wheel MAZDA PROTEGE 1992 Owner's Manual

DISASSEMBLY
23UOW056
03UOB2-073
Disassembly Note
Timing belt pulley
1. Hold the flywheel or the drive plate with the SST or
equivalent.
2. Loosen the pulley lock bolt.
3. Remove the pulley lock bolt.
4. Remove the timing belt pulley.
5. Remove the pulley Woodruff key.
23UOB2-049
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
Backing plate, drive plate, and adapter (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 pan
1. Remove the oil pan mounting bolts.
Caution
l Do not force a prying tool between the cylinder
block and the oil pan, which may damage the con-
tact surfaces.
l Do not damage or scratch the contact surfaces
when removing the old sealant.
2. Insert a screwdriver or a suitable tool only at the points
shown in the figure.
3. Remove the oil pan.
82-49

B2 ASSEMBLY
I
03UOB2-09
I
05UOBX-20 6
9
OWOBX-211 0
05uoax-21 1
03UOB2-097
Oil Pan
1. Remove all foreign material from the contact surfaces.
2. Apply silicone sealant to the shaded areas shown in the
figure.
3. install new gaskets onto the oil pump body and the rear
cover with the projections in the notches shown in the figure.
4. Apply a continuous bead of silicone sealant to the oil pan
along the inside of the bolt holes and overlap the ends.
5. Install the oil pan.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
End Plate
1. Install the end plate.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
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.
82-76

--
ASSEMBLY B2
2311082-06
2311082.04
1
03UO62-09!
J 2311062-063
4. Hold the flywheel with the SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
96-l 03 N.m (9.6-10.5 m-kg, 71-76 ft-lb)
Clutch Disc and Clutch Cover (MTX)
1. Install the clutch disc and clutch cover using the SST or
equivalent. (Refer to Section H.)
Tightening torque:
16-26 N.m (1.8-2.7 m-kg, 13-20 ft-lb)
Drive Plate (ATX)
1. Remove the sealant from the drive plate holes in the crank-
shaft and from the drive plate lock 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 adapter, drive plate, and backing plate onto the
crankshaft.
3. Apply sealant to the drive plate bolts and install them.
4. Hold the drive plate with the
SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
96-103 N.m (9.8-10.5 m-kg, 71-76 ft-lb)
Timing Belt Pulley
1, Reverse the direction of the SST or equivalent on the
flywheel.
2311082.064
B2-77

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)

OUTLINE
Component Function Remark
Engine control unit (ECU) Controls operation of the following:
(Cont’d)
1. A/C (Cut-off) 1. A/C relay
2. Fail-safe function 2. Self-Diagnosis Checker and MIL
3. Fuel injection system 3. Injector
4. idle speed control 4. Idle speed control (ISC) valve
5. Ignition timing control system 5. Igniter
6. Monitor function 6. Monitor lamp (Self-Diagnosis Checker)
7. Pressure regulator control system 7. Solenoid valve
(Pressure regulator control) (BP)
8. Purge control system 8. Purge control solenoid valve
9. VICS 9. Solenoid valve (WCS) (DOHC) Fuel filter
Filters particles from fuel Fuel pump
Provides fuel to injectors l Operates while engine running l Installed in fuel tank Igniter
Receives spark signal from ECU and gener-
ates high voltage in ignition coil Ignition switch
Engine cranking signal sent to ECU (START position)
Inhibitor switch (ATX)
Detects in-gear condition; sends signal to Switch ON in N or P range
ECU Injector
Intake air thermosensor
Idle speed control (ISC)
valve
Main relay
(FUEL INJ relay)
MIL (Malfunction
indicator lamp)
Neutral switch (MTX)
Oxygen sensor
PCV valve
P/S pressure switch
Pressure regulator
Resonance chamber
Resonance duct
Separator
Stoplight switch
Solenoid valve
(Purge control)
Shutter valve actuator
(DOHC)
Throttle body
Throttle sensor
Injects fuel into intake port l Controlled by signals from ECU
l High-ohmic injector
Detects intake air temperature; sends signal Installed on dynamic chamber
to ECU
Controls bypass air amount Controlled by duty signal from ECU
Supplies electric current to injectors, ECU,
etc.
Lamp flashes to indicate malfunction code
number of input and output devices
Detects in-gear condition; sends signal to
ECU
Detects oxygen concentration; sends signal
to ECU
Controls blowby gas introduced into engine
Detects P/S operation; sends signal to ECU
Adjusts fuel pressure supplied to injectors
Reduces intake air noise
Reduces intake air noise
Prevents fuel from flowing into charcoal
canister
Detects braking operation (deceleration),
sends signal to ECU
Controls evaporative fumes from canister to
intake manifold
Closes/opens shutter valve to improve
torque characteristics
Controls intake air quantity
l Detects throttle valve fully closed/fully
opened condition (MTX) TEN terminal grounded
Switch ON in neutral
Zirconia ceramic and platinum coating
P/S: ON when steering wheel turned right or
left
Controlled by duty signal from ECU
For Variable inertia charging system (VICS*)
Integrated throttle sensor, dashpot, and ISC
valve
l Detects throttle valve opening angle
(A-W
l Sends signals to ECU
F-l 7

