1994 MAZDA MX-5 Oil

2 (Unique driving conditions) (MT) (Cont'd) Number of months or kilometers miles), whichever comes first 24 28 32 36 40 44 48 48 56 64 72 80 88 96 Service data and inspection point Page Maintenance interval Maintenance item .# CHASSIS AND BODY Proper attachment and connections Brake lines, hoses, and connections IIII Disc brakes I Steering operation and linkage Disc plate thickness Front: 18.0mm (0.71 inkMinimum Rear: 8.0mm I0.31 in)--Minimum Pad thickness: 1 .Omm 10.04 inbMinimum Free play: O-30mm {0-1.18 in) Operation and looseness Fluid leakage or oozing Front suspension ball joints 1111 Damage, looseness and arease leakaae I I I I Drive shaft dust boots Cracking and damage Manual transmission oil Oil capacity: 2.0 L (2.1 US at, 1.8 I~D at1 Differential oil Oil capacity: 1 .OO L(1.06 US qt, 0.88 Imp qt} Retighten all loose bolts and nuts I I I Bolts and nuts on chassis and body Exhaust system heat shield Insulator clearance between bodv and exhaust svstem I I I I All locks and hinges ILlLlLlL Lubricate all locks and hinges - I AIR CONDITIONER SYSTEM ~p - ~-~p- Refrigerant Inspect the refrigerant amount annually Refrigerant pressure Low pressure: 0.1 5-0.25 MPa {I S-2.5 kgf/cm2, 21 -36 psi} High pressure: 1.37-1 57 MPa (1 4.0-1 6.0 kgf/cm2, 194-228 psi) Comoressor I lnsoect the ooeration annuallv I I - Gartner Banana

Schedule 2 (Unique driving conditions) (AT) Maintenance interval Maintenance item ENGINE Engine oil I R I R I R I R I R I R I R I R I R I R I R I R Engine oil filter Drive belts Number of months or kilometers {miles}, whichever comes first eoilpancapacity: 4.0 L {4.2 US qt, 3.5 Imp qt} Engine oil (Puerto Rico) I I IGNITION SYSTEM Service data and inspection point Months Kilometers (x 1,m) Miles (x 1,000) D-5 Replace every 4,800 km (3,000 miles) or every 3 months I I I I I I I I - - Engine timing belt (California) Spark plugs Page - - Air cleaner element I I FUEL SYSTEM 4 8 5 I F-99 8-1 2 -. . . '21nspect at 96,000 km {60,000 miles}, and again at 144,000 km {90,000 miles) Replace every 168,000 km (1 05,000 miles) - - R*' - 1'1 l Oilfiltercapacity: 0.15 L (0.16 US qt, 0.13 Imp qt} l Cracks or damage l Tension I R 1 Ie2 1 Engine timing belt ~ --- - - l Plug gap: 1 .&I -1 mm (0.040-4.043 in) l Recommended dark ~luas: 8 16 10 D-6 B-6 Replace every 96,000 km (60,000 miles) Idle speed Fuel filter Fuel lines and hoses NGK , BKRGE-11 BKR5E-I 1 12 24 15 IRI I*2 lt2 l Idle speed MT: 800-900 rpm (Neutral) 1 F-76 AT: 75M0 rpm (P range) 16 32 20 I!*'2 1 20 40 25 24 48 30 - Fittings, connections and com~onents for leaks 36 72 45 F-113 F-1 07 Fuel hoses (California) Hose and tube for emission 28 56 35 Cooling system Engine coolant 32 64 40 COOLING SYSTEM Replace every 168,000 km {I 05,000 miles} 1 1*2 48 96 60 40 80 50 I R 44 88 55 l Fittings, connections and components for leaks Fittings and connections F-1 07 - I R l Hoses for cracks or wear l Coolant level - E4 E-5 Gartner Banana

I Brake lines. hoses, and connections Ill Schedule 2 (Unique driving conditions) (AT) (Cont'd) Disc brakes Steering operation and linkage I Front suspension ball joints 111 Page I Drive shaft dust boots I I I CHASSIS AND BODY Service data and inspection point Maintenance Number of months or kilometers {miles}, whichever comes first I Differential oil 111 I Bolts and nuts on chassis and body 111 48 96 60 I Exhaust system heat shield Ill interval Months Kilometers Maintenance (x1,OOO) Miles(x1,OOO) All locks and hinges AIR CONDIVONER SYSTEM 12 24 15 4 8 5 Disc plate thickness Front: 18.0mm (0.71 in)-Minimum Rear: 8.0mm i0.31 in)-Minimum Pad thickness: 1 .Omm (0.04 in)--Minimum Free play: 0-30mm {O-1 .I 8 in} Operation and looseness Fluid leakage or oozing 16 32 20 8 16 10 P--6 I l Oil capacity: I I I I 1 I 1.00 L 11-06 US at. 0.88 lm~ at I M-25 l Proper attachment and connections I I I I I I I I 7, .' , Ill I 1 I I Retighten all loose bolts and nuts I - 20 40 25 l Damage, looseness and grease leakage Cracking and damage Insulator clearance between I I I I I1Iob odv and exhaust svstem 28 56 35 24 48 30 L 1 L I L I L 1 L 1 L 1 Lubricatealllocksandhinges I - Refrigerant 32 64 40 Inspect the refrigerant amount annually 36 72 45 l Refrigerant pressure Low pressure: 0.1 5-0.25 MPa (1.5-2.5 kgf/cm2, 21-36 psi} High pressure: 1.37-1 57 MPa {I 4.0-1 6.0 kgfld, 19%-228 psi] - I 40 80 50 Compressor 44 88 55 Inspect the operation annually Gartner Banana

