1992 MAZDA PROTEGE height

I32 INSPECTION / REPAIR
INSPECTION / REPAIR
PREPARATION
SST
49 6012 005 49 6012 005
Remover & Remover &
installer, valve installer, valve
guide guide
49 LO12 002
Body
(Part of
49 LO12 OAO)
49 LO12 004
Nut
(Part of
49 LO12 OAO) For
removal of
valve guide
For
installation of
valve guide
For
installation of
valve guide 49 LO12 OAO
Installer set,
valve seal &
valve guide
49 LO12 003
Installer
(Part of
49 LO12 OAO) For
installation of
valve guide
For
installation of
valve guide
05UOBX-1
1. Clean all parts, being sure to remove all gasket fragments, dirt, oil or grease, carbon, moisture residue,
and other foreign materials.
2. Inspection and repairs must be performed in the order specified. -.,
Caution
l Do not damage the joints or friction surfaces of aluminum alloy components (such as the cyl-
inder head or pistons).
0311082-162
03UOB2-70 OWOBX-119
CYLINDER HEAD
1, Inspect the cylinder head for damage, cracks, and leakage
of water and oil. Replace the cylinder head if necessary.
2. Measure the cylinder head distortion in the six directions
shown in the figure.
Distortion: O.lOmm (0.004 in) max.
Cautlon
l Before grinding the cylinder head, check the follow-
ing and repair or replace the cylinder head as
necessary.
Sinking of valve seats
Damage of manifold contact surface
Camshaft oil clearances and end play
3. If the cylinder head distortion exceeds specification, grind
the cylinder head surface.
If the cylinder head height is not within specification, replace
it. Height: 133.8-l 34.0mm (5.268-5.276
in)
Grinding: O.lOmm (0.004 in) max.
62-64

82 INSPECTION / REPAIR
03UOB2-082
13UOB2-0.
1
9MUOB2-112
I
03UOB2-08:
8. Measure the height @of each valve guide. Replace the
valve guide if necessary.
Height: 18.3-l 8.9mm (0.720-0.744 in)
Replacement of valve guide
Note
l The valve guides are different between intake and
exhaust sides, use the correct valve guide.
Removal
1. Remove the valve guide from the side opposite the com-
bustion chamber with the
SST.
Installation
1. Assemble the SST so that depth L is as specified.
Depth L: 18.3-18.9mm (0.720-0.744 in)
2. lighten the locknut.
3. Tap the valve guide in from the side opposite the combus-
tion chamber until the
SST contacts the cylinder head.
4. Verify that the valve guide height is within specification.
5. If not within specification, repeat Steps 1-4.
82-56

B2 INSPECTION / REPAIR
23UOB2-060
i$
03UOB2-08
ANGLE LIMIT
Ii
0311082.Ot
w v
05UOBX-138
03UOB2-OE
82-58
I8
9. Measure the protruding length (dimension L) of the valve
stem.
Dimension L: 45.0mm (1.7717 in)
(1) If L is 45.0-45.5mm (1.772-l .791 in), no correc-
tion needed.
(2) If L is 45.5-46.5mm (1.791-l .831 in), adjust with
washer on spring seat area of cylinder head.
(3) If L is 46.5mm (1.831 in) or more, replace cylinder
head.
Valve Spring
1. Inspect each valve spring for cracks or damage.
2. Measure the free length and out-of-square. Replace the
valve spring if necessary.
Free length
Standard: 46.26mm (1.821 in)
Minimum:
224-253 N (22.8-25.8 kg, 50-57 lb)/
395mm (1.555 in)
Out-of-square: 1.62mm (0.064 in) max.
CAMSHAFT
1. Set the front and rear journals on V-blocks.
2. Measure the camshaft runout. Replace the camshaft if
necessary.
Runout: 0.03mm (0.0012 in) max.
3. Inspect the camshaft for wear or damage. Replace the cam-
shaft if necessary.
4. Measure the cam lobe heights at the two points as shown.
Height
Standard
IN : 44.094mm (1.7360 in)
EX: 44.600mm (1.7560 in)
Minimum
IN : 43.894mm (1.7281 in)
EX: 44.400mm (1.7480 in)

