🏷️ Basic Information

Make:

Mazda

Model:

Protegé

Model Years Covered:

2002 onwards

Chassis Codes Covered:

BJ

👋 Introduction

Vehicle Segment:

Compact Car / Economy Sedan & Hatchback

Target Audience:

Budget-conscious car buyers, first-time car owners, small families.

Key Competitors:

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

Protege Strengths:

Reputation for reliability, engaging driving dynamics (especially in SP23 trims), good value for money, practical interior space.

Available Body Styles:

4-door Sedan, 5-door Hatchback (MP3 hatchback was also available in certain markets).

Performance Orientated Trims:

The 'SP23' (or similar performance variants) offered sportier suspension tuning, larger wheels, and more powerful engine options.

📋 Manual Details

Engine Types Covered:

Naturally Aspirated & Turbocharged Gasoline Engines (Specifics may vary by sub-model and region)

Transmission Types Covered:

Manual & Automatic Transmissions

Drivetrain Covered:

Front-Wheel Drive (FWD)

Estimated Page Count:

Extensive (typically 2000+ pages for comprehensive workshop manuals)

Manual Type:

Professional Workshop Service and Repair Manual

Language:

English

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Detailed component removal, inspection, overhaul, and reassembly procedures for all engine variants. Includes cylinder head, pistons, crankshaft, camshafts, valve train, oil pump, etc.

Engine Management:

Fuel injection systems (EFI), ignition system, emissions control systems (EVAP, EGR), sensor diagnostics, and ECU troubleshooting.

Transmission Manual:

Clutch operation, gearbox removal, disassembly, inspection, repair, and reassembly. Includes shift linkage and components.

Transmission Automatic:

Transmission removal, fluid service, valve body inspection, torque converter service, and general troubleshooting. Likely includes diagnostic flowcharts.

Brake System:

Disc brake component service (pads, rotors, calipers), drum brake service (shoes, drums, wheel cylinders), parking brake system, hydraulic lines, and ABS system diagnostics.

Suspension System:

Front and rear suspension component replacement (struts, shocks, control arms, ball joints, tie rods, bushings), alignment specifications, and troubleshooting.

Steering System:

Power steering system service (pump, rack and pinion, hoses), manual steering components, and alignment procedures.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting systems, power windows, locks, mirrors, wipers, and HVAC blower motor.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all major systems, facilitating troubleshooting and repair of electrical faults.

Body And Frame:

Body panel removal/installation, door mechanisms, hood, trunk, glass replacement, interior trim, and basic body repair guidance.

Heating Ventilation And Air Conditioning HVAC:

AC system service (refrigerant, compressor, condenser, evaporator), heater core replacement, climate control systems, and blower motor diagnostics.

Scheduled Maintenance:

Detailed maintenance schedules including oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection/replacement, and tire rotations.

Troubleshooting Guides:

Systematic diagnostic procedures and troubleshooting flowcharts for common problems, ranging from engine performance issues to electrical faults.

Component Removal And Installation:

Step-by-step instructions for removing and installing virtually every component on the vehicle, with torque specifications and critical alignment data.

Engine Rebuilding:

Comprehensive engine overhaul procedures, including cylinder honing, piston ring installation, bearing clearance checks, and valve seat grinding.

Brake System Overhaul:

Detailed procedures for caliper rebuilding, master cylinder replacement, and bleeding the brake system.

Diagnostic Procedures:

OBD-II diagnostic trouble code (DTC) interpretation and guided diagnostic steps for various systems.

Depth Of Coverage:

Comprehensive, covering basic owner maintenance to complete factory-level overhauls and diagnostics.

Diagrams Illustrations:

Step-by-step diagrams and detailed illustrations for component identification, disassembly, assembly, and torque values.

Special Tools Required:

Identification of specific tools required for certain procedures, often referencing OEM tool numbers or their equivalents.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Yes (assuming a professionally scanned and OCR'd document)

Printable:

Yes

Resolution:

High (suitable for clear viewing of diagrams and text)

Print Quality Equivalent:

Factory OEM publication quality

Binding Type Equivalent:

Perfect Bound or Spiral Bound (typical for workshop manuals)

Paper Type Equivalent:

Durable, matte finish paper stock to prevent glare and withstand shop use

⚙️ Engine Specifications

Engine Codes Common:

FS-DE (2.0L DOHC), Z5-DE (1.5L SOHC), FP-DE (1.8L DOHC - less common in later years, but possible).

