1992 MAZDA PROTEGE check engine

.
ON-VEHICLE MAINTENANCE
Installation note
Cylinder head bolt Bl
1. Apply clean engine oil to the bolt threads and seat faces.
2. Install the cylinder head bolts.
3. Tighten the cylinder head bolts in two or three steps in the
order shown in the figure.
Tightening torque:
76-61 N#m (7.7-6.3 m-kg, 56-60 f&lb)
Accelerator cable
1. Install the accelerator cable.
2. Check the accelerator cable deflection.
If the deflection is not correct, adjust by turning nut A.
Deflection: I-3mm (0.04-0.12 in)
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E.)
2. Connect the negative battery cable.
3. Start the engine and check as follows:
(1) Engine oil and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page 81-8.)
(3) Operation of emission control system.
4. Recheck the engine coolant levels.
2311081-020
Bl-19

Bl ON-VEHICLE MAINTENANCE
01 EOBX-056
23UOBi -0:
Steps After Installation
1. Lower the vehicle.
2. Connect the negative battery cable.
3. Start the engine and check the ignition timing.
(Refer to page 61-8)
Installation Note
Oil seal
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. 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 oil pump body.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 50.5mm (1.98 in)
Timing belt pulley
1. Install the timing belt pulley.
2. Install the pulley woodruff key with the tapered side toward
the oil pump body.
Pulley lock bolt
1. Hold the crankshaft with the SST and tighten the pulley lock
bolt.
Tightening torque:
157-167 N*rn (16-17 m-kg, 116-123 ft-lb)
23UOBi-026
Bl-24

ASSEMBLY Bl
I-
r
I 03UOBl-12
A NO.1
M
9MUOB2-14 I ‘NDENTIFICATION MARK
03UOBl-02
I
23UOBl-04
05UOBX.179
2. Set the stopper bolt (49 LO1 1 005) so that the depth L is
as specified.
Depth L
B6 SOHC
BP SOHC mm (in)
I 56.9-57.1 (2.240-2.248)
58.9-59.1 (2.319-2.327)
3. Tighten the locknut.
4. Insert the
SST No.2 into the piston pin as shown and fully
screw in the
SST No.1.
5. Apply engine oil to the piston pin.
6. Set the piston on the
SST with the F mark facing upward.
7. Assemble the piston and the connecting rod in the direc-
tion from which they were disassembled.
8. Press the piston pin into the piston and connecting rod un-
til the SST contacts the stopper bolt.
9. While inserting the piston pin, check the pressure force. If
it is less than specified, replace the piston pin or the con-
necting rod.
Pressure force:
4,905-14,715 N (500-l ,500 kg, 1 ,lOO-3,300 lb)
10. Check the oscillation torque of the connecting rod.
(Refer to page Bl-51.)
Piston Ring 1,
Install the three-piece oil rings on the pistons.
(1) Apply clean engine oil to the oil ring spacer and rails.
(2) Install the oil ring spacer with the ends upward.
Note
l The upper rail and lower rail are the same.
l The rails may be installed with either face upward. (3) Install the upper rail and lower rail
Bl-69

INSTALLATION
OWOBX-27!
Resonance chamber
1. Install the resonance chamber.
Tightening torque:
7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
Undercover and side cover
1. Install the undercover 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.)
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut @.
Deflection: I-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
2. Install the battery carrier.
Tightening torque:
7.8-11 N.m (80-110 cm-kg, 69-95 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.
lightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
2. Connect the airflow sensor connector.
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 J, 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 61-8.)
(3) Operation of emission control system.
6. Perform a road test,
7. Recheck the engine oil and engine coolant levels.
.-’
23UOBl-057
81-102

