coolant MAZDA PROTEGE 1992 Workshop Manual

PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Following items may be done at any time prior to delivery to your customer.
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Glass, exterior bright metal and paint for damage
Cl Wheel lug nuts, and locks (if equipped)
88-118 N.m (9-12 m-kg, 65-87 ft-lb)
q All weatherstrips for damage or detachment
0 Operation of hood release and lock
0 Operation of trunk lid, rear hatch, and fuel lid opener
Cl With trunk open, check for spare jack, tire, tools, and
fasteners securing these items in place.
Cl Door operation and alignment
Cl Headlight aim
INSTALL the following parts:
Cl Wheel caps or rings (if equipped)
q Outside rearview mirror(s)
1 UNDER HOOD-ENGINE OFF )
INSPECT and ADJUST, if necessary, the following items to
the specifications:
0 Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
Cl Engine oil level
0 Power steering fluid level
0 Brake and clutch master cylinder fluid level
El Windshield washer reservoir fluid level
Cl Radiator coolant level
Cl Tightness of battery terminals
Cl Manual transaxle oil level
riizmiq
INSTALL the following parts:
Cl Rubber stopper for inside rearview mirror
CHECK operation of the following items:
0 Seat controls (sliding and reclining) and head restraint
Cl Folding rear seat
0 Door locks, including childproof door locks (if equipped)
Seat belts and warning system
Cl Ignition switch and steering lock
0 Inhibitor switch (ATX only)
U Starter interlock switch (clutch pedal, MTX only)
Cl All lights, including warning and indicator lamps
Cl Sound warning system
Cl Horn, wipers and washers (front and rear, if equipped)
0 Audio system (if equipped) 0 Cigarette lighter and clock
0 Sunroof (if equipped)
II Remote control outside rearview mirrors (if equipped)
Cl Power windows (if equipped)
q Heater, defroster and air conditioner at various mode
selections (if equipped)
CHECK the following items:
Cl Presence of spare fuse
0 Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
0 Pedal height and free play of brake and clutch pedal
Pedal height mm (in) Free play mm (in)
0 Parking brake
5-7 notches/98 N (10 kg, 22lb)
UNDER HOOD-ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
q Automatic transaxle fluid level
[I
CHECK the following items:
Cl Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
0 Tires for cuts or bruises
0 Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
[I
CHECK the following items:
0 Brake operation
0 Clutch operation
Cl Steering control
Cl Operation of gauges
q Squeaks, rattles or unusual noise
Cl Emergency locking retractors
0 Cruise control system (if equipped)
1 AFTER ROAD TEST (
CHECK for necessary owner information materials.
Following items must be done just before the delivery to your customer.
q Load test battery and charge if necessary
1 Volts 1 0 Install fuses for accessories
i.. _
0 Adjust tire pressure to the specification
Load test result cl Remove seat and floor mat protective covers
(Refer to door label) 0 Vacuum and clean interior of vehicle
0 Clean outside of vehicle q Inspect installation of option parts with invoice
23UOAX-002
A-2

7 Schedule 1 (Normal Driving Conditions) (Cont’d)
MAINTENANCE
INTERVALS 1 ::::“’ rths ’ 7.5
DPERATION x 1,000 miles
x 1,000 km 3r mi
15
15
24
1
Page
l- . whichever comes first s (kilometer!
37.5
37.5
60 52.5
52.5
64 60
60
96
I
l-7
Service data and inspection points
l Hoses for cracks or wear l Coolant level E-5
Zooling system
Engine coolant
Fuel filter
‘die speed
Fuel lines
Brake lines, hoses and connections
l Coolant capacity:
5.0 liters (5.3 US qt, 4.4 Imp qt) . . . . . . . . . . MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) . . . . . . . . . . ATX
I E-6 -
F-l 24
l ATX: P range, MTX: Neutral
700-800 rpm (with parking brake applied)
l Fittings, connections, and components for F-80
F-120
-
H-6
P-28
P-29
P-20
P-25
P-18
P-25
---
N-27
N-8
-
M-21
-
F-136
u-35
u-39 leaks
0 Proper attachment and connections
l Operation l Pedal height (with carpet):
196-204mm (7.72-8.03 in)
l Free play:
5--13mm 10.197-0.512 in) Clutch pedal
l Wheel cylinder operation and leakage
l Lining for wear or damage l Lining thickness:
Minimum . . . . . 1 .Omm (0.04 in)
l Drum inner diameter
Maximum..... 201mm (7.91 in) Drum brake
l Caliper operation l Disc plate thickness:
Minimum.... Front 20mm (0.79 in)
Rear 7.0mm (0.28 in)
l Pad thickness:
Minimum.... Front 2.0mm (0.08 in)
Rear l.Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozing l Free play.... O-30mm (O-l .18 in)
l Damage, looseness, and grease leakage
l Cracking and damage
l Retighten all loose nuts and bolts I
1
Disc brake
I
---l-T
Steering operation and linkage
Front suspension ball joints
Drive shaft dust boots
Bolts and nuts on chassis and body
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor am01 anni I
l Insulation clearance
- ,.
Inspect rerrlgerar
Inspect operation annually -

