engine MAZDA PROTEGE 1992 User Guide

y Schedule 2 (Unique Driving Conditions)
OPERATION
Drive belts MAINTENANCE / Number of months or miles (kilometers), whichever comes first
INTERVALS Months
5 IO 15 20 25 30 35 40 45 50 55 60
x 1,000 milea i 5 10 15 20 25 30 35 40 45 50 55 60
x 1,000 km 8 16 24 32 40 48 56 64 72
80 88 96
I I Service data and inspection points Page
l Cracks or damage Bl-5 l Tension B2-5
l Oil pan capacity
B6 SOHC: 3.0 liters (3.2 US qt, 2.6 Imp qt)
All BP : 3.6 liters (3.8 US qt, 3.2 Imp qt)
l Oil filter capacity: D-5
I I I I I I I I I I I
RRRRRRR R R R R R
Replace every 3,000 miles (4,800 km) or every 3 months
R R R R R RRRRRRR
0.17 liter (0.18 US qt, 0.15 Imp qt) Engine oil
Engine oil (For Puer-to-Rico)
Oil filter D-5
81-12
82-12
F-79
G-18 Replace every 60,000 miles (96,000 km)
Engine timing belt*’
Air cleaner element -
-
-
-
-
-
-
-
- -
-
-
-
-
-
-
-
-
FL
-
R
-
I
-
R
-
4 *;
-
-
*3
T
- -
-
-
-
-
-
-
-
- -
-
-
-
-
-
-
-
-
*2 -
-
-
-
-
-
-
-
- - R -
l Plug gap: l.O--l.lmm (0.039-0.043 in)
l Recommended spark plugs
Engine NGK NIPPONDENSO
B6 SOHC BKR5E-11
KlGPR-Ull
BKRGE-I 1 K20PR-U 11
BP SOHC BKR5E-I 1 KlGPR-Ull
BKRGE-11 K20PR-U 11
BKRSE-I 1 Kl GPR-Ul 1
BP DOHC BKRGE-11 K20PRUll
BKR7E-11 K22PR-U 11 R
Spark plugs
I
l Hoses for cracks or wear l Coolant level E-5
Cooling system
R
l Coolant capacity:
5.0 liters (5.3 US qt, 4.4 Imp qt) MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) ...,,,,,. ATX
l ATX: P range, MTX: Neutral E-6
Engine coolant
A
-
R
-
I
-
I Idle speed , F-80
F-124 / 700-800 rbrn (with parkina brake applied) -
- -
- , , I .I
-
Fuel filter
l Fittings, connections, and components for
leaks
l Prooer attachment and connections F-120
- Fuel lines
Brake lines. hoses and connections

Note
I .*.. inspect, and if necessary correct, clean, or replace (Inspect, and if necessary replace..... Air cleaner element only)
A.... Adjust
FL.. Replace or change
T.... Tighten
After 60 months or 60,000 miles (96,000 km), continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points:
*I Replacement of the timing belt is required every 60,000 miles (96,000 km). Failure to replace the timing belt may result in damage to the engine.
*2 This maintenance is required for all states except California. However, we recommend that it also be performed on California vehicles.
*3 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability.

