light MAZDA PROTEGE 1992 User Guide

Bl ON-VEHICLE MAINTENANCE
OIL SEAL LIP
L I I
OWOBX-063
05UOBX-069
Drive plate (ATX)
1. Hold the drive plate with the SST or equivalent.
2. Remove the drive plate lock bolts.
3. Remove the backing plate, drive plate, and adapter.
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
Installation note
Oil seal
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. Push the oil seal slightly in by hand.
Caution
l The oil seal must be tapped in until it is flush with
the edge of the rear cover.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 1OOmm (3.94 in)
Flywheel (MTX)
1. Remove the sealant from the flywheel bolt holes in the crank-
shaft and from the flywheel bolts.
Caution
l If all the previous sealant cannot be removed from
a bolt, replace the bolt.
l Do not apply sealant if a new bolt is used.
2. Set the flywheel onto the crankshaft.
3. Apply sealant to the flywheel bolts and install them.
4. Hold the flywheel with the SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown
in the figure.
Tightening torque:
96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)

Bl ASSEMBLY
CYLINDER BLOCK (EXTERNAL PARTS)
Torque Specifications
19-25
(1.9-2.6, 14-19)
GASKET, NEW
OIL SEAL,
NEW
7.6-11 N.m
(60-l 10 cm-kg,
69-95 in-lb)
GASKET, NE
16-21 (1.6-2.1, 12--15)-j
R
A -22% / 7.6-11 N.m
(60-110 cm-kg, 69-95 in-lb) 6-103 w
,..6-10.6,
71-76) 16-26
(1.6-2.7, 13-20)
7.6-11 N-m
(60-110 cm-kg, 69-95 in-lb)
N.m (m-kg, R-lb)
Bl-74
OWOBX-201 0
Rear Cover
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. Push the oil seal slightly in by hand.
Caution
l The oil seal must be pressed in until it is flush with
the edge of the rear cover.
3. Press the oil seal in evenly with a suitable pipe.
Oil seal outer diameter: 1OOmm (3.94 in)
4. Apply silicone sealant to the shaded area shown in the
figure.

ASSEMBLY Bl
OWOBX-20
23UOBl-049
5. Install the rear cover.
Tightening torque:
7.8-l 1 N*m (80-l 10 cm-kg, 89-95 in-lb)
Oil Pump
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. Push the oil seal slightly in by hand.
Caution
l The oil seal must be pressed in until it is flush with
the edge of the oil pump body.
3. Press the oil seal in evenly with a suitable pipe.
Oil seal outer diameter: 44mm (1.73 in)
4. Install the oil pump and a new gasket.
Tightening torque:
19-25 N-m (1.9-2.8 m-kg, 14-19 ft-lb)
Caution
l Do not scratch the oil pump.
5. Cut away the portion of the gasket that projects from the
body toward the oil pan side.
Main Bearing Support Plate (MBSP)
1, Remove all foreign material from the contact surfaces of the
cylinder block and the MBSP.
Caution
l The oil pan must be secured within 5 minutes after
the sealant is applied to the MBSP.
2. Apply silicon sealant to the shaded areas shown in the figure.
81-75

ASSEMBLY
03UOBi -144
03UOBl-214
GREATER THAN (i
CYLINDER HEAD SIDE
05UOBX-21
f36 SOHC
B6 SOHC
1. Assemble the SST so that depth L is as specified.
Depth L mm (in) 1 IN 14.9-15.2 (0.587-0.598)
EX 14.9-15.2 (0.587-0.598)
2. Slide the valve seal onto the valve guide.
3. Set the
SST against the valve seal.
4. Tap the valve seal on until the
SST contacts the cylinder
head.
Valve and Valve Spring
1. Install the lower spring seat.
2. Install the valve.
Caution
l Install the spring with the closer pitch toward the
cylinder head.
3. Install the valve spring and the upper spring seat.
4. Compress the valve spring with the
SST, and install the
valve keepers.
5. Remove the
SST.
6. Tap the end of the valve stem lightly two or three times with
a plastic hammer to verify that the keepers are all fully
seated.
131-81

INSTALLkTlON Bl
03UOBl-188
03UOBl-18
Step 4
1. Connect the hoses shown in the figure.
Caution Speedometer cable
1. Install the speedometer cable.
Tightening torque:
7.8-l 1 Nom (80-l 10 cm-kg, 69-95 in-lb)
Exhaust pipe
1. Install the exhaust pipe and a gasket; then loosely tighten
the locknuts.
2. Loosely tighten the bracket bolts.
3. Tighten the locknuts.
Tightening torque:
31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
4. Tighten the bracket bolts.
Tightening torque:
37-52 Nmrn (3.8-5.3 m-kg, 27-38 ft-lb)
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good-fit.
BP SOHC
03UOBl-1s
Bl-9

