MAZDA PROTEGE 1992 Workshop Manual

ASSEMBLY 82
CYLINDER HEAD
Torque Specifications
11.3-l 4.2 N.m
(1.15-1.45 m-kg, loo-126 In-lb) 4.9-8.6 N.m
(50-90 cm-kg, 43-76 In-lb)
I I I I -
I I I . 7.6-11 N.m JOURNALS AND
-CAM FACES
(60-I 10 cm-kg, 69-96 in-lb) BOLT THREADS
AND SEAL FACES
5.9-6.6 N.m
(60-90 cm-kg, 52-76 in-lb)
a .e..IC..T .*-*.a
I
UHYKtl NtW
.g~fET NEW
. *
-96 cm-kg,
N.rn (m-kg, &lb)
Valve Seal
03UOB2-1
1. Assemble the SST so that depth L is as specified.
Depth L: 19.b20.0mm (0.780-0.787 in)
B2-79

62 ASSEMBLY
I OWOBX-21!
I CYLINDER HEAD SIDE
05UOBX-2
I
05UOBX-21 6
i
17
05UOBX-2
2. Slide the valve seal onto the valve guide.
3. Set the
SST against the valve seal.
Caution
l Do not use a hammer.
4. Press the valve seal on until the SST contacts the cylinder
head.
Valve and Valve Spring
1. Install the lower spring seat.
2. Install the valve.
Caution
l Install the spring with the closer pitch toward the
cylinder head. .---
3. Install the valve spring and the upper spring seat.
4. Compress the valve spring with the
SST, and install the
valve keepers.
5. Remove the
SST.
6. Tap the end of the valve stem lightly two or three times with
a plastic hammer to verify that the keepers are all fully
seated.
Cylinder Head Gasket
1. Remove all foreign material from the top of the cylinder
block.
2. Place the new cylinder head gasket in position.
82-80

ASSEMBLY
05UOBX-221
I 0311082-10
Cylinder Head
1. Install the cylinder head.
2. Apply clean engine oil to the bolt threads and seat faces.
3. Tighten the cylinder head bolts in two or three steps in the
order shown.
Tightening torque:
76-61 Nsrn (7.7-8.3 m-kg, 56-60 ft-lb)
Water Thermoswitch, Heat Gauge Unit
1. Install the water thermoswitch.
Tightening torque:
5.9-8.8 N#m (60-90 cm-kg, 52-78 in-lb)
2. Install the heat gauge unit.
Tightening torque:
6.4-9.3 N.m (65-95 cm-kg, 56-82 in-lb)
Thermostat, Thermostat Cover
1. Remove all foreign material from the thermostat cover
mounting surface.
2. Install the thermostat with the jiggle pin facing upward.
Caution
l The printed side of the gasket must face the ther-
mostat.
3. Install a new gasket and the thermostat cover.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
HLA
1. Apply clean engine oil to the friction surfaces.
2. If the HLA are being reused, install them in the position from
which they were removed.
3. Verify that the HLA move smoothly in their bores.
05UOBX.223
B2-81

B2 ASSEMBLY
DlSTRlBUfOR
DRIVE GROOVE
-- 03umx-01
-
05UOBX-05
--____--
udOBX-056
---I
Camshaft
Note
l The exhaust camshaft is grooved for the distribu-
tor drive.
1. Apply clean engine oil to the camshaft journals and bearings.
2. Install the camshaft in position.
Caution
l Do not allow any sealant on the camshaft journal
surfaces.
3. Apply silicone sealant to the shaded areas shown in the
figure.
4. Install the camshaft caps according to the cap number and
arrow mark.
5. Install the camshaft cap bolts and tighten them in two or
three steps in the order shown in the figure.
Tightening torque:
11.3-14.2 Nlm (1.15-l .45 m-kg, loo-126 in-lb)
6. Apply a small amount of clean engine oil to the lip of a new
camshaft oil seal.
7. 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 camshaft cap.
8. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 48mm (1.89 in)
Seal Plate
1. Install the seal plate on the cylinder head.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
~,. ,
03”oEm10:
B2-82

