1994 MAZDA MX-5 engine

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

ASSEMBLY Dipstick, Dipstick Pipe 1. Apply a small amount of clean engine oil to the new 0- ring. 2. Push the dipstick pipe into the oil pan. u 3. Tighten the dipstick pipe bracket nut. Tightening torque: 7.9-10.7 N.m (80-1 10 kgfem, 70-95.4 in4bf) 4. lnstall the dipstick. Spark Plug lnstall the spark plugs. Tightening torque: 15-22 N.m (1 .%2.3 kgf-m, 11-1 6 ft4bf) Water Outlet Pipe 1. Remove all foreign material from the water outlet pipe mounting surface. 2. lnstall a new gasket and the water outlet pipe. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft4bf) Oil Pressure Switch lnstall the oil pressure switch. Tightening torque: 12-17 N.m (1.2-1.8 kgf-m, 9-13 ft4bf) Gartner Banana

ASSEMBLY B Oil Filter 1. Remove all foreign material from the oil filter mounting surface. 2. Apply a small amount of clean engine oil to the rubber seal of the oil filter. 3. Install the oil filter and tighten it by hand until the rubber seal contacts the base. 4. Hand tightening type (Numbers printed on filter) Tighten the filter 314 of a turn by hand after it contacts the cylinder block. If tightening by hand is difficult, use the filter wrench. Example When the oil filter contacts the cylinder block at "l", turn it 314 of a turn further to "4". Filter wrench tightening type (No numbers printed on fil- ter) Tighten the filter 1 and 116 turns with the filter wrench af- ter it contacts the cylinder block. Right Engine Mount Install the right engine mount. Tightening torque: 37-53 N-m (3.7-5.5 kgf.m, 27-39 ft.lbf) Alternator Bracket Install the alternator bracket. Tightening torque: 64-49 N-m (6.5--9.1 kgf-m, 48-45 ft4bf) Alternator Install the alternator and hand tighten the mounting bolts. Gartner Banana

ENGINE STAND DISMOUNTING B ENGINE STAND DISMOUNTING PROCEDURE i_/ 1. Remove the engine from the SST (engine stand). 2. Remove the SST (engine hanger) from the engine. 3. lnstall the parts shown in the figure. Torque Specifications 05UOBX-251 Left Engine Mount Install the left engine mount. Tightening torque: 37-53 N-m (3.7-5.5 kgf.m, 27-39 ftlbf) 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

INSTALLATION B INSTALLATION PROCEDURE u Tighten all bolts and nuts to the specified torques. Step 1 Torque Specifications I RIGHT I LEFT 05UOBX-258 Engine assembly 1. Suspend the engine assembly. Slowly lower the engine assembly as a unit. Keep the en- gine from swinging or bumping into components in the engine compartment. 2. Install the engine tilting downward. 3. Align the engine mounts with the crossmember mount- ing holes. 4. Install the engine mount nuts and hand tighten them. Engine mount nut Tighten the engine mount nuts. Tightening torque: 57-78 N.m (5.8--8.0 kgf.m, 42-57 ft-lbf) I-, /-b -1 45UOBX-173 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