engine MAZDA PROTEGE 1992 Manual PDF

B2 COMPRESSION
COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1, Ignition system (Refer to Section G.)
2. Compression
3. Fuel system (Refer to Section F.)
23UOB2-013
13UOl32.004
2311087-014
-_
B2-10
2311082-012
INSPECTION
1. Check that the battery is fully charged. Recharge it if neces-
sary. (Refer to Section G.)
2. Warm up the engine to normal operating temperature.
3. Turn the engine OFF.
4. Remove all spark plugs.
5, Disconnect the ignition coil connector.
6. Connect a compression gauge to the No.1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.
9. Check each cylinder.
Compression:
1,256 kPa (12.6 kg/cm’, 182 psi)-300 rpm
Minimum:
883 kPa (9.0 kg/cm2, 128 psi)-300 rpm
Max. difference between cylinders:
196 kPa (2.0 kg/cm2, 28 psi)
10. If the compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder wall may be worn.
(2) If the compression stays low, the valve may be stuck
or seating improperly.
(3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be defective or the cylinder
head distorted.
Il. Connect the ignition coil connector.
12. Install the spark plugs.
05UOBX-020
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 11-17 ft-lb)

ON-VEHICLE MAINTENANCE 62
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 DO11 102
Lock tool,
crankshaft
49 E011 103
Shaft
(Part of
49 EOl 1 1AO) @
49 EOI 1 104
Collar
(Part of
49 EOl 1 1AO) For
removal and
installation of
timing belt pulley
For
prevention of
engine rotation
For
prevention of
engine rotation 49 EOll IA0
Ring gear brake
set
49 EOll 105
Stopper
0
(Part of
49 EOI 1
1AO) w
49 SE01 310A
Centering tool,
clutch disc For
prevention of
engine rotation
For
prevention of
engine rotation
For
installation of
clutch disc
2311082-0‘
02-I 1

ON-VEHICLE MAINTENANCE
13EOB2-015
DEFLECTION CHECKING POINT
13EOE2-011
23UOB2-017
23UOB2-018
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page B2-8.) 10. Loosen the tensioner lock bolt to apply spring tension to
the timing belt.
11. Tighten the tensioner lock bolt.
Tightening torque:
37-52 Narn (3.8-5.3 m-kg, 27-38 ft-lb)
12. Install the pulley boss and pulley lock bolt.
13. Turn the crankshaft 2 and 116 turns clockwise and verify
that the timing marks are correctly aligned.
14. Measure the timing belt deflection by applying moderate
pressure (98 N,
10 kg, 22 lb) midway between the cam-
shaft pulleys.
If the deflection is not correct, repeat from Step 10 above.
Deflection:
9.0-11.5mm (0.35-0.45 In) at 98 N (10 kg, 22 lb)
Spark plug
1. Install the spark plugs.
Tightening torque:
15-23 Nern (1.5-2.3 m-kg, 11-17 ft-lb)
Pulley lock bolt
1, Hold the crankshaft with the SST and tighten the pulley lock
bolt.
Tightening torque:
157-187 N*rn (18-17 m-kg, 118-123 ft-lb)
23UOB2-019
82-l 5

82 ON-VEHICLE MAINTENANCE
CYLINDER HEAD GASKET
Replacement
Warning
l Release the fuel pressure. (Refer to Section F.)
l Keep sparks and open flame away from the fuel area.
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.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. install in the reverse order of removal, referrina to Installation Note.
BOLT THREADS ?&d 4.9-8.8 N.m
fsn-an om.h 41-‘71( ir
AND SEAT FACES ,-- -- -... ..=, _” . _ ..I-lb)
78-81 - /
(7.7-8.3, 58-60)
7.8-11 N.m
(80-l 10 cm-ka, 69-95
, . . . . . . (80-l 10 cm-kg, 69-9: in-lb) (j-$15-23 (1.5-2.3, 11-17)
82-l 6
7.8-11 N.m
(80-110 cm-k?, 69-95 In-lb) 180-110 cm-ka. 69-95 in-lb
-37-52
(3.8-5.3, 27-38)
’
nl MTX:?64-69 (6.6-9.1,
PTX: 55-60 (6.6-8.2, 69-95 in. .Ib)
47-86)
41-69)
7.8-11 N./n (3.2-4.7, 23-34)
37-52
(80-110 cm-kg, 69-95 in-lb) (3.8-5.3, 27-38)
N-m (m-kg, N-lb)
^^. .^_^ __

