torque MAZDA PROTEGE 1992 Repair Manual

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
* 62
Step 6
1. intake manifold bracket
2. Starter
3. Throttle cable (ATX)
4. No.2 engine mount rubber and bracket
5. Torque converter nuts (ATX) 6. Transaxle mounting bolts
7. Manual transaxle
8. Automatic transaxle
9. Engine assembly
03UOB2.06
B2-37

INSPECTION / REPAIR B2
23UOB2-06
051JOBX.14
05UOBX.14
OWOBX-14
05UOBX-14
5. Measure the journal diameters in X and Y directions at the
two points (A and 8) shown.
Diameter:
25.940-25.965mm (1.0213-l .0222 in)
Out-of-round: 0.03mm (0.001 in) max.
6. Measure the camshaft journal oil clearances.
Caution
l Do not install the HLA when measuring the oil
clearance.
(1) Remove all foreign material and oil from the journals and
bearing surface.
(2) Set the camshaft onto the cylinder head.
(3) Position Plastigage atop the journals in the axial
direction.
(4) Install the camshaft caps according to the cap number
and arrow mark.
(5) Install the camshaft cap bolts and tighten them in two
or three steps in the order shown in the figure.
Tightening torque:
11.3-14.2 N-m (1.15-l .45 m-kg, loo-126 in-lb)
(6) Loosen the camshaft cap bolts in two or three steps in
the order shown in the figure.
(7) Remove the camshaft caps.
82-59

ASSEMBLY B2
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.
93GOBl-082
B2-67

B2 ASSEMBLY
CYLINDER BLOCK (INTERNAL PARTS)
Torque Specifications
12-18 N.m (1.2-1.8
JOURNALS AND
47-50 (4.8--/6.1, 35-37)
N-m (m-kg, ft-lb)
Connecting Rod
o5uoBx-175
1. Install one piston pin clip into the clip groove in the piston.
2. Assemble the piston and the connecting rod, a ligning the
oil groove in the large end of connecting rod opposite the
“F” mark on the piston.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin from the side opposite the clip.
I 23uor32.039
82-68

ASSEMBLY
2311082-04
05UOBX-17
OSUOBX-17
SPACER TANG
OIL RING
SPACER ENDS
-I
a
5. Tap the piston pin in with the SST until the pin contacts the
clip.
If the pin cannot be installed easily, replace the connecting
rod.
6. Install the second clip into the clip groove in the piston.
7. Check the oscillation torque of the connecting rod. If the
large end does not drop by its own weight, replace the pis-
ton and/or piston pin.
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.
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 Fl 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).
132-69

B2 ASSEMBLY
- OWOBX-182
OWOBX-18
PLASTIGAGE
OSJOBX-18
5. Position the end gaps of the rings as shown in the figure.
Oil Jet
1. Install the oil jets.
Tightening torque:
12-l 8 N-m (1.2-l .8 m-kg, 104-l 58 in-lb)
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 wlth 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 measuring 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 (5.5-8.0 m-kg, 40-43 ft-lb)
B2-70

ASSEMBLY B2
r
03UOB2-09
__~~
05UOBX-188
.
OWOBX-19(
WIDTH
I
05UOBX-19
(7) Remove the main bearing caps, and measure the Plasti-
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 B2-64.)
Oil clearance: 0.018-0.036mm (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 C= mark.
4. 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)
5. Measure the crankshaft end play.
End play : 0.080-0.282mm (0.0031-0.0111 in)
Maximum: 0.30mm (0.012 in)
6. If the end play exceeds the maximum, grind the crankshaft
and install an oversize thrust bearing or replace the crank-
shaft and thrust bearing.
Thrust bearlng width
Standard:
2.500-2.550mm (0.0984-0.1004 in)
0.25mm (0.010 in) oversize:
2.625-2.675mm (0.1033-0.1053 in)
0.50mm (0.020 in) oversize:
2.750-2.800mm (0.1083-0.1102 in)
0.75mm (0.030 in) oversize:
2.875-2.925mm (0.1132-0.1152 In)
B2-71

B2 ASSEMBLY
RUBBER SLEEVE
I
OYJOBX-192
03UOB2-17
03UOB2-09 2 '0
05UOBX-196 Piston and Connecting Rod Assembly
Caution
l Protect the connecting rod bolts with rubber sleeves
to prevent damage to the crankpin journals.
1. Apply a liberal amount of clean engine oil to the cylinder
walls, pistons, and piston rings.
2. Check the piston rings for correct end gap alignment.
3. Insert each piston assembly into the cylinder block with the
F mark facing the front of the engine. Use a piston ring com-
pressor (commercially available).
Connecting Rod Cap
1. Measure the connecting rod bearing oil clearances using
the same procedure as for the main bearing oil clearance.
Caution
l Align the matching marks on the cap and the con-
netting rod when installing the connecting rod cap.
Tightening torque:
47-50 N-m (4.8-5.1 m-kg, 35-37 &lb)
Oil clearance: 0.028.0.088mm (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 82-64.)
3. Measure the connecting rod side clearances.
Side clearance: 0.1 lo-0.282mm (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.

ASSEMBLY B2
MATCHING MARKS
CYLINDER BLOCK (EXTERNAL PARTS)
Toraue SPecifications 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:
47-50 N*m (4.8-5.1 m-kg, 35-37 ft-lb)
19-25 (1.9-2.6, 14-19)

157-l 67
(16-17, 116-1’23)

OIL SEAL.’
/ GASKET. NEW
[SO--110 cm-ka. 69-95 in-lb) 16-26 (1.6-2.7,
13-20
16-21
(1.6-2.1, 12-16)
GASKET, NEW
SEAT FACE
SEAT FACE
N-m (m-kg, ft-lb)
05UOBX-19
B2-7: