width MAZDA PROTEGE 1992 Workshop Manual

INSPECTION / REPAIR Bl
-- 05lJOBX-13
.- __--- 0
-_.--__I__
--
05UOBX.131
B6 SOHC
EX
IN
BP SOHC --~ -____
03uoEI-09
--__.
86 SOHC -
23UOBl-073
Valve Seat
1, Inspect the contact surface of each valve seat and valve
face for the following:
(1) Roughness.
(2) Damage.
2. If necessary, resurface the valve seat with a 45O valve seat
cutter and/or resurface the valve face.
3. Apply a thin coat of Prussian blue to the valve face.
4. Inspect the valve seating by pressing the valve against the
seat.
(1) If blue does not appear 360° around the valve face, re-
place the valve.
(2) If blue does not appear 360° around the valve seat,
resurface the seat
5. Measure the seat contact width.
Width
mm (in)
96 SOHC BP SOHC
IN l.l--1.7 0.8-l .4
(0.043-0.067) (0.031-0.055)
EX 1.1-1.7 0.8-l .4
(0.043-0.067) (0.031-0.055)
6. Verify that the valve seating position is at the center of the
valve face.
B6 SOHC
(1) If the seating position is too high, correct the valve seat
with a 75O (IN) or 70° (EX) cutter and a 45O cutter.
(2) If the seating position is too low, correct the valve seat
with a 35O (IN) or 15O (EX) cutter and a 45O cutter.
BP SOHC
(1) If the seating position is too high, correct the valve seat
with a 70° cutter and a 45O cutter.
(2) If the seating position is too low, correct the valve seat
with a O” cutter and a 45O cutter.
7. Seat the valve to the valve seat with lapping compound.
8. Inspect the sinking of the valve seat.
Measure the protruding length (dimension L) of the valve
stem.
Dimension L
B6 SOHC: 39mm
(1.5354 in) mm fin

Bl ASSEMBLY
05UOBX-18s
WIDTH
05lJOBX-l!
, MATCHING MARKS’,
03UOBl-1;
4. Tighten the main bearing cap bolts in two or three steps
in the order shown in the figure.
Tightening torque:
54-59 N.m (5.5-6.0 m-kg, 40-43 ft-lb)
5. Measure the crankshaft end play.
End play : 0.060-0.262mm (0.0031-0.0111 in)
Maximum: 0.30mm (0.012 in)
6. If the end play exceeds the maximum, grind the crankshaft
and install an oversize thrust bearing or replace the crank-
shaft and thrust bearing.
Thrust bearing width
Standard:
2.500-2.550mm (0.0964-0.1004 in)
0.25mm (0.010 in) oversize:
2.625-2.675mm (0.1033-0.1053 in)
0.50mm (0.020 in) oversize:
2.750-2.600mm (0.1063-0.1102 in)
0.75mm (0.030 in) oversize:
2.675-2.925mm (0.1132-0.1152 in)
Piston and Connecting Rod Assembly
Caution
l Protect the connecting rod bolts with rubber sleeves
to prevent damage to the crankpin journals.
OSUOBX-192
Connecting Rod Cap
1. Measure the connecting rod bearing oil clearances using
the same procedure as for the main bearing oil clearance.
Caution
l Align the matching marks on the cap and the con-
necting rod when installing the connecting rod cap.
Tightening torque:
47-52 N-m (4.6-5.3 m-kg, 35-36 ft-lb)
. . . . . . . . . . . . . . . . . . .
B6 SOHC
49-51 N.m (5.0-5.2 m-kg, 36-36 ft-lb)
. . . . . . . . . . . . . . . . . . . BP SOHC .-’
Bi-72