ON-VEHICLE MAINTENANCE B2
- 05UOBX-04:
---_____~
OWOBX 04
----
05UOBX-03
4
2. Loosen the tensioner lock bolt.
Caution
l To prevent damage to the tensioner, secure it with
a rag.
3. Temporarily secure the tensioner with the spring fully ex-
tended.
Caution
Q Do not allow any oil or grease on the timing belt.
4. Remove the timing belt and secure it out of the way to pre-
vent damage during removal and installation of the cylin-
der head.
Cylinder head bolt
1. Loosen the cylinder head bolts in two or three steps in the
order shown in the figure.
2. Remove the cylinder head bolts.
Installation note
Cylinder head bolt
1. Apply clean engine oil to the bolt threads and seat faces.
2. Install the cylinder head bolts.
3. Tighten the cylinder head bolts in two or three steps in the
order shown in the figure.
Tightening torque:
76-81 N-m (7.7-8.3 m-kg, 56-60 ft-lb)
Cylinder head cover
1, Apply silicone sealant to the shaded areas as shown in the
figure.
2. Install the cylinder head cover.
Tightening torque:
4.9-8.8 N-m (50-90 cm-kg, 43-78 in-lb)
B2-19

ON-VEHICLE MAINTENANCE
DEFLECTION CHECKING POINT
05UOBX-03 3 10. Measure the timing belt deflection by applying moderate
pressure (98 N, 10 kg, 22 lb) midway between the two cam-
shaft pulleys.
If the deflection is not correct, repeat from Step 7 above.
Deflection:
9.0-11.5mm (0.35-0.45 in) at 98 N (10 kg, 22 lb)
Harness
1. Connect the harness connectors. (Refer to page 82-l 8.)
Hose
1. Connect the hoses. (Refer to page 82-17.)
03UOB2-035
Accelerator cable
1. Install the accelerator cable.
2. Check the accelerator cable deflection.
If the deflection is not correct, adjust by turning nut A.
Deflection: l-3mm (0.04-0.12 In)
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E.)
2. Connect the negative battery cable.
3. Start the engine and check as follows:
(1) Engine oil and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page B2-8.)
(3) Operation of emission control system.
4. Recheck the engine coolant levels.
2311082-022
B2-21

ON-VEHICLE MAINTENANCE 82
I 05UOBX-049
05UOBX-C
05UOBX-0
03UOB2-1
Removal 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.
HLA
Caution
l Mark the HLA with a felt pen so that they can be rein-
stalled in the position from which they were
removed.
1. Remove the HLA from the cylinder head.
Installation note
HLA
1. Apply clean engine oil to the friction surfaces.
2. If the HLA are being reused, install them in the position from
which they were removed.
3. Verify that the HLA move smoothly in their bores.
Camshaft
Note
l The intake camshaft is grooved for the distributor
drive.
1. Apply clean engine oil to the camshaft journals and bearings.
2. Install the camshaft in position.
82-23

ON-VEHICLE MAINTENANCE
OWOBX-05.
OxJOBX-05,
ENOBX-056
--
Caution
l Do not allow any sealant on the camshaft journal
surfaces.
.-
3. Apply silicone sealant to the shaded areas shown in the
figure.
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-l 4.2 N-m (1 .15--l .45 m-kg, loo-126 in-lb)
6. Apply a small amount of clean engine oil to the lip of a new
camshaft oil seal.
7. Push the oil seal slightly in by hand.
Caution
l The oil seal must be tapped in until it is flush with
the edge of the camshaft cap.
8. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 46mm (1.69 in)
Camshaft pulley
1. Turn the camshafts until the camshaft dowel pins face
straight up.
2. Install the camshaft pulleys with the I mark (intake side) or
the E mark (exhaust side) straight up.
I II’- ,
J
05UOBX-057
B2-24

ON-VEHICLE MAINTENANCE B2
05UOBX-05
BLA-DE 0-dlNG
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 82-8.) 3. Install the camshaft pulley lock bolts.
4. Hold the camshaft with a wrench.
5. Tighten the camshaft pulley lock bolt.
Tightening torque:
49-61 N-m (5.0-6.2 m-kg, 36-45 ft-lb)
Distributor
1. Apply grease to a new O-ring and the blade.
2. Install the distributor and loosely tighten the installation bolt.
3. Connect the distributor connector.
0311082-039
B2-25

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