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1997-2005 Mazda Protege Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Model Generations Covered: Third Generation (BJ Series) Year Range: 1997-2005 Codes Chassis Code Primary: BJ 👋 Introduction Market Position Segment: Compact Car Target Audience: DIY mechanics, professional repair shops, Mazda owners Competitive Analysis Competitors: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Subaru Impreza Key Features Vehicle Strengths: Reliability, Fuel efficiency, Sporty handling (especially Mazdaspeed variants), Affordability Manual Value Proposition: Empowers owners and technicians with detailed repair procedures, diagnostic information, and specifications to maintain and repair the vehicle efficiently and accurately. 📋 Manual Details Coverage Areas Global Coverage: North America (USDM, CNDM), Global Markets Page Count Estimated Page Count: 2000+ Manual Type Type: Workshop Service Repair Manual Language Primary Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (mechanical, lubrication, cooling, fuel, ignition, exhaust), Transmission (manual, automatic), Drivetrain (FWD, AWD) Chassis: Suspension (front, rear), Steering, Brakes (hydraulic, parking), Wheels, Tires Electrical: Body electrical, Lighting, Instrumentation, Powertrain control, Chassis control, HVAC control, Audio systems, Wiring diagrams Body And Interior: Exterior body panels, Doors, Windows, Seats, Trim, HVAC components, Safety restraints Procedures Included Maintenance: Scheduled maintenance, Fluid changes, Filter replacements, Tune-ups Diagnostics: Symptom-based troubleshooting, Diagnostic trouble codes (DTCs), Component testing Repair: Component removal, Installation, Adjustment, Overhaul procedures Specifications: Torque specifications, Gapping specifications, Pressures, Tolerances Technical Depth Depth: Comprehensive (from basic maintenance to complete engine/transmission rebuilds) 📊 Manual Specifications File Format File Type: PDF Searchability: Full text searchable Printability: Printable Print Quality Resolution: High-resolution (suitable for clear viewing of diagrams and text) Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code Common: FS (2.0L DOHC) Engine Displacement: 1991 cc (2.0 Liters) Engine Configuration: Inline 4-cylinder Engine Type: Naturally Aspirated (standard), Turbocharged (Mazdaspeed) Performance Horsepower Fs 2.0: 126-130 hp @ 5500-6000 rpm Torque Fs 2.0: 135-135 lb-ft @ 4000-4500 rpm Horsepower Fs Det 2.0 Turbo: 170 hp @ 5500 rpm (Mazdaspeed) Torque Fs Det 2.0 Turbo: 170 lb-ft @ 2500 rpm (Mazdaspeed) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 AKI recommended) Engine Features Valvetrain: DOHC, 16-valve (4 valves per cylinder) Engine Management: EC-AT (Electronic Controlled Automatic Transmission), ECU (Electronic Control Unit) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (Type-B, FS5A-EL) Optional Transmission Type Optional: 4-speed Automatic Transmission (Type-F, FS5A-EL) Features Clutch Type: Hydraulically actuated dry single plate clutch Automatic Transmission Modes: Normal, Power (on some models) Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 Automatic Transmission Fluid: Mazda ATF JWS3317 or equivalent (Dexron III/Mercon compatible for earlier models) 📐 Dimensions Exterior Wheelbase: Approx. 102.7 inches (2609 mm) Length: Approx. 171.7 - 175.0 inches (4360 - 4445 mm) Width: Approx. 67.7 inches (1720 mm) Height: Approx. 55.5 - 56.3 inches (1410 - 1430 mm) Weights Curb Weight Range: Approx. 2600 - 2900 lbs (1180 - 1315 kg) Gross Vehicle Weight Rating: Varies by model/trim, refer to VIN plate 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4-Star (for most models) NHTSA Front Impact Passenger: 4-Star (for most models) Active Features ABS: Standard on most higher trims and later model years Traction Control: Optional on some models, standard on Mazdaspeed Turbo Passive Features Airbags: Driver and Passenger front airbags standard; optional side airbags on later models Seatbelts: 3-point front and rear seatbelts with pretensioners and load limiters Child Seat Anchors: LATCH system (Lower Anchors and Tethers for Children) on rear seats (introduced mid-generation) 