coolant MAZDA PROTEGE 1992 User Guide

ENGINE STAND DISMOUNTING Bl
VIEW A
c==A
03UOBi -17
I
03UOBi-2C
05UOBX-25
03UOBl-171
OWOBX-25
3. Apply a small amount of engine coolant to the new O-ring.
4. Install the water bypass pipe.
Exhaust Pipe Bracket
1. Install the exhaust pipe bracket.
Tightening torque:
37-52 N*m (3.8-5.3 m-kg, 27-38 ft-lb)
A/C Compressor Bracket
1. Install the A/C compressor bracket.
Tightening torque
@: 19-25 N-m (1.9-2.8 m-kg, 14-19 ft-lb)
@I: 37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
Exhaust Manifold
1. Remove all foreign material from the exhaust manifold con-
tact surface.
2. Install a new gasket and the exhaust manifold.
Tightening torque:
18-23 N-m (1.8-2.3 m-kg, 12-17 ft-lb)
Exhaust Manifold Insulator
1. Install the exhaust manifold insulator.
Tightening torque:
7.8-l 1 N*m (80-l 10 cm-kg, 89-95 in-lb)
Bl-93

INSTALLATION Bl
I I
03UOBl-193
03UOBl-19
1
PULLEY
P/S AND A/C
OWOBl-19
03UOBl-15
A/C compressor
1. Install the A/C compressor.
Tightening torque:
24-35 N-m (2.4-3.6 m-kg, 17-26 ft-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N-m (3.6-5.3 m-kg, 27-36 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page Bl-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.6-11 N#m (60-110 cm-kg, 69-95 in-lb)
2. Tighten the A/C pipe bracket to the radiator.
Tightening torque:
6.4-9.3 N*rn (65-95 cm-kg, 56-62 in-lb)
3. Connect the upper and lower radiator hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good fit.
4. Connect the coolant reservoir hose.
5. Connect the cooling fan connector.
6. Connect the oil cooler hose. (ATX)
Bl-=lOl

INSTALLATION
OWOBX-27!
Resonance chamber
1. Install the resonance chamber.
Tightening torque:
7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
Undercover and side cover
1. Install the undercover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut @.
Deflection: I-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
2. Install the battery carrier.
Tightening torque:
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
lightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
2. Connect the airflow sensor connector.
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page 61-8.)
(3) Operation of emission control system.
6. Perform a road test,
7. Recheck the engine oil and engine coolant levels.
.-’
23UOBl-057
81-102

82
ENGINE
m :
(DOHC)
INDEX .......................................... B2- 2
OUTLINE ...................................... B2- 3
SPECIFICATIONS ........................ B2- 3
TROUBLESHOOTING GUIDE .......... B2- 3
ENGINE TUNE-UP PROCEDURE ......
B2- 5
PREPARATION ............................
B2- 5
ENGINE OIL ............................... B2- 5
ENGINE COOLANT.. ....................
B2- 5
DRIVE BELT ............................... B2- 5
HLA .......................................... B2- 7
IGNITION TIMING, IDLE SPEED ..... B2- 8
COMPRESSION ............................. 82-l 0
INSPECTION ...............................
82-l 0
ON-VEHICLE MAINTENANCE.. ........ 82-l 1
PREPARATION ............................
B2-11
TIMING BELT .............................. 82-l 2
CYLINDER HEAD GASKET ...........
82-16
HLA .......................................... 82-22
FRONT OIL SEAL.. ......................
62-26
REAR OIL SEAL .......................... 82-28
REMOVAL ..................................... 82-31
PROCEDURE .............................. 82-31
ENGINE STAND MOUNTING.. .........
82-38
PREPARATION ............................ 82-38
PROCEDURE ..............................
82-39
DISASSEMBLY .............................. 82-41
PREPARATION ............................ B2-41
AUXILIARY PARTS.. ..................... 82-42
TIMING BELT ..............................
82-43
CYLINDER HEAD.. ...................... 82-45
CYLINDER BLOCK
(EXTERNAL PARTS) ...................
B2-48
CYLINDER BLOCK
(INTERNAL PARTS). ................... 82-51 INSPECTION / REPAIR.. ................. 82-54
PREPARATION ............................ 82-54
CYLINDER HEAD.. ...................... B2-54
VALVE MECHANISM.. .................. 82-55
CAMSHAFT ................................ B2-58
HLA .......................................... 82-80
CYLINDER BLOCK ...................... 82-60
OIL JET ..................................... B2-61
PISTON, PISTON RING, AND
PISTON PIN .............................. 82-62
CONNECTING ROD.. ...................
82-63
CRANKSHAFT ............................ B2-64
BEARING ................................... 82-64
TIMING BELT ..............................
82-65
TENSIONER, IDLER.. ................... 82-65
TENSIONER SPRING ................... 82-65
PULLEY ..................................... 82-65
ASSEMBLY ................................... B2-66
PREPARATION ............................ B2-66
CYLINDER BLOCK
(INTERNAL PARTS). ................... 82-68
CYLINDER BLOCK
(EXTERNAL PARTS) ................... 82-73
CYLINDER HEAD.. ...................... 82-79
TIMING BELT .............................. 82-84
AUXILIARY PARTS.. .....................
B2-87
ENGINE STAND DISMOUNTING ..a” . . 82-91
PROCEDURE ..............................
82-91
INSTALLATION ............................. 82-93
PROCEDURE .............................. 82-93
23UOB2-001

