height MAZDA PROTEGE 1992 Workshop Manual

HOW TO USE THIS MANUAL GI
HOW TO USE THIS MANUAL
PREPARATION
PREPARATION points out the needed Special Service Tool (SST) for the service operation that it pro- m
ceeds. Gather all necessary
SST before beginning work.
Example:
49 0118 850C
removal of be-rod
9MUGIX-033
REPAIR PROCEDURE
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the
parts fit together, and visual parts inspections. If a damaged or worn part is found, repair or replace it
as necessary.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration.
3. Pages related to service procedures are shown under the illustration. Refer to this information when ser-
vicing the related part.
Example:
SHOWS
NEEDED SST

SHOWS
APPLICATION
#T OF OIL,
SHOWS
RELATED
PAGE FOR
SERVICE ----

3. Bearing cup 1. Bolt
2. Lock Dlate
4. Adjusting screw
5. Bearing outer race
6. Locknut
7. Washer
8. Companion flange 16. Bearing Inner race
@ Removal. ,,,..,,,..
lnstallatlon page
page M--5 M-Z
i 7. Spacer
18. Drive pinion
Removal, .,,, ,.,, .,......... page M--i
Inspect spllnes and teeth for wear or damagl
Adjustment of height page M-2
Adurstp- w
SHOWS TIGHTENING
TORQUE
SPECIFICATION ‘2
SHOWS TIGHTENING
rORQlJE UNIT
SHOWS VISUAL
INSPECTION
INFORMATION
* 1: The numbering (ex.a) shows service procedure.
*2: Units shown in N.m (m-kg, ft-lb) unless otherwise specified.
9MUGIX-034
GI-3

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 -

I
Schedule 2 (Unique Driving Conditions) (Cont’d)
(kil
I :
I :
’ 1 iii ichever comes first lometers), Y
25 30 35
25 30 35
40 48 58
I
45
45
72 50
50
80
-
-
I
I
I
I
I
T
I
,
40
iii
i5i
-
-
-
-
-
-
-
-
-
I
-
-
T -
-
-
- -
1 nspec L :t rerngeranr amount annually
Inspect operation annually m
rs
E
24
-
-
-
I
-
-
-
T
-
T fn
iiF
is
w
-
-
-
-
-
-
-
-
- iii
iii
,s
-
I
-
I
-
I
-
I
T
I-
r
T
-
T7
Service data and inspection points Page l
Operation l Pedal height (with carpet):
196-204mm (7.72-8.03 in) l
Free play
5-13mm (0.197-0.512 in) l
Wheel cylinder operation and leakage l Lining for wear or damage l Lining thickness:
Minimum l.Omm (0.04 in) l
Drum inner diameter: H-6
Clutch pedal
P-28
P-29 Drum brake
Maximum 201mm (7.91 in) 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 . . . . . 1 .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 l
Insulator clearance
-
- P-20
P-25
P-18
P-25
N-27
N-8 Disc brake
Steering operation and linkage
Front suspension ball joint
Drive shaft dust boots
Bolts and nuts on chassis and body
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor -
M-21
-
F-136
u-35
u-39

Bl INSPECTION / REPAIR
INSPECTION / REPAIR
PREPARATION
SST
49 LO12 OAO)
Remover and
03UOBi-08
1. Clean all parts, being sure to remove all gasket fragments, dirt, oil or grease, carbon, moisture residue,
and other foreign materials.
2. Inspection and repairs must be performed in the order specified. .__a
Caution
l Do not damage the joints or friction surfaces of aluminum alloy components (such as the cyl-
inder head or pistons).
81-54
03UOBl-090 05UOBX-119
CYLINDER HEAD
1. Inspect the cylinder head for damage, cracks, and leakage
of water and oil. Replace the cylinder head if necessary.
2. Measure the cylinder head distortion in the six directions
shown in the figure.
Distortion B6 SOHC: 0.15mm (0.006 in) max.
BP SOHC: O.lOmm (0.004 in) max.
Caution
l Before grinding the cylinder head, check the follow-
ing and repair or replace the cylinder head as
necessary.
Sinking of valve seats
Damage of manifold contact surface
Camshaft oil clearances and end play
3. If the cylinder head distortion exceeds specification, grind
the cylinder head surface.
If the cylinder head height is not within specification, replace
it.
Height: 107.4-l 07.6mm (4.228-4.236 in)
Grinding B6 SOHC: 0.20mm (0.008 in) max.
BP SOHC: O.lOmm (0.004 in) max.

