MAZDA PROTEGE 1992 Manual PDF

DISASSEMBLY Bl
TIMING BELT
23UOBl-032
1. Water pump pulley
2. Crank shaft pulley bolt 6. Crankshaft pulley boss
3. Plate 7. Timing belt cover, upper
4. Pulley lock bolt 8. Timing belt cover, lower
9. Timing belt
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page Bl-42
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page
81-42
5. Crankshaft pulley
10. Tensioner and tensioner spring
Bl-41

DISASSEMBLY
23UOBl-067
; MARKS
MARKS
Qe
x
25mm (1.0 in) MIN
13EOBl-0:
Disassembly Note
Pulley lock bolt
1. Hold the flywheel (MTX) or drive plate (ATX) with the SST
or equivalent.
2. Remove the pulley lock bolt.
Timing belt
1. Turn the crankshaft and align the marks.
2. Mark the timing belt rotation for proper reinstallation.
Caution
l Never forcefully twist the timing belt. Do not turn
it inside out or bend it.
l Do not allow oil or grease on the belt.
81-42

DISASSEMBLY Bl
CYLINDER HEAD
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
GASKET, REPLA
B6 SOHC
1. Cylinder head cover and gasket 14. Cylinder head bolts
2. Thermostat cover and gasket
3. Thermostat
4. Heat gauge unit
5. Bracket
6. Rocker arm and shaft assembly
Disassembly Note . . . . . . . . . . . . . . . . . . . .
7. Rocker arm
8. Rocker arm spring
9. Rocker shaft Disassembly Note . . . . . , , . . . . . . . . . . . . . page Bl-45
15. Cylinder head
Inspection . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B l-54
16. Cylinder head gasket
17. Valve keeper
page Bl-45 Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-46
18. Valve spring seat, upper
19. Valve spring
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-58
10. Hydraulic lash adjuster (HLA) 20. Valve spring seat, lower
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-45 21. Valve
Inspection ., . . . . . . . . . . . . . . . ,.,.......... . . . page Bl-60 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-55
11. Camshaft pulley 22. Valve seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-45 Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-46
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-65 Inspect for wear or damage
12. Thrust plate 23. Valve guide
13. Camshaft Inspection . . . . . ,.,.............. . . . . . . . . . . . page Bl-55
Inspection . . . . . . . . . . . . . . . page B l-58 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-56
24. Camshaft oil seal
Bl-43

Bl DISASSEMBLY
BP SOHC
GASKET, REPLACE @g-p--
1. Cylinder head cover and gasket 14. Cylinder head bolts
2. Thermostat cover and gasket Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-45
3. Thermostat 15. Cylinder head
4. Heat gauge unit
5. Bracket
6. Rocker arm and shaft assembly
Disassembly
note . . . . . . . . . . . . . . . . . . . . . page Bl-45
7. Rocker arm
8. Rocker arm spring
9. Rocker shaft
10. Hydraulic lash adjuster (HLA)
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page 81-45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-60
11. Camshaft pulley
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page 81-45
Inspection .,....,...,...................... page Bl-65
12. Thrust plate
13. Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . ,........ page Bl-54
16. Cylinder head gasket
17. Valve keeper
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-46
18. Valve spring seat, upper
19. Valve spring
Inspection ,...*.......*..................*. page Bl-58
20. Valve spring seat, lower
21. Valve
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..t. page 81-54
22. Valve seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-46
Inspect for wear or damage
23. Valve guide
Inspection . . . . . . . . . . . . . . . . . ,.. ..,..,., ,.,
page Bl-58 Inspection ..,.,.........,..,............... page 81-54
Replacement . . . . . . . . . . . . . . . . . . . . . . . . ..I. page Bl-56
24. Camshaft oil seal
..-..
Y’
81-44

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
36 SOHC Valve keeper
1. Set the SST against the upper valve spring seat as shown
in the figure.
2. Remove the valve keepers.
Valve seal
1. Remove the valve seal with the SST.
-’
.-r
81-46

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

Bl DISASSEMBLY
23UOBl-068
23UOBl-06!
I 2311081-070
23UOBl-071
Disassembly Note
Timing belt pulley
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. -
4. Remove the timing belt pulley.
5. Remove the pulley Woodruff key.
2311081-059
Clutch cover (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Loosen the clutch cover lock bolts in two or three steps in
the order shown in the figure.
3. Remove the clutch cover.
-
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
4. Remove the
SST or equivalent.
Backing plate, drive plate, and adapter (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.
4. Remove the
SST or equivalent.
Bl-48

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