1994 MAZDA MX-5 Workshop Manual

AIR CONDITIONER u BUSHING 5. Removal of shaft seal Remove the shaft seal from the shaft. Do not disas- semble the compressor body. 6. Removal of shaft seal plate Remove the shaft seal plate by using a suitably sized bushing. 7. Installation of shaft seal plate Install the shaft seal plate by using a suitably sized bush- ing. 8. Installation of shaft seal (1) Lubricate the shaft seal with the compressor oil. (2) Install the shaft seal on the shaft. 9. Installation of front and rear housings (1) Install the new gaskets and pin on the compressor body. Gartner Banana

u AIR CONDITIONER (2) Install the front and rear housings and tighten the through bolts loosely. 10. Installation of discharge valve Install the discharge valve and discharge valve plate and tighten the bolts. Tightening torque: 4.6 N.m (47 kgtcm, 41 in-lbf) 11. lnstallation of discharge valve body (1) Install the discharge valve body and tighten the bolts loosely. (2) Tighten the discharge valve installation through bolts loosely. 12. Tightening of bolts (1) Tighten the through bolts. Tightening torque: 25 N-m (2.6 kgtm, 19 ftslbf) Gartner Banana

AIR CONDITIONER u O-RING (2) Tighten the discharge valve body installation through bolts. Tightening torque: 10.8 N-m (110 kgf-cm, 95.5 in-lbf) (3) Tighten the discharge valve body installation bolts. Tightening torque: 10.8 N-m (110 kgf-cm, 95.5 in-lbf) 1 3. Pour compressor oil (ND-OILS) Pour compressor oil into the A/C compressor. Compressor oil amount: Same amount as drained, plus 20 ml(20 cc, 0.6 fl or) 14. Installation of service valve (1) Apply the compressor oil to the new O-rings. (2) Install the service valves to the compressor and tight- en the installation bolts. Tightening torque: 12.3 N-m (125 kgf-cm, 109 in-lbf) Gartner Banana

u AIR CONDITIONER I NC COMPRESSOR 45UOUX-119 Adjustment Drive belt (With PIS) 1. Loosen PIS oil pump bolts @ and @ and nut 0. ...-' 2. Adjust the belt tension and deflection to specification by turning adjusting bolt 0. 3. Tighten bolts @ and @J and nut 0. (Without PIS) 1. Loosen the locknut. 2. Adjust the belt tension and deflection to specification by Tightening torque: @I: 3246 N.m (3.2-4.7 kgf-m, 24-33 ftelbf) @I: 37-53 Nem (3.7-5.5 kgf-m, 27-39 ft-lbf) 0: 19-25 N.m (1 3-2.6 kgf-m, 14--18 ft-lbf) turning the adjusting bolt. 3. Tighten the locknut. 1 Tension t Deflection when applying moderate pressure 98 N {lo 1 kgf, 22 Ibf) Tightening torque: 38-51 N-m (3.8-5.3 kgf-m, 28-38 ft-lbf) Specification NC COMPRESSOR 45UOUX-121 New 490-588 N (50.0-60.0 kgf, 11 0-1 32 Ibf) 8.0-9.0 mm {0.31-0.35 in) Specification Used 422490 N (43.0-50.0 kgf, 9!5-110 Ibf) 9.0-1 0.0 mm I0.35--0.39 in) New Used Tension Deflection when applying moderate pressure 98 N (10 kgf, 22 Ibf) 490-588 N {50.0-60.0 kgf, 110-132 IbfJ 8.0-9.0 mm i0.31-0.35 in) 422490 N (43.0-50.0 kgf, 95-1 1 0 Ibf) 9.0-1 0.0 mm I0.35-0.39 in) Gartner Banana

TECHNICAL DATA MEASUREMENTS ......................... TD- 2 ................................... ENGINE TD- 2 .................... LUBRICATION SYSTEM TD- 5 ........................ COOLING SYSTEM TD- 5 FUEL AND EMISSION CONTROL SYSTEMS . TD- 6 ENGINE ELECTRICAL SYSTEM ............. TD- 7 .................................. CLUTCH TD- 7 .................. MANUAL TRANSMISSION TD- 8 AUTOMATIC TRANSMISSION ............... TD- 9 ....................... PROPELLER SHAFT TD-11 FRONT AND REAR AXLES ................. TD-12 STEERING SYSTEM ....................... TD-12 BRAKING SYSTEM ........................ TD-13 WHEELS AND TIRES ...................... TD-13 ............................. SUSPENSION TD-14 BODY ELECTRICAL SYSTEM ............... TD-15 HEATER AND AIR CONDITIONING SYSTEM . TD-15 STANDARD BOLT AND NUT TIGHTENING ................................. TORQUE TD-15 45UTDX-001 Gartner Banana