Bl INSPECTION / REPAIR
VALVE GUIDE
8. Measure the protrusion height of each valve guide. Replace
the valve guide if necessary.
13UOBl-026
P SOHC m
9MUOB2-112
OSUOBX-12’
Bi-56
Height
B6 SOHC mm (in)
BP SOHC
I
IN 13.2-13.8 18.3-i 8.9
(0.520-0.543)
(0.720-0.744)
-.. --
EX 13.2-13.8 16.8-17.4
(0.520-0.543) (0.661-0.685)
Replacement of valve guide
Note
l The valve guides are different between intake and
exhaust sides, use the correct valve guide.
Removal
1. Remove the valve guide from the side opposite the com-
bustion chamber with the SST.
Installation
1. Assemble the SST so that depth L is as specified.
Depth L
mm (in)
I B6 SOHC
I BP SOHC
I
IN 13.2-13.8 18.3-l 8.9
(0.520-0.543) (0.720-0.744)
EX 13.2-13.8 16.8-17.4
(0.520-0.543) (0.661-0.685)
2. Tighten the locknut.
3. Tap the valve guide in from the side opposite the combus-
tion chamber until the SST contacts the cylinder head.
4. Verify that the valve guide height is within specification.
5. If not within specification, repeat Steps l-4.

Bl INSPECTION / REPAIR
r
BP SPHC
I /
._~~ ~_ ’
--
23UOB1-06(
1
I 2-l

_I_
23UOBl-074
lt- OUT-OF-SQUARE
BP SOHC, IN: 42.5mm (1.673 in)
EX: 41 .Omm ‘(1.614 ii)
mm (in)
Measurement Action
IN . 42.5-43.0 (1,673-l ,693) No correction needed
More than 44.0 (1.732) Replace cylinder head
EX 41 .O-41.5 (1,614-l ,634) No correction needed
More than 42.5 (1.673) Replace cylinder head
Valve Spring
1. Inspect each valve spring for cracks or damage.
2. Measure the free length and out of square. Replace the
valve spring if necessary.
Free length
Standard...mm (in), Minimum...N (kg, Ib)/mm (in)
B6 SOHC BP SOHC
I
IN Standard 43.66 (1.7188) 46.12 (1.8157)
224-253 (22.8-25.8, 205-231 (20.9-23.5,
Minimum 50-57)/35.5 (1.398) 46-52)/39 (1.535)
EX Standard 43.66 (1.7188) 43.61 (1.7169)
224-253 (22.8-25.8, 129-147 (13.1-15.0,
Minimum 50-57Y35.5 (1.398) 29-331137.5 (1.476)
Out-of-square max. mm (in)
B6 SOHC BP SOHC I
I I IN 1.52 (0.060) 1.61 (0.063)
t I I
I I EX 1.52 (0.060) 1.52 (0.060)
CAMSHAFT
1. Set the front and rear journals on V-blocks.
2. Measure the camshaft runout. Replace the camshaft if
necessary.
Runout BP SOHC: 0.03mm (0.0012 in) max.
B6 SOHC: O.Olmm (0.0004 in) max.
13UOBl.02; 3. Inspect the camshaft for wear or damage. Replace the cam-
shaft if necessary.
4. Measure the cam lobe heights at the two points as shown.
0311081-103
91-58
mm (in)

