lock MAZDA PROTEGE 1992 Repair Manual

ON-VEHICLE MAINTENANCE
I 05UOBX-063
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
13EOB2-02
ALIGN.KEY GRCi&E
13EOB2-02
23UOB2-025
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 92-8.)
3
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.
3. Tap the oil seal in evenly with a suitable pipe and a ham-
mer until it is about flush with the face of the oil pump body.
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:
157-187 N.m (18-17 m-kg, 116-123 ft-lb)
23UOB2-026
82-27

B2 ON-VEHICLE MAINTENANCE
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.
t
I 1
ITX 16-26 (1.6-2.7, 13-20)

L
\TX
N.m (m-kg, ft-It 0
23UOBZ-027
1. Transaxle
MTX
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section J2
ATX
Service . . . , . . . . ,.......................... Section K
2. Clutch cover, clutch disc (MTX)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
3. Flywheel (MTX)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Installation Note .,.....,..,............. page 82-29 4. Drive plate (ATX)
Removal Note ..,........................ page B2-29
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 62-30
5. Oil seal
Removal Note .,......................... page 52-29
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-29
23UOB2-05
82-28
il
Removal note
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.

ON-VEHICLE MAINTENANCE
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.
2311082-052
I
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
I I
I
05UOBX-063
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.
OWOBX-069
APPLY SEALANT
03UOB2.04
Caution
l The oil seal must be tapped in untjl 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:
1 96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)
2311082-053
B2--29

B2 ON-VEHICLE MAINTENANCE
0311082-04
23UOB2-05 4
Drive plate (ATX)
1. Remove the sealant from the drive plate holes in the crank-
shaft and from the drive plate lock bolts.
Caution
..i
l if ail 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
in the figure.
Tightening torque:
96-103 N-m (9.6-10.6 m-kg, 71-76 ft-lb)
Steps After installation
1. Connect the negative battery cable.
2. Start the engine and perform engine adjustments as necessary.
OWOBX-072
82-30

REMOVAL B2
13UOB2-021
0311082-059
Tie-rod end
1. Remove the cotter pin and loosen the nut so that it flushes
with the ball joint edge.
Caution
l Do not reuse the cotter pin.
2. Separate the knuckle arm and ball joint with the SST.
Driveshaft
1. Remove the joint shaft.
2. Remove the bolts and nuts at the left and right lower arm
ball joints.
Caution
l Do not damage the ball joint dust boots.
3. Pull the lower arm downward to separate them from the
knuckles.
4. Remove the engine mount member. (ATX)
Caution
l Support the engine before removing the 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
remove the engine mount member.
Caution
l Do not damage the oil seal.
5. Separate the driveshafts from the transaxle by prying with
a bar inserted between the shaft and the case.
B2-35

DISASSEMBLY B2
DISASSEMBLY
PREPARATION
SST
._
49 EOll 1AO
Ring gear brake
set
49 EOll 104
Collar
(Part of
49 EOI 1 1 AO)
49 8012 OA2
Pivot, valve
spring lifter
49 B021 013
Foot
(Part of
49 B012 OA2)
49 0636 IOOA
Arm, valve spring
lifer
.
Remover, valve
seal For
prevention of
engine rotation
For
prevention of
engine rotation
For
removal /
installation of
valves
For
removal /
installation of
valves
For
removal and
installation of
valves
For
removal of
valve seals 49 EOll 103
Shaft
(Part of
49 EOll 1AO)
49 EOll 105 49 EOll 105
Stopper Stopper 0
(Part of (Part of
49 E011 1AO 49 E011 1AO
w
49 B012 012
Body
(Part of
49 8012 OA2)
49 8012 014
Locknut
(Part of
49 8012 OA2)
49 0221 061A
Remover &
installer, piston
pin For
prevention of
engine rotation
For
prevention of
engine rotation
For
removal /
installation of
valves
For
removal /
installation of
valves
For
removal and
installation of
piston pins
2311082.03
1. Code all identical parts (such as piston, piston rings, connecting rods, and valve springs) so that they
can be reinstalled in the cylinder from which they were removed.
2. Clean the parts with a steam cleaner. Blow off any remaining water with compressed air.
Note
l During disassembly of any part or system, be sure to study its order of assembly. Also, note
any deformation, wear, or damage.
05UOBX-091
B2-41

DISASSEMBLY 82
TIMING BELT
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
23UOB2-0:
1. Water pump pulley
2. Crankshaft pulley
3. Timing belt cover, upper
4. Timing belt cover, middle
5. Timing belt cover, lower
6. Pulley lock bolt
7. Pulley boss
8. Timing belt
Disassembly Note . . . . . . . . . . . . . . . . . . . . page B2-44
9. Tensioner and tensioner spring
10. Idler
Disassembly Note . . . . . . . . . . . . . . . . . . . . page B2-44
B2-43

B2 DISASSEMBLY
23UOB2-055
13EOB2-030
Disassembly Note
Pulley lock bolt
1. Hold the flywheel (MTX) or drive plate (ATX) with the SST
or equivalent.
2. Loosen the pulley lock bolt.
3. Remove the pulley lock bolt.
Timing belt
1. Loosen the tensioner lock bolt and using a suitable bar, pry
the tensioner outward.
Caution
l Protect the tensioner with a rag before prying.
2. Tighten the lock bolt with the tensioner spring fully extended.
Note
l Mark the timing belt rotation for proper reinstal-
lation.
3. Remove the timing belt.
82-44

82 DISASSEMBLY
2311082-03
r HLA
r
05UOBX-04!
2311082-03
I
05UOBX-1C
82-46
Disassembly Note
Camshaft pulley
1, Hold the camshaft with a wrench at hexagonal portion.
2. Remove the camshaft pulley lock bolt.
3. Remove the camshaft pulley.
Camshaft
1. Loosen the camshaft cap bolts in two or three steps in the
order shown in the figure.
2. Remove the camshaft caps
3. Remove the camshaft.
4. Remove the camshaft oil seal from the camshaft.
Caution
l Mark the HLA with a felt pen so that they can be reln-
stalled in the position from which they were
removed.
1. Remove the HLA from the cylinder head.
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.
Valve keeper
1. Set the SST against the upper valve spring seat as shown
in the figure.
2. Remove the valve keepers.

B2 DISASSEMBLY
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
I
@ma @a% GASST, REPLACE
GASKET,
REPLACE
/
d I @REPLACE
23UOB2-0
1. Water pump
Service ..,....,..,......,.,.,,.....,,.,.......... Section E
2. Timing belt pulley and lock bolt
Disassembly Note . . . . . ..,.,........,. page 82-49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-65
3. Clutch cover, clutch disc (MTX)
Service . . . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
4. Flywheel (MTX)
Disassembly Note ,.. . . . . . . . . . . . . . . . . . page 82-49
Inspect for wear or damage
5. Backing plate, drive plate, and adapter (ATX)
Disassembly Note . . . . ,., ,..... . . . . . . . page B2-49
6. End plate 7. Oil pan and gasket
Disassembly Note .,.................. page 82-49
Inspect for damage
8. Oil strainer
9. Main bearing support plate (MBSP)
Disassembly Note . . . ., . . . . . ..,.... . . . page B2-50
Inspect for damage
10. Oil pump
Service . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
11. Front oil seal
Disassembly Note .,.................. page 82-50
12. Rear cover
13. Rear oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page B2-50
B2--48