Mazda Protege 1989-1994 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Generation: BG Model Years Covered: 1989, 1990, 1991, 1992, 1993, 1994 Codes Chassis Codes: BG8S, BG8Z, BGFP, BG5S, BG5P 👋 Introduction Market...

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Type: Car

Vendor:

Sku: 58192

Tags: 1989 1990 1991 1992 1993 1994 Car Cars Mazda Misc Protege

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Generation:

Model Years Covered:

1989, 1990, 1991, 1992, 1993, 1994

Codes

Chassis Codes:

BG8S, BG8Z, BGFP, BG5S, BG5P

👋 Introduction

Market Position

Vehicle Segment:

Compact Car

Target Audience:

Budget-conscious consumers, first-time car buyers, enthusiasts seeking affordable and reliable transportation.

Competitive Analysis

Key Competitors:

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

Key Features

Value Proposition:

Affordability, good fuel economy, practical design, dependable mechanicals.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

~1000+

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Ignition System, Exhaust System, Transmission (Manual & Automatic)

Chassis:

Suspension (Front & Rear), Steering System, Brake System, Drivetrain (FWD)

Electrical:

Battery, Charging System, Starting System, Lighting, Instrumentation, Wiring Diagrams, HVAC Control, Audio System

Body:

Body Panels, Doors, Windows, Seats, Interior Trim, Bumpers, Glass

Procedures Included

Maintenance:

Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks, Tune-ups

Troubleshooting:

Diagnostic Procedures, Symptom-based Troubleshooting Guides, Fault Code Interpretation

Repair:

Component Removal and Installation, Overhaul Procedures, Adjustments, Replacements

Technical Specifications:

Torque Specifications, Clearances, Tolerances, Diagnostic Data

Technical Depth

Scope:

Comprehensive, from basic maintenance to complete engine and transmission overhauls.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (dependent on original scan quality)

Print Quality

Printability:

Printable

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

BP-ZE (DOHC)

Engine Displacement 1:

1.8 Liters (1839 cc)

Engine Configuration 1:

Inline 4-cylinder, DOHC, 16-valve

Horsepower 1:

125-130 hp @ 6000 rpm (approx.)

Torque 1:

115-120 lb-ft @ 4500 rpm (approx.)

Secondary Engine

Engine Code 2:

B6 (SOHC)

Engine Displacement 2:

1.6 Liters (1598 cc)

Engine Configuration 2:

Inline 4-cylinder, SOHC, 16-valve

Horsepower 2:

98-105 hp @ 6000 rpm (approx.)

Torque 2:

95-100 lb-ft @ 4000 rpm (approx.)

Performance

Engine Management:

Electronic Fuel Injection (EFI)

Fuel System

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Manual Transmission Type:

5-speed Manual

Optional

Automatic Transmission Type:

4-speed Automatic

Features

Clutch Type:

Hydraulic Actuated

📐 Dimensions

Exterior

Wheelbase:

approx. 100.4 inches (2550 mm)

Length:

approx. 167.9 inches (4265 mm)

Width:

approx. 66.7 inches (1694 mm)

Height:

approx. 54.1 inches (1374 mm)

Weights

Curb Weight:

approx. 2400-2600 lbs (1089-1179 kg) depending on trim and engine

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact:

Not Rated (NHTSA ratings were less standardized in this era)

IIHS Crash Test Ratings:

Not Rated (IIHS ratings were less common/comprehensive)

Active Features

Brakes:

Front Disc, Rear Drum (ABS optional on higher trims/later models)

Passive Features

Airbags:

Driver airbag standard on most models from ~1992 onwards. Passenger airbag optional or unavailable.

Seatbelts:

3-point front seatbelts, 2-point rear lap belts (later models may have 3-point rear belts)

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM Radio with Cassette Player, often with 4 speakers. Optional CD player on higher trims/later models.

Climate Control:

Manual air conditioning and heater controls. Automatic climate control was not a common feature.

Driver Assistance

Cruise Control:

Optional on many models, especially sedans and higher trim levels.

Connectivity

Connectivity Options:

None (No Bluetooth, USB, or auxiliary inputs from the factory).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions).

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for standard plugs, or 60,000 miles (96,000 km) for platinum plugs.

Timing Belt Replacement:

Crucial! Every 60,000 miles (96,000 km) or 4 years for BP-ZE/B6 engines (interference engine).

Fluid Specifications

Engine Oil Type 1:

API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific recommendations based on climate).

Engine Oil Capacity 1:

Approx. 4.5 US quarts (4.3 liters) with filter change.

Coolant Type:

Ethylene Glycol based, 50/50 mix with distilled water.

Automatic Transmission Fluid:

Dexron II/III or equivalent.

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90.

Known Issues

Timing Belt:

Failure to replace on time due to it being an interference engine leads to catastrophic engine damage.

Rust:

Common in areas with road salt, especially on wheel arches, rocker panels, and rear quarter panels.

Idler Pulley Bearing:

On some BP-ZE engines, the idler pulley bearing can fail, causing noise and potential belt issues.

Oxygen Sensor:

Can become fouled over time, affecting fuel economy and emissions.

Exhaust System:

Rust and corrosion can lead to leaks or component failure.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Focus on Jinba Ittai ('horse and rider as one') driving dynamics, reliable and affordable vehicles.

Model Evolution

Generation 1 Introduction:

Introduced globally in 1989 for the 1990 model year, replacing the Mazda 323/Familia in many markets.

Body Styles:

3-door Hatchback, 4-door Sedan, 5-door Wagon (availability varied by market and year).

Performance Variants:

GT and GTX trims offered sportier suspension, aerodynamic kits, and the more powerful BP-ZE engine (GTX featured AWD).

Production

Manufacturing Locations:

Primarily Japan (Hiroshima).

Production Period:

1989-1994 (for this generation)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Protege models, particularly the GT and GTX, often received accolades from automotive publications for their value and driving dynamics.

Automotive Journalism Acclaim:

Praised for its competent handling and sharp steering, often outperforming larger or more expensive rivals in its class.

Certifications

Emission Standards:

Meets EPA and California Air Resources Board (CARB) emission standards for its respective model years.