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CAS o-ring change, and cam gasket

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Ricolas
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Posts: 325
Joined: Sun Oct 07, 2012 12:28 pm

CAS o-ring change, and cam gasket

Postby Ricolas » Thu Aug 15, 2013 8:35 pm

There's oil around the place, and the finger of doom is pointing at the CAS o-ring.

Time to replace it. Not that tricky a job, I managed it and it was the first thing I have done on the engine!

You will need sockets, 10, 12 and 14; torque wrench, pliers.

(I should add that this car is a standard UK '91 MX5 1.6)

1
Sparks out. You'll need a socket extension for this as they are buried in the head between the two camshafts! Remember to hold and pull off the cables by the rubber plug bits, not by tugging on the cables themselves! Remember where the HT leads go!

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2
Unplug the CAS and the coil pack. In the case of the 1.6 this is 3 connections.

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2a
unbolt coil. Top bolts - easy peasy

3
bottom coil bolt - not so easy! Fiddly, but doable.

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4
move coil - in the case of the 1.6 I moved it to the passenger side of the engine, and left it there tucked out of harms way

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5
remove PCV positive crankcase ventilation. Pull it, pop! out it comes.

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6
remove breather pipe from air intake pipe. Move clip using pliers to loosen and slide it up pipe.

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7
undo 11 cam cover bolts.

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8
cam cover off, care not to drip oil on timing belt. So move it across the engine bay, not forwards over the belts!

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9
Silicone off. Scrapey scrapey. Stanley blade useful here. You'll find it in the corners by the humps where the cam passed through to the timing cogs, and the CAS. If it is there, you'll see it, if not, you'll wonder what on earth I am on about...

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Last edited by Ricolas on Fri Aug 16, 2013 8:35 am, edited 1 time in total.
Ricolas
UK registered MX5 1991 Mariner Blue pretty much all original!

Beckenham, Kent
User avatar
Ricolas
Serial Poster
Posts: 325
Joined: Sun Oct 07, 2012 12:28 pm

Re: CAS o-ring change, and cam gasket

Postby Ricolas » Thu Aug 15, 2013 8:45 pm

There are less photos here, as my phone was dying - so I hope to get a couple from elsewhere. In the meantime, this will be mainly written.

10
mark CAS. If your CAS is anything like mine, you'll need to clean it off first. Spot of degreaser, or just a decent wipe with an old rag. Permanent marker'll do. You *could* scribe the metal, but if in future you need to adjust the timing, how will you know which mark is which? So pen is easier here.

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11
Crack the two 12mm bolts that hold the CAS bracket CAS bolt underneath its body on top, and the 12mm bolt at the back this is also what you loosen to adjust the CAS angle and thus the timing.

12
Undo and remove the two 12mm bolts from the CAS bracket and the CAS will still be held in place by the 12mm adjuster bolt, remove the bolt and lift the CAS free from the engine, wipe everything down with a rag to remove old oil.

13
Removing the CAS this way is much easier, , and avoids pinching the new o-ring as you put the CAS back in.

14
The o-ring on mine was slightly flattened - obviously worn, obviously no longer providing a good seal. It snapped as I levered it off with a small screwdriver.

15
new o ring on. Spot of oil on the rubber to help it get in again.

16
The CAS will only fit in one way to the cam due to two different length lugs. Actually you might well be able to see the groove in the end of the cam where the CAS lug fits in. Look closely at the end of the camshaft and you will see the metal lug of the CAS a different colour

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17
push CAS on - bit stiff due to new o ring. Line up your marker. Tighten up the CAS mount bolt.

18
remove old cam cover gasket

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19

silicone sealer - your choice. I asked around here and some don't use it. I reckon that Mazda may have got it right in the first place, so don't bother. I did not do it, so have no pictures!

20

tighten up cam cover. ALUMINIUM!! You will strip the thread in a moment, so please, either be careful or use a torque wrench. And it is not tight - 8mm.

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21
high tension leads - back on in the order you took them off! If you cannot remember how to do this, take a picture on your phone first. No mistakes possible then.
Last edited by Ricolas on Fri Aug 16, 2013 11:37 am, edited 1 time in total.
Ricolas
UK registered MX5 1991 Mariner Blue pretty much all original!

Beckenham, Kent

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