1992 MAZDA PROTEGE oil

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
BP SOHC
THRUST PLATE
DOWEL PIN AND PIN GROOVE
63UOlX-121
63UOlX-12
01; RESERVOIR
03UOBl-1’ 16
Camshaft
1. Apply engine oil to the journals and bearings; then insert
and mount the camshaft into position with the thrust plate.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 89-95 In-lb)
Camshaft Pulley
1. Install the camshaft pulley onto the dowel pin with the pin
groove facing straight upward.
Note
l Be certain that the dowel pin of the camshaft also
faces straight upward.
2. Tighten the camshaft pulley bolt. Hold the camshaft using
a suitable wrench on the cast hexagon as shown.
Tightening torque:
49-81 N-m (5.0-8.2 m-kg, 38-45 ft-lb)
Hydraulic Lash Adjuster (HLA)
1. Pour engine oil into the oil reservoir in the rocker arm.
2. Apply engine oil to the new HLA.
3. install the HLA in the rocker arm.
Caution
l Be careful not to damage the O-ring when installing.
81-83

Bl ASSEMBLY
No.1 CYLINDER No.4 CYLINDER
0311081-14
No.1 CYLINDER
No.4 CYLINDER
INTAKE
\. A
0’ Y Y 0 1
”
P
/ Y)
6
EXHAUST
No.1, 2 CYLINDERS No.3, 4 CYLINDERS
(IN & EX) (IN & EX)
93UOlA-08
I I I I I
000 @ @3
93UOiA-08
0311081-14
81-84
IN
EX
Rocker Arm and Rocker Shaft Assembly
66 SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure.
Caution
l Be sure both rocker arm shaft oil holes face
downward.
l The installation bolt holes are different for the ex-
haust and intake sides as shown in the figure.
Note
l There are two types of rocker arms with different
offsets. One type for No.1 and No.2 cylinders ex-
haust and intake. And the other for cylinders No.3
and No.4.
2. Install the rocker arm and rocker shaft assembly.
Caution
l The bolts must be tightened gradually and In the or-
der shown.
Tightening torque:
22-26 N-m (2.2-2.9 m-kg, 16-21 ft-lb)
BP SOHC
1. Assemble the rocker arm and rocker shaft assembly as
shown in the figure.
Caution
l Face the rocker shaft identification mark upward.
l The installation bolt holes are different for the ex-
haust and intake sides.
identification mark
IN . . . ..White
EX.....Biue

Bl ASSEMBLY
05UOBX-24:
Spark Plug
1. Install the spark plugs.
Tightening torque:
15-23 N*m (1.5-2.3 m-kg, 1 I-17 ft-lb)
Oil Level Gauge
1. Install the oil level gauge.
Oil Pressure switch
1. Install the oil pressure switch.
Tightening torque:
12-18 N-m (120-180 cm-kg, 104-158 in-lb)
Oil Filter
1. Remove all foreign material from the oil filter mounting
surface.
2. Apply a small amount of clean engine oil to the rubber seal
of the oil filter.
3. Install the oil filter and tighten it by hand until the rubber
seal contacts the base.
4. Tighten the filter 1 and l/6 turns with a filter wrench.
No.3 Engine Mount Bracket
1. Install the No.3 engine mount bracket.
Tightening torque:
93-l 13 N-m (9.5-l 1.5 m-kg, 89-83 ft-lb)
Alternator
1. Install the alternator strap.
Tightening torque:
37-52 N#m (3.8-5.3 m-kg, 27-38 ft-lb)
2. Install the alternator and alternator drive belt. Loosely tight-
en the alternator installation bolt.
3. Adjust the drive belt deflection. (Refer to page Bl-6.)
Tightening torque
Alternator installation bolt @ :
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
Belt-adjusting bolt @ :
19-25 N#m (1.9-2.8 m-kg, 14-19 f&lb) --’ I
I 0311081-165
Bl-90

ASSEMBLY Bl
03UOBl-16
03UOB1.21 38
Injector and Distribution Pipe Assembly (BP SOHC)
1. Install the injector and distribution pipe assembly with new
insulators.
Tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
Intake Manifold Assembly
1, Remove all foreign material from the intake manifold con-
tact surface.
2. Install a new gasket and the intake manifold assembly.
Tightening torque:
19-25 N*m (1.9-2.6 m-kg, 14-19 ft-lb)
Distributor and High-tension Lead
1. Apply engine oil to the O-ring, and position it on the dis-
tributor.
2. Apply engine oil to the blade.
3. Install the distributor with the blade fit into the camshaft
groove.
4. Temporarily, loosely tighten the distributor installing bolt.
5. Adjust the ignition timing after engine installation.
(Refer to Section G.)
6. Connect the high-tension leads.
81-91

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

Bl INSTALLATION
Step 5
1. Connect the harness connectors shown in the figure.
GROUND ALTERNATOR
OIL PRESSURE SWITCH
I- THFOTTLE SENSOR
NEUTRAL SWITCH (MTX)
IGNITION COIL
$A_c_K;u_p LIGHT SWITCH
____------- ;
Step 6
Torque Specifications
7.8-11 N.m (80-110 cm-kg, 89-95 in-lb)
19-25 (1.9-2.6, 14-19)
2.9-5.9 N.m
(30-60 cm-kg, 26-52 in-lb)
7.8-11 N.m
(80-l 10 cm-kg,
6.4-9.3 N.m 37-52
(3.8-5.3, 27-38)
24-35
(2.4-3.6, 17-26)
7.8-11 N.m 160-110 cmika, 69-95 in-lb) ‘-- -- -..’ ‘-=’ -’ / 166-96 r?m.ka.
66-82 in-lb) 69-95 in-lb)
N.m (m-kg, ft-lb -- OBUOBl-1E
Bl-100

INSTALLATION Bl
I I
03UOBl-193
03UOBl-19
1
PULLEY
P/S AND A/C
OWOBl-19
03UOBl-15
A/C compressor
1. Install the A/C compressor.
Tightening torque:
24-35 N-m (2.4-3.6 m-kg, 17-26 ft-lb)
P/S oil pump and bracket
1. Install the P/S oil pump and bracket.
Tightening torque:
37-52 N-m (3.6-5.3 m-kg, 27-36 ft-lb)
Drive belt
1. Install the P/S and/or A/C drive belt.
2. Adjust the drive belt deflections. (Refer to page Bl-6.)
Radiator and cooling fan assembly
1. Install the radiator and cooling fan assembly.
Tightening torque:
7.6-11 N#m (60-110 cm-kg, 69-95 in-lb)
2. Tighten the A/C pipe bracket to the radiator.
Tightening torque:
6.4-9.3 N*rn (65-95 cm-kg, 56-62 in-lb)
3. Connect the upper and lower radiator hoses.
Caution
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.
4. Connect the coolant reservoir hose.
5. Connect the cooling fan connector.
6. Connect the oil cooler hose. (ATX)
Bl-=lOl