1992 MAZDA PROTEGE lock

DISASSEMBLY Bl
CYLINDER BLOCK (EXTERNAL PARTS)
1. Disassemble in the order shown in the fiaure, referrina to Disassembly Note.
.-.
1. Water pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
2. Timing belt pulley and lock bolt
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl -65
3. Clutch cover, clutch disc (MTX)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
4. Flywheel (MTX)
Disassembly Note . . . . . . . . . . . . . . . . . . . page 81-48
Inspect for wear or damage
5. Backing plate, drive plate, and adapter (ATX)
Disassembly Note ..,.....,.,........, page 81-48
6. End plate 7. Oil pan and gasket
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Inspect for damage
8. Oil strainer
9. Main bearing support plate (MBSP)
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-49
Inspect for damage
10. Oil pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
11. Front oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
12. Rear cover
13. Rear oil seal
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-49
Bl-47

Bl DISASSEMBLY
23UOBl-068
23UOBl-06!
I 2311081-070
23UOBl-071
Disassembly Note
Timing belt pulley
1. Hold the flywheel (MTX) or drive plate (ATX) with the SST
or equivalent.
2. Loosen the pulley lock bolt.
3. Remove the pulley lock bolt. -
4. Remove the timing belt pulley.
5. Remove the pulley Woodruff key.
2311081-059
Clutch cover (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Loosen the clutch cover lock bolts in two or three steps in
the order shown in the figure.
3. Remove the clutch cover.
-
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
4. Remove the
SST or equivalent.
Backing plate, drive plate, and adapter (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.
4. Remove the
SST or equivalent.
Bl-48

DISASSEMBLY Bl
0311081-08
PROTECT PUMP w
BODY WITH RAG
OTECT REAR COVER 0
Oil pan
B6 SOHC
1. Remove the oil pan mounting bolts.
2. Insert a screwdriver or a suitable tool between the MBSP
and oil pan, and pry them.
Caution
l Do not insert the prying tool between the MBSP and
cylinder block.
l Do not damage or scratch the contact surfaces.
BP SOHC
1. Remove the oil pan mounting bolts.
Caution
l Do not force a prying tool between the cylinder
block and the oil pan, which may damage the con-
tact surfaces.
l Do not damage or scratch the contact surfaces
when removing the old sealant.
2. Insert a screwdriver or a suitable tool only at the points
shown in the figure.
3. Remove the oil pan.
Main bearing support plate (MBSP)
1. Remove the MBSP mounting bolts to the main bearing cap.
2. Insert a screwdriver or a suitable tool between the MBSP
and cylinder block, and pry them.
Caution
l Do not damage or scratch the contact surfaces
when removing old sealant.
Front oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
Rear oil seal
1. Remove the oil seal with a screwdriver protected with a rag.
Bl-49

Bl DISASSEMBLY
CYLINDER BLOCK (INTERNAL PARTS)
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
1. Connecting rod cap
7. Main bearing cap
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-51
Disassembly Note . . . . . . . . . . . . . . . . . . . . page
81-52
2. Connecting rod
8. Crankshaft
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51
Disassembly Note . . . . . . . . . . . . . . . . . . . . page 81-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-64
3. Connecting rod bearing
9. Main bearing
Inspection . . . . . . . . . . . . . . . . . . . . . . page Bl-64 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-64
4. Piston ring
10. Thrust bearing
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51 11. Oil filter joint
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Bl-62 12. Oil jet
5. Piston pin
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-61
Disassembly Note . . . . . . . . . . . . . . . . . . . . page Bl-51 13. Cylinder block
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-60 ‘-”
6. Piston
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Bl-62
Bl-50

DISASSEMBLY Bl
23UOBl-03
05UOBX-1’ 9
23UOBl-040
03UOBl-08 5
Disassembly Note
Connecting rod cap
1. Before removing the connecting rod caps, measure the con-
necting rod side clearance. (Refer to page Bl-73.)
Connecting rod
1. Before removing the connecting rods, measure the connect-
ing rod oil clearance. (Refer to page Bl-73.)
2. Remove the Plastigage from the crankpin journals.
Caution
l Do not scratch the crankshaft journal or the cylin-
der wall.
3. Use the handle of a hammer to remove the piston and con-
necting rod assembly through the top of the cylinder block.
Piston ring
Caution
l Do not apply excessive tension, which may cause
the rings to snap out.
1. Remove the piston rings with a piston ring expander (com-
mercially available).
Piston pin
Caution
l Mark the connecting rod direction for proper reas-
sembly.
1. Before disassembling the piston and connecting rod, check
the oscillation torque as shown.
If the large end does not drop by its own weight, replace
the piston or the piston pin.
81-51

Bl INSPECTION / REPAIR
VALVE GUIDE
8. Measure the protrusion height of each valve guide. Replace
the valve guide if necessary.
13UOBl-026
P SOHC m
9MUOB2-112
OSUOBX-12’
Bi-56
Height
B6 SOHC mm (in)
BP SOHC
I
IN 13.2-13.8 18.3-i 8.9
(0.520-0.543)
(0.720-0.744)
-.. --
EX 13.2-13.8 16.8-17.4
(0.520-0.543) (0.661-0.685)
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
mm (in)
I B6 SOHC
I BP SOHC
I
IN 13.2-13.8 18.3-l 8.9
(0.520-0.543) (0.720-0.744)
EX 13.2-13.8 16.8-17.4
(0.520-0.543) (0.661-0.685)
2. Tighten 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 l-4.

