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Mazda PROTEGE Service Repair Manual 2000 2001 2002 2003 2004

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🏷️ Basic Information Identification Make: Mazda Model: Protegé Model Years Covered: 2000, 2001, 2002, 2003, 2004 Codes Platform Code: BJ 👋 Introduction Market Position Segment: Compact car, known for its...
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Mazda PROTEGE Service Repair Manual 2000 2001 2002 2003 2004
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protegé
Model Years Covered:
2000, 2001, 2002, 2003, 2004
Codes
Platform Code:
BJ
👋 Introduction
Market Position
Segment:
Compact car, known for its sporty handling and value for money.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Chevrolet Cavalier.
Key Features
Handling:
Often praised for its 'Zoom-Zoom' driving dynamics, responsive steering, and well-tuned suspension.
Reliability:
Generally considered reliable, though some specific issues can arise as detailed in maintenance sections.
Value Proposition:
Offered a good balance of features, performance, and affordability, making it a popular choice.
📋 Manual Details
Coverage Areas
Vehicle Models And Trims:
All Protegé models and trim levels, including DX, ES, LX, Mazdaspeed (if applicable within years), and wagon variants.
Engine Variants:
All engines offered during the 2000-2004 model years, including 1.6L (Z5), 1.8L (BP-Z3, BP-VE), and 2.0L DOHC (FS-DE).
Transmission Options:
Manual (M5) and Automatic (FJ4A-EL, GF4A-EL) transmissions.
Page Count
Estimated Pages:
High (typically over 2000 pages for a complete factory service manual set)
Manual Type
Type:
Complete Service & Repair Manual
Language
Language:
English
Format
Format:
Digital (Downloadable PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (including disassembly, inspection, assembly, timing belt/chain service), fuel system (injectors, pump, pressure regulator), cooling system, exhaust system, ignition system, engine control system (ECU, sensors, actuators), clutch, manual transmission, automatic transmission (diagnostics, overhaul, valve body).
Chassis:
Brake system (front/rear discs, ABS, parking brake), steering system (power steering pump, rack and pinion), suspension system (front struts, rear shocks, control arms, bushings), wheels and tires, alignment specifications.
Electrical:
Starting and charging system, lighting system (headlights, taillights, interior), instrument panel and gauges, wipers and washers, horn, power windows, door locks, mirrors, audio system, body control modules, wiring diagrams, fuses and relays, diagnostic trouble codes (DTCs).
Body And Interior:
Body panels, doors, hoods, trunk lid, bumpers, glass, seats, interior trim, HVAC system (heater core, A/C compressor, refrigerant, blower motor), airbags, seat belts.
Procedures Included
Maintenance:
Routine service (oil changes, filter replacements, fluid checks), tune-ups, spark plug replacement, belt replacement, coolant flushing, brake fluid replacement, A/C service.
Diagnostics And Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon problems, identification of symptoms, use of scan tools, troubleshooting flowcharts for electrical and mechanical issues.
Repair And Rebuild:
Detailed instructions for component removal, installation, and rebuilding (e.g., engine overhaul, transmission repair, brake caliper replacement, strut replacement).
Special Tools And Jigs:
Identification and usage instructions for specialized tools required for specific repairs or adjustments.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed wiring diagrams and diagnostic procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable text content
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or sections
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1.6L:
Z5-DE
Displacement 1.6L:
1.597 cc
Configuration 1.6L:
Inline-4, DOHC, 16-valve
Horsepower 1.6L:
~105-110 hp @ 6000 rpm
Torque 1.6L:
~105-110 lb-ft @ 4000 rpm
Secondary Engine
Engine Code 1.8L:
BP-Z3, BP-VE
Displacement 1.8L:
1839 cc
Configuration 1.8L:
Inline-4, DOHC, 16-valve
Horsepower 1.8L:
~120-125 hp @ 6000 rpm
Torque 1.8L:
~118-120 lb-ft @ 4000 rpm
Performance Engine
Engine Code 2.0L:
FS-DE
Displacement 2.0L:
1991 cc
Configuration 2.0L:
Inline-4, DOHC, 16-valve, Variable Valve Timing (VVT)
Horsepower 2.0L:
~130-135 hp @ 6000 rpm
Torque 2.0L:
~135-140 lb-ft @ 4300 rpm
Fuel System
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Recommended Octane:
87 (minimum), 91 recommended for optimal performance on some engines.
