engine MAZDA PROTEGE 1992 Service Manual

Bl ENGINE STAND MOUNTING
PROCEDURE
Step 1
1. Remove in the order shown in the figure.
GASKET, REPLACE
I
1. Exhaust manifold insulator
2. Exhaust manifold
3. Water bypass pipe
23UOBl-03
4. A/C compressor bracket (If equipped) and idler
5. Water inlet pipe
6. Exhaust pipe bracket
‘0
Step 2
Caution
l When installing the SST (engine hanger), use the
holes shown in the figure.
Bl-36

ENGINE STAND MOUNTING Bl
OBUOBX-Ot
OWOBX-0; 36
ENGINE
NlJ/ WkSHER b&i THAP
2Omm (0.79 il
OWOBX-0
I
-I n)
80
OWOBX-089
1. Install the SST (arms) to the holes as shown in the figure,
and loosely tighten the SST (bolts).
2. Assemble the SST (bolts and plate) in the specified po-
sition.
3. Assemble the SST (nuts, hooks, and bolts).
4. Install the SST to the respective arms.
Note
l Adjust the SST (bolts) so that less than 20mm (0.79
in) of thread is exposed.
l Make the SST (plate and arms) parallel by adjust-
ing the SST (bolts and nuts).
5. Tighten the SST (bolts and nuts) to affix the SST firmly.
6. Mount the engine on the SST (engine stand).
81-37

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

ASSEMBLY Bl
19 LO11 002
Body
:Part of
49 LO12 OAO)
49 8012 006
Pivot, valve
spring lifter
49 8012 OA2
Pivot, valve
spring lifter
49 8012 013
Foot
(Part of
49 B012 OA2)
49 SE01 310
Centering tool,
clutch disc For
installation of
valve seals
(B6 SOHC)
For
removal and
installation of
valves
(BP SOHC)
For
removal I
installation of
valves
For
removal I
installation of
valves
For
installation of
clutch disc 49 0636 1OOA
Arm, valve spring
lifter
49 s120 222
0
Pivot, valve
spring lifter
%
49 8012 012
Body
(Part of
49 8012 OA2)
49 B012 014
Locknut
(Part of
49 8012 OA2)
1. Clean all parts before reinstallation.
2. Apply new engine oil to all sliding and rotating parts.
3. Replace plain bearings if they are peeling, burned, or otherwise damaged.
4. Tighten all bolts and nuts to the specified torques.
Caution
l Do not reuse gaskets or oil seals.
I
3 For
removal and
installation of
valves
For
removal and
installation of
valves
(B6 SOHC)
For
removal I
installation of
valves
For
removal I
installation of
valves
23UOBl-0,
05UOBX-174
Bl-67

ASSEMBLY Bl
I-
r
I 03UOBl-12
A NO.1
M
9MUOB2-14 I ‘NDENTIFICATION MARK
03UOBl-02
I
23UOBl-04
05UOBX.179
2. Set the stopper bolt (49 LO1 1 005) so that the depth L is
as specified.
Depth L
B6 SOHC
BP SOHC mm (in)
I 56.9-57.1 (2.240-2.248)
58.9-59.1 (2.319-2.327)
3. Tighten the locknut.
4. Insert the
SST No.2 into the piston pin as shown and fully
screw in the
SST No.1.
5. Apply engine oil to the piston pin.
6. Set the piston on the
SST with the F mark facing upward.
7. Assemble the piston and the connecting rod in the direc-
tion from which they were disassembled.
8. Press the piston pin into the piston and connecting rod un-
til the SST contacts the stopper bolt.
9. While inserting the piston pin, check the pressure force. If
it is less than specified, replace the piston pin or the con-
necting rod.
Pressure force:
4,905-14,715 N (500-l ,500 kg, 1 ,lOO-3,300 lb)
10. Check the oscillation torque of the connecting rod.
(Refer to page Bl-51.)
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
Bl-69

Bl ASSEMBLY
SPACER TANG
OIL RING
SPACER ENDS
PISTON
I
05u0Bx-180
R I
OWOBX-18.
81-70
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 R 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).
5. Position the end gaps of the rings as shown in the figure.
05UOBX-182 Oil Filter Joint
1. Install the oil filter joint so that it protrudes as specified
03UOBl-21:
Protrusion: 19mm (0.75 in)
Oil Jet (BP SOHC)
1. Install the oil jets.
Tightening torque:
12-18 N*m (1.2-1.8 m-kg, 104-158 in-lb)

ASSEMBLY
f
05UOW18
THRUST BEARING
OYJOBX-18
05UOBX-18
23UOBl-04
OWOBX-181
Crankshaft
1. Before installing the crankshaft, inspect the main bearing
oil clearances as follows.
Oil clearance inspection
(1) Remove all foreign material and oil from the journals and
bearings.
Caution
l Install the grooved upper main bearings in the cyl-
inder block.
l Install the thrust bearings with the oil groove fac-
ing the crankshaft.
(2) Install the upper main bearings and thrust bearings.
(3) Set the crankshaft in the cylinder block.
Caution
l Do not rotate the crankshaft when measurlng the
oil clearances.
(4) Position Plastigage atop the journals in the axial di-
rection.
(5) Install the lower main bearings and the main bearing
caps according to the cap number and + mark.
(6) Tighten the main bearing cap bolts in two or three steps
in the order shown in the figure.
Tightening torque:
54-59 N-m (5.5-6.0 m-kg, 40-43 ft-lb)
(7) Remove the main bearing caps, and measure the P lasti-
gage at each journal at the widest point for the smallest
clearance and at the narrowest point for the largest
clearance.
(8) If the oil clearance exceeds specification, grind the
crankshaft and use undersize main bearings.
(Refer to page Bl-64.)
Oil clearance: 0.016-0.036mm (0.0007-0.0014 in)
Maximum: O.lOmm (0.004 in)
2. Apply a liberal amount of clean engine oil to the main bear-
ings, thrust bearings and main journals.
3. Install the crankshaft and the main bearing caps accord-
ing to the cap number and + mark.
61-71

ASSEMBLY Bl
23UOEl-04
03UOBl-1:
MATCHING MARKS
‘\, 1
0311081.132
Oil clearance: 0.028-0.068mm (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 Bl-64.)
3. Measure the connecting rod side clearances.
Side clearance: 0.11 O-0.262mm (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.
5. Apply a liberal amount of clean engine oil to the crankpin
journals and connecting rod bearings.
6. Install the connecting rod caps with the matching marks
aligned.
7. Tighten the connecting rod cap nuts in two or three steps.
Tightening torque:
47-52 N-m (4.8-5.3 m-kg, 35-38 ft-lb)
. . . . . . . . . . . . . . . . . . . 66 SOHC
49-51 N*m (5.0-5.2 m-kg, 36-38 ft-lb)
. . . . . . . . . . . . . . . . . . . BP SOHC
Bl-73

Bl ASSEMBLY
CYLINDER BLOCK (EXTERNAL PARTS)
Torque Specifications
19-25
(1.9-2.6, 14-19)
GASKET, NEW
OIL SEAL,
NEW
7.6-11 N.m
(60-l 10 cm-kg,
69-95 in-lb)
GASKET, NE
16-21 (1.6-2.1, 12--15)-j
R
A -22% / 7.6-11 N.m
(60-110 cm-kg, 69-95 in-lb) 6-103 w
,..6-10.6,
71-76) 16-26
(1.6-2.7, 13-20)
7.6-11 N-m
(60-110 cm-kg, 69-95 in-lb)
N.m (m-kg, R-lb)
Bl-74
OWOBX-201 0
Rear Cover
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 pressed in until it is flush with
the edge of the rear cover.
3. Press the oil seal in evenly with a suitable pipe.
Oil seal outer diameter: 1OOmm (3.94 in)
4. Apply silicone sealant to the shaded area shown in the
figure.

ASSEMBLY Bl
OWOBX-20
23UOBl-049
5. Install the rear cover.
Tightening torque:
7.8-l 1 N*m (80-l 10 cm-kg, 89-95 in-lb)
Oil Pump
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 pressed in until it is flush with
the edge of the oil pump body.
3. Press the oil seal in evenly with a suitable pipe.
Oil seal outer diameter: 44mm (1.73 in)
4. Install the oil pump and a new gasket.
Tightening torque:
19-25 N-m (1.9-2.8 m-kg, 14-19 ft-lb)
Caution
l Do not scratch the oil pump.
5. Cut away the portion of the gasket that projects from the
body toward the oil pan side.
Main Bearing Support Plate (MBSP)
1, Remove all foreign material from the contact surfaces of the
cylinder block and the MBSP.
Caution
l The oil pan must be secured within 5 minutes after
the sealant is applied to the MBSP.
2. Apply silicon sealant to the shaded areas shown in the figure.
81-75