engine oil MAZDA PROTEGE 1992 User Guide

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

ENGINE TUNE-UP PROCEDURE Bl
Tightening torque
@ : 37-52 N,m (3.8-5.3 m-kg, 27-38 ft-lb)
@ : 19-25 Nsm (1.9-2.6 m-kg, 14-19 ft-lb)
23UOBl-OC
P/S belt, P/S + A/C belt
If necessary, loosen the P/S oil pump bolts @and nut @and
Oand adjust the belt deflection by turning the adjusting bolt
0.
Tightening torque
@I : 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)
@ : 19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
0: 31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
A/C belt
If necessary, loosen the locknut @and adjust rhe belt deflec-
tion by turning the adjusting bolt @.
Tightening torque:
31-34 N-m (3.2-3.5 m-kg, 23-25 ft-lb)
1
HLA
Problem Possible Cause Action
1. Noise when engine is started immedi- Oil leakage in oil passage Run engine 2000-3000 rpm.
ately after oil is changed. If noise stops after 2 second-10
2. Noise when engine is started after set- minutes(*), HLA is normal.
ting approx. one day. If not, replace HLA.
3. Noise when engine is started after Oil leakage in HLA - * Time required for engine oil to circu-
cranking for 3 seconds or more. late within engine, includes tolerance
4. Noise when engine is started after for engine oil condition and ambient
new HLA is installed. temperature.
5. Noise continues more than 10 minutes Insufficient oil pressure Check oil pressure.
If lower than specification, check for
cause.
Oil pressure; 294-392 kPa
(3.0-4.0 kg/cm*, 43-57 psi)-3000 rpm
(Refer to page 81-60)
Press down HLA by hand.
If it does not move,. HLA is normal.
If it moves, replace HLA.
t
I
Measure valve clearance.
If more than Omm (0 in), replace HLA.
5. Noise occurs durning idle after high-
speed running Incorrect oil amount
Deteriorated oil Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
23UOBl-01
Bl-7

Bl COMPRESSION
COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1. Ignition system (Refer to Section G.)
2. Compression
3. Fuel system (Refer to Section F.)
23UOBl-01
23UOBl-06
23UOBl-014 23UOBl-012
INSPECTION
1. Check that the battery is fully charged. Recharge it if neces-
sary. (Refer to Section G.)
2. Warm up the engine to normal operating temperature.
3. Turn the engine OFF.
4. Remove all spark plugs.
5. Disconnect the ignition coil connector.
6. Connect a compression gauge to the No. 1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder.
Compression kPa (kg/cm*, psi)-rpm
10. If the compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder wall may be worn.
(2) If the compression stays low, the valve may be stuck
or seating improperly.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be defective or the cylinder
head distorted.
11. Connect the ignition coil connector.
12. Install the spark plugs.
05UOBX-020
Tightening torque:
15-23 N*m (1 S-2.3 m-kg, 11-17 ft-lb)
Bl-10

.
ON-VEHICLE MAINTENANCE
Installation note
Cylinder head bolt Bl
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:
76-61 N#m (7.7-6.3 m-kg, 56-60 f&lb)
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: I-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 81-8.)
(3) Operation of emission control system.
4. Recheck the engine coolant levels.
2311081-020
Bl-19

ON-VEHICLE MAINTENANCE Bl
Removal note
Rocker arm and rocker shaft assembly
1. Loosen the rocker arm bolts in two or three steps in the or-
der shown in the figure.
2. Remove the rocker arms and rocker shaft assembly.
3. Code all rocker arms and springs so that they can be rein-
stalled in the same places from which they were removed.
I
23UOBi-02 1
Installation note
HLA
1. Pour engine oil into the oil reservoir in the rocker arm.
2. Apply engine oil to the new HLA.
3. Install the HLA in the rocker arm.
Caution
l Be careful not to damage the O-ring when installing.
Oli RESERVOIR
o3uoB1-o?
Rocker arm and rocker shaft assembly
B6 SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure. No.1 CYLINDER No.4 CYLINDEF
[ ’ ” 0 D 0
0311081-034
Caution
l Be sure both rocker arm shaft oil holes face
downward.
l The installation bolt holes are different for the ex-
haust and intake sides as shown in the figure. No.1 CYLINDER
No.4 CYLINDER
INTAKE

l---A--l
0 = ‘, I I
Y Y
0 \L
.a Y
r Y)
/
6
EXHAUST
A>B
Note
l There are two types of rocker arms with different
offsets. One type for No.1 and No.2 cylinders ex-
haust and intake. And the other for cylinders No.3
and No.4.
No. 1.2 CYLINDERS No.3,4 CYLINDERS
(IN & EX) (IN & EX)
81-21

Bl ON-VEHICLE MAINTENANCE
01 EOBX-056
23UOBi -0:
Steps After Installation
1. Lower the vehicle.
2. Connect the negative battery cable.
3. Start the engine and check the ignition timing.
(Refer to page 61-8)
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.
Caution
l The oil seal must be tapped in until it is flush with
the edge of the oil pump body.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
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:
157-167 N*rn (16-17 m-kg, 116-123 ft-lb)
23UOBi-026
Bl-24

Bl ON-VEHICLE MAINTENANCE
OIL SEAL LIP
L I I
OWOBX-063
05UOBX-069
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.
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
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.
Caution
l The oil seal must be tapped in until 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:
96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)

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
2. Air cleaner assembly 10. Cooling fan connector
3. Battery and battery cover 11. Oil cooler hose (ATX)
4. Battery carrier 12. Radiator and cooling fan assembly
13. P/S and/or A/C drive belt
5. Battery duct
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Accelerator cable page Bl- 6
7. Resonance chamber 14. P/S oil pump and bracket
8. Radiator hose Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
9. Coolant reservoir hose 15. A/C compressor (if equipped)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
81-28

REMOVAL I31
Step 2
2311081-O: ii
1.
Disconnect the harness connectors shown in the figure.
Removal note
P/S oil pump
Caution
l Do not damage the hoses.
1. Remove the P/S oil pump 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.
ALTERNATOR
OIL PRESSURE SWITCH
GROUND THROTTLE SENSOR
------- I
INJECTOR
NEUTRAL SWITCH (MTX)

Bl REMOVAL
I 03UOBi-05 I
14
‘5
03UOBl-056
Bl-32
Tie-rod end
1. Remove the cotter pin and loosen the nut so that it flushes
with the ball joint edge.
2. Separate the knuckle arm and ball-joint with the
SST.
Caution
l Do not reuse the cotter pin.
Engine mount 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 the
engine mount member.
Caution
l Be careful so that the engine does not fall when
removing the member.
Driveshaft
1. Remove the bolts and nuts at the left and right lower arm
ball joints.
2. Pull the lower arm downward to separate them from the
knuckles.
Caution
l Do not damage the ball joint dust boots.
3. Separate the driveshafts from the transaxle by prying with
a bar inserted between the shaft and the case.
Caution
l Do not damage the oil seal.