oil MAZDA PROTEGE 1992 Repair Manual

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

Bl ASSEMBLY
3. Apply a continuous bead of silicone sealant to the MBSP
along the inside of the bolt holes,
4. Install the MBSP onto the cylinder block.
5. Tighten the MBSP bolts in two or three steps in the order
shown in the figure.
Tightening torque:
16-21 N.m (1.6-2.1 m-kg, 12-15 ft-lb)
Oil Strainer
1. Install the oil strainer and a new gasket.
Tightening torque:
7.6-11 N.m (60-110 cm-kg, 69-95 in-lb)
Oil Pan
1. Remove all foreign material from the contact surfaces.
2. Apply silicone sealant to the shaded areas shown in the
figure.
-137 3. Install new gaskets onto the oil pump body and the rear
cover with the projections in the notches shown in the figure.
81-76

ASSEMBLY Bl
05UOBX.21’
OYJOBX-21
23UOBl-07
23UOBl-Ot
4. Apply a continuous bead of silicone sealant to the oil pan
along the inside of the bolt holes and overlap the ends.
5. Install the oil pan.
Tightening torque:
7.8-l 1 N,m (80-l 10 cm-kg, 89-95 in-lb)
End Plate
1. Install the end plate.
Tightening torque:
7.8-l 1 N,m (80-l 10 cm-kg, 89-95 in-lb)
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.
Tightening torque:
98-103 N+m (9.8-10.5 m-kg, 71-78 ft-lb)
Clutch Disc and Clutch Cover (MTX)
1. Install the clutch disc and clutch cover using the SST or
equivalent. (Refer to Section H.)
Tightening torque:
18-28 N.m (1.8-2.7 m-kg, 13-20 ft-lb)
B-l -77

ASSEMBLY Bl
CYLINDER HEAD
Torque Specifications
I
36 SOHC 1
GASKET, NEW
,-’
/
76-81
, /
--.
/
(2.2-2.9, 16-21)
“,A
OIL SEAL,
NEW 49-61
(5.0-6.2, 36-45)
P- (80-110 cm-kg, 69-95 in-lb)
w GA&ET, NEW -
19-25 ;1.9-2.6, 14-19) 6.4-9.3 N.m
19-25
(65-95 cm-kg, 56-82 in-lb)
(1.9-2.6, 14-19)
N.m (m-kg, ft-lb
03UOBl-I(
1)
-I 43
81-79

Bl ASSEMBLY
BP SOHC
4.9-8.8 N.m
(50-90 cm-kg, 43-76 in-lb)
76-61
(7.7-8.3, 56-60)
49-61
(5.0-6.2, 36-45)

OIL SEAL, -‘L-l
3
NEW
/
I - GASKET, NEW
19-25 (1.9-2.6, 14-19) 6.4-9.3 N-m
(65-95 cm-kg, 56-62 in-lb) I
19-25
(1.9-2.6, 14-19)
N.m (m-kg, ft-lb)
03UOBl-211 3
Valve Seal
BP SOHC
1. Install the new valve seal onto the valve guide by hand.
2. After installation adjust the protrusion A to specification.
Protrusion
IN : 19.6-20.2mm (0.772-0.795 in)
EX: 18.1-l 8.7mm (0.713-0.736 in)

Bl ASSEMBLY
Cylinder Head Gasket
1. Remove all foreign material from the top of the cylinder
block.
2. Place the new cylinder head gasket in position.
05UOBX-219
36 SOHC
Cylinder Head
1. Install the cylinder head.
2. Apply clean engine oil to the bolt threads and seat faces
3. Tighten the cylinder head bolts in two or three steps in the
order shown.
Tightening torque:
76-81 N.m (7.7-8.3 m-kg, 56-80 ft-lb)
3P SOHC OWOBX-221
03UOBl-205
Camshaft Oil Seal
1. Apply a thin coat of engine oil to the camshaft oil seal and
cylinder head.
2. Tap the camshaft oil seal into the cylinder head with a suita-
ble pipe.
Caution
. The oil seal must be tapped in until it is flush with
the cylinder head.
Oil seal outer diameter: 40mm (1.57 in)
--
Bl-82

