Mazda Protege 2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2004 Codes Chassis Code: BJ 👋 Introduction Market Position Segment: Compact Car Target Audience: Budget-conscious buyers seeking reliable and economical transportation,...

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标签: 2004 Car Cars Mazda Misc Protege

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Car

Target Audience:

Budget-conscious buyers seeking reliable and economical transportation, also appeals to those who value sporty handling and distinctive styling.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Mitsubishi Lancer.

Key Features

Handling:

Praised for its sporty handling and engaging driving dynamics, often outperforming competitors in this regard.

Styling:

Features a distinctive and youthful exterior design for its era.

Value Proposition:

Offers a strong balance of features, performance, and affordability.

📋 Manual Details

Coverage Areas

Language:

English

Format:

PDF Download

Manual Type:

Full Service Repair Manual

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul procedures, component testing, timing belt replacement, cylinder head assembly, piston and connecting rod installation, crankshaft and bearing service, engine block machining.

Engine Fuel System:

Fuel injection system (MPI), fuel pump, fuel injectors, fuel pressure regulator, EVAP system, throttle body maintenance, component testing.

Engine Ignition System:

Ignition coils, spark plugs, ignition control module (ICM), troubleshooting ignition issues, diagnostic procedures.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, cooling fan operation, coolant capacity and specifications, flushing and refilling procedures.

Lubrication System:

Oil pump, oil filter replacement, oil pan removal and installation, oil pressure testing, recommended oil types and capacities.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipes, O2 sensors, inspection and replacement.

Transmission Manual:

Clutch system, gearbox overhaul, gear shifting mechanisms, transmission fluid type and capacity, seal replacement.

Transmission Automatic:

Automatic transmission overhaul, torque converter, valve body, planetary gear sets, transmission fluid type and capacity, troubleshooting.

Drivetrain Suspension:

Front and rear suspension components, struts, shocks, control arms, ball joints, bushings, wheel bearings, alignment procedures.

Drivetrain Axles Cv Joints:

Front and rear drive axles, CV joints, boots, replacement procedures, inspection.

Brakes System:

Front and rear disc brakes, brake pads, rotors, calipers, brake lines, master cylinder, ABS system (if equipped), brake bleeding procedures, parking brake.

Steering System:

Power steering system, steering rack, power steering pump, fluid type and capacity, tie rods, troubleshooting steering issues.

Electrical System Charging:

Alternator, battery, charging system troubleshooting, voltage regulation.

Electrical System Starting:

Starter motor, starter solenoid, ignition switch, troubleshooting starting problems.

Electrical System Lighting:

Headlights, taillights, interior lighting, bulb replacement, wiring diagrams for lighting circuits.

Electrical System Accessories:

Power windows, power locks, mirrors, radio, wipers, horn, accessory circuits, fuse box layout.

Body Exterior:

Doors, hood, trunk, fenders, bumpers, glass replacement, body panel alignment, rust repair techniques.

Body Interior:

Dashboard removal and installation, seat removal, door panel trim, headliner, carpet, interior component repair.

HVAC System:

Air conditioning system, heater core, blower motor, climate control panel, refrigerant recharge, troubleshooting A/C issues.

Procedures Included

Preventive Maintenance:

Oil and filter changes, fluid level checks, tire rotation, brake inspection, belt and hose inspection, spark plug replacement.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, common fault identification and repair strategies for all major systems.

Repair Overhaul:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Diagnostics:

On-board diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool usage, sensor testing, actuator testing.

Wiring Diagrams:

Comprehensive electrical schematics for all major systems, including engine, transmission, ABS, lighting, and interior electronics.

Specifications Data:

Torque specifications, clearances, fluid capacities, diagnostic values, emissions data, component dimensions.

Technical Depth

Level Of Detail:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic maintenance to full engine and transmission rebuilds.

📊 Manual Specifications

File Format

Type:

Searchability:

Searchable text content for easy navigation and information retrieval.

Printability:

Printable pages for on-the-go reference or workshop use.

Print Quality

Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE (for most trims)

Engine Type:

2.0L DOHC 16-valve Inline-4

Displacement:

1991 cc (121.5 cu in)

Performance

Horsepower:

Approx. 130 hp @ 6000 rpm

Torque:

Approx. 135 lb-ft @ 4000 rpm

Fuel System

System:

Electronic Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Other

Bore X Stroke:

83.0 mm x 92.0 mm (3.27 in x 3.62 in)

Compression Ratio:

9.2:1

Engine Mounting:

Transverse, front-wheel drive

Engine Control Unit:

Mazda Electronic Control Unit (ECU) with integrated diagnostics.

