1999 Mazda Protege Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 1999 Generation Generation Code: BJ Codes Chassis Code: BJ3P 👋 Introduction Market Position Vehicle Segment: Compact Car Target Audience: Budget-conscious buyers,...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Generation

Generation Code:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact Car

Target Audience:

Budget-conscious buyers, young drivers, individuals seeking reliable and economical transportation.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Hyundai Elantra.

Key Features

Vehicle Strengths:

Affordability, good fuel economy, reliable powertrain, practical interior, sporty handling (in certain trims like GT).

Manual Value Proposition:

Provides comprehensive, factory-level information for DIY repairs and maintenance, saving significant costs on professional labor.

📋 Manual Details

Coverage Areas

Engine Coverage:

1.6L BP-ZE, 1.8L BP-VE, 2.0L FS-DE

Transmission Coverage:

5-speed Manual, 4-speed Automatic

Drivetrain Coverage:

Front-Wheel Drive (FWD)

Body Style Coverage:

Sedan, Hatchback

Page Count

Estimated Page Count:

Over 1000

Manual Type

Manual Type:

Official Service and Repair Manual Software

Language

Language:

English

Format

Format:

Digital Software (likely PDF or proprietary executable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing system, lubrication system, cooling system, fuel system (injection), emission control system.

Engine Performance:

Engine tuning, diagnostics, compression testing, idle speed control, power output.

Fuel System:

Fuel pump, fuel injectors, fuel pressure regulator, fuel filter, evaporative emission control (EVAP) system.

Ignition System:

Spark plugs, ignition coils, ignition timing, distributor (if applicable), Crankshaft Position Sensor (CKP), Camshaft Position Sensor (CMP).

Transmission Manual:

Clutch system, gearbox assembly, gear shift mechanism, internal components, maintenance.

Transmission Automatic:

Transmission fluid, valve body, torque converter, shift solenoids, electronic control module (ECM) interface, diagnostics, maintenance.

Drivetrain Axles And Differentials:

Front axle shafts, CV joints, differential unit (if applicable), maintenance.

Suspension Front:

MacPherson struts, control arms, ball joints, sway bar, bushings, wheel bearings, alignment specifications.

Suspension Rear:

Independent rear suspension (IRS) design (e.g., multi-link), shock absorbers, springs, control arms, bushings, alignment specifications.

Steering System:

Power steering pump, steering rack, tie rods, power steering fluid, column components, diagnostics.

Brake System Front:

Disc brakes, calipers, brake pads, rotors, hydraulic lines, ABS components (if equipped).

Brake System Rear:

Disc or drum brakes (depending on trim), calipers/wheel cylinders, pads/shoes, rotors/drums, parking brake mechanism.

Anti Lock Braking System ABS:

ABS control module, wheel speed sensors, hydraulic modulator unit, diagnostic procedures.

Electrical System Power Generation:

Alternator, battery, charging system diagnostics.

Electrical System Starting:

Starter motor, starter solenoid, ignition switch, starting system diagnostics.

Electrical System Lighting:

Headlights, taillights, turn signals, interior lighting, bulb types, wiring diagrams.

Electrical System Accessories:

Wipers, horn, power windows, power locks, mirrors, audio system, climate control system operation.

Body And Interior:

Door panels, upholstery, dashboard, trim, seating, noise insulation.

Body And Exterior:

Bumpers, fenders, hood, trunk lid, doors, glass, mirrors, seals, rust prevention.

Climate Control HVAC:

Air conditioning system, heater core, blower motor, controls, refrigerant, servicing.

Safety Systems Airbags:

Airbag modules, control module, sensors, deployment, SRS system diagnostics.

Diagnostics:

On-Board Diagnostics (OBD-II) system, fault codes (DTCs), diagnostic connectors, scan tool usage.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, air filter replacement, brake pad replacement, tire rotation.

Engine Repair:

Complete engine disassembly and reassembly, head gasket replacement, piston ring replacement, valve jobs, timing belt/chain replacement.

