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1.6L 4-CYLINDER: Specifications Mazda Protege BJ

Mechanical

Crankcase Capacity

Crankcase capacity after overhaul is 3.6 qts. (3.4L). Oil capacity with filter change is 3.1 qts. (2.9L).

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Axle Shaft Nut173-235 (235-319)
Camshaft Sprocket Bolt37-44 (50-60)
Clutch Assembly Bolt14-19 (19-26)
Clutch Assembly Cover Bolt14-19 (19-26)
Clutch Release Cylinder Bolt14-18 (19-24)
Compressor Bracket-To-Engine Bolt28-38 (38-51)
Compressor-To-Bracket Bolt14-18 (19-24)
Connecting Rod Cap Nut35-37 (48-50)
Coolant Temperature Sensor12-17 (16-23)
Crankshaft Pulley Boss Bolt116-123 (157-167)
Crossmember-To-Frame Bolt & Nut49-69 (67-93)
Cylinder Head Bolt
Step 1(1) 13-16 (18-22)
Step 2Additional 85-95 Degrees
Step 3Additional 85-95 Degrees
Exhaust Header Pipe-To-Exhaust Manifold Nut28-38 (38-51)
Exhaust Manifold Nut(2) 14-16 (19-22)
Flywheel/Flexplate Bolt71-76 (96-103)
Fuel Rail Bolt14-18 (19-24)
Generator Lower Bolt27-38 (37-51)
Generator-To-Bracket Bolt14-18 (19-24)
Idler Pulley Bolt28-38 (38-51)
Intake Manifold Bolt/Nut(2) 14-18 (19-24)
Intake Manifold Support Bracket28-38 (38-51)
Lower Ball Joint Nut32-43 (44-58)
Main Bearing Cap Bolt
Step 1(3) 22-27 (30-37)
Step 2(3) 40-43 (54-58)
Main Bearing Support Plate12-15 (16-20)
No. 1 Mount-To-Engine Bolt49-69 (67-93)
No. 2 Mount-To-Engine Bolt28-38 (38-51)
No. 3 Mount-To-Engine Bolt55-77 (75-104)
No. 3 Mount-To-Frame Bolt44-59 (59-80)
No. 4 Mount-To-Frame Bolt44-59 (59-80)
Oil Pump-To-Block Bolt14-18 (19-24)
Power Steering Pump-To-Bracket Bolt28-38 (38-51)
Spark Plug11-17 (15-23)
Stiffener Bolt (Engine-To-Transaxle Brace)28-38 (38-51)
Thermostat Cover Bolt14-18 (19-24)
Throttle Body Bolts14-18 (19-24)
Tie Rod Nut32-43 (44-58)
Timing Belt Tensioner Bolt28-38 (38-51)
Water Inlet Bolt12-17 (16-23)
Water Pump Bolt12-17 (16-23 )
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt(4) 100-125 (11.3-14.1)
Coolant Temperature Sensor57-82 (6.4-9.3)
Crankshaft Pulley Bolts106-150 (12-17)
Oil Jet106-150 (12-17)
Oil Pan-To-Stiffener Bolt71-97 (8-11)
Oil Pressure Switch106-150 (12-17)
Oil Pump Cover Screws53-80 (6-9)
Oil Strainer Bolt71-97 (8-11)
Rear Cover Bolt71-97 (8-11)
Timing Cover Bolt71-97 (8-11)
Valve Cover Bolt(5) 61-97 (7-11)
Water Pump Pulley Bolt71-97 (8-11)
(1) Tighten to specification in alternating sequence. (Схема №10) (2) Tighten evenly to specification in alternating sequence. (3) Tighten in sequence. (Схема №19)(4) Tighten in sequence. (Схема №14) (5) Tighten in sequence. (Схема №9)
(1)Tighten to specification in alternating sequence. (Схема №10)
(2)Tighten evenly to specification in alternating sequence.
(3)Tighten in sequence. (Схема №19)
(4)Tighten in sequence. (Схема №14)
(5)Tighten in sequence. (Схема №9)

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

ApplicationSpecification
Displacement97.5 Cu. In. (1.6L)
Bore3.08" (78 mm)
Stroke3.29" (83.6 mm)
Compression Ratio9.0:1
Fuel SystemSFI

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

ApplicationIn. (mm)
Crankshaft
End Play
Standard.0031-.0111 (.080-.282)
Maximum.0118 (.30)
Maximum Runout.0016 (.04)
Main Bearings
Journal Diameter
Standard1.9661-1.9667 (49.938-49.956)
Minimum1.9647 (49.904)
Oil Clearance
Standard.0007-.0014 (.018-.036)
Maximum.0039 (.10)
Connecting Rod Bearings
Journal Diameter
Standard1.7693-1.7699 (44.940-44.956)
Minimum1.7496 (44.440)
Oil Clearance
Standard.0011-.0019 (.028-.048)
Maximum.0039 (.10)

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

ApplicationIn. (mm)
Bore Diameter
Crankpin Bore(1) 1.8898-1.8904 (48.000-48.016)
Pin Bore.7852-.7859 (19.943-19.961)
Center-To-Center Length5.2303-5.2342 (132.85-132.95)
Maximum Bend(2)
Side Play
Standard.0043-.0103 (.110-.262)
Maximum.012 (.30)
(1) Plus thickness of standard bearing. (2) Bend must not exceed .002" per 1.97" (.050 mm per 50 mm) of rod length.
(1)Plus thickness of standard bearing.
(2)Bend must not exceed .002" per 1.97" (.050 mm per 50 mm) of rod length.