SCHEDULED MAINTENANCE SERVICES (CANADA)
Schedule
2 1,000 km
x 1,000 mile! Number of months or kilometers (miles), whichever comes first
Months 5 10 15 20 25 30 35 40 45 50 55 60
8 16 24
32 40 40 56 64 72 80 88 96
s 5 10 15 20 25 30 35 40 45 50 55 60
I I I Service data and inspection points Page
MAINTENANCE
OPERATION
l Cracks or damage Bl-5 l Tension 82-5
l Oil pan capacity
B6 SOHC: 3.0 liters (3.2 US qt, 2.6 Imp qt)
All BP : 3.6 liters (3.8 US qt, 3.2 Imp qt)
l Oil filter capacity: D-5
0.17 liter (0.18 US qt, 0.15 Imp qt) Drive belts I I I I I I I I I I I I
Engine oil RRRRRRR R R R R R
Oil filter R R R R R R R R R R R R D-5
81-12
82-12
F-79 Replace every 96,000 km (60,000 miles)
Engine timing belt*’
Air cleaner element
T
-
-
I
-
-i
-
I
-
-
-
-
-
-i-
- -
R -
-
-
-
T
-
-
-
-
-
-
-7
- -
-
-
-
T
-
-
-
-
-
-
T
- -r
-
-
I
-
T
-
I
-
-
-
-
-
-i
-
-
-
-
-
T
-
-
-
-
-
-
T
- -
-
-
-
T
-
-
-
-
-
-
T
- i?-
-
R
-
I
-
R
-i
-
I
F
T
T
-
I
-i
-i
-
-
-
-
-
T
-
-
-
-
-
-
-i
- -
l Plug gap: 1.0-l .l mm (0.039-0.043 in)
l Recommended spark plugs .-
Engine NGK NIPPONDENSO
86 SOHC BKR5E-11 KlGPR-Ull
BKRGE-11 K20PR-U 11
BP SOHC BKR5E-11 KlGPR-Ull
BKRGE-11 K20PR-U
11
BKRSE-11 KlGPR-Ull
BP DOHC BKRGE-11 K20PR-U 11
BKR7E-11 K22PRU 11 G-18
R
-
I
-
R
-i- Spark plugs -
-
-
-
I
-
-
E-5
Cooling system l Hoses for cracks or wear
l Coolant level
0 Coolant capacity: 5.0
liters (5.3 US qt, 4.4 imp qt) ..,.,..,,. MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) . . . . . . . . . . ATX
l Level and condition
l ATX: P range, MTX: Neutral
700-800 rpm (with parking brake applied) E-6
Engine coolant
E-5
F-80
F-124 I
- I
Idle speed
Fuel filter
PCV valve *’
Emission hoses and tubes
Fuel lines
Brake lines, hoses and connections
Automatic transaxle fluid (ATF) -
-
-
I *2
l Operation - F-138
F-6 -
-
- -
-
-
l Fittings and connections
l Fittings, connections, and components for
leaks
l Proper attachment and connections
l Level and conditinn F-l 20 - K-l 35
I I
- I
- I

Note
I . . . . . Inspect, and if necessary correct, clean, or replace (Inspect, and if necessary replace..... Air cleaner element only)
L . . . . . Lubricate
R . . . . . Replace or change
T . . . . . Tighten
After 60 months or 96,000 km (60,000 miles), continue to follow the described maintenance at the recommended intervals.
As for * marked items in this maintenance chart, note the following points:
*l Replacement of the timing belt is required every 96,000 km (60,000 miles). Failure to replace the timing belt may result in damage to the engine.
*2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability.
*3 This maintenance is recommended by Mazda.

Bl
ENGINE
(SOHC)
INDEX .......................................... Bl- 2
OUTLINE ...................................... Bl- 3
SPECIFICATIONS ........................
Bl- 3
TROUBLESHOOTING GUIDE ..........
Bl- 3
ENGINE TUNE-UP PROCEDURE ......
Bl- 5
PREPARATION ............................ Bl- 5
ENGINE OIL ............................... Bl- 5
ENGINE COOLANT.. ....................
Bl- 5
DRIVE BELT ............................... Bl- 5
HLA .......................................... Bl- 7
IGNITION TIMING, IDLE SPEED
..... Bl- 8
COMPRESSION ............................. Bl-10
INSPECTION ............................... 81-10
ON-VEHICLE
MAINTENANCE.. ........
Bl-1 1
PREPARATION ............................ Bl-11
TIMING BELT .............................. Bl-12
CYLINDER
HEAD GASKET ........... Bl-16
HLA .......................................... Bl-20
FRONT OIL SEAL.. ...................... 81-23
REAR OIL SEAL ..........................
Bl-25
REMOVAL ..................................... 81-28
PROCEDURE .............................. Bl-28
ENGINE STAND MOUNTING.. .........
Bl-35
PREPARATION
............................ 81-35
PROCEDURE ..............................
Bl-36
DISASSEMBLY .............................. Bl-38
PREPARATION ............................ Bl-38
AUXILIARY PARTS.. ..................... 81-40
TIMING BELT .............................. 81-41
CYLINDER HEAD.. ......................
81-43
CYLINDER BLOCK
(EXTERNAL PARTS)
................... 81-47
CYLINDER BLOCK
(INTERNAL
PARTS). ................... Bl-50 INSPECTION /
REPAIR.. .................
81-54
PREPARATION ............................ Bl-54
CYLINDER HEAD.. ...................... Bl-54
VALVE
MECHANISM.. .................. Bl-55
CAMSHAFT ................................ 81-58
HLA .......................................... Bl-60
CYLINDER BLOCK ......................
Bl-60
OIL JET ..................................... Bl-61
PISTON, PISTON RING, AND
PISTON PIN .............................. Bl-62
CONNECTING ROD.. ...................
Bl-63
CRANKSHAFT ............................ Bl-64
BEARING ................................... 81-64
TIMING BELT .............................. Bl-65
TENSIONER,
IDLER.. ................... 81-65
TENSIONER SPRING ...................
81-65
PULLEY ..................................... Bl-65
ASSEMBLY ................................... Bl-66
PREPARATION ............................ Bl-66
CYLINDER BLOCK
(INTERNAL PARTS). ................... Bl-68
CYLINDER BLOCK
(EXTERNAL PARTS) ...................
Bl-74
CYLINDER
HEAD.. ...................... 81-79
TIMING BELT .............................. Bl-86
AUXILIARY
PARTS.. ..................... Bl-89
ENGINE STAND DISMOUNTING.. .... Bl-92
PROCEDURE .............................. 81-92
INSTALLATION ............................. 81-94
PROCEDURE .............................. Bl-94
23UOBl-001

