1992 MAZDA PROTEGE lock

Bl ASSEMBLY
3. Apply a continuous bead of silicone sealant to the MBSP
along the inside of the bolt holes,
4. Install the MBSP onto the cylinder block.
5. Tighten the MBSP bolts in two or three steps in the order
shown in the figure.
Tightening torque:
16-21 N.m (1.6-2.1 m-kg, 12-15 ft-lb)
Oil Strainer
1. Install the oil strainer and a new gasket.
Tightening torque:
7.6-11 N.m (60-110 cm-kg, 69-95 in-lb)
Oil Pan
1. Remove all foreign material from the contact surfaces.
2. Apply silicone sealant to the shaded areas shown in the
figure.
-137 3. Install new gaskets onto the oil pump body and the rear
cover with the projections in the notches shown in the figure.
81-76

Bl ASSEMBLY
Cylinder Head Gasket
1. Remove all foreign material from the top of the cylinder
block.
2. Place the new cylinder head gasket in position.
05UOBX-219
36 SOHC
Cylinder Head
1. Install the cylinder head.
2. Apply clean engine oil to the bolt threads and seat faces
3. Tighten the cylinder head bolts in two or three steps in the
order shown.
Tightening torque:
76-81 N.m (7.7-8.3 m-kg, 56-80 ft-lb)
3P SOHC OWOBX-221
03UOBl-205
Camshaft Oil Seal
1. Apply a thin coat of engine oil to the camshaft oil seal and
cylinder head.
2. Tap the camshaft oil seal into the cylinder head with a suita-
ble pipe.
Caution
. The oil seal must be tapped in until it is flush with
the cylinder head.
Oil seal outer diameter: 40mm (1.57 in)
--
Bl-82

ASSEMBLY Bl
CYLINDER HEAD
MARKS
03UOBl-15!
TENSION
SIDE
03UOBl-15
03UOBl-15
03UOBl-158
I
98 N
(10 kg, 22 lb)
1
03UOBl-159
2. Verify that the camshaft pulley marks are aligned with the
cylinder head cover marks.
3. Install the timing belt so that there is no looseness at the
tension side.
Caution
l Do not turn the crankshaft counterclockwise.
4. Turn the crankshaft two turns clockwise, and align the tim-
ing belt pulley mark with the timing mark.
5. Verify that the camshaft pulley marks are aligned with the
cylinder head cover mark.
if not aligned, remove the timing belt and repeat from ten-
sioner installation.
6. Loosen the tensioner lock bolt to apply tension to the tim-
ing belt.
Caution
l Be sure not to apply tension other than that of the
tensioner spring.
7. Tighten the tensioner lock bolt.
Tightening torque:
19-25 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
8. Turn the crankshaft 2 turns clockwise and verify that the
timing marks are correctly aligned.
9. Measure the timing belt deflection by applying moderate
pressure (96 N, 10 kg, 22 lb) midway between the crank-
shaft pulley and the camshaft pulley.
If the timing belt deflection is not correct, temporarily se-
cure tensioner lock bolt so the spring is fully extended and
repeat steps 4-8 above or replace the tensioner spring.
Deflection:
11 .O-13.0mm (0.43-0.51 In) at 96 N (10 kg, 22 lb)
Bl-87

Bl ASSEMBLY
1IMING
COVER
Timing Belt Cover
1. Install the lower and upper timing belt covers and new
gaskets.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
Crankshaft Pulley
1. Install the pulley boss.
01 EOBX-164
2. Mount the SST or equivalent and tighten the pulley lock bolt.
Tightening torque:
157-167 N,m (16-17 m-kg, 116-123 ft-lb)
3. Remove the SST or equivalent,
4. Install the crankshaft pulley.
5. Install the plate.
Tightening torque:
12-17 N*m (1.25-l .75 m-kg, 109-152 in-lb)
Water Pump Pulley
1. Install the water pump pulley.
Tightening torque:
7.8-11 N,m (80-110 cm-kg, 69-95 in-lb)
I
I OSJOBX-236
Bl-88