CONTROL SYSTEM F
23UOFX-151
WASHER,
REPLACE
9MUOF2-24
05UOFX-25

9MUOF2-24
NEUTRAL SWITCH (MTX)
Inspection
1. Disconnect the neutral switch connector.
2. Connect an ohmmeter to the switch.
3. Check continuity of the switch.
Transmission Continuity
Neutral Yes
Other ranges No
4. If not as specified, replace the neutral switch.
Replacement
Replace the neutral switch as shown in the figure.
POWER STEERING PRESSURE SWITCH
Inspection
1. Disconnect the P/S pressure switch connector.
2. Connect an ohmmeter to the switch.
3. Start the engine and let it idle. Check continuity of the switch
while turning the steering wheel.
P/S
Turning
Not turning Continuity
Yes
No
4. If not as specified, replace the P/S pressure switch.
Replacement
Replace the P/S pressure switch as shown in the figure.
F-l 73

H
CLUTCH
INDEX ......................................................
OUTLINE ..................................................
SPECIFICATIONS .................................... H- 3
TROUBLESHOOTING GUIDE.. .................... H- 3
CLUTCH FLUID ......................................... H- 4
PREPARATION ....................................... H- 4
REPLACEMENT ...................................... H- 4
CLUTCH PEDAL ....................................... H- 5
ADJUSTMENT ........................................ H- 5
REMOVAL / INSPECTION / INSTALLATION.. H- 6
CLUTCH MASTER CYLINDER.. ................... H- 7
PREPARATION ....................................... H- 7
REMOVAL / INSPECTION / INSTALLATION.. H- 7
AIR BLEEDING ....................................... H- 6
OVERHAUL ............................................ H-10
CLUTCH RELEASE CYLINDER ................... H-l 2
PREPARATION ....................................... H-12
REMOVAL / INSTALLATION ...................... H-l 2
AIR BLEEDING (REFER TO PAGE H-8)
OVERHAUL ............................................ H-13
CLUTCH UNIT .......................................... H-14
PREPARATION ....................................... H-14
REMOVAL I INSTALLATION.. .................... H-15
RELEASE BEARING .................................. H-17
INSPECTION .......................................... H-17
CLUTCH COVER ....................................... H-17
INSPECTION .......................................... H-17
CLUTCH DISC .......................................... H-17
INSPECTION .......................................... H-17
PILOT BEARING ....................................... H-16
INSPECTION .......................................... H-16
FLYWHEEL ............................................... H-16
INSPECTION .......................................... H-16
23UOHX-001

H INDEX
NDEX
CLUTCH SWITCH
SERVICE, SECTION F
23UOHX-00:
2
5. Clutch release fork
Removal / Installation . . . . . . . . . . . . . . . . . . page
H-l 5
6. Clutch cover 1. Clutch pedal
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H- 5
Removal / Inspection /
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H- 6
2. Clutch master cylinder
Removal I Inspection I
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H- 7
Air bleeding ,............,..... I ,.,........, page H- 8
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . I ,,.,........
page H-10
3. Clutch release cylinder
Removal / Installation.. . . . . . . . . . . . . . . . . page
H-l 2
Air bleeding . . . . . . . . . . . ..*..................
page H- 8
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page
H-l 3
4. Release bearing
Removal / installation . . . . . . . . . . . . . . . . . . page
H-l 5
Inspection ,.....,..,.,~.,..........,.,,..,,.. page H-l 7
H-2
Removal / Installation .,.......,..,..... page H-l 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H-l 7
7. Clutch disc
Removal I Installation . . . . . . . . . . . . . . . . . . page
H-l 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H-l 7
8. Pilot bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page H-l 8
Removal / Installation.. . . . . . . . . . . . . . . .
page H-l 5
9. Flywheel
Removal I Installation . . . . . . . . . . . . . . . . . . page
H-l 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-18

OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
-
-
Item
Clutch control Engine/Transaxle B6 SOHC BP SOHC BP DOHC
F!Wl-R GBM-R Hvdraulic
Clutch cover
Clutch disc Type
Set load Diaphragm spring
N
(kg, lb) 1 3,630 (370, 814) 1 3,826 (390, 858) 1 3,846 (392, 862)
30 17.48)
200 (7.87) 215 (8.46) Outer diameter mm (in)
Inner diameter mm (in)
Pressure plate
side mm (in)
Thickness
Flywheel side
mm lit-d
1! , I
130 (5.12) ’ ’
150 i5.91 j
3.5 (0.138) 3.8 (0.150)
3.5 (0.138)
Type Suspended
Clutch pedal
Master cylinder
Release cylinder
Clutch fluid Pedal ratio 6.55
Full stroke mm (in) 135 (5.32)
Height (With carpet)
mm (in) 196-204 (7.72-8.03)
Inner diameter mm (in) 15.87 (0.625)
Inner diameter
mm (in) 19.05 (0.750)
SAE J1703 or FMVSS116 DOT-3
23UOHX-003
TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page
Slipping
Clutch disc facing worn excessively Replace H-15, 17
Clutch disc facing surface hardened or oil on surface Repair or replace H-15
Pressure plate damaged Repair or replace H-15
Diaphragm spring damaged or weakened Replace H-15
Insufficient clutch pedal play Adjust H- 5
Clutch pedal sticking Repair or replace H- 6
Flywheel damaged Repair or replace H-15, 17 Faulty disen-
Excessive runout or damaged clutch disc Replace H-15, 17 gagement Clutch disc splines rusted or worn Remove rust or replace H-15
Oil on facing Repair or replace H-15
Diaphragm spring weakened Replace H-15
Excessive clutch pedal play Adjust H- 5
Insufficient clutch fluid
Add fluid H- 3
Leakage of clutch fluid Locate and repair or -
replace Clutch vibrates
Oil on facing Repair or replace H-15 when accelerating Torsion rubbers weakened Replace H-15
Clutch disc facing hardened or damaged Repair or replace H-15
Clutch disc facing rivets loose Replace H-15
Pressure plate damaged or excessive runout Replace H-15
Flywheel surface hardened or damaged Repair or replace H-15
Loose or worn engine mount Tighten or replace - Clutch pedal
Pedal shaft not properly lubricated Lubricate or replace H- 6 sticking
Abnormal noise
Clutch release bearing damaged Replace H-15, 17
Poor lubrication of release bearing sleeve Lubricate or replace H-15
Torsion rubbers weakened Replace H-15
Excessive crankshaft end play Repair Refer to Section E
Pilot bearing worn or damaged Replace H-15, 18
Worn pivot points of release fork Repair or replace H-15
^^. .^. I~, ^r
H-3

H CLUTCH FLUID
CLUTCH FLUID
PREPARATION
SST
49 0259 7708 For
Wrench, flare nut ~ air bleeding
03UOHX-007
REPLACEMENT
Note
l A common reservoir is used for the clutch and brake
system fluids.
l The fluid in the reservoir must be maintained at the
3/4 level or higher during replacement.
Caution
l Be careful not to spill the fluid on a painted surface.
If this should happen, wash it off Immediately.
l Do not mix different brands of fluid.
l Do not reuse the clutch fluid that was drained.
1. Drain the brake fluid from the master cylinder through a
wheel cylinder.
2. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder plug.
03UOHX-006 -
3. Place the other end of the vinyl hose in a clear container.
4. Slowly pump the clutch pedal several times.
5. With the clutch pedal depressed, loosen the bleeder screw
with the
SST to let the fluid escape. Close the bleeder screw
with the
SST.
6. Repeat Steps 4 and 5 until only clean fluid is seen.
7. Tighten the bleeder screw.
Tightening torque:
5.9-8.8 N.m (80-90 cm-kg, 52-78 in-lb)
8. Add fluid to the MAX mark.
9. Slowly pump the clutch pedal several times.
Verify that there is no fluid leakage.
10. Check operation of the clutch system.
11. Check operation of the brake system.
H-4