🔧 Transmission
Standard
Transmission Type Base:
5-speed Manual (M5)
Optional
Transmission Type Optional:
4-speed Automatic (FJ4A-EL / GF4A-EL)
Features
Automatic Features:
Electronic control, 'Hold' mode function on some models.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (Check manual for specific viscosity and type)
Automatic Transmission Fluid:
Mazda ATF-III / MERCON / DEXRON-III compatible
📐 Dimensions
Exterior
Length:
Approx. 170-173 inches (sedan), 174-176 inches (wagon)
Width:
Approx. 67 inches
Height:
Approx. 55-56 inches (sedan), 57-59 inches (wagon)
Wheelbase:
Approx. 102.7 inches
Weights
Curb Weight:
Approx. 2600-2800 lbs (depending on model and features)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test Driver:
Likely 4-star for the 2000-2002 models, potentially improving with later revisions.
NHTSA Front Crash Test Passenger:
Likely 4-star for the 2000-2002 models.
Active Features
ABS:
Available on higher trims, standard on some later models.
Passive Features
Airbags:
Driver and front passenger airbags standard across most trims; side airbags available on some ES models.
Seat Belts:
Three-point front and rear seat belts, pretensioners for front belts.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player and/or cassette player. Speaker configurations vary by trim.
Climate Control:
Manual or optional automatic climate control systems.
Driver Assistance
Cruise Control:
Available on most mid to higher trim levels.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors available on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first.
Engine Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
Every 60,000-100,000 miles depending on spark plug type (standard vs. iridium/platinum).
Timing Belt Replacement:
Every 60,000 miles for 1.8L (BP engines) and 2.0L (FS engines) if equipped with a belt. The 1.6L (Z5) also uses a belt. Crucial interval to prevent catastrophic engine damage.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.7-4.3 quarts (with filter), depending on engine.
Engine Oil Type:
API SJ or higher, SAE 5W-30 or 5W-20 (check owner's manual for specific recommendation based on climate).
Coolant Type:
Mazda Long Life Coolant (Blue) or equivalent ethylene glycol-based coolant with demineralized water.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine Oil Consumption:
Some engines, particularly the 1.8L BP, can experience increased oil consumption with age/mileage, potentially due to worn piston rings or valve seals.
Suspension Wear:
Front and rear struts, control arm bushings, and sway bar links can wear out, leading to clunking noises and poor handling.
Catalytic Converter:
Can become clogged or fail over time, impacting performance and emissions.
Transmission Issues Automatic:
Early 4-speed automatics can exhibit slipping or harsh shifting; the valve body or torque converter may be suspect.
Power Steering Pump Leaks:
Leaks from the power steering pump or lines can occur.
Rear Wheel Bearings:
Can become noisy or fail, especially on higher mileage vehicles.
📚 Vehicle History
Brand Heritage
Mazda Focus:
Mazda's long history of producing driver-focused and reliable vehicles.
Model Evolution
Generation Bj:
The second generation of the Mazda Protegé, introduced in late 1998 for the 1999 model year, with significant updates and facelifts throughout its run until 2003 (US market). This manual covers the later years of this generation.
Production
Manufacturing Locations:
Primarily Hofu, Yamaguchi, Japan; also some production in other Mazda plants globally.
Sales Figures
Popularity:
Consistently one of Mazda's top-selling models in North America during its production run.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Protegé (especially the ES trim and later Mazdaspeed versions) was often noted for its excellent handling and value, frequently appearing on 'Best Value' lists and considered a strong contender against more established rivals.
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