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Mazda Protege 2000-2004 Service Repair Workshop Manual

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The Mazda Protege, specifically the BJ generation produced from 2000 to 2004, represents a continuation of Mazda's commitment to driver-focused compact vehicles. Available in sedan and hatchback body styles, this...
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Mazda Protege 2000-2004 Service Repair Workshop ManualMazda Protege 2000-2004 Service Repair Workshop ManualMazda Protege 2000-2004 Service Repair Workshop Manual
The Mazda Protege, specifically the BJ generation produced from 2000 to 2004, represents a continuation of Mazda's commitment to driver-focused compact vehicles. Available in sedan and hatchback body styles, this generation offered a range of efficient inline-4 engines, including 1.6L, 1.8L, and 2.0L variants, with power outputs typically ranging from approximately 105 to 130 horsepower, and a performance-oriented 170 horsepower for the Mazdaspeed model. Known for its agile handling and reliable engineering, the Protege was a popular choice for daily commuting and offered a spirited driving experience. Safety features included standard front airbags and available Anti-lock Braking System (ABS) and Traction Control System (TCS) on certain trims. This workshop service and repair manual provides comprehensive coverage for the Mazda Protege (BJ generation, 2000-2004). It is designed to assist DIY enthusiasts, independent mechanics, and Mazda Protege owners in maintaining and repairing their vehicles. The manual details a wide array of systems, including engine mechanical and electrical components, fuel and emission control systems, clutch and transmission operation (both manual and automatic), driveshafts, suspension, steering, brake systems, and body electricals. It also covers interior and exterior bodywork, HVAC, and safety restraint systems. Included are step-by-step repair procedures, diagnostic troubleshooting guides, wiring schematics, and detailed technical specifications, ensuring accurate and efficient service.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Generation:
BJ (Third Generation)
Years Covered:
2000-2004
Codes
Chassis Code:
BJ
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent mechanics, Mazda Protege owners
Value Proposition:
Enables cost savings on maintenance and repairs, empowers informed communication with technicians
Competitive Analysis
Differentiation:
Vehicle-specific, not generic; direct equivalent to dealership service manuals
Key Features
Content Quality:
Accurate, clear, concise text with step-by-step instructions, diagrams, and illustrations
Completeness:
Complete and intact, no missing or corrupt parts
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive Service and Repair
Secondary Coverage:
Troubleshooting, Diagnostics, Maintenance
Page Count
Estimated Page Count:
Varies by specific engine/transmission, typically over 1500 pages for complete coverage
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, internal components, timing, lubrication, cooling
Engine Electrical:
Ignition system, starting, charging, engine sensors, ECU diagnostics
Emission Control:
Emissions systems, diagnosis, component testing
Fuel System:
Fuel injection, fuel pump, injectors, fuel lines, fuel pressure
Clutch System:
Clutch operation, adjustment, replacement, hydraulic system
Manual Transaxle:
Gearbox removal, overhaul, gear ratios, fluid specifications
Automatic Transaxle:
Transmission removal, overhaul, control systems, fluid specifications
Driveshaft Axle:
CV joints, driveshafts, differentials, wheel bearings
Suspension:
Front and rear suspension components, shock absorbers, springs, alignment
Steering:
Power steering system, rack and pinion, steering column, alignment
Restraint System:
Airbag system, seat belts, SRS diagnosis
Brake System:
Disc and drum brakes, ABS, brake fluid, components, bleeding
Body Interior Exterior:
Body panels, trim, doors, windows, seats, interior components
Body Electrical:
Lighting, power accessories, instrument cluster, body control modules
HVAC:
Heating, ventilation, air conditioning system diagnosis and repair
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, fluid checks, filter replacements, spark plug changes
Repair Procedures:
Step-by-step instructions for component replacement and repair
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), sensor testing, actuator testing
Wiring Schematics:
Complete electrical wiring diagrams for all systems
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine/transmission rebuilds
Detail Level:
Includes detailed diagrams, illustrations, and specifications used by dealership technicians
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Windows and Mac OS