INSPECTION / REPAIR 82
OWOBX-13
SEAT CONTACT WIDTH
I OWOBX-132
IN EX
700
Li!!b!J
700
45O 450
r
----
0311082 Oe
_---- _---
1
05UOBX-1:
Gi
Valve Seat
1, Inspect the contact surface of each valve seat and valve
face for the following:
(1) Roughness.
(2) Damage.
2. If necessarv, resurface the valve seat with a 45’ valve seat
cutter and/br resurface the valve face.
3. Apply a thin coat of Prussian blue to the valve face.
4. Inspect the valve seating by pressing the valve against the
seat.
(1) If blue does not appear 360° around the valve face, re-
place the valve.
(2) If blue does not appear 360° around the valve seat,
resurface the seat.
5. Measure the seat contact width.
Width: 0.8-l .4mm (0.031-0.055 in)
6. Verify that the valve seating position is at the center of the
valve face.
(1) If the seating position is too high, correct the valve seat
with a 70° cutter and a 45O cutter.
(2) If the seating position is too low, correct the valve seat
with a O” cutter and a 45’ cutter.
7. Seat the valve to the valve seat with lapping compound.
8. Inspect the sinking of the valve seat.
B2-57

ASSEMBLY B2
r
03UOB2-09
__~~
05UOBX-188
.
OWOBX-19(
WIDTH
I
05UOBX-19
(7) Remove the main bearing caps, and measure the Plasti-
gage at each journal at the widest point for the smallest
clearance, and at the narrowest point for the largest
clearance.
(8) If the oil clearance exceeds specification, grind the
crankshaft and use undersize main bearings.
(Refer to page B2-64.)
Oil clearance: 0.018-0.036mm (0.0007-0.0014 in)
Maximum: O.lOmm (0.004 in)
2. Apply a liberal amount of clean engine oil to the main bear-
ings, thrust bearings and main journals.
3. Install the crankshaft and the main bearing caps accord-
ing to the cap number and C= mark.
4. Tighten the main bearing cap bolts in two or three steps
in the order shown in the figure.
Tightening torque:
54-59 N*m (5.5-6.0 m-kg, 40-43 ft-lb)
5. Measure the crankshaft end play.
End play : 0.080-0.282mm (0.0031-0.0111 in)
Maximum: 0.30mm (0.012 in)
6. If the end play exceeds the maximum, grind the crankshaft
and install an oversize thrust bearing or replace the crank-
shaft and thrust bearing.
Thrust bearlng width
Standard:
2.500-2.550mm (0.0984-0.1004 in)
0.25mm (0.010 in) oversize:
2.625-2.675mm (0.1033-0.1053 in)
0.50mm (0.020 in) oversize:
2.750-2.800mm (0.1083-0.1102 in)
0.75mm (0.030 in) oversize:
2.875-2.925mm (0.1132-0.1152 In)
B2-71

E OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
B6 SOHC
BP SOHC BP DOHC
MTX
1 ATX 1 MTX ATX 1 MTX
ATX
Cooling system
Water-cooled, forced circulation
Coolant capacity liters (US qt, Imp qt) 5.0 6.0
5.0
(5.3, 4.4) (6.3, 5.3)
(5.35.04.4) (6.zi.3) (5.3, 4.4) (6.::.3)
Water
pump
Thermostat
Radiator
Cooling fan
L Type
Water seal Centrifugal
Unified mechanical seal
Type Opening temperature
‘C (OF’) Wax, two-stage
Main: 86.5-89.5 (188-193)
Sub : 83.5-86.5 (182-188)
Full-open temperature
OC (OF)
Full-open lift mm (in)
Type
Cap valve opening
pressure 100 (212)
Main: 8.0 (0.31) min.
Sub : 1.5 (0.06) min.
Corrugated fin
74-103 (0.75-1.05, 11-15)
kPa (kg/cm2, psi)
Width
Core size Height
mm (in)
Depth
Fin pitch
mm (in) 647 (25.47)
390 (15.35)
16 (0.63) 1 25 (0.98) 1 16 (0.63) 1 25 (0.98) 1 16 (0.63) 1 25 (0.98)
1.3 (0.051)
Heat dissipation capacity
kcallh 1 38,800 [ 43,800 ( 38,800 1 43,800 1 38,800 1 43,800 1
Type
Transaxle Heat
oil cooler dissipation
capacity
kcallh
Tvoe
- Laminated - Laminated -
Laminated
1,700
I .I -?nn
- -
I,,“”
I
I - I 4 Ye,-. I,IVV 1
, a-
- Electric
Number of blades 4
Outer diameter mm (in)
320 (12.6)
Capacity w-v 80-12 1 160-12 ) 80-12 ) 160-12 1 80-12 1 160-12
1 Hi: 13.3+ 1 1 Hi: 13.3+ 1 1 Hi: 13.3+
Current
TROUBLESHOOTING GUIDE I I I I
Problem Possible Cause
Overheating
Coolant level insufficient
Coolant leakage
Radiator fins clogged
Radiator cap malfunction
Cooling fan malfunction
Thermostat malfunction
Water passage clogged
Water puma malfunction .- Remedy Page
Add
Repair
Clean
Replace
Replace
Replace
Clean
Reolace E- 6
E-9
E- 7
E-13
E- 9
E- 6
E-11
I Corrosion
1 Impurities in coolant 1 Replace
I E-6 I
03UOEX-005

