MAZDA PROTEGE 1992 Workshop Manual

ASSEMBLY
f
05UOW18
THRUST BEARING
OYJOBX-18
05UOBX-18
23UOBl-04
OWOBX-181
Crankshaft
1. Before installing the crankshaft, inspect the main bearing
oil clearances as follows.
Oil clearance inspection
(1) Remove all foreign material and oil from the journals and
bearings.
Caution
l Install the grooved upper main bearings in the cyl-
inder block.
l Install the thrust bearings with the oil groove fac-
ing the crankshaft.
(2) Install the upper main bearings and thrust bearings.
(3) Set the crankshaft in the cylinder block.
Caution
l Do not rotate the crankshaft when measurlng the
oil clearances.
(4) Position Plastigage atop the journals in the axial di-
rection.
(5) Install the lower main bearings and the main bearing
caps according to the cap number and + mark.
(6) Tighten the main bearing cap bolts in two or three steps
in the order shown in the figure.
Tightening torque:
54-59 N-m (5.5-6.0 m-kg, 40-43 ft-lb)
(7) Remove the main bearing caps, and measure the P lasti-
gage at each journal at the widest point for the smallest
clearance and at the narrowest point for the largest
clearance.
(8) If the oil clearance exceeds specification, grind the
crankshaft and use undersize main bearings.
(Refer to page Bl-64.)
Oil clearance: 0.016-0.036mm (0.0007-0.0014 in)
Maximum: O.lOmm (0.004 in)
2. Apply a liberal amount of clean engine oil to the main bear-
ings, thrust bearings and main journals.
3. Install the crankshaft and the main bearing caps accord-
ing to the cap number and + mark.
61-71

Bl ASSEMBLY
05UOBX-18s
WIDTH
05lJOBX-l!
, MATCHING MARKS’,
03UOBl-1;
4. Tighten the main bearing cap bolts in two or three steps
in the order shown in the figure.
Tightening torque:
54-59 N.m (5.5-6.0 m-kg, 40-43 ft-lb)
5. Measure the crankshaft end play.
End play : 0.060-0.262mm (0.0031-0.0111 in)
Maximum: 0.30mm (0.012 in)
6. If the end play exceeds the maximum, grind the crankshaft
and install an oversize thrust bearing or replace the crank-
shaft and thrust bearing.
Thrust bearing width
Standard:
2.500-2.550mm (0.0964-0.1004 in)
0.25mm (0.010 in) oversize:
2.625-2.675mm (0.1033-0.1053 in)
0.50mm (0.020 in) oversize:
2.750-2.600mm (0.1063-0.1102 in)
0.75mm (0.030 in) oversize:
2.675-2.925mm (0.1132-0.1152 in)
Piston and Connecting Rod Assembly
Caution
l Protect the connecting rod bolts with rubber sleeves
to prevent damage to the crankpin journals.
OSUOBX-192
Connecting Rod Cap
1. Measure the connecting rod bearing oil clearances using
the same procedure as for the main bearing oil clearance.
Caution
l Align the matching marks on the cap and the con-
necting rod when installing the connecting rod cap.
Tightening torque:
47-52 N-m (4.6-5.3 m-kg, 35-36 ft-lb)
. . . . . . . . . . . . . . . . . . .
B6 SOHC
49-51 N.m (5.0-5.2 m-kg, 36-36 ft-lb)
. . . . . . . . . . . . . . . . . . . BP SOHC .-’
Bi-72

ASSEMBLY Bl
23UOEl-04
03UOBl-1:
MATCHING MARKS
‘\, 1
0311081.132
Oil clearance: 0.028-0.068mm (0.001 l-0.0027 in)
Maximum: O.lOmm (0.004 in)
2. If the oil clearance exceeds the maximum, grind the crank-
shaft and use undersize bearings. (Refer to page Bl-64.)
3. Measure the connecting rod side clearances.
Side clearance: 0.11 O-0.262mm (0.0043-0.0103 in)
Maximum: 0.30mm (0.012 in)
4. If the clearance exceeds the maximum, replace the con-
necting rod and cap.
5. Apply a liberal amount of clean engine oil to the crankpin
journals and connecting rod bearings.
6. Install the connecting rod caps with the matching marks
aligned.
7. Tighten the connecting rod cap nuts in two or three steps.
Tightening torque:
47-52 N-m (4.8-5.3 m-kg, 35-38 ft-lb)
. . . . . . . . . . . . . . . . . . . 66 SOHC
49-51 N*m (5.0-5.2 m-kg, 36-38 ft-lb)
. . . . . . . . . . . . . . . . . . . BP SOHC
Bl-73

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
23UOBi-08
0311081-14
Drive Plate (ATX)
1. Remove the sealant from the drive plate bolt holes in the
crankshaft and from the drive plate 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. Install the adapter, drive plate, and backing plate onto the
crankshaft.
3. Apply sealant to the drive plate bolts and install them.
4. Hold the drive plate with the
SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)
Water Pump
1. Remove all foreign material from the water pump mount-
ing surface.
2. Place a new water pump gasket in position.
3. Install the water pump.
Tightening torque:
19-25 N,m (1.9-2.6 m-kg, 14-19 ft-lb)
81-78

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)