1992 MAZDA PROTEGE oil

I32 ASSEMBLY
Qill’ ’ 23UOB2-050
03UOB2-10
2. Install the timing belt pulley.
3. install the pulley Woodruff key with the tapered side toward
the oil pump body.
4. Install the pulley lock bolt.
5. Tighten the pulley lock bolt.
Tightening torque:
157-167 N#rn (16-17 m-kg, 116-123 ft-lb)
Water Pump
1. Remove all foreign material from the water pump mount-
ing surface.
2. Install the water pump and a new gasket.
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
82-78

ASSEMBLY
05UOBX-221
I 0311082-10
Cylinder Head
1. Install the cylinder head.
2. Apply clean engine oil to the bolt threads and seat faces.
3. Tighten the cylinder head bolts in two or three steps in the
order shown.
Tightening torque:
76-61 Nsrn (7.7-8.3 m-kg, 56-60 ft-lb)
Water Thermoswitch, Heat Gauge Unit
1. Install the water thermoswitch.
Tightening torque:
5.9-8.8 N#m (60-90 cm-kg, 52-78 in-lb)
2. Install the heat gauge unit.
Tightening torque:
6.4-9.3 N.m (65-95 cm-kg, 56-82 in-lb)
Thermostat, Thermostat Cover
1. Remove all foreign material from the thermostat cover
mounting surface.
2. Install the thermostat with the jiggle pin facing upward.
Caution
l The printed side of the gasket must face the ther-
mostat.
3. Install a new gasket and the thermostat cover.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
HLA
1. Apply clean engine oil to the friction surfaces.
2. If the HLA are being reused, install them in the position from
which they were removed.
3. Verify that the HLA move smoothly in their bores.
05UOBX.223
B2-81

B2 ASSEMBLY
DlSTRlBUfOR
DRIVE GROOVE
-- 03umx-01
-
05UOBX-05
--____--
udOBX-056
---I
Camshaft
Note
l The exhaust camshaft is grooved for the distribu-
tor drive.
1. Apply clean engine oil to the camshaft journals and bearings.
2. Install the camshaft in position.
Caution
l Do not allow any sealant on the camshaft journal
surfaces.
3. Apply silicone sealant to the shaded areas shown in the
figure.
4. Install the camshaft caps according to the cap number and
arrow mark.
5. Install the camshaft cap bolts and tighten them in two or
three steps in the order shown in the figure.
Tightening torque:
11.3-14.2 Nlm (1.15-l .45 m-kg, loo-126 in-lb)
6. Apply a small amount of clean engine oil to the lip of a new
camshaft oil seal.
7. Push the oil seal slightly in by hand.
Caution
l The oil seal must be tapped in until it is flush with
the edge of the camshaft cap.
8. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 48mm (1.89 in)
Seal Plate
1. Install the seal plate on the cylinder head.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
~,. ,
03”oEm10:
B2-82

82 ASSEMBLY
Oil Level Gauge Pipe Stay
1. Install the oil level gauge pipe stay.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 in-lb)
Oil Level Gauge
1. Install the level gauge.
Spark Plug
1, Install the spark plugs.
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 11-17 ft-lb)
Oil Pressure Switch
1. Install the oil pressure switch.
Tightening torque:
12-18 N-m (120-180 cm-kg, 104-156 in-lb)
Oil Cooler
1. Remove all foreign material from the oil cooler mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil cooler.
3. Install the oil cooler with paint mark (white) facing up.
4. Tighten the oil cooler lock nut.
Tightening torque:
29-39 N.m (3.0-4.0 m-kg, 22-29 ft-lb)
5. Connect the harness to oil pressure switch.
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 116 turns with a filter wrench. --_

INSTALLATION
Step 3
Torque Specifications
16-23 (1.6-2.3, 12-17) 6.9-9.8 N.m (70-100 cm-kg, 61-87 in-lb)
I

m- ,,
// / 31-46 (3.2-4.7, 23-34)
ATX
Y
16-23 (1.6-2.3, 12-17) I 37-52 (3.8-5.3, 27-38) \/r-]z$/ 43-59 (4.4-6.0, 31-43)
COTTER PIN, NEW
/ 31-46 (3.2-4.7. 23-34) 42-67 (4.3-5.8, 31-42)
-_ ..------_ N.m (m-kg, R-lb)
no, Inor, 1.3
L 03UOB2 131
I 0311082-13.
Driveshaft
1. Apply grease to the end of the driveshaft.
Caution
l When installing the driveshaft, be careful not to
damage the oil seal.
l After installation, pull the front hub outward to con-
firm that the driveshaft is securely held by the clip.
2. Install the driveshaft and a new clip.
3. Install the lower arm ball-joint to the knuckle; then tighten
the lock nut.
Tightening torque:
43-59 N-m (4.4-6-O m-kg, 31-43 ft-lb)
4. Install the joint shaft.
5. Tighten the bolts in the order shown.
Tightening torque:
42-62 N-m (4.3-6.3 m-kg, 31-46 ft-lb)
82-97

B2 INSTALLATION
Step 5
1. Connect the harness connectors shown in the figure.
___---
r-
OIL PRESSURE SWITCH
THROTTLE
GROUND ITX
INHIBITOR SWITCH
TRAL SWITCH (MTX)
7.6-11 N.m
I N.m
0 cm-kg, 69-95 in-lb)
2.9-5.9 N-m
30-60 cm-kg,
26-52 in-lb)
cm-kg, 56-82 in-lb) 03UOB2-1~
Step 6
Torque Specifications
7.6-11 N.m (60~110 cm-kg, 69-95 in-lb)
N-m (m-kg, ft-lb]
03UOB2-14
.-
-’
82-l 00

INSTALLATION
03UOB2-141
/ 03UOB2-14!
1 03UOB2-150
03UOB2-151
8,’
1
a : :“.;,
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s,::, ; i .:.;...
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‘zi :
I 0311082-152
A/C compressor (If equipped)
1. Install the A/C compressor.
Tightening torque:
24-35 N,m (2.4-3.6 m-kg, 17-26 ft-lb)
2. Tighten the A/C pipe bracket to the engine mount member.
Tightening torque:
6.4-9.3 N-m (65-95 cm-kg, 56-62 in-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page B2-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)
2. Connect the upper and lower radiator hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good
fit.
3. Connect the coolant reservoir hose.
4. Connect the cooling fan connector.
5. Connect the oil cooler hose. (ATX)
B2-101

92 INSTALLATION
RESOiANCE CHAMBER
03UOBZ-154
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut A.
Deflection: 1-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 Nlm (80-l 10 cm-kg, 69-96 In-lb)
2. Install the battery carrier.
Tightening torque:
7.8-l 1 N*m (80-l 10 cm-kg, 69-96 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
Tightening torque
@: 19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N*m (80-l 10 cm-kg, 69-95 In-lb)
2. Connect the air flow sensor connector.
Resonance chamber
I, Install the resonance chamber.
Tightening torque:
7.8-l 1 N#m (80-l 10 cm-kg, 69-95 In-lb)
Under cover and side cover
1. Install the under cover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J2, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following:
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) ignition timing, idle speed. (Refer to page 82-8.)
(3) Operation of emission control system.
6. Perform a road test.
7. Recheck the engine oil and engine coolant levels.
B2-102
2311082.047