1992 MAZDA PROTEGE Workshop Manual

ASSEMBLY Bl
BP SOHC
THRUST PLATE
DOWEL PIN AND PIN GROOVE
63UOlX-121
63UOlX-12
01; RESERVOIR
03UOBl-1’ 16
Camshaft
1. Apply engine oil to the journals and bearings; then insert
and mount the camshaft into position with the thrust plate.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 In-lb)
Camshaft Pulley
1. Install the camshaft pulley onto the dowel pin with the pin
groove facing straight upward.
Note
l Be certain that the dowel pin of the camshaft also
faces straight upward.
2. Tighten the camshaft pulley bolt. Hold the camshaft using
a suitable wrench on the cast hexagon as shown.
Tightening torque:
49-81 N-m (5.0-8.2 m-kg, 38-45 ft-lb)
Hydraulic Lash Adjuster (HLA)
1. Pour engine oil into the oil reservoir in the rocker arm.
2. Apply engine oil to the new HLA.
3. install the HLA in the rocker arm.
Caution
l Be careful not to damage the O-ring when installing.
81-83

Bl ASSEMBLY
No.1 CYLINDER No.4 CYLINDER
0311081-14
No.1 CYLINDER
No.4 CYLINDER
INTAKE
\. A
0’ Y Y 0 1
”
P
/ Y)
6
EXHAUST
No.1, 2 CYLINDERS No.3, 4 CYLINDERS
(IN & EX) (IN & EX)
93UOlA-08
I I I I I
000 @ @3
93UOiA-08
0311081-14
81-84
IN
EX
Rocker Arm and Rocker Shaft Assembly
66 SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure.
Caution
l Be sure both rocker arm shaft oil holes face
downward.
l The installation bolt holes are different for the ex-
haust and intake sides as shown in the figure.
Note
l There are two types of rocker arms with different
offsets. One type for No.1 and No.2 cylinders ex-
haust and intake. And the other for cylinders No.3
and No.4.
2. Install the rocker arm and rocker shaft assembly.
Caution
l The bolts must be tightened gradually and In the or-
der shown.
Tightening torque:
22-26 N-m (2.2-2.9 m-kg, 16-21 ft-lb)
BP SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure.
Caution
l Face the rocker shaft identification mark upward.
l The installation bolt holes are different for the ex-
haust and intake sides.
identification mark
IN . . . ..White
EX.....Biue

ASSEMBLY 81
23UOBl-05. 2
Y@ 0311081-206
03UOBl-20
03UOBl-15’
2. Install the rocker arm and rocker shaft assembly.
Caution
l The bolts must be tightened gradually and in the or-
der shown.
3. Tighten the rocker arm bolts in two or three steps in the or-
der shown in the figure.
Tightening torque:
22-28 N.m (2.2-2.9 m-kg, 18-21 ft-lb)
Bracket and Heat Gauge Unit
1. Install the heat gauge unit into the cylinder head with seal
tape on the threads.
Tightening torque:
8.4-9.3 N-m (85-95 cm-kg, 58-82 in-lb)
2. Install the bracket.
Tightening torque:
19-25 (1.9-2.8 m-kg, 14-19 ft-lb)
Thermostat and Thermostat Cover
1. Remove all foreign material from the thermostat cover
mounting surface.
2. Install the thermostat with the jiggle pin facing upward.
3. Install a new gasket and the thermostat cover.
Tightening torque:
19-25 Narn (1.9-2.8 m-kg, 14-19 ft-lb)
Caution
l The printed side of the gasket must face the thermo-
stat.
Cylinder Head Cover
1. Install the cylinder head cover.
Tightening torque:
4.9-8.8 N-m (50-90 cm-kg, 43-78 in-lb)
Caution
l If the head cover gasket is reused, apply sealant in
the groove as shown.
131-85

ASSEMBLY
TIMING BELT
Torque Specifications
78-l 1 N-m (80-l 10 -kg, 69-95 in-lb)
12-17 (1.25-1.75, 109-152) N-m (m-kg, Mb)
03UOBl-15 2
Timing Belt Tensioner
1. Install the tensioner and the tensioner spring.
2. Temporarily secure the tensioner with the spring fully ex-
tended.
Timing Belt
1. Verify that the timing belt pulley mark is aligned with the tim-
ing mark.

ASSEMBLY Bl
CYLINDER HEAD
MARKS
03UOBl-15!
TENSION
SIDE
03UOBl-15
03UOBl-15
03UOBl-158
I
98 N
(10 kg, 22 lb)
1
03UOBl-159
2. Verify that the camshaft pulley marks are aligned with the
cylinder head cover marks.
3. Install the timing belt so that there is no looseness at the
tension side.
Caution
l Do not turn the crankshaft counterclockwise.
4. Turn the crankshaft two turns clockwise, and align the tim-
ing belt pulley mark with the timing mark.
5. Verify that the camshaft pulley marks are aligned with the
cylinder head cover mark.
if not aligned, remove the timing belt and repeat from ten-
sioner installation.
6. Loosen the tensioner lock bolt to apply tension to the tim-
ing belt.
Caution
l Be sure not to apply tension other than that of the
tensioner spring.
7. Tighten the tensioner lock bolt.
Tightening torque:
19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
8. Turn the crankshaft 2 turns clockwise and verify that the
timing marks are correctly aligned.
9. Measure the timing belt deflection by applying moderate
pressure (96 N, 10 kg, 22 lb) midway between the crank-
shaft pulley and the camshaft pulley.
If the timing belt deflection is not correct, temporarily se-
cure tensioner lock bolt so the spring is fully extended and
repeat steps 4-8 above or replace the tensioner spring.
Deflection:
11 .O-13.0mm (0.43-0.51 In) at 96 N (10 kg, 22 lb)
Bl-87

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

ASSEMBLY Bl
AUXILIARY PARTS
Torque Specifications
DRIVE BELT
INSTALLATION
PAGE Bl-6 19-25 (1.9-2.6, 14-19)
w-113 (9.5-11.5, 69-83) I _______ _ - ..- - -,
(3.8-5.3, 27-38)
19-25 Il.9-2.8. 14- 37-63 (3.8-6.4, 27-46)
15-23 (1.5-2.3, 11-17)
N.m (m-kg, ft-It
OWOBX-2
03UOBl.16
Engine Hanger
1. Install the front and rear engine hangers.
Tightening torque
Front: 37-63 N-m (3.8-6.4 m-kg, 27-46 ft-lb)
Rear: 19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
81-89

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