Target Audience:
Budget-conscious buyers seeking reliability, practicality, and engaging driving dynamics
Key Competitors:
Honda Civic, Toyota Corolla, Nissan Sentra, Ford Focus, Chevrolet Cavalier
Design Philosophy:
Jinba Ittai (Horse and Rider as One) - Mazda's focus on driver engagement and handling
Body Styles:
Sedan, Hatchback (3-door and 5-door)
Notable Trims:
DX, LX, ES, Sport, Mazdaspeed (later models)
Engine Management:
Fuel injection (MPI), Ignition system, ECU diagnostics, Emissions controls (OBD-II)
Engine Mechanical:
Engine assembly, Cylinder head, Block assembly, Pistons, Crankshaft, Camshafts, Timing belt/chain replacement, Sealing systems
Transmission Manual:
Clutch system, Gearbox disassembly and assembly, Shift linkage, Torque specifications
Transmission Automatic:
Automatic transmission operation, Fluid change, Valve body, Torque converter, Electronic controls
Drivetrain:
CV joints, Axles, Differential (FWD)
Suspension:
Front suspension (MacPherson struts), Rear suspension (Multi-link, Torsion beam - depending on model/year), Shock absorbers, Springs, Bushings, Alignment procedures
Steering:
Power steering system, Rack and pinion, Tie rods, Steering column
Brakes:
Front disc brakes, Rear drum/disc brakes, ABS system, Brake hydraulics, Bleeding procedures
Electrical System:
Battery, Charging system (alternator), Starting system, Fuses and relays, Lighting (headlamps, taillamps, interior), Wiring diagrams
HVAC:
Air conditioning system, Heating, Ventilation, Blower motor, Evaporator, Condenser
Body And Chassis:
Body panels, Doors, Hood, Trunk, Bumpers, Frame construction, Underbody protection
Interior:
Seats, Dashboard, Trim panels, Airbag system (SRS) diagnostics and replacement
Maintenance:
Oil changes, Filter replacements (oil, air, fuel, cabin), Spark plug replacement, Coolant flush, Brake fluid replacement, Transmission fluid change
Troubleshooting:
Diagnostic trouble codes (DTCs), Symptom-based diagnostics, Common problems and solutions
Repair:
Component removal and installation, Major component overhauls (engine, transmission), Electrical component repair
Diagnostics:
On-Board Diagnostics (OBD-II) procedures, Scan tool usage, Sensor testing, Actuator testing
Specifications:
Torque values for all fasteners, Fluid capacities, Component dimensions, Electrical resistance values
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds
Diagnostic Capability:
Advanced, including detailed wiring diagrams, sensor readings, and troubleshooting trees
Repair Detail:
Step-by-step instructions with accompanying diagrams and photos (where applicable in original manual)
Configuration:
1.5L Inline-4 (SOHC)
Horsepower:
90-105 hp @ 6000 rpm (varies by market and year)
Torque:
93-98 lb-ft @ 4000 rpm (varies by market and year)
Configuration:
1.8L Inline-4 (DOHC)
Horsepower:
118-122 hp @ 6000 rpm (varies by market and year)
Torque:
110-117 lb-ft @ 4000 rpm (varies by market and year)
Configuration:
2.0L Inline-4 (DOHC)
Horsepower:
125-130 hp @ 6000 rpm (varies by market and year)
Torque:
130-135 lb-ft @ 4500 rpm (varies by market and year)
Configuration:
2.0L Inline-4 (DOHC, VICS/VIS)
Horsepower:
170 hp @ 7000 rpm (Mazdaspeed Protege)
Torque:
140 lb-ft @ 5500 rpm (Mazdaspeed Protege)
Type:
Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended, higher for performance variants)
Belt Or Chain Z5 Zl Fs:
Timing Belt (for Z5, ZL, FS-DE, FS-ZE engines)
Length:
Approx. 175.4 inches
Width:
Approx. 67.3 inches
Height:
Approx. 56.1 inches
Wheelbase:
Approx. 102.4 inches
Length:
Approx. 167.3 inches
Width:
Approx. 67.3 inches
Height:
Approx. 56.1 inches
Wheelbase:
Approx. 102.4 inches
Trunk Volume Sedan:
Approx. 12.1 cu ft
Cargo Volume Hatchback:
Approx. 16.5 cu ft (seats up)
Curb Weight:
Approx. 2500-2800 lbs (varies by model and equipment)
Gross Vehicle Weight Rating:
Varies by model, typically around 3600-3900 lbs
Wheel Size:
14-inch, 15-inch, 16-inch (depending on trim)
Tire Size:
185/65R14, 195/55R15, 205/50R16 (common sizes)
Offset:
ET35-ET45 (approximate)
NHTSA Front Driver Side:
Four Stars (for certain years/configurations)
NHTSA Front Passenger Side:
Four Stars (for certain years/configurations)
IIHS Side Impact:
Good (for some models with side airbags)
ABS:
Available (standard on higher trims and later years)
Traction Control:
Not commonly available on standard models, available on some later performance variants.
