water pump MAZDA PROTEGE 1992 Workshop Manual

Bl TROUBLESHOOTING GUIDE
Problem
Insufficient power
Abnormal
combustion
Engine noise Possible Cause
Insufficient compression
Malfunction of HLA*
Compression leakage from valve seat
Seized valve stem
Weak or broken valve spring
Failed cylinder head gasket
Cracked or distorted cylinder head
Sticking, damaged, or worn piston ring
Cracked or worn piston Malfunction of fuel system
Malfunction of ignition system
Others
Slipping clutch
Dragging brakes
Wrong size tires Malfunction of engine-related components
Malfunction of HLA’
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber Malfunction of fuel system
Malfunction of ignition system
Crankshaft- or bearing-related parts
Excessive main bearing oil clearance
Main bearing seized or heat-damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil clearance
Connecting rod bearing seized or heat-damaged Piston-related parts
Worn cylinder
Worn piston or piston pin
Seized piston
Damaged piston ring
Bent connecting rod Valves or timing-related parts
Malfunction of HLA*
Broken valve spring
Excessive valve guide clearance Malfunction of cooling system
Malfunction of fuel system
Others
Malfunction of water pump bearing
Improper drive belt tension
Malfunction of alternator bearing
Exhaust gas leakage
Malfunction of timing belt tensioner Action
Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section F
Refer to Section G
Refer to Section H
Refer to Section P
Refer to Section Q
Replace
Replace
Replace
Eliminate carbon
Refer to Section F
Refer to Section G
Replace or repair
Replace
Replace or repair
Replace or repair
Replace
Replace or repair
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section E
Refer to Section F
Refer to Section E
Adjust
Refer to Section G
Refer to Section F
Replace Page 81-20
Bl-57
81-55
81-58
81-16
81-54
81-62
al-62
81-20
81-55
81-58
-
61-71
Bl-64
81-72
81-73 8-i-64
Bl-60
81-63
81-62
81-62
El-63
Bl-20
El-58
81-55
Bl- 5
81-12
911 IORI .N)J LI.,“l. --
* Tappet noise may occur if the engine has set idle for an extended period. The noise should
normal operating temperature. (HLA troubleshooting: Refer to page Bl-7) dissipate after the engine has reached
81-4

Bl ON-VEHICLE MAINTENANCE
TIMING BELT
Removal / Installation
1. Disconnect the negative battery cable.
2. Raise the vehicle on a lift and remove the right front wheel.
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.
7.6-11 N.m
[SO-110 cm-kg, 69-95 in-lb)

7.6-11 N.m
(60-l 10 cm-kg,
0 69-95 in-lb)
, .v- I . (60-110 cm-kg, 69-95 in-lb)
157-167 (16-17, 116-123) /@ 7.i11 N.m
(60-110 cm-kg,
69-95 in-lb)
N.m (m-kg, ft-lb]
23UOBl-01
1. Under cover and side cover 10. Timing belt cover, lower
2. P/S and/or A/C drive belt 11. High-tension leads
3. Alternator drive belt 12. Spark plugs
4. Water pump pulley 13. Timing belt
5. Plate Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-13
6. Pulley lock bolt Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-13
Removal Note ..,.,,.,....,....,...,...,, page Bl-13 14. Tensioner
installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-14 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 81-13
7. Crankshaft pulley 15. Tensioner spring .__
8. Pulley boss Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 61-13
9. Timing belt cover, upper
131-12

ON-VEHICLE MAINTENANCE Bl
I. Air hose assembly 1 I. Timing belt cover, upper
2. Resonance chamber 12. Timing belt
3. Accelerator cable Removal / Installation.. . . . . . . . . . . . . . . page Bl-12
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page BI-I9 13. Front exhaust pipe
4. Throttle cable (ATX)
14. Intake manifold bracket
Removal / Installation . . . . . . . . . . . . . . . . . . . . . Section K 15. Cylinder head bolt
5. Hoses Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page BI-18
Removal I Installation Note ..,............... below Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-I9
6. Harnesses 16. Cylinder head
Removal I Installation Note....... page BI-I8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 61-43
7. Water bypass pipe nut
Inspection . . , . . . . . . . . . . . . . . . . . . . . . . . . . ., . . page BI -54
8. Drive belt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page BI-79
9. Water pump pulley 17. Cylinder head gasket
10. Cylinder head cover
23UOBl-019
Removal / Installation note
Hoses
I. Disconnect the hoses shown in the figure.
\ / DlSCOtjNECT
, w I.,,, -----. WARNING ’ ’ ’ l KEEP SPARKS AND OPEN FLAME AWAY FROM THE FUEL
AREA.
CAUTION
l COVER THE HOSE WITH A RAG BECAUSE FUEL WILL
SPRAY OUT WHEN DISCONNECTING.
. PLUG THE DISCONNECTED HOSES TO AVOID FUEL
LEAKAGE.
I. Brake vacuum hose
2. Fuel hose
3. Vacuum hose (Purge control) 4. Vacuum hose (Cruise control)
5. Heater hose

