1992 MAZDA PROTEGE Workshop Manual

DISASSEMBLY B2
CYLINDER HEAD
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
OIL SEAL, REPLACE
GASKET, REPLACE
1. Cylinder head cover 11. Cylinder head
2. Camshaft pulley Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-54
Disassembly Note . . . .., ,.... . . . . . . . . . page 82-46 12. Cylinder head gasket
Inspection . . . . . . . . . . . . . . . .., . . . . . . . . . . . . . page 82-65 13. Valve keeper
3. Seal plate Disassembly Note . . . . . . . . . . . . . . . . . . . . page B2-46
4. Camshaft 14. Valve spring seat, upper
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 82-46 15. Valve spring
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-58 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-58
5. HLA 16. Valve spring seat, lower
Disassembly Note . . . . . . . . . . . . . . . . . . . . page B2-46 17. Valve
Inspection ,........,,..,.,....,..,,.,..,... page B2-60 Inspection ..,.............................. page 82-55
6. Thermostat cover 18. Valve seal
7. Thermostat Disassembly Note ..,................. page B2-47
8. Water thermoswitch Inspect for wear or damage
9. Heat gauge unit 19. Valve guide
IO. Cylinder head bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-55
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 82-46 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-56
82-45

82 DISASSEMBLY
2311082-03
r HLA
r
05UOBX-04!
2311082-03
I
05UOBX-1C
82-46
Disassembly Note
Camshaft pulley
1, Hold the camshaft with a wrench at hexagonal portion.
2. Remove the camshaft pulley lock bolt.
3. Remove the camshaft pulley.
Camshaft
1. Loosen the camshaft cap bolts in two or three steps in the
order shown in the figure.
2. Remove the camshaft caps
3. Remove the camshaft.
4. Remove the camshaft oil seal from the camshaft.
Caution
l Mark the HLA with a felt pen so that they can be reln-
stalled in the position from which they were
removed.
1. Remove the HLA from the cylinder head.
Cylinder head bolts
1. Loosen the cylinder head bolts in two or three steps in the
order shown in the figure.
2. Remove the cylinder head bolts.
Valve keeper
1. Set the SST against the upper valve spring seat as shown
in the figure.
2. Remove the valve keepers.

DISASSEMBLY 82
Valve seal
1 I Remove the valve seal with the SST.
02-47

B2 DISASSEMBLY
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
I
@ma @a% GASST, REPLACE
GASKET,
REPLACE
/
d I @REPLACE
23UOB2-0
1. Water pump
Service ..,....,..,......,.,.,,.....,,.,.......... Section E
2. Timing belt pulley and lock bolt
Disassembly Note . . . . . ..,.,........,. page 82-49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-65
3. Clutch cover, clutch disc (MTX)
Service . . . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
4. Flywheel (MTX)
Disassembly Note ,.. . . . . . . . . . . . . . . . . . page 82-49
Inspect for wear or damage
5. Backing plate, drive plate, and adapter (ATX)
Disassembly Note . . . . ,., ,..... . . . . . . . page B2-49
6. End plate 7. Oil pan and gasket
Disassembly Note .,.................. page 82-49
Inspect for damage
8. Oil strainer
9. Main bearing support plate (MBSP)
Disassembly Note . . . ., . . . . . ..,.... . . . page B2-50
Inspect for damage
10. Oil pump
Service . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
11. Front oil seal
Disassembly Note .,.................. page 82-50
12. Rear cover
13. Rear oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page B2-50
B2--48

DISASSEMBLY
23UOW056
03UOB2-073
Disassembly Note
Timing belt pulley
1. Hold the flywheel or the drive plate 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.
23UOB2-049
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
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.
Oil pan
1. Remove the oil pan mounting bolts.
Caution
l Do not force a prying tool between the cylinder
block and the oil pan, which may damage the con-
tact surfaces.
l Do not damage or scratch the contact surfaces
when removing the old sealant.
2. Insert a screwdriver or a suitable tool only at the points
shown in the figure.
3. Remove the oil pan.
82-49

82 DISASSEMBLY
-. 05UOBX-10
-
REAR COVER
-.
05UOBX-10
Main bearing support plate (MBSP)
1, Remove the MBSP mounting bolts.
Caution
l Do not damage or scratch the contact surfaces
when removing the old sealant.
2. Insert a screwdriver or a suitable tool at the points shown
in the figure.
3. Remove the MBSP.
Front oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
Rear oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
92-50

B2
CYLINDER BLOCK (INTERNAL PARTS)
1. Disassemble in the order shown in the fioure, referring to Disassembly Note.
I. Connecting rod cap 7. Piston
Disassembly Note ,..,.,., ,.,..... ,, ,. page B2-52 Inspection ,.. . . ,.. . . . . . . . . . page 82-62
2. Connecting rod 8. Main bearing cap
Disassembly Note ..,.. . . . . . . ,. page B2-52 Disassembly Note .,,,..,..,...... ~.,. page 82-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . page B2-63 9. Crankshaft
3. Connecting rod bearing Disassembly Note ,... . . . . . . page 92-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-64 Inspection ,......,,.,._.................... page B2-64
4. Piston ring 10. Main bearing
Disassembly Note .,...........,.,..,. page B2-52 Inspection ., ,... . . . page B2-64
Inspection ..~ ,., . . . . . . . . . page B2-62 Il. Thrust bearing
5. Piston pin clip 12. Oil jet
6. Piston pin Inspection ,..,..,., ,..,.., . . . . . . . . . . . . . . . . page B2-61
Disassembly Note ,.. . . . . . . page B2-52 13. Cylinder block
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 82-63 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page B2-60
B2-51

82 DISASSEMBLY
03UOB2-071 6
- ____-______---..----. 05UOBX 113
------ -__ .---
7
Disassembly Note
Connecting rod cap
1. Before removing the connecting rod caps, measure the con-
necting rod side clearance. (Refer to page B2-71.) 1
Connecting rod
1. Before removing the connecting rods, measure the connect-
ing rod oil clearance. (Refer to page B2-71.)
2. Remove the Plastigage from the crankpin journals,
Caution
l Do not scratch the crankshaft journal or the cylin-
der wall.
-,
3. Use the handle of a hammer to remove the piston and con-
necting rod assembly through the top of the cylinder block.
Piston ring
Caution
l Do not apply excessive tension, which may cause
the rings to snap out.
1. Remove the piston rings with a piston ring expander (com-
mercially available).
Piston pin
1. Remove the piston pin with the SST.