height MAZDA PROTEGE 1992 User Guide

B2 INSPECTION / REPAIR
23UOB2-060
i$
03UOB2-08
ANGLE LIMIT
Ii
0311082.Ot
w v
05UOBX-138
03UOB2-OE
82-58
I8
9. Measure the protruding length (dimension L) of the valve
stem.
Dimension L: 45.0mm (1.7717 in)
(1) If L is 45.0-45.5mm (1.772-l .791 in), no correc-
tion needed.
(2) If L is 45.5-46.5mm (1.791-l .831 in), adjust with
washer on spring seat area of cylinder head.
(3) If L is 46.5mm (1.831 in) or more, replace cylinder
head.
Valve Spring
1. Inspect each valve spring for cracks or damage.
2. Measure the free length and out-of-square. Replace the
valve spring if necessary.
Free length
Standard: 46.26mm (1.821 in)
Minimum:
224-253 N (22.8-25.8 kg, 50-57 lb)/
395mm (1.555 in)
Out-of-square: 1.62mm (0.064 in) max.
CAMSHAFT
1. Set the front and rear journals on V-blocks.
2. Measure the camshaft runout. Replace the camshaft if
necessary.
Runout: 0.03mm (0.0012 in) max.
3. Inspect the camshaft for wear or damage. Replace the cam-
shaft if necessary.
4. Measure the cam lobe heights at the two points as shown.
Height
Standard
IN : 44.094mm (1.7360 in)
EX: 44.600mm (1.7560 in)
Minimum
IN : 43.894mm (1.7281 in)
EX: 44.400mm (1.7480 in)

B2 INSPECTION / REPAIR
r--
1
05UOBX-14
I -
L
05UOBX-149
82-60
(8) Measure the oil clearances.
Oil clearance:
0.035-0.081 mm (0.0014-0.0032 in)
Maximum: 0.15mm (0.006 in)
(9) If the oil clearance exceeds specification, replace the
cylinder head.
7. Measure the camshaft end play. If the end play exceeds
specification, replace the camshaft and/or the cylinder head.
End play : 0.07-0.19mm (0.0028-0.0075 in)
Maximum: 0.20mm (0.008 in)
HLA
Caution
l Do not attempt to repair the HLA.
1, Inspect the HLA friction surfaces for wear or damage. Re-
place the HLA if necessary.
2. Hold the bucket body and press the plunger by hand. If
the plunger moves, replace the HLA.
CYLINDER BLOCK
1. Inspect the cylinder block for the following. Repair or re-
place the cylinder block as necessary.
(1) ‘Leakage damage.
(2) Cracks.
(3j Scoring of wall.
2. Measure the distortion of the top surface of the cylinder block
in the six directions shown in the figure.
Distortion: 0.15mm (0.006 in) max.
3. If the distortion exceeds specification, repair by grinding’or
replace the cylinder block.
Height : 221 Smm (8.720 in)
Grinding: 0.20mm (0.008 in) max.

E OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
B6 SOHC
BP SOHC BP DOHC
MTX
1 ATX 1 MTX ATX 1 MTX
ATX
Cooling system
Water-cooled, forced circulation
Coolant capacity liters (US qt, Imp qt) 5.0 6.0
5.0
(5.3, 4.4) (6.3, 5.3)
(5.35.04.4) (6.zi.3) (5.3, 4.4) (6.::.3)
Water
pump
Thermostat
Radiator
Cooling fan
L Type
Water seal Centrifugal
Unified mechanical seal
Type Opening temperature
‘C (OF’) Wax, two-stage
Main: 86.5-89.5 (188-193)
Sub : 83.5-86.5 (182-188)
Full-open temperature
OC (OF)
Full-open lift mm (in)
Type
Cap valve opening
pressure 100 (212)
Main: 8.0 (0.31) min.
Sub : 1.5 (0.06) min.
Corrugated fin
74-103 (0.75-1.05, 11-15)
kPa (kg/cm2, psi)
Width
Core size Height
mm (in)
Depth
Fin pitch
mm (in) 647 (25.47)
390 (15.35)
16 (0.63) 1 25 (0.98) 1 16 (0.63) 1 25 (0.98) 1 16 (0.63) 1 25 (0.98)
1.3 (0.051)
Heat dissipation capacity
kcallh 1 38,800 [ 43,800 ( 38,800 1 43,800 1 38,800 1 43,800 1
Type
Transaxle Heat
oil cooler dissipation
capacity
kcallh
Tvoe
- Laminated - Laminated -
Laminated
1,700
I .I -?nn
- -
I,,“”
I
I - I 4 Ye,-. I,IVV 1
, a-
- Electric
Number of blades 4
Outer diameter mm (in)
320 (12.6)
Capacity w-v 80-12 1 160-12 ) 80-12 ) 160-12 1 80-12 1 160-12
1 Hi: 13.3+ 1 1 Hi: 13.3+ 1 1 Hi: 13.3+
Current
TROUBLESHOOTING GUIDE I I I I
Problem Possible Cause
Overheating
Coolant level insufficient
Coolant leakage
Radiator fins clogged
Radiator cap malfunction
Cooling fan malfunction
Thermostat malfunction
Water passage clogged
Water puma malfunction .- Remedy Page
Add
Repair
Clean
Replace
Replace
Replace
Clean
Reolace E- 6
E-9
E- 7
E-13
E- 9
E- 6
E-11
I Corrosion
1 Impurities in coolant 1 Replace
I E-6 I
03UOEX-005

F CONTROL SYSTEM
23UOFX-15
23UOFX-15
23UOFX-15
LOCK
4
I
13UOFX-oc
F-l 72
6. Turn the ignition switch OFF.
7. Disconnect the negative battery terminal for
at least 20 sec.
to eliminate the malfunction code that was created during
inspection from the control unit memory.
Replacetnent
1. Disconnect the oxygen sensor connector.
2. Remove the oxygen sensor.
3. Install in the reverse order of removal.
Tightening torque:
29-49 N-m (3-5 m-kg, 22-36 ft-lb)
MAIN RELAY (FUEL INJ RELAY)
Inspection
1. Verify that the main relay clicks when turning the ignition
switch ON and OFF.
2. Apply battery voltage to terminal A and ground terminal E3
of the main relay.
3. Check continuity of the terminals as shown.
VB: Battery voltage
Terminals 1 Ve not applied VB applied
C-D No continuity Continuity
4. If not as specified, replace the main relay.
CLUTCH SWITCH (MTX)
Inspection
1, Disconnect the clutch switch connector.
2. Connect an ohmmeter to the switch.
3. Check continuity of the switch.
Pedal Continuity
Depressed Yes
Released No
4. If not as specified, replace the clutch switch. ,
Replacement
1. Disconnect the clutch switch connector.
2. Loosen the locknuts.
3. Remove the clutch switch.
4. Install in the reverse order of removal.
5. Adjust the pedal height. (Refer to page H-6.)

OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
-
-
Item
Clutch control Engine/Transaxle B6 SOHC BP SOHC BP DOHC
F!Wl-R GBM-R Hvdraulic
Clutch cover
Clutch disc Type
Set load Diaphragm spring
N
(kg, lb) 1 3,630 (370, 814) 1 3,826 (390, 858) 1 3,846 (392, 862)
30 17.48)
200 (7.87) 215 (8.46) Outer diameter mm (in)
Inner diameter mm (in)
Pressure plate
side mm (in)
Thickness
Flywheel side
mm lit-d
1! , I
130 (5.12) ’ ’
150 i5.91 j
3.5 (0.138) 3.8 (0.150)
3.5 (0.138)
Type Suspended
Clutch pedal
Master cylinder
Release cylinder
Clutch fluid Pedal ratio 6.55
Full stroke mm (in) 135 (5.32)
Height (With carpet)
mm (in) 196-204 (7.72-8.03)
Inner diameter mm (in) 15.87 (0.625)
Inner diameter
mm (in) 19.05 (0.750)
SAE J1703 or FMVSS116 DOT-3
23UOHX-003
TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page
Slipping
Clutch disc facing worn excessively Replace H-15, 17
Clutch disc facing surface hardened or oil on surface Repair or replace H-15
Pressure plate damaged Repair or replace H-15
Diaphragm spring damaged or weakened Replace H-15
Insufficient clutch pedal play Adjust H- 5
Clutch pedal sticking Repair or replace H- 6
Flywheel damaged Repair or replace H-15, 17 Faulty disen-
Excessive runout or damaged clutch disc Replace H-15, 17 gagement Clutch disc splines rusted or worn Remove rust or replace H-15
Oil on facing Repair or replace H-15
Diaphragm spring weakened Replace H-15
Excessive clutch pedal play Adjust H- 5
Insufficient clutch fluid
Add fluid H- 3
Leakage of clutch fluid Locate and repair or -
replace Clutch vibrates
Oil on facing Repair or replace H-15 when accelerating Torsion rubbers weakened Replace H-15
Clutch disc facing hardened or damaged Repair or replace H-15
Clutch disc facing rivets loose Replace H-15
Pressure plate damaged or excessive runout Replace H-15
Flywheel surface hardened or damaged Repair or replace H-15
Loose or worn engine mount Tighten or replace - Clutch pedal
Pedal shaft not properly lubricated Lubricate or replace H- 6 sticking
Abnormal noise
Clutch release bearing damaged Replace H-15, 17
Poor lubrication of release bearing sleeve Lubricate or replace H-15
Torsion rubbers weakened Replace H-15
Excessive crankshaft end play Repair Refer to Section E
Pilot bearing worn or damaged Replace H-15, 18
Worn pivot points of release fork Repair or replace H-15
^^. .^. I~, ^r
H-3

CLUTCH PEDAL H
@ 14-19
(1.4-1.9, 10-13)
N.m (m-kg, R-lb)
CLUTCH PEDAL
ADJUSTMENT
Clutch Pedal Height
Inspection
1. Measure the distance from the upper surface of the pedal
pad to the carpet.
Pedal height: 196-204mm (7.72-6.03 in)
(With carpet)
2. If necessary, adjust the pedal height.
Adjustment
1. Disconnect the clutch switch connector.
2. Loosen locknut @and turn clutch switch @until the height
is correct.
3. Tighten locknut @ .
Tightening torque:
14-16 N*m (1.4-1.6 m-kg, IO-13 f&lb)
4. After adjustment, measure the pedal free play.
Clutch Pedal Free Play
Inspection
1. Depress the clutch pedal by hand until clutch resistance
is felt.
Pedal free play: 0.7-3.3mm (0.03-0.13 in)
Total pedal free play: 5.0-13mm (0.197-0.512 in)
2. If necessary, adjust the pedal free play.
Adjustment
1. Loosen locknut Oand turn push-rod @until pedal free play
is correct.
2. Check that the disengagement height (from the upper sur-
face of the pedal to the carpet) is correct when the pedal
is fully depressed. 23UOHX-OC
Minimum disengagement height: 41 mm (1.61 in)
(With carpet)
3. Tighten locknut 0.
Tightening torque:
12-17 N-m (1.2-I .7 m-kg, 9-12 ft-lb)
4. After adjustment, inspect the pedal height.
H-5

H CLUTCH MASTER CYLINDER
23UOHX-Ot ,a
\ I 03UOHX-016
7
I
03UOHX-014
Removal Note
Clutch pipe
1, Disconnect the clutch pipe with the SST.
2. Disconnect the clutch hose from the reservoir.
3. Plug the outlet of the reservoir.
Installation Note
Clutch pipe
1. Tighten the clutch pipe with the SST.
Tightening torque:
13-22 N.m (1.3-2.2 m-kg, 9-16 ft-lb)
Air Bleeding
I. After installation, bleed the clutch system.
(Refer to page below.)
Inspection and Adjustment
Clutch pedal height and free play
(Refer to page H-5.)
AIR BLEEDING
The clutch hydraulic system must be bled to remove air in-
troduced whenever a hydraulic line is disconnected.
Note
l The fluid in the reservoir must be maintained at the
3/4 level or higher during air bleeding.
Caution
l Clutch fluid will damage a painted surface. If fluid
does get on a painted surface, wipe it off im-
mediately.
l Do not mix different brands of clutch fluid.
l Do not reuse the clutch fluid that was drained. __,