y Schedule 2 (Unique Driving Conditions)
OPERATION
Drive belts MAINTENANCE / Number of months or miles (kilometers), whichever comes first
INTERVALS Months
5 IO 15 20 25 30 35 40 45 50 55 60
x 1,000 milea i 5 10 15 20 25 30 35 40 45 50 55 60
x 1,000 km 8 16 24 32 40 48 56 64 72
80 88 96
I I Service data and inspection points Page
l Cracks or damage Bl-5 l Tension B2-5
l Oil pan capacity
B6 SOHC: 3.0 liters (3.2 US qt, 2.6 Imp qt)
All BP : 3.6 liters (3.8 US qt, 3.2 Imp qt)
l Oil filter capacity: D-5
I I I I I I I I I I I
RRRRRRR R R R R R
Replace every 3,000 miles (4,800 km) or every 3 months
R R R R R RRRRRRR
0.17 liter (0.18 US qt, 0.15 Imp qt) Engine oil
Engine oil (For Puer-to-Rico)
Oil filter D-5
81-12
82-12
F-79
G-18 Replace every 60,000 miles (96,000 km)
Engine timing belt*’
Air cleaner element -
-
-
-
-
-
-
-
- -
-
-
-
-
-
-
-
-
FL
-
R
-
I
-
R
-
4 *;
-
-
*3
T
- -
-
-
-
-
-
-
-
- -
-
-
-
-
-
-
-
-
*2 -
-
-
-
-
-
-
-
- - R -
l Plug gap: l.O--l.lmm (0.039-0.043 in)
l Recommended spark plugs
Engine NGK NIPPONDENSO
B6 SOHC BKR5E-11
KlGPR-Ull
BKRGE-I 1 K20PR-U 11
BP SOHC BKR5E-I 1 KlGPR-Ull
BKRGE-11 K20PR-U 11
BKRSE-I 1 Kl GPR-Ul 1
BP DOHC BKRGE-11 K20PRUll
BKR7E-11 K22PR-U 11 R
Spark plugs
I
l Hoses for cracks or wear l Coolant level E-5
Cooling system
R
l Coolant capacity:
5.0 liters (5.3 US qt, 4.4 Imp qt) MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) ...,,,,,. ATX
l ATX: P range, MTX: Neutral E-6
Engine coolant
A
-
R
-
I
-
I Idle speed , F-80
F-124 / 700-800 rbrn (with parkina brake applied) -
- -
- , , I .I
-
Fuel filter
l Fittings, connections, and components for
leaks
l Prooer attachment and connections F-120
- Fuel lines
Brake lines. hoses and connections