Bl INSPECTION / REPAIR
r
BP SPHC
I /
._~~ ~_ ’
--
23UOB1-06(
1
I 2-l

_I_
23UOBl-074
lt- OUT-OF-SQUARE
BP SOHC, IN: 42.5mm (1.673 in)
EX: 41 .Omm ‘(1.614 ii)
mm (in)
Measurement Action
IN . 42.5-43.0 (1,673-l ,693) No correction needed
More than 44.0 (1.732) Replace cylinder head
EX 41 .O-41.5 (1,614-l ,634) No correction needed
More than 42.5 (1.673) Replace cylinder head
Valve Spring
1. Inspect each valve spring for cracks or damage.
2. Measure the free length and out of square. Replace the
valve spring if necessary.
Free length
Standard...mm (in), Minimum...N (kg, Ib)/mm (in)
B6 SOHC BP SOHC
I
IN Standard 43.66 (1.7188) 46.12 (1.8157)
224-253 (22.8-25.8, 205-231 (20.9-23.5,
Minimum 50-57)/35.5 (1.398) 46-52)/39 (1.535)
EX Standard 43.66 (1.7188) 43.61 (1.7169)
224-253 (22.8-25.8, 129-147 (13.1-15.0,
Minimum 50-57Y35.5 (1.398) 29-331137.5 (1.476)
Out-of-square max. mm (in)
B6 SOHC BP SOHC I
I I IN 1.52 (0.060) 1.61 (0.063)
t I I
I I EX 1.52 (0.060) 1.52 (0.060)
CAMSHAFT
1. Set the front and rear journals on V-blocks.
2. Measure the camshaft runout. Replace the camshaft if
necessary.
Runout BP SOHC: 0.03mm (0.0012 in) max.
B6 SOHC: O.Olmm (0.0004 in) max.
13UOBl.02; 3. Inspect the camshaft for wear or damage. Replace the cam-
shaft if necessary.
4. Measure the cam lobe heights at the two points as shown.
0311081-103
91-58
mm (in)

Bl INSPECTION / REPAIR
a3
03UOBl.109
03UOBl-11t
03UOBl-111 i
3
03UOBl-112
Rocker Arm and Rocker Arm Shaft
1. Check for wear or damage to the contact surface of the rock-
er arm shaft or the rocker arm. Replace if necessary.
2. Check the oil clearance between the rocker arm and shaft,
replace if necessary.
(1) Measure the rocker arm inner diameter.
Diameter mm (in)
B6 SOHC
BP SOHC
IN 18.000-l 8.027
19.000-19.027
(0.7087-0.7097)
(0.7480-0.7491)
EX 18.000-l 8.027
19.000-19.033
(0.7087-0.7097) (0.7480-0.7493)
(2) Measure the rocker arm shaft diameter.
Diameter mm tin1
IN
EX B6 SOHC
BP SOHC ’ ’
17.959-l 7.980
18.959-18.980
(0.7070-0.7079)
(0.7464-0.7472)
17.959-l 7.980
18.959-l 8.980
(0.7070-0.7079)
(0.7464-0.7472)
(3) Subtract the shaft diameter from the rocker arm di-
ameter.
Oil clearance
IN
EX
Maximum mm (in)
B6 SOHC
BP SOHC
0.020-0.068
0.020-0.068
(0.0008-0.0027) (0.0008-0.0027)
0.020-0.068
0.020-0.074
(0.0008-0.0027) (0.0008-0.0029)
0.10 (0.004) -_
HYDRAULIC LASH ADJUSTER (HLA)
Check the HLA face for wear or damage and replace if
necessary.
Caution
l To prevent damaging the O-ring, do not remove the
HLA unless necessary.
CYLINDER BLOCK
1. Check the cylinder block for the following and repair or re-
place the cylinder block as necessary.
(1) Leakage damage.
(2) Cracks.
(3) Scoring of wall.
2. Measure the distortion of the top surface of the cylinder block
in the six directions shown in figure.
Distortion: 0.15mm (0.006 in) max.
3. If the distortion exceeds the maximum, repair by grinding
or replace the cylinder block.
Height
t mm (in)
86 SOHC
BP SOHC _._
221.5 (8.720)
Grinding: 0.20mm (0.006 in) max. U3UU81-113