1992 MAZDA PROTEGE alternator

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 ENGINE TUNE-UP PROCEDURE
ALTERNATOR DRIVE BELT
2311082-00
P/S OIL PUMP
DRIVE BELT
-
A/C AND P/S OIL
PUMP DRIVE BELT
23UOB2-001
1
23UOB2-00
23UOB2-OC
3. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
l A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specified below accordingly.
l Check the belt deflectlon when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflectlon
Drive belt
Alternator
P/S, PAS + A/C New Used
8.0-9.0 9.0-10.0
(0.31-0.35) (0.35-0.39)
8.0-9.0 9.0-I 0.0
(0.31-0.35) (0.35-0.39) mm (in)
Limit
12.5
(0.49)
11.5
(0.45)
4. If the deflection is not within specification, adjust it.
5. Install the air intake pipe.
Drive belt tension check
Note
l Belt tension can be checked in place of belt
deflection.
l Belt tension can be measured between any two
pulleys.
1. Removal the air intake pipe.
2. Using the
SST, check the belt tension.
_-
Tenslon
N (kg, lb)
Drive belt
Alternator New
383-461 Used
304-383 Limit
167
(39-47, 85.8-103.4) (31-39, 68.2-85.8) (17, 37)
P/S, P/S + AIC 491-589 422-491 245
(5040, 110-132) (43-50,95-l 10) (25, 55)
3. If the tension is not within specification, adjust it.
4. Install the air intake pipe.
Adjustment
Cautlon
l If a new belt is used, adjust the belt deflection at
the midpoint of new belt specification.
l A belt is considered “New” If it has been used on
a runnlng engine for less than five minutes.
1. Alternator belt
(1) Loosen the alternator mounting bolt @ and adjusting
lock bolt @.
(2) Lever the alternator outward and apply tension to the
belt.
(3) Tighten adjusting lock bolt @I.
82-6

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

B2 ON-VEHICLE MAINTENANCE
HLA
Removal / Installation
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. install in the reverse order of removal, referring to Installation Note --- ----- -__ __-- ,‘.
11.3-14.2 N.m
(1.15-1.45 m-\g, 100-126 in-lb)
49-61
(5.0~6.2,-36-45)
4.9-6.6 N.m
(50-90 cm-kg, 43-76 in-lb)
7.6All N-m
(80-110 cm-kg, 69-95 in-lb) 1 Q’-25
(1.9-2.6, 14-19)
N.m (m-kg, ft-lb)
0311082-03
1. High-tension lead
10. Cylinder head cover
2. Distributor
Installation Note..
....................
Installation Note.. ......................
page 62-25
11. Camshaft pulley
3. P/S and/or A/C drive belt
Removal note ..........................
Removal / Installation..
.............. page E32-
6
Installation Note .......................
4. Alternator drive belt
12. Seal plate
Removal / Installation
......... . ...... page B2- 6
13. Camshaft
5. Water pump pulley
Removal Note.. ........................
6. Timing belt cover, upper
Installation Note.. .....................
7. Timing belt cover, middle
14. HLA
8. Spark plug
Removal note ..........................
9. Timing belt
Installation
Note.. .....................
Removal Note.. .........................
page B2-18 Inspection
................................
Installation Note.. ......................
page B2-20
7
page 62-19
page 82-23
page 82-24
page B2-23
page 62-23
page B2-23
page B2-23 ‘--’
page 82-60
82-22

REMOVAL
0311082-046
Removal note
P/S oil pump and bracket
Caution
l Do not damage the hoses.
1. Remove the P/S oil pump and bracket with the hoses still
connected.
2. Position the pump away from the engine and affix it with wire.
A/C compressor (if equipped)
Caution
l Do not damage the hoses.
1. Remove the A/C compressor with the hoses still connected.
2. Position the compressor away from the engine and affix it
with wire.
Step 2
1. Disconnect the harness connectors shown in the figure.
OIL PRESSURE SWITCH ATX
THROTTLE INHIBITOR SWITCH
ALTERNATOR
I SENSOR 1
II
rl (MTX)
-03UOB2-05( .-,’

B2 DISASSEMBLY
AUXILIARY PARTS
1, Drain the engine oil.
2. Disassemble in the order shown in the figure
GASKET, REPLACE ..______-.
-___ -
03UOB2-064
1. Distributor and high-tension lead 7. Oil cooler
2. Intake manifold assembly 8. Oil pressure switch
3. Injector and distribution pipe assembly 9. Spark plug
4. Alternator and drive belt 10. Oil level gauge
5. No.3 engine mount bracket 11. Oil level gauge pipe stay
6. Oil filter 12. Engine hanger
82-42

ASSEMBLY B2
03UOB2-111
03UOB2-ill
03UOB2-119
No.3 Engine Mount Bracket
1. Install the No.3 engine mount bracket.
Tightening torque:
93-l 17 N-m (9.5-l 1.9 m-kg, 69-86 ft-lb)
Alternator and Drive Belt
1. Install the alternator and loosely tighten the mounting bolts.
2. Install the alternator drive belt.
3. Adjust the drive belt deflections. (Refer to page B2-6.)
Injector and Distribution Pipe Assembly
1. Install the new injector insulators to the cylinder head.
2. Install the injector and distribution pipe assembly to the cyl-
inder head.
Tightening torque:
19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
Intake Manifold Assembly
1. Remove all foreign material from the intake manifold con-
tact surface.
2. Install a new gasket and the intake manifold assembly.
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-l 9 ft-lb)
82-89