1992 MAZDA PROTEGE engine

ENGINE STAND DISMOUNTING Bl
VIEW A
c==A
03UOBi -17
I
03UOBi-2C
05UOBX-25
03UOBl-171
OWOBX-25
3. Apply a small amount of engine coolant to the new O-ring.
4. Install the water bypass pipe.
Exhaust Pipe Bracket
1. Install the exhaust pipe bracket.
Tightening torque:
37-52 N*m (3.8-5.3 m-kg, 27-38 ft-lb)
A/C Compressor Bracket
1. Install the A/C compressor bracket.
Tightening torque
@: 19-25 N-m (1.9-2.8 m-kg, 14-19 ft-lb)
@I: 37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
Exhaust Manifold
1. Remove all foreign material from the exhaust manifold con-
tact surface.
2. Install a new gasket and the exhaust manifold.
Tightening torque:
18-23 N-m (1.8-2.3 m-kg, 12-17 ft-lb)
Exhaust Manifold Insulator
1. Install the exhaust manifold insulator.
Tightening torque:
7.8-l 1 N*m (80-l 10 cm-kg, 89-95 in-lb)
Bl-93

81 INSTALLATION
INSTALLATION
PROCEDURE
Tighten all bolts and nuts to the specified torques.
Step 1
Join the engine and transmission,
Torque Specifications
MTX
BP SOHC
19-25 (1.9-2.8, 14-19)
W
y
37-52 (3.8-5.3, 27-38)
37-52 (3.8-5.3, 27-38)
84-89 (6.5-9.1, 47-66)
ATX
BP SOHC
19-2ii (1.9-2.8, 14-19)
An
I
y 37-52 /
b ‘i
--< ($8-5.3, 27-36)
34-49
(3.5-S
37-52 (3.8-5.3, 27-38)
Bl--94
S--i0 (5.6-8.2, 41-59)
N.m (m-kg, R-lb)
23UOBl-0%

INSTALLATION Bl
Step 2
Warning
l Be sure the vehicle is securely supported on safety stands.
Taraue Soecifications
'S-80 (5.6-6.2, 41-59) 74-103 (7.5-10.5, 54-76)
h // 67-93 43-61
(6.8-9.5, 49-69) (4.4-6.2, 32- .45)
64-89 (6.5-9.1, 47-66)'
'
/cR-x&l /84-89 (6.5-9.1, 47-66)
>\----37-L5i (3.8-5.3.
27-38)
N.m (m-kg, ft-II
0311081-i
Ii------ //Ill 1 Engine mount member
1. Install the engine mount member.
Tightening torque:
64-69 N#m (6.5-9.1 m-kg, 47-66 f&lb)
Bl-95

INSTALLATION
03UOBl-17
No.2 ENGINE /I Ill
03UOBl-171
DYNAMIC DAMPER
03UOBl-17;
03UOBl-178
ATX
1 03UOBl.179
91-96
Engine and transaxle assembly
1. Suspend the engine and transaxle assembly.
Caution
l Do not damage any components in the engine com-
partment.
2. Align the No.1 and No.2 engine mount bolts with the en-
gine mount member mounting holes.
Engine mount
1. Install the No.1 engine mount nut and tighten.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 f&lb)
2. Install the No.2 engine mount nut and tighten.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
3. Install the engine mount rubber with new washer and tight-
en nut @.
Tightening torque:
74-103 N.m (7.5-10.5 m-kg, 54-76 ft-lb)
4. Install the bolt @, while aligning the engine location and
tighten nut (I!$.
Tightening torque:
67-93 N-m (6.8-9.5 m-kg, 49-69 ft-lb)
5. Install the dynamic damper.
Tightening torque:
55-80 N.m (5.6-8.2 m-kg, 41-59 ft-lb)
6. Install the No.4 engine mount rubber and bracket and loose-
ly tighten nuts @.
7. Align the bracket bolt holes with the body side holes, and
install the bolt @and tighten in the sequence shown in the
figure.
Tightening torque:
43-61 N-m (4.4-6.2 m-kg, 32-45 f&lb)
8. Tighten the nuts @.
Tightening torque: 67-93 N.m (6.6-9.5 m-kg, 49-69 ft-lb)

INSTALLATION
OWOBX-27!
Resonance chamber
1. Install the resonance chamber.
Tightening torque:
7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
Undercover and side cover
1. Install the undercover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut @.
Deflection: I-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
2. Install the battery carrier.
Tightening torque:
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
lightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
2. Connect the airflow sensor connector.
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page 61-8.)
(3) Operation of emission control system.
6. Perform a road test,
7. Recheck the engine oil and engine coolant levels.
.-’
23UOBl-057
81-102

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

82 INDEX
NDEX
COMPRESSION INSPECTION, PAGE 92-10
STANDARD: 1,256 kPa (12.8 kg/cm2, 182 psi)-300 rpm
MINIMUM: 883 kPa (9.0 kg/cm2, 128 psi)-300 rpm
INTAKE MANIFOLD
TIGHTENING TORQUE
*(I-I)* hl.m I, (I-0 c m.h.
DRIVE BELT
ADJUSTMENT, PAGE 82-6 TIGHTENIF
36-46 N.m (3.9-4.7 rlG TORQUE
m-kg, 26-34 ft-lb)
JEFLECTION
mm (in)
DRIVE BELT
New Used Limit
ALTERNATOR
8.0-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39)
12.5 (0.49)
PIS, PIS + AIC 8.0-9.0 (0.31-0.35) 9.0-10.0 (0.35-0.39)
11.5 (0.45)
23UOB2-00:
1. Timing belt
6. Engine
Removal I Installation..
..............
page 62-l 2 Removal ...................................
page 82-31
2. Cylinder head gasket
Engine stand mounting..
.......... page 82-38
Replacement ............................
page B2-16 Disassembly
.............................
page 82-41
3. HLA
Inspection / Repair.. ..................
page B2-54
Removal / Installation
................ page
82-22 Assembly ..................................
page B2-66
4. Front oil seal
Engine stand dismounting
....... page 62-91
Replacement
page 82-26 Installation..
.-- ............................
............................... page 62-93
5. Rear oil seal
Replacement ............................
page 82-28
82-2

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