MAZDA PROTEGE 1992 Workshop Manual

ON-VEHICLE MAINTENANCE B2
- 05UOBX-04:
---_____~
OWOBX 04
----
05UOBX-03
4
2. Loosen the tensioner lock bolt.
Caution
l To prevent damage to the tensioner, secure it with
a rag.
3. Temporarily secure the tensioner with the spring fully ex-
tended.
Caution
Q Do not allow any oil or grease on the timing belt.
4. Remove the timing belt and secure it out of the way to pre-
vent damage during removal and installation of the cylin-
der head.
Cylinder head bolt
1. Loosen the cylinder head bolts in two or three steps in the
order shown in the figure.
2. Remove the cylinder head bolts.
Installation note
Cylinder head bolt
1. Apply clean engine oil to the bolt threads and seat faces.
2. Install the cylinder head bolts.
3. Tighten the cylinder head bolts in two or three steps in the
order shown in the figure.
Tightening torque:
76-81 N-m (7.7-8.3 m-kg, 56-60 ft-lb)
Cylinder head cover
1, Apply silicone sealant to the shaded areas as shown in the
figure.
2. Install the cylinder head cover.
Tightening torque:
4.9-8.8 N-m (50-90 cm-kg, 43-78 in-lb)
B2-19

B2 ON-VEHICLE MAINTENANCE
03UOB2-033
FOUR TEETH
13UOB2-015
05UOBX-032
B2-20
Timing belt
1. Check that the ignition timing mark (yellow) on the crank-
shaft pulley and the timing mark on the timing belt cover
are aligned.
2. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
Caution
l For intake side, align the I mark.
l For exhaust side, align the E mark.
3. Install the timing belt so that there is no looseness at the
idler side or between the two camshaft pulleys.
Caution
l Do not turn the crankshaft counterclockwise.
4. Turn the crankshaft two turns clockwise, and align the tim-
ing belt pulley mark with the timing mark.
5. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
If not aligned, remove the timing belt and repeat from ten-
sioner installation.
6. Turn the crankshaft 1 and 5/6 turns clockwise, and align
the fourth tooth from the
I mark with the seal plate mark.
7. Loosen the tensioner lock bolt to apply tension to the tim-
ing belt.
8. Tighten the tensioner lock bolt.
Tightening torque:
37-52 N#rn (3.8-5.3 m-kg, 27-38 ft-lb)
9. Turn the crankshaft 2 and l/6 turns clockwise and verify
that the timing marks are correctly aligned.

ON-VEHICLE MAINTENANCE
DEFLECTION CHECKING POINT
05UOBX-03 3 10. Measure the timing belt deflection by applying moderate
pressure (98 N, 10 kg, 22 lb) midway between the two cam-
shaft pulleys.
If the deflection is not correct, repeat from Step 7 above.
Deflection:
9.0-11.5mm (0.35-0.45 in) at 98 N (10 kg, 22 lb)
Harness
1. Connect the harness connectors. (Refer to page 82-l 8.)
Hose
1. Connect the hoses. (Refer to page 82-17.)
03UOB2-035
Accelerator cable
1. Install the accelerator cable.
2. Check the accelerator cable deflection.
If the deflection is not correct, adjust by turning nut A.
Deflection: l-3mm (0.04-0.12 In)
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E.)
2. Connect the negative battery cable.
3. Start the engine and check as follows:
(1) Engine oil and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page B2-8.)
(3) Operation of emission control system.
4. Recheck the engine coolant levels.
2311082-022
B2-21

B2 ON-VEHICLE MAINTENANCE
HLA
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. install in the reverse order of removal, referring to Installation Note --- ----- -__ __-- ,‘.
11.3-14.2 N.m
(1.15-1.45 m-\g, 100-126 in-lb)
49-61
(5.0~6.2,-36-45)
4.9-6.6 N.m
(50-90 cm-kg, 43-76 in-lb)
7.6All N-m
(80-110 cm-kg, 69-95 in-lb) 1 Q’-25
(1.9-2.6, 14-19)
N.m (m-kg, ft-lb)
0311082-03
1. High-tension lead
10. Cylinder head cover
2. Distributor
Installation Note..
....................
Installation Note.. ......................
page 62-25
11. Camshaft pulley
3. P/S and/or A/C drive belt
Removal note ..........................
Removal / Installation..
.............. page E32-
6
Installation Note .......................
4. Alternator drive belt
12. Seal plate
Removal / Installation
......... . ...... page B2- 6
13. Camshaft
5. Water pump pulley
Removal Note.. ........................
6. Timing belt cover, upper
Installation Note.. .....................
7. Timing belt cover, middle
14. HLA
8. Spark plug
Removal note ..........................
9. Timing belt
Installation
Note.. .....................
Removal Note.. .........................
page B2-18 Inspection
................................
Installation Note.. ......................
page B2-20
7
page 62-19
page 82-23
page 82-24
page B2-23
page 62-23
page B2-23
page B2-23 ‘--’
page 82-60
82-22