P CONVENTIONAL BRAKE SYSTEM
03UOPX.01
03UOPX-01
03UOPX-01
23UOPX-0
BRAKE FLUID
Inspection
Leakage inspection
Depress the brake pedal several times, and inspect for leak-
age of the brake line system. __,
Brake Fluid Level
Leakage check
Verify that the fluid level in the reservoir is between the MAX
and MIN lines on the reservoir.
Add fluid if it is below MAX.
Replacement
1. Follow the procedure outlined in Air Bleeding.
(Refer to page P-6).
2. Continue bleeding and replacing the brake fluid until only
clean fluid is expelled.
3. Fill the reservoir to the MAX level.
BRAKEPEDAL
Inspection, On-vehicle
Brake pedal height
Inspection
Verify that the distance from the center on the pedal pad to
the floor mat is as specified.
Specification: 193-196mm (7.60-7.72 in)
Adjustment
1. Disconnect the stoplight switch connector.
2. Loosen locknuts @J and turn switch @ until it does not con-
tact the pedal.
3. Loosen locknuts (I?J and turn rod @ to adjust the height
of the brake pedal.
4. Tighten the stoplight switch until it contacts the pedal; then
turn it an additional 112 turn. Tighten locknuts @ and @I.
5. Connect the stoplight switch connector.
6. Verify operation of the stoplights.
P-8

CONVENTIONAL BRAKE SYSTEM
03UOPX-021
PEDAL-TO-FLOOR
CLEARANCE

03UOPX-02
Pedal Play
Inspection
1. Depress the pedal a few times to eliminate the vacuum in
the system.
2. Gently depress the pedal by hand and check the free play
(until resistance is felt).
Pedal play: 4-7mm (0.16-0.26 in)
Adjustment
1. Loosen locknut @and turn rod @to adjust the free play.
2. Verify the pedal height and the stoplight operation.
Pedal-To-Floor Clearance
Inspection
Verifv that the distance from the floor panel to the center of
the pedal pad is as specified when the pedal is depressed
with a force of 569 N (60
kg, 132 lb).
Pedal-to-floor clearance: 70mm (2.76 in) min.
If the distance is less than specified, check for the following
problems:
1. Air in brake system
2. Malfunction of automatic adjuster (Rear drum brakes)
3. Worn shoes or pads
P-9

P CONVENTIONAL BRAKE SYSTEM
Removal / Inspection / Installation
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. install in the reverse order of removal.
4. After installation, check and adjust the pedal height and free play if necessary.
r
20-34 (2.0-3.5, 14-25)
N-m (m-kg, ft-lb)
23UOPX-01
1. Cotter pin
2. Clevis pin
3. Nut
4. Lock washer
5. Bolt 6. Return spring 9. Bushing
Inspect for wear and damage Inspect for wear
7. Pedal 10. Bushing
Inspect for bending and Inspect for wear
damage 11. Pad
8, Pedal pipe Inspect for wear
MASTER CYLINDER
Removal / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
3. After installation. add brake fluid. bleed air, and check for fluid leakage.
1.3-2.2, 9.4-16)
9.6-16 (1.0-1.6, 7.2-12)
13-22 (1.3-2.2, 9.4-l
N.m (m-kg, ft-lb)
23UOPX-01
1. Connector 4. Nut and washer
2. Brake pipe 5. Master cylinder
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-i 1 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page P-l 1
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page P-l 1 Disassembly / Assembly /
3. Hose (MTX) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-l 2
P-l 0