2004 Mazda Protege Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2004 Codes Chassis Code: BJ Vin Code: M 👋 Introduction Market Position Segment: Compact car Target Audience: Everyday drivers seeking reliable...

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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:

Vin Code:

👋 Introduction

Market Position

Segment:

Compact car

Target Audience:

Everyday drivers seeking reliable and fuel-efficient transportation, often families and young professionals.

Competitive Analysis

Key Competitors:

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

Value Proposition:

Offered a balance of sporty handling (especially with the 's' trim), affordability, and decent fuel economy.

Key Features

Design Philosophy:

Jinba-Ittai (horse and rider as one) driving feel, emphasizing driver engagement and responsive handling.

Body Styles:

Sedan, hatchback (5-door).

Performance Variant:

Mazdaspeed Protege (though not specified for the 2004 manual, it's part of the model's broader identity).

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Downloadable (likely PDF)

Version Coverage:

All trims and engine variants of the 2004 Mazda Protege

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing system

Engine Management:

Fuel injection system (MPI), ignition system, emissions control systems (EGR, EVAP), sensors, actuators, engine control module (ECM) diagnosis and repair

Transmission Manual:

Clutch system, gearbox assembly, shift linkages, internal components, fluid specifications

Transmission Automatic:

Automatic transaxle assembly, valve body, torque converter, transmission control module (TCM) diagnosis, fluid specifications

Drivetrain:

Front-wheel drive system, axles, CV joints, differential

Suspension:

Front and rear suspension systems (e.g., MacPherson strut front, multi-link rear), springs, shock absorbers, control arms, stabilizer bars, alignment procedures

Steering:

Power steering system (hydraulic), steering rack, power steering pump, steering column, wheel alignment

Brakes:

Front and rear brake systems (disc/drum or disc/disc depending on trim), hydraulic system, ABS (Anti-lock Braking System) operation and diagnosis, parking brake

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting system (headlights, taillights, interior), horn, power windows, power locks, mirrors, wipers, washers

Body And Chassis:

Body panel removal and installation, interior trim, exterior trim, doors, hood, trunk, bumpers, glass, chassis structure, corrosion protection

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant handling, compressor, condenser, evaporator, heater core, controls

Interior Systems:

Seats, seat belts, airbags (SRS - Supplemental Restraint System), dashboard, instrument cluster, audio system, climate controls

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks/changes), spark plug replacement, belt inspection/replacement, brake pad replacement, tire rotation

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), using diagnostic scan tools, electrical circuit testing

Repair:

Detailed step-by-step repair procedures for all major components and systems, including engine overhauls, transmission rebuilds, suspension component replacement, brake system repairs

Rebuilding:

Procedures for rebuilding major assemblies like engines, transmissions, and steering racks, often including specifications for machining and component replacement

Restoration:

Guidance for bringing older vehicles back to original or improved condition, including bodywork, paint, interior refurbishment, and mechanical overhauls

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, essential for diagnosing electrical faults

Technical Depth

Depth Level:

Factory-level technical detail, suitable for professional technicians and advanced DIY enthusiasts

Data Accuracy:

Precise torque specifications, clearances, fluid capacities, and diagnostic data derived directly from Mazda factory specifications

Illustrations:

Detailed diagrams, schematics, and exploded views illustrating component locations and assembly procedures

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval

Printability:

Printable pages for on-the-job use

Print Quality

Image Resolution:

High-resolution images and diagrams

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Manual Completeness

Completeness:

Comprehensive coverage, encompassing all major systems and repair procedures for the specified model year.

