1992 MAZDA PROTEGE Workshop Manual

INSPECTION / REPAIR
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2311081-07
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5. Measure the journal diameters X and Y directions at the two
points (A and B) shown.
Diameter
B6 SOHC
Front and Rear
Center mm (in)
43.440-43.460 (1.7102-1.7110)
43.430-43.455 (1.7098--1.7108)
BP SOHC
1 No.1 & No.5 1 43.440-43.460 (1.7102-1.7110) 1
1 No.2 & No.4
1 43.425-43.450 (1.7096-1.7106) 1
1 No.3
I 43.410-43.435 (1.7091-1.7100) I
Out of round: 0.05 (0.002) max.
6. Measure the oil clearances between the camshaft and cyl-
inder head.
(1) Remove all foreign material and oil from the journals and
the camshaft bore.
(2) Measure the camshaft bore diameter.
03UOBV105
Diameter
B6 SOHC
Front and Rear
Center mm (in)
43.515-43.535 (1.7132-1.7139)
43.515-43.535 (1.7132-1.7139)
BP SOHC
1 No.1 & No.5 ] 43.500-43.515 (1.7126-1.7132) 1
1 No.2, No.3, No.4 1 43.485-43.505 (1.7120-1.7128) 1
(3) Subtract the journal diameter from the bore diameter.
Oil clearance
B6 SOHC
mm fin)
Front and Rear 0.055-0.095 (0.0021-0.0037)
Center 0.060-0.105 (0.0023-0.0041)
I
I Maximum
I 0.15 (0.006) I
BP SOHC mm fin
No.1 & No.5
No.2 & No.4
No.3
Maximum 0.040-0.075 (0.0016-0.0030)
0.035-0.080 (0.0014-0.0031)
0.050-0.095 (0.0020-0.0037)
0.15 (0.006)
(4) If the clearance exceeds the maximum, replace the cam-
shaft or cylinder head.
23UOBl-077
7. Measure the camshaft end play. If it exceeds the maximum,
replace the thrust plate or camshaft.
End play
B6 SOHC: 0.05-O. 18mm (0.0020-0.0071 in)
BP SOHC: 0.06-0.19mm (0.0024-0.0075 in)
Maximum: 0.20mm (0.008 in)
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Bl INSPECTION / REPAIR
a3
03UOBl.109
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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

INSPECTION / REPAIR Bl
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il
2
3
_I
5
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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

ER DIAMETER
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Bl INSPECTION / REPAIR
PISTON, PISTON RING, AND PISTON PIN
Piston
Caution
l If the piston is replaced, the piston rings must also
be replaced.
1. inspect the outer circumferences of all pistons for seizure
or scoring. Replace the piston if necessary.
2. Measure the outer diameter of each piston at a right angle
(90°) to the piston pin,
16Smm (0.650 in) below the oil
ring land lower edge.
Piston diameter mm (in)
B6 SOHC BP SOHC
Standard 77.954-77.974 82.954-82.974
(3.0690-3.0698) (3.2659-3.2667)
0.25 (0.010) oversize 78.21 I-78.21 7 83.211-83.217
(3.0792-3.0794) (3.2760-3.2763)
0.50 (0.020) oversize 78.461-78.467 83.461-83.467
(3.0890-3.0892) (3.2859-3.2861)
-+-CLEARANCE
05UOBX-156
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-A”’
3. Measure the piston-to-cylinder clearance.
Clearance: 0.039-0.052mm (0.0015-0.0020 in)
Maximum: 0.15mm (0.006 in)
4. If the clearance exceeds the maximum, replace the piston
or rebore the cylinders to fit oversize pistons. -I
Piston and Piston Rings
1. Measure the piston ring to ring land clearance around the
entire circumference using a new piston ring.
Clearance (Top and Second) mm (in)
7
B6 SOHC BP SOHC
Standard 0.030-0.065
(0.0012-0.0026)
Maximum 0.15 (0.006)
2. If the clearance exceeds the maximum, replace the piston.
3. Inspect the piston rings for damage, abnormal wear, or
breakage. Replace the piston rings if necessary.
4. Insert the piston ring into the cylinder by hand and use the
piston to push it to the bottom of the ring travel.

