1994 MAZDA MX-5 width

INSPECTION 1 REPAIR Valve Seat 1. lnspect the contact surface of each valve seat and valve face for the following: (1) Roughness u (2) Damage 2. If necessary, resurface the valve seat with a 45" valve seat cutter andlor resurface the valve face. 3. Apply a thin coat of Prussian blue to the valve face. 4. lnspect the valve seating by pressing the valve against the seat. (1) If blue does not appear 360" around the valve face, replace the valve. (2) If blue does not appear 360" around the valve seat, resurface the seat. 5. Measure the seat contact width. Width: 0.8-1.4mm (0.032-4.055 in) 6. Verify that the valve seating position is at the center of the valve face. (1) If the seating position is too high, correct the valve seat with a 70" cutter and a 45" cutter. (2) If the seating position is too low, correct the valve seat with a 0° cutter and a 45" cutter. 7. Seat the valve to the valve seat with lapping compound. 8. lnspect the sinking of the valve seat. Gartner Banana

ASSEMBLY B I RUBBER SLEEVE 2. Apply a liberal amount of clean engine oil to the main bearings, thrust bearings and main journals. 3. Install the crankshaft and the main bearing caps accord- ing to the cap number and + mark. 4. Tighten the main bearing cap bolts in two or three steps in the order shown in the figure. Tightening torque: 54--58 N.m (5.5-6.0 kgf.m, 40-43 ft4bf) 5. Measure the crankshaft end play. End play: 0.080-0.282mm (0.0032-0.0111 in) Maximum: 0.30mm (0.012 in) 6. If the end play exceeds the maximum, grind the crank- shaft and install an oversize thrust bearing or replace the crankshaft and thrust bearing. Thrust bearing width Standard: 2.500-2.550mm (0.0985-0.1 003 in) 0.25mm (0.01 0 in) oversize: 2.625--2.675mm (0.1 034-O.1053 in) 0.50mm (0.020 in) oversize: 2.750-2.800mm (0.1 083-0.1 102 in) 0.75mm (0.030 in) oversize: 2.875-2.925mm (0.1 132-0.1151 in) Piston and Connecting Rod Assembly 1. Protect the connecting rod bolts with rubber sleeves. Gartner Banana

REAR WINDOW INSULATION TAPE RIVET MOUNTING A INSULATION TAPE INSULATION TAPE SEC. A-A THE END OF THE ZIPPER 11. Remove the rivets from the rain rail with a cutter, and remove the rain rail from the convertible top. 12. Remove the rivets from the rear window with a cutter. 13. Peel apart the Velcro. Note Save the zipper stops for reuse. 14. Carefully remove the zipper stops from the rear window ,-- and top fabric, and remove the rear window. Installation Note Rear window 1. Decrease the rain rail with ethyl alcohol. 2. Install insulation tape to the rivet mounting holes of the rain rail. Insulation tape Width : 20 mm (0.79 in) Height : 15 mm 10.59 in) Thickness : 3 mm I0.12 in) 3. Align the ends of the zipper, and install the zipper pull tab. 4. Zip the rear window into place. Gartner Banana

T INSTRUMENT CLUSTER Symptom: Water temperature gauge does not operate. 05UOTX-466 Preparation SST ( ) ... CANADA ONLY I 45UOTX-036 49 0839 285 Checker, fuel and thermometer 05UOTX-052 Step 1 1. Disconnect the water temperature sensor connector. 2. Connect the red lead of the SST to terminal A of the con- nector and the black lead to ground. 3. Turn the ignition switch to ON. 4. Set the SST to the resistance values shown in the figure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the water temperature gauge indicates the correct values. The allowable indication error is twice the width of the needle. For inspection of gauges Gauge display I Action Correct Incorrect I ( ) ... CANADA ONLY 45UOTX-038 T-26 Replace water temperature sensor Go to Step 2 Gauge display Correct Step 2 1. Remove the instrument cluster. (Refer to page T-29.) 2. Apply battery positive voltage to terminal 2K of the instrument cluster and connect terminal 2J of the instru- ment cluster to ground. 3. Connect the red lead of the SST to terminal 2L of the instrument cluster and the black lead to ground. 4. Set the SST to the resistance values shown in the figure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the water temperature gauge indicates the correct values. The allowable indication error is twice the width of the needle. Action Repair wiring harness (Instrument cluster - Water temperature sensor) I Incorrect I ReDlace water tem~erature aauae I Gartner Banana

