oil level 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

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

7 Schedule (Cont’d)
rile
iii
48
30
-
R
I
R !rs
25
40
25
-
-i- , whichever comes first
OPERATION MAINTENANCE Number of m
INTERVALS Months
x 1,000 km
x 1,000 miles
ii
is
G
-
i-
-
-
I
5-
T
-
-
-
-
-
-
- ii
z
ro
-
I-
-
-
I
- 45
72
45
-
-i-
-
-
I
-
ry 15 month:
I I I
A
t
A
j
milt Service data and inspection points Page
l Capacity
MTX B6, BP SOHC:
2.68 liters (2.83 US qt, 2.36 Imp qt)
BP DOHC
3.35 liters (3.55 US qt, 2.96 Imp qt)
ATX: 6.3 liters (6.7 US qt, 5.5 Imp qt)
l Level and condition
- Jl-7
J2-7
- Transaxle oil
l Wear and damaae -i- -i- -i- -
Brake fluid, clutch fluid
Brake fluid*3 -
Q-3, 5
Q-6
N-27
P-28
P-29 I I
- I
1,oo
-i
-
-
-
-
-
-
- I
G
T
-
-
-
-
-
-
- I
15,(
I Tire inflation pressure and wear l Proper pressure-
-
l Level and condition
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. 3s) or f
I I
I
:t r
- Rotate tires
Power steering fluid
Drum brake ? every
I I
Disc brake I I
Maximum 201mm (7.91 in)
l Caliper operation l Disd plate thickness:
Minimum Front.... 20mm (0.79 in)
Rear . . . . . 7.0mm (0.28 in)
l Pad thickness:
Minimum Front.... 2.0mm (0.08 in) P-20
P-25
P-l 8
P-25
N-27
N-8 Rear . . . . . 1 .Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozina
l Free play.... O--3OmmjO-1.18 in)
l Damage looseness and grease leakage
l Cracking and damage
l Insulator clearawp .-v
-
Steering operation and linkage
I
-i-
-I-
-i- Front suspension ball joint
Drive shaft dust boots
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor
Suspension components (front and rear)
All chassis and body nuts and bolts
All locks and hinaes
Washer fluid -
M-21
F-136
u-35
u-39
-
- IY efrigerant amount ann
*. I# mspec
Inspect operation annualry -
l Damaae
l Retighten all loose nuts and bolts
l Lubricate all locks and hinges
l Level
l ODeration - Function of all lights l !%t and damage -

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

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

.
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

Bl DISASSEMBLY
AUXILIARY PARTS
1. Drain the engine oil.
2. Disassemble in the order shown in the figure.
- REPLACE - ’ ,/ I’

1. Distributor and high-tension lead
2. Intake manifold assembly
3, Alternator and drive belt
4. Alternator bracket
5. No.3 engine mount bracket 6. Oil filter
7. Oil pressure switch
8. Spark plug
9. Oil level gauge and pipe 10. Engine hanger
61-40

INSPECTION / REPAIR Bl
.-J-
03UOBl-11
05UOBX-1:
OWOBX-15 4
il
2
3
_I
5
OWOBX-15:
03UOBl-11:
4. Measure the cylinder bores in X and Y directions at three
levels (A, B, and C) in each cylinder as shown.
Cylinder bore mm h-d
I I B6 SOHC I BP SOHC ’ ‘I
,r jtanciard 1 78.006-78.013 1 83.006-83.013
(3.0711-3.0714) (3.2679-3.2682)
0.25 (0.010) oversize 78.256-78.263 83.256-83.263
(3.0809-3.0812) (3.2778-3.2781)
I 0.50 (0.020) oversize 78.506-78.513 83.506-83.513
(3.0908-3.0911) (3.2876-3.2879)
I
Caution
l The boring size should be based on the size of an
oversize piston and be the same for all cylinders.
(1) If the cylinder bore exceeds the maximum, rebore the
cylinder to oversize.
(2) If the difference between measurements A and C ex-
ceeds the maximum taper, rebore the cylinder to
oversize.
Taper: 0.019mm (0.0007 in) max.
(3) If the difference between measurements X and Y ex-
ceeds the maximum out-of-round, rebore the cylinder
to oversize.
Out-of-round: 0.019mm (0.0007 in) max.
5. If the upper part of a cylinder wall shows uneven wear, re-
move the ridge with a ridge reamer.
OIL JET (BP SOHC)
1. Push the check ball and verify that it moves smoothly.
2. Blow through the oil jet and verify that air flows.
81-61

Bl ASSEMBLY
05UOBX-24:
Spark Plug
1. Install the spark plugs.
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 1 I-17 ft-lb)
Oil Level Gauge
1. Install the oil level gauge.
Oil Pressure switch
1. Install the oil pressure switch.
Tightening torque:
12-18 N-m (120-180 cm-kg, 104-158 in-lb)
Oil Filter
1. Remove all foreign material from the oil filter mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil filter.
3. Install the oil filter and tighten it by hand until the rubber
seal contacts the base.
4. Tighten the filter 1 and l/6 turns with a filter wrench.
No.3 Engine Mount Bracket
1. Install the No.3 engine mount bracket.
Tightening torque:
93-l 13 N-m (9.5-l 1.5 m-kg, 89-83 ft-lb)
Alternator
1. Install the alternator strap.
Tightening torque:
37-52 N#m (3.8-5.3 m-kg, 27-38 ft-lb)
2. Install the alternator and alternator drive belt. Loosely tight-
en the alternator installation bolt.
3. Adjust the drive belt deflection. (Refer to page Bl-6.)
Tightening torque
Alternator installation bolt @ :
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
Belt-adjusting bolt @ :
19-25 N#m (1.9-2.8 m-kg, 14-19 f&lb) --’ I
I 0311081-165
Bl-90