INDEX
NDEX
INTAKE MANIFOLD,
TIGHTENING TORQUE
.-’ HYDRAULIC LASH ADJUSTER (HLA)
INSPECTION, PAGE Bl-7 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
DEFLECTION AT (98 N, 10 kc
19
22 lb)
r “Y7 ENGINE COOLANT/
SECTION
EXHAUST MANIFOLD
TIGHTENING TORQUE
16-23 N.m (1.6-2.3 m-kg,
12-17 ft-lb
mm (in)
11 DRIVE BELT NEW USED LIMIT
COMPRESSION INSPECTION PAGE 61-10 kPa (kg/cm*, psi)-rpm
y-1, Sta,,dar‘-j , ,238;;;;;;$))-3(J() , ,,97;;2~;;&)0
883 (8.8, 125)-300 834 (8.5, 121)-300 II A/C 8.0-9.
(0.31-0.35) I (0.35-0.39) I (0.45) 11 Minimum
-
E
1. Timing belt
23UOBl-00:
Removal / installation . . . . . . . . . . . . . . . . page 61-l 2
2. Cylinder head gasket
Rep!acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-16
3. HLA
Removal / Installation . . . . . . . . . . . . . . . page 81-20
4. Front oil seal
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl -23
5. Rear oil seal Removal ................................... 6. Engine
page Bl-28
Engine stand mounting.. .......... page 81-35
Disassembly ............................. page Bl-38
Inspection / Repair .................... page Bl-54
Assembly.. ................................ page 81-66
Engine stand dismounting.. ..... page 81-92
Installation page 81-94 .+- .................................
Replacement . . , . . ,.. . . . . . . . . . . . . . . . . . . . page Bl-25
81-2

OUTLINE, TROUBLESHOOTING GUIDE Bl
OUTLINE
SPECIFICATIONS
item Engine
Type
Cylinder arrangement and number
Combustion chamber
Valve system
Displacement cc (cu in)
Bore and stroke mm (in)
Compression ratio
Compression pressure
kPa (kg/cm2, psi)-rpm
Open BTDC
IN
Close ABDC
Valve timing
EX Open
BBDC
Close ATDC
IN
Valve clearance
mm (in)
EX
Idle speed*‘*’ MTX
rpm ATX
Ignition timing*2
BTDC
Firing order
*‘.....With parking brake applied. (Canada)
*‘.....TEN terminal of diagnosis connector grounded B6 SOHC BP SOHC
Gasoline, 4-cycle
in-line, 4 cylinders
Multispherical Pentroof
OHC, belt-driven OHC, belt-driven 16 valves
1,597 (97.4) 1,839&i 12.23
78.0 x 83.6 (3.07 x 3.29) 83.0x 85.0 -3.35)
9.3 8.9
1,236 (12.6, 179)300 1,197 (12.2, 173)-300
140 2O
50° 5o”
52O 55O
120 8
0: Maintenance-free
0: Maintenance-free
700-800
700-800 (P range)
6O----8O 4O--6O
1-3-4-2
23UOBl-003
TROUBLESHOOTING GUIDE
Problem
Difficult starting
Poor idling
Excessive oil
consumption Possible Cause
Malfunction of engine-related components
Burned valve
Worn piston, piston ring, or cylinder
Failed cvlinder head aasket Action Page
Replace 81-55
Replace or repair 81-60, 62
Reolace Bl-16
Malfunction of fuel system
1 Refer to Section F
I
Malfunction of ignition system
Malfunction of engine-related components
Malfunction of HLA*
Poor valve-to-valve seat contact
Failed cvlinder head aasket Refer to Section G
Replace
Replace or repair
Reolace 81-20
81-57
81-16
Malfunction of fuel system 1 Refer to Section F
I
Malfunction of ignition system Refer to Section G
Oil working up
Worn piston ring groove or sticking piston ring
Worn piston or cylinder
Oil working down
Worn valve seal
Worn valve stem or wide Replace
Replace or repair
Replace
Replace 81-62
Bl-60, 62
81-46, 81
81-55
Oil leakage Refer to Section D
81-3

