lock MAZDA PROTEGE 1992 Owner's Manual

DISASSEMBLY Bl
I I
49 LO11 010
Centering tool
(Part of
49 LO1 1 OAO) For
removal I
installation of
piston pins 49 LO11 011
Holder
(Part of
49 LO1 1 OAO) For
removal I
installation of
piston pins
49 HO11 OOlA
Support block
head For
removal /
installation of
piston pins
1. Code all identical parts (such as piston, piston rings, connecting rods, and valve springs) so that they
can be reinstalled in the cylinder from which they were removed.
2. Clean the parts with a steam cleaner. Blow off any remaining water with compressed air.
Note
l During disassembly of any part or system, be sure to study its order of assembly. Also, note
any deformation, wear, or damage.
05UOBX-091
81-39

DISASSEMBLY Bl
TIMING BELT
23UOBl-032
1. Water pump pulley
2. Crank shaft pulley bolt 6. Crankshaft pulley boss
3. Plate 7. Timing belt cover, upper
4. Pulley lock bolt 8. Timing belt cover, lower
9. Timing belt
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page Bl-42
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page
81-42
5. Crankshaft pulley
10. Tensioner and tensioner spring
Bl-41

DISASSEMBLY
23UOBl-067
; MARKS
MARKS
Qe
x
25mm (1.0 in) MIN
13EOBl-0:
Disassembly Note
Pulley lock bolt
1. Hold the flywheel (MTX) or drive plate (ATX) with the SST
or equivalent.
2. Remove the pulley lock bolt.
Timing belt
1. Turn the crankshaft and align the marks.
2. Mark the timing belt rotation for proper reinstallation.
Caution
l Never forcefully twist the timing belt. Do not turn
it inside out or bend it.
l Do not allow oil or grease on the belt.
81-42

DISASSEMBLY Bl
23tlOBl-03
03UOBl-07
B6 SOHC
23UOBl-03
3P SOHC
Disassembly Note
Rocker arm and rocker shaft assembly
1, Loosen the rocker arm bolts in two or three steps in the or-
der shown in the figure.
2. Remove the rocker arm and rocker shaft assembly.
3. Code all rocker arms and springs so that they can be rein-
stalled in the same places from which they were removed.
Hydraulic lash adjuster (HLA)
Remove the HLA by hand.
If it is difficult, remove the HLA by using pliers.
Caution
l Do not remove the HLA unless necessary because
oil leakage will occur, if the O-ring is damaged.
Camshaft pulley
1. Hold the camshaft using a suitable wrench on the cast
hexagon.
2. Remove the camshaft pulley lock bolt.
3. Remove the camshaft pulley.
Cylinder head bolts
1. Loosen the cylinder head bolts in two or three steps in the
order shown in the figure.
2. Remove the cylinder head bolts.
Bl-45

DISASSEMBLY Bl
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the fiaure, referrina to Disassembly Note.
.-.
1. Water pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
2. Timing belt pulley and lock bolt
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl -65
3. Clutch cover, clutch disc (MTX)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
4. Flywheel (MTX)
Disassembly Note . . . . . . . . . . . . . . . . . . . page 81-48
Inspect for wear or damage
5. Backing plate, drive plate, and adapter (ATX)
Disassembly Note ..,.....,.,........, page 81-48
6. End plate 7. Oil pan and gasket
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Inspect for damage
8. Oil strainer
9. Main bearing support plate (MBSP)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-49
Inspect for damage
10. Oil pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
11. Front oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
12. Rear cover
13. Rear oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Bl-47

Bl DISASSEMBLY
23UOBl-068
23UOBl-06!
I 2311081-070
23UOBl-071
Disassembly Note
Timing belt pulley
1. Hold the flywheel (MTX) or drive plate (ATX) with the SST
or equivalent.
2. Loosen the pulley lock bolt.
3. Remove the pulley lock bolt. -
4. Remove the timing belt pulley.
5. Remove the pulley Woodruff key.
2311081-059
Clutch cover (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Loosen the clutch cover lock bolts in two or three steps in
the order shown in the figure.
3. Remove the clutch cover.
-
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
4. Remove the
SST or equivalent.
Backing plate, drive plate, and adapter (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.
4. Remove the
SST or equivalent.
Bl-48

