🏷️ Basic Information

Make:

Mazda

Model:

Protege

Year:

2004

Body Style:

Sedan, Hatchback

Chassis Code:

BJ

👋 Introduction

Market Segment:

Compact car, known for value, reliability, and sporty handling

Key Competitors:

Honda Civic, Toyota Corolla, Nissan Sentra, Ford Focus, Chevrolet Cavalier

Vehicle Reputation:

Praised for its engaging driving dynamics, solid build quality for its class, and practicality. The Protege line offered a good balance of performance and economy.

Cost Savings:

Enables DIY repairs and maintenance, significantly reducing labor costs at professional service centers.

Knowledge Empowerment:

Provides the in-depth technical knowledge required to correctly diagnose, repair, and maintain the vehicle, ensuring optimal performance and longevity.

📋 Manual Details

Systems Covered:

General Information, Engine, Lubrication System, Cooling System, Fuel and Emission Control Systems, Engine Electrical System, Clutch, Manual Transaxle, Automatic Transaxle, Front and Rear Axles, Steering System, Braking System, Suspension, Body, Body Electrical System, Heater and Air Conditioner Systems, Technical Data, Special Tools

Estimated Page Count:

Varies by specific factory publication, typically 1500-2500+ pages for a complete factory service manual

Manual Type:

Factory Service Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed breakdown of engine components, including cylinder head, block, pistons, crankshaft, camshafts, timing systems, valve train, and seals. Includes torque specifications, assembly procedures, and diagnostic information.

Engine Management:

Covers fuel delivery, ignition system, electronic engine control (ECM), sensors (MAP, TPS, O2, crankshaft position, camshaft position), actuators (injectors, ignition coils), and emission control systems (catalytic converter, EGR, EVAP).

Lubrication Cooling:

Details on oil pump, oil filter, oil cooler, lubrication passages, radiator, coolant pump, thermostat, hoses, and coolant specifications. Includes capacity and change intervals.

Drivetrain:

Comprehensive coverage of manual and automatic transaxles, including clutch assembly, gear shifting mechanisms, torque converter (for automatic), internal components, fluid types, capacities, and service procedures. Also covers front and rear axles, CV joints, and differentials.

Suspension Steering:

In-depth information on front and rear suspension components (struts, shocks, control arms, bushings, springs), steering rack, power steering system (pump, fluid, hoses), wheel alignment specifications, and tire/wheel information.

Braking System:

Detailed procedures for front and rear brake systems, including disc brake components (calipers, pads, rotors), drum brake components (shoes, drums, wheel cylinders), brake fluid type and bleeding procedures, parking brake system, and ABS system diagnosis.

Body Exterior Interior:

Repair and maintenance procedures for body panels, doors, hood, trunk lid, bumpers, glass, and interior trim. Includes panel alignment, rust repair, and component replacement.

Body Electrical:

Comprehensive wiring diagrams for all vehicle systems, including lighting (headlights, taillights, interior), power windows, power locks, mirrors, horn, wipers, instrument cluster, audio system, and accessory circuits. Includes fuse box locations and component testing.

HVAC System:

Covers air conditioning system components (compressor, condenser, evaporator, refrigerant), heating system components (heater core, blower motor, climate controls), and ventilation system. Includes refrigerant type and charging procedures.

Maintenance Procedures:

Scheduled maintenance intervals for oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, air filter replacement, and general inspection points.

Repair Procedures:

Step-by-step guides for engine rebuilds, transmission overhauls, brake caliper replacement, suspension component renewal, electrical component repair, body panel replacement, and HVAC system service.

Diagnostic Procedures:

Troubleshooting charts and flow diagrams for identifying and resolving common and complex vehicle issues. Includes guidance on interpreting diagnostic trouble codes (DTCs) and using specialized diagnostic tools.

Technical Data Specifications:

Provides essential technical data, including torque specifications for all fasteners, fluid capacities, electrical system voltages, diagnostic parameters, and measurements for critical components.

Special Tools:

Lists and describes specific tools required for certain repair and maintenance procedures that are not standard automotive tools. May include illustrations of these tools.