TD TECHNICAL DATA A. MEASUREMENTS I Item I Measurements I B. ENGINE Overall length mm {in) Overall width mm (in) Overall height mm {in) Wheelbase mm {in) 3,948 (1 55.4) 1,676 i65.9) 1,224 I48.2) 2,266 I89.2) 1,410 (55.5) 1,428 (56.2) Tread - ltem Tvoe u Front mm (in) Rear mm {in) BP DOHC Gasoline. 4-cvcle . In-line, 4-cylinders Pentroof DOHC, belt-driven 16 valves 83.0 x 85.0 {3.27 x 3.35) 1,840 (1,840, 11 2) 9.0 1,255 {I 2.8, 1823-300 883 (9.0, 1281-300 196 {2.0, 28) s. Cylinder arrangement and number Combustion chamber Valve system Bore x Stroke mm {in] Total piston displacement ml {cc, cu in) Compression ratio Valve timing Compression pressure kPa (kgflcm2. psil-r~m I Valve and valve auide I Standard Minimum Maximum difference between each cvlinder - - IN openz (BTDCO) Close (ABDCO) Open (BBDCO) EX close (ATDC") Valve clearance mm {in) Cylinder head 5 48 56 14 IN 133.8-1 34.0 i5.268-5.275) 0.1 0 {0.004) max. 0.10 {0.004) max. 0.02G0.066 {0.0010-0,0025) 0.18 {0.0071) Height mm (in) Distortion mm {in) Grinding mm {in) - 0: Maintenance-free Cylinder head-to-HLA clearance mm (in} Valve head diameter mm Iin) Valve head margin thickness mm {in} Valve face angle I Valve seat 1 u Standard Maximum Valve length mm {in) EX IN EX IN EX IN EX Standard Minimum Standard Minimum IN EX IN EX 5.99--6.03 iO.2359--0.2374) 0.005--0.060 (0.0002-0.0023) 0.01 b0.065 (0.0004-0,0025) 0.20 {0.008} 18.3-1 8.9 {0.7214.744) 18.3-1 8.9 (0.721-0.744) Guide inner diameter mm (in) 0: Maintenance-free 32.9-33.1 {I .296--1.303) 27.85-28.15 {I .097-1 .I 08) 0.9 {0.035) 1 .O (0.039) 45" 45" 101.89 {4.0114} 100.39 {3.9524) 101.99 (4.0153) 100.49 (3,9563) 5.970-5.985 {0.2351-0.2356) 5.96G5.980 l0.2349-0.2354) Valve stem diameter mm {in) Valve stem-to-guide clearance mm (in) Guide projection (Height "A) mm {in) Seat angle IN EX Maximum IN EX IN 45" EX 45" Gartner Banana

TECHNICAL DATA TD BP DOHC 0.8-1.4 {0.0324.055) 45.0 (1.772) 46.5 11.831) Engine Item Seat contact width mm {in) Valve spring End gap (Measured in cylinder) mm {in) Seat sinking mm {in) Free length mm {in) Minimum length mm {in) Out-of-square mm {in) Camshaft bearing oil clearance mm {in} Ring groove width in piston mm {in) Standard Maximum Piston ring-to-ring groove clearance mm {in) IN EX IN EX IN EX Standard (No.1-No.5) Maximum 46.26 (1.821) 46.26 (1.821) 39.5 {I 56) with a set load of 224--253 N I22.8-25.8 kgf, 50.2-56.7 Ibf) 39.5 (1 56) with a set load of 224-253 N I22.8-25.8 kgf, 50.2-56.7 Ibf) 1.62 (0.0638) max. 1.62 (0.0638) max. Camshaft 0.035-0.081 {0.0014-0..0031) 0.1 5 (0.006) 0.03 {0.001 2) max. 0.07-0.1 9 {0.002~.0074) 0.20 {0.008) Camshaft runout mm {in) TOP Second Cam height mm {in) Camshaft end play mm (in) 0.15-0.30 {0.006-0.011) 0.15-0.30 {0.006--0.011) -- - I Standard Minimum Standard Minimum Standard (No.1-N0.5) IN EX Standard Maximum Oil (rail) Maximum I 1 .O {0.039) 44.094 {I .7360) 43.894 {I .7281) 44.600 11.7559) 44.400 {I .7480) 25.940-25.965 11.021 3-1.0222) Journal diameter mm Iin) Cylinder block 0.20-0.70 {0.00&0.027) TOD Second Oil 1.52-1 535 {0.0594--0.0604) 1.52-1.54 (0.0599--0.0606} 3.02-3.04 f0.11894.1196) Second Maximum 221.5 (8.720) 0.1 5 {0.006) max. 0.20 {0.008) max. 83.00&83.019 i3.2678-3.2684) 83.25683.263 {3.277&3.2780) 83.508-883.51 3 (3.2877-3.2879) 0.01 9 {0.0007} max. Height mm {in) Distortion mm (in) Grinding mm {in} 0.03-0.07 {0.00124.0027) 0.1 5 {0.006) Cylinder bore diameter mm {in] Standard size 0.25 {0.01) oversize 0.50 (0.02) oversize Piston , Cylinder bore taper and out-of-round mm {in) 82.95442.974 i3.2659--3.2666) 83.211-43.21 7 (3.2761-3.2762) 83.461-83.467 (3.2853--3.2860) 0.0324.059 {0.001 3--0.0023) 0.15 (0.006) Piston diameter Measured at 90" to Pin bore axis and 16.5mm i0.65 in) below oil ring groove mm {in) Standard size 0.25 {0.01) oversize 0.50 (0.02) oversize Piston ring Piston-to-cylinder clearance mm (in) Thickness mm {in) Standard Maximum TOP 1.47-1 -49 (0.0579--0.0586} Second 1.47-1.49 {0.0579--0.0586) Gartner Banana