⚙️ Engine Specifications

Primary Engine

Engine Family:

FS-DE / FS-Z

Displacement:

2.0 Liters (1991 cc)

Configuration:

Inline 4-cylinder, DOHC, 16 valves

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Performance

Horsepower Std:

Approx. 120-130 hp (depending on sub-model/market)

Torque Std:

Approx. 130-135 lb-ft

Redline:

Approximately 6500 RPM

Fuel System

Fuel Type:

Unleaded Gasoline (87 octane minimum recommended)

Fuel Tank Capacity:

Approximately 13.2 US gallons (50 Liters)

🔧 Transmission

Standard

Type:

5-speed Manual Transaxle

Optional

Type:

4-speed Automatic Transaxle

Features

Manual Fluid Type:

GL-4 Gear Oil (e.g., SAE 75W-90)

Automatic Fluid Type:

Mazda ATF-Type M-III or equivalent

📐 Dimensions

Exterior

Length:

Approx. 171.7 inches (Sedan)

Width:

Approx. 67.7 inches

Height:

Approx. 55.7 inches (Sedan)

Wheelbase:

Approx. 102.7 inches

Ground Clearance:

Varies, but typically around 5.0 - 5.5 inches

Weights

Curb Weight:

Approx. 2600 - 2900 lbs (depending on trim and transmission)

Cargo

Trunk Volume:

Approx. 12.0 - 13.0 cubic feet (Sedan)

Hatchback Volume:

Approx. 18.0 - 35.0 cubic feet (with rear seats folded)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Driver: 4 stars, Passenger: 4 stars (for 2004 model year)

IIHS Side Impact:

Good (for vehicles tested)

Active Features

Available (standard on higher trims)

Traction Control:

Not commonly available on this model year

Passive Features

Airbags:

Front driver and passenger airbags standard. Side airbags available on some trims.

Seatbelts:

Three-point seatbelts with pretensioners in the front.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system in rear seats.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player. Optional premium audio system may be available.

Display:

Basic digital or analog displays for climate control and audio. No integrated navigation or large touchscreen on standard models.

Driver Assistance

Cruise Control:

Available on most trims.

Connectivity

Aux Input:

Not standard. Aftermarket solutions may be available.

Bluetooth:

Not available on factory systems for this model year.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 miles or 6-12 months, depending on driving conditions (refer to manual for specifics).

Engine Air Filter:

Inspect every 15,000 miles, replace as needed (typically every 30,000 miles).

Cabin Air Filter:

Replace annually or every 15,000 miles (if equipped).

Spark Plugs:

Replace every 60,000 - 100,000 miles (depending on plug type, e.g., Iridium).

Transmission Fluid Change:

Automatic: Every 30,000 - 50,000 miles. Manual: Inspect at 60,000 miles, replace as needed.

Coolant Replacement:

Replace every 30,000 - 50,000 miles or 2-4 years.

Fluid Specifications

Engine Oil Spec:

API SN/SP or ILSAC GF-5/GF-6A, SAE 5W-20 or 5W-30 (verify owner's manual for exact recommendation).

Coolant Spec:

Mazda FL22 Long Life Coolant or equivalent (a P-HOAT type).

Brake Fluid Spec:

DOT 3 or DOT 4.

Known Issues

Engine Mounts:

Can degrade over time, leading to increased vibration.

Exhaust Manifold Cracks:

Some FS-DE engines experienced exhaust manifold cracking due to heat cycles.

Oil Leaks:

Valve cover gasket and oil pan gasket can be common leak points.

Suspension Components:

Worn control arm bushings, ball joints, and sway bar links are common wear items.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Known for 'Zoom-Zoom' marketing emphasizing driving pleasure, sporty handling, and innovative design.

Model Evolution

Generation:

Second Generation (2003-2003.5) - though the 2004 model falls into the later part of this generation's lifecycle with minor updates.

Predecessor:

First generation Mazda Protege (1990-1997).

Successor:

Mazda3 (introduced for the 2004 model year in some markets, replaced the Protege line).

Production

Manufacturing Location:

Hofu, Yamaguchi, Japan.

Production Years:

1990-2003 (global, with the '2003.5' update for North America leading into the Mazda3).

🏆 Awards & Recognition

Recognitions

Car And Driver:

Often received positive mentions for handling and value in Car and Driver's annual '10Best' lists during its production run.