warning MAZDA MX-5 1994 Workshop Manual

SAFETY INFORMATION SAFETY INFORMATION LUBRICANTS ) Avoid prolonged and repeated contact with petroleum-based oils. Used oil may irritate the skin, and can ...--/ cause skin cancer and other skin disorders. Wash thoroughly after working with oil. We recommend water soluble hand cleaners. Do not use kero- sene, gasoline, or any other solvent, to remove oil from your skin. If repeated or prolonged contact with oil is necessary, wear protective clothing. Soiled clothing, particu- larly those soiled with used oils and greases containing lead, should be cleaned at regular intervals. 46UGIX-002 JACKING POSITIONS Warning Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking positions and block the wheels. Use safety stands to support the vehicle after it has been lifted. Front At the center of the crossmember SAFETY STAND POSITIONS Front Both sides of the vehicle, on side sills Rear At the center of the differential Rear Both sides of the vehicle, on side sills 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

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

PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE The following items may be done at any time prior to delivery to your customer. INSPECT and ADJUST, if necessary, the following items to specification: 0 Glass, exterior bright metal and paint for damage 0 Convertible top and detachable hardtop (if equipped) for damage 0 Wheel lug nuts and locks 89-117 N.m (9-1 2 kgf.m, 66-86 ft4bf) 0 All weatherstrips for damage or detachment Operation of hood release and lock Operation of fuel lid 0 Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps (if equipped) 0 Outside mirror(s) 0 Mast antenna (if equipped) UNDER HOOD-ENGINE OFF INSPECT and ADJUST, if necessary, the following items to specification : Fuel, coolant, and hydraulic lines, fittings, connections, and components for leaks Engine oil level 0 Power steering fluid level (if equipped) Brake and clutch master cylinder fluid level 0 Windshield washer reservoir fluid level 0 Radiator coolant level and specific gravity 0 Tightness of battery terminals pKiq INSTALL the following parts: CHECK operation of the following items: 0 Seat controls (sliding and reclining) 0 Door locks 0 Seat belts and warning system 0 Air bag system using indicator light (Refer to section T) Ignition switch and steering lock 0 Starter interlock switch (clutch pedal) All lights, including warning, and indicator lights 0 Audible warning system 0 Horn, wipers, and washers Audio system 0 Cigarette lighter Power windows (if equipped) 0 Power outside mirrors (if equipped) 0 Heater, defroster, and air conditioner at all mode selections (if equipped) CHECK the following items: Presence of spare fuses 0 Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: 0 Pedal height and free play of brake and clutch pedals I Pedal height mm {in} I Ft: $iy I Clutch pedal {6.89--7.28) (with carpet) Parking brake 7-9 notchesil96 N (20 kgf, 44 Ibf) 0.63.1 (0.024. 12) Brake pedal RUNNING AT OPERATING TEMPERATURE CHECK the following items: 0 Automatic transmission oil level 171-181 (6.73--7.13) (with carpet) I ON HOIST I 4--7 {0.16-0.28} CHECK the following items: 0 Underside fuel, coolant, and hydraulic lines, fittings, con- nections, and components for leaks 4 Tires for cuts or bruises 0 Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage Manual transmission oil level Differential oil level I ROAD TEST I CHECK the following items: Brake operation Clutch operation 0 Steering control 0 Operation of meters and gauges Squeaks, rattles and unusual noises 0 Overall engine performance Seat belt emergency locking retractors 0 Cruise control system (if equipped) I AFTER ROAD TEST I CHECK for necessary owner information materials, tools and spare tire in vehicle The following items must be done just before the delivery to your customer. 0 Load test battery and charge if necessary -1 Install fuses for accessories Adjust tire pressure to specification Load test fesuk 0 Remove seat and floor mat protective covers (Refer to Door Label) 0 Vacuum and clean interior of vehicle Clean outside of vehicle Inspect installation of option parts with invoice 45UOAX-002 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 INDEX ............................. B- 2 OUTLINE .......................... B- 3 SPECIFICATIONS ................ B- 3 TROUBLESHOOTING GUIDE ........ B- 3 ENGINE TUNE-UP .................. 8- 5 PREPARATION ................... B- 5 ENGINE OIL ..................... B- 5 ENGINE COOLANT ............... B- 5 DRIVE BELT ..................... 8- 6 HLA TROUBLESHOOTING GUIDE . 8- 8 IGNITION TIMING. IDLE SPEED .... B- 8 COMPRESSION .................... 8-10 INSPECTION ..................... B-10 ON-VEHICLE MAINTENANCE ....... B-11 PREPARATION ................... B-11 TIMING BELT ..................... 8-12 CYLINDER HEAD GASKET ........ B-16 H LA ............................. 8-20 FRONT OIL SEAL ................. 8-24 REAR OIL SEAL .................. 8-26 REMOVAL ......................... 8-28 PROCEDURE .................... B-28 ENGINE STAND MOUNTING ......... 8-32 PREPARATION ................... 8-32 PROCEDURE .................... B-33 DISASSEMBLY ..................... B-35 PREPARATION ................... 8-35 AUXILIARY PARTS ............... 8-36 TIMING BELT ..................... 8-37 CYLINDER HEAD ................. 8-39 CYLINDER BLOCK (EXTERNAL PARTS) ............. 8-42 CYLINDER BLOCK .............. (INTERNAL PARTS) 8-44 .............. INSPECTION I REPAIR 8-47 ................... PREPARATION 8-47 ................. CYLINDER HEAD 8-47 .............. VALVE MECHANISM 8-48 ...................... CAMSHAFT B-51 HLA ............................. 8-53 ............... CYLINDER BLOCK B-53 .......................... OIL JET B-54 PISTON. PISTON RING. AND ..................... PISTON PIN 8-55 CONNECTING ROD .............. B-56 ................... CRANKSHAFT 8-57 BEARING ........................ 8-57 TIMING BELT ..................... 8-58 TENSIONER. IDLER .............. 8-58 TENSIONER SPRING ............. 8-58 PULLEY ......................... 8-58 ........................ ASSEMBLY 8-59 ................... PREPARATION 8-59 CYLINDER BLOCK (INTERNAL PARTS) .............. B-60 CYLINDER BLOCK (EXTERNAL PARTS) ............. B-65 CYLINDER HEAD ................. B-69 TIMING BELT ..................... 8-73 ............... AUXILIARY PARTS 8-77 ..... ENGINE STAND DISMOUNTING 8-81 .................... PROCEDURE 8-81 INSTALLATION ..................... 8-83 .................... PROCEDURE 843 45UOBX-001 Gartner Banana

ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION SST I 49 9200 020 Tension gauge, V-ribbed belt For inspection of ignition timing and idle speed For inspection of drive belt tension ENGINE OIL 49 801 9 9AO System selector Warning Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water im- mediately after this work. 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 if 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}. ENGINE COOLANT Inspection Coolant level (engine cold) Warning Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding cool- ant and steam can shoot out and cause serious in- jury. It can also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press down on the cap-still using a cloth - turn it, and remove it. 1. Verify that the coolant level is near the radiator filler neck. 2. Verify that the coolant level in the coolant reservoir is be- tween the FULL and LOW marks. 3. Add coolant if necessary. Gartner Banana

ON-VEHICLE MAINTENANCE CYLINDER HEAD GASKET Replacement 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 section F. Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E.) 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to Installation Note. Gartner Banana

B REMOVAL is connect the hoses shown in the figure. 1. Brake vacuum hose 4. Vacuum hose (Cruise control) 2. Fuel hose 5. Water inlet hose Removal Note . . . . . . . . . . . . . . . . . . below 6. Heater hose 3. Vacuum hose (Purge control) Removal Note Fuel hose Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Disconnect the fuel hoses. 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 . LUBRICATION SYSTEM INDEX ....................................... D- 2 ..................................... OUTLINE D- 3 ........................... SPECIFICATIONS D- 3 TROUBLESHOOTING GUIDE .................. D- 3 OIL PRESSURE .............................. D- 4 PREPARATION ............................. D- 4 INSPECTION ............................... D- 4 ENGINE OIL .................................. D- 5 INSPECTION ............................... D- 5 REPLACEMENT ............................ D- 5 OIL FILTER ................................... D- 6 REPLACEMENT ............................ D- 6 OIL COOLER ................................. D- 7 REMOVAL / INSTALLATION .................. D- 7 OIL PAN ..................................... D- 8 REMOVAL / INSTALLATION .................. D- 8 OIL PUMP .................................... D-11 DISASSEMBLY / ASSEMBLY ................. D-11 INSPECTION ............................... D-12 45UODX401 Gartner Banana

OUTLINE, TROUBLESHOOTING GUIDE D OUTLINE SPECIFICATIONS Engine BP DOHC Lubrication system Oil capacity Engine oil Force-fed type Trochoid gear 344--441 {3.5-4.5,50--63) Full-flow, paper element 79--117 {0.&1.2, 12-1 7) Oil pump Oil filter Oil and oil filter replacement L {US qt, Imp qt) API service SG, SH (ECII) l LSAC TY pe Relief pressure kPa {kgf/cm2, psi) Type Relief pressure differential kPa {kgf/cm2, psi) Total (dry engine) L (US qt, Imp qt} Oil replacement L {US qt, Imp qt} 3.75 (4.0, 3.3) 4.0 f4.2, 3.5) 3.6 (3.8,3.2) I TROUBLESHOOTING GUIDE Problem SAE 1 OW-30 SAE 5W-30 Viscosity number Engine hard starting 45UODX-003 Above -25°C (-1 3°F) Below 0°C {32"F} Excessive oil consumption Oil pressure drop Oil pressure gauge (meter) does not operate Warning Possible Cause Improper engine oil Insufficient engine oil Oil working up or down Oil leakage Insufficient oil Oil leakage Worn and/or damaged oil pump inner and outer rotor Worn plunger (inside oil pump) or weak spring Clogged oil strainer Excessive main bearing or connecting rod bearing clearance Oil pressure drop Malfunction of oil pressure gauge Malfunction of electrical system Remedy Replace Add oil Refer to section 6 Repair Add oil Repair Replace Replace Clean Refer to section B As described above Refer to section T Refer to section T Page D-5 D-5 - 0-5 - D-11,12 D-ll,12 - - 45UODX-004 Conthuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. Gartner Banana