OUTLINE
OUTLINE
SPECIFICATIONS
item Specifications
Brake pedal
Master cylinder
Front disc brake
Rear disc brake
Rear drum brake
Power brake unit
Braking force control device
Brake fluid Type Suspended
Pedal lever ratio
I 4.1
I
Max. stroke mm (in) 140 (5.51)
I
Type
Cylinder inner diameter mm (in)
Type
Cylinder bore mm (in)
Pad dimensions (area x thickness)
mm’ (in2) x mm (in)
Disc plate dimensions mm (in)
(outer diameter x thickness) Tandem (with level sensor)
22.22 (0.875)
Ventilated disc (integral)
53.97 (2.12)
13-in wheel: 3,800 (5.89)x 10 (0.39)
14-in wheel: 4,300 (6.66) x 10 (0.39)
13-in wheel: 235 x 22 (9.25 x 0.87)
14-in wheel: 257 x 22 (10.12 x 0.87)
We
I Solid disc (mounting support)
I
Cylinder bore mm (in)
I 30.2 (1.19)
I
Pad dimensions (area x thickness)
mm2 (in’) x mm (in)
Disc plate dimensions mm (in)
(outer diameter x thickness)
Type 2,600 x 8.0 (4.03 x 0.31)
251 x 9 (9.88 x 0.35)
Leading-trailing
Wheel cylinder inner diameter mm (in) 17.46 (0.687)
I
Lining dimensions mm (in)
(width x length x thickness) 35x192.0x4.5 (1.38x7.56x0.18)
I
Drum inner diameter mm (in) 200 (7.9)
I
Shoe clearance adjustment Automatic adjuster
Vacuum multiplier
@ : 214 (8.43) @ : 239 (9.41)
Dual proportioning valve
FMVSS 116: DOT-3, SAE: J1703
Type
Diameter
Type mm (in)
Parking brake
Type
Operation system Mechanical two rear wheel control
Center lever I
3 With BP SMTX, B6, @With BP 4EATX
I I
23UOPX-001
P-3

INSTRUMENT CLUSTER T
Symptom: Water temperature gauge does not operate.
9MUOTX-072
W/ TACHO W/O TACHO
OSUOTX-111
0
23UOTX-041
WI TACHO
W/O TACHO
9MUOTX-076
Step 1
1. Disconnect the connector from the water thermosensor.
2. Connect the red lead of the
SST to the connector and the
black lead to a body ground.
3. Set the
SST to the resistance values shown in the figure.
4. Turn the ignition switch ON, and check that the needle in-
dicates the correct values.
Gauge displays correct Action
Yes Replace water therm0 sensor
No Go to Step 2
Caution
l Continue the above checks for at least two minutes
each to correctly judge the condition.
l The allowable indication error is twice the width of
the needle.
Step 2
1. Remove the instrument cluster. (Refer to page T-69.)
2. Apply battery voltage to terminal 2L and ground terminal 2E.
3. Connect the red lead of the
SST to terminal 3L and the black
lead to a negative battery terminal.
4. Set the
SST to the resistance values shown in the figure.
5. Verify that the needle indicates the correct values.
Indicates correct
Yes Action
Repair wiring harness
(instrument cluster - Water thermosensor)
I--~ No I ReDlace water temperature gauge
I
Caution
l Continue the above checks for at least two minutes
each to correctly judge the condition.
l The allowable indication error is twice the width of
the needle.
T-67

