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Mazda Protege 2004 Repair Service Manual

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The Mazda Protege, produced around the 2004 model year, is a compact car recognized for its engaging driving dynamics and solid engineering. As part of the BJ series, this vehicle...
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Mazda Protege 2004 Repair Service ManualMazda Protege 2004 Repair Service ManualMazda Protege 2004 Repair Service ManualMazda Protege 2004 Repair Service Manual
The Mazda Protege, produced around the 2004 model year, is a compact car recognized for its engaging driving dynamics and solid engineering. As part of the BJ series, this vehicle offered a compelling blend of performance, reliability, and affordability, often competing with segment leaders like the Honda Civic and Toyota Corolla. Its design emphasized Mazda's philosophy, providing a sporty and responsive driving experience. The Protege was generally well-regarded for its durability and consistent performance, making it a popular choice for drivers seeking a practical yet enjoyable vehicle. This comprehensive repair service manual in English provides detailed information for the maintenance and repair of the Mazda Protege BJ Series. It covers a wide array of systems, including engine mechanicals and performance, manual and automatic transmissions, drivetrain, suspension, brakes, steering, and the electrical system. The manual also details body and chassis components, HVAC, and safety systems, along with diagnostic procedures. Included are step-by-step instructions for routine maintenance, component repair, troubleshooting, and electrical system fixes, making it an essential resource for owners and technicians alike to ensure the optimal performance and longevity of their vehicle.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Year:
2004
Codes
Chassis Code:
BJ Series
👋 Introduction
Market Position
Segment:
Compact car, known for its sporty handling and reliability.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Chevrolet Cavalier.
Key Features
Handling:
Renowned for its well-tuned suspension and engaging driving dynamics.
Reliability:
Generally considered a reliable vehicle with a good reputation for longevity.
Value Proposition:
Offered a good balance of performance, features, and affordability.
📋 Manual Details
Coverage Areas
Language:
English
Manual Type:
Repair Service Manual
Availability:
Instant PDF Download
Page Count
Estimated Page Count:
Varies by specific edition, typically 1500-2500+ pages for a complete factory service manual
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing system.
Engine Performance:
Fuel injection, ignition system, emission control systems, turbocharging (if applicable).
Transmission Manual:
Clutch, transmission assembly, gears, bearings, seals, shift mechanism, service and overhaul procedures.
Transmission Automatic:
Automatic transmission assembly, hydraulic control, torque converter, gear sets, service and overhaul procedures, electronic control unit (ECU) interface.
Drivetrain:
Front-wheel drive, half-shafts, CV joints, differential.
Suspension:
Front suspension (struts, control arms, ball joints, sway bar), rear suspension (independent or semi-independent, depending on model), wheel alignment specifications.
Brakes:
Front and rear brake systems (disc/drum configurations), ABS system, hydraulic components, brake fluid specifications, bleeding procedures.
Steering:
Power steering system, steering rack, tie rods, steering column, fluid specifications.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams.
Body And Chassis:
Body construction, panels, doors, windows, locks, interior trim, exterior trim, frame components.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate control diagnostics.
Safety Systems:
Airbag system (SRS), seat belts, safety restraint system diagnostics.
Diagnostics:
On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool procedures, troubleshooting flowcharts.
Procedures Included
Routine Maintenance:
Oil change, filter replacement, fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection/replacement.
Component Repair:
Engine overhaul, transmission rebuild, brake system repair, suspension component replacement, steering system repair.
Troubleshooting:
Diagnostic procedures for various systems, identifying causes of common problems.
Electrical Repair:
Wiring repair, component testing, diagnosing electrical faults using wiring diagrams.
Bodywork Repair:
Panel replacement, dent repair, rust repair, glass replacement, interior trim removal/installation.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.
📊 Manual Specifications
File Format
Searchable Text:
Yes, typically indexed and searchable PDF for quick access to information.
Printable:
Yes, designed to be printable for workshop use.
Print Quality
Clarity:
High resolution, ensuring clarity of diagrams, illustrations, and text.
Binding Type
Digital:
N/A (Digital PDF)
Paper Type
Digital:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
1.8L (1839 cc) - Common for many US models
Engine Code:
FS-DE (US market)
Performance
Horsepower:
Approximately 125-130 hp @ 6000 rpm (depending on market and specific trim)
Torque:
Approximately 115-120 lb-ft @ 4000-4500 rpm (depending on market and specific trim)
Fuel System
Induction:
Electronic Fuel Injection (EFI), Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU:
Engine Control Unit (ECU) manages fuel, ignition, and emissions.
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Optional
Transmission Type:
4-Speed Automatic
Features
Clutch:
Hydraulically actuated diaphragm clutch (manual transmission).
Automatic Transmission Control:
Electronically controlled with lock-up torque converter.
📐 Dimensions
Exterior
Length:
Approximately 170-174 inches (varies slightly by body style - sedan/hatchback)
Width:
Approximately 67.5 inches
Height:
Approximately 55.5-56.5 inches (varies slightly by body style)
Wheelbase:
Approximately 102.7 inches
Weights
Curb Weight:
Approximately 2600-2800 lbs (depending on trim and transmission)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Good (Top safety rating)
IIHS Frontal Offset:
Good (Top safety pick)
Active Features
ABS:
Available Anti-lock Braking System (ABS) on select trims.
Traction Control:
Limited availability, generally not a standard feature.
Passive Features
Airbags:
Driver and passenger front airbags standard. Side airbags available on some trims.
Seatbelts:
Three-point seat belts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player. Premium sound systems may have been optional on higher trims.
Display:
Basic analog gauges for speed, RPM, fuel, and temperature. Digital odometer.
Driver Assistance
Cruise Control:
Available as an option or standard on higher trims.
Connectivity
Auxiliary Input:
Rarely present on factory head units; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (refer to specific manual for exact recommendation).
Air Filter Replacement:
Every 30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
Approximately 60,000 miles (depending on spark plug type: standard or platinum).
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30 recommended for most conditions.
Coolant Type:
Mazda Genuine Long Life Coolant (Green) or equivalent ethylene glycol based coolant with silicate inhibitors. A 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 gear oil (refer to manual for specific capacity).
Transmission Fluid Automatic:
Mazda Genuine ATF JWS3314 or equivalent Dexron III compatible fluid (refer to manual for specific capacity).
Known Issues
Engine Mounts:
Premature wear and failure of engine mounts leading to vibration.
Exhaust Manifold:
Cracking of the exhaust manifold, leading to exhaust leaks and ticking noises.
Automatic Transmission:
Occasional issues with shifting, particularly in earlier models of the generation.
Power Steering Pump:
Potential for noisy or failing power steering pumps.
Window Regulators:
Failure of power window regulators.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Focus on 'Zoom-Zoom' driving dynamics, engaging handling, and reliable engineering.
Model Evolution
Generation:
Third Generation Protege (BJ Series, 1998-2003, with facelift for 2001-2003 models). The 2004 model falls within this generation's later years, potentially a carryover or slight update before discontinuation in many markets.
Production
Production Period:
The Protege line was produced from 1977 to 2003. The 2004 model year might be a transition year or represent specific market availability before the Mazda3 replaced it.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Awarded for excellent performance in frontal offset crash tests.
Consumer Reports:
Consistently rated as a reliable vehicle by automotive consumer organizations.
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