1994 MAZDA MX-5 alternator belt

B INDEX INDEX 1. Timing belt Removal / Installation ....... page 8-1 2 2. Cylinder head gasket Replacement .............. page 6-1 6 3. HLA Removal / Installation ....... page 8-20 4. Front oil seal Replacement .............. page 6-24 5. Rear oil seal Replacement .............. page 6-26 INTAKE MANIFOLD COMPRESSION INSPECTION, PAGE B-10 TIGHTENING TORQUE STANDARD: 1,255 kPa (1 2.8 k f/cm2, 182 psi)-300 rpm 19-25 Nm (1.9-2.6 kgfq 14--18 ft4bf) MINIMUM: 883 kPa (9.0 kgflcm 9 , 128 psi}-300 rpm TIGHTENING TORQUE 3946 Nm i3.9--4.7 kgf m, 29-33 ftdbf) DRIVE BELT ADJUSTMENT. PAG ENGINE OIL INSPECTION, SERVICE, SECTION D DEFLECTION mm (in) ENGINE COOLANT INSPECTION, 6. Engine Removal .................. page 8-28 Engine stand mounting ..... page 6-32 Disassembly .............. page 6-35 Inspection / Repair ......... page B-47 Assembly ................. page 559 Engine stand dismounting ... page 8-81 , Installation ................ page B-83 SERVICE, SECTION E DRIVE BELT ALTERNATOR PIS. PIS + AlC AlC NEW 55-7.0 (0.224.27) 8.&9.0{0.324.35] 8.0-9.0{0.324.35) USED 6.0-7.5 (0.24-0.29) 9.0-10.0{0.364.39) 9.0-10.0{0.364.39} LIMIT 8.0 (0.31) 11.5 (0.45) 11.5 (0.453 Gartner Banana

B TROUBLESHOOTING GUIDE Problem nsufficlent power 4bnormal combustion Engine noise Possible Cause Insufficient compression Malfunction of HLA' Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Stuck, damaged, or worn piston ring Cracked or worn piston Malfunction of fuel system Malfunction of ignition system Others Slipping clutch Dragging brakes Wrong size tires Malfunction of engine-related components Malfunction of HLA* Stuck or burned valve Weak or broken valve spring Carbon accumulation in combustion chamber Malfunction of fuel system Malfunction of ignition system Crankshaft- or bearing-related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged Piston-related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod Valves or timing-related parts Malfunction of HLA' Broken valve spring Excessive valve auide clearance Malfunction of cooling system Malfunction of fuel system Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage Malfunction of timina belt tensioner Remedy Replace Repair Replace Replace Replace Replace Replace Replace Refer to section F Refer to section G Refer to section H Refer to section P Refer to section Q Replace Replace Replace Eliminate carbon Refer to section F Refer to section G Replace or repair Replace Replace or repair Replace or repair Replace Replace or repair Replace Replace Replace Replace Replace Replace Replace Refer to section E Refer to section F Refer to section E Adjust Refer to section G Refer to section F Replace Page Tappet noise may occur if the engine has set idle for an extended period. The noise should dissipate after the engine has reached normal operating temperature. (HLA troubleshooting: Refer to page 6-8) Gartner Banana

ENGINE TUNE-UP V-RIBBED BELT PIS or PIS + A/C EQUIPPED AIC EQUIPPED IDLER Coolant quality 1. Verify that there is no buildup of rust or scale around the radiator cap or radiator filler neck. 2. Verify that the coolant is free of oil. d 3. Replace the coolant if necessary. DRIVE BELT Inspection 1. Remove the air intake pipe. 2. Check the drive belts for wear, cracks, and fraying. Re- place if necessary. 3. Verify that the drive belts are correctly mounted on the pulleys. 4. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Ap- ply moderate pressure 98 N (10 kgf, 22 Ibf) midway be- tween the specified pulleys. Deflection rnrn {in) Drive belt New' Used Limit Alternator 5.5-7.0 6.0-7.5 m.22-0.27) (0.24-0.29) 8.0 (0.31) t" NC 8.0-9.0 9'0-'0.0 11.5 {0.45} {0.32-0.35) {0.36-0.39) A belt that has been on a running engine for less than five minutes. 5. If the deflection is not within specification, adjust it. 6. Install the air intake pipe. Drive belt tension check Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys. Gartner Banana