CONNECTING RODS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

ApplicationIn. (mm)
Pistons
Clearance
Standard.0015-.0021 (.038-.053)
Maximum.0039 (.10)
Diameter
Standard3.0690-3.0699 (77.953-77.975)
Oversize
.010" (0.25 mm)3.0789-3.0797 (78.203-78.225)
.020" (0.50 mm)3.0887-3.0896 (78.453-78.475)
Pin Bore Diameter.7869-.7874 (19.988-20.000)
Pins
Diameter.7864-.7866 (19.974-19.980)
Piston Fit.0003-.0010 (.008-.026)
Rings
No. 1
End Gap
Standard.006-.012 (.15-.30)
Maximum.039 (1.0)
Side Clearance
Standard.0014-.0026 (.035-.065)
Maximum.006 (.15)
No. 2
End Gap
Standard.012-.017 (.30-.45)
Maximum.039 (1.0)
Side Clearance
Standard.0012-.0028 (.030-.070)
Maximum.006 (.15)
No. 3 (Oil)
End Gap
Standard.008-.027 (.20-.70)
Maximum.039 (1.0)
Side Clearance
Standard.0024-.006 (.06-.15)
Maximum.008 (.20)

PISTONS, PINS & RINGS

CYLINDER BLOCK SPECIFICATIONS

ApplicationIn. (mm)
Cylinder Bore
Standard Diameter3.0709-3.0716 (78.00-78.019)
Oversize
.010" (0.25 mm)3.0807-3.0815 (78.250-78.269)
.020" (0.50 mm)3.0905-3.0912 (78.50-78.519)
Maximum Deck Warpage.006 (.15)
Minimum Deck Height (1)8.720 (221.5)
(1) DO NOT machine more than .008" (.20 mm) from cylinder block deck surface.
(1)DO NOT machine more than .008" (.20 mm) from cylinder block deck surface.

CYLINDER BLOCK

CYLINDER HEAD SPECIFICATIONS

ApplicationIn. (mm)
Cylinder Head
Height4.733-4.741 (120.23-120.43)
Grinding Limit.008 (.20)
Maximum Warpage.0024 (.06)
Valve Seat Angle45 Degrees
Valve Seat Width.031-.055 (0.80-1.40)
Valve Guide I.D..2366-.2374 (6.01-6.03)
Valve Guide Installed Height.531-.555 (13.5-14.1)
Valve Stem-To-Guide Oil Clearance
Standard.0014-.0024 (.035-.060)
Maximum.0008 (.020)

CYLINDER HEAD

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

ApplicationIn. (mm)
Valves
Face Angle45 Degrees
Installed Height1.524 (38.7)
Minimum Margin
Intake.043 (1.10)
Exhaust.047 (1.20)
Refinish Length
Intake
Standard3.574-3.598 (90.78-91.38)
Minimum3.566 (90.58)
Exhaust
Standard3.554-.3.578 (90.27-90.87)
Minimum3.546 (90.07)
Stem Diameter
Intake
Standard.2350-.2356 (5.970-5.985)
Minimum.2331 (5.920)
Exhaust
Standard.2348-.2354 (5.965-5.980)
Minimum.2329 (5.915)
Valve Springs
Maximum Out-Of-Square.06 (1.53)
Lbs. @ In. (kg @ mm)
Compressed Length
Minimum29-32 @ 1.440 (13-15 @ 36.5)

VALVES & VALVE SPRINGS

CAMSHAFT SPECIFICATIONS

ApplicationIn. (mm)
End Play
Standard.0028-.0075 (.07-.19)
Maximum.008 (.20)
Journal Diameter
Standard1.0213-1.0222 (25.940-25.965)
Minimum1.0201 (25.910)
Maximum Journal Runout & Out-Of-Round.0012 (.030)
Journal Oil Clearance.0014-.0032 (.035-.081)
Lobe Height
Exhaust
Standard1.6102 (40.900)
Minimum1.6024 (40.700)
Intake
Standard1.6281 (41.354)
Minimum1.6202 (41.154)

CAMSHAFT

TAPPETS SPECIFICATIONS

ApplicationIn. (mm)
Bore Diameter1.1811-1.1821 (30.000-30.025)
Tappet Diameter1.1795-1.1801 (29.959-29.975)
Oil Clearance
Standard.0010-.0026 (.025-.066)
Maximum.0071 (.180)

TAPPETS

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