🏷️ Basic Information

Make:

Mazda

Model:

Protege

Year:

1991

Product Name:

1991 Mazda Protege Complete Workshop Manual

Product Description:

1991 Mazda Protege Complete Workshop Manual - Covers All Models & All Repairs A-Z. This is not generic repair or parts information; it is specific to your model. This is the exact same manual used by technicians at dealerships to maintain and service.

👋 Introduction

Segment:

Compact car, known for reliability, fuel efficiency, and value.

Key Competitors:

Honda Civic, Toyota Corolla, Nissan Sentra, Ford Escort, Chevrolet Cavalier.

Strengths:

Practicality, affordability, good fuel economy, responsive handling for its class, reliable powertrain.

Value:

Provides dealership-level repair information, enabling owners to perform complex repairs and maintenance, saving significant costs.

📋 Manual Details

Coverage Scope:

Comprehensive A-Z repair and maintenance

Model Variants Covered:

All 1991 Mazda Protege models (sedan, hatchback, specific trims)

Estimated Page Count:

1000+

Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English

Format:

Likely Printed (based on description of dealership use), potentially available digitally as PDF

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, cylinder head, pistons, connecting rods, crankshaft, lubrication system, cooling system, timing belt/chain, internal components.

Engine Performance:

Fuel injection system, ignition system, emission control systems (catalytic converter, EGR), engine diagnostics, performance tuning.

Transmission Manual:

Clutch system, gearbox overhaul, gear shifting mechanisms, maintenance, repair.

Transmission Automatic:

Automatic transmission operation, overhaul, fluid checks and changes, torque converter, electronic controls (if applicable).

Drivetrain:

Front-wheel drive system, CV axles, differential, driveshafts, wheel bearings.

Suspension:

Front and rear suspension components, shock absorbers, struts, coil springs, control arms, bushings, alignment procedures.

Steering:

Power steering system, steering rack, tie rod ends, steering column, alignment.

Brakes:

Front and rear brake systems (disc/drum), hydraulic components, ABS (if equipped), brake fluid specifications, bleeding procedures, component replacement.

Electrical System:

Wiring diagrams, fuses, relays, lighting system, starting system, charging system, battery, power windows, locks, wipers, horn.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, blower motor, climate controls, diagnosis.

Body And Interior:

Body panel removal and installation, interior trim, seats, doors, windows, sunroof, corrosion protection, paint codes.

Chassis And Frame:

Frame construction, unibody structure, rust repair, chassis components.

Diagnostic Troubleshooting:

Systematic diagnostic procedures, symptom-based troubleshooting charts, fault code interpretation (OBD-I).

Scheduled Maintenance:

Oil changes, filter replacements, tune-ups, fluid flushes, belt inspections and replacements, tire rotations.

Component Replacement:

Step-by-step guides for replacing all major and minor components across all vehicle systems.

Engine Rebuild:

Detailed instructions for complete engine disassembly, inspection, measurement, and reassembly.

Transmission Overhaul:

Comprehensive guides for the complete rebuilding of both manual and automatic transmissions.

Brake System Repair:

Pad/shoe replacement, rotor/drum service, caliper/wheel cylinder repair, hydraulic line replacement, brake bleeding.

Suspension And Steering Repair:

Replacement of struts, shocks, control arms, tie rods, ball joints, power steering pump/rack.

Electrical Diagnostics:

Troubleshooting electrical issues using wiring diagrams, component testing, and common fault identification.

Bodywork And Paint:

Minor body repair, panel alignment, rust mitigation, paint code identification.

Troubleshooting Guides:

Specific guides for diagnosing and resolving common and uncommon vehicle problems.

Depth:

In-depth diagnostic procedures, component specifications, tolerances, and torque values. Suitable for professional technicians and advanced DIYers.

Detail Level:

Detailed step-by-step instructions with clear diagrams and illustrations.

Diagnostic Tools:

Information for using basic diagnostic tools and understanding OBD-I codes specific to the 1991 model year.

📊 Manual Specifications

Format Type:

Likely Printed (high quality paper), potential for PDF conversion.

Quality:

High-resolution printing, clear diagrams, legible text.

Binding:

Likely Spiral-bound or perfect-bound for durability and ease of use in a workshop environment.

Paper Quality:

Durable, possibly coated paper to withstand workshop conditions.

⚙️ Engine Specifications

Engine Code Common:

BP (1.8L DOHC)

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Camshaft)

Displacement:

1.8 Liters (1839 cc)

Horsepower Approx:

125-130 hp @ 6000 rpm

Torque Approx:

100-110 lb-ft @ 4500 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Compression Ratio:

9.1:1 (approx.)

Bore X Stroke:

83.0 mm x 85.0 mm (approx.)

Timing Belt Replacement Interval:

Refer to manual; typically 60,000-90,000 miles

🔧 Transmission

Type Standard:

5-speed Manual Transmission

Type Optional:

4-speed Automatic Transmission

Transmission Fluid Type Auto:

Dexron-III or equivalent (check manual for exact specification)

Transmission Fluid Capacity Auto Approx:

3.5 - 4.0 Liters (initial fill)

Clutch Type:

Dry, single-plate, diaphragm spring

📐 Dimensions

Length:

Approx. 166-170 inches (depending on body style)

Width:

Approx. 66.5 inches

Height:

Approx. 53.5-54.5 inches (depending on body style)

Wheelbase:

Approx. 98.4 inches

Curb Weight Approx:

2400-2600 lbs (depending on trim and transmission)

Wheel Bolt Pattern:

4x100

Typical Tire Size:

185/65R14

🛡️ Safety Features

NHTSA Ratings:

Not readily available for this specific year/model; typical for the era focused on passive safety.

ABS:

Optional on some trims

Airbags:

Driver airbag standard on most, passenger airbag uncommon for this year.

Seatbelts:

3-point front and rear seatbelts

Child Safety Anchors:

Not standard (LATCH system not common at this time)

💡 Technology Features

Audio System:

Factory AM/FM cassette stereo, optional CD player on higher trims.

Speakers:

4-6 speakers depending on trim level.

Cruise Control:

Optional on most trims.

Connectivity Features:

Limited to basic audio inputs, no integrated Bluetooth or USB for this era.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 7,500 miles or 6 months (refer to manual for exact spec)

Engine Oil Type:

10W-30 or 10W-40 API SG or higher (refer to manual)

Oil Filter Part Number Example:

Mazda genuine: B601-14-302; Aftermarket: Fram PH5796, Wix 51515 (verify fitment)

Coolant Type:

Ethylene glycol-based, typically green (Mazda FL22 may be backward compatible, but check manual)

Coolant Capacity Approx:

6.0 - 6.5 Liters

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF Dexron-II/III or specific Mazda fluid (refer to manual)

Common Wear Items:

Clutch, CV axles, strut mounts, exhaust system, interior plastics, O2 sensors, fuel injectors.

Rust Prone Areas:

Wheel wells, rocker panels, rear quarter panels, undercarriage.

Engine Specific Concerns:

Timing belt tensioner noise, oil leaks from seals, carbon buildup in advanced models.

📚 Vehicle History

Mazda Philosophy:

Mazda's reputation for building engaging and reliable vehicles, often with a sporting edge.

Third Generation:

1991 marked the debut of the third generation (BG chassis) Protege, representing a significant redesign with a more aerodynamic and modern appearance.

Manufacturing Locations:

Japan, and potentially other Mazda assembly plants.

Production Years For Bg Chassis:

1990-1994

🏆 Awards & Recognition

General Reputation:

Often praised for reliability and value in its class during its production run.