1992 MAZDA PROTEGE Workshop Manual

--
ASSEMBLY B2
2311082-06
2311082.04
1
03UO62-09!
J 2311062-063
4. Hold the flywheel with the SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
96-l 03 N.m (9.6-10.5 m-kg, 71-76 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:
16-26 N.m (1.8-2.7 m-kg, 13-20 ft-lb)
Drive Plate (ATX)
1. Remove the sealant from the drive plate holes in the crank-
shaft and from the drive plate lock 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 adapter, drive plate, and backing plate onto the
crankshaft.
3. Apply sealant to the drive plate bolts and install them.
4. Hold the drive plate with the
SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown.
Tightening torque:
96-103 N.m (9.8-10.5 m-kg, 71-76 ft-lb)
Timing Belt Pulley
1, Reverse the direction of the SST or equivalent on the
flywheel.
2311082.064
B2-77

I32 ASSEMBLY
Qill’ ’ 23UOB2-050
03UOB2-10
2. Install the timing belt pulley.
3. install the pulley Woodruff key with the tapered side toward
the oil pump body.
4. Install the pulley lock bolt.
5. Tighten the pulley lock bolt.
Tightening torque:
157-167 N#rn (16-17 m-kg, 116-123 ft-lb)
Water Pump
1. Remove all foreign material from the water pump mount-
ing surface.
2. Install the water pump and a new gasket.
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
82-78

ASSEMBLY 82
CYLINDER HEAD
Torque Specifications
11.3-l 4.2 N.m
(1.15-1.45 m-kg, loo-126 In-lb) 4.9-8.6 N.m
(50-90 cm-kg, 43-76 In-lb)
I I I I -
I I I . 7.6-11 N.m JOURNALS AND
-CAM FACES
(60-I 10 cm-kg, 69-96 in-lb) BOLT THREADS
AND SEAL FACES
5.9-6.6 N.m
(60-90 cm-kg, 52-76 in-lb)
a .e..IC..T .*-*.a
I
UHYKtl NtW
.g~fET NEW
. *
-96 cm-kg,
N.rn (m-kg, &lb)
Valve Seal
03UOB2-1
1. Assemble the SST so that depth L is as specified.
Depth L: 19.b20.0mm (0.780-0.787 in)
B2-79

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

ASSEMBLY
05UOBX-221
I 0311082-10
Cylinder Head
1. Install the cylinder head.
2. Apply clean engine oil to the bolt threads and seat faces.
3. Tighten the cylinder head bolts in two or three steps in the
order shown.
Tightening torque:
76-61 Nsrn (7.7-8.3 m-kg, 56-60 ft-lb)
Water Thermoswitch, Heat Gauge Unit
1. Install the water thermoswitch.
Tightening torque:
5.9-8.8 N#m (60-90 cm-kg, 52-78 in-lb)
2. Install the heat gauge unit.
Tightening torque:
6.4-9.3 N.m (65-95 cm-kg, 56-82 in-lb)
Thermostat, Thermostat Cover
1. Remove all foreign material from the thermostat cover
mounting surface.
2. Install the thermostat with the jiggle pin facing upward.
Caution
l The printed side of the gasket must face the ther-
mostat.
3. Install a new gasket and the thermostat cover.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
HLA
1. Apply clean engine oil to the friction surfaces.
2. If the HLA are being reused, install them in the position from
which they were removed.
3. Verify that the HLA move smoothly in their bores.
05UOBX.223
B2-81

B2 ASSEMBLY
DlSTRlBUfOR
DRIVE GROOVE
-- 03umx-01
-
05UOBX-05
--____--
udOBX-056
---I
Camshaft
Note
l The exhaust camshaft is grooved for the distribu-
tor drive.
1. Apply clean engine oil to the camshaft journals and bearings.
2. Install the camshaft in position.
Caution
l Do not allow any sealant on the camshaft journal
surfaces.
3. Apply silicone sealant to the shaded areas shown in the
figure.
4. Install the camshaft caps according to the cap number and
arrow mark.
5. Install the camshaft cap bolts and tighten them in two or
three steps in the order shown in the figure.
Tightening torque:
11.3-14.2 Nlm (1.15-l .45 m-kg, loo-126 in-lb)
6. Apply a small amount of clean engine oil to the lip of a new
camshaft oil seal.
7. Push the oil seal slightly in by hand.
Caution
l The oil seal must be tapped in until it is flush with
the edge of the camshaft cap.
8. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 48mm (1.89 in)
Seal Plate
1. Install the seal plate on the cylinder head.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
~,. ,
03”oEm10:
B2-82

ASSEMBLY 82
DOWEL PIN
23UOB2-042
03UOB2-1 OL Camshaft Pulley
1. Turn the camshafts until the camshaft dowel pins face
straight up.
2. Install the camshaft pulleys with the
I mark (intake side) or
the E mark (exhaust side) straight up.
3. Install the camshaft pulley lock bolts.
4. Hold the camshaft with a wrench at hexagonal portion.
5. Tighten the camshaft pulley lock bolt.
Tightening torque:
49-61 N.m (5.0-6.2 m-kg, 36-45 ft-lb)
Cylinder Head Cover
1. Apply silicone sealant to the shaded areas shown in the
figure.
2. Install the cylinder head cover.
Tightening torque:
4.9-6.6 N.m (50-90 cm-kg, 43-76 in-lb)
82-83

B2 ASSEMBLY
TIMING BELT
Torque Specifications
7.6-11 N:m
(60-l 10 cm-kg,
69-95 in-lb) \
-kg, 69-95 in-lb)
37-52
(3.8-5.3, 27-38)
157-167 (16-17, 116-123)
?.a--11 N-m
(60-110 cm-kg, 69-95 in-lb) /
12-17 (1.25-1.76, 9-13)
N-m (m-kg, ft-it
03UOB2.1
Idler
1. Install the idler.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Tensioner and Tensioner Spring
1. Install the tensioner and the tensioner spring.
2. Temporarily secure the tensioner with the spring fully ex-
tended.
-’
o5uoBx-229
02-84