Mazda Protege 1998-2003 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mazda Model: Protegé Years Covered: 1998, 1999, 2000, 2001, 2002, 2003 Codes Platform Code: BJ (Third Generation) 👋 Introduction Market Position Vehicle Segment: Compact Car Target Demographic: Young drivers, budget-conscious buyers, families Competitive Analysis Key Rivals: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Hyundai Elantra Key Features Distinguishing Features: Sporty handling (especially Mazdaspeed), reliable engines, practical interior, good value for money Target Audience Benefit: Empowers DIY mechanics and professional technicians with the detailed information needed for efficient and accurate repairs. 📋 Manual Details Coverage Areas Description: Comprehensive coverage for all mechanical, electrical, and body systems. Page Count Approximate Pages: 2000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: 1.6L ZM-DE I4, 1.8L BP-Z3 I4, 2.0L FS-DE I4 (including MP3 and Mazdaspeed variants) Transmission: 5-speed manual, 4-speed automatic Suspension: Front MacPherson struts, Rear multi-link beam axle (FWD), independent rear suspension (AWD) Brakes: Front disc, Rear disc (standard), ABS system Electrical: Wiring diagrams, lighting, power accessories, starting and charging, diagnostics HVAC: Air conditioning, heating, ventilation system repair and diagnostics Body: Exterior and interior body panel removal and installation, structural repair, glass replacement Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt adjustments Diagnostics: Troubleshooting guides for common and uncommon problems, diagnostic trouble codes (DTCs) Repair: Engine component removal and installation, transmission overhaul, brake caliper rebuild, suspension component replacement Component Overhaul: Detailed instructions for rebuilding major components like engines and transmissions Technical Depth Depth: Comprehensive (from basic maintenance to complete engine/transmission rebuilds and advanced electrical diagnostics) 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text content Print Quality Resolution: High-resolution scans, suitable for printing Binding Type Binding Method: N/A (Digital PDF download) Paper Type Paper Quality: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 1.6 Liters Engine 1 Type: ZM-DE DOHC I4 Engine 1 Power: Approx. 105 hp @ 6000 rpm Engine 1 Torque: Approx. 105 lb-ft @ 4000 rpm Secondary Engine Engine 2 Displacement: 1.8 Liters Engine 2 Type: BP-Z3 DOHC I4 Engine 2 Power: Approx. 120 hp @ 6000 rpm Engine 2 Torque: Approx. 125 lb-ft @ 4000 rpm Tertiary Engine Engine 3 Displacement: 2.0 Liters Engine 3 Type: FS-DE DOHC I4 Engine 3 Power: Approx. 127-130 hp @ 6000 rpm (standard), 170 hp @ 6600 rpm (Mazdaspeed) Engine 3 Torque: Approx. 135 lb-ft @ 4000 rpm (standard), 145 lb-ft @ 4000 rpm (Mazdaspeed) Performance Fuel Type: Unleaded gasoline Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Engine Features Timing Drive: Timing belt (ZM-DE, BP-Z3), Timing chain (FS-DE) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Optional Transmission Type Optional: 4-speed Automatic Features Clutch Type: Hydraulically actuated single dry plate clutch Fluid Specs Automatic Transmission Fluid: Dexron III or equivalent (Check specific year/model for exact specification) Manual Transmission Fluid: GL-4 Gear Oil, SAE 75W-90 (Check specific year/model for exact specification) 📐 Dimensions Exterior Wheelbase: Approx. 102.7 inches (2606 mm) Length: Approx. 171.5 inches (4356 mm) Width: Approx. 67.7 inches (1720 mm) Height: Approx. 55.7 inches (1415 mm) Interior Passenger Volume: Approx. 90 cubic feet Cargo Trunk Volume: Approx. 11-13 cubic feet (sedan) Weights Curb Weight Min: Approx. 2600 lbs (1180 kg) Curb Weight Max: Approx. 2800 lbs (1270 kg) Wheels Tires Wheel Bolt Pattern: 4x100 mm Tire Size Standard: 185/65R14, 195/55R15 (depending on trim and year) 🛡️ Safety Features Ratings NHTSA Frontal Driver: 4/5 stars (for applicable models) NHTSA Frontal Passenger: 4/5 stars (for applicable models) Active Features ABS: Available on higher trims and as an option Traction Control: Rarely available on this generation Passive Features Airbags: Driver and passenger front airbags standard Seatbelts: Three-point front and rear seatbelts 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with optional premium sound system Climate Control: Manual or automatic climate control systems Driver Assistance Cruise Control: Available on most higher trims Connectivity Auxiliary Input: Not standard, aftermarket options usually required 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles (8,000 km) or 6 months, whichever comes first (using quality oil) Air Filter Replacement: Every 15,000 miles (24,000 km) or annually Spark Plug Replacement: Every 30,000 miles (48,000 km) for standard plugs, 60,000 miles (96,000 km) for platinum (check manual) Timing Belt Replacement: Every 60,000 miles (96,000 km) or 4 years for ZM-DE and BP-Z3 engines Fluid Specifications Engine Oil Type: API SG, SH, or SJ certified SAE 5W-30 (check manual for specific viscosity and API rating) Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (Mazda Genuine Long Life Coolant or equivalent) Brake Fluid Type: DOT 3 or DOT 4 brake fluid Known Issues Engine Mounts: Premature wear on engine and transmission mounts can cause vibrations Power Steering Pump: Leaking power steering pumps and lines are a common concern Rear Wheel...