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD or Cassette players, optional premium audio systems (Bose on some higher trims) Speaker Configuration: Typically 4-6 speakers, optional subwoofer in some models Driver Assistance Cruise Control: Available on most models, standard on higher trims Connectivity Power Accessories: Power windows, power door locks, power mirrors available on higher trims Keyless Entry: Optional on many models 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles (8,000 km) or 6 months, whichever comes first (refer to manual for specific conditions) Engine Oil Filter Replacement: With every oil change Engine Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) Spark Plug Replacement: Every 30,000-100,000 miles (48,000-160,000 km) depending on plug type (standard copper vs. platinum/iridium) Coolant Flush: Every 30,000-60,000 miles (48,000-96,000 km) Timing Belt Replacement: Crucial! Every 60,000-90,000 miles (96,000-144,000 km) for FS engines (non-interference). Fluid Specifications Engine Oil Capacity: Approx. 4.0-4.5 Quarts (3.8-4.3 Liters) with filter change (refer to manual for exact capacity) Engine Oil Viscosity: 5W-30 API SG or higher (check manual for climate variations) Coolant Type: Mazda Genuine Long Life Coolant (FL22) or equivalent (typically Asian Green) Brake Fluid Type: DOT 3 or DOT 4 Known Issues Common Wear Items: Clutch wear (manual transmission), CV joint boots, O2 sensors, Catalytic converter (older models), Radiator hoses Engine Specific Concerns: Intake manifold gasket leaks (FS engine), timing belt maintenance is critical to prevent catastrophic engine damage if it breaks....
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1997-2005 Mazda Protege Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Model Generations Covered:
Third Generation (BJ Series)
Year Range:
1997-2005
Codes
Chassis Code Primary:
BJ
👋 Introduction
Market Position
Segment:
Compact Car
Target Audience:
DIY mechanics, professional repair shops, Mazda owners
Competitive Analysis
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Subaru Impreza
Key Features
Vehicle Strengths:
Reliability, Fuel efficiency, Sporty handling (especially Mazdaspeed variants), Affordability
Manual Value Proposition:
Empowers owners and technicians with detailed repair procedures, diagnostic information, and specifications to maintain and repair the vehicle efficiently and accurately.
📋 Manual Details
Coverage Areas
Global Coverage:
North America (USDM, CNDM), Global Markets
Page Count
Estimated Page Count:
2000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Primary Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (mechanical, lubrication, cooling, fuel, ignition, exhaust), Transmission (manual, automatic), Drivetrain (FWD, AWD)
Chassis:
Suspension (front, rear), Steering, Brakes (hydraulic, parking), Wheels, Tires
Electrical:
Body electrical, Lighting, Instrumentation, Powertrain control, Chassis control, HVAC control, Audio systems, Wiring diagrams
Body And Interior:
Exterior body panels, Doors, Windows, Seats, Trim, HVAC components, Safety restraints
Procedures Included
Maintenance:
Scheduled maintenance, Fluid changes, Filter replacements, Tune-ups
Diagnostics:
Symptom-based troubleshooting, Diagnostic trouble codes (DTCs), Component testing
Repair:
Component removal, Installation, Adjustment, Overhaul procedures
Specifications:
Torque specifications, Gapping specifications, Pressures, Tolerances
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Full text searchable
Printability:
Printable
Print Quality
Resolution:
High-resolution (suitable for clear viewing of diagrams and text)
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
FS (2.0L DOHC)
Engine Displacement:
1991 cc (2.0 Liters)
Engine Configuration:
Inline 4-cylinder
Engine Type:
Naturally Aspirated (standard), Turbocharged (Mazdaspeed)
Performance
Horsepower Fs 2.0:
126-130 hp @ 5500-6000 rpm
Torque Fs 2.0:
135-135 lb-ft @ 4000-4500 rpm
Horsepower Fs Det 2.0 Turbo:
170 hp @ 5500 rpm (Mazdaspeed)
Torque Fs Det 2.0 Turbo:
170 lb-ft @ 2500 rpm (Mazdaspeed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 AKI recommended)
Engine Features
Valvetrain:
