1992 MAZDA PROTEGE engine

ON-VEHICLE MAINTENANCE Bl
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 DO1 1 102
Lock tool,
crankshaft For
removal and
installation of
timing belt pulley 49 EOll 1AO
Ring gear brake
set For
prevention of
engine rotation
49 EOll 103
For
49 EOl 1 105
For
prevention of
prevention of
Shaft
engine rotation
Stopper
engine rotation
(Part of
(Part of
49 EOl 1 1AO)
49 EOI 1 1AO)
49 EOll 104
For
49 SE01 310A
For
prevention of
installation of
Collar
engine rotation
Centering tool,
clutch disc
(Part of
clutch disc
49 EOl 1 1 AO)
23UOBl-01
81-11

ON-VEHICLE MAINTENANCE Bl
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 91-8.)
03UOBl-026
. .
81-15

Bl 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, referring to Installation Note.
7.8-11 N.m
16-23 (1 4.9-8.8 N.m (50-90 cm-kg, 43-78 in-lb)
(80-l 10 cm-kg, 69-95 in-lb)
L
.8-11 N.m
(80-110 cm-kg,
69-95 in-lb)
-25 (1.9-2.6, 14-19)
BP SOHC: 37-52 (3.8-5.3, 27-38)
37-52 (3.8-5.3, 27-38)
7.8-11 N.m
(80-l 10 cm-kg, 89-95 in-lb)
N-m (m-kg, ft-lb)
23UOBl-01
81-16

.
ON-VEHICLE MAINTENANCE
Installation note
Cylinder head bolt Bl
1. Apply clean engine oil to the bolt threads and seat faces.
2. Install the cylinder head bolts.
3. Tighten the cylinder head bolts in two or three steps in the
order shown in the figure.
Tightening torque:
76-61 N#m (7.7-6.3 m-kg, 56-60 f&lb)
Accelerator cable
1. Install the accelerator cable.
2. Check the accelerator cable deflection.
If the deflection is not correct, adjust by turning nut A.
Deflection: I-3mm (0.04-0.12 in)
Steps After Installation
1. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E.)
2. Connect the negative battery cable.
3. Start the engine and check as follows:
(1) Engine oil and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page 81-8.)
(3) Operation of emission control system.
4. Recheck the engine coolant levels.
2311081-020
Bl-19

ON-VEHICLE MAINTENANCE Bl
Removal note
Rocker arm and rocker shaft assembly
1. Loosen the rocker arm bolts in two or three steps in the or-
der shown in the figure.
2. Remove the rocker arms and rocker shaft assembly.
3. Code all rocker arms and springs so that they can be rein-
stalled in the same places from which they were removed.
I
23UOBi-02 1
Installation note
HLA
1. Pour engine oil into the oil reservoir in the rocker arm.
2. Apply engine oil to the new HLA.
3. Install the HLA in the rocker arm.
Caution
l Be careful not to damage the O-ring when installing.
Oli RESERVOIR
o3uoB1-o?
Rocker arm and rocker shaft assembly
B6 SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure. No.1 CYLINDER No.4 CYLINDEF
[ ’ ” 0 D 0
0311081-034
Caution
l Be sure both rocker arm shaft oil holes face
downward.
l The installation bolt holes are different for the ex-
haust and intake sides as shown in the figure. No.1 CYLINDER
No.4 CYLINDER
INTAKE

l---A--l
0 = ‘, I I
Y Y
0 \L
.a Y
r Y)
/
6
EXHAUST
A>B
Note
l There are two types of rocker arms with different
offsets. One type for No.1 and No.2 cylinders ex-
haust and intake. And the other for cylinders No.3
and No.4.
No. 1.2 CYLINDERS No.3,4 CYLINDERS
(IN & EX) (IN & EX)
81-21

Bl ON-VEHICLE MAINTENANCE
8 e
93UOlA.08
EX
03UOBl-035
HEAD COVER
)
23UOBl-023
Steps After Installation
1, Connect the negative battery cable.
2. Start the engine and fully warm up.
3. Verify that there is no tappet noise. 2. Install the rocker arm and rocker shaft assembly.
Caution
l The bolts must be tightened gradually and in the or-
der shown in the figure.
Tightening torque:
22-28 N-m (2.2-2.9 m-kg, 18-21 ft-lb)
BP SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure.
Caution
l Face the rocker shaft identification mark upward.
l The installation bolt holes are different for the ex-
haust and intake sides.
Identification mark
IN . . . . . . . . . . White
EX . . . . . . . . . . . Blue
2. Install the rocker arm and rocker shaft assembly.
3. Tighten the rocker arm bolts in two or three steps in the or-
der shown in the figure.
Tightening torque:
22-28 Nsrn (2.2-2.9 m-kg, 16-21 ft-lb)
Cylinder head cover
1. Install the cylinder head cover.
Tightening torque
Bolt @:
4.9-8.8 N-m (50-90 cmikg, 43-78 in-lb)
Bolt @:
7.8-l 1 Nnrn (80-l 10 cm-kg, 69-95 in-lb)
Caution
l If the head cover gasket is reused, apply sealant in
the groove as shown.
03UOBl-038
.-
Bl-22

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

Bl ON-VEHICLE MAINTENANCE
OIL SEAL LIP
L I I
OWOBX-063
05UOBX-069
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.
Oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal with a screwdriver protected with a rag.
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 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:
96-103 N-m (9.6-10.5 m-kg, 71-76 ft-lb)