Mazda Protege 2000 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2000 Codes Chassis Code: BJ Platform Code: Mazda B-platform 👋 Introduction Market Position Market Segment: Compact sedan/hatchback, positioned as a practical...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Codes

Chassis Code:

Platform Code:

Mazda B-platform

👋 Introduction

Market Position

Market Segment:

Compact sedan/hatchback, positioned as a practical and engaging option

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Chevrolet Cavalier

Key Features

Vehicle Strengths:

Reliability, sporty handling (especially with certain trims), fuel efficiency, good value

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive repair and maintenance information

Specific Sections:

Engine, transmission, drivetrain, suspension, steering, brakes, HVAC, electrical, body, diagnostics

Page Count

Approximate Pages:

1500+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Management:

Detailed diagnostics, component testing, ECM operation, sensor data

Fuel System:

Fuel pump testing, injector diagnostics, fuel pressure regulation, evaporative emission control (EVAP)

Ignition System:

Ignition coil testing, spark plug specifications, timing adjustment procedures

Cooling System:

Thermostat operation, radiator and fan diagnostics, coolant specifications

Exhaust System:

Catalytic converter function, muffler replacement, emission control components

Transmission Manual:

Clutch operation, gearshift linkage, gearbox disassembly and assembly, fluid specifications

Transmission Automatic:

ATF specifications, valve body diagnostics, torque converter operation, transmission control module (TCM) diagnostics

Drivetrain Frontend:

CV axle inspection and replacement, differential service

Suspension Front:

MacPherson strut replacement, ball joint inspection, control arm bushings

Suspension Rear:

Multi-link suspension service, shock absorber replacement, trailing arm bushings

Steering System:

Power steering pump and rack diagnostics, tie rod end replacement, steering column service

Brake System Front:

Disc brake pad and rotor replacement, caliper servicing, brake fluid specifications

Brake System Rear:

Drum brake adjustment and shoe replacement (if applicable), disc brake service (if applicable)

Anti-Lock Brakes (ABS):

ABS sensor diagnostics, hydraulic unit testing, ABS warning light troubleshooting

Body Exterior:

Door panel removal, bumper repair, panel alignment, paint codes

Body Interior:

Seat removal, dashboard component service, headliner replacement

Climate Control (HVAC):

A/C system recharge, blower motor testing, heater core replacement, cabin air filter service

Electrical System Charging:

Alternator testing, battery specifications, wiring diagrams for charging system

Electrical System Starting:

Starter motor testing, ignition switch diagnostics, wiring diagrams for starting system

Lighting System:

Headlight bulb replacement, taillight assembly service, interior lighting diagnostics

Instrument Panel:

Gauge cluster removal and repair, warning light explanation, switch diagnostics

Audio System:

Radio removal and installation, speaker replacement, antenna troubleshooting

Security System:

Keyless entry system operation, alarm system diagnostics

Cruise Control:

Cruise control actuator testing, switch diagnostics, speed sensor troubleshooting

Airbags:

Airbag system components, SRS warning light troubleshooting, replacement procedures (with safety precautions)

Procedures Included

Routine Maintenance:

Oil and filter changes, fluid level checks and top-offs, tire rotation, spark plug replacement

Troubleshooting:

Step-by-step diagnostic flowcharts for common and uncommon issues

Component Replacement:

Detailed instructions for replacing nearly all major and minor components

Diagnostics:

OBD-II system analysis, diagnostic trouble code (DTC) interpretation, component testing procedures

Rebuilds And Overhauls:

Engine and transmission overhaul procedures, complete disassembly and reassembly guides

Wiring Diagrams:

Complete, color-coded wiring schematics for all vehicle systems

Specifications And Tolerances:

Engine torque specifications, valve clearances, bearing clearances, etc.

