MAZDA PROTEGE 1992 Workshop Manual

ON-VEHICLE MAINTENANCE
Drive plate (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.
2311082-052
I
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
I I
I
05UOBX-063
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.
OWOBX-069
APPLY SEALANT
03UOB2.04
Caution
l The oil seal must be tapped in untjl it is flush with
the edge of the rear cover.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 1OOmm (3.94 in)
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
in the figure.
Tightening torque:
1 96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)
2311082-053
B2--29

B2 ON-VEHICLE MAINTENANCE
0311082-04
23UOB2-05 4
Drive plate (ATX)
1. Remove the sealant from the drive plate holes in the crank-
shaft and from the drive plate lock bolts.
Caution
..i
l if ail 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 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
in the figure.
Tightening torque:
96-103 N-m (9.6-10.6 m-kg, 71-76 ft-lb)
Steps After installation
1. Connect the negative battery cable.
2. Start the engine and perform engine adjustments as necessary.
OWOBX-072
82-30

REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section F.)
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil,.
3. Remove in the order shown in the figure, referring to
Removal Note.
Step
1
1. Undercover and side cover 12. Oil cooler hose (ATX)
2. Resonance chamber 13. Cooling fan connector
3. Air cleaner assembly 14. Radiator switch connector (ATX)
4. Battery bracket 15. Radiator bracket
5. Battery cover 16. Radiator and cooling fan assembly
6. Battery
17. P/S and/or A/C drive belt
7. Battery carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2- 6
8. Battery duct 18. P/S oil pump and bracket
9. Accelerator cable Removal Note . . . . . . . . . . . . . . . . . . . . + . . . . . . page 82-32
10. Radiator hose 19. A/C compressor (if equipped)
11. Coolant reservoir hose Removal Note.. . . . . . . . . . . . . . . . . . . . . . . . . . page 82-32
B2-31

REMOVAL
0311082-046
Removal note
P/S oil pump and bracket
Caution
l Do not damage the hoses.
1. Remove the P/S oil pump and bracket with the hoses still
connected.
2. Position the pump away from the engine and affix it with wire.
A/C compressor (if equipped)
Caution
l Do not damage the hoses.
1. Remove the A/C compressor with the hoses still connected.
2. Position the compressor away from the engine and affix it
with wire.
Step 2
1. Disconnect the harness connectors shown in the figure.
OIL PRESSURE SWITCH ATX
THROTTLE INHIBITOR SWITCH
ALTERNATOR
I SENSOR 1
II
rl (MTX)
-03UOB2-05( .-,’

REMOVAL
Step 3
1. Disconnect the hoses shown in the figure.
J”“DC-” I I
1. Fuel hose
3. Brake vacuum hose
Removal
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
below
4. Vacuum hose (Purge control)
2. Heater hose
Removal Note . . . . . . . . . . . . . , . . . . . . . . . . . .
05UOBX-078
0311082-052
. . . . .
below 5. Vacuum hose (Cruise control)
Removal note
Fuel hose
Warning
l Keep sparks and open flame away from the fuel
area.
Caution
l Cover the hose with a rag because fuel will spray
out when disconnecting.
l Plug the disconnected hoses to avoid fuel leakage.
1. Disconnect the fuel hoses.
Heater hose
Caution
l Heater hose joint has O-rings and spacer.
l Do not lose them when removing.
1. Push the heater hose retainer and remove the heater hose.
82-33

82 REMOVAL
Won A
ATX
I e- ENGINE MOUNT MEMBER
COTTER PIN, REPLACE
1. Speedometer cable
2. Clutch release cylinder (MTX)
Removal Note . . . . .., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
below
3. Shift control rod (MTX)
4. Extension bar (MTX)
5. Shift control cable (ATX)
1311082.Ol!
82-34
3
6. Exhaust pipe
7, Stabilizer
8. Tie-rod end
Removal Note ..,......,................. page B2--35
9. Driveshaft
Removal Note. ,............,............ page 82-35
Removal note
Clutch release cylinder (MTX)
1, Remove the release cylinder pipe bracket from the transaxle.
Caution
l Do not damage the pipe or hose.
2. Position the release cylinder away from the transaxle for eas-
ier removal with the hose still connected. . __

REMOVAL B2
13UOB2-021
0311082-059
Tie-rod end
1. Remove the cotter pin and loosen the nut so that it flushes
with the ball joint edge.
Caution
l Do not reuse the cotter pin.
2. Separate the knuckle arm and ball joint with the SST.
Driveshaft
1. Remove the joint shaft.
2. Remove the bolts and nuts at the left and right lower arm
ball joints.
Caution
l Do not damage the ball joint dust boots.
3. Pull the lower arm downward to separate them from the
knuckles.
4. Remove the engine mount member. (ATX)
Caution
l Support the engine before removing the member.
(1) Suspend the engine with a chain block.
(2) Remove the No.1 and No.2 engine mount nuts.
(3) Remove the engine mount member bolts and nuts and
remove the engine mount member.
Caution
l Do not damage the oil seal.
5. Separate the driveshafts from the transaxle by prying with
a bar inserted between the shaft and the case.
B2-35

B2 REMOVAL
Step 5
., 13UOB2-02:
1. No.1 engine mount nuts (MTX)
5. No.4 engine mount rubber and bracket
2. No.2 engine mount nuts (MTX)
6. Engine support bracket (MTX)
3. Dynamic damper
7. Engine and transaxle assembly
4. No.3 engine mount rubber
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
below
Removal note
Engine and transaxle assembly
Caution
l Do not damage any components in the engine com-
partment.
1. Lift the engine and transaxle assembly out as a unit.
03UOB2.061
B2-36

REMOVAL
* 62
Step 6
1. intake manifold bracket
2. Starter
3. Throttle cable (ATX)
4. No.2 engine mount rubber and bracket
5. Torque converter nuts (ATX) 6. Transaxle mounting bolts
7. Manual transaxle
8. Automatic transaxle
9. Engine assembly
03UOB2.06
B2-37

82 ENGINE STAND MOUNTING
ENGINE STAND MOUNTING
PREPARATION
SST
49 0107 680A
Engine stand For
49 LO10 1AO For
disassembly and
f% disassembly and
assembly of Hanger set, assembly of
engine engine stand
f&b engine
t4b3
49 LO10 101 For
49 LO10 102 For
disassembly and disassembly and
Plate assembly of Arms assembly of
(Part of engine (Part of engine
49 LO10 1AO)
49 LO10 IAO)
49 LO10 103
Hooks
(Part of
49 LO10 1AO)
49 LO10 105
49 LO10 1AO)
62-38