHICLE LIFT POSITIONS .................. GI- 3 DYNAMOMETER ........................... GI- 3 COMPRESSED AIR ........................ GI- 3 HOW TO USE THIS MANUAL ................. GI- 4 ADVISORY MESSAGES .................... GI- 4 PREPARATION ............................ GI- 4 REPAIR PROCEDURE ...................... GI- 4 SYMBOLS ................................. GI- 5 IDENTIFICATION NUMBER LOCATIONS ....... GI- 6 UNITS ...................................... GI- 6 ABBREVIATIONS ............................ GI- 7 SAE STANDARDS ........................... GI- 8 FUNDAMENTAL PROCEDURES ............... GI-11 PROTECTION OF THE VEHICLE ............ GI-11 PREPARATION OF TOOLS AND MEASURING EQUIPMENT ............................. GI-11 SPECIAL TOOLS ........................... GI-11 REMOVALOF PARTS ...................... GI-11 DISASSEMBLY ............................ GI-11 REASSEMBLY ............................. GI-1 2 ADJUSTMENTS ............................ GI-13 RUBBER PARTS AND TUBING .............. GI-13 HOSE CLAMPS ............................ GC13 TORQUE FORMULAS ...................... GI-13 VISE ...................................... GI-13 ELECTRICAL TROUBLESHOOTING TOOLS ... GI-14 TEST LIGHT ............................... GI-14 JUMPER WIRE ............................ GC14 VOLTMETER .............................. GI-14 OHMMETER ............................... GI-14 ELECTRICAL PARTS ......................... GI-1 4 BATTERY ................................. GI-1 4 BATTERY CABLE .......................... GI-1 5 CONNECTORS ............................ GI-15 TERMINALS ............................... GI-16 SENSORS. SWITCHES. AND RELAYS ....... GI-17 WIRING HARNESS ......................... GI-17 FUSE ..................................... GI-17 INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEM ................................... GI-18 AUDIO ANTITHEFT SYSTEM ................. GI-18 TOWING .................................... GI-19 45UGIX-001 Gartner Banana

GI HOW TO USE THIS MANUAL HOW TO USE THlS MANUAL ADVISORY MESSAGES You'll find several Warnings, Cautions, and Notes in this manual. Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note A Note provides added information that will help you to complete a particular procedure. PREPARATION This points out the needed SSTs for the service operation. It is best to gather all necessary SSTs before beginning work. Example: 46UGIX-013 REPAIR PROCEDURE MANUAL STEERING PREPARATION SST NUMBER USAGE SST 1 1 Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. If a damaged or worn part is found, repair or replace it as necessary. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the over- view illustration. Pages related to service procedures are shown under the illustration. Refer to this information when servicing the related part. 46UGIX-014 I id' I SST NAME SST ILLUSTRATION For removal of t~e rod end 49 01 18 850C Puller, ball pnt 49 01 18 850C For removal of t~e rod end Gartner Banana

HOW TO USE THIS MANUAL Example: SHOWS EXPENDABLE PARTS SHOWS APPLICATION POINT OF OIL, ETC SHOWS RELATED PAGE FOR. SERVICE SELECTIVE 1. 8011 2. Lock plate 3. Bearing cup t. Adjusting screw 5. Bearing outer race 5. Locknul 16. Bearing inner race 18. drive pinion 1. Washer Removal ..................... .. .... page M-2' SHOWS TIGHTENING TORQUE SPECIFICATIONS *2 SHOWS TIGHTENING TORQUE UNIT -SHOWS VISUAL INSPECTION INFORMATION *1: The numbers (0, etc.) refer to part identification and servicing procedures. *2: Units are in N.m {kgf.m, ftlbf} unless otherwise specified. $ L SYMBOLS There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such materials during service. Symbol I Meaning ~pp~y oil Apply brake fluid I Apply automatic transmission fluid Apply grease Apply sealant Kind 0 New engine oil or gear oil as appropriate Apply petroleum jelly Appropriate grease Appropriate sealant Appropriate petroleum jelly Gartner Banana

