1994 MAZDA MX-5 lock

ON-VEHICLE MAINTENANCE B ON-VEHICLE MAINTENANCE PREPARATION L SST 49 DO11 102 Lock tool, crankshaft Shaft (Part of 49 E011 1AO) Collar (Part of 49 E011 1 AO) Warninq For removal / installat ion of timing belt pulley For prevention of engine rotation For prevention of engine rotation 49 EOl 1 105 Stopper (Part of 49 EOll 1AO) 49 EOll 1 A0 Ring gear brake set For prevention of engine rotation For prevention of engine rotation ~onhuous 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. 49 SEO1 310 A Centering tool, clutch disc For installation of clutch disc Gartner Banana

B ON-VEHICLE MAINTENANCE TIMING BELT Removal / lnstallation 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove the under cover. 4. Remove in the order shown in the figure, referring to Removal Note. 5. Install in the reverse order of removal, referring to lnstallation Note. (80-110 kgfmn, 7.9-10.7 Nm 13-17 Nm (125-175 kgfcm, 109-151 In4bf) Nm (kgfm, ft4bf) 45UOBX425 1. Air intake pipe 12. Spark plug 2. Upper radiator hose Removal / Installation ......... section G 3. Water hoses (Connected to thermostat 13. PCV valve housing) 14. Cylinder head cover 4. PIS andlor A/C drive belt 15. Upper timing belt cover Removal 1 Installation ....... page B- 6 16. Middle timing belt cover 5. Alternator drive belt 17. Lower timing belt cover Removal / Installation ....... page 5 6 18. Timing belt 6. Water pump pulley Removal Note ............. page B-13 7. Plate Installation Note ........... page B-14 8. Crankshaft pulley Inspection ................. page 8-58 9. Pulley lock bolt 19. Tensioner, tensioner spring Removal Note ............. page B-13 Installation Note ........... page B-14 /' Installation Note ........... page 51 5 Inspection ................. page 558 10. Pulley boss 20. Idler 11. Ignition coil and high-tension lead Inspection ................. page 8-58 Gartner Banana

ON-VEHICLE MAINTENANCE B IDLER L ROTATION ARROW - Removal Note Pulley lock bolt 1. Hold the pulley boss with the SST. 2. Using the SST, loosen the pulley lock bolt. 3. Remove the bolt and the pulley boss. Timing belt 1. Install the pulley boss. 2. Install the pulley lock bolt. 3. Turn the crankshaft to align the timing marks. 4. Do not turn the crankshaft after aligning the timing marks. 5. Remove the pulley lock bolt and pulley boss. 6. Mark the timing belt rotation for proper reinstallation. 7. Loosen the tensioner lock bolt and pry the tensioner out- ward with a bar. 8. Tighten the lock bolt with the tensioner spring fully ex- tended. 9. Remove the timing belt. Gartner Banana

ON-VEHICLE MAINTENANCE Installation Note Tensioner and tensioner spring 1. Install the tensioner and the tensioner spring. 2. Protect the tensioner with a rag. Pry the tensioner out- -,, ward with a bar. 3. Temporarily tighten the tensioner lock bolt with the ten- sioner spring fully extended. Timing belt 1. Verify that the timing belt pulley mark is aligned with the timing mark. 2. Verify that the camshaft pulley marks are aligned with the seal plate marks. E for intake side, and I for exhaust side. 3. Install the timing belt so that there is no looseness at the idler side or between the camshaft pulleys. 4. Install the pulley boss and pulley lock bolt. 5. Turn the crankshaft two turns clockwise and face the pin on the pulley boss upright. Do not turn the crankshaft counterclockwise. 6. Verify that the camshaft pulley marks are again aligned with the seal plate marks. If not aligned, remove the timing belt and repeat from tensioner installation. 7. Turn the crankshaft 1 and 516 turns clockwise and align the timing belt pulley mark with the tension set mark for proper timing belt tension adjustment. 8. Using the SST, loosen the pulley lock bolt and remove the bolt and pulley boss. Do not turn the crankshaft. 9. Verify that the timing belt pulley mark is aligned with the tension set mark. Gartner Banana

ON-VEHICLE MAINTENANCE B Stem After Installation 10. Loosen the tensioner lock bolt to apply spring tension to the timing belt. 11. Tighten the tensioner lock bolt. Tightening torque: 38-51 N-m (3.8-5.3 kgf.m, 28--38 ftlbf) 12. Install the pulley boss and pulley lock bolt. 13. Turn the crankshaft 2 and 116 turns clockwise and verify that the timing marks are correctly aligned. 14. Measure the timing belt deflection by applying moderate pressure 98 N (10 kgf, 22 Ibf) midway between the cam- shaft pulleys. If the deflection is not correct, repeat from Step 10 above. Deflection: 9.0-11.5mm (0.36-4.45 in) at 98 N (10 kgf, 22 Ibf) Pulley lock bolt Hold the crankshaft with the SST and tighten the pulley lock bolt. Tightening torque: 157-166 N.m (16-17 kgf.m, 116-122 ftlbf) 1. till the radiator with specified amount and type of engine coolant. (Refer to section E.) 2. Connect the negative battery cable. 3. Start the engine and check, and if necessary, adjust the ignition timing. Gartner Banana

ON-VEHICLE MAINTENANCE B CRANKSHAFT POSITION SENSOR DRIVE GROOVE 45UOBX-04 Removal Note Camshaft pulley 1. Hold the camshaft with a wrench at the cast hexagon. 2. Remove the camshaft pulley lock bolts. 3. Remove the camshaft pulleys. Camshaft 1. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure. 2. Remove the camshaft caps. 3. Remove the camshafts. 4. Remove the camshaft oil seals from the camshafts. HLA Caution The HLA must be reinstalled in the same posi- tions from which they were removed. If they are not, it can cause premature and uneven wear. Note Mark the HLA to show their original positions. Remove the HLA from the cylinder head. Installation Note HLA 1. Apply clean engine oil to the friction surfaces. 2. If the HLA are being reused, install them in the position from which they were removed. 3. Verify that the HLA move smoothly in their bores. Camshaft Note The exhaust camshaft has a groove for the crank- shaft position sensor drive. 1. Apply clean engine oil to the camshaft journals and bear- ings. 2. Install the camshaft in position. Gartner Banana

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

DISASSEMBLY B DISASSEMBLY PREPARATION SST 49 EOll 1AO For prevention of engine rotation 49 EOll 103 For prevention of engine rotation Ring gear brake set Shaft (Part of 49 EOl 1 1 AO) 49 E011 105 Stopper (Part of 49 EOll lAO) a For prevention of engine rotation 49 EOll 104 For prevention of engine rotation Collar (Part of 49 E011 1 AO) For removal / installation of valves 49 8012 012 Body (Part of 49 801 2 0A2) For removal I installation of valves Pivot, valve spring lifter For removal / installation of valves For removal / installation of valves Foot (Part of 49 80 1 2 0A2) Locknut (Part of 49 B012 0A2) For removal / installation of valves 49 S120 170 Remover, valve seal For removal of valve seals Arm, valve spring lifter 49 0221 061 A Remover & installer, piston pin For removal / installation of piston pins 1. Code all identical parts (such as piston, piston rings, connecting rods, and valve springs) so that they can be reinstalled in the cylinder from which they were removed. 2. Clean the parts with a steam cleaner. Blow off any remaining water with compressed air. 45UOBX-065 Gartner Banana