MAZDA PROTEGE 1992 Workshop Manual

ASSEMBLY B2
03UOB2-111
03UOB2-ill
03UOB2-119
No.3 Engine Mount Bracket
1. Install the No.3 engine mount bracket.
Tightening torque:
93-l 17 N-m (9.5-l 1.9 m-kg, 69-86 ft-lb)
Alternator and Drive Belt
1. Install the alternator and loosely tighten the mounting bolts.
2. Install the alternator drive belt.
3. Adjust the drive belt deflections. (Refer to page B2-6.)
Injector and Distribution Pipe Assembly
1. Install the new injector insulators to the cylinder head.
2. Install the injector and distribution pipe assembly to the cyl-
inder head.
Tightening torque:
19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
Intake Manifold Assembly
1. Remove all foreign material from the intake manifold con-
tact surface.
2. Install a new gasket and the intake manifold assembly.
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-l 9 ft-lb)
82-89

B2 ASSEMBLY
03UOB2-15:
I
03UOB2-121
3. Connect the harness and hose.
--’
Distributor and High-tension Lead
1. Apply grease to a new O-ring and the blade.
2. Install the distributor and loosely tighten the installation bolts.
3. Connect the high-tension leads.
82-90

ENGINE STAND DISMOUNTING
ENGINE STAND DISMOUNTING
PROCEDURE
1. Remove the engine from the SST (engine stand).
2. Remove the SST (engine hanger) from the engine.
3. Install the parts shown in the figure.
Torque Specifications
0-RiNGa NEW-m I’,
19-i% (1.9-2.6, 14-19)
37-62 (3.6-5.3, 27-36)
19-25 (1.9-2.6, 14-19)
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
N-m (m-kg, R-lb)
05UOBX-25
Exhaust Pipe Bracket
1. Install the exhaust pipe bracket.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
B2-91

92 ENGINE STAND DISMOUNTING
03UOB2 122
-l!----- - 0311082-70
05UOEX-25
__._.__ -- _... -- _____II-___p--.-
051JOBX-25
82-92
Water Inlet Pipe
1. Remove all foreign material from the water inlet pipe mount-
ing surface.
2. Install a new gasket and the water inlet pipe. -
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Water Bypass Pipe
1. Apply a small amount of engine coolant to the new O-ring.
2. install the water bypass pipe.
A/C Compressor Bracket (If equipped)
1. Install the A/C compressor bracket.
Tightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Exhaust Manifold
1. Remove all foreign material from the exhaust manifold con-
tact surface.
2. Install a new gasket and the exhaust manifold.
Tightening torque:
38-46 N*m (3.9-4.7 m-kg, 28-34 ft-lb)
Exhaust Manifold insulator
1. Install the exhaust manifold insulator.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)
v

INSTALLATION 82
INSTALLATION
PROCEDURE
1. Tighten all bolts and nuts to the specified torques.
Step 1
Torque Specifications
ATX 34-49
(3.5-5.0, 25-36)
I
\56-60 (6.6-6.2, 41-59)
7-52 (3.6-5.3, 27-36)
37-52 (3.6~-5.3, 27-38)
64-89 (615-g. 1, 47-66)
N-m (m-kg, Mb)
0311082-123
Manual transaxle
1. Join the engine and transaxle.
2. Install the transaxle mounting bolts shown in the figure.
3. Tighten the bolts.
Tightening torque
@: 64-89 N#m (6.5-9.1 m-kg, 47-66 ft-lb)
0: 37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
37-52 (3.8-5.3, 27-38)
03UOB2-12
62-93

62 INSTALLATION
03UOB2-12
. ,
03UOB2-12’
13UOB2-01.
Automatic transaxle
1. Join the engine and transaxle.
2. Install the transaxle mounting bolts shown in the figure.
3. Tighten the bolts.
Tightening torque
@I: 55-80 N-m (5.6-8.2 m-kg, 41-59 ft-lb)
@I: 37-52 Narn (3.8-5.3 m-kg, 27-38 ft-lb)
4. Align the torque converter bolts and drive plate holes.
5. Install the torque converter nuts and tighten them.
Tlghtening torque:
34-49 N,m (3.5-5.0 m-kg, 25-36 ft-lb)
No.2 engine mount rubber and bracket
1. Install the mount rubber and bracket.
Tightening torque:
37-52 N#m (3.8-5.3 m-kg, 27-38 ft-lb)
Throttle Cable (ATX)
1, Connect the throttle cable and adjust it.
(Refer to Section Kl.)
Starter
1, Install the starter to the transaxle housing.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
Intake manifold bracket
1. Install the intake manifold bracket.
Tightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@I: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
B2-94

