oil MAZDA PROTEGE 1992 Owner's Guide

DISASSEMBLY Bl
23tlOBl-03
03UOBl-07
B6 SOHC
23UOBl-03
3P SOHC
Disassembly Note
Rocker arm and rocker shaft assembly
1, Loosen the rocker arm bolts in two or three steps in the or-
der shown in the figure.
2. Remove the rocker arm and rocker shaft assembly.
3. Code all rocker arms and springs so that they can be rein-
stalled in the same places from which they were removed.
Hydraulic lash adjuster (HLA)
Remove the HLA by hand.
If it is difficult, remove the HLA by using pliers.
Caution
l Do not remove the HLA unless necessary because
oil leakage will occur, if the O-ring is damaged.
Camshaft pulley
1. Hold the camshaft using a suitable wrench on the cast
hexagon.
2. Remove the camshaft pulley lock bolt.
3. Remove the camshaft pulley.
Cylinder head bolts
1. Loosen the cylinder head bolts in two or three steps in the
order shown in the figure.
2. Remove the cylinder head bolts.
Bl-45

DISASSEMBLY Bl
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the fiaure, referrina to Disassembly Note.
.-.
1. Water pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
2. Timing belt pulley and lock bolt
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl -65
3. Clutch cover, clutch disc (MTX)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
4. Flywheel (MTX)
Disassembly Note . . . . . . . . . . . . . . . . . . . page 81-48
Inspect for wear or damage
5. Backing plate, drive plate, and adapter (ATX)
Disassembly Note ..,.....,.,........, page 81-48
6. End plate 7. Oil pan and gasket
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Inspect for damage
8. Oil strainer
9. Main bearing support plate (MBSP)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-49
Inspect for damage
10. Oil pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
11. Front oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
12. Rear cover
13. Rear oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Bl-47

DISASSEMBLY Bl
0311081-08
PROTECT PUMP w
BODY WITH RAG
OTECT REAR COVER 0
Oil pan
B6 SOHC
1. Remove the oil pan mounting bolts.
2. Insert a screwdriver or a suitable tool between the MBSP
and oil pan, and pry them.
Caution
l Do not insert the prying tool between the MBSP and
cylinder block.
l Do not damage or scratch the contact surfaces.
BP SOHC
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.
Main bearing support plate (MBSP)
1. Remove the MBSP mounting bolts to the main bearing cap.
2. Insert a screwdriver or a suitable tool between the MBSP
and cylinder block, and pry them.
Caution
l Do not damage or scratch the contact surfaces
when removing old sealant.
Front oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
Rear oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
Bl-49

Bl DISASSEMBLY
CYLINDER BLOCK (INTERNAL PARTS)
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
1. Connecting rod cap
7. Main bearing cap
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-51
Disassembly Note . . . . . . . . . . . . . . . . . . . . page
81-52
2. Connecting rod
8. Crankshaft
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-64
3. Connecting rod bearing
9. Main bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . page Bl-64 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-64
4. Piston ring
10. Thrust bearing
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51 11. Oil filter joint
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-62 12. Oil jet
5. Piston pin
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-61
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51 13. Cylinder block
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-60 ‘-”
6. Piston
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-62
Bl-50

DISASSEMBLY Bl
23UOBl-03
05UOBX-1’ 9
23UOBl-040
03UOBl-08 5
Disassembly Note
Connecting rod cap
1. Before removing the connecting rod caps, measure the con-
necting rod side clearance. (Refer to page Bl-73.)
Connecting rod
1. Before removing the connecting rods, measure the connect-
ing rod oil clearance. (Refer to page Bl-73.)
2. Remove the Plastigage from the crankpin journals.
Caution
l Do not scratch the crankshaft journal or the cylin-
der wall.
3. Use the handle of a hammer to remove the piston and con-
necting rod assembly through the top of the cylinder block.
Piston ring
Caution
l Do not apply excessive tension, which may cause
the rings to snap out.
1. Remove the piston rings with a piston ring expander (com-
mercially available).
Piston pin
Caution
l Mark the connecting rod direction for proper reas-
sembly.
1. Before disassembling the piston and connecting rod, check
the oscillation torque as shown.
If the large end does not drop by its own weight, replace
the piston or the piston pin.
81-51

DISASSEMBLY
Crankshaft
1. Before removing the crankshaft, measure the main bear-
ing oil clearances. (Refer to page Bl-71.)
2311081-042
Bl-53

Bl INSPECTION / REPAIR
INSPECTION / REPAIR
PREPARATION
SST
49 LO12 OAO)
Remover and
03UOBi-08
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. .__a
Caution
l Do not damage the joints or friction surfaces of aluminum alloy components (such as the cyl-
inder head or pistons).
81-54
03UOBl-090 05UOBX-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 B6 SOHC: 0.15mm (0.006 in) max.
BP SOHC: O.lOmm (0.004 in) max.
Caution
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: 107.4-l 07.6mm (4.228-4.236 in)
Grinding B6 SOHC: 0.20mm (0.008 in) max.
BP SOHC: O.lOmm (0.004 in) max.