ENGINE TUNE-UP PROCEDURE 82
ENGINE TUNE-UP PROCEDURE
PREPARATION
SST
49 BO19 9AO
drive belt tension
23UOB2-048
OBUOBX-158
I’ ,
OSJOBX-001
V BELT
V RIBBED BELT
_
x 0 x
3
L
03UOB2-005
ENGINE OIL
Inspection
1. Be sure the vehicle is on level ground.
2. Warm up the engine to normal operating temperature and
stop it.
3. Wait for 5 minutes.
4. Remove the oil level gauge and check the oil level and con-
dition.
5. Add or replace oil if necessary.
Note
l The distance between the L and F marks on the level
gauge represents 0.8 liter (0.85 US qt, 0.70 Imp qt).
ENGINE COOLANT
Inspection
Coolant level (engine cold)
Warning
l Never remove the radiator cap while the engine is
hot.
l Wrap a thick cloth around the cap when removing it.
1. Verify that the coolant level is near the radiator filler neck.
2. Remove the coolant level gauge and check the coolant level.
3. Add coolant if necessary.
Coolant quality
1. Verify that there is no buildup of rust or scale around the
radiator cap or radiator filler neck.
2. Verify that the coolant is free of oil.
3. Replace the coolant if necessary.
DRIVE BELT
Inspection
1. Check the drive belts for wear, cracks, and fraying. Replace
if necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
B2-5

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

ENGINE TUNE-UP PROCEDURE 92
23UOB2-OC
DRIVE PULLEY
I I
2311082.010
HLA
I Problem
1. Noise when engine is started immedi-
ately after oil is changed.
2. Noise when engine is started after set-
tina aporox. one dav.
3. Noise when engine is started after
cranking for 3 seconds or more.
4. Noise when engine is started after
new HLA is installed.
5. Noise continues more than 10 minutes
6. Noise occurs durning idle after high-
“”
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-16 ft-lb)
(4) Tighten mounting bolt @.
Tightening torque:
37-52 N#rn (3.6-5.3 m-kg, 27-36 ft-lb)
(5) Recheck the belt tension or deflection.
2. P/S belt, P/S + A/C belt
(1) Loosen the P/S oil pump bolt @and nuts @, 0.
(2) Adjust the belt tension and deflection by turning the ad-
justing belt 0.
(3) Tighten the adjusting lock nut @J and the P/S oil pump
bolt @ and nut 0.
Tightening torque
@: 36-54 N-m (3.7-5.5 m-kg, 27-40 ft-lb)
@ : 19-25 N*m (1.9-2.6 m-kg, 14-19 ft-lb)
0: 31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb) Possible Cause
Oil leakage in oil passage
Oil leakage in HLA
Insufficient oil pressure
Faulty HLA
Incorrect oil amount
Deteriorated oil Action Run engine 2000-3000 rpm.
If noise stops after 2 second-10
minutes(*), HLA is normal.
If not, replace HLA.
* Time required for engine oil to circu-
late within engine, includes tolerance
for engine oil condition and ambient
temperature.
Check oil pressure.
If lower than specification, check for
cause. Oil pressure; 294-392 kPa
(3.0-4.0 kg/cm’, 43-57 psi)-3000 rpm
(Refer to page 82-60)
Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.
If more than Omm (0 in), replace HLA.
Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
2311082-01
B2-7

82 ENGINE TUNE-UP PROCEDURE
03UOB2-013
IGNITION TIMING, IDLE SPEED
Preparation
1. Warm up the engine to normal operating temperature.
2. Turn all electric loads OFF.
3. Connect the
SST to the diagnosis connector.
4. Connect the timing light.
5. Connect a tachometer to the diagnosis connector
IO- ter-
minal as shown.
TEN
03UOB2-01
I
-&k BOLT
0311082-01’
82-8
6. Set switch @to position 1.
7. Set TEST SW to SELF-TEST.
Note
l If the SST is not used, jump across the TEN termi-
nal and the GND terminal of the diagnosis con-
nector.
Ignition Timing
Inspection / Adjustment
1. Perform “Preparation.” (Refer to above.)
2. Check if the timing mark (yellow) on the crankshaft pulley
and the mark on the timing belt cover are aligned.
Ignition timing: 10 * f lo BTDC (at Idle speed)
3. If the marks are not aligned, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
4. Tighten the distributor lock bolts to the specified torque.
Tightening torque:
19-25 N*m (1 .Q-2.6 m-kg, 14-19 ft-lb)
5. Disconnect the SST.