ASSEMBLY 82
DOWEL PIN
23UOB2-042
03UOB2-1 OL Camshaft Pulley
1. Turn the camshafts until the camshaft dowel pins face
straight up.
2. Install the camshaft pulleys with the
I mark (intake side) or
the E mark (exhaust side) straight up.
3. Install the camshaft pulley lock bolts.
4. Hold the camshaft with a wrench at hexagonal portion.
5. Tighten the camshaft pulley lock bolt.
Tightening torque:
49-61 N.m (5.0-6.2 m-kg, 36-45 ft-lb)
Cylinder Head Cover
1. Apply silicone sealant to the shaded areas shown in the
figure.
2. Install the cylinder head cover.
Tightening torque:
4.9-6.6 N.m (50-90 cm-kg, 43-76 in-lb)
82-83

B2 ASSEMBLY
TIMING BELT
Torque Specifications
7.6-11 N:m
(60-l 10 cm-kg,
69-95 in-lb) \
-kg, 69-95 in-lb)
37-52
(3.8-5.3, 27-38)
157-167 (16-17, 116-123)
?.a--11 N-m
(60-110 cm-kg, 69-95 in-lb) /
12-17 (1.25-1.76, 9-13)
N-m (m-kg, ft-it
03UOB2.1
Idler
1. Install the idler.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Tensioner and Tensioner Spring
1. Install the tensioner and the tensioner spring.
2. Temporarily secure the tensioner with the spring fully ex-
tended.
-’
o5uoBx-229
02-84

ASSEMBLY
13EOB2.03
13EOB2-03.
3 1
03UOB2-111
23UOB2-04: 3
Timing Belt
1. Verify that the timing belt pulley mark is aligned with the tim-
ing mark.
2. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
3. Install the timing belt so that there is no looseness at the
idler side or between the camshaft pulleys.
4. Install the pulley boss and pulley lock bolt.
Caution
l Do not turn the crankshaft counterclockwise.
5. Turn the crankshaft two turns clockwise and face the pin
on the pulley boss upright.
6. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
If not aligned, remove the timing belt and repeat from ten-
sioner installation.
7. Turn the crankshaft 1 and 5/6 turns clockwise, and align
the timing belt pulley mark with the tension set mark for prop-
er timing belt tension adjustment.
8. Loosen the tensioner lock bolt to apply tension to the tim-
ing belt.
9. Tighten the tensioner lock bolt.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
10. Turn the crankshaft 2 and l/6 turns clockwise and verify
that the timing marks are correctly aligned.
B2-85

I 23UOB2-044
82 ASSEMBLY
DEFLECTION CHECKING POlNT
--; 11. Measure the timing belt deflection by applying moderate
oressure (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)
Timing Belt Cover
1. Install the lower, middle, and upper covers.
Tightening torque:
7.8-11 N.m (80- ,110 cm-kg, 69-95 in-lb)
I 13EOB2-037
82-86
Pulley lock bolt
1. Hold the flywheel (MIX) or drive plate (ATX) with the SST
and tighten the pulley lock bolt.
Tlghtening torque:
157-167 N.m (16-17 m-kg, 116-123 ft-lb)
Cankshaft pully
1. Install the crankshaft pulley.
2. Install the plate.
3. Tighten the pulley bolts.
Tightening torque:
12-17 N-m (1.25-l -75 m-kg, 9-13 ft-lb)
Water Pump Pulley
1. Install the water pump pulley.
Tightening torque:
7.8-11 N*m (80-110 cm-kg, 69-95 in-lb)

ASSEMBLY B2
AUXILIARY PARTS
Toraue Specifications
19-25 19-25
O-RING, NEW
(1.9-2.6, 14-19) (1.9-2.6, 14-19)
-
I 19-25
mfi GASKET. NEW (1.9-2.6, 14-19)
37-52
(33-5.3, 27-38)
(3.8-5.3, 27-38)
7.8-11 N.m /
(80-110 cm-kg, 69-95 in-lb)
N.m (m-kg, A-lb)
.-. 05UOBX-23
Engine Hanger
1. Install the front and rear engine hangers.
OYJOBX-238
Tightening torque:
37-52 N*m (3.8-5.3 m-kg, 27-38 ft-lb)
82-87

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. --_