1994 MAZDA MX-5 lock

Schedule 1 (Normal driving conditions) (MT) (Cont'd) Maintenance 1 Number of months or kilometers {miles), whichever comes first I I 1 Months 1 6 18 124 130 136 142148 Service data and inspection point 36,000 1 48,000 1 60,000 1 72,000 1 84,000 1 96,000 Maintenance item I CHASSIS AND BODY Brake lines, hoses, and connections Disc plate thickness Front: 18.0mm (0.71 in)--Minimum I I 1 near: 8.0mm {o31 inFMnimum P-6 I Disc brakes I Pad thickness: I I I I I ~10mrn~0.04inMlinimum I Proper attachment and connections Steering operation and linkage I I I I I I I 0-3'0mm (0-1.1 8 in) Operation and looseness Fluid leakaae or oozina I I Front suspension ball joints I I Free play: I I I I I I I - - Manual transmission oil I I I I I , I Damage, looseness and I grease leakage Oil capacity: 2.0 L (2.1 US at. 1.8 Imp qtJ Ill I I I I I Cracking and damage I , I Oil capacity: I I I Differential oil I Drive shaft dust boots I Bolts and nuts on chassis and body I I I n I 1 .OO L {I .06 US qt, 0.88 Imp qt} Ill Exhaust system heat shield I I I I 1 Retiahten all loose bolts and nuts L All locks and hinges lLlLl - AIR CONDITIONER SYSTEM I L Refrigerant pressure Low pressure: 0.1 5-0.25 MPa {I -52.5 kgf/cm2, 21-36 psi) High pressure: 1.37-1 -57 MPa {I 4.0-1 6.0 kgf/cm2, 1 XI-228 psi] - L Corn~ressor I lnswct the o~eration annuallv Refrigerant L Inspect the refrigerant amount annually L I L " Insulator clearance between body and exhaust system Lubricate all locks and hinges F-128 - Gartner Banana

Schedule 1 (Normal driving conditions) (AT) (Cont'd) - .. .. Brake lines, hoses, and connections -- Front suspension ball joints Page I Disc brakes Steering operation and linkage I I 1 I I I I Drive shaft dust boots Ill CHASSIS AND BODY Service data and inspection point Maintenance Number of months or kilometers {miles), whichever comes first I I Differential oil I interval Months Maintenance Kilometers item Miles Exhaust system heat shield I 36 72,000 45,000 I I I I I I I I I 1 I I I I All locks and hinaes lLlLlLlLlLlLlL 6 12,000 7,500 Bolts and nuts on chassis and body - AIR CONDIIONER SYSTEM 42 84,000 52,500 I Ill 12 24,000 15,000 96,000 60,000 Proper attachment and connections Disc plate thickness Front: 18.0mm (0.71 in)-Minimum Rear: 8.0mm f0.31 in)--Minimum Pad thickness: 1 .Omm 10.04 inl-Minimum .-- Free play: C-30mm (0-1 .I 8 in) Operation and looseness Fluid leakage or oozing 18 36,000 22,500 Refrigerant Compressor Damage, looseness and arease leakaae Inspect the refrigerant amount annually Inspect the operation annually 24 48,000 30,000 30 60,000 37,500 Cracking and damage Oil capacity: 1 .OO L 11.06 US at. 0.88 Irn~ at} M-17 M-25 Retighten all loose bolts and nuts Insulator clearance between bodv and exhaust system Refrigerant pressure Low pressure: 0.1 5-0.25 MPa (1 .5-2.5 kgf/:, 21-36 psi) 1 LJ: High pressure: 1.37-1.57 MPa {I 4.0-1 6.0 kgf/cm2, 194--228 psi) - F-128 Lubricate all locks and hinges - Gartner Banana

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

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

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

ENGINE TUNE-UP B 2 ADJUSTING BOLT LOCKNUT Tension N {kgf, lbfl I Drive belt New* Used I Limit I A belt that has been on a running engine for less than five minutes. 45UOBX-011 Alternator PIS, PIS + A/C AIC Adjustment (1) Alternator belt Loosen the alternator bolts @J and @ and adjust the belt deflection by turning the adjusting bolt 0. Tightening torque @: 19-25 N-m {I .9-2.6 kgf.m, 14-18 ft4bf) @: 38-51 N-m (3.8-5.3 kgf.m, 28-38 ft4bf) 491 -745 (50-76, 11 0-1 67) 491-588 (50-60, 11C-132) 49 1-588 (50-60, 11 0-1 32) (2) PIS belt, PIS + A/C belt Loosen the PIS oil pump bolt @ and nuts @ and @ and adjust the belt deflection by turning the adjusting bolt @. Tightening torque @: 3246 N.m (3.24.7 kgf.m, 24-33 ftlbf) @: 37-53 N-m I3.7-5.5 kgf.m, 27-39 ft4bf) 0: 19-25 N-m {I .9-2.6 kgf.m, 14-18 ft4bf) 491 -706 (50-72, 11 0-1 58) 422-490 (43-50, 95-1 10) 422490 {43-50, 95-1 lo} (3) AIC belt If necessary, loosen the lock nut and adjust the belt deflection by turning the adjusting bolt. 343 (35,771 245 {25, 55) 245 {25,55) Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbf) Gartner Banana

ENGINE TUNE-UP B lgnition Timing 1. Connect the SST and set the TEST SW to "SELF TEST or connect data link connector terminals TEN and GND with a ium~er wire. ~ 4 2. Check the'idle speed, and set it to specification if neces- sary. (Refer to section F.) ldle speed (Neutral): 800-900 (850 + 50) rpm [MT] (P range): 750-450 (800 + 50) rpm [AT] 3. Verify that the timing mark (White) on the crankshaft pulley and the timing belt cover are aligned. lgnition timing: BTDC 9"-11" (1 0" + 1 ") 4. If the marks are not aligned, loosen the crankshaft posi- tion sensor lock bolt, and turn the crankshaft position sensor to make the adjustment 5. Tighten the crankshaft position sensor lock bolt to the specified torque. Tightening torque: 19-25 N.m {I .9--2.6 kgf.m, 1 &-I8 ft-lbf) 6. Disconnect the SST. 7. Verify that the ignition timing is within the specification. Ignition timing: BTDC 6-18" ldle Speed 1. Connect the SST and set the TEST SW to "SELF-TEST or connect data link connector terminals TEN and GND with a jumper wire. 2. Verify that the idle speed is within specification. ldle speed (Neutral): 800-900 (850 + 50) rpm [MT] (P range): 75-50 (800 -e 50) rpm [AT] 3. If the idle speed is not within specification, remove the blind cap from the air adjusting screw and adjust it. 4. After adjusting the idle speed, install the blind cap and disconnect the SST or jumper wire from the data link connector. Gartner Banana