oil MAZDA PROTEGE 1992 Repair Manual

ASSEMBLY Bl
03UOBl-16
03UOB1.21 38
Injector and Distribution Pipe Assembly (BP SOHC)
1. Install the injector and distribution pipe assembly with new
insulators.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
Intake Manifold Assembly
1, Remove all foreign material from the intake manifold con-
tact surface.
2. Install a new gasket and the intake manifold assembly.
Tightening torque:
19-25 N*m (1.9-2.6 m-kg, 14-19 ft-lb)
Distributor and High-tension Lead
1. Apply engine oil to the O-ring, and position it on the dis-
tributor.
2. Apply engine oil to the blade.
3. Install the distributor with the blade fit into the camshaft
groove.
4. Temporarily, loosely tighten the distributor installing bolt.
5. Adjust the ignition timing after engine installation.
(Refer to Section G.)
6. Connect the high-tension leads.
81-91

Step 3
Torque Specifications
INSTALLATION
ATX
Bl
6.9-11 N-m
(70-110 cm-kg, 61-95 in-lb)
GAs~~~~~~~~c~~~,~
(3.2-4.7, 23-34) 16-23 6.9-9.6 N.m
11.6-2.3. 12-17) (70-100 cm-kg, (4.3-5.6, 31-42) -43)
NEW \.~ 61-67 in-lb)
N.m (m-ka. R-lb
Driveshaft
1. Apply grease to the end of the driveshaft.
Caution
l When installing the driveshaft, be careful not to
damage the oil seal.
l After installation, pull the front hub outward to con-
firm that the driveshaft is securely held by the clip.
2. Install the driveshaft and a new clip.
3. Install the lower arm ball-joint to the knuckle; then tighten
the locknut.
Tightening torque:
43-59 N,rn (4.4-6.0 m-kg, 32-43 f&lb)
Bl-97

Bl INSTALLATION
Step 5
1. Connect the harness connectors shown in the figure.
GROUND ALTERNATOR
OIL PRESSURE SWITCH
I- THFOTTLE SENSOR
NEUTRAL SWITCH (MTX)
IGNITION COIL
$A_c_K;u_p LIGHT SWITCH
____------- ;
Step 6
Torque Specifications
7.8-11 N.m (80-110 cm-kg, 89-95 in-lb)
19-25 (1.9-2.6, 14-19)
2.9-5.9 N.m
(30-60 cm-kg, 26-52 in-lb)
7.8-11 N.m
(80-l 10 cm-kg,
6.4-9.3 N.m 37-52
(3.8-5.3, 27-38)
24-35
(2.4-3.6, 17-26)
7.8-11 N.m 160-110 cmika, 69-95 in-lb) ‘-- -- -..’ ‘-=’ -’ / 166-96 r?m.ka.
66-82 in-lb) 69-95 in-lb)
N.m (m-kg, ft-lb -- OBUOBl-1E
Bl-100

INSTALLATION Bl
I I
03UOBl-193
03UOBl-19
1
PULLEY
P/S AND A/C
OWOBl-19
03UOBl-15
A/C compressor
1. Install the A/C compressor.
Tightening torque:
24-35 N-m (2.4-3.6 m-kg, 17-26 ft-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N-m (3.6-5.3 m-kg, 27-36 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page Bl-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.6-11 N#m (60-110 cm-kg, 69-95 in-lb)
2. Tighten the A/C pipe bracket to the radiator.
Tightening torque:
6.4-9.3 N*rn (65-95 cm-kg, 56-62 in-lb)
3. Connect the upper and lower radiator hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good fit.
4. Connect the coolant reservoir hose.
5. Connect the cooling fan connector.
6. Connect the oil cooler hose. (ATX)
Bl-=lOl

INSTALLATION
OWOBX-27!
Resonance chamber
1. Install the resonance chamber.
Tightening torque:
7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
Undercover and side cover
1. Install the undercover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut @.
Deflection: I-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
2. Install the battery carrier.
Tightening torque:
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
lightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
2. Connect the airflow sensor connector.
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page 61-8.)
(3) Operation of emission control system.
6. Perform a road test,
7. Recheck the engine oil and engine coolant levels.
.-’
23UOBl-057
81-102

