🏷️ Basic Information

Make:

Mazda

Model:

Protege

Generation:

BG

Years Covered:

1989-1994

👋 Introduction

Target Audience:

DIY mechanics, professional automotive repair shops, Mazda enthusiasts, and vehicle owners seeking in-depth repair and maintenance knowledge.

Manual Value Proposition:

Provides factory-level accuracy and completeness, enabling users to perform tasks typically requiring expensive dealership service, saving significant costs.

Key Feature 1:

Official Factory Documentation: Unfiltered access to original Mazda repair procedures and specifications.

Key Feature 2:

Comprehensive Coverage: Addresses all systems of the vehicle for the specified model years.

Key Feature 3:

Detailed Diagrams and Illustrations: Aids in understanding complex procedures and component locations.

Key Feature 4:

Troubleshooting Expertise: Built-in guidance for diagnosing and resolving common and complex issues.

📋 Manual Details

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

Completeness:

Complete Official Factory Service Manual

Manual Type:

Workshop Service Repair Manual (WSRM)

Page Count:

Hundreds of pages (estimated 1000+ based on typical factory manuals of this era)

File Format:

PDF (Digital Download)

Print Quality:

High-resolution scans, suitable for printing individual pages or the entire manual. Clear diagrams and text.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

📖 Manual Coverage

Engine Service:

Detailed repair and overhaul procedures for all engine variants, including timing belt replacement, cylinder head service, piston and ring replacement, crankshaft and bearing service, and lubrication system repair.

Fuel System:

Diagnosis and repair of fuel injection systems (MPI), fuel pumps, injectors, fuel pressure regulators, and fuel tank service. Includes procedures for fuel filter replacement.

Cooling System:

Radiator, water pump, thermostat, cooling fan diagnosis and replacement, coolant type specifications, and leak detection procedures.

Ignition System:

Spark plug specifications, ignition coil diagnosis, distributor service (if applicable), ignition timing adjustment procedures.

Exhaust System:

Catalytic converter service, muffler and pipe replacement, exhaust manifold repair, and oxygen sensor diagnosis.

Transmission Manual:

Complete overhaul and repair procedures for manual transmissions, including clutch service, gear replacement, bearing inspection, and shift linkage adjustments.

Transmission Automatic:

Diagnosis, repair, and overhaul of automatic transmissions, including valve body service, torque converter replacement, and transmission fluid and filter change procedures. Specific AT models covered.

Drivetrain Axles:

Front and rear axle service, CV joint inspection and replacement, driveshaft and U-joint repair.

Suspension System:

Front and rear suspension component inspection and replacement (struts, shocks, control arms, ball joints, bushings), alignment specifications.

Steering System:

Power steering system diagnosis and repair, steering rack and pinion service, tie rod end replacement, steering column repair.

Brake System:

Front and rear brake pad and rotor replacement, caliper service, brake line and hose inspection and replacement, parking brake adjustment, ABS system diagnosis (if equipped).

Electrical System:

Comprehensive wiring diagrams, fuse box layouts, diagnostic procedures for starting and charging systems, lighting system repair, instrument cluster diagnosis, power window and lock repair.

Body And Interior:

Door panel removal, seat adjustment and replacement, dashboard disassembly, exterior trim repair, body panel alignment, glass replacement, and weather stripping installation.

Heating And Air Conditioning:

HVAC system diagnosis, refrigerant recharge procedures, blower motor replacement, evaporator and condenser service, and climate control system repair.

Diagnostics Troubleshooting:

Systematic troubleshooting guides, symptom-based diagnosis trees, fault code interpretation (OBD-I for specific years/models), and diagnostic connector locations.

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid changes, power steering fluid changes, transmission fluid and filter changes.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls, steering system rebuilds, and electrical system diagnostics and repairs.

Component Replacement:

Detailed step-by-step instructions for replacing virtually all major and minor components of the vehicle.

Torque Specifications:

Comprehensive list of all essential torque values for engine, chassis, and component fasteners.

Special Tools:

Identification and usage instructions for any specialized tools required for specific repair procedures.

Depth Of Information:

Factory-level detail covering everything from basic preventive maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork.

Diagnostic Capabilities:

Advanced diagnostic procedures, troubleshooting charts, and explanations of system operation to pinpoint faults effectively.

