1992 MAZDA PROTEGE light

INSTALLATION Bl
I I
03UOBl-193
03UOBl-19
1
PULLEY
P/S AND A/C
OWOBl-19
03UOBl-15
A/C compressor
1. Install the A/C compressor.
Tightening torque:
24-35 N-m (2.4-3.6 m-kg, 17-26 ft-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N-m (3.6-5.3 m-kg, 27-36 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page Bl-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.6-11 N#m (60-110 cm-kg, 69-95 in-lb)
2. Tighten the A/C pipe bracket to the radiator.
Tightening torque:
6.4-9.3 N*rn (65-95 cm-kg, 56-62 in-lb)
3. Connect the upper and lower radiator hoses.
Caution
l Position the hose clamp in the original location on
the hose, and squeeze the clamp lightly with large
pliers to ensure a good fit.
4. Connect the coolant reservoir hose.
5. Connect the cooling fan connector.
6. Connect the oil cooler hose. (ATX)
Bl-=lOl

INSTALLATION
OWOBX-27!
Resonance chamber
1. Install the resonance chamber.
Tightening torque:
7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
Undercover and side cover
1. Install the undercover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut @.
Deflection: I-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
2. Install the battery carrier.
Tightening torque:
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
lightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
2. Connect the airflow sensor connector.
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page 61-8.)
(3) Operation of emission control system.
6. Perform a road test,
7. Recheck the engine oil and engine coolant levels.
.-’
23UOBl-057
81-102

82 ENGINE TUNE-UP PROCEDURE
03UOB2-013
IGNITION TIMING, IDLE SPEED
Preparation
1. Warm up the engine to normal operating temperature.
2. Turn all electric loads OFF.
3. Connect the
SST to the diagnosis connector.
4. Connect the timing light.
5. Connect a tachometer to the diagnosis connector
IO- ter-
minal as shown.
TEN
03UOB2-01
I
-&k BOLT
0311082-01’
82-8
6. Set switch @to position 1.
7. Set TEST SW to SELF-TEST.
Note
l If the SST is not used, jump across the TEN termi-
nal and the GND terminal of the diagnosis con-
nector.
Ignition Timing
Inspection / Adjustment
1. Perform “Preparation.” (Refer to above.)
2. Check if the timing mark (yellow) on the crankshaft pulley
and the mark on the timing belt cover are aligned.
Ignition timing: 10 * f lo BTDC (at Idle speed)
3. If the marks are not aligned, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
4. Tighten the distributor lock bolts to the specified torque.
Tightening torque:
19-25 N*m (1 .Q-2.6 m-kg, 14-19 ft-lb)
5. Disconnect the SST.

82 ON-VEHICLE MAINTENANCE
CYLINDER HEAD GASKET
Replacement
Warning
l Release the fuel pressure. (Refer to Section F.)
l Keep sparks and open flame away from the fuel area.
Caution
l Position the hose clamp in the original location on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
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.
BOLT THREADS ?&d 4.9-8.8 N.m
fsn-an om.h 41-‘71( ir
AND SEAT FACES ,-- -- -... ..=, _” . _ ..I-lb)
78-81 - /
(7.7-8.3, 58-60)
7.8-11 N.m
(80-l 10 cm-ka, 69-95
, . . . . . . (80-l 10 cm-kg, 69-9: in-lb) (j-$15-23 (1.5-2.3, 11-17)
82-l 6
7.8-11 N.m
(80-110 cm-k?, 69-95 In-lb) 180-110 cm-ka. 69-95 in-lb
-37-52
(3.8-5.3, 27-38)
’
nl MTX:?64-69 (6.6-9.1,
PTX: 55-60 (6.6-8.2, 69-95 in. .Ib)
47-86)
41-69)
7.8-11 N./n (3.2-4.7, 23-34)
37-52
(80-110 cm-kg, 69-95 in-lb) (3.8-5.3, 27-38)
N-m (m-kg, N-lb)
^^. .^_^ __

ON-VEHICLE MAINTENANCE
OWOBX-05.
OxJOBX-05,
ENOBX-056
--
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-l 4.2 N-m (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: 46mm (1.69 in)
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.
I II’- ,
J
05UOBX-057
B2-24

ON-VEHICLE MAINTENANCE
I 05UOBX-063
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
13EOB2-02
ALIGN.KEY GRCi&E
13EOB2-02
23UOB2-025
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 92-8.)
3
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.
3. Tap the oil seal in evenly with a suitable pipe and a ham-
mer until it is about flush with the face of the oil pump body.
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:
157-187 N.m (18-17 m-kg, 116-123 ft-lb)
23UOB2-026
82-27

ON-VEHICLE MAINTENANCE
Drive plate (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.
2311082-052
I
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
I I
I
05UOBX-063
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.
OWOBX-069
APPLY SEALANT
03UOB2.04
Caution
l The oil seal must be tapped in untjl it is flush with
the edge of the rear cover.
3. Tap the oil seal in evenly with a suitable pipe and a hammer.
Oil seal outer diameter: 1OOmm (3.94 in)
Flywheel (MTX)
1. Remove the sealant from the flywheel bolt holes in the crank-
shaft and from the flywheel 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 flywheel onto the crankshaft.
3. Apply sealant to the flywheel bolts and install them.
4. Hold the flywheel with the
SST or equivalent.
5. Tighten the bolts in two or three steps in the order shown
in the figure.
Tightening torque:
1 96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)
2311082-053
B2--29

82 INSPECTION / REPAIR
03UOB2-082
13UOB2-0.
1
9MUOB2-112
I
03UOB2-08:
8. Measure the height @of each valve guide. Replace the
valve guide if necessary.
Height: 18.3-l 8.9mm (0.720-0.744 in)
Replacement of valve guide
Note
l The valve guides are different between intake and
exhaust sides, use the correct valve guide.
Removal
1. Remove the valve guide from the side opposite the com-
bustion chamber with the
SST.
Installation
1. Assemble the SST so that depth L is as specified.
Depth L: 18.3-18.9mm (0.720-0.744 in)
2. lighten the locknut.
3. Tap the valve guide in from the side opposite the combus-
tion chamber until the
SST contacts the cylinder head.
4. Verify that the valve guide height is within specification.
5. If not within specification, repeat Steps 1-4.
82-56