T INSTRUMENT CLUSTER
Symptom: Fuel gauge does not operate.
SMUOTX-077 -_d
,
1
OBUOTX-186
W/ TACHO W/O TACHO
7R 7cl
9MUOTX-079
23UOTX-04:
WI TACHO W/O TACHO
7Q 7cl
Step 1
1. Disconnect the connector from the fuel gauge sender unit.
2. Connect the red lead of the SST to the terminal-wire (Y) and
the black lead to a body ground.
3. Set the SST to the resistance values shown in the figure.
4. Turn the ignition switch ON, and verify that the needle indi-
cates the correct values.
Indicates correct Action
Yes Replace fuel gauge sender unit (in fuel tank)
/
No Go
to Step 2
Caution
l Continue the above checks for at least two minutes
each to correctly judge the condition.
l The allowable indication error is twice the width of
the needle.
Step 2
1. Remove the instrument cluster. (Refer to page T-69.)
2. Apply battery voltage to terminal 2L and ground terminal 2E.
3. Connect the red lead of the SST to terminal 1C and the
black lead to a negative battery terminal.
4. Set the SST to the resistance values shown in the figure.
5. Verify that the needle indicates the correct values.
Indicates correct Action
Yes Repair wiring harness
(Instrument cluster - fuel gauge sender unit)
No Replace fuel gauge sender unit
Caution
. Continue the above checks for at least two minutes
each to correctly judge the condition.
l The allowable indication error is twice the width of
the needle. .-/

INSTRUMENT CLUSTER T
(For Canada)
(For USA)
11
OSUOTX-114
Standard Indication
(rpm)
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000 Allowable range
@pm)
880-l ,060
1,970-2,150
3,000-3,180
4,000-4,240
5,000-5,300
6,000-6,360
7.000-7.420
8:600-8:480
03UOTX-11 5
I 23UOTX-044 WI TACHO WIO MACHO
32.50
ssn
9MUOTX-087
Inspection
Speedometer
1. Using a speedometer tester, check the speedometer for ai-
lowable indication error, and check the operation of the
odometer. Replace if necessary.
2. Check the speedometer for fluctuation and/or abnormal
noise.
Caution
l If significant fluctuation occurs or the speedome-
ter does not move at all, remove the speedometer
cable. If it is normal, replace the speedometer as-
sembly.
l Tire wear and improper inflation will Increase
speedometer error.
Tachometer
1. Connect a test tachometer to the engine, and start the
engine.
2. Check the tachometer for allowable indication error. Replace
if necessary.
Caution
l When removing or installing the tachometer, do not
drop it or subject it to sharp shocks.
Fuel gauge
1. Remove the instrument cluster. (Refer to page T-69.)
2. Apply battery voltage to terminal 2L and ground terminal 2E.
3. Connect the red lead of the
SST to terminal 1C and the
black lead to a negative battery terminal.
4. Set the
SST to the resistance values shown in the figure.
5. Verify that the needle indicates the correct values.
Caution
l Continue the above checks for at least two minutes
each to correctly judge the condition.
l The allowable indication error is twice the width of
the needle.
T-71

T INSTRUMENT CLUSTER
I
23UOTX-045
W/ TACHO WI0 TACHO
QMUOTX-08!
03UOTX- 11,
03UOTX.11
OBUOTX-
T-72
Water temperature gauge
1. Remove the instrument cluster. (Refer to page T-69.)
2. Apply battery voltage to terminal 2L and ground terminal 2E.
3. Connect the red lead of the SST to terminal 3L and the black
lead to a negative battery terminal.
____,
4. Set the SST to the resistance values shown in the figure.
5. Turn the ignition switch ON, and verify that the needle indi-
cates the correct values.
Cautlon
l Continue the above checks for at least two minutes
each to correctly judge the condition.
l The allowable indication error is twice the width of
the needle.
Speed sensor
1. Remove the instrument cluster.
2. Check continuity between terminals 2A and 2F while rotat-
ing the speedometer cable shaft.
3. If there are not four pulses per shaft rotation, replace the
speed sensor.
WATER THERMOSENSOR
Removal / Installation
1. Remove the connector.
2. Remove the thermosensor.
3. Install in the reverse order of removal.
Inspection 1.
Remove the sensor.
2. Place the sensor in water.
3. Heat the water gradually, and check the resistance of the
sensor with an ohmmeter. 4.
If the resistance is not as specified, replace the sensor.
Resistance: 190-2603 at 5O*C (122OF)