1994 MAZDA MX-5 Oil

B ASSEMBLY 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. ij Tightening torque: 7.9-10.7 N.m (80-110 kgf-cm, 70-95.4 in4bf) End Plate Install the end plate. Tightening torque: 7.9--10.7 N.m (80-110 kgf.cm, 70-95.4 in-lbf) Flywheel (MT) or drive plate (AT) 1. Remove the sealant from the bolt holes in the crankshaft and from the bolts. Caution If all of the old thread locking sealant cannot be re- moved from the bolt, it will not torque properly. - Replace the bolt. Note If a new bolt is used, do not apply thread locking seal- ant. New Mazda bolts have sealant on them. 2. Set the flywheel onto the crankshaft. 3. Apply sealant to the flywheel bolts and install them. 4. Hold the flywheel with the SST. 5. Tighten the bolts in two or three steps in the order shown. Tightening torque: 97-102 N.m (9.8-10.5 kgf+m, 71-75.9 ft.lbf) Clutch Disc and Clutch Cover (MT) Install the clutch disc and clutch cover using the SST. (Refer to section H.) Tightening torque: 18-26 N.m (1.8-2.7 kgf.m, 14--19 ftlbf) Gartner Banana

ASSEMBLY Cylinder Head Gasket 1. Remove all foreign material from the top of the cylinder block. 2. Place the new cylinder head gasket in position. Cylinder Head 1. Install the cylinder head. 2. Apply clean engine oil to the bolt threads and seat faces. 3. Tighten the cylinder head bolts in two or three steps in the order shown. Tightening torque: 76-81 N-m (7.7--8.3 kgf.m, 56-60 ft4bf) Thermostat Housing 1. Remove all foreign material from the thermostat housing mounting surface. 2. Install a new O-ring and the thermostat housing. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14--18 ft-lbf) Seal Plate Install the seal plate on the cylinder head. Tightening torque: 7.9-10.7 N-m (80-110 kgfem, 70-95.4 in4bf) 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. Gartner Banana

ASSEMBLY Camshaft Note The rear end of exhaust camshaft is grooved for the L/ crankshaft position sensor drive. 1. Apply clean engine oil to the camshaft journals and bear- ings. 2. Install the camshaft in position. CRANKSHAFT POSITION SENSOR DRIVE GROOVE 45UOBX-151 3. Apply silicone sealant to the shaded areas shown in the figure. Do not let any sealant get on the journal 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. Tightening torque: Il.3--14.2 N.m {ll5-l4S kgfem, 100-125 in4bf) ij 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 (1.89 in) Oil seal inner diameter: 34mm (1.34 in) Camshaft Pulley 1. Turn the camshafts until the camshaft dowel pins face straight up. 2. lnstall the camshaft pulleys with the I mark (intake side) or the E mark (exhaust side) straight up. Gartner Banana

B ASSEMBLY TIMING MARK Timing Belt Pulley 1. lnstall the timing belt pulley. 2. lnstall the pulley woodruff key with the tapered side to- ward the oil pump body. d Idler lnstall the idler. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ftlbf) Tensioner and Tensioner Spring 1. lnstall the tensioner and the tensioner spring. 2. Temporarily secure the tensioner with the spring fully ex- tended. Timing Belt 1, Turn the crankshaft and align the timing belt pulley mark with the timing mark. Do not turn the crankshaft counter- clockwise. 2. Verify that the camshaft pulley marks are aligned with the seal plate marks. E for intake side and I for exhaust side. Do not turn the crankshaft counterclockwise. 3. lnstall the timing belt so that there is no looseness at the idler side or between the two camshaft pulleys. 4. lnstall the pulley boss and pulley lock bolt. 5. Turn the crankshaft two turns clockwise, and align the timing belt pulley mark with the timing mark. Do not turn the crankshaft counterclockwise. 6. Verify that the camshaft pulley marks are aligned with the seal plate marks. J If not aligned, remove the timing belt and repeat from tensioner installation. Gartner Banana

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

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