Mazda Protege 2004 All Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2004 Codes Chassis Code: BJ Platform: BJ (Global) 👋 Introduction Market Position Segment: Compact Sedan/Hatchback Target Audience: DIY car owners, independent...

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Type: Car

Vendor:

Sku: 105331

Tags: 2004 Car Cars Mazda Misc Protege

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Codes

Chassis Code:

Platform:

BJ (Global)

👋 Introduction

Market Position

Segment:

Compact Sedan/Hatchback

Target Audience:

DIY car owners, independent repair shops, enthusiasts seeking in-depth knowledge.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Mitsubishi Lancer.

Protege Advantage:

Known for good handling dynamics, reliable engines, and practical interior for its class.

Key Features

Manual Benefit:

Empowers owners to perform maintenance and repairs, saving money and ensuring quality workmanship.

Manual Value:

Provides access to factory-level technical data and procedures typically only available to dealership technicians.

📋 Manual Details

Coverage Areas

Covered Models:

Mazda Protege (BJ Chassis) 2004

Region Applicability:

Global (North America, Europe, Asia, etc.)

Page Count

Estimated Pages:

Approximately 1500-2000 pages (typical for comprehensive service manuals)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, disassembly, assembly, component testing, timing belt replacement, piston and ring replacement, cylinder head service, valve train components.

Engine Performance:

Fuel injection system diagnosis and repair, ignition system service, emission control systems, sensor testing and replacement, throttle body service.

Transmission Manual:

Clutch system service, gear inspection and replacement, shift linkage adjustment, bearing and seal replacement.

Transmission Automatic:

Automatic transmission overhaul, valve body diagnosis, torque converter service, fluid and filter replacement, shift control systems.

Drivetrain:

CV joints, drive shafts, differential service, axle replacement, wheel bearing service.

Suspension:

Front and rear suspension component inspection, replacement of control arms, ball joints, tie rod ends, bushings, struts, and shock absorbers.

Steering:

Power steering system diagnosis and repair, steering rack and pump service, steering column components.

Brakes:

Disc brake service (pads, rotors, calipers), drum brake service (shoes, drums, wheel cylinders), ABS system diagnosis and repair, hydraulic system bleeding.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting systems, fuse and relay identification, wiring diagrams.

HVAC:

Air conditioning system service, refrigerant handling, heater core replacement, blower motor service, climate control systems.

Body And Interior:

Body panel repair and replacement, door and window mechanisms, interior trim removal and installation, seat adjustment mechanisms.

Chassis And Frame:

Frame inspection and repair, subframe mounting, unibody structure details.

Diagnostics And Troubleshooting:

On-Board Diagnostics (OBD-II) codes and troubleshooting procedures, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, fluid level checks and top-offs, tire rotation and pressure checks.

Preventive Maintenance:

Scheduled maintenance intervals, timing belt replacement procedures, coolant flushes, brake fluid replacement.

Major Repairs:

Engine rebuilding, transmission overhaul, suspension component replacement, brake system overhauls.

Electrical Troubleshooting:

Step-by-step diagnostic charts, wiring diagram interpretation, component testing procedures.

Bodywork And Restoration:

Dent repair, panel replacement, rust treatment, corrosion prevention.

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable, allowing quick location of specific information.

Print Quality

Resolution:

High-resolution scans, ensuring clarity of text and diagrams.

Illustrations:

Includes detailed diagrams, schematics, and photographic illustrations.

Binding Type

Binding:

Not applicable (Digital Download)

Paper Type

Paper:

Not applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

FS-DE (2.0L DOHC)

Engine Type 1:

Inline 4-cylinder, DOHC, 16-valve

Displacement 1:

1991 cc (2.0 Liters)

Bore X Stroke 1:

83.0 mm x 92.0 mm

Compression Ratio 1:

9.2:1

Horsepower 1:

130 hp @ 5500 rpm (approx.)

Torque 1:

135 lb-ft @ 4000 rpm (approx.)

Engine Code 2

Engine Code 2:

FP-DE (1.8L DOHC)

Engine Type 2

Engine Type 2:

Inline 4-cylinder, DOHC, 16-valve

Displacement 2

Displacement 2:

1839 cc (1.8 Liters)

Horsepower 2

Horsepower 2:

122 hp @ 5500 rpm (approx.)

