1994 MAZDA MX-5 Workshop Manual

ASSEMBLY 1. Do not reuse gaskets or oil seals. 2. Clean all parts before reinstallation. 3. Apply new engine oil to all sliding and rotating parts. 4. Replace plain bearings if they are peeled, burned, or otherwise damaged. 5. Tighten all bolts and nuts to the specified torques. CYLINDER BLOCK (INTERNAL PARTS) Torque Specifications CYLINDER WALLS I#- WASHER, NEW JOURNALS AND BEARINGS NEW Connecting Rod and Piston Assembly 1. Install one piston pin clip into the clip groove in the pis- ton. 2. Assemble the piston and the connecting rod. 3. Apply clean engine oil to the piston pin. 4. Install the piston pin from the side opposite the clip. 5. Tap the piston pin in with the SST until the pin contacts the clip. . , If the pin cannot be installed easily, replace the connect- ing rod. 6. Install the second clip into the clip groove in the piston. Gartner Banana

ASSEMBLY B SPACER TANG UPPER RAIL ...-.. OIL RlNG SPACER ENDS LOWER RAlL PISTON OIL RlNG UPPER RAIL TOP RING OIL RING + PISTOI PIN OIL RING. SECOND LOWER RAIL RING 7. Check the oscillation torque of the connecting rod. If the large end does not drop by its own weight, replace the piston and/or piston pin. Piston Ring 1. Install the three-piece oil rings on the pistons. (1) Apply clean engine oil to the oil ring spacer and rails. (2) lnstall the oil ring spacer with the ends upward. Note The upper and lower rails are the same. They can be installed with either face upward (3) Install the upper and lower rails. 2. Verify that the spacer tang separates the rails, and that the rails turn smoothly in both directions. 3. lnstall the rings with the R marks upward. 4. Using a piston ring expander, install the second ring with the scraper face downward. 5. Using a piston ring expander, install the top ring. 6. Apply clean engine oil to the top and second piston rings. 7. Position the end gaps of the rings as shown in the figure. Gartner Banana

B ASSEMBLY I PLASTIGAGE I Oil Jet lnstall the oil jets. Tightening torque: 12-1 7 N.m (1.2-1.8 kgf.m, 9-1 3 ft4bf) Crankshaft 1. Before installing the crankshaft, inspect the main bear- ing oil clearances as follows. Oil clearance inspection (1) Remove all foreign material and oil from the journals and bearings. (2) lnstall the grooved upper main bearings in the cylin- der block. (3) lnstall the thrust bearings with the oil groove facing the crankshaft. (4) Set the crankshaft in the cylinder block. (5) Position plastigage atop the journals in the axial direction. (6) Do not rotate the crankshaft when measuring the oil clearances. Install the lower main bearings and the main bearing caps according to the cap number and + mark. Tighten the main bearing cap bolts in two or three steps in the order shown in the figure. Tightening torque: 54--58 N-m I5.5--6.0 kgf.m, 40-43 ft4bf) (9) Remove the main bearing caps, and measure the plastigage at each journal at the widest point for the smallest clearance, and at the narrowest point for the largest clearance. (10) If the oil clearance exceeds specification, grind the crankshaft and use undersize main bearings. (Refer to page B-57.) , d' Oil clearance: 0.018-0.036mm (0.0008--0.0014 in) Maximum: 0.lOmm (0.004 in) Gartner Banana

ASSEMBLY B I RUBBER SLEEVE 2. Apply a liberal amount of clean engine oil to the main bearings, thrust bearings and main journals. 3. Install the crankshaft and the main bearing caps accord- ing to the cap number and + mark. 4. Tighten the main bearing cap bolts in two or three steps in the order shown in the figure. Tightening torque: 54--58 N.m (5.5-6.0 kgf.m, 40-43 ft4bf) 5. Measure the crankshaft end play. End play: 0.080-0.282mm (0.0032-0.0111 in) Maximum: 0.30mm (0.012 in) 6. If the end play exceeds the maximum, grind the crank- shaft and install an oversize thrust bearing or replace the crankshaft and thrust bearing. Thrust bearing width Standard: 2.500-2.550mm (0.0985-0.1 003 in) 0.25mm (0.01 0 in) oversize: 2.625--2.675mm (0.1 034-O.1053 in) 0.50mm (0.020 in) oversize: 2.750-2.800mm (0.1 083-0.1 102 in) 0.75mm (0.030 in) oversize: 2.875-2.925mm (0.1 132-0.1151 in) Piston and Connecting Rod Assembly 1. Protect the connecting rod bolts with rubber sleeves. Gartner Banana

