MAZDA PROTEGE 1992 Workshop Manual

INSTALLATION
Step 4
I. Connect the hoses shown in the figure.
Caution Speedometer cable
1. Install the speedometer cable.
Exhaust pipe
1. Install the exhaust pipe and a gasket; then loosely tighten
the lock nuts.
2. Loosely tighten the bracket bolts.
3. Tighten the lock nuts.
Tightening torque:
31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
4. Tighten the bracket bolts.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
VACUUM HOSE
(CRUISE CONTROL) BRAKE, VACUUM HOSE 1 VACUUM HOSE
(PURGE CONTROL)
HEATER HOSE
FUE’L HOSE
03UOB2-14
B2-9:

B2 INSTALLATION
Step 5
1. Connect the harness connectors shown in the figure.
___---
r-
OIL PRESSURE SWITCH
THROTTLE
GROUND ITX
INHIBITOR SWITCH
TRAL SWITCH (MTX)
7.6-11 N.m
I N.m
0 cm-kg, 69-95 in-lb)
2.9-5.9 N-m
30-60 cm-kg,
26-52 in-lb)
cm-kg, 56-82 in-lb) 03UOB2-1~
Step 6
Torque Specifications
7.6-11 N.m (60~110 cm-kg, 69-95 in-lb)
N-m (m-kg, ft-lb]
03UOB2-14
.-
-’
82-l 00

INSTALLATION
03UOB2-141
/ 03UOB2-14!
1 03UOB2-150
03UOB2-151
8,’
1
a : :“.;,
.’
s,::, ; i .:.;...
..:.a.. :..,:.
. .
. .
” . : 0 ,.: ::
: .:.. ..,
., ‘:;
.<.,:.,);
‘zi :
I 0311082-152
A/C compressor (If equipped)
1. Install the A/C compressor.
Tightening torque:
24-35 N,m (2.4-3.6 m-kg, 17-26 ft-lb)
2. Tighten the A/C pipe bracket to the engine mount member.
Tightening torque:
6.4-9.3 N-m (65-95 cm-kg, 56-62 in-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page B2-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)
2. Connect the upper and lower radiator hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good
fit.
3. Connect the coolant reservoir hose.
4. Connect the cooling fan connector.
5. Connect the oil cooler hose. (ATX)
B2-101

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

LUBRICATION SYSTEM
INDEX ...................................................... D- 2
OUTLINE .................................................. D- 5
SPECIFICATIONS .................................... D- 5
TROUBLESHOOTING GUIDE.. .................... D- 5
OIL PRESSURE ......................................... D- 6
PREPARATION ....................................... D- 6
INSPECTION .......................................... D- 6
ENGINE OIL ............................................. D- 7
INSPECTION .......................................... D- 7
REPLACEMENT ...................................... D- 7
OIL FILTER .............................................. D- 6
REPLACEMENT ...................................... D- 6
OIL COOLER ............................................ D- 6
REMOVAL ............................................. D- 6
INSTALLATION ....................................... D- 6
OIL PAN .................................................. D- 9
REMOVAL I INSTALLATION ......................
OIL PUMP ................................................ ;-,;
-
DISASSEMBLY I ASSEMBLY ..................... D-l 3
INSPECTION .......................................... D-14
23UODX-001

D INDEX
INDEX
66 SOHC
.-A
23UODX-0 -I
02
1. Oil pressure
Inspection ,..,............................ . . . page D- 6
2. Engine oil
Inspection .,,...........,.................... page D- 7
Replacement . . . . ., , . . . . . . . . . . . . . . . . , page D- 7
3. Oil filter
Replacement . . . . . ,.. . . . . . . . . . . . . . . . . . . . . . . page D- 8 4. Oil pan and main bearing support plate
(MBSP)
Removal I Installation.. . . . . . . . . . . . . . . . . page D- 9
5. Oil pump
Disassembly I Assembly page D-13 x-
.............
Inspection ................................... page D-l 4
D-2

INDEX D
/I? HYDRAULIC LASH ADJUSTER (HLA)
SERVICE, SECTION Bl
TION B‘
ENGINE &L SPECIFICATION
API SERVICE SG ECII ONLY
TOTAL CAPACITY
4.0 liters (4.2 US qt, 3.5 Imp qt)
I 23UODX-003
1. Oil pressure 4. Oil pan and main bearing support plate
Inspection.. ................................. page D- 6 (MBSP)
2. Engine oil Removal / Installation .................. page D- 9
Inspection page D- 7 5. Oil
................................... pump
Replacement .............................. page D- 7 Disassembly I Assembly.. ........... page D-l 3
LA-”
3. Oil filter Inspection.. ................................. page D-l 4
Replacement .............................. page D- 8
D-3

