1992 MAZDA PROTEGE Workshop Manual

ASSEMBLY
13EOB2.03
13EOB2-03.
3 1
03UOB2-111
23UOB2-04: 3
Timing Belt
1. Verify that the timing belt pulley mark is aligned with the tim-
ing mark.
2. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
3. Install the timing belt so that there is no looseness at the
idler side or between the camshaft pulleys.
4. Install the pulley boss and pulley lock bolt.
Caution
l Do not turn the crankshaft counterclockwise.
5. Turn the crankshaft two turns clockwise and face the pin
on the pulley boss upright.
6. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
If not aligned, remove the timing belt and repeat from ten-
sioner installation.
7. Turn the crankshaft 1 and 5/6 turns clockwise, and align
the timing belt pulley mark with the tension set mark for prop-
er timing belt tension adjustment.
8. Loosen the tensioner lock bolt to apply tension to the tim-
ing belt.
9. Tighten the tensioner lock bolt.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
10. Turn the crankshaft 2 and l/6 turns clockwise and verify
that the timing marks are correctly aligned.
B2-85

I 23UOB2-044
82 ASSEMBLY
DEFLECTION CHECKING POlNT
--; 11. Measure the timing belt deflection by applying moderate
oressure (98 N, 10 kg, 22 lb) midway between the two cam-
shaft pulleys.
If the deflection is not correct, repeat from Step 7 above.
Deflection:
9.0-11.5mm (0.35-0.45 in) at 98 N (10 kg, 22 lb)
Timing Belt Cover
1. Install the lower, middle, and upper covers.
Tightening torque:
7.8-11 N.m (80- ,110 cm-kg, 69-95 in-lb)
I 13EOB2-037
82-86
Pulley lock bolt
1. Hold the flywheel (MIX) or drive plate (ATX) with the SST
and tighten the pulley lock bolt.
Tlghtening torque:
157-167 N.m (16-17 m-kg, 116-123 ft-lb)
Cankshaft pully
1. Install the crankshaft pulley.
2. Install the plate.
3. Tighten the pulley bolts.
Tightening torque:
12-17 N-m (1.25-l -75 m-kg, 9-13 ft-lb)
Water Pump Pulley
1. Install the water pump pulley.
Tightening torque:
7.8-11 N*m (80-110 cm-kg, 69-95 in-lb)

ASSEMBLY B2
AUXILIARY PARTS
Toraue Specifications
19-25 19-25
O-RING, NEW
(1.9-2.6, 14-19) (1.9-2.6, 14-19)
-
I 19-25
mfi GASKET. NEW (1.9-2.6, 14-19)
37-52
(33-5.3, 27-38)
(3.8-5.3, 27-38)
7.8-11 N.m /
(80-110 cm-kg, 69-95 in-lb)
N.m (m-kg, A-lb)
.-. 05UOBX-23
Engine Hanger
1. Install the front and rear engine hangers.
OYJOBX-238
Tightening torque:
37-52 N*m (3.8-5.3 m-kg, 27-38 ft-lb)
82-87

82 ASSEMBLY
Oil Level Gauge Pipe Stay
1. Install the oil level gauge pipe stay.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 in-lb)
Oil Level Gauge
1. Install the level gauge.
Spark Plug
1, Install the spark plugs.
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 11-17 ft-lb)
Oil Pressure Switch
1. Install the oil pressure switch.
Tightening torque:
12-18 N-m (120-180 cm-kg, 104-156 in-lb)
Oil Cooler
1. Remove all foreign material from the oil cooler mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil cooler.
3. Install the oil cooler with paint mark (white) facing up.
4. Tighten the oil cooler lock nut.
Tightening torque:
29-39 N.m (3.0-4.0 m-kg, 22-29 ft-lb)
5. Connect the harness to oil pressure switch.
Oil Filter
1. Remove all foreign material from the oil filter mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil filter.
3. Install the oil filter and tighten it by hand until the rubber
seal contacts the base.
4. Tighten the filter 1 and 116 turns with a filter wrench. --_

ASSEMBLY B2
03UOB2-111
03UOB2-ill
03UOB2-119
No.3 Engine Mount Bracket
1. Install the No.3 engine mount bracket.
Tightening torque:
93-l 17 N-m (9.5-l 1.9 m-kg, 69-86 ft-lb)
Alternator and Drive Belt
1. Install the alternator and loosely tighten the mounting bolts.
2. Install the alternator drive belt.
3. Adjust the drive belt deflections. (Refer to page B2-6.)
Injector and Distribution Pipe Assembly
1. Install the new injector insulators to the cylinder head.
2. Install the injector and distribution pipe assembly to the cyl-
inder head.
Tightening torque:
19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
Intake Manifold Assembly
1. Remove all foreign material from the intake manifold con-
tact surface.
2. Install a new gasket and the intake manifold assembly.
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-l 9 ft-lb)
82-89

B2 ASSEMBLY
03UOB2-15:
I
03UOB2-121
3. Connect the harness and hose.
--’
Distributor and High-tension Lead
1. Apply grease to a new O-ring and the blade.
2. Install the distributor and loosely tighten the installation bolts.
3. Connect the high-tension leads.
82-90

ENGINE STAND DISMOUNTING
ENGINE STAND DISMOUNTING
PROCEDURE
1. Remove the engine from the SST (engine stand).
2. Remove the SST (engine hanger) from the engine.
3. Install the parts shown in the figure.
Torque Specifications
0-RiNGa NEW-m I’,
19-i% (1.9-2.6, 14-19)
37-62 (3.6-5.3, 27-36)
19-25 (1.9-2.6, 14-19)
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
N-m (m-kg, R-lb)
05UOBX-25
Exhaust Pipe Bracket
1. Install the exhaust pipe bracket.
Tightening torque:
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
B2-91

92 ENGINE STAND DISMOUNTING
03UOB2 122
-l!----- - 0311082-70
05UOEX-25
__._.__ -- _... -- _____II-___p--.-
051JOBX-25
82-92
Water Inlet Pipe
1. Remove all foreign material from the water inlet pipe mount-
ing surface.
2. Install a new gasket and the water inlet pipe. -
Tightening torque:
19-25 N.m (1.9-2.6 m-kg, 14-19 ft-lb)
Water Bypass Pipe
1. Apply a small amount of engine coolant to the new O-ring.
2. install the water bypass pipe.
A/C Compressor Bracket (If equipped)
1. Install the A/C compressor bracket.
Tightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Exhaust Manifold
1. Remove all foreign material from the exhaust manifold con-
tact surface.
2. Install a new gasket and the exhaust manifold.
Tightening torque:
38-46 N*m (3.9-4.7 m-kg, 28-34 ft-lb)
Exhaust Manifold insulator
1. Install the exhaust manifold insulator.
Tightening torque:
7.8-11 N-m (80-110 cm-kg, 69-95 in-lb)
v