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INSPECTION / REPAIR Bl
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X
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5. Measure each piston ring end gap with a feeler gauge. Re-
place the piston ring if necessary.
End gap
Top : 0.15--0.30mm (0.006-0.012 in)
Second : 0.1 S-0.30mm (0.006-0.012 in)
Oil rail : 0.20-0.70mm (0.006-0.028 in)
Maximum: l.Omm (0.039 in)
Piston and Piston Pin
‘1. Measure each piston pin hole diameter in X and Y direc-
tions at four points.
Diameter: 19.988--2O.OOOmm (0.7869-0.7874 in)
2. Measure each piston pin diameter in X and Y directions at
four points,
Diameter: 19,974-l 9.980mm (0.7864-0.7866 in)
3. Calculate the piston pin-to-piston clearance.
Clearance: 0.008-0.026mm (0.0003-0.0010 in)
4. If the clearance exceeds specification, replace the piston
and/or piston pin.
CONNECTING ROD
1. Measure each connecting rod bushing inner diameter.
Diameter: 19.943-l 9.961 mm (0.7852-0.7859 in)
2. Calculate the clearance between the connecting rod bush-
ing and piston pin.
Interference: 0.013-0.037mm (0.0005-0.0015 in)
3. Measure each connecting rod for bending. Repair or re-
place the connecting rod if necessary.
Bending: 0.075mm (0.0030 in) max./fiOmm (1.97 in)
81-63

INSPECTION / REPAIR
05UOBX-1E
X
8 Y
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CRANKPIN
MAIN JOURNAL
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BP SOHC .r -
FILLET ROLL
DO NOT REMOVE FILLET ROLL AREA
WHEN GRINDING
1311081-028
CRANKSHAFT
1. Check the journals and pins for damage, scoring, and oil
hole clogging.
2. Set the crankshaft on V-blocks.
3. Measure the crankshaft runout at the center journal.
Replace the crankshaft if necessary. -.
Runout: 0.04mm (0.0016 in) max.
4. Measure each journal diameter in X and Y directions at two
points.
Main journal
Diameter: 49.938-49.956mm (1.9661-l .9668 in)
Out-of-round: 0.05mm (0.0020 in) max.
Crankpin journal
Diameter: 44.940-44.956mm (1.7693-l .7699 in)
Out-of-round: 0.05mm (0.0020 in) max.
5. If the diameter is less than the minimum, grind the journals
to match an undersize bearing.
Undersize bearing:
0.25mm (0.010 in), 0.50mm (0.020 in),
0.75mm (0.030 in).... B6 Only
Main journal diameter undersize
mm iin) 1. Bearing size Journal diameter
_-.---
0.25 (0.010) undersize 49.704.-49.708 (1.9568-l .9570)
---.-___
0.50 (0.020) undersize 49.454-49.458 (1.9470-l .9472)
0.75 (0.030) undersize (B6 Only) 49.204-49.208(1.9372--l .9373)
Crankpin journal diameter undersize ” ” ” 1” Bearing size Journal diameter
-_ ____~_.
0.25 (0.010) undersize 44.690-44.706
(1.7594 -1 7601) .--.._-.~.--~-.~
0.50
(0.020) underslze 44.440-44.456 (1.7496-I .7502) -- _____----.
0.75 (0.030) undersize 44.190--44.206 (1.7398---i .7404)
BEARING
Main Bearing and Connecting Rod Bearing
1. Check the main bearings and the connecting rod bearings
for peeling, scoring, and other damage.
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INSPECTION / REPAIR 81
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L
25mm (1 .O in) min.
OSJOBX-161
DAMAGE,
WEAR
05UOBX-16!
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05UOBX-17: 2 05UOBX-170
TIMING BELT
Caution
l Never forcefully twist, turn inside out, or bend the
timing belt.
l Do not allow oil or grease on the belt.
1. Replace the timing belt if there is any oil or grease on it.
2. Check the timing belt for damage, wear, peeling, cracks,
and hardening. Replace the timing belt if necessary.
TENSIONER, IDLER
Caution
l Do not clean the tensioner or idler with cleaning
fluids. If necessary, use a soft rag to wipe them
clean, and avoid scratching them.
1. Check the tensioner and idler for smooth rotation and ab-
normal noise. Replace the tensioner or idler if necessary,
TENSIONER SPRING
1. Measure the free length of the tensioner spring. Replace
the tensioner spring if necessary.
Free length: 64.0mm (2.520 in)
PULLEY
Timing Belt Pulley, Camshaft Pulley
Caution
l Do not clean the pulleys with cleaning fluids. If
necessary, use a soft rag to wipe them clean, and
avoid scratching them.
1. Inspect the pulley teeth for wear, deformation, and other damage. Replace the pulley if necessary.
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Bl ASSEMBLY
ASSEMBLY
PREPARATION
SST
49 LO1 1 OAO
Piston pin setting
tool set
49 LO1 1 004 I
Screw
(Part of
49 LO1 1 OAO)
49 LO1 1 006
Puller & installer
49 LO1 1 OAO) For
removal and
installation of
piston pins 49 LO11 001
Support block
body
(Part of
49 LO11 OAO)
49 LO1 1 005
Stopper bolt
(Part of
49 LO1 1 OAO)
49 LO1 1 007 For
removal and
installation of
piston pins
For
removal and
installation of
piston pins
Centering tool
49 LO1 1 OAO)
49 HO11 OOlA
Support block
49 EOll 103
49 EOll 104
installation of
Collar
49 LO12 001
installation of