1992 MAZDA PROTEGE lock

Bl
ENGINE
(SOHC)
INDEX .......................................... Bl- 2
OUTLINE ...................................... Bl- 3
SPECIFICATIONS ........................
Bl- 3
TROUBLESHOOTING GUIDE ..........
Bl- 3
ENGINE TUNE-UP PROCEDURE ......
Bl- 5
PREPARATION ............................ Bl- 5
ENGINE OIL ............................... Bl- 5
ENGINE COOLANT.. ....................
Bl- 5
DRIVE BELT ............................... Bl- 5
HLA .......................................... Bl- 7
IGNITION TIMING, IDLE SPEED
..... Bl- 8
COMPRESSION ............................. Bl-10
INSPECTION ............................... 81-10
ON-VEHICLE
MAINTENANCE.. ........
Bl-1 1
PREPARATION ............................ Bl-11
TIMING BELT .............................. Bl-12
CYLINDER
HEAD GASKET ........... Bl-16
HLA .......................................... Bl-20
FRONT OIL SEAL.. ...................... 81-23
REAR OIL SEAL ..........................
Bl-25
REMOVAL ..................................... 81-28
PROCEDURE .............................. Bl-28
ENGINE STAND MOUNTING.. .........
Bl-35
PREPARATION
............................ 81-35
PROCEDURE ..............................
Bl-36
DISASSEMBLY .............................. Bl-38
PREPARATION ............................ Bl-38
AUXILIARY PARTS.. ..................... 81-40
TIMING BELT .............................. 81-41
CYLINDER HEAD.. ......................
81-43
CYLINDER BLOCK
(EXTERNAL PARTS)
................... 81-47
CYLINDER BLOCK
(INTERNAL
PARTS). ................... Bl-50 INSPECTION /
REPAIR.. .................
81-54
PREPARATION ............................ Bl-54
CYLINDER HEAD.. ...................... Bl-54
VALVE
MECHANISM.. .................. Bl-55
CAMSHAFT ................................ 81-58
HLA .......................................... Bl-60
CYLINDER BLOCK ......................
Bl-60
OIL JET ..................................... Bl-61
PISTON, PISTON RING, AND
PISTON PIN .............................. Bl-62
CONNECTING ROD.. ...................
Bl-63
CRANKSHAFT ............................ Bl-64
BEARING ................................... 81-64
TIMING BELT .............................. Bl-65
TENSIONER,
IDLER.. ................... 81-65
TENSIONER SPRING ...................
81-65
PULLEY ..................................... Bl-65
ASSEMBLY ................................... Bl-66
PREPARATION ............................ Bl-66
CYLINDER BLOCK
(INTERNAL PARTS). ................... Bl-68
CYLINDER BLOCK
(EXTERNAL PARTS) ...................
Bl-74
CYLINDER
HEAD.. ...................... 81-79
TIMING BELT .............................. Bl-86
AUXILIARY
PARTS.. ..................... Bl-89
ENGINE STAND DISMOUNTING.. .... Bl-92
PROCEDURE .............................. 81-92
INSTALLATION ............................. 81-94
PROCEDURE .............................. Bl-94
23UOBl-001

ENGINE TUNE-UP PROCEDURE Bl
Tightening torque
@ : 37-52 N,m (3.8-5.3 m-kg, 27-38 ft-lb)
@ : 19-25 Nsm (1.9-2.6 m-kg, 14-19 ft-lb)
23UOBl-OC
P/S belt, P/S + A/C belt
If necessary, loosen the P/S oil pump bolts @and nut @and
Oand adjust the belt deflection by turning the adjusting bolt
0.
Tightening torque
@I : 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)
A/C belt
If necessary, loosen the locknut @and adjust rhe belt deflec-
tion by turning the adjusting bolt @.
Tightening torque:
31-34 N-m (3.2-3.5 m-kg, 23-25 ft-lb)
1
HLA
Problem Possible Cause Action
1. Noise when engine is started immedi- Oil leakage in oil passage Run engine 2000-3000 rpm.
ately after oil is changed. If noise stops after 2 second-10
2. Noise when engine is started after set- minutes(*), HLA is normal.
ting approx. one day. If not, replace HLA.
3. Noise when engine is started after Oil leakage in HLA - * Time required for engine oil to circu-
cranking for 3 seconds or more. late within engine, includes tolerance
4. Noise when engine is started after for engine oil condition and ambient
new HLA is installed. temperature.
5. Noise continues more than 10 minutes Insufficient oil pressure 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 81-60)
Press down HLA by hand.
If it does not move,. HLA is normal.
If it moves, replace HLA.
t
I
Measure valve clearance.
If more than Omm (0 in), replace HLA.
5. Noise occurs durning idle after high-
speed running Incorrect oil amount
Deteriorated oil Check oil level.
Drain or add oil as necessary.
Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
23UOBl-01
Bl-7

