1992 MAZDA PROTEGE brake

7 Schedule (Cont’d)
rile
iii
48
30
-
R
I
R !rs
25
40
25
-
-i- , whichever comes first
OPERATION MAINTENANCE Number of m
INTERVALS Months
x 1,000 km
x 1,000 miles
ii
is
G
-
i-
-
-
I
5-
T
-
-
-
-
-
-
- ii
z
ro
-
I-
-
-
I
- 45
72
45
-
-i-
-
-
I
-
ry 15 month:
I I I
A
t
A
j
milt Service data and inspection points Page
l Capacity
MTX B6, BP SOHC:
2.68 liters (2.83 US qt, 2.36 Imp qt)
BP DOHC
3.35 liters (3.55 US qt, 2.96 Imp qt)
ATX: 6.3 liters (6.7 US qt, 5.5 Imp qt)
l Level and condition
- Jl-7
J2-7
- Transaxle oil
l Wear and damaae -i- -i- -i- -
Brake fluid, clutch fluid
Brake fluid*3 -
Q-3, 5
Q-6
N-27
P-28
P-29 I I
- I
1,oo
-i
-
-
-
-
-
-
- I
G
T
-
-
-
-
-
-
- I
15,(
I Tire inflation pressure and wear l Proper pressure-
-
l Level and condition
l Wheel cylinder operation and leakage l Lining for wear or damage l Lining thickness:
Minimum 1 .Omm (0.04 in)
l Drum inner diameter. 3s) or f
I I
I
:t r
- Rotate tires
Power steering fluid
Drum brake ? every
I I
Disc brake I I
Maximum 201mm (7.91 in)
l Caliper operation l Disd plate thickness:
Minimum Front.... 20mm (0.79 in)
Rear . . . . . 7.0mm (0.28 in)
l Pad thickness:
Minimum Front.... 2.0mm (0.08 in) P-20
P-25
P-l 8
P-25
N-27
N-8 Rear . . . . . 1 .Omm (0.04 in)
l Operation and looseness l Fluid leakage or oozina
l Free play.... O--3OmmjO-1.18 in)
l Damage looseness and grease leakage
l Cracking and damage
l Insulator clearawp .-v
-
Steering operation and linkage
I
-i-
-I-
-i- Front suspension ball joint
Drive shaft dust boots
Exhaust system heat shield
Air conditioner system (if equipped) Refrigerant
Compressor
Suspension components (front and rear)
All chassis and body nuts and bolts
All locks and hinaes
Washer fluid -
M-21
F-136
u-35
u-39
-
- IY efrigerant amount ann
*. I# mspec
Inspect operation annualry -
l Damaae
l Retighten all loose nuts and bolts
l Lubricate all locks and hinges
l Level
l ODeration - Function of all lights l !%t and damage -

OUTLINE, TROUBLESHOOTING GUIDE Bl
OUTLINE
SPECIFICATIONS
item Engine
Type
Cylinder arrangement and number
Combustion chamber
Valve system
Displacement cc (cu in)
Bore and stroke mm (in)
Compression ratio
Compression pressure
kPa (kg/cm2, psi)-rpm
Open BTDC
IN
Close ABDC
Valve timing
EX Open
BBDC
Close ATDC
IN
Valve clearance
mm (in)
EX
Idle speed*‘*’ MTX
rpm ATX
Ignition timing*2
BTDC
Firing order
*‘.....With parking brake applied. (Canada)
*‘.....TEN terminal of diagnosis connector grounded B6 SOHC BP SOHC
Gasoline, 4-cycle
in-line, 4 cylinders
Multispherical Pentroof
OHC, belt-driven OHC, belt-driven 16 valves
1,597 (97.4) 1,839&i 12.23
78.0 x 83.6 (3.07 x 3.29) 83.0x 85.0 -3.35)
9.3 8.9
1,236 (12.6, 179)300 1,197 (12.2, 173)-300
140 2O
50° 5o”
52O 55O
120 8
0: Maintenance-free
0: Maintenance-free
700-800
700-800 (P range)
6O----8O 4O--6O
1-3-4-2
23UOBl-003
TROUBLESHOOTING GUIDE
Problem
Difficult starting
Poor idling
Excessive oil
consumption Possible Cause
Malfunction of engine-related components
Burned valve
Worn piston, piston ring, or cylinder
Failed cvlinder head aasket Action Page
Replace 81-55
Replace or repair 81-60, 62
Reolace Bl-16
Malfunction of fuel system
1 Refer to Section F
I
Malfunction of ignition system
Malfunction of engine-related components
Malfunction of HLA*
Poor valve-to-valve seat contact
Failed cvlinder head aasket Refer to Section G
Replace
Replace or repair
Reolace 81-20
81-57
81-16
Malfunction of fuel system 1 Refer to Section F
I
Malfunction of ignition system Refer to Section G
Oil working up
Worn piston ring groove or sticking piston ring
Worn piston or cylinder
Oil working down
Worn valve seal
Worn valve stem or wide Replace
Replace or repair
Replace
Replace 81-62
Bl-60, 62
81-46, 81
81-55
Oil leakage Refer to Section D
81-3