Bl INSPECTION / REPAIR
a3
03UOBl.109
03UOBl-11t
03UOBl-111 i
3
03UOBl-112
Rocker Arm and Rocker Arm Shaft
1. Check for wear or damage to the contact surface of the rock-
er arm shaft or the rocker arm. Replace if necessary.
2. Check the oil clearance between the rocker arm and shaft,
replace if necessary.
(1) Measure the rocker arm inner diameter.
Diameter mm (in)
B6 SOHC
BP SOHC
IN 18.000-l 8.027
19.000-19.027
(0.7087-0.7097)
(0.7480-0.7491)
EX 18.000-l 8.027
19.000-19.033
(0.7087-0.7097) (0.7480-0.7493)
(2) Measure the rocker arm shaft diameter.
Diameter mm tin1
IN
EX B6 SOHC
BP SOHC ’ ’
17.959-l 7.980
18.959-18.980
(0.7070-0.7079)
(0.7464-0.7472)
17.959-l 7.980
18.959-l 8.980
(0.7070-0.7079)
(0.7464-0.7472)
(3) Subtract the shaft diameter from the rocker arm di-
ameter.
Oil clearance
IN
EX
Maximum mm (in)
B6 SOHC
BP SOHC
0.020-0.068
0.020-0.068
(0.0008-0.0027) (0.0008-0.0027)
0.020-0.068
0.020-0.074
(0.0008-0.0027) (0.0008-0.0029)
0.10 (0.004) -_
HYDRAULIC LASH ADJUSTER (HLA)
Check the HLA face for wear or damage and replace if
necessary.
Caution
l To prevent damaging the O-ring, do not remove the
HLA unless necessary.
CYLINDER BLOCK
1. Check the cylinder block for the following and repair or re-
place the cylinder block as necessary.
(1) Leakage damage.
(2) Cracks.
(3) Scoring of wall.
2. Measure the distortion of the top surface of the cylinder block
in the six directions shown in figure.
Distortion: 0.15mm (0.006 in) max.
3. If the distortion exceeds the maximum, repair by grinding
or replace the cylinder block.
Height
t mm (in)
86 SOHC
BP SOHC _._
221.5 (8.720)
Grinding: 0.20mm (0.006 in) max. U3UU81-113

I32 INSPECTION / REPAIR
INSPECTION / REPAIR
PREPARATION
SST
49 6012 005 49 6012 005
Remover & Remover &
installer, valve installer, valve
guide guide
49 LO12 002
Body
(Part of
49 LO12 OAO)
49 LO12 004
Nut
(Part of
49 LO12 OAO) For
removal of
valve guide
For
installation of
valve guide
For
installation of
valve guide 49 LO12 OAO
Installer set,
valve seal &
valve guide
49 LO12 003
Installer
(Part of
49 LO12 OAO) For
installation of
valve guide
For
installation of
valve guide
05UOBX-1
1. Clean all parts, being sure to remove all gasket fragments, dirt, oil or grease, carbon, moisture residue,
and other foreign materials.
2. Inspection and repairs must be performed in the order specified. -.,
Caution
l Do not damage the joints or friction surfaces of aluminum alloy components (such as the cyl-
inder head or pistons).
0311082-162
03UOB2-70 OWOBX-119
CYLINDER HEAD
1, Inspect the cylinder head for damage, cracks, and leakage
of water and oil. Replace the cylinder head if necessary.
2. Measure the cylinder head distortion in the six directions
shown in the figure.
Distortion: O.lOmm (0.004 in) max.
Cautlon
l Before grinding the cylinder head, check the follow-
ing and repair or replace the cylinder head as
necessary.
Sinking of valve seats
Damage of manifold contact surface
Camshaft oil clearances and end play
3. If the cylinder head distortion exceeds specification, grind
the cylinder head surface.
If the cylinder head height is not within specification, replace
it. Height: 133.8-l 34.0mm (5.268-5.276
in)
Grinding: O.lOmm (0.004 in) max.
62-64

82 INSPECTION / REPAIR
03UOB2-082
13UOB2-0.
1
9MUOB2-112
I
03UOB2-08:
8. Measure the height @of each valve guide. Replace the
valve guide if necessary.
Height: 18.3-l 8.9mm (0.720-0.744 in)
Replacement of valve guide
Note
l The valve guides are different between intake and
exhaust sides, use the correct valve guide.
Removal
1. Remove the valve guide from the side opposite the com-
bustion chamber with the
SST.
Installation
1. Assemble the SST so that depth L is as specified.
Depth L: 18.3-18.9mm (0.720-0.744 in)
2. lighten the locknut.
3. Tap the valve guide in from the side opposite the combus-
tion chamber until the
SST contacts the cylinder head.
4. Verify that the valve guide height is within specification.
5. If not within specification, repeat Steps 1-4.
82-56