INSPECTION / REPAIR
23UOBl-07
2311081-07
23UOBl.07t
5. Measure the journal diameters X and Y directions at the two
points (A and B) shown.
Diameter
B6 SOHC
Front and Rear
Center mm (in)
43.440-43.460 (1.7102-1.7110)
43.430-43.455 (1.7098--1.7108)
BP SOHC
1 No.1 & No.5 1 43.440-43.460 (1.7102-1.7110) 1
1 No.2 & No.4
1 43.425-43.450 (1.7096-1.7106) 1
1 No.3
I 43.410-43.435 (1.7091-1.7100) I
Out of round: 0.05 (0.002) max.
6. Measure the oil clearances between the camshaft and cyl-
inder head.
(1) Remove all foreign material and oil from the journals and
the camshaft bore.
(2) Measure the camshaft bore diameter.
03UOBV105
Diameter
B6 SOHC
Front and Rear
Center mm (in)
43.515-43.535 (1.7132-1.7139)
43.515-43.535 (1.7132-1.7139)
BP SOHC
1 No.1 & No.5 ] 43.500-43.515 (1.7126-1.7132) 1
1 No.2, No.3, No.4 1 43.485-43.505 (1.7120-1.7128) 1
(3) Subtract the journal diameter from the bore diameter.
Oil clearance
B6 SOHC
mm fin)
Front and Rear 0.055-0.095 (0.0021-0.0037)
Center 0.060-0.105 (0.0023-0.0041)
I
I Maximum
I 0.15 (0.006) I
BP SOHC mm fin
No.1 & No.5
No.2 & No.4
No.3
Maximum 0.040-0.075 (0.0016-0.0030)
0.035-0.080 (0.0014-0.0031)
0.050-0.095 (0.0020-0.0037)
0.15 (0.006)
(4) If the clearance exceeds the maximum, replace the cam-
shaft or cylinder head.
23UOBl-077
7. Measure the camshaft end play. If it exceeds the maximum,
replace the thrust plate or camshaft.
End play
B6 SOHC: 0.05-O. 18mm (0.0020-0.0071 in)
BP SOHC: 0.06-0.19mm (0.0024-0.0075 in)
Maximum: 0.20mm (0.008 in)
Bl-59

Bl INSPECTION / REPAIR
a3
03UOBl.109
03UOBl-11t
03UOBl-111 i
3
03UOBl-112
Rocker Arm and Rocker Arm Shaft
1. Check for wear or damage to the contact surface of the rock-
er arm shaft or the rocker arm. Replace if necessary.
2. Check the oil clearance between the rocker arm and shaft,
replace if necessary.
(1) Measure the rocker arm inner diameter.
Diameter mm (in)
B6 SOHC
BP SOHC
IN 18.000-l 8.027
19.000-19.027
(0.7087-0.7097)
(0.7480-0.7491)
EX 18.000-l 8.027
19.000-19.033
(0.7087-0.7097) (0.7480-0.7493)
(2) Measure the rocker arm shaft diameter.
Diameter mm tin1
IN
EX B6 SOHC
BP SOHC ’ ’
17.959-l 7.980
18.959-18.980
(0.7070-0.7079)
(0.7464-0.7472)
17.959-l 7.980
18.959-l 8.980
(0.7070-0.7079)
(0.7464-0.7472)
(3) Subtract the shaft diameter from the rocker arm di-
ameter.
Oil clearance
IN
EX
Maximum mm (in)
B6 SOHC
BP SOHC
0.020-0.068
0.020-0.068
(0.0008-0.0027) (0.0008-0.0027)
0.020-0.068
0.020-0.074
(0.0008-0.0027) (0.0008-0.0029)
0.10 (0.004) -_
HYDRAULIC LASH ADJUSTER (HLA)
Check the HLA face for wear or damage and replace if
necessary.
Caution
l To prevent damaging the O-ring, do not remove the
HLA unless necessary.
CYLINDER BLOCK
1. Check the cylinder block for the following and repair or re-
place the cylinder block as necessary.
(1) Leakage damage.
(2) Cracks.
(3) Scoring of wall.
2. Measure the distortion of the top surface of the cylinder block
in the six directions shown in figure.
Distortion: 0.15mm (0.006 in) max.
3. If the distortion exceeds the maximum, repair by grinding
or replace the cylinder block.
Height
t mm (in)
86 SOHC
BP SOHC _._
221.5 (8.720)
Grinding: 0.20mm (0.006 in) max. U3UU81-113

INSPECTION / REPAIR Bl
.-J-
03UOBl-11
05UOBX-1:
OWOBX-15 4
il
2
3
_I
5
OWOBX-15:
03UOBl-11:
4. Measure the cylinder bores in X and Y directions at three
levels (A, B, and C) in each cylinder as shown.
Cylinder bore mm h-d
I I B6 SOHC I BP SOHC ’ ‘I
,r jtanciard 1 78.006-78.013 1 83.006-83.013
(3.0711-3.0714) (3.2679-3.2682)
0.25 (0.010) oversize 78.256-78.263 83.256-83.263
(3.0809-3.0812) (3.2778-3.2781)
I 0.50 (0.020) oversize 78.506-78.513 83.506-83.513
(3.0908-3.0911) (3.2876-3.2879)
I
Caution
l The boring size should be based on the size of an
oversize piston and be 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 (BP SOHC)
1. Push the check ball and verify that it moves smoothly.
2. Blow through the oil jet and verify that air flows.
81-61