Mazda Protege 5. Manual - part 118

MECHANICAL [ZM]

01–10A–6

•

If the valve clearance exceeds the
standard, replace the adjustment shim.
(See 01–10A–6 VALVE CLEARANCE
ADJUSTMENT [ZM].)

Standard [Engine cold]

IN: 0.25—0.31 mm {0.010—0.012 in}

(0.28

±±±±

0.03 mm {0.011

±±±±

0.001 in})

EX: 0.25—0.31 mm {0.010—0.012 in}

(0.28

±±±±

0.03 mm {0.011

±±±±

0.001 in})

(3) Turn the crankshaft 360

°°°°

clockwise so that

the No.4 piston is at TDC of the compression
stroke.

(4) Measure the valve clearance at B in the figure.

•

If the valve clearance exceeds the standard, replace the adjustment shim. (See 01–10A–6 VALVE
CLEARANCE ADJUSTMENT [ZM].)

Standard [Engine cold]

IN: 0.25—0.31 mm {0.010—0.012 in} (0.28

±±±±

0.03 mm {0.011

±±±±

0.001 in})

EX: 0.25—0.31 mm {0.010—0.012 in} (0.28

±±±±

0.03 mm {0.011

±±±±

0.001 in})

4. Install the cylinder head cover. (See 01–10A–9 TIMING BELT REMOVAL/INSTALLATION [ZM].)

End Of Sie

VALVE CLEARANCE ADJUSTMENT [ZM]

A3U011012010W04

Perform this same procedure for all camshafts requiring valve clearance adjustment.

1. Turn the crankshaft clockwise so that the cams on the camshaft requiring valve clearance adjustment are

positioned straight up.

2. Remove the camshaft cap bolts as necessary.

Note

•

Remove only one pair of cap bolts at a time.

•

Reinstall the cap bolts before removing the
next pair.
— A: For EX side No.1, 2, 3 cylinder

adjustment shim removal.

— B: For IN side No.1, 2, 3 cylinder

adjustment shim removal.

— C: For EX side No.2, 3, 4 cylinder

adjustment shim removal.

— D: For IN side No.2, 3, 4 cylinder

adjustment shim removal.

•

For EX side No.2, 3 cylinder adjustment shim removal, remove either bolt A or C.

•

For IN side No.2, 3 cylinder adjustment shim removal, remove either bolt B or D.

3. Install the SSTs on the camshaft using the

camshaft cap bolt holes.

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MECHANICAL [ZM]

01–10A–7

01–10A

Tightening torque

11.3—14.2 N·m {115—145 kgf·cm, 100—125

in·lbf}

4. Align the marks on the SSTs (shaft and shaft

clamp).

5. Tighten bolts A to secure the SST (shaft).

6. Face the SST (body) toward the center of the

cylinder head, and mount it on the SST (shaft) at
the point of the adjustment shim to be replaced.

7. Face the notch of the tappet so that a fine

screwdriver can be inserted.

8. Set the SST on the tappet by its notch.

9. Tighten bolt B to secure the SST (body).

Caution

••••

Cylinder head can be damaged when the
tappet is pressed down.

10. Tighten bolt C, and press down the tappet.

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MECHANICAL [ZM]

01–10A–8

11. Using a fine screwdriver, pry up the adjustment

shim through the notch on the tappet. Remove
the shim using a magnet.

12. Select proper adjustment shim.

New adjustment shim

= Removed shim thickness + Measured

valve clearance - Standard valve clearance
(0.28 mm {0.011 in})

13. Push the selected shim into the tappet.
14. Loosen bolt C to allow the tappet to move up.
15. Loosen bolt B and remove the SST (body).
16. Remove the SSTs and tighten the camshaft cap

bolts.

Tightening torque

11.3—14.2 N·m {115—145 kgf·cm, 100—125 in·lbf}

17. Inspect the valve clearance. (See 01–10A–5 VALVE CLEARANCE INSPECTION [ZM].)

End Of Sie

COMPRESSION INSPECTION [ZM]

A3U011002000W05

Warning

••••

When the engine and the oil are hot, they can cause severe burns. Be careful not to burn yourself
during removal/installation of each component.

1. Verify that the battery is fully charged.

•

Recharge it if necessary. (See 01–17–1 Battery.)

2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool off for about 10 min.
4. Perform “Fuel Line Safety Procedure”. Leave the fuel pump relay removed. (See 01–14–4 BEFORE REPAIR

PROCEDURE.)

5. Remove the ignition coils. (See 01–18–1 IGNITION COIL REMOVAL/INSTALLATION.)
6. Remove the spark plugs.
7. Connect a compression gauge into the No.1 spark plug hole.
8. Fully depress the accelerator pedal and crank the engine.
9. Note the maximum gauge reading.

10. Inspect each cylinder as below.

•

If the compression in one or more cylinders is low or the compression difference between cylinders
exceeds the maximum, pour a small amount of clean engine oil into the cylinder and reinspect the
compression.
— If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is

required.

— If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
— If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the

cylinder head distorted and overhaul is required.

Compression

kPa {kgf/cm

, psi} [rpm]

1. Disconnect the compression gauge.
2. Install the spark plugs.

Tightening torque

15—22 N·m {1.5—2.3 kgf·m, 11—16 ft·lbf}

3. Install the ignition coils.
4. Install the fuel pump relay.

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Item

Engine type

Standard

1,373 {14.0, 199} [300]

Minimum

981 {10.0, 142} [300]

Maximum difference
between cylinders

196 {2.0, 28}

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MECHANICAL [ZM]

01–10A–9

01–10A

End Of Sie

TIMING BELT REMOVAL/INSTALLATION [ZM]

A3U011012040W02

1. Disconnect the negative battery cable.
2. Remove the CMP sensor. (See 01–40A–35 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/

INSTALLATION [ZM].)

3. Remove the ignition coils. (See 01–18–1 IGNITION COIL REMOVAL/INSTALLATION.)
4. Remove the drive belt. (See 01–10A–4 DRIVE BELT ADJUSTMENT [ZM].)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Inspect the air gap. (See 01–40A–32 Air Gap Inspection.)
8. Adjust the drive belt deflection/tension. (See 01–10A–4 DRIVE BELT ADJUSTMENT [ZM].)
9. Start the engine and:

(1) Inspect the pulleys and drive belt for runout and contact.
(2) Inspect the ignition timing. (See 01–10A–25 Ignition Timing Inspection.)

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Crankshaft pulley

Plate

Water pump pulley

Cylinder head cover
(See 01–10A–13 Cylinder Head Cover Installation
Note)

No.3 engine mount
(See 01–10A–10 No.3 Engine Mount Removal
Note)
(See 01–10A–13 No.3 Engine Mount Installation
Note)

Timing belt cover

Pulley lock bolt
(See 01–10A–10 Pulley Lock Bolt Removal/
Installation Note)

Pulley boss

Timing belt
(See 01–10A–10 Timing Belt Removal Note)
(See 01–10A–11 Timing Belt Installation Note)

Tensioner, tensioner spring
(See 01–10A–11 Tensioner, Tensioner Spring
Installation Note)

Idler

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