1992 MAZDA PROTEGE engine oil

REMOVAL
0311082-046
Removal note
P/S oil pump and bracket
Caution
l Do not damage the hoses.
1. Remove the P/S oil pump and bracket with the hoses still
connected.
2. Position the pump away from the engine and affix it with wire.
A/C compressor (if equipped)
Caution
l Do not damage the hoses.
1. Remove the A/C compressor with the hoses still connected.
2. Position the compressor away from the engine and affix it
with wire.
Step 2
1. Disconnect the harness connectors shown in the figure.
OIL PRESSURE SWITCH ATX
THROTTLE INHIBITOR SWITCH
ALTERNATOR
I SENSOR 1
II
rl (MTX)
-03UOB2-05( .-,’

REMOVAL B2
13UOB2-021
0311082-059
Tie-rod end
1. Remove the cotter pin and loosen the nut so that it flushes
with the ball joint edge.
Caution
l Do not reuse the cotter pin.
2. Separate the knuckle arm and ball joint with the SST.
Driveshaft
1. Remove the joint shaft.
2. Remove the bolts and nuts at the left and right lower arm
ball joints.
Caution
l Do not damage the ball joint dust boots.
3. Pull the lower arm downward to separate them from the
knuckles.
4. Remove the engine mount member. (ATX)
Caution
l Support the engine before removing the member.
(1) Suspend the engine with a chain block.
(2) Remove the No.1 and No.2 engine mount nuts.
(3) Remove the engine mount member bolts and nuts and
remove the engine mount member.
Caution
l Do not damage the oil seal.
5. Separate the driveshafts from the transaxle by prying with
a bar inserted between the shaft and the case.
B2-35

B2 DISASSEMBLY
AUXILIARY PARTS
1, Drain the engine oil.
2. Disassemble in the order shown in the figure
GASKET, REPLACE ..______-.
-___ -
03UOB2-064
1. Distributor and high-tension lead 7. Oil cooler
2. Intake manifold assembly 8. Oil pressure switch
3. Injector and distribution pipe assembly 9. Spark plug
4. Alternator and drive belt 10. Oil level gauge
5. No.3 engine mount bracket 11. Oil level gauge pipe stay
6. Oil filter 12. Engine hanger
82-42

ASSEMBLY B2
1. Clean all parts before reinstallation.
2. Apply new engine oil to all sliding and rotating parts.
3. Replace plain bearings if they are peeling, burned, or otherwise damaged.
4. Tighten all bolts and nuts to the specified torques.
Caution
l Do not reuse gaskets or oil seals.
93GOBl-082
B2-67

B2 ASSEMBLY
CYLINDER BLOCK (INTERNAL PARTS)
Torque Specifications
12-18 N.m (1.2-1.8
JOURNALS AND
47-50 (4.8--/6.1, 35-37)
N-m (m-kg, ft-lb)
Connecting Rod
o5uoBx-175
1. Install one piston pin clip into the clip groove in the piston.
2. Assemble the piston and the connecting rod, a ligning the
oil groove in the large end of connecting rod opposite the
“F” mark on the piston.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin from the side opposite the clip.
I 23uor32.039
82-68

ASSEMBLY
2311082-04
05UOBX-17
OSUOBX-17
SPACER TANG
OIL RING
SPACER ENDS
-I
a
5. Tap the piston pin in with the SST until the pin contacts the
clip.
If the pin cannot be installed easily, replace the connecting
rod.
6. Install the second clip into the clip groove in the piston.
7. Check the oscillation torque of the connecting rod. If the
large end does not drop by its own weight, replace the pis-
ton and/or piston pin.
Piston Ring
1. Install the three-piece oil rings on the pistons.
(1) Apply clean engine oil to the oil ring spacer and rails.
(2) Install the oil ring spacer with the ends upward.
Note
l The upper rail and lower rail are the same.
l The rails may be installed with either face upward.
(3) Install the upper rail and lower rail.
2. Verify that both rails are expanded by the spacer tangs as
shown in the figure by making certain the rails turn smoothly
in both directions.
Caution
l The rings must be installed with the Fl marks
upward.
l The second ring must be installed with the scraper
face downward.
3. Apply clean engine oil to the top and second piston rings.
4. install the second ring to the piston; then install the top ring.
Use a piston ring expander (commercially available).
132-69

ASSEMBLY B2
r
03UOB2-09
__~~
05UOBX-188
.
OWOBX-19(
WIDTH
I
05UOBX-19
(7) Remove the main bearing caps, and measure the Plasti-
gage at each journal at the widest point for the smallest
clearance, and at the narrowest point for the largest
clearance.
(8) If the oil clearance exceeds specification, grind the
crankshaft and use undersize main bearings.
(Refer to page B2-64.)
Oil clearance: 0.018-0.036mm (0.0007-0.0014 in)
Maximum: O.lOmm (0.004 in)
2. Apply a liberal amount of clean engine oil to the main bear-
ings, thrust bearings and main journals.
3. Install the crankshaft and the main bearing caps accord-
ing to the cap number and C= mark.
4. Tighten the main bearing cap bolts in two or three steps
in the order shown in the figure.
Tightening torque:
54-59 N*m (5.5-6.0 m-kg, 40-43 ft-lb)
5. Measure the crankshaft end play.
End play : 0.080-0.282mm (0.0031-0.0111 in)
Maximum: 0.30mm (0.012 in)
6. If the end play exceeds the maximum, grind the crankshaft
and install an oversize thrust bearing or replace the crank-
shaft and thrust bearing.
Thrust bearlng width
Standard:
2.500-2.550mm (0.0984-0.1004 in)
0.25mm (0.010 in) oversize:
2.625-2.675mm (0.1033-0.1053 in)
0.50mm (0.020 in) oversize:
2.750-2.800mm (0.1083-0.1102 in)
0.75mm (0.030 in) oversize:
2.875-2.925mm (0.1132-0.1152 In)
B2-71

B2 ASSEMBLY
RUBBER SLEEVE
I
OYJOBX-192
03UOB2-17
03UOB2-09 2 '0
05UOBX-196 Piston and Connecting Rod Assembly
Caution
l Protect the connecting rod bolts with rubber sleeves
to prevent damage to the crankpin journals.
1. Apply a liberal amount of clean engine oil to the cylinder
walls, pistons, and piston rings.
2. Check the piston rings for correct end gap alignment.
3. Insert each piston assembly into the cylinder block with the
F mark facing the front of the engine. Use a piston ring com-
pressor (commercially available).
Connecting Rod Cap
1. Measure the connecting rod bearing oil clearances using
the same procedure as for the main bearing oil clearance.
Caution
l Align the matching marks on the cap and the con-
netting rod when installing the connecting rod cap.
Tightening torque:
47-50 N-m (4.8-5.1 m-kg, 35-37 &lb)
Oil clearance: 0.028.0.088mm (0.001 l-0.0027 in)
Maximum: O.lOmm (0.004 in)
2. If the oil clearance exceeds the maximum, grind the crank-
shaft and use undersize bearings. (Refer to page 82-64.)
3. Measure the connecting rod side clearances.
Side clearance: 0.1 lo-0.282mm (0.0043-0.0103 in)
Maximum: 0.30mm (0.012 in)
4. If the clearance exceeds the maximum, replace the con-
necting rod and cap.