1992 MAZDA PROTEGE tow

62 ASSEMBLY
I OWOBX-21!
I CYLINDER HEAD SIDE
05UOBX-2
I
05UOBX-21 6
i
17
05UOBX-2
2. Slide the valve seal onto the valve guide.
3. Set the
SST against the valve seal.
Caution
l Do not use a hammer.
4. Press the valve seal on until the SST contacts the cylinder
head.
Valve and Valve Spring
1. Install the lower spring seat.
2. Install the valve.
Caution
l Install the spring with the closer pitch toward the
cylinder head. .---
3. Install the valve spring and the upper spring seat.
4. Compress the valve spring with the
SST, and install the
valve keepers.
5. Remove the
SST.
6. Tap the end of the valve stem lightly two or three times with
a plastic hammer to verify that the keepers are all fully
seated.
Cylinder Head Gasket
1. Remove all foreign material from the top of the cylinder
block.
2. Place the new cylinder head gasket in position.
82-80

OIL PUMP D
OIL PUMP
DISASSEMBLY / ASSEMBLY
1 Disassemble in the order shown in the figure, referring to Disassembly Note.
2: Assemble in the reverse order of disassembly, referring to Assembly Note.
FACE THE DIMPLE
TOWARD THE PUMP COVER
WHEN ASSEMBLING
O-90 cm-kg, 52-78 in-lb)
-8
23UODX-014
1. Oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Assembly Note .,,..,.....,..,............ page D-14
2. Pump cover
Inspect for distortion or damage 6. Spring seat
7. Pressure spring
Inspection ..,..,.....,..,..,..,.............. page D-l 4
8. Control plunger
Inspect for wear or damage
9. Pump body
3. Outer rotor
4. Inner rotor
5. Roll pin
PROTECT PUMP
BODY WITH RAG
x9 05UODX-OC IO
Inspect for distortion or damage
Disassembly Note
Oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
D-13

J2 TRANSAXLE
03UOJZ018
Driveshaft
Caution
l Do not shock the tripod joint when removing the
driveshaft.
1. Separate the driveshaft from the transaxle by prying with
a bar inserted between the outer ring and the transaxle.
2. Suspend the driveshaft with a rope.
Transaxle
1. Lean the engine toward the transaxle.
2. Support the transaxle with a jack.
3. Remove the transaxle mounting bolts.
4. Remove the transaxle.
DISASSEMBLY
Precaution
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry
with compressed air. Clean out all holes and passages with compressed air, and verify that there are no
obstructions.
3. Wear eye protection when using compressed air to clean components.
03UOJ2-020
J2-12

ENGINE SPEED SENSING POWER STEERING N
I I
-.
* :I
-3==T
I
, 93GONX-031
93GONX-03 2
I
93GONX-03 3
I
03UONX-822
t
~ t
93WJNX-03
Oil seal and bearing
1. Use the SST to remove the bearing and the oil seal from
the plug.
Caution
l The oil seal can not be reused.
Outer box assembly
1. Use the SST to remove the outer box.
Oil seal and inner guide
1, Use the SST to remove the oil seal and inner guide toward
the cylinder side.
Caution
l The oil seal can not be reused.
lnspectlon
Steerlng rack
1. Check the rack for cracking or other damage or for abnor-
mal wear of the teeth; replace it if necessary.
2. Check the seal ring installation part of the rack for abnor-
mal wear or damage; replace it if necessary.
3. Use V blocks to support both ends of the large-diameter
part of the rack; check for excessive bending; replace it if
necessary.
Bending limit: 0.15mm (0.006 In) (near rack center)
Plug
1. Check for scratches or other damage at the oil seal instal-
lation inner diameter; replace it if necessary.