SCHEDULED MAINTENANCE SERVICES (CANADA)
Schedule
2 1,000 km
x 1,000 mile! Number of months or kilometers (miles), whichever comes first
Months 5 10 15 20 25 30 35 40 45 50 55 60
8 16 24
32 40 40 56 64 72 80 88 96
s 5 10 15 20 25 30 35 40 45 50 55 60
I I I Service data and inspection points Page
MAINTENANCE
OPERATION
l Cracks or damage Bl-5 l Tension 82-5
l Oil pan capacity
B6 SOHC: 3.0 liters (3.2 US qt, 2.6 Imp qt)
All BP : 3.6 liters (3.8 US qt, 3.2 Imp qt)
l Oil filter capacity: D-5
0.17 liter (0.18 US qt, 0.15 Imp qt) Drive belts I I I I I I I I I I I I
Engine oil RRRRRRR R R R R R
Oil filter R R R R R R R R R R R R D-5
81-12
82-12
F-79 Replace every 96,000 km (60,000 miles)
Engine timing belt*’
Air cleaner element
T
-
-
I
-
-i
-
I
-
-
-
-
-
-i-
- -
R -
-
-
-
T
-
-
-
-
-
-
-7
- -
-
-
-
T
-
-
-
-
-
-
T
- -r
-
-
I
-
T
-
I
-
-
-
-
-
-i
-
-
-
-
-
T
-
-
-
-
-
-
T
- -
-
-
-
T
-
-
-
-
-
-
T
- i?-
-
R
-
I
-
R
-i
-
I
F
T
T
-
I
-i
-i
-
-
-
-
-
T
-
-
-
-
-
-
-i
- -
l Plug gap: 1.0-l .l mm (0.039-0.043 in)
l Recommended spark plugs .-
Engine NGK NIPPONDENSO
86 SOHC BKR5E-11 KlGPR-Ull
BKRGE-11 K20PR-U 11
BP SOHC BKR5E-11 KlGPR-Ull
BKRGE-11 K20PR-U
11
BKRSE-11 KlGPR-Ull
BP DOHC BKRGE-11 K20PR-U 11
BKR7E-11 K22PRU 11 G-18
R
-
I
-
R
-i- Spark plugs -
-
-
-
I
-
-
E-5
Cooling system l Hoses for cracks or wear
l Coolant level
0 Coolant capacity: 5.0
liters (5.3 US qt, 4.4 imp qt) ..,.,..,,. MTX
6.0 liters (6.3 US qt, 5.3 Imp qt) . . . . . . . . . . ATX
l Level and condition
l ATX: P range, MTX: Neutral
700-800 rpm (with parking brake applied) E-6
Engine coolant
E-5
F-80
F-124 I
- I
Idle speed
Fuel filter
PCV valve *’
Emission hoses and tubes
Fuel lines
Brake lines, hoses and connections
Automatic transaxle fluid (ATF) -
-
-
I *2
l Operation - F-138
F-6 -
-
- -
-
-
l Fittings and connections
l Fittings, connections, and components for
leaks
l Proper attachment and connections
l Level and conditinn F-l 20 - K-l 35
I I
- I
- I

Bl
ENGINE
(SOHC)
INDEX .......................................... Bl- 2
OUTLINE ...................................... Bl- 3
SPECIFICATIONS ........................
Bl- 3
TROUBLESHOOTING GUIDE ..........
Bl- 3
ENGINE TUNE-UP PROCEDURE ......
Bl- 5
PREPARATION ............................ Bl- 5
ENGINE OIL ............................... Bl- 5
ENGINE COOLANT.. ....................
Bl- 5
DRIVE BELT ............................... Bl- 5
HLA .......................................... Bl- 7
IGNITION TIMING, IDLE SPEED
..... Bl- 8
COMPRESSION ............................. Bl-10
INSPECTION ............................... 81-10
ON-VEHICLE
MAINTENANCE.. ........
Bl-1 1
PREPARATION ............................ Bl-11
TIMING BELT .............................. Bl-12
CYLINDER
HEAD GASKET ........... Bl-16
HLA .......................................... Bl-20
FRONT OIL SEAL.. ...................... 81-23
REAR OIL SEAL ..........................
Bl-25
REMOVAL ..................................... 81-28
PROCEDURE .............................. Bl-28
ENGINE STAND MOUNTING.. .........
Bl-35
PREPARATION
............................ 81-35
PROCEDURE ..............................
Bl-36
DISASSEMBLY .............................. Bl-38
PREPARATION ............................ Bl-38
AUXILIARY PARTS.. ..................... 81-40
TIMING BELT .............................. 81-41
CYLINDER HEAD.. ......................
81-43
CYLINDER BLOCK
(EXTERNAL PARTS)
................... 81-47
CYLINDER BLOCK
(INTERNAL
PARTS). ................... Bl-50 INSPECTION /
REPAIR.. .................
81-54
PREPARATION ............................ Bl-54
CYLINDER HEAD.. ...................... Bl-54
VALVE
MECHANISM.. .................. Bl-55
CAMSHAFT ................................ 81-58
HLA .......................................... Bl-60
CYLINDER BLOCK ......................
Bl-60
OIL JET ..................................... Bl-61
PISTON, PISTON RING, AND
PISTON PIN .............................. Bl-62
CONNECTING ROD.. ...................
Bl-63
CRANKSHAFT ............................ Bl-64
BEARING ................................... 81-64
TIMING BELT .............................. Bl-65
TENSIONER,
IDLER.. ................... 81-65
TENSIONER SPRING ...................
81-65
PULLEY ..................................... Bl-65
ASSEMBLY ................................... Bl-66
PREPARATION ............................ Bl-66
CYLINDER BLOCK
(INTERNAL PARTS). ................... Bl-68
CYLINDER BLOCK
(EXTERNAL PARTS) ...................
Bl-74
CYLINDER
HEAD.. ...................... 81-79
TIMING BELT .............................. Bl-86
AUXILIARY
PARTS.. ..................... Bl-89
ENGINE STAND DISMOUNTING.. .... Bl-92
PROCEDURE .............................. 81-92
INSTALLATION ............................. 81-94
PROCEDURE .............................. Bl-94
23UOBl-001

