1992 MAZDA PROTEGE engine

TECHNICAL DATA TD
Item
Carrier hub
Sun gear drum
Small sun gear TransaxlelEngine
Clearance between pinion washer
and planet carrier mm (in) Maximum
Bushing inner diameter
mm (in) Maximum
Bushing inner diameter
mm (in) Maximum F4A-EL
B6 SOHC BP SOHC BP DOHC
0.2-0.7 (0.008-0.028)
30.425 (1.198)
21.021 (0.828)
Gear assembly
Total end play
End play adjust race
Idle gear bearing preload
Preload
adjust shims
Output gear bearing preload
Preload adjust shims
Differential
Bearing preload
Preload
adjust shims
Backlash of side gear and pinion mm (in)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
N.m (cm-kg, in-lb)
mm (in)
mm (in) Standard
Maximum 0.25-0.50 (0.010-0.020)
1.2 (0.047) 1.4 (0.055), 1.6 (0.063)
1.8 (0.071) 2.0 (0.079) 2.2 (0.087)
-
0.03-0.9 (0.3-9.0, 0.26-7.8)
3.80 (0.150) 3.85 (0.152) 3.90 (0.154) 3.95
(0.156)
4.00 (0.158) 4.05 (0.159) 4.10 (0.161) 4.15 (0.163)
4.20 (0.165) 4.25 (0.167) 4.30 (0.169) 4.35 (0.171)
4.40 (0.173), 4.45 (0.175) 4.50 (0.177) 4.55
(0.179)
4.60 (0.181) 4.65 (0.183) 4.70 (0.185) 4.75 (0.187)
0.03-0.9 (0.3-9.0, 0.26-7.8)
0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65
(0.026).
0.70 (0.028) 0.75 (0.030) 0.80 (0.032) 0.85
(0.034)
0.90 (0.035) 0.95 (0.037) 1.00 (0.039) 1.05 (0.041)
1.10 (0.043) 1.15 (0.045) 1.20 (0.047) 1.25 (0.049)
1.30 (0.051), 1.35 (0.053) 1.40 (0.055) 1.45
(0.057)
2.9-3.9 (30-40, 26-35)
0.50 (0.020) 0.55 (0.022) 0.60 (0.024) 0.65
(0.026)
0.70 (0.028) 0.75 (0.030) 0.80 (0.032) 0.85 (0.034)
0.90 (0.035) 0.95 (0.037) 1.00 (0.039), 1.05 (0.041)
1.10 (0.043) 1.15 (0.045) 1.20 (0.047). 1.25 (0.049)
1.30 (0.051) 1.35 (0.053) 1.40 (0.055), 1.45 (0.057)
0.025-0.1 (0.001-0.004)
0.5 (0.020)
Torque converter
Bushing inner diameter mm (in) Standard 1 53.030-53.075 (2.088-2.090)
Maximum 1 53.075 (2.090)
Spring Specification
Spring name Outer diameter Free length
No. of coil Wire diameter
mm (in) mm (in) mm (in)
Throttle modulator 8.1 I I--.._ ^^^1-^1 1 spring 1 (0.319)
1 43.4 (1.709) 1 10.5 1 0.8 (0.031)
1
” cJIJtz:I li”I IL, “I
valve body Throttle spring
Throttle assist spring 1 5.4 (0.213) 46.2 (1.819) 1 29.0
0.88 (0.035)
1 5.15 (0.203)
26.88 (1.058) 1 16.2 0.6 (0.024)
,
^ -- ,^ ^^^
Mnin contrnl I Low reducina sprina I 7.9 (0.311) .._... __.._. -
valve body
-. .- \“---I 29.98 (1.180) 10.0
0.8 (0.03lj
1 3-4
shift spring / 7.4 (0.291) I 36.6 (1.441)
12.0 0.8 (0.031)
B6 SOHC
23.0
Bypass spring BP
SOHC 4.9 (0.193) 27.6 (1.087) 0.55 (0.022)
Premain control BP
DOHC 4.9 (0.193) 30.5 (1.201) 23.0
0.55 (0.022)
valve body
2-3 shift spring 7.4 (0.291) 36.6 (1.441)
12.0 0.8 (0.031)
Converter relief spring
8.6 (0.339) 68.4 (2.693) 27.5
1.2 (0.057)
Lockup control spring
5.0 (0.197) 30.1 (1.185) 21.5 0.55 (0.022)
Control valve body Throttle relief spring
6.6 (0.260) 21.6 (0.850) 11.5
0.8 (0.031)
Oil
pump Spring
13.0 (0.512) 53.0 (2.087)
12.0 1.2 (0.047)
TD-15