DOHC, 16-valve (4 valves per cylinder)
Engine Management:
EC-AT (Electronic Controlled Automatic Transmission), ECU (Electronic Control Unit)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (Type-B, FS5A-EL)
Optional
Transmission Type Optional:
4-speed Automatic Transmission (Type-F, FS5A-EL)
Features
Clutch Type:
Hydraulically actuated dry single plate clutch
Automatic Transmission Modes:
Normal, Power (on some models)
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90
Automatic Transmission Fluid:
Mazda ATF JWS3317 or equivalent (Dexron III/Mercon compatible for earlier models)
📐 Dimensions
Exterior
Wheelbase:
Approx. 102.7 inches (2609 mm)
Length:
Approx. 171.7 - 175.0 inches (4360 - 4445 mm)
Width:
Approx. 67.7 inches (1720 mm)
Height:
Approx. 55.5 - 56.3 inches (1410 - 1430 mm)
Weights
Curb Weight Range:
Approx. 2600 - 2900 lbs (1180 - 1315 kg)
Gross Vehicle Weight Rating:
Varies by model/trim, refer to VIN plate
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4-Star (for most models)
NHTSA Front Impact Passenger:
4-Star (for most models)
Active Features
ABS:
Standard on most higher trims and later model years
Traction Control:
Optional on some models, standard on Mazdaspeed Turbo
Passive Features
Airbags:
Driver and Passenger front airbags standard; optional side airbags on later models
Seatbelts:
3-point front and rear seatbelts with pretensioners and load limiters
Child Seat Anchors:
LATCH system (Lower Anchors and Tethers for Children) on rear seats (introduced mid-generation)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette players, optional premium audio systems (Bose on some higher trims)
Speaker Configuration:
Typically 4-6 speakers, optional subwoofer in some models
Driver Assistance
Cruise Control:
Available on most models, standard on higher trims
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors available on higher trims
Keyless Entry:
Optional on many models
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (refer to manual for specific conditions)
Engine Oil Filter Replacement:
With every oil change
Engine Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km)
Spark Plug Replacement:
Every 30,000-100,000 miles (48,000-160,000 km) depending on plug type (standard copper vs. platinum/iridium)
Coolant Flush:
Every 30,000-60,000 miles (48,000-96,000 km)
Timing Belt Replacement:
Crucial! Every 60,000-90,000 miles (96,000-144,000 km) for FS engines (non-interference).
Fluid Specifications
Engine Oil Capacity:
Approx. 4.0-4.5 Quarts (3.8-4.3 Liters) with filter change (refer to manual for exact capacity)
Engine Oil Viscosity:
5W-30 API SG or higher (check manual for climate variations)
Coolant Type:
Mazda Genuine Long Life Coolant (FL22) or equivalent (typically Asian Green)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear (manual transmission), CV joint boots, O2 sensors, Catalytic converter (older models), Radiator hoses
Engine Specific Concerns:
Intake manifold gasket leaks (FS engine), timing belt maintenance is critical to prevent catastrophic engine damage if it breaks.
Suspension Concerns:
Worn front and rear struts/shocks, stabilizer bar links
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Zoom-Zoom driving dynamics, Jinba-Ittai (horse and rider as one)
Model Evolution
Generation Introduction:
Third generation (BJ) introduced for the 1998 model year in North America, replacing the BG generation.
Mid-Cycle Refresh:
Facelifted for the 2001 model year with revised styling, interior, and optional equipment.
Mazdaspeed Variant:
Introduced for the 2003 model year, featuring a turbocharged 2.0L engine, sport-tuned suspension, and unique styling.
Production
Manufacturing Locations:
Japan (primarily), Mexico (some units)
🏆 Awards & Recognition
Recognitions
Automotive Journal Awards:
Consistently rated well for value, reliability, and driving dynamics by automotive publications like Car and Driver, MotorTrend during its production run.
Safety Ratings:
Generally received good marks in NHTSA crash testing for its era.
Certifications
Emissions Compliance:
Meets EPA and CARB emissions standards for its respective model years.
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