INDEX
NDEX
INTAKE MANIFOLD,
TIGHTENING TORQUE
.-’ HYDRAULIC LASH ADJUSTER (HLA)
INSPECTION, PAGE Bl-7 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
DEFLECTION AT (98 N, 10 kc
19
22 lb)
r “Y7 ENGINE COOLANT/
SECTION
EXHAUST MANIFOLD
TIGHTENING TORQUE
16-23 N.m (1.6-2.3 m-kg,
12-17 ft-lb
mm (in)
11 DRIVE BELT NEW USED LIMIT
COMPRESSION INSPECTION PAGE 61-10 kPa (kg/cm*, psi)-rpm
y-1, Sta,,dar‘-j , ,238;;;;;;$))-3(J() , ,,97;;2~;;&)0
883 (8.8, 125)-300 834 (8.5, 121)-300 II A/C 8.0-9.
(0.31-0.35) I (0.35-0.39) I (0.45) 11 Minimum
-
E
1. Timing belt
23UOBl-00:
Removal / installation . . . . . . . . . . . . . . . . page 61-l 2
2. Cylinder head gasket
Rep!acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-16
3. HLA
Removal / Installation . . . . . . . . . . . . . . . page 81-20
4. Front oil seal
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl -23
5. Rear oil seal Removal ................................... 6. Engine
page Bl-28
Engine stand mounting.. .......... page 81-35
Disassembly ............................. page Bl-38
Inspection / Repair .................... page Bl-54
Assembly.. ................................ page 81-66
Engine stand dismounting.. ..... page 81-92
Installation page 81-94 .+- .................................
Replacement . . , . . ,.. . . . . . . . . . . . . . . . . . . . page Bl-25
81-2

ENGINE TUNE-UP PROCEDURE Bl
ENGINE TUNE-UP PROCEDURE
PREPARATION
-.
SST
drive belt tension
m :
I 1 2311081-058
- 03UOBX-20
---
OSUOBX-OC
V-BELT
LhEd
V-RIBBED BELT
OSJOBX-00
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, Remove the air intake pipe.
2. Check the drive belts for wear, cracks, and fraying. Replace
if necessary.
3. Verify that the drive belts are correctly mounted on the
pulleys.
Bl--5

Bl 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, referring to Installation Note.
7.8-11 N.m
16-23 (1 4.9-8.8 N.m (50-90 cm-kg, 43-78 in-lb)
(80-l 10 cm-kg, 69-95 in-lb)
L
.8-11 N.m
(80-110 cm-kg,
69-95 in-lb)
-25 (1.9-2.6, 14-19)
BP SOHC: 37-52 (3.8-5.3, 27-38)
37-52 (3.8-5.3, 27-38)
7.8-11 N.m
(80-l 10 cm-kg, 89-95 in-lb)
N-m (m-kg, ft-lb)
23UOBl-01
81-16

.
ON-VEHICLE MAINTENANCE
Installation note
Cylinder head bolt Bl
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:
76-61 N#m (7.7-6.3 m-kg, 56-60 f&lb)
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: I-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 81-8.)
(3) Operation of emission control system.
4. Recheck the engine coolant levels.
2311081-020
Bl-19

REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section F.)
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil.
3. Remove in the order shown in the figure, referring to Removal Note,
Step 1
1. Undercover and side cover
2. Air cleaner assembly 10. Cooling fan connector
3. Battery and battery cover 11. Oil cooler hose (ATX)
4. Battery carrier 12. Radiator and cooling fan assembly
13. P/S and/or A/C drive belt
5. Battery duct
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Accelerator cable page Bl- 6
7. Resonance chamber 14. P/S oil pump and bracket
8. Radiator hose Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
9. Coolant reservoir hose 15. A/C compressor (if equipped)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
81-28