oil MAZDA PROTEGE 1992 Owner's Manual

Bl ON-VEHICLE MAINTENANCE
01 EOBX-056
23UOBi -0:
Steps After Installation
1. Lower the vehicle.
2. Connect the negative battery cable.
3. Start the engine and check the ignition timing.
(Refer to page 61-8)
Installation Note
Oil seal
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. 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 oil pump body.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 50.5mm (1.98 in)
Timing belt pulley
1. Install the timing belt pulley.
2. Install the pulley woodruff key with the tapered side toward
the oil pump body.
Pulley lock bolt
1. Hold the crankshaft with the SST and tighten the pulley lock
bolt.
Tightening torque:
157-167 N*rn (16-17 m-kg, 116-123 ft-lb)
23UOBi-026
Bl-24

-.
ON-VEHICLE MAINTENANCE Bl
REAR OIL SEAL
Replacement
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. install in the reverse order of removal, referring to Installation Note !.
I
16-26 (1.6-2.7, 13-20) I HTX
ATX
N.m (m-kg, R-lb)
23UOBl-027
1. Transaxle
MTX
Service.. ............................... Sections Jl , J2
ATX
Service .......................................... Section K
2. Clutch cover, clutch disc
Service .......................................... Section H 3. Flywheel (MTX)
Removal Note ..................................... below
Installation Note ........................ page 81-26
4. Drive plate (ATX)
Removal Note.. ......................... page Bl-26
Installation Note.. ...................... page Bl-27
5. Oil seal
Removal Note.. ......................... page 81-26
Installation Note ........................ page 81-26
Removal note
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
Bl-25

Bl ON-VEHICLE MAINTENANCE
OIL SEAL LIP
L I I
OWOBX-063
05UOBX-069
Drive plate (ATX)
1. Hold the drive plate with the SST or equivalent.
2. Remove the drive plate lock bolts.
3. Remove the backing plate, drive plate, and adapter.
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
Installation note
Oil seal
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. 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 rear cover.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 1OOmm (3.94 in)
Flywheel (MTX)
1. Remove the sealant from the flywheel bolt holes in the crank-
shaft and from the flywheel bolts.
Caution
l If all the previous sealant cannot be removed from
a bolt, replace the bolt.
l Do not apply sealant if a new bolt is used.
2. Set the flywheel onto the crankshaft.
3. Apply sealant to the flywheel bolts and install them.
4. Hold the flywheel with the SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown
in the figure.
Tightening torque:
96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)

REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section F.)
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil.
3. Remove in the order shown in the figure, referring to Removal Note,
Step 1
1. Undercover and side cover
2. Air cleaner assembly 10. Cooling fan connector
3. Battery and battery cover 11. Oil cooler hose (ATX)
4. Battery carrier 12. Radiator and cooling fan assembly
13. P/S and/or A/C drive belt
5. Battery duct
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Accelerator cable page Bl- 6
7. Resonance chamber 14. P/S oil pump and bracket
8. Radiator hose Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
9. Coolant reservoir hose 15. A/C compressor (if equipped)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
81-28

REMOVAL I31
Step 2
2311081-O: ii
1.
Disconnect the harness connectors shown in the figure.
Removal note
P/S oil pump
Caution
l Do not damage the hoses.
1. Remove the P/S oil pump with the hoses still connected.
2. Position the pump away from the engine and affix it with wire.
A/C compressor (if equipped)
Caution
l Do not damage the hoses.
1, Remove the A/C compressor with the hoses still connected.
2. Position the compressor away from the engine and affix it
with wire.
ALTERNATOR
OIL PRESSURE SWITCH
GROUND THROTTLE SENSOR
------- I
INJECTOR
NEUTRAL SWITCH (MTX)

Bl REMOVAL
I 03UOBi-05 I
14
‘5
03UOBl-056
Bl-32
Tie-rod end
1. Remove the cotter pin and loosen the nut so that it flushes
with the ball joint edge.
2. Separate the knuckle arm and ball-joint with the
SST.
Caution
l Do not reuse the cotter pin.
Engine mount member
1. Suspend the engine with a chain block.
2. Remove the No.1 and No.2 engine mount nuts.
3. Remove the engine mount member bolts and nuts and the
engine mount member.
Caution
l Be careful so that the engine does not fall when
removing the member.
Driveshaft
1. Remove the bolts and nuts at the left and right lower arm
ball joints.
2. Pull the lower arm downward to separate them from the
knuckles.
Caution
l Do not damage the ball joint dust boots.
3. Separate the driveshafts from the transaxle by prying with
a bar inserted between the shaft and the case.
Caution
l Do not damage the oil seal.

