check oil MAZDA PROTEGE 1992 Owner's Manual

I32 INSPECTION / REPAIR
INSPECTION / REPAIR
PREPARATION
SST
49 6012 005 49 6012 005
Remover & Remover &
installer, valve installer, valve
guide guide
49 LO12 002
Body
(Part of
49 LO12 OAO)
49 LO12 004
Nut
(Part of
49 LO12 OAO) For
removal of
valve guide
For
installation of
valve guide
For
installation of
valve guide 49 LO12 OAO
Installer set,
valve seal &
valve guide
49 LO12 003
Installer
(Part of
49 LO12 OAO) For
installation of
valve guide
For
installation of
valve guide
05UOBX-1
1. Clean all parts, being sure to remove all gasket fragments, dirt, oil or grease, carbon, moisture residue,
and other foreign materials.
2. Inspection and repairs must be performed in the order specified. -.,
Caution
l Do not damage the joints or friction surfaces of aluminum alloy components (such as the cyl-
inder head or pistons).
0311082-162
03UOB2-70 OWOBX-119
CYLINDER HEAD
1, Inspect the cylinder head for damage, cracks, and leakage
of water and oil. Replace the cylinder head if necessary.
2. Measure the cylinder head distortion in the six directions
shown in the figure.
Distortion: O.lOmm (0.004 in) max.
Cautlon
l Before grinding the cylinder head, check the follow-
ing and repair or replace the cylinder head as
necessary.
Sinking of valve seats
Damage of manifold contact surface
Camshaft oil clearances and end play
3. If the cylinder head distortion exceeds specification, grind
the cylinder head surface.
If the cylinder head height is not within specification, replace
it. Height: 133.8-l 34.0mm (5.268-5.276
in)
Grinding: O.lOmm (0.004 in) max.
62-64

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

OSUOBX-1E
X
a3 Y
03UOB2-11
CRANKPIN
MAIN JOURNAL
OSUOBX-1
B2 INSPECTION / REPAIR
CRANKSHAFT
1. Check the journals and pins for damage, scoring, and oil
hole clogging.
2. Set the crankshaft on V-blocks.
3. Measure the crankshaft runout at the center journal.
Replace the crankshaft if necessary.
Runout: 0.04mm (0.0016 in) max.
4. Measure each journal diameter in X and Y directions at two
points.
Main journal
Diameter: 49.938-49.956mm (1.9661-l .9668 in)
Out-of-round: 0.05mm (0.0020 in) max.
Crankpin journal
Diameter: 44.940-44.956mm (1.7693-l .7699 in)
Out-of-round: 0.05mm (0.0020 in) max.
5. If the diameter is less than the minimum, grind the journals
to match an undersize bearing.
Undersize bearing:
0.25mm (0.010 in), OSOmm (0.020 in),
0.75mm (0.030 in)
Main journal diameter undersize
mm (in)
Bearing size Journal diameter
0.25 (0.010) undersize 49.704-49.708 (1.9568-l
.9570)
0.50 (0.020) undersize
49.454-49.458 (1.9470-l .9472)
0.75 (0.030) undersize 49.204-49.208
(1.9372-l .9373)
Crankpin journal diameter undersize mm (in)
Bearing size Journal diameter
0.25 (0.010) undersize 44.690-44.706
(1.7594-l .7601)
0.50 (0.020) undersize 44.440-44.456 (1.7496-l
.7502)
0.75 (0.030) undersize
44.190-44.206 (1.7398-l .7404)
05UOBX-166
BEARING
Main Bearing and Connecting Rod Bearing
1. Check the main bearings and the connecting rod bearings
for peeling, scoring, and other damage.
05UOBX-167
B2-64

INSPECTION / REPAIR B2
25mm (1 .O in) MIN.
05UOEX-16;
DAMAGE,
WEAR
05UOBX-16
1
s
9
OWOBX-170
O-WOBX-171 .___--__-____--
OSUOBX-172
TIMING BELT
Caution
l Never forcefully twist, turn inside out, or bend the
timing belt.
l Do not allow oil or grease on the belt.
1. Replace the timing belt if there is any oil or grease on it.
2. Check the timing belt for damage, wear, peeling, cracks,
and hardening. Replace the timing belt if necessary.
TENSIONER, IDLER
Caution
l Do not clean the tensioner or idler with cleaning
fluids. If necessary, use a soft rag to wipe them
clean, and avoid scratching them.
1. Check the tensioner and idler for smooth rotation and ab-
normal noise. Replace the tensioner or idler if necessary.
TENSIONER SPRING
1. Measure the free length of the tensioner spring. Replace
the tensioner spring if necessary.
Free length: 58.8mm (2.315 in)
PULLEY
Timing Belt Pulley, Camshaft Pulley
Caution
l Do not clean the pulleys with cleaning fluids. If
necessary, use a soft rag to wipe them clean, and
avoid scratching them.
1. Inspect the pulley teeth for wear, deformation, and other
damage. Replace the pulley if necessary.
B2-65

ASSEMBLY
2311082-04
05UOBX-17
OSUOBX-17
SPACER TANG
OIL RING
SPACER ENDS
-I
a
5. Tap the piston pin in with the SST until the pin contacts the
clip.
If the pin cannot be installed easily, replace the connecting
rod.
6. Install the second clip into the clip groove in the piston.
7. Check the oscillation torque of the connecting rod. If the
large end does not drop by its own weight, replace the pis-
ton and/or piston pin.
Piston Ring
1. Install the three-piece oil rings on the pistons.
(1) Apply clean engine oil to the oil ring spacer and rails.
(2) Install the oil ring spacer with the ends upward.
Note
l The upper rail and lower rail are the same.
l The rails may be installed with either face upward.
(3) Install the upper rail and lower rail.
2. Verify that both rails are expanded by the spacer tangs as
shown in the figure by making certain the rails turn smoothly
in both directions.
Caution
l The rings must be installed with the Fl marks
upward.
l The second ring must be installed with the scraper
face downward.
3. Apply clean engine oil to the top and second piston rings.
4. install the second ring to the piston; then install the top ring.
Use a piston ring expander (commercially available).
132-69

B2 ASSEMBLY
RUBBER SLEEVE
I
OYJOBX-192
03UOB2-17
03UOB2-09 2 '0
05UOBX-196 Piston and Connecting Rod Assembly
Caution
l Protect the connecting rod bolts with rubber sleeves
to prevent damage to the crankpin journals.
1. Apply a liberal amount of clean engine oil to the cylinder
walls, pistons, and piston rings.
2. Check the piston rings for correct end gap alignment.
3. Insert each piston assembly into the cylinder block with the
F mark facing the front of the engine. Use a piston ring com-
pressor (commercially available).
Connecting Rod Cap
1. Measure the connecting rod bearing oil clearances using
the same procedure as for the main bearing oil clearance.
Caution
l Align the matching marks on the cap and the con-
netting rod when installing the connecting rod cap.
Tightening torque:
47-50 N-m (4.8-5.1 m-kg, 35-37 &lb)
Oil clearance: 0.028.0.088mm (0.001 l-0.0027 in)
Maximum: O.lOmm (0.004 in)
2. If the oil clearance exceeds the maximum, grind the crank-
shaft and use undersize bearings. (Refer to page 82-64.)
3. Measure the connecting rod side clearances.
Side clearance: 0.1 lo-0.282mm (0.0043-0.0103 in)
Maximum: 0.30mm (0.012 in)
4. If the clearance exceeds the maximum, replace the con-
necting rod and cap.

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

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)

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.)