1994 MAZDA MX-5 Workshop Manual

B ASSEMBLY Cylinder Head Cover 1. Apply silicone sealant to the shaded areas shown in the figure. 2. Install the cylinder head cover. Tightening torque: 5.0-8.8 N.m (50-90 kgf-cm, 44--78 in.lbf) Crankshaft Pulley 1. lnstall the crankshaft pulley. 2. Install the plate. 3. Tighten the pulley bolts. Tightening torque: 13-1 7 N.m (1 25--175 kgf.cm, 109-1 51 in4bf) Water Pump Pulley Install the water pump pulley and tighten the bolts. Tightening torque: 7.9-10.7 N-m (80-110 kgfern, 70-95.4 in.lbf) Gartner Banana

ASSEMBLY B AUXILIARY PARTS Torque Specifications I FRONT OIL COOLER INSTALLATION REFER TO SECTION D Engine Hanger Install the front and rear engine hangers. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft4bf) Gartner Banana

ASSEMBLY Dipstick, Dipstick Pipe 1. Apply a small amount of clean engine oil to the new 0- ring. 2. Push the dipstick pipe into the oil pan. u 3. Tighten the dipstick pipe bracket nut. Tightening torque: 7.9-10.7 N.m (80-1 10 kgfem, 70-95.4 in4bf) 4. lnstall the dipstick. Spark Plug lnstall the spark plugs. Tightening torque: 15-22 N.m (1 .%2.3 kgf-m, 11-1 6 ft4bf) Water Outlet Pipe 1. Remove all foreign material from the water outlet pipe mounting surface. 2. lnstall a new gasket and the water outlet pipe. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft4bf) Oil Pressure Switch lnstall the oil pressure switch. Tightening torque: 12-17 N.m (1.2-1.8 kgf-m, 9-13 ft4bf) Gartner Banana

ASSEMBLY B Oil Filter 1. Remove all foreign material from the oil filter mounting surface. 2. Apply a small amount of clean engine oil to the rubber seal of the oil filter. 3. Install the oil filter and tighten it by hand until the rubber seal contacts the base. 4. Hand tightening type (Numbers printed on filter) Tighten the filter 314 of a turn by hand after it contacts the cylinder block. If tightening by hand is difficult, use the filter wrench. Example When the oil filter contacts the cylinder block at "l", turn it 314 of a turn further to "4". Filter wrench tightening type (No numbers printed on fil- ter) Tighten the filter 1 and 116 turns with the filter wrench af- ter it contacts the cylinder block. Right Engine Mount Install the right engine mount. Tightening torque: 37-53 N-m (3.7-5.5 kgf.m, 27-39 ft.lbf) Alternator Bracket Install the alternator bracket. Tightening torque: 64-49 N-m (6.5--9.1 kgf-m, 48-45 ft4bf) Alternator Install the alternator and hand tighten the mounting bolts. Gartner Banana

B ASSEMBLY BLADE NEW Intake Manifold Assembly 1. Remove all foreign material from the intake manifold contact surface. 2. Install a new gasket and the intake manifold assembly. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft.lbf) Manifold Bracket Install the manifold bracket. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft.lbf) Crankshaft Position Sensor 1. Apply grease to a new O-ring and the blade. 2. Install the crankshaft position sensor to the rear end of exhaust-side camshaft and hand tighten the installation bolt. -J Ignition Coil and High-tension Lead 1. Install the ignition coil. Tightening torque: 19-25 N.m (1 .%--2.6 kgf.m, 14-18 ftdbf) 2. Connect the high-tension leads. Gartner Banana

ENGINE STAND DISMOUNTING B ENGINE STAND DISMOUNTING PROCEDURE i_/ 1. Remove the engine from the SST (engine stand). 2. Remove the SST (engine hanger) from the engine. 3. lnstall the parts shown in the figure. Torque Specifications 05UOBX-251 Left Engine Mount Install the left engine mount. Tightening torque: 37-53 N-m (3.7-5.5 kgf.m, 27-39 ftlbf) Gartner Banana

B ENGINE STAND DISMOUNTING PIS Oil Pump Bracket lnstall the PIS oil pump bracket. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) Idler lnstall the A/C idler. Tightening torque: 38-51 N.m (3.8-5.3 kgf-m, 2U8 ft4bf) Water Inlet Pipe and Bypass Pipe 1. Remove all foreign material from the water inlet pipe mounting surface. 2. lnstall a new gasket and the water inlet pipe. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ftlbf) 3. Apply a small amount of engine coolant to the new 0- ring. 4. lnstall the water bypass pipe. AIC Compressor Bracket lnstall the A/C compressor bracket. Tightening torque @: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ftlbf) 0: 38-51 N.m (3.8-5.3 kgf-m, 28-38 ft-lbf) Exhaust Manifold 1. Remove all foreign material from the exhaust manifold contact surface. 2. lnstall a new gasket and the exhaust manifold. Tightening torque: 3-6 N-m (3.9-4.7 kgf-m, 29--33 ft-lbf) Exhaust Manifold Insulator lnstall the exhaust manifold insulator. Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in4bf) Gartner Banana

INSTALLATION B INSTALLATION PROCEDURE u Tighten all bolts and nuts to the specified torques. Step 1 Torque Specifications I RIGHT I LEFT 05UOBX-258 Engine assembly 1. Suspend the engine assembly. Slowly lower the engine assembly as a unit. Keep the en- gine from swinging or bumping into components in the engine compartment. 2. Install the engine tilting downward. 3. Align the engine mounts with the crossmember mount- ing holes. 4. Install the engine mount nuts and hand tighten them. Engine mount nut Tighten the engine mount nuts. Tightening torque: 57-78 N.m (5.8--8.0 kgf.m, 42-57 ft-lbf) I-, /-b -1 45UOBX-173 Gartner Banana