oil change MAZDA PROTEGE 1992 Workshop Manual

ENGINE TUNE-UP PROCEDURE Bl
Tightening torque
@ : 37-52 N,m (3.8-5.3 m-kg, 27-38 ft-lb)
@ : 19-25 Nsm (1.9-2.6 m-kg, 14-19 ft-lb)
23UOBl-OC
P/S belt, P/S + A/C belt
If necessary, loosen the P/S oil pump bolts @and nut @and
Oand adjust the belt deflection by turning the adjusting bolt
0.
Tightening torque
@I : 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)
@ : 19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
0: 31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
A/C belt
If necessary, loosen the locknut @and adjust rhe belt deflec-
tion by turning the adjusting bolt @.
Tightening torque:
31-34 N-m (3.2-3.5 m-kg, 23-25 ft-lb)
1
HLA
Problem Possible Cause Action
1. Noise when engine is started immedi- Oil leakage in oil passage Run engine 2000-3000 rpm.
ately after oil is changed. If noise stops after 2 second-10
2. Noise when engine is started after set- minutes(*), HLA is normal.
ting approx. one day. If not, replace HLA.
3. Noise when engine is started after Oil leakage in HLA - * Time required for engine oil to circu-
cranking for 3 seconds or more. late within engine, includes tolerance
4. Noise when engine is started after for engine oil condition and ambient
new HLA is installed. temperature.
5. Noise continues more than 10 minutes Insufficient oil pressure Check oil pressure.
If lower than specification, check for
cause.
Oil pressure; 294-392 kPa
(3.0-4.0 kg/cm*, 43-57 psi)-3000 rpm
(Refer to page 81-60)
Press down HLA by hand.
If it does not move,. HLA is normal.
If it moves, replace HLA.
t
I
Measure valve clearance.
If more than Omm (0 in), replace HLA.
5. Noise occurs durning idle after high-
speed running Incorrect oil amount
Deteriorated oil Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
23UOBl-01
Bl-7

ENGINE TUNE-UP PROCEDURE 92
23UOB2-OC
DRIVE PULLEY
I I
2311082.010
HLA
I Problem
1. Noise when engine is started immedi-
ately after oil is changed.
2. Noise when engine is started after set-
tina aporox. one dav.
3. Noise when engine is started after
cranking for 3 seconds or more.
4. Noise when engine is started after
new HLA is installed.
5. Noise continues more than 10 minutes
6. Noise occurs durning idle after high-
“”
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-16 ft-lb)
(4) Tighten mounting bolt @.
Tightening torque:
37-52 N#rn (3.6-5.3 m-kg, 27-36 ft-lb)
(5) Recheck the belt tension or deflection.
2. P/S belt, P/S + A/C belt
(1) Loosen the P/S oil pump bolt @and nuts @, 0.
(2) Adjust the belt tension and deflection by turning the ad-
justing belt 0.
(3) Tighten the adjusting lock nut @J and the P/S oil pump
bolt @ and nut 0.
Tightening torque
@: 36-54 N-m (3.7-5.5 m-kg, 27-40 ft-lb)
@ : 19-25 N*m (1.9-2.6 m-kg, 14-19 ft-lb)
0: 31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb) Possible Cause
Oil leakage in oil passage
Oil leakage in HLA
Insufficient oil pressure
Faulty HLA
Incorrect oil amount
Deteriorated oil Action Run engine 2000-3000 rpm.
If noise stops after 2 second-10
minutes(*), HLA is normal.
If not, replace HLA.
* Time required for engine oil to circu-
late within engine, includes tolerance
for engine oil condition and ambient
temperature.
Check oil pressure.
If lower than specification, check for
cause. Oil pressure; 294-392 kPa
(3.0-4.0 kg/cm’, 43-57 psi)-3000 rpm
(Refer to page 82-60)
Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.
If more than Omm (0 in), replace HLA.
Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
2311082-01
B2-7