Bl DISASSEMBLY
AUXILIARY PARTS
1. Drain the engine oil.
2. Disassemble in the order shown in the figure.
- REPLACE - ’ ,/ I’

1. Distributor and high-tension lead
2. Intake manifold assembly
3, Alternator and drive belt
4. Alternator bracket
5. No.3 engine mount bracket 6. Oil filter
7. Oil pressure switch
8. Spark plug
9. Oil level gauge and pipe 10. Engine hanger
61-40

DISASSEMBLY
23UOBl-067
; MARKS
MARKS
Qe
x
25mm (1.0 in) MIN
13EOBl-0:
Disassembly Note
Pulley lock bolt
1. Hold the flywheel (MTX) or drive plate (ATX) with the SST
or equivalent.
2. Remove the pulley lock bolt.
Timing belt
1. Turn the crankshaft and align the marks.
2. Mark the timing belt rotation for proper reinstallation.
Caution
l Never forcefully twist the timing belt. Do not turn
it inside out or bend it.
l Do not allow oil or grease on the belt.
81-42

DISASSEMBLY Bl
CYLINDER HEAD
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
GASKET, REPLA
B6 SOHC
1. Cylinder head cover and gasket 14. Cylinder head bolts
2. Thermostat cover and gasket
3. Thermostat
4. Heat gauge unit
5. Bracket
6. Rocker arm and shaft assembly
Disassembly Note . . . . . . . . . . . . . . . . . . . .
7. Rocker arm
8. Rocker arm spring
9. Rocker shaft Disassembly Note . . . . . , , . . . . . . . . . . . . . page Bl-45
15. Cylinder head
Inspection . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B l-54
16. Cylinder head gasket
17. Valve keeper
page Bl-45 Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-46
18. Valve spring seat, upper
19. Valve spring
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-58
10. Hydraulic lash adjuster (HLA) 20. Valve spring seat, lower
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-45 21. Valve
Inspection ., . . . . . . . . . . . . . . . ,.,.......... . . . page Bl-60 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-55
11. Camshaft pulley 22. Valve seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-45 Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-46
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-65 Inspect for wear or damage
12. Thrust plate 23. Valve guide
13. Camshaft Inspection . . . . . ,.,.............. . . . . . . . . . . . page Bl-55
Inspection . . . . . . . . . . . . . . . page B l-58 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-56
24. Camshaft oil seal
Bl-43

Bl DISASSEMBLY
BP SOHC
GASKET, REPLACE @g-p--
1. Cylinder head cover and gasket 14. Cylinder head bolts
2. Thermostat cover and gasket Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-45
3. Thermostat 15. Cylinder head
4. Heat gauge unit
5. Bracket
6. Rocker arm and shaft assembly
Disassembly
note . . . . . . . . . . . . . . . . . . . . . page Bl-45
7. Rocker arm
8. Rocker arm spring
9. Rocker shaft
10. Hydraulic lash adjuster (HLA)
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page 81-45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-60
11. Camshaft pulley
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page 81-45
Inspection .,....,...,...................... page Bl-65
12. Thrust plate
13. Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . ,........ page Bl-54
16. Cylinder head gasket
17. Valve keeper
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-46
18. Valve spring seat, upper
19. Valve spring
Inspection ,...*.......*..................*. page Bl-58
20. Valve spring seat, lower
21. Valve
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..t. page 81-54
22. Valve seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-46
Inspect for wear or damage
23. Valve guide
Inspection . . . . . . . . . . . . . . . . . ,.. ..,..,., ,.,
page Bl-58 Inspection ..,.,.........,..,............... page 81-54
Replacement . . . . . . . . . . . . . . . . . . . . . . . . ..I. page Bl-56
24. Camshaft oil seal
..-..
Y’
81-44