Bl TROUBLESHOOTING GUIDE
Problem
Insufficient power
Abnormal
combustion
Engine noise Possible Cause
Insufficient compression
Malfunction of HLA*
Compression leakage from valve seat
Seized valve stem
Weak or broken valve spring
Failed cylinder head gasket
Cracked or distorted cylinder head
Sticking, damaged, or worn piston ring
Cracked or worn piston Malfunction of fuel system
Malfunction of ignition system
Others
Slipping clutch
Dragging brakes
Wrong size tires Malfunction of engine-related components
Malfunction of HLA’
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber Malfunction of fuel system
Malfunction of ignition system
Crankshaft- or bearing-related parts
Excessive main bearing oil clearance
Main bearing seized or heat-damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil clearance
Connecting rod bearing seized or heat-damaged Piston-related parts
Worn cylinder
Worn piston or piston pin
Seized piston
Damaged piston ring
Bent connecting rod Valves or timing-related parts
Malfunction of HLA*
Broken valve spring
Excessive valve guide clearance Malfunction of cooling system
Malfunction of fuel system
Others
Malfunction of water pump bearing
Improper drive belt tension
Malfunction of alternator bearing
Exhaust gas leakage
Malfunction of timing belt tensioner Action
Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section F
Refer to Section G
Refer to Section H
Refer to Section P
Refer to Section Q
Replace
Replace
Replace
Eliminate carbon
Refer to Section F
Refer to Section G
Replace or repair
Replace
Replace or repair
Replace or repair
Replace
Replace or repair
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section E
Refer to Section F
Refer to Section E
Adjust
Refer to Section G
Refer to Section F
Replace Page 81-20
Bl-57
81-55
81-58
81-16
81-54
81-62
al-62
81-20
81-55
81-58
-
61-71
Bl-64
81-72
81-73 8-i-64
Bl-60
81-63
81-62
81-62
El-63
Bl-20
El-58
81-55
Bl- 5
81-12
911 IORI .N)J LI.,“l. --
* Tappet noise may occur if the engine has set idle for an extended period. The noise should
normal operating temperature. (HLA troubleshooting: Refer to page Bl-7) dissipate after the engine has reached
81-4

ENGINE TUNE-UP PROCEDURE Bl
ENGINE TUNE-UP PROCEDURE
PREPARATION
-.
SST
drive belt tension
m :
I 1 2311081-058
- 03UOBX-20
---
OSUOBX-OC
V-BELT
LhEd
V-RIBBED BELT
OSJOBX-00
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, Remove the air intake pipe.
2. Check the drive belts for wear, cracks, and fraying. Replace
if necessary.
3. Verify that the drive belts are correctly mounted on the
pulleys.
Bl--5

Bl ENGINE TUNE-UP PROCEDURE
iLTERNATOR
ALTERNATOR
I
I I I
IDLER
h ANKSHAFT /A/C
-LEY %OMPRESSC
PULLEY
AIC P/S AND A/C
23UOBl-006
WHEN MEASURED
WHEN SET
23UOBl.00
1 /
23UOBl-001
Bl-6
6
4. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
l A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specified below accordingly.
l Check the belt deflection when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflection
mm (in)
Drive
belt New Used Limit
Alternator 8.0-9.0
9.0-10.0 12.5
(0.31-0.35) (0.35-0.39) (0.49)
P/S, P/S + A/C 8.0-9.0
9.0-10.0 11.5
(0.31-0.35) (0.35-0.39) (0.45) A/C 8.0-9.0 9.0-l 0.0
11.5
(0.31-0.35) (0.35-0.39) (0.45)
5. If the deflection is not within specification, adjust it.
6. Install the air intake pipe.
Drive belt tension check
Note
l Belt tension can be checked in place of belt
deflection.
l Belt tension can be measured between any two
pulleys.
1. Removal the air intake pipe.
2. Using the
SST, check the belt tension.
Tension
N (kg, lb)
Drive belt New Used Limit
Alternator
383-461 304-383 167 (39-47, 85.8-103.4) (31-39, 68.2-85.8) (17, 37) PIS, P/S + AIC
491-589 422-491 245
(50-60, 110-132) (43~-50,95--110) (25, 55)
245 A/C 491-589 422-491
(50-60,110-132) (43-50,95-l 10) (25, 55)
3. If the tension is not within specification, adjust it.
4. Install the air intake pipe.
Adjustment
Caution
l If a new belt is used, adjust the belt deflection at
the midpoint of new belt specification.
l A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Alternator belt
1. If necessary, loosen the alternator mounting bolts @and
adjusting bolt @I.
2. Lever the alternator outward and apply tension to the belt.