1994 MAZDA MX-5 water pump

OUTLINE, TROUBLESHOOTING GUIDE D OUTLINE SPECIFICATIONS Engine BP DOHC Lubrication system Oil capacity Engine oil Force-fed type Trochoid gear 344--441 {3.5-4.5,50--63) Full-flow, paper element 79--117 {0.&1.2, 12-1 7) Oil pump Oil filter Oil and oil filter replacement L {US qt, Imp qt) API service SG, SH (ECII) l LSAC TY pe Relief pressure kPa {kgf/cm2, psi) Type Relief pressure differential kPa {kgf/cm2, psi) Total (dry engine) L (US qt, Imp qt} Oil replacement L {US qt, Imp qt} 3.75 (4.0, 3.3) 4.0 f4.2, 3.5) 3.6 (3.8,3.2) I TROUBLESHOOTING GUIDE Problem SAE 1 OW-30 SAE 5W-30 Viscosity number Engine hard starting 45UODX-003 Above -25°C (-1 3°F) Below 0°C {32"F} Excessive oil consumption Oil pressure drop Oil pressure gauge (meter) does not operate Warning Possible Cause Improper engine oil Insufficient engine oil Oil working up or down Oil leakage Insufficient oil Oil leakage Worn and/or damaged oil pump inner and outer rotor Worn plunger (inside oil pump) or weak spring Clogged oil strainer Excessive main bearing or connecting rod bearing clearance Oil pressure drop Malfunction of oil pressure gauge Malfunction of electrical system Remedy Replace Add oil Refer to section 6 Repair Add oil Repair Replace Replace Clean Refer to section B As described above Refer to section T Refer to section T Page D-5 D-5 - 0-5 - D-11,12 D-ll,12 - - 45UODX-004 Conthuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. 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 . COOLING SYSTEM INDEX ....................................... E- 2 OUTLINE ..................................... E- 3 SPECIFICATIONS ........................... E- 3 TROUBLESHOOTING GUIDE .................. E- 3 ENGINE COOLANT ........................... E- 4 PREPARATION ............................. E- 4 INSPECTION ............................... E- 4 REPLACEMENT ............................ E- 5 REFILLING ................................. E- 6 .............................. RADIATOR CAP E- 7 ............................. PREPARATION E- 7 INSPECTION ............................... E- 7 RADIATOR ................................... E- 8 REMOVAL I INSTALLATION .................. E- 8 INSPECTION ............................... E- 8 THERMOSTAT ................................ E- 9 REMOVAL I INSTALLATION .................. E- 9 INSPECTION ............................... E- 9 WATER PUMP ................................ E-10 REMOVAL / INSTALLATION .................. E-10 COOLANT FAN MOTOR ....................... E-12 INSPECTION ............................... E-12 REPLACEMENT ............................ E-12 ........................ COOLANT FAN RELAY E-13 ............................... INSPECTION E-13 45UOEX-001 Gartner Banana

INDEX INDEX 1. Engine coolant Inspection ................... page E-4 Replacement ................ page E-5 2. Radiator cap Inspection ................... page E-7 3. Radiator Removal / Installation ......... page E-8 Inspection ................... page E-8 4. Thermostat Removal / Installation ......... page E-9 Inspection ................... page E-9 5. Water pump Removal / Installation ....... page E-10 6. Coolant fan motor Inspection ................. page E-12 Replacement .............. page E-12 7. Coolant fan relay Inspection ................. page E-13 Gartner Banana

OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS Cooling system I Water-cooled, forced circulation I - - Engine Item - Water pump BP DOHC Coolant capacity L {US qt, Imp qt) TY ~e Thermostat 6.0 {6.3,5.3} Centrifugal, V-ribbed belt driven Radiator - Coolant fan Opening temperature Water seal TY pe Main: 86.5-89.5 {l 88-1 93) Sub : 83.5-86.5 (1 83-1 87) Unified mechanical seal Wax, two-stage I Full-open temperature "C ("F) 100 {212} 1 Full-open lift mm {in} Main: 8.0 (0.31) min. Sub : 1.5 (0.06) min. TY pe Corrugated fin Cap valve opening pressure kPa {kgf/cm2, psi} 1 TROUBLESHOOTING GUIDE Problem Electric 320 {l 2.6) 5 120-1 2 below 7.7 Type 45UOEX-003 Blade Motor Coolant level insufficient 1 Add Outer diameter mm {in) Number Capacity W-V Current A Possible Cause Coolant leakage 1 Repair Remedy Radiator fins clogged ( Clean Radiator cap malfunction 1 Replace Coolant fan malfunction 1 Replace Thermostat malfunction 1 Replace Water passage clogged 1 Clean Water pump malfunction Impurities in coolant Replace Replace Gartner Banana

WATER PUMP WATER PUMP REMOVAL I INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to page E-5 for WARNING and procedure) 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal. 1. Timing belt 4. Water pump Service . . . . . . . . . . . . . . . . . . . . . Section B Inspect for cracks, damaged mounting sur- 2. PIS oil pump face, bearing condition, and leakage. Removal Note . . . . . . . . . . . . . . page E-1 1 If the water pump is damage, replace it. 3. Water hose Do not repair it. 5. Water inlet pipe Gartner Banana

WATER PUMP Stens After Installation 1. connect the neaative batterv cable. Removal Note PIS oil pump 1. Remove the PIS oil pump with the hoses still connected. 2. Position the pump away from the water pump and affix it with wire. 2. Fill the radiator kith coolant: (Refer to page E-6 for WARNING and procedure.) Gartner Banana

EXHAUST GAS RECIRCULATION (EGR) EGR CONTROL VALVE I EGR CONTROL VALVE Inspection 1. Start the engine and let it idle. 2. Connect a vacuum pump as shown and apply vacuum. 3. Verify that the engine runs roughly or stalls at more than the specified vacuum. Specification: 5.4--12.0 kPa (40-90 mmHg, 1.6-3.5 inHg) 4. If not as specified, replace the EGR control valve. Replacement Plug the water hoses after disconnecting them. 1. Remove the EGR control valve in the sequence shown below. (1 ) EGR hoses (2) Vacuum hose (3) EGR function sensor connector (4) EGR control valve and gasket 2. Install a new gasket, and then install the EGR control valve in the reverse order of removal. Gartner Banana

CONVERTIBLE TOP s 6. Place the link assembly onto the top fabric. 7. Install the top fabric to the bows, beginning from the rear bow. 8. Align the center of the retainer and the V notch in the top fabric, and roll the top fabric over the bow u retainer. 9. Hang the end of the top fabric on the bow retainer. 10. Clamp the top fabric to the bow with protected water pump pliers. Pull the top fabric by hand to verify that it is held securely. 11. Affix the top fabric to the rear bow with the Velcro. REAR BOW SEC. A-A I pg TOP FABRIC I CENTER BOW 12. Set the convertible top upright. 13. Rivet the cables to the front of the link assembly. Gartner Banana