Transmission Repair:

Clutch replacement, transmission overhaul (manual and automatic), component replacement.

Brake System Repair:

Brake caliper overhaul, rotor replacement, brake line replacement, bleeding the brake system.

Suspension And Steering Repair:

Strut replacement, control arm replacement, ball joint replacement, tie rod end replacement, power steering pump replacement.

Electrical Diagnostics And Repair:

Troubleshooting electrical circuits, component testing, wiring harness repair, module replacement.

Body And Paint Repair:

Panel replacement, dent repair, rust repair, painting procedures.

Troubleshooting Guides:

Systematic diagnostic flowcharts for common and uncommon problems, symptom-based troubleshooting.

Component Testing:

Detailed procedures for testing the functionality of individual components (e.g., sensors, actuators, pumps).

Torque Specifications:

Precise torque values for all critical fasteners.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Technical Depth

Depth Of Information:

Comprehensive factory-level detail covering routine maintenance, diagnostics, troubleshooting, and complete repair procedures for all major systems.

Diagnostic Capability:

Includes OBD-II fault codes, diagnostic strategies, and component testing procedures.

Special Tools:

Lists and descriptions of specialized tools required for specific repair procedures.

📊 Manual Specifications

File Format

File Format Details:

Likely a proprietary executable or a well-structured PDF. Searchable text functionality is highly probable for digital formats.

Print Quality

Print Quality:

High resolution, clear diagrams and illustrations suitable for printing individual pages.

Binding Type

Binding Type:

N/A (Digital Software)

Paper Type

Paper Type:

N/A (Digital Software)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

BP-ZE

Engine Displacement 1:

1.8 Liters (1839 cc)

Engine Configuration 1:

Inline 4-cylinder, DOHC, 16 valves

Horsepower 1:

122 hp @ 6000 rpm (approx.)

Torque 1:

111 lb-ft @ 4000 rpm (approx.)

Secondary Engine

Engine Code 2:

FS-DE

Engine Displacement 2:

2.0 Liters (1991 cc)

Engine Configuration 2:

Inline 4-cylinder, DOHC, 16 valves

Horsepower 2:

130 hp @ 6000 rpm (approx.)

Torque 2:

127 lb-ft @ 4000 rpm (approx.)

Tertiary Engine

Engine Code 3:

Engine Displacement 3:

1.6 Liters (1598 cc)

Engine Configuration 3:

Inline 4-cylinder, SOHC, 16 valves

Horsepower 3:

105 hp @ 5500 rpm (approx.)

Torque 3:

104 lb-ft @ 4000 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Emission Controls:

Catalytic Converter, EGR (Exhaust Gas Recirculation), EVAP (Evaporative Emission Control).

🔧 Transmission

Standard

Standard Transmission:

5-Speed Manual Transmission

Optional

Optional Transmission:

4-Speed Automatic Transmission

Features

Clutch Type:

Dry, single-plate, diaphragm spring clutch

Automatic Transmission Features:

Lock-up torque converter, electronically controlled shifts.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or SAE 75W-85 (refer to specific vehicle manual for exact spec)

Automatic Transmission Fluid:

Dexron-III or equivalent (refer to specific vehicle manual for exact spec)

📐 Dimensions

Exterior

Length Sedan:

169.1 inches (4295 mm)

Width Sedan:

67.1 inches (1704 mm)

Height Sedan:

55.7 inches (1415 mm)

Wheelbase Sedan:

102.8 inches (2611 mm)

Interior

Passenger Volume:

Approx. 90-95 cubic feet

Cargo

Cargo Volume Sedan:

Approx. 12-14 cubic feet

Weights

Curb Weight Base:

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

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle placard (typically 3700-3900 lbs)

Towing Capacity:

Not recommended or specified for towing

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Driver:

4-star (1999 model year, may vary)

NHTSA Front Crash Test Passenger:

4-star (1999 model year, may vary)

IIHS Small Overlap Front:

Not tested or rated for this specific year/generation.

