MAZDA PROTEGE 1992 Owner's Guide

Bl
ENGINE
(SOHC)
INDEX .......................................... Bl- 2
OUTLINE ...................................... Bl- 3
SPECIFICATIONS ........................
Bl- 3
TROUBLESHOOTING GUIDE ..........
Bl- 3
ENGINE TUNE-UP PROCEDURE ......
Bl- 5
PREPARATION ............................ Bl- 5
ENGINE OIL ............................... Bl- 5
ENGINE COOLANT.. ....................
Bl- 5
DRIVE BELT ............................... Bl- 5
HLA .......................................... Bl- 7
IGNITION TIMING, IDLE SPEED
..... Bl- 8
COMPRESSION ............................. Bl-10
INSPECTION ............................... 81-10
ON-VEHICLE
MAINTENANCE.. ........
Bl-1 1
PREPARATION ............................ Bl-11
TIMING BELT .............................. Bl-12
CYLINDER
HEAD GASKET ........... Bl-16
HLA .......................................... Bl-20
FRONT OIL SEAL.. ...................... 81-23
REAR OIL SEAL ..........................
Bl-25
REMOVAL ..................................... 81-28
PROCEDURE .............................. Bl-28
ENGINE STAND MOUNTING.. .........
Bl-35
PREPARATION
............................ 81-35
PROCEDURE ..............................
Bl-36
DISASSEMBLY .............................. Bl-38
PREPARATION ............................ Bl-38
AUXILIARY PARTS.. ..................... 81-40
TIMING BELT .............................. 81-41
CYLINDER HEAD.. ......................
81-43
CYLINDER BLOCK
(EXTERNAL PARTS)
................... 81-47
CYLINDER BLOCK
(INTERNAL
PARTS). ................... Bl-50 INSPECTION /
REPAIR.. .................
81-54
PREPARATION ............................ Bl-54
CYLINDER HEAD.. ...................... Bl-54
VALVE
MECHANISM.. .................. Bl-55
CAMSHAFT ................................ 81-58
HLA .......................................... Bl-60
CYLINDER BLOCK ......................
Bl-60
OIL JET ..................................... Bl-61
PISTON, PISTON RING, AND
PISTON PIN .............................. Bl-62
CONNECTING ROD.. ...................
Bl-63
CRANKSHAFT ............................ Bl-64
BEARING ................................... 81-64
TIMING BELT .............................. Bl-65
TENSIONER,
IDLER.. ................... 81-65
TENSIONER SPRING ...................
81-65
PULLEY ..................................... Bl-65
ASSEMBLY ................................... Bl-66
PREPARATION ............................ Bl-66
CYLINDER BLOCK
(INTERNAL PARTS). ................... Bl-68
CYLINDER BLOCK
(EXTERNAL PARTS) ...................
Bl-74
CYLINDER
HEAD.. ...................... 81-79
TIMING BELT .............................. Bl-86
AUXILIARY
PARTS.. ..................... Bl-89
ENGINE STAND DISMOUNTING.. .... Bl-92
PROCEDURE .............................. 81-92
INSTALLATION ............................. 81-94
PROCEDURE .............................. Bl-94
23UOBl-001

INDEX
NDEX
INTAKE MANIFOLD,
TIGHTENING TORQUE
.-’ HYDRAULIC LASH ADJUSTER (HLA)
INSPECTION, PAGE Bl-7 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
DEFLECTION AT (98 N, 10 kc
19
22 lb)
r “Y7 ENGINE COOLANT/
SECTION
EXHAUST MANIFOLD
TIGHTENING TORQUE
16-23 N.m (1.6-2.3 m-kg,
12-17 ft-lb
mm (in)
11 DRIVE BELT NEW USED LIMIT
COMPRESSION INSPECTION PAGE 61-10 kPa (kg/cm*, psi)-rpm
y-1, Sta,,dar‘-j , ,238;;;;;;$))-3(J() , ,,97;;2~;;&)0
883 (8.8, 125)-300 834 (8.5, 121)-300 II A/C 8.0-9.
(0.31-0.35) I (0.35-0.39) I (0.45) 11 Minimum
-
E
1. Timing belt
23UOBl-00:
Removal / installation . . . . . . . . . . . . . . . . page 61-l 2
2. Cylinder head gasket
Rep!acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-16
3. HLA
Removal / Installation . . . . . . . . . . . . . . . page 81-20
4. Front oil seal
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl -23
5. Rear oil seal Removal ................................... 6. Engine
page Bl-28
Engine stand mounting.. .......... page 81-35
Disassembly ............................. page Bl-38
Inspection / Repair .................... page Bl-54
Assembly.. ................................ page 81-66
Engine stand dismounting.. ..... page 81-92
Installation page 81-94 .+- .................................
Replacement . . , . . ,.. . . . . . . . . . . . . . . . . . . . page Bl-25
81-2