ENGINE TUNE-UP B 2 ADJUSTING BOLT LOCKNUT Tension N {kgf, lbfl I Drive belt New* Used I Limit I A belt that has been on a running engine for less than five minutes. 45UOBX-011 Alternator PIS, PIS + A/C AIC Adjustment (1) Alternator belt Loosen the alternator bolts @J and @ and adjust the belt deflection by turning the adjusting bolt 0. Tightening torque @: 19-25 N-m {I .9-2.6 kgf.m, 14-18 ft4bf) @: 38-51 N-m (3.8-5.3 kgf.m, 28-38 ft4bf) 491 -745 (50-76, 11 0-1 67) 491-588 (50-60, 11C-132) 49 1-588 (50-60, 11 0-1 32) (2) PIS belt, PIS + A/C belt Loosen the PIS oil pump bolt @ and nuts @ and @ and adjust the belt deflection by turning the adjusting bolt @. Tightening torque @: 3246 N.m (3.24.7 kgf.m, 24-33 ftlbf) @: 37-53 N-m I3.7-5.5 kgf.m, 27-39 ft4bf) 0: 19-25 N-m {I .9-2.6 kgf.m, 14-18 ft4bf) 491 -706 (50-72, 11 0-1 58) 422-490 (43-50, 95-1 10) 422490 {43-50, 95-1 lo} (3) AIC belt If necessary, loosen the lock nut and adjust the belt deflection by turning the adjusting bolt. 343 (35,771 245 {25, 55) 245 {25,55) Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbf) 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

B REMOVAL REMOVAL Caution Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death -d and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line safety Procedures" on section F. PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E.) 3. Remove the transmission. 4. Remove in the order shown in the figure, referring to Removal Note. Step 1 1. Air cleaner housing assembly 2. Accelerator cable 3. Radiator hose 4. Oil cooler hose 5. Coolant reservoir hose 6. Fan connector 7. Radiator and fan assembly 8. PIS andlor A/C drive belt ................ Removal 9. Alternator drive belt .................. Removal page B- 6 10. PIS oil pump (If equipped) ............. Removal Note page 529 11. AIC compressor (If equipped) Removal Note ............. page 529 1 page B- 6 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 . ENGINE ELECTRICAL SYSTEM INDEX ....................................... G- 2 OUTLINE ..................................... G- 3 SPECIFICATIONS ........................... G- 3 TROUBLESHOOTING GUIDE .................. G- 4 CHARGING SYSTEM .......................... G- 6 PREPARATION ............................. G- 6 CIRCUIT DIAGRAM ......................... G- 6 TROUBLESHOOTING ....................... G- 7 BATTERY .................................. G- 8 ALTERNATOR .............................. G-10 DRIVE BELT ................................ G-13 IGNITION SYSTEM ............................ G-15 PREPARATION ............................. G-15 CIRCUIT DIAGRAM ......................... G-15 TROUBLESHOOTING ....................... G-16 IGNITION TIMING ........................... G-17 SPARK PLUG ............................... G-18 IGNITION COIL ............................. G-19 IGNITER ................................... G-19 HIGH-TENSION LEAD ....................... G-20 STARTING SYSTEM ........................... G-21 CIRCUIT DIAGRAM ......................... G-21 TROUBLESHOOTING ....................... G-21 STARTER .................................. G-22 STARTER INTERLOCK SWITCH (MT) ......... G-28 45UOGX401 Gartner Banana