1992 MAZDA PROTEGE belt

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 Bl
I. Air hose assembly 1 I. Timing belt cover, upper
2. Resonance chamber 12. Timing belt
3. Accelerator cable Removal / Installation.. . . . . . . . . . . . . . . page Bl-12
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page BI-I9 13. Front exhaust pipe
4. Throttle cable (ATX)
14. Intake manifold bracket
Removal / Installation . . . . . . . . . . . . . . . . . . . . . Section K 15. Cylinder head bolt
5. Hoses Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page BI-18
Removal I Installation Note ..,............... below Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Bl-I9
6. Harnesses 16. Cylinder head
Removal I Installation Note....... page BI-I8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 61-43
7. Water bypass pipe nut
Inspection . . , . . . . . . . . . . . . . . . . . . . . . . . . . ., . . page BI -54
8. Drive belt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page BI-79
9. Water pump pulley 17. Cylinder head gasket
10. Cylinder head cover
23UOBl-019
Removal / Installation note
Hoses
I. Disconnect the hoses shown in the figure.
\ / DlSCOtjNECT
, w I.,,, -----. WARNING ’ ’ ’ l KEEP SPARKS AND OPEN FLAME AWAY FROM THE FUEL
AREA.
CAUTION
l COVER THE HOSE WITH A RAG BECAUSE FUEL WILL
SPRAY OUT WHEN DISCONNECTING.
. PLUG THE DISCONNECTED HOSES TO AVOID FUEL
LEAKAGE.
I. Brake vacuum hose
2. Fuel hose
3. Vacuum hose (Purge control) 4. Vacuum hose (Cruise control)
5. Heater hose

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

Bl ON-VEHICLE MAINTENANCE
01 EOBX-056
23UOBi -0:
Steps After Installation
1. Lower the vehicle.
2. Connect the negative battery cable.
3. Start the engine and check the ignition timing.
(Refer to page 61-8)
Installation Note
Oil seal
1. Apply a small amount of clean engine oil to the lip of a new
oil seal.
2. 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 oil pump body.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 50.5mm (1.98 in)
Timing belt pulley
1. Install the timing belt pulley.
2. Install the pulley woodruff key with the tapered side toward
the oil pump body.
Pulley lock bolt
1. Hold the crankshaft with the SST and tighten the pulley lock
bolt.
Tightening torque:
157-167 N*rn (16-17 m-kg, 116-123 ft-lb)
23UOBi-026
Bl-24

REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section F.)
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil.
3. Remove in the order shown in the figure, referring to Removal Note,
Step 1
1. Undercover and side cover
2. Air cleaner assembly 10. Cooling fan connector
3. Battery and battery cover 11. Oil cooler hose (ATX)
4. Battery carrier 12. Radiator and cooling fan assembly
13. P/S and/or A/C drive belt
5. Battery duct
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Accelerator cable page Bl- 6
7. Resonance chamber 14. P/S oil pump and bracket
8. Radiator hose Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
9. Coolant reservoir hose 15. A/C compressor (if equipped)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
81-28

Bl DISASSEMBLY
AUXILIARY PARTS
1. Drain the engine oil.
2. Disassemble in the order shown in the figure.
- REPLACE - ’ ,/ I’

1. Distributor and high-tension lead
2. Intake manifold assembly
3, Alternator and drive belt
4. Alternator bracket
5. No.3 engine mount bracket 6. Oil filter
7. Oil pressure switch
8. Spark plug
9. Oil level gauge and pipe 10. Engine hanger
61-40