TROUBLESHOOTING GUIDE
DIAGNOSTIC INDEX
No. TROUBLESHOOTING ITEM DESCRIPTION
1 Will not crank or cranks slowly Refer to Engine Electrical System PAGE
G- 4
Engine cranks at normal speed but shows no sign of 1 F-30
Engine cranks at normal speed but shows only par-
I
tial combustion and will not continue to run
Engine starts normally when cold, but will not start af-
After warm-up
5 Cranks normally but
Always
hard to start Engine cranks at normal speed but requires exces-
sive cranking time before starting F-36
F-38
I----
F-40 Same condition as No.5 when engine cold
Restarts normally after warm-up
Same cond;ion as No.5 after running and hot
soaked
Starts normally when cold
8
H
Rough idle
9 (Low idle speed)/
Engine stalls at idle Enaine stalls or vibrates excessivelv at idle
Engine stalls or vibrates excessively at idle during
warm-up 1 F-42
F-44
Engine runs normally at idle during warm-up but
vibrates excessively or stalls after warm-up
Engine stalls or vibrates excessively at idle when
A/C, P/S, or E/L ON F-46
F-46
starting (acceleration from idle)
l---- Engine stalls or vibrates excessively only just after
Idle speed excessive after warm-up 1 F-50 F-49 12 Rough idle/Engine stalls just after starting
13 High idle speed after warm-up
1 14 1 Idle moves up and down/Idle hunting Engine speeds up and down periodically at idle
1 F-52
I l5 I Engine stalls on deceleration
Engine unexpectedly stops running while decelerat-
ing or after deceleration F-54
Engine intermittently stops running
Flat spot occurs just after accelerator depressed or
mild jerkrng occurs during acceleration
Unexpected change in engine speed which is usually
repetitive F-56
F-57
F-59 16 Engine stalls suddenly (Intermittent)
17 Hesitates/Stumbles on acceleration
1 18 1 Surges while cruising
19
I I
Lack of power Performance poor under load when throttle valve F-61
wide open
Maximum speed reduced
Performance poor-while accelerating
-I- F-65 20 Poor acceleration
21 Runs rough on deceleration/Backfire Engine runs rough while decelerating and abnormal
combustion occurs in exhaust system F-69
Abnormal combustion accompanied by audible
“pinging” noise
Gasoline odor in cabin 22 Knocking
23 Fuel odor
24 Exhaust sulfur smell
26 High oil consumption Exhaust gas smells abnormal
Oil consumption excessive
Fuel economy unsatisfactory 1 26 1 Poor fuel economy 1 F-75
Self-Diagnosis Checker does not indicate malfunction
23UOFX~O’
F-27

TROUBLESHOOTING GUIDE F
DAMAGE AND
DETERIORATION
Check if resistance of high-tension leads are OK Resistance: 16 kQ per 1 m (3.26 ft)
li;;g
‘&
d No
Replace
.
12 Check if resistance of ignition coil is OK Yes Go to next step c7 page G-19
Resistance (at 20°C [6SaF]):
Primary coil winding . . . . . . . . 0.61-0.99n
Secondary coil winding.... lo-16 kdl
PRIMARY COIL SECONDARY COIL
WINDING
WINDING
No
Replace
13 Check for correct engine compression Yes Go to next step u page Bl-10
92-10 No
Check engine condition ~7 page 81-10
Engine compression: 82-l 0
. BP DOHC
*Worn piston, piston rings or cylinder 663 kPa (9.0 kg/cm2, 126 psi)-300 rpm wall
l BP SOHC l Defective cylinder head gasket 634 kPa (6.5 kg/cm2, 121 psi)-300 rpm l Distorted cylinder head
l 66 l improper valve seating 932 kPa (9.5 kg/cm2, 136 psi)300 rpm *Valve sticking in guide
14 Change fuel and check if condition improves Yes Change fuel to another brand
No SOHC
Go to Step 16 DOHC
Go to next step
F-63

F TROUBLESHOOTING GUIDE
I 24 I EXHAUST SULFUR SMELL I
DESCRIP-
l Exhaust gas smells abnormally
TION
[TROUBLESHOOTING HINTS]
High sulfur content fuel used
STEP INSPECTION
1
Change fuel to another brand ACTION
03UOFX-039
25 HIGH OIL CONSUMPTION
DESCRIP-
l Oil consumption excessive
TION
[TROUBLESHOOTING HINTS]
@ PCV system malfunction
@ Engine malfunction (Oil working up, working down, or leakage)
iTEP
INSPECTION
1 Check if PCV hose, ventilation hose or their at- Yes Repair or replace
taching nipples are separated, damaged,
clogged, or restricted
w page F-138 No Go to next step
2 Check if air pressure or oil is present at ventila- Yes Go to next step
tion hose ACTION
No Check engine condition w page 81-3
82-3
l Oil leakage
*Worn valve seal
*Worn valve stem
*Worn valve guide
3 Check if vacuum is felt at PCV valve at idle Yes Check engine condition w page 91-3
w page F-138 82-3
*Worn piston ring groove
*Stuck piston rings l
Worn piston or cylinder
No Replace PCV valve
23UOFX-040 /-.
F-74

