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Mazda PROTEGE Digital Workshop Repair Manual 1999-2003

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🏷️ Basic Information Identification Make: Mazda Model: Protege Model Years Covered: 1999-2003 Codes Platform Code: BJ 👋 Introduction Market Position Segment: Compact car, known for sporty handling and value. Competitors:...
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Mazda PROTEGE Digital Workshop Repair Manual 1999-2003
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Model Years Covered:
1999-2003
Codes
Platform Code:
BJ
👋 Introduction
Market Position
Segment:
Compact car, known for sporty handling and value.
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra.
Key Features
Vehicle Appeal:
Reliability, engaging driving dynamics, practical interior, affordable pricing.
Manual Value
Target Audience:
DIY mechanics, professional technicians, owners seeking to maintain or repair their vehicle.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive repair, maintenance, rebuilding, refurbishing, and restoration.
Diagnostic Coverage:
All diagnostic and repair procedures.
Page Count
Estimated Pages:
Extensive (Exact count not provided, but described as 'highly detailed').
Manual Type
Type:
Digital Workshop Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF or similar e-book format)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, engine performance, fuel injection, ignition, cooling, lubrication, emission controls.
Transmission:
Manual and automatic transmission diagnosis, repair, and overhaul.
Drivetrain:
Front-wheel drive (FWD) system, axles, CV joints, differentials.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, bushings.
Steering:
Power steering system, steering rack, tie rods, steering column.
Brakes:
Hydraulic brake system, front and rear brakes (discs/drums), ABS system, parking brake.
Electrical:
Wiring diagrams, charging system, starting system, lighting, instrumentation, body electronics, power distribution.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair.
Body:
Exterior body panels, doors, hood, trunk, glass, interior trim, body sealing.
Chassis:
Frame, subframes, and related components.
Procedures Included
Maintenance:
Routine maintenance, fluid changes, filter replacements, tune-ups, inspections.
Diagnostics:
Symptom-based troubleshooting, diagnostic trouble codes (DTCs), electrical circuit testing.
Repair:
Component replacement, adjustments, and major repair procedures.
Rebuild:
Engine, transmission, and other major component rebuild procedures.
Installation:
Installation of new or replacement parts and accessories.
Technical Depth
Depth:
Comprehensive, covering from basic fluid checks to complex engine and transmission overhauls.
Detail Level:
Includes torque specifications, clearances, diagnostic flowcharts, and step-by-step instructions.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, optimized for searching and printing.
Print Quality
Print Readability:
High-resolution diagrams and text for clear printing.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
FP-DE (1.8L DOHC 4-cylinder)
Displacement 1:
1839 cc (1.8 Liters)
Horsepower 1:
Approx. 122-125 hp @ 5500-6000 rpm (varies by market/year)
Torque 1:
Approx. 118-120 lb-ft @ 3500-4500 rpm (varies by market/year)
Bore X Stroke 1:
83.0 mm x 85.0 mm
Compression Ratio 1:
9.1:1
Fuel System 1:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (SMPI)
Valve Train 1:
DOHC, 16 valves, belt-driven camshafts
Optional Engine
Engine Code 2:
FS-DE (2.0L DOHC 4-cylinder - used in 'ES' and 'GT' trims)
Displacement 2:
1991 cc (2.0 Liters)
Horsepower 2:
Approx. 130-135 hp @ 5500-6000 rpm (varies by market/year)
Torque 2:
Approx. 135-138 lb-ft @ 4500-5000 rpm (varies by market/year)
Fuel System 2:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (SMPI)
Valve Train 2:
DOHC, 16 valves, belt-driven camshafts
Engine Code 3:
FS-ZE (2.0L DOHC 4-cylinder - used in Mazdaspeed Protege)
Displacement 3:
1991 cc (2.0 Liters)
Horsepower 3:
Approx. 170 hp @ 6000 rpm
Torque 3:
Approx. 170 lb-ft @ 3000 rpm
Fuel System 3:
Electronic Fuel Injection (EFI), Turbocharged
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual transmission
Optional
Optional Transmission Type:
4-speed automatic transmission with electronic control
Features
Clutch Type:
Dry single plate clutch (manual transmission)
Transmission Fluid Spec Auto:
Mazda ATF-M III or equivalent (e.g., Dexron-III)
Transmission Fluid Spec Manual:
API GL-4, SAE 75W-90 or SAE 80W-90 gear oil
📐 Dimensions
Exterior
Length:
Approx. 170.1 inches (4320 mm)
Width:
Approx. 67.5 inches (1715 mm)
Height:
Approx. 55.7 inches (1415 mm)
Wheelbase:
Approx. 102.8 inches (2610 mm)
Front Track:
Approx. 59.1 inches (1500 mm)
Rear Track:
Approx. 58.5 inches (1485 mm)
Weights
Curb Weight Min:
Approx. 2600 lbs (1180 kg)
Curb Weight Max:
Approx. 2850 lbs (1295 kg)
Gross Vehicle Weight Rating:
Varies by model, typically around 3700-3800 lbs.