⚙️ Engine Specifications

Engine Options:

1.6L B6 SOHC I4, 1.8L BP DOHC I4 (available in later years/trims)

Displacement 1.6L:

1597 cc

Horsepower 1.6L:

Approx. 88-90 hp @ 5500 rpm (varies by market and specific model year)

Torque 1.6L:

Approx. 90-95 lb-ft @ 3000-3500 rpm (varies by market and specific model year)

Displacement 1.8L:

1839 cc

Horsepower 1.8L:

Approx. 125-130 hp @ 6000 rpm (varies by market and specific model year)

Torque 1.8L:

Approx. 105-110 lb-ft @ 4500-5000 rpm (varies by market and specific model year)

Injection Type:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended, higher for performance variants)

Timing Belt Replacement Interval:

Recommended every 60,000 miles or 5 years (refer to manual for exact interval for specific engine).

🔧 Transmission

Standard Transmission:

5-Speed Manual Transmission

Optional Transmission:

4-Speed Automatic Transmission

Transmission Fluid Type:

Dexron III/Mercon for automatic, GL-4 gear oil for manual (refer to manual for specific viscosity).

Clutch Type:

Dry single plate clutch for manual transmission.

📐 Dimensions

Wheelbase:

Approx. 2575 mm (101.4 in)

Overall Length:

Approx. 4365 mm (171.9 in)

Overall Width:

Approx. 1690 mm (66.5 in)

Overall Height:

Approx. 1370 mm (53.9 in)

Curb Weight:

Approx. 1050-1150 kg (2315-2535 lbs), varies by model and equipment.

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle placard, typically around 1500-1600 kg.

Wheel Bolt Pattern:

4x100mm

Tire Size Standard:

185/65R14 (typical for base models), 195/60R15 (for sportier trims/later years)

🛡️ Safety Features

Crash Test Performance:

Limited official crash test data available for this specific generation from independent agencies like IIHS/NHTSA. Generally considered adequate for its era, but lacks modern safety advancements.

ABS Availability:

Optional on some trims/model years, standard on higher trims later in the production run.

Airbags:

Driver-side airbag typically standard from mid-generation onwards; passenger airbag often not available or optional on very late models.

Seatbelts:

Front 3-point automatic locking retractors, rear 2-point lap belts (center rear often 2-point as well).

💡 Technology Features

Audio System:

Basic AM/FM radio with cassette player. Optional CD player available on higher trims. Speaker configurations vary.

Cruise Control:

Available as an option on some trims, particularly higher-spec models.

Connectivity Features:

Minimal by modern standards. Primarily focused on basic vehicle operation. No Bluetooth, USB, or integrated navigation available.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions. Manual specifies exact intervals.

Air Filter Replacement:

Inspect every 15,000 miles, replace as needed. Manual provides guidance.

Spark Plug Replacement:

Typically every 30,000-60,000 miles depending on plug type (copper vs. platinum). Manual specifies exact type and interval.

Engine Oil Type:

API SG or SH certified, SAE 5W-30 or 10W-30 recommended (refer to manual for exact viscosity and capacity based on engine).

Coolant Type:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Mazda specified coolant or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Common Issue 1:

Timing belt failure (if not replaced at recommended intervals), leading to catastrophic engine damage on interference engines.

Common Issue 2:

Rust and corrosion, especially in areas exposed to road salt. Key areas include wheel wells, rocker panels, and rear quarter panels.

Common Issue 3:

Vacuum leaks causing rough idle or poor performance, often due to aging rubber hoses.

Common Issue 4:

Door lock actuators and window regulators can become slow or fail over time.

Common Issue 5:

EGR valve clogging can lead to poor performance and check engine lights.

📚 Vehicle History

Mazda Heritage:

Mazda has a long history of producing reliable and enjoyable-to-drive vehicles, often focusing on value and sporty handling.

Protege Positioning:

The Protege was Mazda's entry-level compact car, competing against models like the Honda Civic, Toyota Corolla, and Nissan Sentra. It was designed to offer good fuel economy, practical space, and engaging driving dynamics.

Production Period:

1989-1994 (BG Generation)

Manufacturing Locations:

Primarily Japan, with some assembly potentially occurring in other global locations.

🏆 Awards & Recognition

Model Recognition:

The Protege series generally received positive reviews for its value, handling, and reliability in its class during its production run. Specific awards for the 1989-1994 generation are less prominently documented than later generations.