1992 MAZDA PROTEGE maintenance

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

-.
ON-VEHICLE MAINTENANCE Bl
REAR 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
16-26 (1.6-2.7, 13-20) I HTX
ATX
N.m (m-kg, R-lb)
23UOBl-027
1. Transaxle
MTX
Service.. ............................... Sections Jl , J2
ATX
Service .......................................... Section K
2. Clutch cover, clutch disc
Service .......................................... Section H 3. Flywheel (MTX)
Removal Note ..................................... below
Installation Note ........................ page 81-26
4. Drive plate (ATX)
Removal Note.. ......................... page Bl-26
Installation Note.. ...................... page Bl-27
5. Oil seal
Removal Note.. ......................... page 81-26
Installation Note ........................ page 81-26
Removal note
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.
Bl-25

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)

82
ENGINE
m :
(DOHC)
INDEX .......................................... B2- 2
OUTLINE ...................................... B2- 3
SPECIFICATIONS ........................ B2- 3
TROUBLESHOOTING GUIDE .......... B2- 3
ENGINE TUNE-UP PROCEDURE ......
B2- 5
PREPARATION ............................
B2- 5
ENGINE OIL ............................... B2- 5
ENGINE COOLANT.. ....................
B2- 5
DRIVE BELT ............................... B2- 5
HLA .......................................... B2- 7
IGNITION TIMING, IDLE SPEED ..... B2- 8
COMPRESSION ............................. 82-l 0
INSPECTION ...............................
82-l 0
ON-VEHICLE MAINTENANCE.. ........ 82-l 1
PREPARATION ............................
B2-11
TIMING BELT .............................. 82-l 2
CYLINDER HEAD GASKET ...........
82-16
HLA .......................................... 82-22
FRONT OIL SEAL.. ......................
62-26
REAR OIL SEAL .......................... 82-28
REMOVAL ..................................... 82-31
PROCEDURE .............................. 82-31
ENGINE STAND MOUNTING.. .........
82-38
PREPARATION ............................ 82-38
PROCEDURE ..............................
82-39
DISASSEMBLY .............................. 82-41
PREPARATION ............................ B2-41
AUXILIARY PARTS.. ..................... 82-42
TIMING BELT ..............................
82-43
CYLINDER HEAD.. ...................... 82-45
CYLINDER BLOCK
(EXTERNAL PARTS) ...................
B2-48
CYLINDER BLOCK
(INTERNAL PARTS). ................... 82-51 INSPECTION / REPAIR.. ................. 82-54
PREPARATION ............................ 82-54
CYLINDER HEAD.. ...................... B2-54
VALVE MECHANISM.. .................. 82-55
CAMSHAFT ................................ B2-58
HLA .......................................... 82-80
CYLINDER BLOCK ...................... 82-60
OIL JET ..................................... B2-61
PISTON, PISTON RING, AND
PISTON PIN .............................. 82-62
CONNECTING ROD.. ...................
82-63
CRANKSHAFT ............................ B2-64
BEARING ................................... 82-64
TIMING BELT ..............................
82-65
TENSIONER, IDLER.. ................... 82-65
TENSIONER SPRING ................... 82-65
PULLEY ..................................... 82-65
ASSEMBLY ................................... B2-66
PREPARATION ............................ B2-66
CYLINDER BLOCK
(INTERNAL PARTS). ................... 82-68
CYLINDER BLOCK
(EXTERNAL PARTS) ................... 82-73
CYLINDER HEAD.. ...................... 82-79
TIMING BELT .............................. 82-84
AUXILIARY PARTS.. .....................
B2-87
ENGINE STAND DISMOUNTING ..a” . . 82-91
PROCEDURE ..............................
82-91
INSTALLATION ............................. 82-93
PROCEDURE .............................. 82-93
23UOB2-001

OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
ItC- Engine
BP DOHC
Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4 cylinders
Combustion chamber Pentroof
Valve svstem DOHC, belt-driven 16 valves
Displacement
Bore and stroke cc (cu in) 1,839 (112.2)
mm (in) I 83.0 x 85.0 (3.27 x 3.35)
Compression ratio
Compression pressure
IN
Valve timing
EX kPa (kg/cm*, psi)-rpm
BTDC Open
Close ABDC
Open BBDC
Close ATDC 9.0
1,256 (12.8, 182)300
!zJ”
48O
56O
140
Valve clearance IN 0: Maintenance-free
mm (in)
EX 0: Marntenance-free
Idle speed *’ *’ MTX
rpm
ATX
Ignition timing*2
Firing order
::...With parking brake applied. (Canada)
. ..TEN terminal of diagnosis connector grounded BTDC 700-800
700-800 (P range)
90-l 1 O
l-3-4-2
P3UOBZ003
TROUBLESHOOTING GUIDE
Problem
Difficult starting
Poor idling
Excessive oil
consumption Possible Cause
Malfunction of engine-related components
Burned valve
Worn piston, piston ring, or cylinder
Failed cylinder head gasket
Malfunction of fuel system
Malfunction of ignition system
Malfunction of engine-related components
Malfunction of HLA*
Poor valve-to-valve seat contact
Failed cylinder head gasket
Malfunction of fuel system
Malfunction of ignition system
Oil working up
Worn piston ring groove or sticking piston ring
Worn oiston or cvlinder
Oil working down
Worn valve seal
Worn valve stem or auide
Oil leakaae i
Replace 82-55
Replace or repair 92-60, 62
Reolace B2-16
Refer to Section F
I
Replace 82-47, 79
Replace 82-55
Refer to Section 0 I
82-3

ON-VEHICLE MAINTENANCE 62
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 DO11 102
Lock tool,
crankshaft
49 E011 103
Shaft
(Part of
49 EOl 1 1AO) @
49 EOI 1 104
Collar
(Part of
49 EOl 1 1AO) For
removal and
installation of
timing belt pulley
For
prevention of
engine rotation
For
prevention of
engine rotation 49 EOll IA0
Ring gear brake
set
49 EOll 105
Stopper
0
(Part of
49 EOI 1
1AO) w
49 SE01 310A
Centering tool,
clutch disc For
prevention of
engine rotation
For
prevention of
engine rotation
For
installation of
clutch disc
2311082-0‘
02-I 1

B2 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, referring to Installation Note.
/ 7.8-11 N.m
(80-l 10 Cm-kg, 69-95 in-lb
1p1\ ’ (3.8-6.3, 2738)
, (80-l 10 cm-kg, 69-95 in-lb)
167--187 (X-17, 116-123)
/ 7.8--11 N-m
(80-110 MI-kg,
7.8-11 N-m
\-
(80-110 Cm-kg, 69-95 in-lb)

12-17 (1.25-1.75, 9-13)
N-m (m-kg, &lb
23UOl32-0
1. Under cover and side cover 11. Timing belt cover, lower
2. P/S and/or A/C drive belt 12. Pulley lock bolt
3. Alternator drive belt Removal Note . . ..*..........*.*......... page 82-13
4. Water pump pulley Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-14
5. Plate 13. Pulley boss
6. Crankshaft pully 14. Timing belt
7. Spark plugs Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 62-13
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 62-15 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-14
8. Oil dip stick 15. Tensioner and tensioner spring ..l
9. Timing belt cover, upper Installation Note ..,..................... page B2-14
10. Timing belt cover, middle 16. Idler
B2-12