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Good (for models tested, check specific year/trim)
NHTSA Frontal Impact Passenger:
Good (for models tested, check specific year/trim)
IIHS Frontal Offset:
Acceptable/Good (for models tested, check specific year/trim)
Active Features
ABS:
Available on most trims, standard on higher trims/later years.
Traction Control:
Available on select models/trims.
Passive Features
Airbags Front:
Driver and front passenger airbags standard.
Airbags Side:
Available on select models/trims.
Seatbelts:
Three-point seatbelts with pretensioners in the front.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD/Cassette player, optional premium sound system.
Climate Control:
Manual or automatic climate control systems depending on trim.
Driver Assistance
Cruise Control:
Available on most models.
Connectivity
Remote Keyless Entry:
Available on most models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed.
Engine Coolant Replacement:
Initial replacement at 75,000 miles (120,000 km), then every 50,000 miles (80,000 km).
Spark Plug Replacement:
Approx. 60,000 miles (96,000 km) for standard plugs; iridium plugs may last longer.
Timing Belt Replacement:
Crucial! Replace every 60,000 miles (96,000 km) or 5 years. Failure can cause severe engine damage (interference engine).
Fluid Specifications
Engine Oil Spec:
API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature).
Engine Oil Capacity:
Approx. 3.7 US quarts (3.5 Liters) with filter change for 1.8L; 4.1 US quarts (3.9 Liters) for 2.0L.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid Spec:
Dexron II or III ATF, or Mazda genuine power steering fluid.
Known Issues
Common Issue 1:
Timing belt failure (due to lack of replacement).
Common Issue 2:
Oil leaks from valve cover gasket and rear main seal.
Common Issue 3:
Catalytic converter failure (especially on higher mileage vehicles).
Common Issue 4:
CV joint wear and tear, leading to clicking noises during turns.
Common Issue 5:
Power steering pump noise or leaks.
Common Issue 6:
Automatic transmission solenoid issues or shifting problems.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Jinba Ittai ('horse and rider as one') - focus on driving feel and connection.
Model Evolution
Generation Bj:
Second generation Protege (also known as Mazda Familia in Japan).
Body Styles:
Sedan, Hatchback (3-door and 5-door).
Performance Variant:
Mazdaspeed Protege (2003 model year), featuring a turbocharged FS-DE engine and sport-tuned suspension.
Production
Manufacturing Location:
Primarily Hofu, Yamaguchi Prefecture, Japan; also assembled in some other international locations.
🏆 Awards & Recognition
Recognitions
Previous Generation Recognition:
Previous generation Protege (BG) was notably praised for its handling and sporty nature, setting a precedent for the BJ generation.
Segment Competitiveness:
Consistently recognized as a strong contender in the compact car segment for its value and driving dynamics.
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