DISASSEMBLY Bl
TIMING BELT
23UOBl-032
1. Water pump pulley
2. Crank shaft pulley bolt 6. Crankshaft pulley boss
3. Plate 7. Timing belt cover, upper
4. Pulley lock bolt 8. Timing belt cover, lower
9. Timing belt
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page Bl-42
Disassembly
Note . . . . . . . . . . . . . . . . . . . . page
81-42
5. Crankshaft pulley
10. Tensioner and tensioner spring
Bl-41

DISASSEMBLY Bl
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the fiaure, referrina to Disassembly Note.
.-.
1. Water pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
2. Timing belt pulley and lock bolt
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl -65
3. Clutch cover, clutch disc (MTX)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
4. Flywheel (MTX)
Disassembly Note . . . . . . . . . . . . . . . . . . . page 81-48
Inspect for wear or damage
5. Backing plate, drive plate, and adapter (ATX)
Disassembly Note ..,.....,.,........, page 81-48
6. End plate 7. Oil pan and gasket
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Inspect for damage
8. Oil strainer
9. Main bearing support plate (MBSP)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-49
Inspect for damage
10. Oil pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
11. Front oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
12. Rear cover
13. Rear oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Bl-47

ASSEMBLY
23UOBi-08
0311081-14
Drive Plate (ATX)
1. Remove the sealant from the drive plate bolt holes in the
crankshaft and from the drive plate bolts.
Caution
l If all the previous sealant cannot be removed from
a bolt, replace the bolt.
l Do not apply sealant if a new bolt is used.
2. Install the adapter, drive plate, and backing plate onto the
crankshaft.
3. Apply sealant to the drive plate bolts and install them.
4. Hold the drive plate with the
SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)
Water Pump
1. Remove all foreign material from the water pump mount-
ing surface.
2. Place a new water pump gasket in position.
3. Install the water pump.
Tightening torque:
19-25 N,m (1.9-2.6 m-kg, 14-19 ft-lb)
81-78

Bl ASSEMBLY
1IMING
COVER
Timing Belt Cover
1. Install the lower and upper timing belt covers and new
gaskets.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
Crankshaft Pulley
1. Install the pulley boss.
01 EOBX-164
2. Mount the SST or equivalent and tighten the pulley lock bolt.
Tightening torque:
157-167 N,m (16-17 m-kg, 116-123 ft-lb)
3. Remove the SST or equivalent,
4. Install the crankshaft pulley.
5. Install the plate.
Tightening torque:
12-17 N*m (1.25-l .75 m-kg, 109-152 in-lb)
Water Pump Pulley
1. Install the water pump pulley.
Tightening torque:
7.8-11 N,m (80-110 cm-kg, 69-95 in-lb)
I
I OSJOBX-236
Bl-88