CONVENTIONAL BRAKE SYSTEM P
03UOPX-039
ARROW MARK
23UOPX-Old
Check valve
Inspection
1. Disconnect the vacuum hose (with intenal check valve) from
the engine side.
2. Apply suction and pressure to the hose from the engine side.
Verify that air flows only toward the engine.
Caution
l If the check valve is bad, replace the hose with the
valve.
3. Install the vacuum hose with the arrow facing the engine.
P-15

WHEEL ALIGNMENT
Camber and Caster
1, Jack up the front of the vehicle and support it with safety
stands.
2. Remove the mounting block nuts.
-
1 BUORX-01
23UORX-0;
3. Push the mounting block downward, and turn it to the
desired position.
Direction indicator
position
A
: Difference from standard position
Camber angle Caster angle
+14’ +14’
+29’ O0
+14’ -14’
4. Install and tighten the mounting nuts to the specified torque.
Tightening torque:
29-40 Nnrn (3.0-4.1 m-kg, 22-30 ft-lb)
Total toe-in
1. Loosen the left and right tie rod locknuts, then turn the tie
rods equally.
Caution
l The left and right tie rods are both right threaded,
so, to increase the toe-in, turn the right tie rod to-
ward the front of the vehicle and the left tie rod
equally toward the rear.
l One turn of the tie rod (both sides) changes the toe-
in by about 6mm (0.24 in).
2. Tighten the tie rod locknuts.
Tightening torque:
34-50 N-m (3.5-5.1 m-kg, 25-37 ft-lb)

WINDSHIELD S
PROTECTOR
I SEALANT
mm (in)
.
03uosx-09
GLASS /
SPACER
mm (in
03uosx-1c
PROTEG6
MOLDING MOLDING
SEALANT SEALANT
CROSS-SECTION
mm (in)
03uosx-1c
7. Align the protector on the body, and attach it securely as
shown.
8. Prepare the nozzle of the sealant gun so that it has a flange
that can run along the edge of the glass and a V from which
the sealant can flow. Once the primer is dry, apply the seal-
ant around the entire circumference of the glass to fill the
gap between the dam and the edge of the glass with a ridge
of sealant
12mm (0.47 in) high.
Keep the bead of sealant smooth and even, reshaping it
where necessary with a spatula.
9. Lift the glass into place. Push it in lightly toward the vehicle
to compress the sealant.
Caution
l Open the windows to prevent the glass from being
pushed out by air pressure if a door is closed.
Hardening time of repair seal
I Temperature Surface hardening Time required until car
time can be put into service
I
5% (41 OF) Approx. 1.5 hrs 12 hrs
2ooc (68OF) Approx. 1 hr
4 hrs
35OC (95OF)
Approx. 10 min 2 hrs
10. Align the upper windshield molding on the body as shown,
and push the molding into place along the top.
Note
l Install the molding before the sealant has hardened.
11. Check for water leaks. If a leak is found, wipe the water off
well and add
sealant (BOO1 77 739) where needed.
S-61

S REAR WINDOW GLASS
03uosx-11
WOTEGk GLASS
SPACER
-lATCHBACk
GLASS
SPACER
mm (in
03uosx-11
6. Prepare the nozzle of the sealant gun so that it has a flange
that can run along the edge of the glass and a V from which
the sealant can flow. Once the primer is dry, apply the seal-
ant around the entire circumference of the glass to fill the
gap between the dam and the edge of the glass with a ridge
of sealant
12mm (0.47 in) high.
Keep the bead of sealant smooth and even, reshaping it
where necessary with a spatula.
7. Lift the glass into place. Push it in lightly toward the vehicle
to compress the sealant.
Caution
l Open the windows to prevent the glass from being
pushed out by air pressure if a door is closed.
Hardening time of repair seal
Temperature Surface hardening Time required until car
time can be put into service
5T (41 OF) Approx. 1.5 hrs 12 hrs
2o”c (6WF) Approx. 1 hr 4 hrs
35% (95OF) Approx. 10 min 2 hrs
8. Use a scraper to smooth away any sealant that oozes out.
Add more sealant to any points of poor contact.
9. Check for water leaks. If a leak is found, wipe the water off
well and add
sealant (BOO1 77 739) where needed.
S-66