INSTALLATION B2
Step 2
Warning
l Be sure the vehicle is securely supported on Safety stands.
Torque Specifications
‘4-l 03
‘.5-10.5, 54-76)
37-52 (3.8-5.3, 27-38)
/
37-52 (3.8-5.3, 27-38)
64-89 (6.5-9.1, 47-66) 64-89 (6.5-9.1, 47-66)
N.m (m-kg, ft-II
OWOBX-21
Engine mount member (ATX)
1. Install the engine mount member.
Tightening torque:
64-89 N*m (6.5-9.1 m-kg, 47-66 ft-lb)
I I 03UOB2-130 1132-95

B2 INSTALLATION
L I I
03UOBZ-132
03UOB2-1 34
Engine and transaxle assembly
1. Suspend the engine and transaxle assembly.
Caution
l Do not damage any components in the engine com-
partment.
2. Install the engine and transaxle assembly in the engine
3. ii?the engine mounts with the engine mount member
mounting holes.
Engine mount
1. Install the engine mount nuts of the No.2 and No.3 mounts
and tighten them.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
2. Install the No.3 engine mount rubber.
Tightening torque
@j: 74-103 N-m (7.5-10.5 m-kg, 54-76 ft-lb)
@: 67-93 N-m (6.8-9.5 m-kg, 49-69 ft-lb)
3. Install the dynamic damper.
Tightening torque:
55-80 N-m (5.6-8.2 m-kg, 41-59 ft-lb)
Caution
l Before installing the engine support bracket, ar-
range the clutch release cylinder and pipe assembly.
4. Install the engine support bracket (MTX).
Tightening torque:
55-80 N-m (5.6-8.2 m-kg, 41-59 ft-lb)
5. Install the No.4 engine mount rubber and bracket, and
loosely tighten nuts @
6. Install bolts @ on the body side, and tighten them in two
or three steps in the order shown.
Tightening torque:
43-61 N-m (4.4-6.2 m-kg, 32-45 ft-lb)
7. Tighten nuts @.
Tightening torque:
67-93 N-m (6.8-9.5 m-kg, 49-69 ft-lb)

INSTALLATION
Step 3
Torque Specifications
16-23 (1.6-2.3, 12-17) 6.9-9.8 N.m (70-100 cm-kg, 61-87 in-lb)
I

m- ,,
// / 31-46 (3.2-4.7, 23-34)
ATX
Y
16-23 (1.6-2.3, 12-17) I 37-52 (3.8-5.3, 27-38) \/r-]z$/ 43-59 (4.4-6.0, 31-43)
COTTER PIN, NEW
/ 31-46 (3.2-4.7. 23-34) 42-67 (4.3-5.8, 31-42)
-_ ..------_ N.m (m-kg, R-lb)
no, Inor, 1.3
L 03UOB2 131
I 0311082-13.
Driveshaft
1. Apply grease to the end of the driveshaft.
Caution
l When installing the driveshaft, be careful not to
damage the oil seal.
l After installation, pull the front hub outward to con-
firm that the driveshaft is securely held by the clip.
2. Install the driveshaft and a new clip.
3. Install the lower arm ball-joint to the knuckle; then tighten
the lock nut.
Tightening torque:
43-59 N-m (4.4-6-O m-kg, 31-43 ft-lb)
4. Install the joint shaft.
5. Tighten the bolts in the order shown.
Tightening torque:
42-62 N-m (4.3-6.3 m-kg, 31-46 ft-lb)
82-97

B2 INSTALLATION
I 1
OBUOEP-138
I
J 13UOB2-024
Tie-rod end
1. Install the tie-rod end to the knuckle.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
2. Install the new split pin.
Stabilizer
1. Install and adjust the stabilizer.
Dimension A: 17-19mm (0.87-0.75 in)
Extension bar (MTX)
1. Install the extension bar to the transaxle.
Tightening torque:
31-48 N#m (3.2-4.7 m-kg, 23-34 ft-lb)
Shift control rod (MTX)
1 Install the shift control rod to the transaxle.
Tightening torque:
18-23 N-m (1.8-2.3 m-kg, 12-17 ft-lb)
Clutch release cylinder (MTX)
1. Install the clutch release cylinder.
Tightening torque:
16-23 N#m (1.6-2.3 m-kg, 12-17 ft-lb)
2. Set the pipe bracket in position.
Tightening torque:
18-23 N-m (1.6-2.3 m-kg, 12-17 ft-lb)
Shift control cable (ATX)
1. Install the shift control cable to the transaxle.
Tightening torque:
6.9-9.8 N-m (70-100 cm-kg, 61-87 in-lb)
03UOB2-142
B2-98