B2 TROUBLESHOOTING GUIDE
Problem
Insufficient power
Abnormal
combustion
Engine noise -
I
I
f
,
I
I
,
I
I Possible Cause Action Page
Insufficient compression
Malfunction of HLA*
Compression leakage from valve seat
Seized valve stem
Ueak or broken valve spring
Failed cylinder head
gasket Cracked or distorted cylinder head
Sticking, damaged, or worn piston ring
Cracked or worn piston Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section F 82-22
82-57
02-55
B2-58
82-16
82-54
82-62
82-62 Malfunction of fuel system
Malfunction of ianition svstem
Others
Slipping clutch
Dragging brakes
Wrong size tires Malfunction of engine-related components
Malfunction of HLA*
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber Malfunction of fuel system
Malfunction of ignition system
Crankshaft- or bearing-related parts
Excessive main bearing oil clearance
Main bearing seized or heat-damaged
Excessive crankshaft end play
Excessive connecting rod bearing oil clearance
Connecting rod bearing seized or heat-damaged Piston-related parts
Worn cylinder
Worn piston or piston pin
Seized piston
Damaged piston ring
Bent connecting rod Valves or timing-related parts
Malfunction of HLA*
Broken valve spring
Excessive valve guide clearance Malfunction of cooling system
Malfunction of fuel svstem
Others
Malfunction of water pump bearing Refer to Section E
Improper drive belt tension Adjust
Malfunction of alternator bearing Refer to Section G
Exhaust gas leakage Refer to Section F
Malfunction of timing belt tensioner Replace Refer to Section G
Refer to Section H
Refer to Section P
Refer to Section C!
Replace B2-22
Replace 82-55
Replace 82-58
Eliminate carbon -
Refer to Section F
Refer to Section G
Replace or repair B2-70
Replace 82-64
Replace or repair 82-7 1
Replace or repair B2-72
Replace B2-64
Replace or repair
82-60
Replace 82-63
Replace 82-62
Replace 82-62
Replace 82-63
Replace
Replace
Replace
Refer to Section E
Refer to Section F 82-22
82-58
82-55
B2- 6
82-12
23UOB2-00,
..J
.-,
l
Tappet noise may occur if the engine has set idle for an extended period. The noise should dissipate after the engine has reached
normal operating temperature. (HLA troubleshooting: Refer to page 82-7.)
82-4

B2 ON-VEHICLE MAINTENANCE
TIMING BELT
Removal / Installation
1. Disconnect the negative battery cable.
2. Raise the vehicle on a lift and remove the right front wheel.
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
(80-l 10 Cm-kg, 69-95 in-lb
1p1\ ’ (3.8-6.3, 2738)
, (80-l 10 cm-kg, 69-95 in-lb)
167--187 (X-17, 116-123)
/ 7.8--11 N-m
(80-110 MI-kg,
7.8-11 N-m
\-
(80-110 Cm-kg, 69-95 in-lb)

12-17 (1.25-1.75, 9-13)
N-m (m-kg, &lb
23UOl32-0
1. Under cover and side cover 11. Timing belt cover, lower
2. P/S and/or A/C drive belt 12. Pulley lock bolt
3. Alternator drive belt Removal Note . . ..*..........*.*......... page 82-13
4. Water pump pulley Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-14
5. Plate 13. Pulley boss
6. Crankshaft pully 14. Timing belt
7. Spark plugs Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 62-13
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 62-15 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-14
8. Oil dip stick 15. Tensioner and tensioner spring ..l
9. Timing belt cover, upper Installation Note ..,..................... page B2-14
10. Timing belt cover, middle 16. Idler
B2-12

ON-VEHICLE MAINTENANCE B2
1. Under cover and side cover
2. Resonance chamber
3. Air hose
4. Accelerator cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-21
5. Throttle cable (ATX)
Removal I Installation . . . . . . . . . . . . . . . . . . . . . Section K
6. High-tension lead
7. Hoses
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-21
8. Harnesses
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-18
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-21
9. Water bypass pipe
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-18
10. P/S and/or A/C drive belt
Removal / Installation . . . . . . . . . . . . . . . . page B2- 6
11. Alternator drive belt
Removal / Installation . . . . . . . . . . . . . . . . page B2- 6 12. Water pump pulley
13. Timing belt cover, upper
14. Timing belt cover, middle
15. Spark plug
16. Timing belt
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-l 8
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-20
17. Front exhaust pipe
18. Intake manifold bracket
19. Cylinder head cover
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 82-19
20. Cylinder head bolt
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-19
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-19
21. Cylinder head
Disassembly . . . . . . . . . . . , . . . . . . . . . . . . . page B2-45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-79
22. Cylinder head gasket
23UOB2-021
Removal / Installation note
Hoses
1. Disconnect the hoses shown in the figure.
VACUUM HOSE BRAYE VACUUM HOSE
‘-;:I::------. CAUT’oN
l COVER THE HOSE WITH A RAG BECAUSE FUEL WILL
SPRAY OUT WHEN DISCONNECTING.
- PLUG THE DISCONNECTED HOSES TO AVO!D FUEL
LEAKAGE.
OWOBX-03
82-l i