oil MAZDA PROTEGE 1992 User Guide

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

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

ON-VEHICLE MAINTENANCE
FRONT OIL SEAL
Replacement
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. Install in the reverse order of removal, referring to Installation Note.
I- I
I
I
I
157-167 (16-17, 116-123)
I
t
I
I
/
L---- -____ - _......_____________ -----------!
N.m (m-kg, It-lb)
^ ^ ^ -
_ _
1. Timing belt
- 3. Timing belt pulley
Removal I Installation..
.............. page
61-12 Installation
Note.. ......................
page Bl-24
2. Pulley lock bolt
4. Oil seal
Installation Note ........................
page Bl-24
Removal Note
..................................... below
Installation
Note.. ......................
page Bl-24
01 EOBX-055
Removal Note
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
61-23