Mazda Protege Shop Manual 2000-2004

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🏷️ Basic Information Identification Make: Mazda Model: Protege Model Years Covered: 2000, 2001, 2002, 2003, 2004 Generation Generation Identifier: BJ (Second Generation) Codes Chassis Codes: BJ3P (Sedan/Hatchback), BJ5P (Sedan/Hatchback), BJ8W...

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类型: Car

斯库: 320149

标签: 2000 2001 2002 2003 2004 Car Cars Mazda Protege

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Model Years Covered:

2000, 2001, 2002, 2003, 2004

Generation

Generation Identifier:

BJ (Second Generation)

Codes

Chassis Codes:

BJ3P (Sedan/Hatchback), BJ5P (Sedan/Hatchback), BJ8W (MPV - unlikely for Protege nameplate but contextually possible for platform sharing)

👋 Introduction

Market Position

Positioning:

Compact sedan and hatchback positioned as a value-oriented, reliable, and driver-friendly vehicle in its segment.

Competitive Analysis

Competitors:

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

Key Features Manual

Usability:

Accessible via PDF on all PC and Mac operating systems, email delivery for instant access, searchable text for quick information retrieval.

Key Features Vehicle

Design Philosophy:

Mazda's 'Zoom-Zoom' philosophy was beginning to be integrated, emphasizing driving dynamics and responsiveness.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Workshop Service and Repair Information

Page Count

Estimated Page Count:

Thousands (typical for factory service manuals)

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Delivery Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, timing, valve train, piston/rod assembly, crankshaft, cylinder head, block assembly

Fuel System:

Fuel tank, fuel pump, fuel lines, injectors, fuel pressure regulator, throttle body, EFI system diagnostics

Cooling System:

Radiator, coolant hoses, water pump, thermostat, cooling fan operation, coolant specifications

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, oxygen sensors

Transmission Manual:

Clutch operation, gearbox disassembly/assembly, gear ratios, shifting mechanism, fluid specifications, overhaul

Transmission Automatic:

Automatic transmission operation, hydraulic control, valve body, torque converter, planetary gear sets, fluid types, service procedures

Suspension Front:

MacPherson struts, control arms, ball joints, sway bar, steering knuckle, wheel bearings, alignment specifications

Suspension Rear:

Independent rear suspension (e.g., multi-link or trailing arm depending on specific model variant), shock absorbers, springs, alignment specifications

Brakes Hydraulic:

Brake pedal, master cylinder, brake lines, proportioning valve, brake fluid specifications, bleeding procedures

Brakes Friction:

Disc brake calipers, brake pads, rotors, drum brake shoes, drums, parking brake mechanism, ABS system components

Steering:

Steering column, steering gear/rack and pinion, power steering pump, fluid specifications, tie rods, steering linkage

Electrical System Charging:

Alternator, battery, voltage regulator, wiring and connections

Electrical System Starting:

Starter motor, starter solenoid, ignition switch, neutral safety switch

Lighting System:

Headlights, taillights, turn signals, interior lighting, bulb types and specifications

Instrumentation:

Instrument cluster, gauges (speedometer, tachometer, fuel, temperature), warning lights, diagnostic indicators

Comfort Controls HVAC:

Heating system, ventilation, air conditioning (AC) system, refrigerant types, compressor, evaporator, condenser, blower motor, climate controls

Body Exterior:

Body panels, doors, hood, trunk lid, bumpers, glass, seals, trim, paint repair guidance

Body Interior:

Seats, dashboard, door panels, headliner, carpeting, trim panels, interior hardware

Safety Restraints:

Seat belts, airbag system components (SRS), diagnostic procedures for airbag system

Emission Control:

EVAP system, EGR system, PCV system, catalytic converter function, emissions testing requirements

Wiring Diagrams:

Comprehensive electrical schematics for all major systems, including engine control, chassis, body, and accessories

Procedures Included

Maintenance Schedule:

Recommended service intervals for oil changes, fluid flushes, filter replacements, inspections

Diagnostic Procedures:

Troubleshooting charts, symptom-based diagnostics, error code interpretation (OBD-II)

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment

Rebuild Procedures:

Detailed instructions for major component overhauls (e.g., engine, transmission)

Lubrication:

Specific lubricant types, capacities, and service points

Specifications Torque:

Torque values for all critical fasteners

Special Tools:

Identification of required specialized tools for specific procedures

Technical Depth

Depth:

Comprehensive from basic maintenance to full component overhaul and diagnostics

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Print Quality

Printability:

Printable by user, section by section or in full

Binding Type

Binding:

N/A (Digital PDF, user prints and binds)

Paper Type

Paper Recommendation:

User-dependent, but standard printer paper is typical

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

FS-DE (2.0L DOHC)

Engine Type:

Inline 4-Cylinder, DOHC, 16-valve

Displacement:

1991 cc (2.0 Liters)

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

9.0:1 (typical)

Performance

Horsepower Fsde:

125-130 hp @ 5500-6000 rpm (varies by market and specific tune)

Torque Fsde:

130-135 lb-ft @ 4000-4500 rpm (varies by market and specific tune)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Engine Variants Possible

Optional Engine:

YF-DE (1.8L DOHC, less common in North America for this generation Protege, but found in some markets)

Performance Yfde:

Approx. 120 hp

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual

Optional

Transmission Type Optional:

4-Speed Automatic

Features

Automatic Features:

Electronically controlled, lock-up torque converter

Fluid Specifications

Automatic Transmission Fluid:

Dexron III or equivalent (verify with specific vehicle application)

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (verify with specific vehicle application)

📐 Dimensions

Exterior

Wheelbase:

Approx. 102.7 inches (2606 mm)

Length:

Approx. 173.7 - 175.5 inches (4412 - 4458 mm) (depending on body style)

Width:

Approx. 67.1 inches (1704 mm)

Height:

Approx. 55.7 - 56.3 inches (1415 - 1430 mm) (depending on body style)

Weights

Curb Weight:

Approx. 2700 - 2900 lbs (1225 - 1315 kg) (depending on configuration)

Gross Vehicle Weight Rating:

Refer to VIN sticker or owner's manual (typically around 3700-3900 lbs)

Towing Capacity:

Generally not recommended or specified for this model.

🛡️ Safety Features

Ratings

NHTSA Front Driver Impact:

Good (for models equipped with side airbags)

NHTSA Front Passenger Impact:

Good (for models equipped with side airbags)

IIHS Side Impact:

Acceptable to Good (depending on year and specific equipment)

Active Features

Available on select trims/options

Traction Control:

Limited availability, not standard on most models

Passive Features

Airbags Standard:

Driver and front passenger airbags

Airbags Optional:

Side-impact airbags (curtain or torso, depending on trim/year)

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, optional premium audio systems available on higher trims. Basic digital displays.

Driver Assistance

Cruise Control:

Available on most trims.

Connectivity

Bluetooth:

Not typically factory-equipped for this model year. Aftermarket solutions are common.

Other Features

Keyless Entry:

Available on higher trim levels.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months (whichever comes first), using recommended oil viscosity.

Air Filter Replacement:

Every 15,000 - 30,000 miles, or as needed based on driving conditions.

Spark Plug Replacement:

Platinum or Iridium plugs: 60,000 - 100,000 miles. Standard plugs: 30,000 miles.

Timing Belt Replacement:

Every 60,000 - 90,000 miles (FS-DE engine uses a timing belt, critical replacement item to prevent catastrophic engine damage).

Fluid Specifications

Engine Oil:

SAE 5W-30 API Service SG or higher (check manual for exact specification and capacity, typically around 4.0-4.5 quarts).

Coolant:

Ethylene glycol-based antifreeze (e.g., Mazda's Super Long Life Coolant or equivalent), 50/50 mix with distilled water. Capacity approx. 6.0-6.5 quarts.

Brake Fluid:

DOT 3 or DOT 4 (verify with manual), typically reservoir capacity is around 0.5-0.75 quarts.

Known Issues

Engine Common Problems:

Worn engine mounts, oil leaks from valve cover gasket or oil pan, occasional radiator fan issues, timing belt failure if not replaced on schedule.

Suspension Common Problems:

Worn front struts and bushings, premature wear of ball joints and tie rod ends, rear wheel bearing noise.

Transmission Common Problems:

Automatic transmission solenoid issues, worn clutches in high-mileage automatics, manual transmission clutch wear.

Electrical Common Problems:

Faulty alternator, battery drain issues, corroded grounds, power window motor failures.

HVAC Common Problems:

Blend door actuator failure, AC blower motor issues, refrigerant leaks.

📚 Vehicle History

Brand Heritage

Mazda Focus:

Mazda has a long history of producing reliable and engaging vehicles, with a reputation for sporty driving dynamics.

Model Evolution

Protege Lineage:

The Protege line has roots in earlier Mazda compact cars, evolving through several generations to meet market demands for affordability, efficiency, and performance.

Production

Manufacturing Locations:

Primarily manufactured in Japan, with some assembly potentially in other global locations.

🏆 Awards & Recognition

Recognitions

Safety Recognition:

Received good safety ratings from NHTSA and IIHS for its time, particularly when equipped with optional safety features.