Special Tools:

Identification of required special tools for specific repair procedures

Technical Depth

Depth:

Factory-level, suitable for professional technicians and experienced DIY enthusiasts

📊 Manual Specifications

File Format

Digital File Type:

N/A (Print Manual)

Print Quality

Print Quality:

High-quality reproduction of original factory documentation

Binding Type

Binding:

Staple-bound or perfect-bound (typical for service manuals)

Paper Type

Paper Quality:

Durable, semi-gloss paper suitable for workshop environments

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE (1.8L)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

1839 cc (1.8 Liters)

Bore X Stroke:

83.0 mm x 85.0 mm

Compression Ratio:

9.1:1

Performance

Horsepower (Net):

122 hp @ 5500 rpm (typical)

Torque (Net):

115 lb-ft @ 4000 rpm (typical)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (SMPI)

Fuel Type:

Unleaded Gasoline, 87 octane (minimum recommended)

Engine Management

Engine Control Module (ECM):

Mazda specific ECM with diagnostic capabilities

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual

Optional

Transmission Type:

4-Speed Automatic

Features

Automatic Transmission Features:

Electronically controlled, lock-up torque converter

Fluid Type

Manual Transmission Fluid (Mtf):

API GL-4, SAE 75W-90 (refer to manual for specific part numbers)

Automatic Transmission Fluid (Atf):

Dexron III or equivalent (refer to manual for specific part numbers)

📐 Dimensions

Exterior

Length:

Approx. 171.5 inches (4356 mm) - Sedan

Width:

Approx. 67.7 inches (1720 mm)

Height:

Approx. 55.9 inches (1420 mm) - Sedan

Wheelbase:

Approx. 102.7 inches (2606 mm)

Weights

Curb Weight:

Approx. 2600 - 2800 lbs (1180 - 1270 kg), depending on trim and transmission

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

4-star driver, 4-star passenger (for the era, refer to specific test results)

Active Features

Available ABS:

Available Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and front passenger airbags standard

Seatbelts:

Front and rear three-point seatbelts

💡 Technology Features

Infotainment

Audio System Standard:

AM/FM stereo with CD player or cassette deck, depending on trim level.

Driver Assistance

Cruise Control:

Available cruise control system.

Connectivity

Auxiliary Input:

Generally not available in its original form; aftermarket head unit installation is common for AUX/USB connectivity.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (typical, consult manual for exact recommendations).

Engine Air Filter:

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

Cabin Air Filter:

If equipped, inspect annually or every 15,000 miles (24,000 km).

Spark Plugs:

Replace every 60,000 - 100,000 miles (96,000 - 160,000 km) depending on plug type (platinum/iridium recommended).

Transmission Fluid Change:

Manual: Inspect every 30,000 miles (48,000 km), replace at 60,000-100,000 miles (96,000-160,000 km) or if contaminated. Automatic: Every 45,000-60,000 miles (72,000-96,000 km) or as per manual.

Fluid Specifications

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) with filter (refer to manual for exact capacity).

Engine Oil Viscosity:

5W-30 or 10W-30 recommended (check manual for ambient temperature suitability).

Coolant Type:

Ethylene glycol based coolant (Mazda recommends FL22 or equivalent).

Known Issues

Engine Lsd Issue:

Some FS-DE engines can develop piston slap when cold, typically not a critical failure but can be noisy.

Suspension Wear:

Rear shock absorbers and control arm bushings can wear over time, leading to a less controlled ride.

Exhaust Rust:

Corrosion of exhaust components can occur in regions with harsh winters and road salt.

Automatic Transmission:

Older automatic transmissions can sometimes exhibit hard shifting or slipping if not properly maintained.

Window Regulators:

Power window regulators can become sluggish or fail over time.

📚 Vehicle History

Brand Heritage

Brand Reputation:

Mazda has a history of producing reliable and often engaging-to-drive vehicles, known for their 'Jinba Ittai' (horse and rider as one) driving philosophy.

Model Evolution

Generation:

Third Generation Protege (BJ Platform, 1998-2003)

Key Updates For 2000:

While 2000 was not a major redesign year, minor feature updates and potentially package adjustments may have occurred. The core platform and powertrain remained consistent.

Production

Manufacturing Locations:

Primarily Japan, with some production in North America depending on market.

🏆 Awards & Recognition

Recognitions

General Reputation:

The Protege lineup generally received positive reviews for its value, reliability, and engaging driving dynamics for its class.