TD TECHNICAL DATA item Main journal diameter mm {in) BP DOHC Diameter mm {in) Piston-to-piston pin clearance mm {in) Connecting rod bush-to-piston pin clearance mm (in) Piston pin 19.987-1 9.993 {0.7869-0..7871) -0.00~0.013 {-0.0002-0.0005) 0.01 0-0.027 {0.0004--0.0010} I Main iournal out-of-round - . - . . - -. - size 0.25 {o.oi) undersize 0.50 (0.02) undersize 0.75 I0.03) undersize mm (in) I 0.05 10.0020) max. I Connectir~g rod and connecting rod bearing . L, . -- 2 - 1 Standard 1 Standard I 44.940-44.956 11.7693--1.7699) Minimum Standard ' Minimum Standard 'Minimum Standard Minimum 1 size 1 ~inimum I 44.908 11.76801 I 132.8S132.95 I5.231-5.234) 0.030 (0.001 2) max.1100 (3.94) 20.003--20.0 14 {0.78760.7879) 48.000-48.01 6 {I .8898-1.8903) 21.838-21.890 (0.8598-0.8618) 0.1 104.262 {0.0044-0.0103) 0.30 (0.01 2) Length (Center to center) mm {in) Bending mm (in) Small end bore (Bush inner diameter) mm {in) Big end bore mm {in) Big end width mm {in) 49.904 (1.9647) 49.704--49.708 {I $9569--1.9570) 49.652 {I .9548) 49.454--49.458 {I .947&1.9471) 49.402 (1.9450) 49.204--49.208 (1.9372-1.9373) 49.152 11.9351) Cranks haft Crankshaft runout mm (in) I 0.04 {0.0016) max. Standard 1 Standard I 49.938--49.956 (1.9661-1.9667) Connecting rod side clearance mm {in) . Standard Maximum Crankpin diameter mm (in) - -- s- - 8 undersize 0.50 10.02) undersize 44.1 90-44.206 {I .7398-1.7403) 44.158 {I .7385) 0.05 (0.00201 max. 0.75 {0.03) undersize " Main bearina Standard Minimum Main journal bearing oil clearance mm (in) - L~inimum Standard 'Minimum Crankpin out-of-round mm {in} Crankpin bearing oil clearance mm (in) Standard Maximum 44.658 (1.7582) 44.440-44.456 {I .7496-1,7502) 44.408 (1.74831 0.01 8-0.036 {0.0008--0.0014) 0.1 0 {0.004) Available undersize bearing mm (in) Standard Maximum - 0.25 {0.010), 0.50 {0.020), 0.75 (0.030) 0.020-0.044 {0.0008--0.0017) 0.10 {0.004} Available undersize bearing mm {in) Crankpin bearing 0.25 {0.010), 0.50 {0.020), 0.75 (0.030) Thrust bearing Crankshaft end play mm {in) Standard Maximum 0.080-0.282 (0.0032--0.0111) 0.30 (0.012) 2.500-2.550 {0.0985--0.1003) 2.625-2.675 (0.1 034-0.1 053) 2.750-2.800 {0.108H.1102) 2.875-2.925 {0.1132--0.1151) Bearing width mm {in) nming belt Belt deflection mm {in)/98 N (10 kgf, 22 Ibf) I 9.0-11.5 i0.360.45) ~U Standard size 0.25 (0.01) oversize 0.50 {0.02) oversize 0.75 (0.03) oversize Gartner Banana