Bl INSTALLATION
Step 5
1. Connect the harness connectors shown in the figure.
GROUND ALTERNATOR
OIL PRESSURE SWITCH
I- THFOTTLE SENSOR
NEUTRAL SWITCH (MTX)
IGNITION COIL
$A_c_K;u_p LIGHT SWITCH
____------- ;
Step 6
Torque Specifications
7.8-11 N.m (80-110 cm-kg, 89-95 in-lb)
19-25 (1.9-2.6, 14-19)
2.9-5.9 N.m
(30-60 cm-kg, 26-52 in-lb)
7.8-11 N.m
(80-l 10 cm-kg,
6.4-9.3 N.m 37-52
(3.8-5.3, 27-38)
24-35
(2.4-3.6, 17-26)
7.8-11 N.m 160-110 cmika, 69-95 in-lb) ‘-- -- -..’ ‘-=’ -’ / 166-96 r?m.ka.
66-82 in-lb) 69-95 in-lb)
N.m (m-kg, ft-lb -- OBUOBl-1E
Bl-100

INSTALLATION Bl
I I
03UOBl-193
03UOBl-19
1
PULLEY
P/S AND A/C
OWOBl-19
03UOBl-15
A/C compressor
1. Install the A/C compressor.
Tightening torque:
24-35 N-m (2.4-3.6 m-kg, 17-26 ft-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N-m (3.6-5.3 m-kg, 27-36 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page Bl-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.6-11 N#m (60-110 cm-kg, 69-95 in-lb)
2. Tighten the A/C pipe bracket to the radiator.
Tightening torque:
6.4-9.3 N*rn (65-95 cm-kg, 56-62 in-lb)
3. Connect the upper and lower radiator hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good fit.
4. Connect the coolant reservoir hose.
5. Connect the cooling fan connector.
6. Connect the oil cooler hose. (ATX)
Bl-=lOl

INSTALLATION
OWOBX-27!
Resonance chamber
1. Install the resonance chamber.
Tightening torque:
7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
Undercover and side cover
1. Install the undercover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut @.
Deflection: I-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
2. Install the battery carrier.
Tightening torque:
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
lightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
2. Connect the airflow sensor connector.
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page 61-8.)
(3) Operation of emission control system.
6. Perform a road test,
7. Recheck the engine oil and engine coolant levels.
.-’
23UOBl-057
81-102

82 ENGINE TUNE-UP PROCEDURE
03UOB2-013
IGNITION TIMING, IDLE SPEED
Preparation
1. Warm up the engine to normal operating temperature.
2. Turn all electric loads OFF.
3. Connect the
SST to the diagnosis connector.
4. Connect the timing light.
5. Connect a tachometer to the diagnosis connector
IO- ter-
minal as shown.
TEN
03UOB2-01
I
-&k BOLT
0311082-01’
82-8
6. Set switch @to position 1.
7. Set TEST SW to SELF-TEST.
Note
l If the SST is not used, jump across the TEN termi-
nal and the GND terminal of the diagnosis con-
nector.
Ignition Timing
Inspection / Adjustment
1. Perform “Preparation.” (Refer to above.)
2. Check if the timing mark (yellow) on the crankshaft pulley
and the mark on the timing belt cover are aligned.
Ignition timing: 10 * f lo BTDC (at Idle speed)
3. If the marks are not aligned, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
4. Tighten the distributor lock bolts to the specified torque.
Tightening torque:
19-25 N*m (1 .Q-2.6 m-kg, 14-19 ft-lb)
5. Disconnect the SST.

82 ON-VEHICLE MAINTENANCE
CYLINDER HEAD GASKET
Replacement
Warning
l Release the fuel pressure. (Refer to Section F.)
l Keep sparks and open flame away from the fuel area.
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. install in the reverse order of removal, referrina to Installation Note.
BOLT THREADS ?&d 4.9-8.8 N.m
fsn-an om.h 41-‘71( ir
AND SEAT FACES ,-- -- -... ..=, _” . _ ..I-lb)
78-81 - /
(7.7-8.3, 58-60)
7.8-11 N.m
(80-l 10 cm-ka, 69-95
, . . . . . . (80-l 10 cm-kg, 69-9: in-lb) (j-$15-23 (1.5-2.3, 11-17)
82-l 6
7.8-11 N.m
(80-110 cm-k?, 69-95 In-lb) 180-110 cm-ka. 69-95 in-lb
-37-52
(3.8-5.3, 27-38)
’
nl MTX:?64-69 (6.6-9.1,
PTX: 55-60 (6.6-8.2, 69-95 in. .Ib)
47-86)
41-69)
7.8-11 N./n (3.2-4.7, 23-34)
37-52
(80-110 cm-kg, 69-95 in-lb) (3.8-5.3, 27-38)
N-m (m-kg, N-lb)
^^. .^_^ __