TECHNICAL DATA TD
1 Throttle condition 1
nrllm pn-t
Mode Rr _ me/ flhrottle sensor 1 Shift 1 -.- -*r2d rpm
Vehicle speed I km/h (mohl , . ,
I
ioltage) 1 B6 sot
iC 1 BP SOHC 1 BP DOHC
66 SOHC 1 BP SOHC 1 BP
I I I
’ ni - n9 I’) 7nn-1 “50 2,500-3,05012,700-3.3001 I I DOHC
Fully opened 27-33 (17-201
3 D (4.0 volt) 50 2,050-2,55012,200-2,750]
40-50 i25-31 j
e I 300-500 1 450-650 / Q-15 16-9) 112-18 (7-111
00 3,250-3,45013,550-3.800~91-97 f56-60&G10’4 (61-64)hOO-106;62-&\I
s
i- f Fully closed
(0.5 volt)
YI -l&c
L, r vv-“,L
Dz + D3 2,150-2,7
D3 -+ DI 300--5O(
S3 -+ S2 3,200-3,4
’ L2 -+ LI 2,350-2,65012,200-2,50012,350-2.7001
43-49 ;27--3b1 ’ ‘I
M. FRONT AND REAR AXLES -
Item
Driveshaft Engine/Transaxle BP SOHC BP DOHC
Joint type
Length of shaft
Shaft diameter Front axle
Bearing play axial direction Rear axle
Bearing play axial direction Inside Tripod joint
Outside Ball joint
Right
919.3 (36.19) 918.7 (36.17) 630.7 (24.83)
mm (in) Left
637.8 (25.11) 640.2 (25.20) 621.2
637.1
(24.46) (25.08)
21.5 (0.85) 23.0 (0.91)
mm (in) 1 0.05 (0.002)
mm (in) I 0.05 (0.002)
N. STEERING SYSTEM Steering wheel
Outer diameter Item Specifications 370 (14.57)
Lock-to-lock I Steering gear
--
Type
Steering gear ratio
Backlash between rack and pinion mm (in)
N.r ’ ’ ” ’ n (cm-Kg, in-01
Preload measured by torque
*rrv~rrdl Rack and pinion
Infinite (00)
0 (0)
M/S : 0.9-l .3 (Q-13, 7.8-l 1.3)
P/S : 1.0-1.3 (10-14, 8.7-12)
Pinion preload ““l~jll~,,
9 (0.4
Preload measured by pull
scale with attachment
Limit of rack housing movement mm (in)
Distance between left and right brackets mm (in)
Rack stroke mm (in M/S : 900-l ,300 (31.8-45.9)
P/S : l,OOO-1,400 (35.3-49.4)
1.5 (0.06)
298.5 (11.75)
140 (5.511
Lubricant type (power steering)
Oil capacity (power steering) Drive belt
liter (US qt, Imp qt) I ATF: M-III or DexronW
0.8 (0.85, 0.70)
I New belt: 8-Q (0.31-0.35)
Deflection with force of 98 N (10 kg, 22 lb) mm (in) Used belt: 9-10 (0.35-0.39)
I imit: 11.5 (0.461
TD-17

