1994 MAZDA MX-5 maintenance

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

B ON-VEHICLE MAINTENANCE I - DOWEL PINS I 3. Apply silicone sealant to the shaded areas shown in the figure. Do not let any sealant get on the sealant surfaces. 4. Install the camshaft caps according to the cap number and arrow mark. 5. Install the camshaft cap bolts and tighten them in two or three steps in the order shown in the figure. Tightening torque: 11.3-1 4.2 N.m (115--145 kgf.cm, 100-125 in-lbf} ii 6. Apply a small amount of clean engine oil to the lip of a new camshaft oil seal. 7. Push the oil seal slightly in by hand. 8. Using a pipe and hammer, tap the oil seal in evenly until it is flush with the edge of the camshaft cap. Note Oil seal outer diameter: 48mm {I .89 in) Oil seal inner diameter: 34mm {I .34 in} Camshaft pulley 1. Turn the camshafts until the camshaft dowel pins face straight up. 2. Install the camshaft pulleys with the I mark (intake side) or the E mark (exhaust side) straight up. 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

B ON-VEHICLE MAINTENANCE FRONT OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove the under cover. 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. 1. Timing belt 3. Oil seal i Removal / Installation ....... page B-12 Removal Note ............. page 525 2. Timing belt pulley Installation Note ........... page B-25 Installation Note ........... page 8-25 Gartner Banana

ON-VEHICLE MAINTENANCE B Steps After Installation 1. Connect the neaative batterv cable. Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. Installation Note Oil seal 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly with a pipe and a hammer until it is flush with the edge of the oil pump body. Note Oil seal outer diameter: 50.5mm (1.99 in} Oil seal inner diameter: 36.5mm (1.44 in} Timing belt pulley 1. Install the timing belt pulley. 2. Install the pulley woodruff key with the tapered side to- ward the oil pump body. 2. Start the enginsand check, and if necessary, adjust the ignition timing. 3. Connect the negative battery cable. 4. Start the engine and check follows: (1) Engine coolant leakage (2) Ignition timing (Refer to page B-9.) 5. Recheck the engine coolant levels. 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

ON-VEHICLE MAINTENANCE Installation Note Oil seal 1. Apply a small amount of clean engine oil to w new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a pipe and hammer, tap the oil seal in it is flush with the edge of the rear cover. Note Oil seal outer diameter: 100mm (3.94 in} Oil seal inner diameter: 83mm (3.27 in} 45UOBX-049 Steps After Installation 1. Connect the negative battery cable. 2. Start the engine and perform engine adjustments as necessary. the lip of a evenly until Gartner Banana

ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION L" SST r I I 16EOF2-012 BASIC INSPECTION Engine Oil 1. Remove the dipstick and check the engine oil level and condition. 2. Add or change oil as necessary. 49 B019 9AO System Selector Coolant (engine cold) For inspection of ignition timing and idle speed Warning Removing the radiator cap or the coolant drain plug while the engine is running, or when the en- gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause seri- ous injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when remov- ing the cap. Wrap a thick cloth around it and slow- ly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you're sure all the pressure is gone, press down on the cap-still using a cloth-turn it, and remove it. 1. Verify that the coolant level is near the radiator filler neck. 2. Verify that the coolant level on the coolant dipstick is be- tween the F and L marks. 3. Add coolant if necessary. Battery Removing the label on the top of the battery or removing the vent caps will void the battery's warranty. 1. Clean any corrosion on the clamps or battery posts. 2. Verify that the battery top is clean. If necessary, clean with baking soda and water. 3. Verify that cables are in good condition and not frayed or corroded. Repair or replace if necessary. 4. Verify that cable clamps are tight. Note Because this is a maintenance free battery, it is not necessary to check the fluid level. Gartner Banana