1994 MAZDA MX-5 SECTION T

ON-VEHICLE MAINTENANCE B I I 35UOBX-020 Stem After Installation 3. Install the camshaft pulley lock bolts. 4. Hold the camshaft with a wrench at the cast hexagon. 5. Tighten the camshaft pulley lock bolt. Tightening torque: 50-60 Nm C5.0-6.2 kgfm, 3744 ft4bf) 1. pill the radiator with the specified amount and type of engine coolant. (Refer 2. Connect the negative battery cable. 3. Start the engine and check follows: (1) Engine coolant leakage (2) Ignition timing (Refer to page 59.) 4. Recheck the engine coolant levels. to section E.) Gartner Banana

B ON-VEHICLE MAINTENANCE REAR OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove the transmission. (MT Refer to section J. AT: Refer to section K.) 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to lnstallation Note. Nm (kgfm, ft-lbf) I 1. Clutch cover, clutch disc (MT) 4. Oil seal Removal / Installation ......... section H Removal Note .................. below 2. Flywheel (MT) Installation Note ........... page 6-27 ......... Removal / Installation section J 3. Drive plate (AT) ......... Removal / Installation section K Removal Note Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. 05UOBX-063 Gartner Banana

B REMOVAL REMOVAL Caution Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death -d and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line safety Procedures" on section F. PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E.) 3. Remove the transmission. 4. Remove in the order shown in the figure, referring to Removal Note. Step 1 1. Air cleaner housing assembly 2. Accelerator cable 3. Radiator hose 4. Oil cooler hose 5. Coolant reservoir hose 6. Fan connector 7. Radiator and fan assembly 8. PIS andlor A/C drive belt ................ Removal 9. Alternator drive belt .................. Removal page B- 6 10. PIS oil pump (If equipped) ............. Removal Note page 529 11. AIC compressor (If equipped) Removal Note ............. page 529 1 page B- 6 Gartner Banana

B DISASSEMBLY CYLINDER BLOCK (EXTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note. GASKET, REPLACE - L 1. Clutch cover, clutch disc (MT) Removal 1 Installation ......... section H 2. Flywheel (MT), drive plate (AT) Disassembly Note .......... page 8-43 3. End plate 4. Oil pan Disassembly Note .......... page B43 5. Oil strainer 6. Oil pan baffle Disassembly Note .......... page B-44 7. Water pump 8. Oil pump ...... Disassembly 1 Assembly section D 9. Front oil seal Disassembly Note .......... page B-43 10. Rear cover 11. Rear oil seal Disassembly Note .......... page 6-43 Gartner Banana

B ASSEMBLY 4. Apply a continuous bead of silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends. 5. Install the oil pan. ij Tightening torque: 7.9-10.7 N.m (80-110 kgf-cm, 70-95.4 in4bf) End Plate Install the end plate. Tightening torque: 7.9--10.7 N.m (80-110 kgf.cm, 70-95.4 in-lbf) Flywheel (MT) or drive plate (AT) 1. Remove the sealant from the bolt holes in the crankshaft and from the bolts. Caution If all of the old thread locking sealant cannot be re- moved from the bolt, it will not torque properly. - Replace the bolt. Note If a new bolt is used, do not apply thread locking seal- ant. New Mazda bolts have sealant on them. 2. Set the flywheel onto the crankshaft. 3. Apply sealant to the flywheel bolts and install them. 4. Hold the flywheel with the SST. 5. Tighten the bolts in two or three steps in the order shown. Tightening torque: 97-102 N.m (9.8-10.5 kgf+m, 71-75.9 ft.lbf) Clutch Disc and Clutch Cover (MT) Install the clutch disc and clutch cover using the SST. (Refer to section H.) Tightening torque: 18-26 N.m (1.8-2.7 kgf.m, 14--19 ftlbf) 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

B INSTALLATION ALTERNATOR Drive belt 1. lnstall the alternator drive belt. (Refer to page B-5.) 2. lnstall the PIS and/or AIC drive belt. 3. Adjust the drive belt deflection, and tighten the alternator - and PIS mounting bolts and nuts. (Refer to page 8-7.) Radiator and coolant fan assembly 1. lnstall the radiator and coolant fan assembly. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft4bf) 2. lnstall the AIC pipe bracket to the radiator Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in4bf) 3. Connect the upper and lower radiator hoses. 4. Connect the coolant reservoir hose. 5. Connect the coolant fan motor connector. Steps After Installation 1. lhstall the transmission. (Refer to sections J, K.) 2. lnstall the under cover. 3. If the engine oil was drained, fill with the specified amount and type of engine oil. (Refer to section D.) 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E.) 5. If the transmission oil was drained, fill with the specified amount and type of transmission oil. (Refer to sections J, K.) 6. Connect the negative battery cable. 7. Start the engine and check the following. (1) Engine oil, transmission oil, and engine coolant leakage (2) Ignition timing, idle speed (Refer to page 59.) (3) Operation of emission control system 8. Perform a road test. 9. Recheck the engine oil and engine coolant levels. 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 . LUBRICATION SYSTEM INDEX ....................................... D- 2 ..................................... OUTLINE D- 3 ........................... SPECIFICATIONS D- 3 TROUBLESHOOTING GUIDE .................. D- 3 OIL PRESSURE .............................. D- 4 PREPARATION ............................. D- 4 INSPECTION ............................... D- 4 ENGINE OIL .................................. D- 5 INSPECTION ............................... D- 5 REPLACEMENT ............................ D- 5 OIL FILTER ................................... D- 6 REPLACEMENT ............................ D- 6 OIL COOLER ................................. D- 7 REMOVAL / INSTALLATION .................. D- 7 OIL PAN ..................................... D- 8 REMOVAL / INSTALLATION .................. D- 8 OIL PUMP .................................... D-11 DISASSEMBLY / ASSEMBLY ................. D-11 INSPECTION ............................... D-12 45UODX401 Gartner Banana