TD TECHNICAL DATA
P. BRAKING SYSTEM
Item
3rake type
Brake pedal
Height mm (in)
Free play mm (in)
Reserve travel mm (in)
Clearance when pedal depressed at 589 N (60 kg, 132 lb)
Master cylinder
Type
Master cylinder
Bore diameter mm (in) 1
Front disc brake
We
Thickness of pad
mm (in) Standard
Minimum
Thickness of disc plate
mm (in) Standard
Minimum
Runout of disc plate mm (in)
Cylinder bore
mm (in) Specifications
Front . . . . . disc, Rear . . . . . disc or drum
193-196 (7.60-7.72)
4-7 (0.16-0.28)
70 (2.76) min
Tandem
22.22 (0.875)
Ventilated
10 (0.39)
2 (0.08)
22 (0.87)
20 (0.79)
0.1 (0.004)
53.97 (2.12)
Rear brake (drum)
We
Thickness of lining
I Drum inside diameter
1
tiheel cylinder bore
I Parking brake
Type
Parking brake lever notches Leading & trailing
mm (in) Standard 4.5 (0.18)
Minimum 1 (0.04)
mm (in) Standard 200 (7.90)
Maximum 201 (7.91)
mm (in) 17.46 (0.687)
Mechanical two-rear-wheel control
When lever is pulled at 98N (10 kg, 22 lb)
Power brake unit
Diameter mm (in) 5-7
(a): 214 (8.43) (b): 239 (9.41)
More than 1,177 (12, 171)/196 (20, 44)
Fluid pressure per treading force
kPa (kg/cm’, psi)/N (kg, lb) (4
@I at 0 mmHg (0 inHg)
More than 7,063 (72, 1,024)/l 96 (20, 44)
at 500 mmHg (19.7 inHg)
More than 1,517 (15, 213)/196 (20, 44)
at 0 mmHg (0 inHg)
More than 8,593 (88, 1,261)/196 (20, 44)
at 500 mmHg (19.7 inHg)
Rear wheel hydraulic control rystem
Type Dual proportioning valve
_-_.
. .- ,. . . . !
P.IF
Switching point (Master cylinder pressure)
KPa (kg/cm-, PSI) ) z,4~j3 (25, 356)
(a): BP engine with SMTX, B6 engine
(b): BP engine with 4EATX ..-
-’
TD-18

TECHNICAL DATA
Q. WHEELS AND TIRES
Item Specifications
Wheel
Size
Off set Standard: 13x5-J, 14x5 l/2-JJ
Temporary
mm (in) 1 _ spare: 14x4-T
45 (1.77)
I Diameter of oitch circle
mm (in) I 100 (3.94)
r I Pl
-
Inflation pressure kPa (kg/cm*, psi) Front 1 8
I 9
Runout limit
Unbalance limit mm (in) ;lii.raltLa’
a (02) ’
13 inch wheel: 11 (0.
R. SUSPENSION Item Specifications
Suspension type Strut
)e Double-acting, oil-filled
I Shock absorber tyf
Coil spring
Type
Dimension
Type Front Taper wound
Rear Straight wound
See next page
Torsion bar
I
I C.rrn,
19.1 (0.75)
20.0 (0.79)
22.0 (0.87)
21 .O f0.83)
Wheel alignment
(“‘Unladened) BP SOHC ;;a;
Diameter
mm (in) BP DOHC - ;la;t
Front -
B6 SOHC
Rear 20.0 (0.79)
Maximum Inner 4o” f 2O
steering angle Outer
Total mm (in) 2 f 3 (0.08 j
Front toe-in
dearee
.-.._
Rear
.--. I --- ~~
Camber angle
Caster angle
Kingpin angle
I Total
I mm OnI I I toe-in
1 dearee I , --U’-- 1
Camber angle
I 33O * 2O
: 0.12)
0.2O f 0.3O
-0OO5’ * 45’
1055’ * 55’
12O25’
2 f 3 (0.08 f 0.12)
0.2O f 0.3O
-0°20’ f 45’
l ’ Fuel tank full; radiator coolant and engine ail at specified level; and spare tire, jack, and tools in designated posmons.
TD-19