📊 Manual Specifications

File Format:

PDF

Printable:

Yes

Searchable Text:

Typically Yes, for digitally created PDFs

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Compatibility:

WINDOWS and MAC

Software Requirements:

Adobe PDF Reader

⚙️ Engine Specifications

Engine Code:

FS-DE (2.0L DOHC)

Engine Type:

Naturally Aspirated Inline 4-Cylinder

Displacement:

1991 cc (2.0 Liters)

Horsepower:

Approx. 130-135 hp @ 6000 rpm (depending on specific market and trim)

Torque:

Approx. 135-140 lb-ft @ 4000-4500 rpm (depending on specific market and trim)

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended, higher octane may be specified for performance variants)

Valve Train:

DOHC (Dual Overhead Camshafts), 16 valves (4 valves per cylinder)

Emission Controls:

Catalytic converter, Oxygen (O2) sensors, Exhaust Gas Recirculation (EGR), Evaporative Emission Control (EVAP) system

🔧 Transmission

Transmission Type Standard:

5-speed Manual Transaxle

Transmission Type Optional:

4-speed Automatic Transaxle with Lock-up Torque Converter

Manual Transaxle Fluid:

API GL-4 (e.g., SAE 75W-90 or SAE 75W-85, consult specific manual for exact specification and capacity)

Automatic Transaxle Fluid:

Mazda Genuine ATF-M III or equivalent (e.g., Dexron III/Mercon). Capacity approximately 7-8 quarts for a complete refill.

Clutch Type:

Dry, single-plate, diaphragm spring clutch (for manual transmission)

📐 Dimensions

Wheelbase:

Approximately 102.7 inches (2606 mm)

Length:

Sedan: ~173.7 inches (4412 mm), Hatchback: ~161.5 inches (4102 mm)

Width:

Approximately 67.7 inches (1720 mm)

Height:

Approximately 55.7 inches (1415 mm)

Curb Weight:

Varies by trim and body style, typically 2600-2900 lbs (1180-1315 kg)

Gross Vehicle Weight Rating:

Consult vehicle specific VIN or door jamb sticker

Cargo Volume:

Varies by body style (Sedan vs. Hatchback)

🛡️ Safety Features

NHTSA Front Crash Test:

Generally good for its era, specific ratings should be verified for individual model year and configuration.

Airbags:

Front driver and passenger airbags (standard). Side-impact airbags may be optional on certain trims.

Seat Belts:

3-point front and rear seat belts, pretensioners for front seats

โครงสร้างความปลอดภัย:

Reinforced body structure, crumple zones

ABS:

Anti-lock Braking System (ABS) typically standard or optional depending on trim level

Traction Control:

Traction Control System (TCS) was an optional feature on some later models.

💡 Technology Features

Audio System:

Factory fitted AM/FM stereo with CD player. Cassette player was also common. Speaker configurations varied by trim.

Climate Control:

Manual or automatic climate control depending on trim level. Recirculation function, cabin air filter is present.

Cruise Control:

Optional on most trims.

🔧 Maintenance

Oil Change Interval:

Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, whichever comes first. Consult manual for specific oil type and viscosity recommendations.

Air Filter Replacement:

Every 15,000 to 30,000 miles (24,000 to 48,000 km), or more frequently in dusty conditions.

Spark Plug Replacement:

Typically every 60,000 to 100,000 miles (96,000 to 160,000 km) for platinum or iridium tipped plugs.

Engine Oil Specification:

0W-20 or 5W-30 API SN/SP, ILSAC GF-5/GF-6 (Consult manual for precise recommendation and capacity, typically around 4.5 quarts with filter).

Coolant Specification:

Mazda Long Life Antifreeze (Green) or equivalent (50/50 mix with distilled water). Capacity approximately 6.5 quarts.

Brake Fluid Specification:

DOT 3 or DOT 4 (Consult manual for exact requirement and change interval)

Power Steering Fluid:

Dexron III/Mercon ATF or Mazda Genuine Power Steering Fluid

Common Protege Issues:

Some reports of premature catalytic converter failure, occasional ignition coil issues, worn control arm bushings, and potential for oil leaks from valve cover or oil pan gaskets.

📚 Vehicle History

Mazda Philosophy:

Mazda's long-standing commitment to driving enjoyment ('Zoom-Zoom') and engineering innovation.

Protege Generation:

This manual covers the third generation Protege (BJ platform), produced from 1998 to 2003 (market-dependent). The 2004 model year often represents a late iteration or a transition year for some markets, but fundamentally builds upon this generation's platform.

Manufacturing Locations:

Primarily Japan and Mexico.

Protege Lineup:

Included various trims like DX, LX, ES, SP (Sport Package), and the performance-oriented Mazdaspeed Protege (which has significant powertrain differences and is not covered by this base manual).

🏆 Awards & Recognition

Car And Driver Ten Best:

The Protege line, particularly the Mazdaspeed variant and some sportier trims, often received praise for handling and value, although not consistently on 'Ten Best' lists for this specific year compared to some competitors.

IIHS Crash Test Ratings:

Check IIHS.org for specific ratings for the 2004 Mazda Protege (BJ platform). Generally performed adequately for its class and time.