2.0L Fs-De Displacement:

1991 cc (2.0 Liters)

2.0L Fs-De Horsepower:

Approx. 130-135 hp (depending on specific market tune and year)

2.0L Fs-De Torque:

Approx. 135-140 lb-ft

1.5L Z5-De Displacement:

1498 cc (1.5 Liters)

1.5L Z5-De Horsepower:

Approx. 95-100 hp

Compression Ratio Fs-De:

9.1:1 (typical)

Redline Fs-De:

Approx. 6500 RPM

Fuel Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 octane recommended for most models, premium may be recommended for SP23)

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission

Optional Transmission:

4-speed Automatic Transmission

Clutch Type:

Hydraulically Operated, Dry Single Plate Clutch

Automatic Transmission Features:

Lock-up torque converter for improved fuel efficiency at cruising speeds.

📐 Dimensions

Wheelbase:

Approx. 102.7 inches (2606 mm) (Sedan)

Length:

Approx. 172.8 inches (4389 mm) (Sedan)

Width:

Approx. 67.1 inches (1704 mm)

Height:

Approx. 55.7 inches (1415 mm) (Sedan)

Trunk Volume Sedan:

Approx. 12.6 cubic feet

Curb Weight Typical:

Approx. 2600-2800 lbs (1180-1270 kg)

Gross Vehicle Weight Rating Gvwr:

Varies by trim, typically around 3700 lbs (1680 kg)

🛡️ Safety Features

NHTSA Front Impact Driver:

5-Star (for comparable model years)

NHTSA Front Impact Passenger:

5-Star (for comparable model years)

IIHS Side Impact Rating:

Good (for comparable model years)

Anti Lock Braking System ABS:

Optional or standard on higher trims.

Traction Control:

Less common on base models, may be available on higher trims.

Airbags Front:

Standard driver and passenger front airbags.

Airbags Side Impact:

Optional or standard on higher trims (curtain or side-impact airbags).

Seatbelts:

3-point seatbelts with pretensioners and load limiters for front seats.

💡 Technology Features

Infotainment System:

Basic AM/FM/CD player with optional premium audio systems. Some higher trims may have cassette tape decks. Limited digital connectivity for the era.

Speaker Configurations:

Typically 4 or 6 speaker configurations, with Rockford Fosgate premium option on some trims.

Cruise Control:

Available on most trims.

Anti Theft System:

Factory immobilizer system available on some models.

Auxiliary Input:

Not typically found on factory systems; aftermarket solutions required.

Bluetooth:

Not available on factory systems; aftermarket solutions required.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (using recommended oil).

Air Filter Replacement:

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

Spark Plug Replacement Fs-De:

Typically every 60,000 - 100,000 miles (96,000 - 160,000 km) with iridium-tipped plugs, depending on type.

Engine Oil Type:

API SG or SH certified, SAE 5W-30 viscosity recommended for most conditions. Consult manual for exact specs.

Engine Oil Capacity Fs-De:

Approx. 4.0 US quarts (3.8 liters) with filter change.

Coolant Type:

Mazda Long Life Antifreeze/Coolant (Blue) or equivalent ethylene glycol-based coolant.

Transmission Fluid Manual:

GL-4 gear oil, SAE 75W-90 recommended.

Transmission Fluid Automatic:

Mazda ATF MV or equivalent DEXRON III / MERCON compatible fluid. Capacity approx. 3.0 US quarts (2.8 liters) for drain and fill.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Common Problems Engine:

Oil leaks from valve cover gasket and oil pan gasket. Potential for intake manifold gaskets to leak. Some reports of crankshaft position sensor failures.

Common Problems Suspension Steering:

Worn front sway bar end links and bushings leading to clunking noises. Power steering pump can become noisy or fail over time. Front strut mounts can wear out.

Common Problems Electrical:

Window regulators can fail. Blower motor resistor may fail, leading to HVAC fan only working on high setting. LCM (Lighting Control Module) issues can occur.

Common Problems Transmission:

Manual transmissions can develop noisy bearings or shift linkage issues. Automatic transmissions can exhibit harsh shifting if fluid and filter are neglected.

Common Problems Body Interior:

Rust can be an issue in areas with heavy salt use, especially on wheel wells and rocker panels. Interior trim pieces can become loose.

📚 Vehicle History

Mazda Philosophy:

Mazda's long-standing commitment to 'Zoom-Zoom' driving dynamics and innovative design.

Protege Generations:

The BJ generation (1998-2003) represents a significant refinement over its predecessors, known for improved chassis dynamics and modern styling. The 2002 onwards models are part of this later update.

Key Updates 2002 Onwards:

Minor styling tweaks, potential updates to suspension tuning, and addition of features on certain trims.

Production Locations:

Primarily Japan, with some production also occurring in other Mazda global facilities.

Production Years Bj Generation:

1998-2003

🏆 Awards & Recognition

Intellichoice Design Award:

Mazda Protegé received an IntelliChoice Design Excellence award in the compact car segment for its styling and value.

Consumer Reports Reliability:

Generally good to excellent reliability ratings from consumer advocacy groups for this generation, contributing to its strong resale value.

Emissions Certification:

Meets or exceeds EPA emissions standards for its model year.