Airbags:
Driver and Passenger Frontal Airbags (standard on most models), Optional Side Airbags (later years)
Seat Belts:
3-point front and rear seat belts, Pretensioners and load limiters for front seats
Child Seat Anchors:
LATCH system (introduced on later models)
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (normal driving conditions)
Oil Type:
API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature)
Oil Capacity:
Approx. 3.7-4.1 US quarts (with filter, depending on engine)
Oil Filter Part Number:
e.g., Mazda: B6Y1-14-302, Fram: PH3569, Wix: 51334
Service Intervals Air Filter
Air Filter Replacement Interval:
Every 15,000-30,000 miles or annually, inspect more frequently
Air Filter Part Number:
e.g., Mazda: BP05-13-Z40, Fram: CA3217, Wix: 42415
Service Intervals Spark Plugs
Spark Plug Replacement Interval:
Every 30,000-60,000 miles (NGK Platinum recommended)
Spark Plug Spec 1:
e.g., NGK BKR5E-11 (for ZL-DE, FS-DE)
Spark Plug Gap:
0.039-0.043 inches (1.0-1.1 mm)
Service Intervals Timing Belt
Timing Belt Replacement Interval:
Every 60,000-90,000 miles or 5-7 years (crucial due to interference engine design)
Coolant Type:
Mazda Super Long Life Coolant (Blue) or equivalent, typically a silicate-free, long-life ethylene glycol coolant.
Coolant Capacity:
Approx. 4.5-5.5 US quarts (varies by engine and cooling system)
Brake Fluid Type:
DOT 3 or DOT 4 (check owner's manual for specific recommendation)
Power Steering Fluid Type:
ATF Dexron II/III or Mazda genuine power steering fluid
Engine Mounts:
Degradation and cracking of engine mounts leading to increased vibration
Catalytic Converter:
Premature failure, especially in earlier models or if engine oil consumption is high
ABS Sensors:
Failure of ABS wheel speed sensors leading to ABS warning light and malfunction
Radiator Leaks:
Cracks or leaks in the radiator or coolant hoses, especially at higher mileage
Rear Wheel Bearings:
Premature wear and noise from rear wheel bearings
Automatic Transmission Sluggishness:
Occasional reports of delayed shifts or sluggish performance in automatic transmissions, often related to fluid degradation or solenoids.
Exhaust Manifold Cracks:
Cracking of the exhaust manifold, particularly on the FS-DE engine, leading to exhaust leaks and ticking noises.
Mazda Philosophy:
Mazda has a long history of producing reliable, fun-to-drive vehicles, often punching above their weight in terms of driving dynamics and design.
Previous Generations:
The Protege nameplate replaced the Mazda 323/Familia. The 1996-2006 period covers the final two generations of the Protege.
First Generation Covered:
1996-1998 (BA chassis, often referred to as the 'last 323' in some markets)
Second Generation Covered:
1999-2003 (BJ chassis, the primary focus for the majority of this manual's coverage)
Facelift:
The BJ generation received a significant facelift for the 2001 model year, updating styling and features.
Replacement:
The Protege was replaced globally by the Mazda3 (Axela in Japan) for the 2004 model year.
Manufacturing Locations:
Primarily Japan, also Mexico for North American markets.
Production Years Total:
1990-2003 (Protege/Familia/323 line)