Step 3
Torque Specifications
INSTALLATION
ATX
Bl
6.9-11 N-m
(70-110 cm-kg, 61-95 in-lb)
GAs~~~~~~~~c~~~,~
(3.2-4.7, 23-34) 16-23 6.9-9.6 N.m
11.6-2.3. 12-17) (70-100 cm-kg, (4.3-5.6, 31-42) -43)
NEW \.~ 61-67 in-lb)
N.m (m-ka. R-lb
Driveshaft
1. Apply grease to the end of the driveshaft.
Caution
l When installing the driveshaft, be careful not to
damage the oil seal.
l After installation, pull the front hub outward to con-
firm that the driveshaft is securely held by the clip.
2. Install the driveshaft and a new clip.
3. Install the lower arm ball-joint to the knuckle; then tighten
the locknut.
Tightening torque:
43-59 N,rn (4.4-6.0 m-kg, 32-43 f&lb)
Bl-97

INSTALLkTlON Bl
03UOBl-188
03UOBl-18
Step 4
1. Connect the hoses shown in the figure.
Caution Speedometer cable
1. Install the speedometer cable.
Tightening torque:
7.8-l 1 Nom (80-l 10 cm-kg, 69-95 in-lb)
Exhaust pipe
1. Install the exhaust pipe and a gasket; then loosely tighten
the locknuts.
2. Loosely tighten the bracket bolts.
3. Tighten the locknuts.
Tightening torque:
31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
4. Tighten the bracket bolts.
Tightening torque:
37-52 Nmrn (3.8-5.3 m-kg, 27-38 ft-lb)
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.
BP SOHC
03UOBl-1s
Bl-9

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

B2 ENGINE TUNE-UP PROCEDURE
ALTERNATOR DRIVE BELT
2311082-00
P/S OIL PUMP
DRIVE BELT
-
A/C AND P/S OIL
PUMP DRIVE BELT
23UOB2-001
1
23UOB2-00
23UOB2-OC
3. Check the drive belt deflection by applying moderate pres-
sure (98 N,
10 kg, 22 lb) midway between the pulleys.
Note
l Measure the belt deflection between the specified
pulleys.
l A belt is considered “New” if it has been used on
a running engine for less than five minutes.
Set the deflection specified below accordingly.
l Check the belt deflectlon when the engine is cold,
or at least 30 minutes after the engine has stopped.
Deflectlon
Drive belt
Alternator
P/S, PAS + A/C New Used
8.0-9.0 9.0-10.0
(0.31-0.35) (0.35-0.39)
8.0-9.0 9.0-I 0.0
(0.31-0.35) (0.35-0.39) mm (in)
Limit
12.5
(0.49)
11.5
(0.45)
4. If the deflection is not within specification, adjust it.
5. Install the air intake pipe.
Drive belt tension check
Note
l Belt tension can be checked in place of belt
deflection.
l Belt tension can be measured between any two
pulleys.
1. Removal the air intake pipe.
2. Using the
SST, check the belt tension.
_-
Tenslon
N (kg, lb)
Drive belt
Alternator New
383-461 Used
304-383 Limit
167
(39-47, 85.8-103.4) (31-39, 68.2-85.8) (17, 37)
P/S, P/S + AIC 491-589 422-491 245
(5040, 110-132) (43-50,95-l 10) (25, 55)
3. If the tension is not within specification, adjust it.
4. Install the air intake pipe.
Adjustment
Cautlon
l If a new belt is used, adjust the belt deflection at
the midpoint of new belt specification.
l A belt is considered “New” If it has been used on
a runnlng engine for less than five minutes.
1. Alternator belt
(1) Loosen the alternator mounting bolt @ and adjusting
lock bolt @.
(2) Lever the alternator outward and apply tension to the
belt.
(3) Tighten adjusting lock bolt @I.
82-6