F ENGINE TUNE-UP
ENGINE TUNE-UP
PREPARATlON
SST
I
I I
49 BO19 9AO
System Selector For
inspection of igni-
tion timing and
idle speed
hA ‘I
03UOFX-04
03UOFX-04
03UOFX-04
NG POINT
03UOFX-04 03UOFX-045
BASIC INSPECTION
Engine Oil
1. Remove the engine oil level gauge and check the engine
oil level and oil condition.
2. Add or change the oil as necessary.
Coolant
Warning
l Never remove the radiator cap while the engine is
hot.
l Wrap a thick cloth around the cap before carefully
removing it.
1. Remove the coolant level gauge from the coolant reservoir.
2. Check that the coolant level is between the L and F marks
of the gauge.
3. Add coolant if necessary.
Battery
1. Check for corrosion on the terminals and for loose cable
connections. If necessary, clean the clamps and tighten
them firmly.
2. Check that the electrolyte level is between the UPPER LEV-
EL and LOWER LEVEL marks.
3. Add distilled water if necessary.
4. Check the specific gravity with a hydrometer.
Gravity: 1.27-l .29 (at 20% [68OF] )

Jl TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Problem
Shift lever won’t shift
smoothly or is hard
to shift
Too much play in
shift lever
I------
Difficult to shift
Won’t stay in gear
Abnormal noise
I
Possible cause
Seized shift lever ball
Seized change control rod joint
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
Worn shift lever ball bushing
Bent change rod
No grease in transaxle control
Insufficient oil
Deterioration of oil quality
Wear or play of shift fork or shift rod
Worn synchronizer ring
Worn synchronizer cone of gear
Bad contact of synchronizer ring and cone of gear
Excessive longitudinal play of gears
Worn bearing
Worn synchronizer key spring
Excessive primary shaft gear bearing preload
improperly adjusted change guide plate
Bent change control rod
Worn change control rod bushing
Weak shift lever ball spring
improperly installed extension bar
Worn shift fork
Worn clutch hub
Worn clutch hub sleeve
Worn gear sliding part of both shaft gears
Worn gear sliding part of each gear
Worn steel sliding groove of control end
Weak spring pressing against steel ball
Excessive thrust clearance
Worn bearing
Improperly installed engine mount
Insufficient oil
Deterioration of oil quality
Worn bearing
Worn sliding surfaces of gears or shafts
Excessive gear backlash
Damaged gear teeth
Foreign material in gears
Damaged differential gear or excessive backlash Remedy Replace
Replace
Replace
Replace
Replace
Replace
Replace
Lubricate with grease
Add oil
Replace with oil of
specified quality
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Replace
Replace
Replace
Tighten
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Tighten
Add oil
Replace
Adjust or replace
Replace
Replace
Replace with oil of
specified quality
Replace
Adjust or replace Page Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl-56
Jl- 7
Jl- 7
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-36
Jl-17
Jl-56
Jl-56
Jl-56
Jl-56
Jl-14
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-14
Jl-14
Jl-22, 24
Jl-22, 24
Jl-48
Jl- 7
Jl- 7
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-22, 24
Jl-53
03UOJl-OC --
-../
51-6