ASSEMBLY , MATCHINGMARKS A SIDE CLEARANCE 1 2. Apply a liberal amount of clean engine oil to the cylinder walls, pistons, and piston rings. 3. Check the piston rings for correct end gap alignment. 4. Insert each piston assembly into the cylinder block with ..-, the F mark facing the front of the engine. Use a piston ring compressor (commercially available). Connecting Rod Cap 1. Align the matching marks on the cap and the connecting rod and install the connecting rod cap. 2. Measure the connecting rod bearing oil clearances us- ing the same procedure as for the main bearing oil clear- ance. Tightening torque: 48-50 N.m (4.8-5.1 kgf.m, 35--36 ftlbf} Oil clearance: 0.020-0.044mm (0.0008-0.0017 in) Maximum: 0.lOmm (0.004 in) 3. If the oil clearance exceeds the maximum, grind the crankshaft and use undersize bearings. (Refer to page 8-57.) U' 4. Measure the connecting rod side clearances. Side clearance: 0.11 O4.262rnm (O.OO44-O.OIO3 in) Maximum: 0.30mm (0.01 2 in) 5. If the clearance exceeds the maximum, replace the con- necting rod and cap. Apply a liberal amount of clean engine oil to the crank pin journals and connecting rod bearings. Install the connecting rod caps with the matching marks aligned. 8. Tighten the connecting rod cap nuts in two or three steps. Tightening torque: 48-50 N-m (4.8-5.1 kgf-m, 35--36 ftdbf) Gartner Banana

ASSEMBLY B CYLINDER BLOCK (EXTERNAL PARTS) Torque Specifications 7.9-10.7 Nm (80-110 kgfwn, 70--95.4 in4bf) OIL SEAL. NEW 7.9-10.7 Nm (80-110 kgfcm, 7045.4 Indbf) Nm (kgf m, ftlbf) 05UOBX-198 Rear Cover 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a pipe, press the oil seal in evenly until it is flush with the edge of the rear cover. L Note Oil seal outer diameter: 100mm (3.94 in} Oil seal inner diameter: 83mm (3.27 in} Gartner Banana

ASSEMBLY 4. Apply silicone sealant to the shaded area shown in the figure. 5. Install the rear cover Tightening torque: 7.9-1 0.7 N.m (80-1 10 kgfem, 70-95.4 in-lbf) Oil Pump 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a pipe, press the oil seal in evenly until it is flush with the edge of the oil pump body. U' Note Oil seal outer diameter: 50.5mm (1.99 in} Oil seal inner diameter: 36.5mm (1.44 in) 4. Install the oil pump and a new gasket. Tightening torque: 19-25 N.m (1 -9-2.6 kgf-m, 14--18 ft-lbf) 5. Cut away the portion of the gasket that projects from the body toward the oil pan side. Gartner Banana

ASSEMBLY B Water Pump 1. Remove all foreign material from the water pump mount- ing surface. 2. Install the water pump and a new gasket. Tightening torque: 19-25 N.m {I .9--2.6 kgf.m, 14--18 ft-lbf) Oil Pan Baffle 1. Remove all foreign material from the contact surfaces. 2. Apply a continuous bead of silicone sealant to the baffle along the inside of the bolt holes, and install within five minutes. Oil Strainer Install the oil strainer and a new gasket. NOTCH NOTCH 05UOBX-20 Tightening torque: 7.9-1 0.7 N.m (80-1 10 kgf.cm, 70-95.4 in4bf) Oil Pan 1. Remove all foreign material from the contact surfaces. 2. Apply silicone sealant to the areas indicated in the figure. 3. Install new gaskets onto the oil pump body and the rear cover with the projections of the notches shown in the figure. Gartner Banana