Active Features

Available on select trims (Anti-lock Braking System)

Traction Control:

Rarely available for this generation.

Passive Features

Airbags Driver:

Standard

Airbags Passenger:

Standard

Seat Belts:

3-point height-adjustable front seat belts, rear lap and shoulder belts.

Child Seat Anchors Latch:

Not equipped with LATCH system; relies on seat belt anchoring.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with cassette player, optional CD player. Basic speaker configurations.

Display Technology:

Analog gauges for speedometer, tachometer, fuel, and temperature. No integrated digital displays or infotainment screens.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Keyless Entry:

Available on select trims, typically as an aftermarket addition or on higher-end models.

Connectivity

Bluetooth Connectivity:

Not equipped from the factory.

Usb Ports:

Not equipped from the factory.

Phone Integration:

Not equipped from the factory; aftermarket solutions required.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, whichever comes first (refer to manual for specific recommendation).

Engine Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 15,000 to 30,000 miles (24,000 to 48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Every 30,000 to 60,000 miles (48,000 to 96,000 km) depending on plug type (copper vs. platinum).

Timing Belt Replacement:

Critical: Every 60,000 to 90,000 miles (96,000 to 144,000 km) or 5-7 years, depending on engine. Failure can cause catastrophic engine damage (interference engine).

Coolant Flush Interval:

Every 30,000 to 50,000 miles (48,000 to 80,000 km) or 2-3 years.

Brake Fluid Flush Interval:

Every 2-3 years or 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil Capacity 1.8L:

Approx. 4.2 US quarts (4.0 Liters) with filter.

Engine Oil Capacity 2.0L:

Approx. 4.2 US quarts (4.0 Liters) with filter.

Engine Oil Viscosity:

5W-30 or 10W-30 (API SG or higher quality, consult manual for climate-specific recommendations).

Coolant Type:

Ethylene glycol based, Asian-type pink or orange coolant (refer to manual for Mazda-specific type).

Power Steering Fluid:

Dexron-III ATF or specific power steering fluid (consult manual).

Known Issues

Engine Oil Leaks:

Valve cover gasket, oil pan gasket, rear main seal.

Suspension Wear:

Worn ball joints, tie rod ends, sway bar links, and bushings due to age and mileage.

Exhaust System Corrosion:

Rusting of muffler, catalytic converter, and exhaust pipes.

Automatic Transmission Shifting:

Erratic shifting or delayed engagement can occur with age and mileage, often related to fluid condition or solenoid issues.

Interior Trim Degradation:

Cracking dashboards, worn seat bolsters, and faded interior panels are common in older vehicles.

Check Engine Light Causes:

Faulty oxygen sensors, mass airflow sensor (MAF), or EGR valve issues are common.

Ac System Performance:

Leaky AC lines or failing compressor can reduce cooling efficiency.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Known for 'Zoom-Zoom' driving dynamics, often offering sporty handling and engaging driving experiences in their segments.

Model Evolution

Protege Generation Start:

First generation introduced in 1977.

Protege Bj Generation:

The 1999 model belongs to the third generation (BJ), which ran from 1998 to 2003.

Key Changes For Bj:

Significant redesign with a more aerodynamic and modern appearance, improved chassis, and new engine options. Offered in sedan and hatchback variants.

Production

Manufacturing Locations:

Primarily Japan (Mazda plants) and also in North America (e.g., Flat Rock, Michigan, USA for some markets).

Production Years For Bj Generation:

1998-2003

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Protege line has received 'Car and Driver' 10 Best honors in previous generations, signifying its competitive standing.

Ratings

Consumer Reports Reliability:

Reliability ratings for the 1999 Protege generally fall in the average to above-average range for its class and era, with some specific components noted for potential issues.

Certifications

Emissions Certification:

Meets EPA and California Air Resources Board (CARB) emission standards for its model year.