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

ABBREVIATIONS 4BDC .... 4BS ...... 4CC ...... 4T ........ 4TDC ..... 4TF ...... 4TS ...... 3AC ...... 3BDC .... 3TDC ..... :ID ....... 2U ....... IOHC .... IRL ...... ITM ...... IC-AT .... iGRA .... EGRV .... ELR ...... EPC ...... ESPS ..... ETS ...... EX ....... FMEM .... HFC ...... HLA ...... H U ....... IC ........ IG ........ IN ........ INT ....... LFC ...... LH ....... LSD ...... M ........ MAF RTN . MT ....... PCTS ..... PCV ...... PIP ....... PRC ...... PIS ....... PMI ...... PWR GND RH ....... RPM ...... RTS ...... SIG RTN . . SLS ...... ... SPOUT S R ....... SST ...... ST ....... SW ....... TDC ...... TNS ...... TRS ...... VPWR .... WSS ..... WTS...... After bottom dead center Antilock brake system Accessory Automatic transmission After top dead center Automatic transmission fluid Ambient temperature sensor Bypass air control Before bottom dead center Before top dead center Cylinder identification display Control unit Double overhead camshaft Daytime running light Diagnostic test mode Electronically controlled automatic transmission EGR air solenoid valve EGR vacuum solenoid valve Emergency locking retractor Electronic pressure control Engine speed sensing power steering Evaporator temperature sensor Exhaust Failure mode effects management High fan control Hydraulic lash adjuster Hydraulic unit Integrated circuit Ignition Intake Intermittent Low fan control Left hand Limited slip differential Motor Mass airflow return Manual transmission Passenger compartment temperature sensor Positive crankcase ventilation Profile ignition pickup Pressure regulator control Power steering Power window Power ground Right hand Revolutions per minute Reduce torque signal Signal return Slip lockup signal Spark output Sensor rotor Special service tool Start Switch Top dead center Tail number side (taillights, license plate lights and side marker lights) Torque reduced signal Vehicle power Wheel speed sensor Water temperature sensor Gartner Banana

SAE STANDARDS Engine and Emission Systems (cont'd) I Previous Standard I SAE Standard b I - Abbreviation ( Name I Oxvaen Sensor - .w- - I I ." I 02s I Oxygen Sensor I - PTC Reed Valve Relief 1 Solenoid Valve Secondary Air lnjection System - Seauential Fuel lniection SMFl L - Service Code(s) DTC - Spark Ignition Dl - Supercharger SC Abbreviation I Name Open Loop Positive Temperature Coefficient Hnatar Secondarv Air Pulse Valve Remark . .--.-. Pressure Sensor Secondary Air Bypass valve Pulsed Secondarv Air lniection H02S I Heated Oxvaen Sensor I With heater OL EFE Secondary Air lnjection Sequential Multipoint Fuel lnjection Diagnostic Trouble Code(s) Open Loop Early Fuel Evaporation MAP MVS Distributor lgnition Supercharger Manifold Absolute Pressure Sensor Manifold Vacuum Sensor I - - - - - - Checks vacuum only Pulsed iniection - Switching Solenoid Valve Test Mode(s) Three Way Catalyst Throttle Body Throttle Sensor Turbocharaer .. Maifold Differential Pressure Manifold Vacuum Zone Switch , - I - 1 VAC I MDP 1-1 Water Thermosensor L - I Vacuum Switch I ECTS I Engine Coolant Temperature Sensor I SASV DTM TWC TB TPS TC MVZS #6: Supplies air to three way catalyst #7: Diagnostic trouble codes depend on the test mode - Secondary Air Switching Valve Diagnostic Test Mode(s) Three Way Catalyst Throttle Body Throttle Position Sensor Turbocharaer Transmission (Transaxle) and Steering System L - - Previous Standard I I I I Abbreviation - - - SAE Standard Fully Open Inhibitor Switch - I Lock-up Position - - Name Clutch Position EC-AT Control Unit Fullv Closed Abbreviation CPP PCMT CTP TCC I Torque Converter Clutch - - - WOT PNS Output Signal(s) Overdrive I Name Clutch Pedal Position Powertrain Control Module (Transaxle) Powertrain Control Module (Transmission) Closed Throttle Position Wide Open Throttle ParWNeutral Switch Power Steering Pressure Switch Pulse Generator Vehicle Speed Sensor - 1 3rd Gear Remark FF FR PTCS 4GR 3GR I Third Gear Powertrain Control Signal(@ Fourth Gear SPS VSPG VSS Steering Pressure Sensor Vehicle Speed Pulse Generator Vehicle Speed Sensor Gartner Banana