ENGINE TUNE-UP PROCEDURE 82
ENGINE TUNE-UP PROCEDURE
PREPARATION
SST
49 BO19 9AO
drive belt tension
23UOB2-048
OBUOBX-158
I’ ,
OSJOBX-001
V BELT
V RIBBED BELT
_
x 0 x
3
L
03UOB2-005
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. Check the drive belts for wear, cracks, and fraying. Replace
if necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
B2-5

82 ON-VEHICLE MAINTENANCE
CYLINDER HEAD GASKET
Replacement
Warning
l Release the fuel pressure. (Refer to Section F.)
l Keep sparks and open flame away from the fuel area.
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. install in the reverse order of removal, referrina to Installation Note.
BOLT THREADS ?&d 4.9-8.8 N.m
fsn-an om.h 41-‘71( ir
AND SEAT FACES ,-- -- -... ..=, _” . _ ..I-lb)
78-81 - /
(7.7-8.3, 58-60)
7.8-11 N.m
(80-l 10 cm-ka, 69-95
, . . . . . . (80-l 10 cm-kg, 69-9: in-lb) (j-$15-23 (1.5-2.3, 11-17)
82-l 6
7.8-11 N.m
(80-110 cm-k?, 69-95 In-lb) 180-110 cm-ka. 69-95 in-lb
-37-52
(3.8-5.3, 27-38)
’
nl MTX:?64-69 (6.6-9.1,
PTX: 55-60 (6.6-8.2, 69-95 in. .Ib)
47-86)
41-69)
7.8-11 N./n (3.2-4.7, 23-34)
37-52
(80-110 cm-kg, 69-95 in-lb) (3.8-5.3, 27-38)
N-m (m-kg, N-lb)
^^. .^_^ __

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

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

92 ENGINE STAND DISMOUNTING
03UOB2 122
-l!----- - 0311082-70
05UOEX-25
__._.__ -- _... -- _____II-___p--.-
051JOBX-25
82-92
Water Inlet Pipe
1. Remove all foreign material from the water inlet pipe mount-
ing surface.
2. Install a new gasket and the water inlet pipe. -
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Water Bypass Pipe
1. Apply a small amount of engine coolant to the new O-ring.
2. install the water bypass pipe.
A/C Compressor Bracket (If equipped)
1. Install the A/C compressor bracket.
Tightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Exhaust Manifold
1. Remove all foreign material from the exhaust manifold con-
tact surface.
2. Install a new gasket and the exhaust manifold.
Tightening torque:
38-46 N*m (3.9-4.7 m-kg, 28-34 ft-lb)
Exhaust Manifold insulator
1. Install the exhaust manifold insulator.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)
v

INSTALLATION
03UOB2-141
/ 03UOB2-14!
1 03UOB2-150
03UOB2-151
8,’
1
a : :“.;,
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s,::, ; i .:.;...
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. .
. .
” . : 0 ,.: ::
: .:.. ..,
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‘zi :
I 0311082-152
A/C compressor (If equipped)
1. Install the A/C compressor.
Tightening torque:
24-35 N,m (2.4-3.6 m-kg, 17-26 ft-lb)
2. Tighten the A/C pipe bracket to the engine mount member.
Tightening torque:
6.4-9.3 N-m (65-95 cm-kg, 56-62 in-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page B2-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)
2. Connect the upper and lower radiator hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good
fit.
3. Connect the coolant reservoir hose.
4. Connect the cooling fan connector.
5. Connect the oil cooler hose. (ATX)
B2-101