TRANSAXLE Jl
Clutch Housing and Transaxle Case Components
Caution
l Do not remove oil seals unless necessary.
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
-
.ACE
23UOJl-O(
1. Speedometer driven gear 17. Boot 28. Adjust shim
assembly 18. Oil seal (Change rod) 29. Adjust shim
2. Oil seal (Differential) Disassembly Note 30. Bearing outer race
Disassembly Note ,.,,,..,............. page Jl-18 (Differential)
..................... page Jl-19 19. Bushing Disassembly Note
Replacement (On-vehicle) 20. Oil seal (Primary shaft) ..................... page Jl-19
.....................
page Jl-20 Disassembly Note 31. Adjust shim (Differential)
3. Pivot ..................... page Jl-19 Disassembly Note
4. Bleeder 21. Bearing outer race ..................... page Jl-19
5. Bleeder cover Disassembly Note 32. Transaxle case
6. Gasket ..................... page Jl-18 33. Roll pin
7. Roll pin 22. Funnel 34. O-ring
8. Blind plug Disassembly Note 35. Driven gear
Disassembly Note ..................... page Jl-18 36. Packing
..................... page Jl-18 23. Bearing outer race 37. Oil seal
9. Reverse lever shaft (Differential) (Speedometer gear cace)
Disassembly Note Disassembly Note Disassembly Note
..................... page Jl-18 ..................... page Jl-19 ..................... page Jl-19
10. Lever set spring 24. Clutch housing 38. Gear case
11. Reverse lever 25. Oil passage 39. Joint
Inspection ....... page Jl-27 26. Oil seal (Differential) 40. Change rod
12. Guide plate assembly Disassembly Note
13. Roll pin ..................... page Jl-19
14. Selector Replacement (On-vehicle)
15. Change arm ..................... page Ji-20
16. Change rod assembly 27, Bearing outer race
Jl-17

Jl TRANSAXLE
03UOJl-025
Disassembly note
Blind plug
1. Remove the roll pin with pliers.
03UOJi-027
03UOJ 1.029
Jl-18
Reverse lever shaft
1. Protect the reverse lever shaft with a rag and remove the
shaft with pliers.
Oil seal (Change rod)
1 .Remove the oil seal with a screwdriver.
Funnel and bearing outer race (Secondary shaft)
Note
l Remove the bearing outer race with a screwdriver
if necessary.
1) Insert a screwdriver between the clutch housing
and bearing outer race.
2)Pt-y the bearing outer race free.
03UOJl-028
1. Remove the bearing outer race by lifting out the funnel and
race together.

TRANSAXLE

I
\m/ 7.8-11 N-m
1. Change
rod
2. Joint
3. Bearing outer race
4. Funnel
Assembly Note 11. Oil passage
29. Guide plate assembly
12. Oil
seal (Differential) 30.
Gear case
Assembly Note 31, Oil seal
,.................... page Jl -41 (Speedometer gear cace)
13. Transaxle case Assembly Note
. . . . . . . . . . . . . . . . . . . . .
page Jl-42
5. Bearing outer race
Assembly Note
. . . . . . . . . . . . . . . . . . . . . page Jl-42
6. Bearing outer race
(Differential)
Assembly Note
. . . . . . . . . . . . . . . . . . . . . page Jl-41
7. Adjust shim (Differential)
Assembly Note
. . . . . . . . . . . . . . . ...*.. page Jl-41
8. Bearing outer race
(Secondary shaft gear)
Assembly Note
,..*.,...............
page Jl -41
9. Adjust shim
(Secondary shaft gear)
Assembly Note
. . . . . . ...*. . . . . . . . . . . page Jl-41
IO. Adjust shim
(Primary shaft gear)
Assembly Note
14. Reverse lever . . . . . . . . . . . . . . . . . . . . . page Jl-41
15. Lever set spring 32. Packing
16. Reverse lever shaft 33. O-ring
17. Roll pin 34. Drive gear
18. Blind plug 35. Roll pin
19. Oil seal (Primary shaft gear) (Speedometer driven gear
Assembly Note assembly)
. . . . . . . . . . . . . . . . . . . . . page Jl-42 Assembly Note
20. Gasket ..,......*. ..,,...... page Jl-41
21. Bleeder cover 36. Speedometer driven gear
22. Bushing assembly
23. Oil seal (Change rod) 37. Bleeder
Assembly Note 38. Pivot
..,..,...,........... page Jl-42 39. Oil seal (Differential)
24. Boot Assembly Note
Assembly Note . . . . . . . . . . . . . . . . . ...* page Jl-41
.,.,.,............... page Jl-42 40. Clutch housing
25. Change rod
Assembly Note
. ..*.................
page J l-42 .,................... page Jl-42
26. Change arm
27. Selector
28. Roll pin
Jl-36