OUTLINE, TROUBLESHOOTING GUIDE Bl
OUTLINE
SPECIFICATIONS
item Engine
Type
Cylinder arrangement and number
Combustion chamber
Valve system
Displacement cc (cu in)
Bore and stroke mm (in)
Compression ratio
Compression pressure
kPa (kg/cm2, psi)-rpm
Open BTDC
IN
Close ABDC
Valve timing
EX Open
BBDC
Close ATDC
IN
Valve clearance
mm (in)
EX
Idle speed*‘*’ MTX
rpm ATX
Ignition timing*2
BTDC
Firing order
*‘.....With parking brake applied. (Canada)
*‘.....TEN terminal of diagnosis connector grounded B6 SOHC BP SOHC
Gasoline, 4-cycle
in-line, 4 cylinders
Multispherical Pentroof
OHC, belt-driven OHC, belt-driven 16 valves
1,597 (97.4) 1,839&i 12.23
78.0 x 83.6 (3.07 x 3.29) 83.0x 85.0 -3.35)
9.3 8.9
1,236 (12.6, 179)300 1,197 (12.2, 173)-300
140 2O
50° 5o”
52O 55O
120 8
0: Maintenance-free
0: Maintenance-free
700-800
700-800 (P range)
6O----8O 4O--6O
1-3-4-2
23UOBl-003
TROUBLESHOOTING GUIDE
Problem
Difficult starting
Poor idling
Excessive oil
consumption Possible Cause
Malfunction of engine-related components
Burned valve
Worn piston, piston ring, or cylinder
Failed cvlinder head aasket Action Page
Replace 81-55
Replace or repair 81-60, 62
Reolace Bl-16
Malfunction of fuel system
1 Refer to Section F
I
Malfunction of ignition system
Malfunction of engine-related components
Malfunction of HLA*
Poor valve-to-valve seat contact
Failed cvlinder head aasket Refer to Section G
Replace
Replace or repair
Reolace 81-20
81-57
81-16
Malfunction of fuel system 1 Refer to Section F
I
Malfunction of ignition system Refer to Section G
Oil working up
Worn piston ring groove or sticking piston ring
Worn piston or cylinder
Oil working down
Worn valve seal
Worn valve stem or wide Replace
Replace or repair
Replace
Replace 81-62
Bl-60, 62
81-46, 81
81-55
Oil leakage Refer to Section D
81-3

Bl TROUBLESHOOTING GUIDE
Problem
Insufficient power
Abnormal
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
Sticking, 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’
Sticking 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 guide 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 timing belt tensioner Action
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 81-20
Bl-57
81-55
81-58
81-16
81-54
81-62
al-62
81-20
81-55
81-58
-
61-71
Bl-64
81-72
81-73 8-i-64
Bl-60
81-63
81-62
81-62
El-63
Bl-20
El-58
81-55
Bl- 5
81-12
911 IORI .N)J LI.,“l. --
* Tappet noise may occur if the engine has set idle for an extended period. The noise should
normal operating temperature. (HLA troubleshooting: Refer to page Bl-7) dissipate after the engine has reached
81-4

ENGINE TUNE-UP PROCEDURE Bl
ENGINE TUNE-UP PROCEDURE
PREPARATION
-.
SST
drive belt tension
m :
I 1 2311081-058
- 03UOBX-20
---
OSUOBX-OC
V-BELT
LhEd
V-RIBBED BELT
OSJOBX-00
ENGINE OIL
Inspection
1. Be sure the vehicle is on level ground.
2. Warm up the engine to normal operating temperature and
stop it.
3. Wait for 5 minutes.
4. Remove the oil level gauge and check the oil level and con-
dition.
5. Add or replace oil if necessary.
Note
l The distance between the L and F marks on the level
gauge represents 0.8 liter (0.85 US qt, 0.70 Imp qt).
ENGINE COOLANT
Inspection
Coolant level (engine cold)
Warning
l Never remove the radiator cap while the engine is
hot.
l Wrap a thick cloth around the cap when removing it.
1. Verify that the coolant level is near the radiator filler neck.
2. Remove the coolant level gauge and check the coolant level.
3. Add coolant if necessary.
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.
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. Replace
if necessary.
3. Verify that the drive belts are correctly mounted on the
pulleys.
Bl--5