FUNDAMENTAL PROCEDURES 1. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. 2. Arrangement of parts All disassembled parts should be carefully arranged for reassembly.Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. 3. Cleaning parts for reuse All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. Warning Using compressed air can cause dirt and other ,, particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using com- pressed air. REASSEMBLY Standard values, such as torques and certain adjust- ments, must be strictly observed in the reassembly of all parts. Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in section TD for tightening torques not men- tioned in the main text. If removed, these parts should be replaced with new ones: 1. Oil seals 4. Gaskets 2. O-rings 5. Lock washers 3. Cotter pins 6. Nylon nuts Depending on location: 1. Sealant should be applied to gaskets. 2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the pre- scribed locations (such as oil seals) before reassembly. 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 INDEX INDEX 1. Timing belt Removal / Installation ....... page 8-1 2 2. Cylinder head gasket Replacement .............. page 6-1 6 3. HLA Removal / Installation ....... page 8-20 4. Front oil seal Replacement .............. page 6-24 5. Rear oil seal Replacement .............. page 6-26 INTAKE MANIFOLD COMPRESSION INSPECTION, PAGE B-10 TIGHTENING TORQUE STANDARD: 1,255 kPa (1 2.8 k f/cm2, 182 psi)-300 rpm 19-25 Nm (1.9-2.6 kgfq 14--18 ft4bf) MINIMUM: 883 kPa (9.0 kgflcm 9 , 128 psi}-300 rpm TIGHTENING TORQUE 3946 Nm i3.9--4.7 kgf m, 29-33 ftdbf) DRIVE BELT ADJUSTMENT. PAG ENGINE OIL INSPECTION, SERVICE, SECTION D DEFLECTION mm (in) ENGINE COOLANT INSPECTION, 6. Engine Removal .................. page 8-28 Engine stand mounting ..... page 6-32 Disassembly .............. page 6-35 Inspection / Repair ......... page B-47 Assembly ................. page 559 Engine stand dismounting ... page 8-81 , Installation ................ page B-83 SERVICE, SECTION E DRIVE BELT ALTERNATOR PIS. PIS + AlC AlC NEW 55-7.0 (0.224.27) 8.&9.0{0.324.35] 8.0-9.0{0.324.35) USED 6.0-7.5 (0.24-0.29) 9.0-10.0{0.364.39) 9.0-10.0{0.364.39} LIMIT 8.0 (0.31) 11.5 (0.45) 11.5 (0.453 Gartner Banana

ENGINE TUNE-UP B 2 ADJUSTING BOLT LOCKNUT Tension N {kgf, lbfl I Drive belt New* Used I Limit I A belt that has been on a running engine for less than five minutes. 45UOBX-011 Alternator PIS, PIS + A/C AIC Adjustment (1) Alternator belt Loosen the alternator bolts @J and @ and adjust the belt deflection by turning the adjusting bolt 0. Tightening torque @: 19-25 N-m {I .9-2.6 kgf.m, 14-18 ft4bf) @: 38-51 N-m (3.8-5.3 kgf.m, 28-38 ft4bf) 491 -745 (50-76, 11 0-1 67) 491-588 (50-60, 11C-132) 49 1-588 (50-60, 11 0-1 32) (2) PIS belt, PIS + A/C belt Loosen the PIS oil pump bolt @ and nuts @ and @ and adjust the belt deflection by turning the adjusting bolt @. Tightening torque @: 3246 N.m (3.24.7 kgf.m, 24-33 ftlbf) @: 37-53 N-m I3.7-5.5 kgf.m, 27-39 ft4bf) 0: 19-25 N-m {I .9-2.6 kgf.m, 14-18 ft4bf) 491 -706 (50-72, 11 0-1 58) 422-490 (43-50, 95-1 10) 422490 {43-50, 95-1 lo} (3) AIC belt If necessary, loosen the lock nut and adjust the belt deflection by turning the adjusting bolt. 343 (35,771 245 {25, 55) 245 {25,55) Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbf) Gartner Banana