ON-VEHICLE MAINTENANCE 82
I 05UOBX-049
05UOBX-C
05UOBX-0
03UOB2-1
Removal note
Camshaft pulley
1, Hold the camshaft with a wrench at hexagonal portion.
2. Remove the camshaft pulley lock bolt.
3. Remove the camshaft pulley.
Camshaft
1. Loosen the camshaft cap bolts in two or three steps in the
order shown in the figure.
2. Remove the camshaft caps.
3. Remove the camshaft.
4. Remove the camshaft oil seal from the camshaft.
HLA
Caution
l Mark the HLA with a felt pen so that they can be rein-
stalled in the position from which they were
removed.
1. Remove the HLA from the cylinder head.
Installation note
HLA
1. Apply clean engine oil to the friction surfaces.
2. If the HLA are being reused, install them in the position from
which they were removed.
3. Verify that the HLA move smoothly in their bores.
Camshaft
Note
l The intake camshaft is grooved for the distributor
drive.
1. Apply clean engine oil to the camshaft journals and bearings.
2. Install the camshaft in position.
82-23

ON-VEHICLE MAINTENANCE
OWOBX-05.
OxJOBX-05,
ENOBX-056
--
Caution
l Do not allow any sealant on the camshaft journal
surfaces.
.-
3. Apply silicone sealant to the shaded areas shown in the
figure.
4. Install the camshaft caps according to the cap number and
arrow mark.
5. install the camshaft cap bolts and tighten them in two or
three steps in the order shown in the figure.
Tightening torque:
11.3-l 4.2 N-m (1 .15--l .45 m-kg, loo-126 in-lb)
6. Apply a small amount of clean engine oil to the lip of a new
camshaft oil seal.
7. 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 camshaft cap.
8. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 46mm (1.69 in)
Camshaft pulley
1. Turn the camshafts until the camshaft dowel pins face
straight up.
2. Install the camshaft pulleys with the I mark (intake side) or
the E mark (exhaust side) straight up.
I II’- ,
J
05UOBX-057
B2-24

ON-VEHICLE MAINTENANCE B2
05UOBX-05
BLA-DE 0-dlNG
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 82-8.) 3. Install the camshaft pulley lock bolts.
4. Hold the camshaft with a wrench.
5. Tighten the camshaft pulley lock bolt.
Tightening torque:
49-61 N-m (5.0-6.2 m-kg, 36-45 ft-lb)
Distributor
1. Apply grease to a new O-ring and the blade.
2. Install the distributor and loosely tighten the installation bolt.
3. Connect the distributor connector.
0311082-039
B2-25

B2 ON-VEHICLE MAINTENANCE
FRONT OIL SEAL
Replacement
1. Disconnect the negative battery cable.
2. Raise the vehicle on a lift and remove the right front wheel.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referring to Installation Note.
I

@Em
157-167 (16-17, 116-123)
N.m (m-kg, ft-lb
1. Timing belt related parts.. ............ page B2-12
2. Pulley lock bolt
Removal Note ..................................... below
Installation Note.. page B2-27 ......................
3. Pulley boss
4. Timing belt
Removal Note.. ......................... page B2-13
Installation Note ........................ page B2-14 5. Timing belt pulley
Installation Note..
...................... page B2-27
6. Oil seal
Removal Note.. ......................... page B2-27
Installation Note.. ...................... page B2-27
Removal Note
Pulley lock bolt
1. Hold the pulley boss with the SST.
2. Loosen and remove the pulley lock bolt.

ON-VEHICLE MAINTENANCE
I 05UOBX-063
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
13EOB2-02
ALIGN.KEY GRCi&E
13EOB2-02
23UOB2-025
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 92-8.)
3
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.
3. Tap the oil seal in evenly with a suitable pipe and a ham-
mer until it is about flush with the face of the oil pump body.
Oil seal outer diameter: 50.5mm (1.98 in)
Timing belt pulley
1. Install the timing belt pulley.
2. Install the pulley Woodruff key with the tapered side toward
the oil pump body.
Pulley lock bolt
1. Hold the crankshaft with the SST and tighten the pulley lock
bolt.
Tightening torque:
157-187 N.m (18-17 m-kg, 116-123 ft-lb)
23UOB2-026
82-27

B2 ON-VEHICLE MAINTENANCE
REAR OIL SEAL
Replacement
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. install in the reverse order of removal, referring to Installation Note.
t
I 1
ITX 16-26 (1.6-2.7, 13-20)

L
\TX
N.m (m-kg, ft-It 0
23UOBZ-027
1. Transaxle
MTX
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section J2
ATX
Service . . . , . . . . ,.......................... Section K
2. Clutch cover, clutch disc (MTX)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
3. Flywheel (MTX)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Installation Note .,.....,..,............. page 82-29 4. Drive plate (ATX)
Removal Note ..,........................ page B2-29
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 62-30
5. Oil seal
Removal Note .,......................... page 52-29
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-29
23UOB2-05
82-28
il
Removal note
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.