Bl ENGINE TUNE-UP PROCEDURE
iLTERNATOR
ALTERNATOR
I
I I I
IDLER
h ANKSHAFT /A/C
-LEY %OMPRESSC
PULLEY
AIC P/S AND A/C
23UOBl-006
WHEN MEASURED
WHEN SET
23UOBl.00
1 /
23UOBl-001
Bl-6
6
4. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
l A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specified below accordingly.
l Check the belt deflection when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflection
mm (in)
Drive
belt New Used Limit
Alternator 8.0-9.0
9.0-10.0 12.5
(0.31-0.35) (0.35-0.39) (0.49)
P/S, P/S + A/C 8.0-9.0
9.0-10.0 11.5
(0.31-0.35) (0.35-0.39) (0.45) A/C 8.0-9.0 9.0-l 0.0
11.5
(0.31-0.35) (0.35-0.39) (0.45)
5. If the deflection is not within specification, adjust it.
6. Install the air intake pipe.
Drive belt tension check
Note
l Belt tension can be checked in place of belt
deflection.
l Belt tension can be measured between any two
pulleys.
1. Removal the air intake pipe.
2. Using the
SST, check the belt tension.
Tension
N (kg, lb)
Drive belt New Used Limit
Alternator
383-461 304-383 167 (39-47, 85.8-103.4) (31-39, 68.2-85.8) (17, 37) PIS, P/S + AIC
491-589 422-491 245
(50-60, 110-132) (43~-50,95--110) (25, 55)
245 A/C 491-589 422-491
(50-60,110-132) (43-50,95-l 10) (25, 55)
3. If the tension is not within specification, adjust it.
4. Install the air intake pipe.
Adjustment
Caution
l If a new belt is used, adjust the belt deflection at
the midpoint of new belt specification.
l A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Alternator belt
1. If necessary, loosen the alternator mounting bolts @and
adjusting bolt @I.
2. Lever the alternator outward and apply tension to the belt.

ENGINE TUNE-UP PROCEDURE Bl
Tightening torque
@ : 37-52 N,m (3.8-5.3 m-kg, 27-38 ft-lb)
@ : 19-25 Nsm (1.9-2.6 m-kg, 14-19 ft-lb)
23UOBl-OC
P/S belt, P/S + A/C belt
If necessary, loosen the P/S oil pump bolts @and nut @and
Oand adjust the belt deflection by turning the adjusting bolt
0.
Tightening torque
@I : 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)
@ : 19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
0: 31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
A/C belt
If necessary, loosen the locknut @and adjust rhe belt deflec-
tion by turning the adjusting bolt @.
Tightening torque:
31-34 N-m (3.2-3.5 m-kg, 23-25 ft-lb)
1
HLA
Problem Possible Cause Action
1. Noise when engine is started immedi- Oil leakage in oil passage Run engine 2000-3000 rpm.
ately after oil is changed. If noise stops after 2 second-10
2. Noise when engine is started after set- minutes(*), HLA is normal.
ting approx. one day. If not, replace HLA.
3. Noise when engine is started after Oil leakage in HLA - * Time required for engine oil to circu-
cranking for 3 seconds or more. late within engine, includes tolerance
4. Noise when engine is started after for engine oil condition and ambient
new HLA is installed. temperature.
5. Noise continues more than 10 minutes Insufficient oil pressure Check oil pressure.
If lower than specification, check for
cause.
Oil pressure; 294-392 kPa
(3.0-4.0 kg/cm*, 43-57 psi)-3000 rpm
(Refer to page 81-60)
Press down HLA by hand.
If it does not move,. HLA is normal.
If it moves, replace HLA.
t
I
Measure valve clearance.
If more than Omm (0 in), replace HLA.
5. Noise occurs durning idle after high-
speed running Incorrect oil amount
Deteriorated oil Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
23UOBl-01
Bl-7

Bl ENGINE TUNE-UP PROCEDURE
13UOBi-036
-i
OWOBX-261
13UOBl-08
LOCK BOLTS
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
IG- ter-
minal as shown.
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) ter-
minal 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: (at idle speed)
B6 SOHC
BTDC 70 f 10 BP SOHC
5O f lo
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 (1.9-2.6 m-kg, 14-19 ft-lb)
5. Disconnect the SST.
Bl-8
13UOBl-039

ENGINE TUNE-UP PROCEDURE Bl
13UOBl-04 0
Idle Speed
1. Perform “Preparation”. (Refer to page Bl-8.)
2. Apply parking brake.
3. Check that the idle speed is within specification.
Idle speed (Neutral or P range): 750 f 50 rpm
Caution
l Check the idle speed without the electric cooling
fan operating.
Note
l When the parking brake is not applied, the idle
speed for ATX model (Canada) is approx. 800 rpm.
4. If not within the specification, adjust the idle by turning the
air adjusting screw.
5. Disconnect the
SST.
Bl-9

Bl COMPRESSION
COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1. Ignition system (Refer to Section G.)
2. Compression
3. Fuel system (Refer to Section F.)
23UOBl-01
23UOBl-06
23UOBl-014 23UOBl-012
INSPECTION
1. Check that the battery is fully charged. Recharge it if neces-
sary. (Refer to Section G.)
2. Warm up the engine to normal operating temperature.
3. Turn the engine OFF.
4. Remove all spark plugs.
5. Disconnect the ignition coil connector.
6. Connect a compression gauge to the No. 1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder.
Compression kPa (kg/cm*, psi)-rpm
10. If the compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder wall may be worn.
(2) If the compression stays low, the valve may be stuck
or seating improperly.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be defective or the cylinder
head distorted.
11. Connect the ignition coil connector.
12. Install the spark plugs.
05UOBX-020
Tightening torque:
15-23 N*m (1 S-2.3 m-kg, 11-17 ft-lb)
Bl-10