ASSEMBLY Bl
BP SOHC
THRUST PLATE
DOWEL PIN AND PIN GROOVE
63UOlX-121
63UOlX-12
01; RESERVOIR
03UOBl-1’ 16
Camshaft
1. Apply engine oil to the journals and bearings; then insert
and mount the camshaft into position with the thrust plate.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 In-lb)
Camshaft Pulley
1. Install the camshaft pulley onto the dowel pin with the pin
groove facing straight upward.
Note
l Be certain that the dowel pin of the camshaft also
faces straight upward.
2. Tighten the camshaft pulley bolt. Hold the camshaft using
a suitable wrench on the cast hexagon as shown.
Tightening torque:
49-81 N-m (5.0-8.2 m-kg, 38-45 ft-lb)
Hydraulic Lash Adjuster (HLA)
1. Pour engine oil into the oil reservoir in the rocker arm.
2. Apply engine oil to the new HLA.
3. install the HLA in the rocker arm.
Caution
l Be careful not to damage the O-ring when installing.
81-83

Bl ASSEMBLY
No.1 CYLINDER No.4 CYLINDER
0311081-14
No.1 CYLINDER
No.4 CYLINDER
INTAKE
\. A
0’ Y Y 0 1
”
P
/ Y)
6
EXHAUST
No.1, 2 CYLINDERS No.3, 4 CYLINDERS
(IN & EX) (IN & EX)
93UOlA-08
I I I I I
000 @ @3
93UOiA-08
0311081-14
81-84
IN
EX
Rocker Arm and Rocker Shaft Assembly
66 SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure.
Caution
l Be sure both rocker arm shaft oil holes face
downward.
l The installation bolt holes are different for the ex-
haust and intake sides as shown in the figure.
Note
l There are two types of rocker arms with different
offsets. One type for No.1 and No.2 cylinders ex-
haust and intake. And the other for cylinders No.3
and No.4.
2. Install the rocker arm and rocker shaft assembly.
Caution
l The bolts must be tightened gradually and In the or-
der shown.
Tightening torque:
22-26 N-m (2.2-2.9 m-kg, 16-21 ft-lb)
BP SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure.
Caution
l Face the rocker shaft identification mark upward.
l The installation bolt holes are different for the ex-
haust and intake sides.
identification mark
IN . . . ..White
EX.....Biue

Bl ASSEMBLY
05UOBX-24:
Spark Plug
1. Install the spark plugs.
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 1 I-17 ft-lb)
Oil Level Gauge
1. Install the oil level gauge.
Oil Pressure switch
1. Install the oil pressure switch.
Tightening torque:
12-18 N-m (120-180 cm-kg, 104-158 in-lb)
Oil Filter
1. Remove all foreign material from the oil filter mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil filter.
3. Install the oil filter and tighten it by hand until the rubber
seal contacts the base.
4. Tighten the filter 1 and l/6 turns with a filter wrench.
No.3 Engine Mount Bracket
1. Install the No.3 engine mount bracket.
Tightening torque:
93-l 13 N-m (9.5-l 1.5 m-kg, 89-83 ft-lb)
Alternator
1. Install the alternator strap.
Tightening torque:
37-52 N#m (3.8-5.3 m-kg, 27-38 ft-lb)
2. Install the alternator and alternator drive belt. Loosely tight-
en the alternator installation bolt.
3. Adjust the drive belt deflection. (Refer to page Bl-6.)
Tightening torque
Alternator installation bolt @ :
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
Belt-adjusting bolt @ :
19-25 N#m (1.9-2.8 m-kg, 14-19 f&lb) --’ I
I 0311081-165
Bl-90