Schedule interval Maintenance ENGINE Number of months or kilometers {miles), whichever comes first I -. Months 5 10 15 20 25 30 35 40 45 50 55 60 Kilometers 8 16 24 32 40 48 56 64 72 80 88 96 - Service data and inspection point 1~1.000~ Page Spark plugs FUEL SYSTEM -- Plug gap: 1 .GI .l mm {0.04M.043 in) l Recommended spark plugs: D-5 D-6 B-6 F-99 8-1 2 IGNITION SYSTEM R I I Engine oil Engine oil filter Drive belts Air cleaner element Engine timing belt 'l R I R I F-76 F-1 1 3 F-107 F-I30 - Idle speed Fuel filter Fuel lines and hoses PCV valve'2 Emission hoses and tubes R I COOLING SYSTEM I Cooling system Engine coolant R I R I I E4 E-5 E4 I R I R I R I R I*z I l Hoses for cracks or wear l Leaks - Level and strength I R RR I R R R I I R I OilPancapacity: 4.0 L (4.2 US qt, 3.5 Imp qt) 0 Oil filter capacity: 0.15L(0.16USqt,0.13Impqt) 'Cracksordamage 0 Tension - - R I I I I I R I l ldle speed MT: 800-900 rpm (Neutral) AT 750-850 rpm (P range) - l Fittings, connections and components for leaks Operation Fittings and connections I I R I I I I I I I I I R I 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

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

OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS Engine Item Tv~e BP DOHC Gasoline, 4-cvcle . . I -, Dis~lacement ml kc. cu inl I 1.840 (1.840. 11 2) I Cylinder arrangement and number Combustion chamber Valve system Bore x stroke mm {in) I 83.0 x 85.0 (3.27 x 3.35) I In-line, 4-cylinders Pentroof DOHC, belt-driven Com~ression ratio I 9.0 I Compression pressure kPa (kgf/cm2, psi)-rpm .- . 1 open (BTDCO) 1,255 {I 2.8, 182)-300 5 Valve timing TROUBLESHOOTING GUIDE tX Valve clearance Problem .. . -. . Difficult starting ' With System Selector (49 B019 9AO) test switch at SELF TEST. 45uo~x-003 Close (ATDCO) IN mm {in) EX mm {in) Poor idling Close (ABDCO) Open (BBDCO) 14 0: Maintenance-free 0: Maintenance-free Excessive oil consumption 48 56 Possible Cause Malfunction of engine-related components Burned valve Worn piston, piston ring, or cylinder Failed cylinder head gasket Malfunction of fuel system Malfunction of ignition system Malfunction of engine-related components Malfunction of HLA' Poor valve-to-valve seat contact Failed cvlinder head aasket Oil leakage I Refer to section D I I Remedy Malfunction of fuel system Malfunction of ignition system Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder Oil working down Worn valve seal Worn valve stem or guide Page Replace Replace or repair Replace Refer to section F Refer to section G Replace Replace or repair Re~lace 8-48 B-53,55 B-1 6 B-20 B-50 B-1 6 Refer to section F Refer to section G Replace Replace or repair Replace Replace B-55 B-53,55 B-39,70 8-48 Gartner Banana

B TROUBLESHOOTING GUIDE Problem nsufficlent power 4bnormal combustion Engine noise Possible Cause Insufficient compression Malfunction of HLA' Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Stuck, damaged, or worn piston ring Cracked or worn piston Malfunction of fuel system Malfunction of ignition system Others Slipping clutch Dragging brakes Wrong size tires Malfunction of engine-related components Malfunction of HLA* Stuck or burned valve Weak or broken valve spring Carbon accumulation in combustion chamber Malfunction of fuel system Malfunction of ignition system Crankshaft- or bearing-related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged Piston-related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod Valves or timing-related parts Malfunction of HLA' Broken valve spring Excessive valve auide clearance Malfunction of cooling system Malfunction of fuel system Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage Malfunction of timina belt tensioner Remedy Replace Repair Replace Replace Replace Replace Replace Replace Refer to section F Refer to section G Refer to section H Refer to section P Refer to section Q Replace Replace Replace Eliminate carbon Refer to section F Refer to section G Replace or repair Replace Replace or repair Replace or repair Replace Replace or repair Replace Replace Replace Replace Replace Replace Replace Refer to section E Refer to section F Refer to section E Adjust Refer to section G Refer to section F Replace Page Tappet noise may occur if the engine has set idle for an extended period. The noise should dissipate after the engine has reached normal operating temperature. (HLA troubleshooting: Refer to page 6-8) Gartner Banana