INSTRUMENT CLUSTER T Symptom: Fuel gauge does not operate. L, Preparation SST Step 1 1. Disconnect the connector from the fuel gauge sender unit. 2. Connect the red lead of the SST to the A (Y) terminal wire and the black lead to ground. 3. Turn the ignition to ON. 49 0839 285 Checker, fuel and thermometer 4. Set the SST to the resistance values shown in the figure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the gauge indicates the correct values. The al- lowable indication error is twice the width of the needle. For inspection of gauges Gauge display Action I Step 2 1. Remove the instrument cluster. (Refer to page T-29.) 2. Apply battery positive voltage to terminal 2K and ground to terminal 2J. 3. Connect the red lead of the SST to terminal 1 A and the black lead to ground. Correct Incorrect 4. Set the SST to the resistance values shown in the figure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the gauge indicates the correct values. The al- lowable indication error is twice the width of the needle. Replace fuel gauge sender unit Go to Step 2 ( Gauge display I Action I Correct Incorrect Repakwiring harness (Instrument cluster - Fuel gauge sender unit) Replace fuel gauge Gartner Banana

T INSTRUMENT CLUSTER Symptom: Oil pressure gauge does not operate. 05UOTX-468 Preparation SST I 49 0839 285 For inspection of Checker, fuel gauges and thermometer Step 1 1. Disconnect the connector from the oil pressure sensor. 2. Connect the red lead of the SST to the A (YIR) terminal wire and the black lead to ground. 3. Turn the ignition switch ON. 4. Set the SST to the resistance values shown in the figure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the gauge indicates the correct values. The al- lowable indication error is twice the width of the needle. I Incorrect I GO to step 2 Gauge display Correct Step 2 1. Remove the instrument cluster. (Refer to page T-29.) 2. Apply battery positive voltage to terminal 2K and ground to terminal 2J. 3. Connect the red lead of the SST to terminal 26 and the black lead to ground. Action Replace oil pressure sensor 4. Set the SST to the resistance values shown in the figure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the gauge indicates the correct values. The al- lowable indication error is twice the width of the needle. Incorrect I Replace oil pressure gauge Gauge display Correct Action Repair wiring harness (Instrument cluster - Oil pressure sensor) Gartner Banana

T INSTRUMENT CLUSTER Standard indication (kmlhl I 80 I 80-84 45UOTX-047 1 Standard Indication 1 Allowable ranae I Allowable range (kmlhl Standard indication (MPH) 30 WATER TEMPERATURE GAUGE Preparation SST Allowable range (MPH) 30-32 SPEEDOMETER lnspection Note .-,' Tire wear and improper inflation will increase speedo- meter error. 1. Using a speedometer tester, check the speedometer for allowable indication error, and check the operation of the odometer. Replace if necessary. 2. Check the speedometer for fluctuation and/or abnormal noise. If there is fluctuation or if the speedometer does not move, remove and inspect the speedometer cable. If it is in good condition, replace the speedometer as- sembly. TACHOMETER lnspection 1. Connect a test tachometer to the engine, and start the engine. 2. Check the tachometer for allowable indication error. Re- place if necessary. lnspection 1. Remove the instrument cluster. (Refer to page T-29.) 2. Apply battery positive voltage to terminal 2K and ground to terminal 2J. 3. Connect the red lead of the SST to terminal 2L and the black lead to ground. 49 0839 285 Checker, fuel and thermometer For inspection of gauges ( ) ... CANADA ONLY I I 45UOTX-050 183R 2on (I sn) 4. Set the SST to the resistance values shown in the figure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the gauge indicates the correct values. The al- lowable indication error is twice the width of the needle. 6. If not as specified, replace the water temperature gauge. -/' Gartner Banana

INSTRUMENT CLUSTER T FUEL GAUGE Preparation SST f OIL PRESSURE GAUGE Preparation SST L lnspection 1. Remove the instrument cluster. (Refer to page T-29.) 2. Apply battery positive voltage to terminal 2K and ground to terminal 2J. 3. Connect the red lead of the SST to terminal 1A and the black lead to ground. 4. Set the SST to the resistance values shown in the figure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the gauge indicates the correct values. The al- lowable indication error is twice the width of the needle. 6. If not as specified, replace the fuel gauge. 49 0839 285 Checker, fuel and thermometer For inspection of gauges Inspection 1. Remove the instrument cluster. (Refer to page T-29.) 2. Apply battery positive voltage to terminal 2K and ground to terminal 2J. 3. Connect the red lead of the SST to terminal 2B and the black lead to ground. 49 0839 285 Checker, fuel and thermometer For inspection of gauges Gartner Banana