DISASSEMBLY Bl
0311081-08
PROTECT PUMP w
BODY WITH RAG
OTECT REAR COVER 0
Oil pan
B6 SOHC
1. Remove the oil pan mounting bolts.
2. Insert a screwdriver or a suitable tool between the MBSP
and oil pan, and pry them.
Caution
l Do not insert the prying tool between the MBSP and
cylinder block.
l Do not damage or scratch the contact surfaces.
BP SOHC
1. Remove the oil pan mounting bolts.
Caution
l Do not force a prying tool between the cylinder
block and the oil pan, which may damage the con-
tact surfaces.
l Do not damage or scratch the contact surfaces
when removing the old sealant.
2. Insert a screwdriver or a suitable tool only at the points
shown in the figure.
3. Remove the oil pan.
Main bearing support plate (MBSP)
1. Remove the MBSP mounting bolts to the main bearing cap.
2. Insert a screwdriver or a suitable tool between the MBSP
and cylinder block, and pry them.
Caution
l Do not damage or scratch the contact surfaces
when removing old sealant.
Front oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
Rear oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
Bl-49

Bl DISASSEMBLY
CYLINDER BLOCK (INTERNAL PARTS)
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
1. Connecting rod cap
7. Main bearing cap
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-51
Disassembly Note . . . . . . . . . . . . . . . . . . . . page
81-52
2. Connecting rod
8. Crankshaft
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-64
3. Connecting rod bearing
9. Main bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . page Bl-64 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-64
4. Piston ring
10. Thrust bearing
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51 11. Oil filter joint
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-62 12. Oil jet
5. Piston pin
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-61
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51 13. Cylinder block
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-60 ‘-”
6. Piston
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-62
Bl-50

DISASSEMBLY Bl
23UOBl-03
05UOBX-1’ 9
23UOBl-040
03UOBl-08 5
Disassembly Note
Connecting rod cap
1. Before removing the connecting rod caps, measure the con-
necting rod side clearance. (Refer to page Bl-73.)
Connecting rod
1. Before removing the connecting rods, measure the connect-
ing rod oil clearance. (Refer to page Bl-73.)
2. Remove the Plastigage from the crankpin journals.
Caution
l Do not scratch the crankshaft journal or the cylin-
der wall.
3. Use the handle of a hammer to remove the piston and con-
necting rod assembly through the top of the cylinder block.
Piston ring
Caution
l Do not apply excessive tension, which may cause
the rings to snap out.
1. Remove the piston rings with a piston ring expander (com-
mercially available).
Piston pin
Caution
l Mark the connecting rod direction for proper reas-
sembly.
1. Before disassembling the piston and connecting rod, check
the oscillation torque as shown.
If the large end does not drop by its own weight, replace
the piston or the piston pin.
81-51

Bl INSPECTION / REPAIR
VALVE GUIDE
8. Measure the protrusion height of each valve guide. Replace
the valve guide if necessary.
13UOBl-026
P SOHC m
9MUOB2-112
OSUOBX-12’
Bi-56
Height
B6 SOHC mm (in)
BP SOHC
I
IN 13.2-13.8 18.3-i 8.9
(0.520-0.543)
(0.720-0.744)
-.. --
EX 13.2-13.8 16.8-17.4
(0.520-0.543) (0.661-0.685)
Replacement of valve guide
Note
l The valve guides are different between intake and
exhaust sides, use the correct valve guide.
Removal
1. Remove the valve guide from the side opposite the com-
bustion chamber with the SST.
Installation
1. Assemble the SST so that depth L is as specified.
Depth L
mm (in)
I B6 SOHC
I BP SOHC
I
IN 13.2-13.8 18.3-l 8.9
(0.520-0.543) (0.720-0.744)
EX 13.2-13.8 16.8-17.4
(0.520-0.543) (0.661-0.685)
2. Tighten the locknut.
3. Tap the valve guide in from the side opposite the combus-
tion chamber until the SST contacts the cylinder head.
4. Verify that the valve guide height is within specification.
5. If not within specification, repeat Steps l-4.