D INDEX
BP DOHC
HYDRAULIC LASH ADJUSTER (HLA)
SERVICE, SECTION B2
/
ICE,
ENGlNi OIL SPECIFICATION
API SERVICE SG EClI ONLY
TOTAL CAPACITY
4.0 liters (4.2 US qt, 3.5 Imp qt)
1. Oil pressure
Inspection ,,...,..,..,...........,.,,.,.,.,.. page D- 6
2. Engine oil
Inspection page D- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement ,.,... . . . . . . . . . ,.,....,..... . . page D-
7
3. Oil filter
Replacement . . . . . . . . . . . . . . . . .,.. , . . . . . . . . , page
D- 8 4. Oil pan and main bearing support plate
(MBSP)
Removal I inspection /
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page D- 9
5. Oil pump
Disassembly / Assembly... .I ,....... page D-l 3
Inspection ,.,,,.,....,..,,..,..,.,,.,..,..,., page D-l 4
6. Oil cooler
Removal I Installation . . . . . . . . . . . . . . . . . . page
D- 8
D-4

OUTLINE, TROUBLESHOOTING GUIDE D
OUTLINE
SPECIFICATIONS
Engine
Item
--
Lubrication system
Type
011 pump
Relief pressure kPa (kg/cm2, psi)
_~__
Type Oil filter
Relief pressure differential kPa (kg/cm2, psi)
Oil pressure switch activation pressure
kPa (kg/cm’, psi)
Total (dry engine)
liters (US qt, Imp qt)
Oil capacity Oil pan liters (US qt, Imp qt)
Oil filter liter (US qt, Imp qt)
Engine oil
Above -25OC (-13’F)
Viscosity number
Below 0% (32OF) BP SOHC BP DOHC
B6 SOHC
Force-fed type
Trochoid gear
343-441 (3.5-4.5, 50-64) m I, Full-flow, paper element
78-l 18 (0.8-l .2, 1 l-i 7)
25 (0.25, 3.6)
3.4 (3.6, 3.0) 4.0 (4.2, 3.5)
3.0 (3.2, 2.6) 3.6 (3.8, 3.2)
0.17 (0.18, 0.15)
API service SG Energy ConservingII (ECII) Only
SAE low-30
SAE 5W-30
23UODX-005
TROUBLESHOOTING GUIDE
Problem
Engine hard starting
Excessive oil
consumption
Oil pressure drop
Warming lamp
illuminates while
engine is running Possible Cause
Improper engine oil
Insufficient engine oil
Oil working up or down
011 leakage
Insufficient oil
Oil leakage
Worn and/or damaged oil pump gear
Worn plunger (inside oil pump) or weak spring
Clogged oil strainer
Excessive main bearing or connecting rod bearing
clearance
Oil pressure drop
Malfunction of oil pressure switch
Malfunction of electrical system Remedy
Replace
Add oil
Refer to Section B
Repair
Add oil
Repair
Replace
Replace
Clean
Refer to Section B
As described above
Refer to Section T
Refer to Section T Page
D- 7
D- 7
-
D- 7
-
D-13, 14
D-13, 14
-
-
23UODX-015
D-5

D OIL PRESSURE
OIL PRESSURE
PREPARATION
SST
49 C 187 280
Gauge,
oil pressure
03UODX-03
2
03UODX-007
INSPECTION
1, Remove the intake manifold bracket.
2. Remove the oil pressure switch.
3. Screw the SST into the oil pressure switch installation hole.
4. Warm up the engine to normal operating temperature.
5. Run the engine at 1,000 rpm and 3,000 rpm, and note the
gauge reading.
Oil pressure:
196-294 kPa (2.0-3.0 kg/cm2, 28-43 psi)-1,000 rpm
294-392 kPa (3.0-4.0 kg/cm2, 43-57 psi)-3,000 rpm
6. If the pressure is not as specified, check for the cause and
repair. (Refer to Troubleshooting Guide.)
7. Remove the SST and install the oil pressure switch.
Tightening torque:
12-18 N-m (1.2-l .8 m-kg, 104-156 in-lb)
8. Install the intake manifold bracket.
Tightening torque
@: 37-52 N*m (3.8-5.3 m-kg, 27-38 ft-lb)
0: 19-25 N,m (1.9-2.6 m-kg, 14-19 ft-lb)