oil level MAZDA PROTEGE 1992 User Guide

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

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

ENGINE TUNE-UP PROCEDURE 92
23UOB2-OC
DRIVE PULLEY
I I
2311082.010
HLA
I Problem
1. Noise when engine is started immedi-
ately after oil is changed.
2. Noise when engine is started after set-
tina aporox. one dav.
3. Noise when engine is started after
cranking for 3 seconds or more.
4. Noise when engine is started after
new HLA is installed.
5. Noise continues more than 10 minutes
6. Noise occurs durning idle after high-
“”
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-16 ft-lb)
(4) Tighten mounting bolt @.
Tightening torque:
37-52 N#rn (3.6-5.3 m-kg, 27-36 ft-lb)
(5) Recheck the belt tension or deflection.
2. P/S belt, P/S + A/C belt
(1) Loosen the P/S oil pump bolt @and nuts @, 0.
(2) Adjust the belt tension and deflection by turning the ad-
justing belt 0.
(3) Tighten the adjusting lock nut @J and the P/S oil pump
bolt @ and nut 0.
Tightening torque
@: 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) Possible Cause
Oil leakage in oil passage
Oil leakage in HLA
Insufficient oil pressure
Faulty HLA
Incorrect oil amount
Deteriorated oil Action Run engine 2000-3000 rpm.
If noise stops after 2 second-10
minutes(*), HLA is normal.
If not, replace HLA.
* Time required for engine oil to circu-
late within engine, includes tolerance
for engine oil condition and ambient
temperature.
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 82-60)
Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.
If more than Omm (0 in), replace HLA.
Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
2311082-01
B2-7

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

B2 DISASSEMBLY
AUXILIARY PARTS
1, Drain the engine oil.
2. Disassemble in the order shown in the figure
GASKET, REPLACE ..______-.
-___ -
03UOB2-064
1. Distributor and high-tension lead 7. Oil cooler
2. Intake manifold assembly 8. Oil pressure switch
3. Injector and distribution pipe assembly 9. Spark plug
4. Alternator and drive belt 10. Oil level gauge
5. No.3 engine mount bracket 11. Oil level gauge pipe stay
6. Oil filter 12. Engine hanger
82-42

INSPECTION / REPAIR B2
A ,-
B
C
I
03UOB2-099
OWOBX-151
1
I
OSJOBX-15
4. Measure the cylinder bores in X and Y directions at three
levels (A, B, and C) in each cylinder as shown.
Cylinder bore
Bore size
Standard
0.25 (0.010) oversize
0.50 (0.020) oversize mm (in)
Diameter
83.006-83.013 (3.2679-3.2682)
83.256-83.263 (3.2778-3.2781)
83.506-83.513 (3.2876-3.2879)
Caution
l The boring size should be based on the size of an
oversize piston and 643 the same for all cylinders.
(1) If the cylinder bore exceeds the maximum, rebore the
cylinder to oversize.
(2) If the difference between measurements A and C ex-
ceeds the maximum taper, rebore the cylinder to
oversize.
Taper: 0.019mm (0.0007 in) max.
(3) If the difference between measurements X and Y ex-
ceeds the maximum out-of-round, rebore the cylinder
to oversize.
Out-of-round: 0.019mm (0.0007 in) max.
5. If the upper part of a cylinder wall shows uneven wear, re-
move the ridge with a ridge reamer.
OIL JET
1. Push the check ball and verify that it moves smoothly.
2. Blow through the oil jet and verify that air flows.
05UOBX-15
82-61

82 ASSEMBLY
Oil Level Gauge Pipe Stay
1. Install the oil level gauge pipe stay.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 in-lb)
Oil Level Gauge
1. Install the level gauge.
Spark Plug
1, Install the spark plugs.
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 11-17 ft-lb)
Oil Pressure Switch
1. Install the oil pressure switch.
Tightening torque:
12-18 N-m (120-180 cm-kg, 104-156 in-lb)
Oil Cooler
1. Remove all foreign material from the oil cooler mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil cooler.
3. Install the oil cooler with paint mark (white) facing up.
4. Tighten the oil cooler lock nut.
Tightening torque:
29-39 N.m (3.0-4.0 m-kg, 22-29 ft-lb)
5. Connect the harness to oil pressure switch.
Oil Filter
1. Remove all foreign material from the oil filter mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil filter.
3. Install the oil filter and tighten it by hand until the rubber
seal contacts the base.
4. Tighten the filter 1 and 116 turns with a filter wrench. --_

92 INSTALLATION
RESOiANCE CHAMBER
03UOBZ-154
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut A.
Deflection: 1-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 Nlm (80-l 10 cm-kg, 69-96 In-lb)
2. Install the battery carrier.
Tightening torque:
7.8-l 1 N*m (80-l 10 cm-kg, 69-96 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.
Tightening torque
@: 19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N*m (80-l 10 cm-kg, 69-95 In-lb)
2. Connect the air flow sensor connector.
Resonance chamber
I, Install the resonance chamber.
Tightening torque:
7.8-l 1 N#m (80-l 10 cm-kg, 69-95 In-lb)
Under cover and side cover
1. Install the under cover 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.)
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 J2, 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 82-8.)
(3) Operation of emission control system.
6. Perform a road test.
7. Recheck the engine oil and engine coolant levels.
B2-102
2311082.047

ENGINE OIL, OIL FILTER D
b
I
03UODX-00
ONODX-01
r
03UODX-011
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 five minutes.
4. Remove the oil level gauge and check the oil level and con-
dition.
5. Add or replace oil as 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).
REPLACEMENT
Warning
l Be careful when draining; the oil is hot.
1. Warm up the engine to normal operating temperature and
stop it.
2. Remove the oil filler cap and the oil pan drain plug.
3. Drain the oil into a suitable container.
4. Install a new gasket and the drain plug.
Tightening torque:
29-41 N,m (3.0-4.2 m-kg, 22-30 ft-lb)
5. Refill the engine with the specified type and amount of en-
gine oil.
6. Refit the oil filler cap.
7. Run the engine and check for leaks.
8. Check the oil level and add oil if necessary.
Oil pan capacity
B6 SOHC
BP SOHC and DOHC
liters (US qt, Imp qt)
3.0 (3.2, 2.6)
3.6G.843.2)
w
03UODX-011
D-7

D OIL FILTER, OIL COOLER
r
\/
OSUODX-0
‘I . 03UODX-01
OIL FILTER
REPLACEMENT
1. Remove the oil filter with a suitable wrench.
2. Use a clean rag to wipe off the mounting surface on the
engine.
3. Apply a small amount of clean engine oil to the rubber seal
of the new filter.
4. Install the oil filter and tighten it by hand until the rubber
seal contacts the base.
5. Tighten the filter 1 and 116 turns with a filter wrench.
6. Start the engine and check for leaks.
7. Check the oil level and add oil if necessary.
Oil filter capacity: 0.17 liter (0.18 US qt, 0.15 Imp qt)
OIL COOLER (BP DOHC)
REMOVAL
1. Drain the engine oil.
2. Remove the oil filter with an oil filter wrench.
3. Disconnect the water hoses.
4. Remove the oil cooler.
INSTALLATION
1. Install the oil cooler.
Tightening torque:
29-39 Nnrn (3.0-4.0 m-kg, 22-29 ft-lb)
2. Install the oil filter. (Refer to page D-8.)
3. Add engine oil to the correct level.
4. After installing the filter, check that there is no oil leakage
while the engine is running.
5. Recheck the oil level using the dipstick.
(Refer to page D-7.)