82
ENGINE
m :
(DOHC)
INDEX .......................................... B2- 2
OUTLINE ...................................... B2- 3
SPECIFICATIONS ........................ B2- 3
TROUBLESHOOTING GUIDE .......... B2- 3
ENGINE TUNE-UP PROCEDURE ......
B2- 5
PREPARATION ............................
B2- 5
ENGINE OIL ............................... B2- 5
ENGINE COOLANT.. ....................
B2- 5
DRIVE BELT ............................... B2- 5
HLA .......................................... B2- 7
IGNITION TIMING, IDLE SPEED ..... B2- 8
COMPRESSION ............................. 82-l 0
INSPECTION ...............................
82-l 0
ON-VEHICLE MAINTENANCE.. ........ 82-l 1
PREPARATION ............................
B2-11
TIMING BELT .............................. 82-l 2
CYLINDER HEAD GASKET ...........
82-16
HLA .......................................... 82-22
FRONT OIL SEAL.. ......................
62-26
REAR OIL SEAL .......................... 82-28
REMOVAL ..................................... 82-31
PROCEDURE .............................. 82-31
ENGINE STAND MOUNTING.. .........
82-38
PREPARATION ............................ 82-38
PROCEDURE ..............................
82-39
DISASSEMBLY .............................. 82-41
PREPARATION ............................ B2-41
AUXILIARY PARTS.. ..................... 82-42
TIMING BELT ..............................
82-43
CYLINDER HEAD.. ...................... 82-45
CYLINDER BLOCK
(EXTERNAL PARTS) ...................
B2-48
CYLINDER BLOCK
(INTERNAL PARTS). ................... 82-51 INSPECTION / REPAIR.. ................. 82-54
PREPARATION ............................ 82-54
CYLINDER HEAD.. ...................... B2-54
VALVE MECHANISM.. .................. 82-55
CAMSHAFT ................................ B2-58
HLA .......................................... 82-80
CYLINDER BLOCK ...................... 82-60
OIL JET ..................................... B2-61
PISTON, PISTON RING, AND
PISTON PIN .............................. 82-62
CONNECTING ROD.. ...................
82-63
CRANKSHAFT ............................ B2-64
BEARING ................................... 82-64
TIMING BELT ..............................
82-65
TENSIONER, IDLER.. ................... 82-65
TENSIONER SPRING ................... 82-65
PULLEY ..................................... 82-65
ASSEMBLY ................................... B2-66
PREPARATION ............................ B2-66
CYLINDER BLOCK
(INTERNAL PARTS). ................... 82-68
CYLINDER BLOCK
(EXTERNAL PARTS) ................... 82-73
CYLINDER HEAD.. ...................... 82-79
TIMING BELT .............................. 82-84
AUXILIARY PARTS.. .....................
B2-87
ENGINE STAND DISMOUNTING ..a” . . 82-91
PROCEDURE ..............................
82-91
INSTALLATION ............................. 82-93
PROCEDURE .............................. 82-93
23UOB2-001

82 INDEX
NDEX
COMPRESSION INSPECTION, PAGE 92-10
STANDARD: 1,256 kPa (12.8 kg/cm2, 182 psi)-300 rpm
MINIMUM: 883 kPa (9.0 kg/cm2, 128 psi)-300 rpm
INTAKE MANIFOLD
TIGHTENING TORQUE
*(I-I)* hl.m I, (I-0 c m.h.
DRIVE BELT
ADJUSTMENT, PAGE 82-6 TIGHTENIF
36-46 N.m (3.9-4.7 rlG TORQUE
m-kg, 26-34 ft-lb)
JEFLECTION
mm (in)
DRIVE BELT
New Used Limit
ALTERNATOR
8.0-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39)
12.5 (0.49)
PIS, PIS + AIC 8.0-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39)
11.5 (0.45)
23UOB2-00:
1. Timing belt
6. Engine
Removal I Installation..
..............
page 62-l 2 Removal ...................................
page 82-31
2. Cylinder head gasket
Engine stand mounting..
.......... page 82-38
Replacement ............................
page B2-16 Disassembly
.............................
page 82-41
3. HLA
Inspection / Repair.. ..................
page B2-54
Removal / Installation
................ page
82-22 Assembly ..................................
page B2-66
4. Front oil seal
Engine stand dismounting
....... page 62-91
Replacement
page 82-26 Installation..
.-- ............................
............................... page 62-93
5. Rear oil seal
Replacement ............................
page 82-28
82-2

OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
ItC- Engine
BP DOHC
Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4 cylinders
Combustion chamber Pentroof
Valve svstem DOHC, belt-driven 16 valves
Displacement
Bore and stroke cc (cu in) 1,839 (112.2)
mm (in) I 83.0 x 85.0 (3.27 x 3.35)
Compression ratio
Compression pressure
IN
Valve timing
EX kPa (kg/cm*, psi)-rpm
BTDC Open
Close ABDC
Open BBDC
Close ATDC 9.0
1,256 (12.8, 182)300
!zJ”
48O
56O
140
Valve clearance IN 0: Maintenance-free
mm (in)
EX 0: Marntenance-free
Idle speed *’ *’ MTX
rpm
ATX
Ignition timing*2
Firing order
::...With parking brake applied. (Canada)
. ..TEN terminal of diagnosis connector grounded BTDC 700-800
700-800 (P range)
90-l 1 O
l-3-4-2
P3UOBZ003
TROUBLESHOOTING GUIDE
Problem
Difficult starting
Poor idling
Excessive oil
consumption Possible Cause
Malfunction of engine-related components
Burned valve
Worn piston, piston ring, or cylinder
Failed cylinder head gasket
Malfunction of fuel system
Malfunction of ignition system
Malfunction of engine-related components
Malfunction of HLA*
Poor valve-to-valve seat contact
Failed cylinder head gasket
Malfunction of fuel system
Malfunction of ignition system
Oil working up
Worn piston ring groove or sticking piston ring
Worn oiston or cvlinder
Oil working down
Worn valve seal
Worn valve stem or auide
Oil leakaae i
Replace 82-55
Replace or repair 92-60, 62
Reolace B2-16
Refer to Section F
I
Replace 82-47, 79
Replace 82-55
Refer to Section 0 I
82-3

B2 TROUBLESHOOTING GUIDE
Problem
Insufficient power
Abnormal
combustion
Engine noise -
I
I
f
,
I
I
,
I
I Possible Cause Action Page
Insufficient compression
Malfunction of HLA*
Compression leakage from valve seat
Seized valve stem
Ueak or broken valve spring
Failed cylinder head
gasket Cracked or distorted cylinder head
Sticking, damaged, or worn piston ring
Cracked or worn piston Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section F 82-22
82-57
02-55
B2-58
82-16
82-54
82-62
82-62 Malfunction of fuel system
Malfunction of ianition svstem
Others
Slipping clutch
Dragging brakes
Wrong size tires Malfunction of engine-related components
Malfunction of HLA*
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber Malfunction of fuel system
Malfunction of ignition system
Crankshaft- or bearing-related parts
Excessive main bearing oil clearance
Main bearing seized or heat-damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil clearance
Connecting rod bearing seized or heat-damaged Piston-related parts
Worn cylinder
Worn piston or piston pin
Seized piston
Damaged piston ring
Bent connecting rod Valves or timing-related parts
Malfunction of HLA*
Broken valve spring
Excessive valve guide clearance Malfunction of cooling system
Malfunction of fuel svstem
Others
Malfunction of water pump bearing Refer to Section E
Improper drive belt tension Adjust
Malfunction of alternator bearing Refer to Section G
Exhaust gas leakage Refer to Section F
Malfunction of timing belt tensioner Replace Refer to Section G
Refer to Section H
Refer to Section P
Refer to Section C!
Replace B2-22
Replace 82-55
Replace 82-58
Eliminate carbon -
Refer to Section F
Refer to Section G
Replace or repair B2-70
Replace 82-64
Replace or repair 82-7 1
Replace or repair B2-72
Replace B2-64
Replace or repair
82-60
Replace 82-63
Replace 82-62
Replace 82-62
Replace 82-63
Replace
Replace
Replace
Refer to Section E
Refer to Section F 82-22
82-58
82-55
B2- 6
82-12
23UOB2-00,
..J
.-,
l
Tappet noise may occur if the engine has set idle for an extended period. The noise should dissipate after the engine has reached
normal operating temperature. (HLA troubleshooting: Refer to page 82-7.)
82-4

ENGINE TUNE-UP PROCEDURE 82
ENGINE TUNE-UP PROCEDURE
PREPARATION
SST
49 BO19 9AO
drive belt tension
23UOB2-048
OBUOBX-158
I’ ,
OSJOBX-001
V BELT
V RIBBED BELT
_
x 0 x
3
L
03UOB2-005
ENGINE OIL
Inspection
1. Be sure the vehicle is on level ground.
2. Warm up the engine to normal operating temperature and
stop it.
3. Wait for 5 minutes.
4. Remove the oil level gauge and check the oil level and con-
dition.
5. Add or replace oil if necessary.
Note
l The distance between the L and F marks on the level
gauge represents 0.8 liter (0.85 US qt, 0.70 Imp qt).
ENGINE COOLANT
Inspection
Coolant level (engine cold)
Warning
l Never remove the radiator cap while the engine is
hot.
l Wrap a thick cloth around the cap when removing it.
1. Verify that the coolant level is near the radiator filler neck.
2. Remove the coolant level gauge and check the coolant level.
3. Add coolant if necessary.
Coolant quality
1. Verify that there is no buildup of rust or scale around the
radiator cap or radiator filler neck.
2. Verify that the coolant is free of oil.
3. Replace the coolant if necessary.
DRIVE BELT
Inspection
1. Check the drive belts for wear, cracks, and fraying. Replace
if necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
B2-5