Reader Requirement:
Adobe PDF Reader
Print Quality
Printability:
All pages are printable
Image Quality:
High-quality diagrams and illustrations
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Displacement 1.6L:
1.6 Liters (1598cc) ZM-DE inline-4
Engine Displacement 1.8L:
1.8 Liters (1839cc) FP-DE inline-4
Engine Displacement 2.0L:
2.0 Liters (1998cc) FS-DE inline-4 (especially for higher trims like GT/Mazdaspeed)
Performance 1.6L
Horsepower 1.6L:
Approx. 105 hp @ 6000 rpm
Torque 1.6L:
Approx. 105 lb-ft @ 3500 rpm
Performance 1.8L
Horsepower 1.8L:
Approx. 120 hp @ 6000 rpm
Torque 1.8L:
Approx. 125 lb-ft @ 4000 rpm
Performance 2.0L
Horsepower 2.0L:
Approx. 130 hp @ 6000 rpm (FS-DE), 170 hp @ 6600 rpm (FS-ZE - Mazdaspeed Protege)
Torque 2.0L:
Approx. 135 lb-ft @ 4000 rpm (FS-DE), 145 lb-ft @ 5000 rpm (FS-ZE - Mazdaspeed Protege)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Engine Management
ECU:
Engine Control Unit (ECU) for fuel injection and ignition timing
🔧 Transmission
Standard Transmission
Type Standard:
5-speed Manual Transaxle
Optional Transmission
Type Optional:
4-speed Automatic Transaxle
Features
Clutch Type:
Hydraulic, single dry plate
📐 Dimensions
Exterior Sedan
Length Sedan:
Approx. 173.4 inches (4405 mm)
Width Sedan:
Approx. 67.5 inches (1715 mm)
Height Sedan:
Approx. 55.7 inches (1415 mm)
Exterior Hatchback
Length Hatchback:
Approx. 166.3 inches (4225 mm)
Width Hatchback:
Approx. 67.5 inches (1715 mm)
Height Hatchback:
Approx. 55.9 inches (1420 mm)
Weights
Curb Weight:
Approx. 2500-2800 lbs (1134-1270 kg), varies by trim and drivetrain
Wheelbase
Wheelbase:
Approx. 102.4 inches (2600 mm)
Wheel Specs
Bolt Pattern:
4x100mm
Wheel Size:
14-inch or 15-inch steel or alloy wheels
Tire Size
Tire Size:
Commonly 185/65R14, 195/60R15 (varies by trim)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Good (for driver and passenger in frontal offset tests where applicable)
IIHS Front Offset:
Good (for driver in frontal offset tests where applicable)
Active Features
ABS:
Anti-lock Braking System (ABS) available on some trims
Traction Control:
Traction Control System (TCS) available on some models (especially Mazdaspeed)
Passive Features
Airbags:
Driver and passenger front airbags standard, optional side airbags on some models
Seat Belts:
Front seatbelt pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or cassette player, optional premium audio systems
Driver Assistance
Cruise Control:
Cruise control available on most trims
Connectivity
Usb Aux:
No factory USB or auxiliary inputs in most models; aftermarket solutions available
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 5,000 miles or 6 months (synthetic blend or full synthetic recommended)
Service Intervals Filters
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving conditions
Cabin Air Filter Replacement:
Every 15,000 - 30,000 miles or annually
Service Intervals Spark Plugs
Spark Plug Replacement:
100,000 miles for iridium-tipped plugs; 30,000 miles for copper plugs (check specific engine)
Service Intervals Fluids
Transmission Fluid Change Manual:
Every 60,000 miles (refer to manual for specific fluid type, typically GL-4 or GL-5 gear oil)
Transmission Fluid Change Automatic:
Every 60,000 miles (refer to manual for specific ATF type, often Dexron III compatible)
Fluid Specifications
Engine Oil Specification:
API SN/SP or ILSAC GF-5/GF-6 certified, SAE 5W-20 or 5W-30 (verify with manual)
Coolant Specification:
Mazda Super Long Life Coolant (or equivalent HOAT coolant, typically P-HOAT)
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid
Known Issues
Common Problems Engine:
Oil leaks (valve cover gasket, oil pan gasket), intake manifold gaskets, occasional piston ring wear
Common Problems Transmission:
Clutch wear (manual), torque converter shudder (automatic), synchro issues (manual)
Common Problems Suspension:
Worn control arm bushings, ball joints, sway bar links
Common Problems Electrical:
Window regulators, power lock actuators, alternator failure
📚 Vehicle History
Brand Heritage
Mazda Focus:
Mazda's history of building reliable and driver-focused compact cars
Model Evolution
Bj Generation:
Third generation Protege, introduced for the 2000 model year, featuring a more modern design and improved dynamics
Trim Levels:
DX, LX, ES, ES Wagon, GT, Mazdaspeed Protege (performance variant)
Production
Production Location:
Japan (primarily), sometimes U.S. assembly for specific models
🏆 Awards & Recognition
Recognitions
Car And Driver:
The Protege often appeared on Car and Driver's '10Best' lists in earlier generations, showcasing its value and driving dynamics. While this specific generation might not have numerous specific awards documented, it carried on the reputation.
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