B2 INSPECTION / REPAIR
r--
1
05UOBX-14
I -
L
05UOBX-149
82-60
(8) Measure the oil clearances.
Oil clearance:
0.035-0.081 mm (0.0014-0.0032 in)
Maximum: 0.15mm (0.006 in)
(9) If the oil clearance exceeds specification, replace the
cylinder head.
7. Measure the camshaft end play. If the end play exceeds
specification, replace the camshaft and/or the cylinder head.
End play : 0.07-0.19mm (0.0028-0.0075 in)
Maximum: 0.20mm (0.008 in)
HLA
Caution
l Do not attempt to repair the HLA.
1, Inspect the HLA friction surfaces for wear or damage. Re-
place the HLA if necessary.
2. Hold the bucket body and press the plunger by hand. If
the plunger moves, replace the HLA.
CYLINDER BLOCK
1. Inspect the cylinder block for the following. Repair or re-
place the cylinder block as necessary.
(1) ‘Leakage damage.
(2) Cracks.
(3j Scoring of wall.
2. Measure the distortion of the top surface of the cylinder block
in the six directions shown in the figure.
Distortion: 0.15mm (0.006 in) max.
3. If the distortion exceeds specification, repair by grinding’or
replace the cylinder block.
Height : 221 Smm (8.720 in)
Grinding: 0.20mm (0.008 in) max.

E OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
B6 SOHC
BP SOHC BP DOHC
MTX
1 ATX 1 MTX ATX 1 MTX
ATX
Cooling system
Water-cooled, forced circulation
Coolant capacity liters (US qt, Imp qt) 5.0 6.0
5.0
(5.3, 4.4) (6.3, 5.3)
(5.35.04.4) (6.zi.3) (5.3, 4.4) (6.::.3)
Water
pump
Thermostat
Radiator
Cooling fan
L Type
Water seal Centrifugal
Unified mechanical seal
Type Opening temperature
‘C (OF’) Wax, two-stage
Main: 86.5-89.5 (188-193)
Sub : 83.5-86.5 (182-188)
Full-open temperature
OC (OF)
Full-open lift mm (in)
Type
Cap valve opening
pressure 100 (212)
Main: 8.0 (0.31) min.
Sub : 1.5 (0.06) min.
Corrugated fin
74-103 (0.75-1.05, 11-15)
kPa (kg/cm2, psi)
Width
Core size Height
mm (in)
Depth
Fin pitch
mm (in) 647 (25.47)
390 (15.35)
16 (0.63) 1 25 (0.98) 1 16 (0.63) 1 25 (0.98) 1 16 (0.63) 1 25 (0.98)
1.3 (0.051)
Heat dissipation capacity
kcallh 1 38,800 [ 43,800 ( 38,800 1 43,800 1 38,800 1 43,800 1
Type
Transaxle Heat
oil cooler dissipation
capacity
kcallh
Tvoe
- Laminated - Laminated -
Laminated
1,700
I .I -?nn
- -
I,,“”
I
I - I 4 Ye,-. I,IVV 1
, a-
- Electric
Number of blades 4
Outer diameter mm (in)
320 (12.6)
Capacity w-v 80-12 1 160-12 ) 80-12 ) 160-12 1 80-12 1 160-12
1 Hi: 13.3+ 1 1 Hi: 13.3+ 1 1 Hi: 13.3+
Current
TROUBLESHOOTING GUIDE I I I I
Problem Possible Cause
Overheating
Coolant level insufficient
Coolant leakage
Radiator fins clogged
Radiator cap malfunction
Cooling fan malfunction
Thermostat malfunction
Water passage clogged
Water puma malfunction .- Remedy Page
Add
Repair
Clean
Replace
Replace
Replace
Clean
Reolace E- 6
E-9
E- 7
E-13
E- 9
E- 6
E-11
I Corrosion
1 Impurities in coolant 1 Replace
I E-6 I
03UOEX-005

F CONTROL SYSTEM
23UOFX-15
23UOFX-15
23UOFX-15
LOCK
4
I
13UOFX-oc
F-l 72
6. Turn the ignition switch OFF.
7. Disconnect the negative battery terminal for
at least 20 sec.
to eliminate the malfunction code that was created during
inspection from the control unit memory.
Replacetnent
1. Disconnect the oxygen sensor connector.
2. Remove the oxygen sensor.
3. Install in the reverse order of removal.
Tightening torque:
29-49 N-m (3-5 m-kg, 22-36 ft-lb)
MAIN RELAY (FUEL INJ RELAY)
Inspection
1. Verify that the main relay clicks when turning the ignition
switch ON and OFF.
2. Apply battery voltage to terminal A and ground terminal E3
of the main relay.
3. Check continuity of the terminals as shown.
VB: Battery voltage
Terminals 1 Ve not applied VB applied
C-D No continuity Continuity
4. If not as specified, replace the main relay.
CLUTCH SWITCH (MTX)
Inspection
1, Disconnect the clutch switch connector.
2. Connect an ohmmeter to the switch.
3. Check continuity of the switch.
Pedal Continuity
Depressed Yes
Released No
4. If not as specified, replace the clutch switch. ,
Replacement
1. Disconnect the clutch switch connector.
2. Loosen the locknuts.
3. Remove the clutch switch.
4. Install in the reverse order of removal.
5. Adjust the pedal height. (Refer to page H-6.)

OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
-
-
Item
Clutch control Engine/Transaxle B6 SOHC BP SOHC BP DOHC
F!Wl-R GBM-R Hvdraulic
Clutch cover
Clutch disc Type
Set load Diaphragm spring
N
(kg, lb) 1 3,630 (370, 814) 1 3,826 (390, 858) 1 3,846 (392, 862)
30 17.48)
200 (7.87) 215 (8.46) Outer diameter mm (in)
Inner diameter mm (in)
Pressure plate
side mm (in)
Thickness
Flywheel side
mm lit-d
1! , I
130 (5.12) ’ ’
150 i5.91 j
3.5 (0.138) 3.8 (0.150)
3.5 (0.138)
Type Suspended
Clutch pedal
Master cylinder
Release cylinder
Clutch fluid Pedal ratio 6.55
Full stroke mm (in) 135 (5.32)
Height (With carpet)
mm (in) 196-204 (7.72-8.03)
Inner diameter mm (in) 15.87 (0.625)
Inner diameter
mm (in) 19.05 (0.750)
SAE J1703 or FMVSS116 DOT-3
23UOHX-003
TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page
Slipping
Clutch disc facing worn excessively Replace H-15, 17
Clutch disc facing surface hardened or oil on surface Repair or replace H-15
Pressure plate damaged Repair or replace H-15
Diaphragm spring damaged or weakened Replace H-15
Insufficient clutch pedal play Adjust H- 5
Clutch pedal sticking Repair or replace H- 6
Flywheel damaged Repair or replace H-15, 17 Faulty disen-
Excessive runout or damaged clutch disc Replace H-15, 17 gagement Clutch disc splines rusted or worn Remove rust or replace H-15
Oil on facing Repair or replace H-15
Diaphragm spring weakened Replace H-15
Excessive clutch pedal play Adjust H- 5
Insufficient clutch fluid
Add fluid H- 3
Leakage of clutch fluid Locate and repair or -
replace Clutch vibrates
Oil on facing Repair or replace H-15 when accelerating Torsion rubbers weakened Replace H-15
Clutch disc facing hardened or damaged Repair or replace H-15
Clutch disc facing rivets loose Replace H-15
Pressure plate damaged or excessive runout Replace H-15
Flywheel surface hardened or damaged Repair or replace H-15
Loose or worn engine mount Tighten or replace - Clutch pedal
Pedal shaft not properly lubricated Lubricate or replace H- 6 sticking
Abnormal noise
Clutch release bearing damaged Replace H-15, 17
Poor lubrication of release bearing sleeve Lubricate or replace H-15
Torsion rubbers weakened Replace H-15
Excessive crankshaft end play Repair Refer to Section E
Pilot bearing worn or damaged Replace H-15, 18
Worn pivot points of release fork Repair or replace H-15
^^. .^. I~, ^r
H-3

CLUTCH PEDAL H
@ 14-19
(1.4-1.9, 10-13)
N.m (m-kg, R-lb)
CLUTCH PEDAL
ADJUSTMENT
Clutch Pedal Height
Inspection
1. Measure the distance from the upper surface of the pedal
pad to the carpet.
Pedal height: 196-204mm (7.72-6.03 in)
(With carpet)
2. If necessary, adjust the pedal height.
Adjustment
1. Disconnect the clutch switch connector.
2. Loosen locknut @and turn clutch switch @until the height
is correct.
3. Tighten locknut @ .
Tightening torque:
14-16 N*m (1.4-1.6 m-kg, IO-13 f&lb)
4. After adjustment, measure the pedal free play.
Clutch Pedal Free Play
Inspection
1. Depress the clutch pedal by hand until clutch resistance
is felt.
Pedal free play: 0.7-3.3mm (0.03-0.13 in)
Total pedal free play: 5.0-13mm (0.197-0.512 in)
2. If necessary, adjust the pedal free play.
Adjustment
1. Loosen locknut Oand turn push-rod @until pedal free play
is correct.
2. Check that the disengagement height (from the upper sur-
face of the pedal to the carpet) is correct when the pedal
is fully depressed. 23UOHX-OC
Minimum disengagement height: 41 mm (1.61 in)
(With carpet)
3. Tighten locknut 0.
Tightening torque:
12-17 N-m (1.2-I .7 m-kg, 9-12 ft-lb)
4. After adjustment, inspect the pedal height.
H-5