Torque 2

Torque 2:

119 lb-ft @ 4000 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Ignition System

Ignition Type:

Electronic Ignition (Distributorless or Distributor-based depending on market)

🔧 Transmission

Standard

Manual Transmission:

5-speed Manual Transmission (e.g., F5M42)

Optional

Automatic Transmission:

4-speed Automatic Transmission (e.g., FN4A-EL)

Features

Clutch Type:

Dry single plate clutch (Manual)

Transmission Fluid Manual:

API GL-4, SAE 75W-90 (Check specific manual for exact spec)

Transmission Fluid Automatic:

Mazda ATF-FZ or equivalent (Check specific manual for exact spec)

📐 Dimensions

Exterior

Length:

Approx. 4405 mm (Sedan) / 4320 mm (Hatchback)

Width:

Approx. 1705 mm

Height:

Approx. 1405 mm (Sedan) / 1410 mm (Hatchback)

Wheelbase:

Approx. 2610 mm

Track Width Front:

Approx. 1470 mm

Track Width Rear:

Approx. 1465 mm

Cargo

Trunk Volume:

Approx. 14.7 cubic feet (Sedan)

Weights

Curb Weight Min:

Approx. 1200 kg (2645 lbs)

Curb Weight Max:

Approx. 1270 kg (2800 lbs)

Gross Vehicle Weight Rating:

Varies by model/trim (Refer to vehicle placard)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Good (Driver) / Good (Passenger) - 2004 models

NHTSA Side Impact:

Good (Front Passenger) / Acceptable (Rear Passenger) - 2004 models (with side airbags)

Active Features

Available (Standard on higher trims/optional on others)

Traction Control:

Rarely equipped on base models, may be available on sport trims.

Passive Features

Airbags Front:

Standard driver and passenger front airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

3-point front and rear seatbelts with pretensioners

💡 Technology Features

Infotainment

Head Unit:

Factory standard AM/FM/CD player, often with cassette tape. Aftermarket head units are common upgrades.

Speakers:

Typically 4-6 speakers depending on trim level.

Driver Assistance

Cruise Control:

Available on most trim levels.

Connectivity

Power Accessories:

Power windows, power locks, and power mirrors available on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (severe conditions: 3,000 miles / 5,000 km).

Engine Oil Filter:

Replace with every oil change.

Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed. Replace every 30,000 miles (48,000 km).

Spark Plugs:

Replace every 60,000 miles (96,000 km) for standard plugs; Platinum/Iridium may vary.

Timing Belt:

Crucial: Replace every 60,000 miles (96,000 km) or 5 years, whichever comes first (non-interference engine in some variants, but belt failure causes significant damage).

Coolant Replacement:

First replacement at 60,000 miles (96,000 km) or 5 years. Subsequent replacements every 30,000 miles (48,000 km) or 2 years.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API SM or higher)

Engine Oil Capacity:

Approx. 4.0-4.3 quarts (3.8-4.1 liters) with filter (check manual)

Coolant Type:

Mazda Genuine Super Long Life Coolant (Blue) or equivalent Asian vehicle coolant (50/50 mix with distilled water).

Brake Fluid:

DOT 3 or DOT 4

Power Steering Fluid:

Mazda Genuine ATF or Dexron II/III (check manual)

Known Issues

Engine Mounts:

Can degrade over time, leading to increased vibration.

Alternator:

Some models may experience premature alternator failure.

Radiator:

Plastic end tanks can crack leading to coolant leaks.

Rear Wheel Bearings:

Can become noisy and require replacement.

ABS Sensors:

Wheel speed sensor failures can illuminate ABS warning light.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Jinba Ittai (Horse and Rider as One) - focus on driving dynamics and connection.

Model Evolution

Third Generation Bj:

The 2004 model falls under the third generation of the Protege (codenamed BJ), which was introduced in 1998 for the 1999 model year.

Facelift:

The BJ generation received a facelift for the 2001 model year, with minor updates for 2004.

Production

Production Period:

BJ generation: 1998-2003 (for model years 1999-2003). The 2004 model year typically represents the final year or carryover of the previous generation before a redesign or discontinuation in many markets.

Manufacturing Locations:

Primary manufacturing plant was Mazda's Hofu Plant in Japan. Some vehicles may have been assembled in other locations depending on the market.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Mazda Protege was named to Car and Driver's 10Best list multiple times in previous generations, reflecting its positive reception and value proposition.