1994 MAZDA MX-5 gasket

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

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

ENGINE OIL D ENGINE OIL 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 as 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}. REPLACEMENT Warning When the engine and the oil are hot, they can badly burn. Don't burn yourself with either. 1. Warm up the engine to normal operating temperature and stop it. 2. Remove the oil filler cap and the oil drain plug. 3. Drain the oil into a container. 4. Install a new gasket and the drain plug. Tightening torque: 3041 N-m 13.0-4.2 kgf.m, 22-30 ft-lbf) 5. Refill the engine with the specified type and amount of engine oil. Oil replacement: 3.6 L 13.8 US qt, 3.2 Imp qt) 6. Refit the oil filler cap. 7. Run the engine and check for leaks. 8. Check the oil level and add oil if necessary. Gartner Banana

D OIL PAN OIL PAN REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine oil. (Refer to page D-5.) 3. Remove the undercover. 4. Remove in the order shown in the figure, referring to Removal Note. 5. Install in the reverse order of removal, referring to Installation Note. 94--117 (9.5-11.9,69-86) 57-78 (5.8--8.0,42-57) 69-83 {7.0-8.5,51-61) GASKET, REPLAC 7.9--10.7 Nm {60-110 kgfan, 70-95 O-RING, REPLACE 'If 64-49 (6.!%9.1,4&65) 7.9-10.7 N.m (80-110 kgf.crn, 70-95 indbf] 1. Dipstick and pipe 5. Oil pan ............. 2. Intermediate shaft Removal Note page D- 9 ........... .......... Removal / lnstllation section N Installation Note page D-10 3. Engine mount nut 6. Oil strainer 7. Oil baffle ,' ............. Removal Note page D- 9 ............. 4. Crossmember installation bolt and nut Removal Note page D- 9 ............. ........... Removal Note page D- 9 Installation Note page D- 9 Gartner Banana

OIL PAN NOTCH NOTCH I 05UODX-209 Steps After Installation 1. Install the undercover. Oil pan 1. Remove all foreign material from the contact surfaces. 2. Apply silicone sealant to the shaded areas shown in the figure. 3. Install new gaskets onto the oil pump body and the rear cover with the projections in the notches shown in the fig- ure. 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 with five minutes. Tightening torque 0: 7.9-10.7 N.m (80-110 kgf-cm, 70-95 in4bf) @: 64-49 N.m (6.5-9.1 kgf-m, 48-45 ft-lbf) 2. Connect the negative battery cable. 3. Fill with the specified amount and type of engine oil. (Refer to page D-5.) 4. Start the engine and check for leaks. 5. Check the oil level and add oil if necessary. Gartner Banana

THERMOSTAT E THERMOSTAT REMOVAL / INSTALLATION u 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. 4. Install in the reverse order of removal. @) REPLACE TAB MUST BE ASSEMBLED TOWARD THERMOSTAT COVER 1. Thermostat cover 3. Thermostat 2. Thermostat cover gasket Inspection . . . . . . . . . . . . . . . . . . . . . . below INSPECTION 1. Visually check that the thermostat valve is airtight. 2. Place the thermostat and a thermometer in water. 3. Heat the water and check the following: Initial-opening temperature Main: 86.5-89.S°C (1 88--193OF) Sub: 83.5--86.S°C (1 8Sl87OF) Full-open temperature: 100°C (21 2°F) Full-open lift Main: 8.0mm 10.31 in) min. Sub: 1.5mm (0.06 in) min. Steps After installation 1. Connect the negative battery cable. 2. Fill the radiator with coolant. (Refer to page €4 for WARNING and procedure.) u Gartner Banana

F TROUBLESHOOTING GUIDE INSPECTION Check if battery positive voltage exists at fuel pump connector fuel pump positive terminal with jumper wire connected.(~tep 3 Check for fuel injector operating sound while crank- ing engine Check if battery positive voltage exists at fuel injector connector B terminal wire with ignition switch ON Connect data link connector terminals F/P and GND with jumper wire and check for correct fuel line pres- sure with ignition switch ON page F-110 Fuel Line pressure: 265--314 kPa f2.7-3.2 kgf/crn2, 38-46 psi) Check for correct engine compression Section B Engine compression: 1,255--883 kPa {12.&9.0 kgf/crn2, 182-1 28 psi)-300 rpm Check if spark plugs are OK WEAR AND CARBON BUILDUP BURNS PLUG GAP 1.0-l.lmm DAMAGE AND (0.040-0.043 in) DETERIORATION DAMAGE Try known good PCME and check if condition im- proves page F-144 - Yes - No Yes Yes - No Yes Yes - No - Yes ACTION Check continuity of fuel pump page F-114 Check fuel pump relay page F-117 Go to Step 7 Go to Step 6 Check PCME terminals 2A, 2U, 2V, 2Y and 22 voltages @3F page F-147 Check for open circuit in wiring between main relay and fuel injector page F-7 Go to next step Low pressure Check fuel line pressure while pinching fuel return hose 0 If fuel line pressure quickly increases, check pressure regulator page F-118 0 If fuel line pressure gradually increases, check for clog- ging between fuel pump and pressure regulator If not clogged, check fuel pump maximum pressure page F-115 Go to next step Check engine condition @3F Section B w Worn piston, piston rings or cylinder wall Defective cylinder head gasket w Distorted cylinder head Improper valve seating w Valve sticking in guide Go to next step Repair, clean, or replace Section G Gartner Banana

TROUBLESHOOTING GUIDE INSPECTION Check if PCME terminal voltages are OK (IC, 1 R, IT, 2D, 20 and 2Q) page F-146 :heck for air leakage of intake air system malfunction page F-100 :heck for EGR system malfunction page F-124 Check if mass airflow sensor US page F-152 Check for correct engine compression Section B Engine compression: 1,255-883 kPa j12.8-9.0 kgf/cm2, 182-128 psil-300 rpm Check if spark plugs are OK WEAR AND CARB/ON BUILDUP BURNS PLUG GAP 1 .O-1 .l mm (0.040-4.043 in) DAMAGE AND DETERIORATION DAMAGE - Yes Yes - No Yes - No Yes - No Yes No - Yes - No - ACTION Go to next step Check for cause (Refer to "Check Point for Each Terminal") page F-148 Repair or replace Go to next step Repair or replace Go to next step Go to next step Repair or replace page F-99 Go to next step Check engine condition Section B Worn piston, piston rings or cylinder wall Defective cylinder head gasket Distorted cylinder head Improper valve seating a Valve sticking in guide Go to next step Repair, clean, or replace @a Section G Try known good PCME and check if condition im- 3rOVeS page F-144 Gartner Banana