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

4-speed Automatic Transmission (with Overdrive)

Features

Manual Gear Ratios:

Specific ratios available in the manual, typically around 3.31:1 for 1st gear.

Automatic Shift Modes:

Standard P-R-N-D-2-1 selector pattern.

Fluid Specifications

Manual Fluid:

API GL-4, SAE 75W-90 Gear Oil

Automatic Fluid:

Mazda ATF JWS3317 or equivalent Dexron III

📐 Dimensions

Exterior

Length:

Approx. 169.1 in (4295 mm)

Width:

Approx. 67.7 in (1720 mm)

Height:

Approx. 55.1 in (1400 mm)

Wheelbase:

Approx. 102.8 in (2610 mm)

Front Track:

Approx. 58.3 in (1480 mm)

Rear Track:

Approx. 57.7 in (1465 mm)

Interior

Front Headroom:

Approx. 38.8 in (985 mm)

Rear Headroom:

Approx. 36.4 in (925 mm)

Front Legroom:

Approx. 41.7 in (1059 mm)

Rear Legroom:

Approx. 33.5 in (851 mm)

Cargo

Trunk Volume:

Approx. 11.8 cu ft (sedan models)

Weights

Curb Weight:

Approx. 2600-2750 lbs (1180-1250 kg) depending on trim and transmission.

Gross Vehicle Weight Rating:

Available in manual.

Towing Capacity:

Not typically rated for towing.

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4-star (as per NHTSA records for similar models in the era)

NHTSA Frontal Impact Passenger:

4-star (as per NHTSA records for similar models in the era)

IIHS Side Impact:

Acceptable (for models equipped with side airbags)

Active Features

Available (standard on some trims, optional on others)

Traction Control:

Available on select models.

Passive Features

Airbags Front:

Standard dual front airbags.

Airbags Side:

Optional front side-impact airbags on certain trims.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium sound system. Basic auxiliary inputs were not common.

Display:

Simple digital or analog displays for climate control and radio.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Keyless Entry:

Optional on most trims.

Connectivity

Bluetooth:

Not available from the factory.

Not available from the factory.

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions).

Engine Air Filter:

Replace every 30,000 miles (48,000 km).

Cabin Air Filter:

Replace every 15,000 miles (24,000 km) or annually.

Spark Plugs:

Replace iridium spark plugs every 100,000 miles (160,000 km).

Timing Belt:

Replace every 60,000 miles (96,000 km) or 4 years, whichever comes first. Critical maintenance item.

Fluid Specifications

Engine Oil:

API SN/SP or ILSAC GF-6A, SAE 5W-30 recommended. Capacity: 4.2 US quarts (4.0 L) with filter.

Coolant:

Mazda Super Long Life Coolant (Blue) or equivalent HOAT coolant. Capacity: Approx. 6.7 US quarts (6.3 L).

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

Mazda Genuine ATF or equivalent Dexron II/III.

Known Issues

Engine Misfires:

Can occur due to worn ignition coils, spark plugs, or fuel injectors. Cracked valve cover gaskets can also cause oil leaks onto spark plug wells.

Timing Belt Failure:

Critical failure if not replaced at recommended intervals, leading to catastrophic engine damage (interference engine).

Automatic Transmission Slipping:

Can indicate low fluid levels or internal wear. Regular fluid changes are important.

Suspension Component Wear:

Worn ball joints, tie rod ends, and bushings can lead to steering looseness and uneven tire wear.

Rust And Corrosion:

Common in older vehicles, particularly in areas with harsh winters. Wheel wells, rocker panels, and floor pans are susceptible.

Ac System Leaks:

Leaking O-rings or condenser issues can lead to refrigerant loss.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Mazda's reputation for building driver-focused, reliable, and engaging vehicles.

Model Evolution

Generation:

Third generation Protege (BJ chassis), produced from 1998 to 2003 (with the 2004 model year often representing the final production run of this generation in some markets before replacement by the Mazda3).

Production

Manufacturing Locations:

Primarily manufactured in Japan and Mexico.

Trim Levels:

DX, LX, ES,Mazdaspeed Protege (performance variant).

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Protege ES was recognized by Car and Driver magazine on its '10Best' list in 1996, setting a precedent for the model's reputation.