1994 MAZDA MX-5 lock

DISASSEMBLY B TIMING BELT Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Water pump pulley 2. Crankshaft pulley, plate 3. Cylinder head cover 4. Upper timing belt cover 5. Middle timing belt cover 6. Lower timing belt cover 7. Pulley lock bolt Disassembly Note ... 8. Pulley boss 9. Timing belt .......... Disassembly Note page 538 ................. Inspection page 558 10. Tensioner, tensioner spring ................. Inspection page B-58 11. Idler ................. Inspection page B-58 page 8-38 12. Timing belt pulley ................. Inspection page 558 Gartner Banana

DISASSEMBLY ROTATION ARROW - Disassembly Note Pulley lock bolt 1. Hold the flywheel (MT) or drive plate (AT 2. Loosen the pulley lock bolt. 3. Remove the pulley lock bolt. ') with the SST. Timing belt 1. ~rGect the tensioner with a rag. 2. Loosen the tensioner lock bolt. Ply the tensioner out- ward with a bar. 3. Tighten the lock bolt with the tensioner spring fully ex- tended. 4. Mark the timing belt rotation for proper reinstallation. 5. Remove the timing belt. Gartner Banana

DISASSEMBLY Disassembly 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 position from which they were removed. If they are not, it can cause premature and uneven wear. L Note Mark the HLA to show their original positions. Remove the HLA from the cylinder head. Cylinder head bolt 1. Loosen the cylinder head bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head bolts. Valve keeper 1. Set the SST against the upper valve spring seat as shown in the figure. 2. Compress the spring and remove the valve keepers. 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

DISASSEMBLY B PROTECT PUMP BODY WlTH RAG 05UOBX-10; I PROTECT REAR COYER WITH RAG I Disassembly Note Flywheel (MT) or drive plate (AT) 1. Hold the flywheel with the SST. 2. Remove the flywheel lock bolts. 3. Remove the flywheel. Oil pan 1. Remove the oil pan mounting bolts. Caution Pry tools can easily scratch the cylinder block and oil pan contact surfaces. 2. Insert a screwdriver only at the points shown in the fig- ure. 3. Remove the oil pan. Oil pan baffle 1. Insert a screwdriver between the cylinder block and the baffle to separate them. 2. Remove the baffle. Front oil seal Remove the oil seal with a screwdriver protected with a rag. Rear oil seal Remove the oil seal with a screwdriver protected with a rag. Gartner Banana

B DISASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Connecting rod cap Inspection ................. page B-45 2. Lower connecting rod bearing Inspection ................. page 8-45 3. Connecting rod and piston assembly Disassembly Note .......... page 545 4. Upper connecting rod bearing Inspection ................. page 8-57 5. Piston ring Disassembly Note .......... page 545 Inspection ................. page 555 6. Piston pin clip 7. Piston pin Disassembly Note Inspection ................. page 6-45 8. Piston Inspection ................. page 555 9. Connecting rod Inspection ................. page I345 10. Main bearing cap Disassembly Note .......... page 8-46 11. Lower main bearing Inspection ................. page B-46 12. Crankshaft Inspection ................. page 8-46 13. Upper main bearing Inspection ................. page 8-46 14. Thrust bearing Inspection ................. page 6-63 15. Oil jet Inspection ................. page B-53 16. Cylinder block Inspection ................. page 553 Gartner Banana

DISASSEMBLY Disassembly Note Connecting rod cap Before removing the connecting rod caps, measure the connecting rod side clearance. (Refer to page 8-64.) Connecting rod and piston assembly 1. Before removing the connecting rod and piston assem- bly, measure the connecting rod oil clearance. (Refer to page 8-64.) 2. Remove the Plastigage from the crankpin journals. 3. Use the handle of a hammer to remove the piston and connecting rod assembly through the top of the cylinder block. Piston ring Remove the piston rings with a piston ring expander (commercially available). Piston pin Remove the piston pin with the SST. Gartner Banana

INSPECTION / REPAIR OUT-OF-SQUARE I 9. Measure the valve stem protruding length (dimension L). Dimension L: 45.0mm (1.772 in) (1) If L is 45.0-E.5mm (l.772-l.79l in), no correc- tion is needed. (2) If L is 45.5-46.5mm (1.792-1.830 in), adjust with washer on spring seat area of cylinder head. (3) If L is 46.5mm (1.831 in) or more, replace cylinder head. Valve Spring 1. lnspect each valve spring for cracks or damage. 2. Measure the free length and out-of-square. Replace the valve spring if necessary. Free length Standard: 46.26mm (1.821 in) Minimum length: 39.5mm (1.56 in) with a set load of 224--253 N (22.G25.8 kgf, 50.2-56.7 Ibf) Out-of-square: 1.62mm (0.0638 in) max. CAMSHAFT 1. Set the front and rear journals on V-blocks. 2. Measure the camshaft runout. Replace the camshaft if necessary. Runout: 0.03mm (0.0012 in) max. 3. lnspect the camshaft for wear or damage. Replace the camshaft if necessary. 4. Measure the cam lobe heights at the two points as shown. Height Standard IN: 44.094mm (1,7360 in) EX: 44.600mm (1.7560 in) Minimum IN: 43.894mm (1,7281 in) EX: 44.400mm (1.7480 in) Gartner Banana