Bl TROUBLESHOOTING GUIDE
Problem
Insufficient power
Abnormal
combustion
Engine noise Possible Cause
Insufficient compression
Malfunction of HLA*
Compression leakage from valve seat
Seized valve stem
Weak or broken valve spring
Failed cylinder head gasket
Cracked or distorted cylinder head
Sticking, damaged, or worn piston ring
Cracked or worn piston Malfunction of fuel system
Malfunction of ignition system
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 system
Others
Malfunction of water pump bearing
Improper drive belt tension
Malfunction of alternator bearing
Exhaust gas leakage
Malfunction of timing belt tensioner Action
Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section F
Refer to Section G
Refer to Section H
Refer to Section P
Refer to Section Q
Replace
Replace
Replace
Eliminate carbon
Refer to Section F
Refer to Section G
Replace or repair
Replace
Replace or repair
Replace or repair
Replace
Replace or repair
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section E
Refer to Section F
Refer to Section E
Adjust
Refer to Section G
Refer to Section F
Replace Page 81-20
Bl-57
81-55
81-58
81-16
81-54
81-62
al-62
81-20
81-55
81-58
-
61-71
Bl-64
81-72
81-73 8-i-64
Bl-60
81-63
81-62
81-62
El-63
Bl-20
El-58
81-55
Bl- 5
81-12
911 IORI .N)J LI.,“l. --
* Tappet noise may occur if the engine has set idle for an extended period. The noise should
normal operating temperature. (HLA troubleshooting: Refer to page Bl-7) dissipate after the engine has reached
81-4

ENGINE TUNE-UP PROCEDURE Bl
13UOBl-04 0
Idle Speed
1. Perform “Preparation”. (Refer to page Bl-8.)
2. Apply parking brake.
3. Check that the idle speed is within specification.
Idle speed (Neutral or P range): 750 f 50 rpm
Caution
l Check the idle speed without the electric cooling
fan operating.
Note
l When the parking brake is not applied, the idle
speed for ATX model (Canada) is approx. 800 rpm.
4. If not within the specification, adjust the idle by turning the
air adjusting screw.
5. Disconnect the
SST.
Bl-9

ON-VEHICLE MAINTENANCE Bl
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 DO1 1 102
Lock tool,
crankshaft For
removal and
installation of
timing belt pulley 49 EOll 1AO
Ring gear brake
set For
prevention of
engine rotation
49 EOll 103
For
49 EOl 1 105
For
prevention of
prevention of
Shaft
engine rotation
Stopper
engine rotation
(Part of
(Part of
49 EOl 1 1AO)
49 EOI 1 1AO)
49 EOll 104
For
49 SE01 310A
For
prevention of
installation of
Collar
engine rotation
Centering tool,
clutch disc
(Part of
clutch disc
49 EOl 1 1 AO)
23UOBl-01
81-11

ON-VEHICLE MAINTENANCE Bl
I. Air hose assembly 1 I. Timing belt cover, upper
2. Resonance chamber 12. Timing belt
3. Accelerator cable Removal / Installation.. . . . . . . . . . . . . . . page Bl-12
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page BI-I9 13. Front exhaust pipe
4. Throttle cable (ATX)
14. Intake manifold bracket
Removal / Installation . . . . . . . . . . . . . . . . . . . . . Section K 15. Cylinder head bolt
5. Hoses Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page BI-18
Removal I Installation Note ..,............... below Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-I9
6. Harnesses 16. Cylinder head
Removal I Installation Note....... page BI-I8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 61-43
7. Water bypass pipe nut
Inspection . . , . . . . . . . . . . . . . . . . . . . . . . . . . ., . . page BI -54
8. Drive belt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page BI-79
9. Water pump pulley 17. Cylinder head gasket
10. Cylinder head cover
23UOBl-019
Removal / Installation note
Hoses
I. Disconnect the hoses shown in the figure.
\ / DlSCOtjNECT
, w I.,,, -----. WARNING ’ ’ ’ l KEEP SPARKS AND OPEN FLAME AWAY FROM THE FUEL
AREA.
CAUTION
l COVER THE HOSE WITH A RAG BECAUSE FUEL WILL
SPRAY OUT WHEN DISCONNECTING.
. PLUG THE DISCONNECTED HOSES TO AVOID FUEL
LEAKAGE.
I. Brake vacuum hose
2. Fuel hose
3. Vacuum hose (Purge control) 4. Vacuum hose (Cruise control)
5. Heater hose

Bl REMOVAL
Step 3
1. Disconnect the hoses shown in the figure.
BP SOHC
1. Brake vacuum hose
2. Fuel hose
Removal
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bl-30
05UOBX-078
03UOBi -050
below 3. Vacuum hose (Purge control)
4. Vacuum hose (Cruise control)
5. Heater hose
Removal Note ..,,,................................ below
Removal note
Fuel hose
Warning
l Keep sparks and open flame away from the fuel
area.
Caution
l Cover the hose with a rag because fuel will spray
out when disconnecting.
l Plug the disconnected hoses to avoid fuel leakage.
1. Disconnect the fuel hoses.
Heater hose
Caution
l Heater hose joint has O-rings and spacer.
l Do not lose them when removing.
1. Push the heater hose retainer and remove the heater hose.

Bl DISASSEMBLY
DISASSEMBLY
PREPARATION
SST
49 EOl 1 1AO
Ring gear brake
49 EOll 104
49 EOl 1 1 AO)
49 0636 100A
Arm, valve spring removal of valve
49 B012 006
Pivot, valve
49 8012 012
49 8012 014
49 LO11 006
Puller 84 installer
(Part of
49 LO1 1 OAO)
81-38