SPECIAL TOOLS
GENERAL INFORMATION ........................
ENGINE .................................................. i;-
- ‘3
CLUTCH AND MANUAL TRANSAXLE.. ...... ST- 4
AUTOMATIC TRANSAXLE.. ...................... ST- 5
FRONT AND REAR AXLES.. ..................... ST- 7
STEERING SYSTEM ................................ ST- 8
BRAKING SYSTEM .................................. ST- 9
FRONT AND REAR SUSPENSIONS.. ......... ST-10
HEATER AND AIR CONDITIONER
SYSTEMS ............................................. ST-l 0
CHECKER AND OTHER EQUIPMENT.. ....... ST-10
23USTX-001

SPECIAL TOOLS ST
.._ ENGINE
9 LO10 1AO
,9 0636 100A
19 B012 OA2
19 LO12 OAO
nstaller set,
/alve seal &
$9 0249 OlOA
3emover &
nstaller, valve
49 8012 005
Remover &
installer, valve
49 0187 280
Oil pressure ‘OOL NUMBER
: DESCRIPTION PRIORITY ILLUSTRATION
9 0221 061A
:emover & B
Istaller, piston
in (BP DOHC)
4 9 HO11 OOlA
s iupport block
h lead (Except
E )P DOHC)
.9 LO1 1 OAO
‘iston pin setting A
DOI set (Except
3P DOHC) 4
F
tl
E
L
(
II
1
I
I I9 DO11 102
;rankshaft
ock tool
19 EOI 1 1AO
3rake, ring gear
49 s120 170
Remover,
valve seal A
@ 0
A
49 9200 145
Adapter set,
radiator cap A cl3JQ
tester
49 9200 020
Tension gauge,
V-ribbed belt A
ST-3

ST SPECIAL TOOLS
ENGINE (CONT’D)
TOOL NUMBER
& DESCRIPTION PRIORITY
49 E301 144
Removing plate A ILLUSTRATION
CLUTCH AND MANUAL TRANSAXLE
TOOL NUMBER
8, DESCRIPTION
49 GO17 5AO
Support, engine
49 SE01 310A
Clutch disc
centering tool
49 1285 071
Puller, bearing
49 GO19 OAO
Hanger, transaxle
49 8017 001
Bolt set
(Except
BP DOHC)
49 GO30 370
Removing plate
ST-4
PRIORITY
A
A
A
A ILLUSTRATION
I
=-a==-=
TOOL NUMBER
81 DESCRIPTION PRIORITY ILLUSTRATION -
- -
TOOL NUMBER
!I DESCRIPTION PRIORITY ILLUSTRATION
19 0636 145
Uler, fan A
oulley boss
49 GO30 440
Holder, primary A
shaft (BP DOHC)
T
49 F401 440
Holder, primary
shaft (Except
BP DOHC) A
49 0187 520
Bearing puller,
rear axle shaft
(Except
BP DOHC) A
49 GO30 455
Holder,
differential
side gear A
49 0259 770B
Wrench, flare nut A

SPECIAL TOOLS ST
CHECKER AND OTHER EQUIPMENT (CONT’D)
49 9200 162
Monitor, engine
49 GO18 903
Adapter harness
49 GO18 904
Sheet (Engine
49 HO18 9Al
49 B019 9AO
System selector TOOL NUMBER
L DESCRIPTION PRIORITY ILLUSTRATION
19 BO19 9Al
X-AT selector
EC-AT tester) A .
19 B019 908
larness, adapter A
;EC-AT tester)
49 FO18 002
Igniter checker A
49 NO18 001
Adapter harness A
(igniter checker)
49 0305 870A
Tool set, window A
ST-l 1