1992 MAZDA PROTEGE clutch

REMOVAL Bl
Step 4 -
ATX
REPLACE
13UOBl-043
1. Speedometer cable 7. Stabilizer
2. Clutch release cylinder
8. Tie rod end
Removal Note below Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 61-32
,...............,....................
3. Shift control rod (MTX)
4. Extension bar (MTX)
5. Shift control cable (ATX)
6. Front exhaust pipe 9. Engine mount member
Removal Note ,.......................... page Bl-32
10. Driveshaft
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-32
Removal note
13UOBl-04 .4
Clutch release cylinder (MTX)
1. Remove the release cylinder pipe bracket from the transaxle.
2. Position the release cylinder away from the transaxle for eas-
ier removal with the hose still connected.
Caution
l Do not damage the pipe or hose.
81-31

DISASSEMBLY Bl
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the fiaure, referrina to Disassembly Note.
.-.
1. Water pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
2. Timing belt pulley and lock bolt
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl -65
3. Clutch cover, clutch disc (MTX)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
4. Flywheel (MTX)
Disassembly Note . . . . . . . . . . . . . . . . . . . page 81-48
Inspect for wear or damage
5. Backing plate, drive plate, and adapter (ATX)
Disassembly Note ..,.....,.,........, page 81-48
6. End plate 7. Oil pan and gasket
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Inspect for damage
8. Oil strainer
9. Main bearing support plate (MBSP)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-49
Inspect for damage
10. Oil pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
11. Front oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
12. Rear cover
13. Rear oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Bl-47

Bl DISASSEMBLY
23UOBl-068
23UOBl-06!
I 2311081-070
23UOBl-071
Disassembly Note
Timing belt pulley
1. Hold the flywheel (MTX) or drive plate (ATX) with the SST
or equivalent.
2. Loosen the pulley lock bolt.
3. Remove the pulley lock bolt. -
4. Remove the timing belt pulley.
5. Remove the pulley Woodruff key.
2311081-059
Clutch cover (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Loosen the clutch cover lock bolts in two or three steps in
the order shown in the figure.
3. Remove the clutch cover.
-
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
4. Remove the
SST or equivalent.
Backing plate, drive plate, and adapter (ATX)
1. Hold the drive plate with the SST or equivalent.
2. Remove the drive plate lock bolts.
3. Remove the backing plate, drive plate, and adapter.
4. Remove the
SST or equivalent.
Bl-48

ASSEMBLY Bl
19 LO11 002
Body
:Part of
49 LO12 OAO)
49 8012 006
Pivot, valve
spring lifter
49 8012 OA2
Pivot, valve
spring lifter
49 8012 013
Foot
(Part of
49 B012 OA2)
49 SE01 310
Centering tool,
clutch disc For
installation of
valve seals
(B6 SOHC)
For
removal and
installation of
valves
(BP SOHC)
For
removal I
installation of
valves
For
removal I
installation of
valves
For
installation of
clutch disc 49 0636 1OOA
Arm, valve spring
lifter
49 s120 222
0
Pivot, valve
spring lifter
%
49 8012 012
Body
(Part of
49 8012 OA2)
49 B012 014
Locknut
(Part of
49 8012 OA2)
1. Clean all parts before reinstallation.
2. Apply new engine oil to all sliding and rotating parts.
3. Replace plain bearings if they are peeling, burned, or otherwise damaged.
4. Tighten all bolts and nuts to the specified torques.
Caution
l Do not reuse gaskets or oil seals.
I
3 For
removal and
installation of
valves
For
removal and
installation of
valves
(B6 SOHC)
For
removal I
installation of
valves
For
removal I
installation of
valves
23UOBl-0,
05UOBX-174
Bl-67

ASSEMBLY Bl
05UOBX.21’
OYJOBX-21
23UOBl-07
23UOBl-Ot
4. Apply a continuous bead of silicone sealant to the oil pan
along the inside of the bolt holes and overlap the ends.
5. Install the oil pan.
Tightening torque:
7.8-l 1 N,m (80-l 10 cm-kg, 89-95 in-lb)
End Plate
1. Install the end plate.
Tightening torque:
7.8-l 1 N,m (80-l 10 cm-kg, 89-95 in-lb)
Flywheel (MTX)
1, Remove the sealant from the flywheel bolt holes in the crank-
shaft and from the flywheel bolts.
Caution
l If all the previous sealant cannot be removed from
a bolt, replace the bolt.
l Do not apply sealant if a new bolt is used.
2. Set the flywheel onto the crankshaft.
3. Apply sealant to the flywheel bolts and install them.
4. Hold the flywheel with the
SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
98-103 N+m (9.8-10.5 m-kg, 71-78 ft-lb)
Clutch Disc and Clutch Cover (MTX)
1. Install the clutch disc and clutch cover using the SST or
equivalent. (Refer to Section H.)
Tightening torque:
18-28 N.m (1.8-2.7 m-kg, 13-20 ft-lb)
B-l -77

Bl INSTALLATION
Tie-rod end
1. Install the tie-rod end to the knuckle.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
2. Install the new split pin.
03UOBl.183
,I / 03UOBl-18
Stabilizer
1. Install and adjust the stabilizer.
Dimension @: 17-19mm (0.67-0.75 in)
Extension bar (MTX)
1. Install the extension bar to the transaxle.
Tightening torque:
31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
Shift control rod (MTX)
1. Install the shift control rod to the transaxle.
Tightening torque:
16-23 N.m (I .6-2.3 m-kg, 12-l 7 ft-lb)
Clutch release cylinder (MTX)
1. Install the clutch release cylinder.
Tightening torque:
16-23 N#m (I .6-2.3 m-kg, 12-17 ft-lb)
2. Set the pipe bracket in position.
Tightening torque
@: 6.9-9.8 N.m (70-100 cm-kg, 61-87 in-lb)
@: 16-23 N.m (I .6-2.3 m-kg, 12-17 ft-lb)
Shift control cable (ATX)
1. Install the shift control cable to the transaxle.
Tightening torque:
6.9-l I N-m (70-l IO cm-kg, 61-95 in-lb)
81-98

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

ON-VEHICLE MAINTENANCE 62
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 DO11 102
Lock tool,
crankshaft
49 E011 103
Shaft
(Part of
49 EOl 1 1AO) @
49 EOI 1 104
Collar
(Part of
49 EOl 1 1AO) For
removal and
installation of
timing belt pulley
For
prevention of
engine rotation
For
prevention of
engine rotation 49 EOll IA0
Ring gear brake
set
49 EOll 105
Stopper
0
(Part of
49 EOI 1
1AO) w
49 SE01 310A
Centering tool,
clutch disc For
prevention of
engine rotation
For
prevention of
engine rotation
For
installation of
clutch disc
2311082-0‘
02-I 1