Bl ENGINE TUNE-UP PROCEDURE
13UOBi-036
-i
OWOBX-261
13UOBl-08
LOCK BOLTS
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
IG- ter-
minal as shown.
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) ter-
minal 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: (at idle speed)
B6 SOHC
BTDC 70 f 10 BP SOHC
5O f lo
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 (1.9-2.6 m-kg, 14-19 ft-lb)
5. Disconnect the SST.
Bl-8
13UOBl-039

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

Bl 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, referrina to Installation Note.
7.6-11 N.m
[SO-110 cm-kg, 69-95 in-lb)

7.6-11 N.m
(60-l 10 cm-kg,
0 69-95 in-lb)
, .v- I . (60-110 cm-kg, 69-95 in-lb)
157-167 (16-17, 116-123) /@ 7.i11 N.m
(60-110 cm-kg,
69-95 in-lb)
N.m (m-kg, ft-lb]
23UOBl-01
1. Under cover and side cover 10. Timing belt cover, lower
2. P/S and/or A/C drive belt 11. High-tension leads
3. Alternator drive belt 12. Spark plugs
4. Water pump pulley 13. Timing belt
5. Plate Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-13
6. Pulley lock bolt Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-13
Removal Note ..,.,,.,....,....,...,...,, page Bl-13 14. Tensioner
installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-14 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 81-13
7. Crankshaft pulley 15. Tensioner spring .__
8. Pulley boss Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 61-13
9. Timing belt cover, upper
131-12

-
. . .
ON-VEHICLE MAINTENANCE Bl
13EOBl-010
Removal Note
Pulley lock bolt
1. Hold the pulley with the SST.
2. Using the SST, loosen the pulley lock bolt.
3. Remove the pulley lock bolt and pulley boss.
MARKS
13EOBl-02
MARK -
DIRECTION
ROTATION
13EOBl-02
OBUOBX-0;
TIMING MARK
13EOBl.022
Timing belt
1. Install the pulley boss and pulley lock bolt.
2. Turn the crankshaft to align the timing marks.
Note
l The pin on the pulley boss must face upward.
Caution
l After setting the marks, do not turn the crankshaft
when removing the pulley lock bolt and pulley boss.
3. Remove the timing belt.
Note
l Mark the timing belt rotatlon for proper relnstal-
latlon.
Installation Note
Tensioner, tensioner spring
1. Install the tensioner and the tensioner spring.
2. Temporarily secure the tensioner with the spring fully ex-
tended.
Timing belt
1. Verify that the timing belt pulley and camshaft pulley mark
is aligned with the timing mark.
Bl-13

Bl ON-VEHICLE MAINTENANCE
13EOBl-023
MARKS
13EOBl-02, 4
I
03UOBl-02
98 N
(10 kg, 22 lb)
13EOBl-02 15
2. Install the timing belt so that there is no looseness at the
tension side.
Caution
l Do not turn the crankshaft. .-
3. Install the pulley boss and lock bolt.
4. Turn the crankshaft two turns clockwise, and face the pin
on the pulley boss upward.
5. Verify that the camshaft pulley marks are aligned with the
cylinder head cover marks.
If not aligned, remove the timing belt and repeat from ten-
sioner installation.
6. Loosen the tensioner lock bolt to apply tension to the tim-
ing belt.
Caution
l Be sure not to apply tension other than that of the
tensioner spring.
7. Tighten the tensioner lock bolt.
--
Tightening torque:
19-25 N,m (1.9-2.6 m-kg, 14-19 ft-lb)
8. Turn the crankshaft 2 turns clockwise and verify that the
marks are again correctly aligned.
9. Check the timing belt deflection by applying moderate pres-
sure (96 N,
10 kg, 22 lb) midway between the crankshaft
pulley and the camshaft pulley.
If the timing belt deflection is not correct, temporarily se-
cure tensioner lock bolt so the spring is fully extended.
Repeat Steps 4-8 above or, if necessary, replace the ten-
sioner spring.
Deflection:
11 .O-13.0mm (0.43-0.51 in) at 96 N (10 kg, 22 lb)
10. Using the SST remove the pulley lock bolt and pulley boss.
Pulley lock bolt
1. Install the crankshaft pulley boss, and using the SST, tight-
en the pulley lock bolt.
Tightening torque:
157-167 N,m (16-17 m-kg, 116-123 ft-lb)
91-14

ON-VEHICLE MAINTENANCE
FRONT OIL SEAL
Replacement
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.
I- I
I
I
I
157-167 (16-17, 116-123)
I
t
I
I
/
L---- -____ - _......_____________ -----------!
N.m (m-kg, It-lb)
^ ^ ^ -
_ _
1. Timing belt
- 3. Timing belt pulley
Removal I Installation..
.............. page
61-12 Installation
Note.. ......................
page Bl-24
2. Pulley lock bolt
4. Oil seal
Installation Note ........................
page Bl-24
Removal Note
..................................... below
Installation
Note.. ......................
page Bl-24
01 EOBX-055
Removal Note
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
61-23