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Mazda PROTEGE Service & Repair Manual (2000 2001 2002 2003 2004)-PDF

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🏷️ Basic Information Identification Make: Mazda Model: Protegé Codes Production Years Covered: 2000, 2001, 2002, 2003, 2004 👋 Introduction Market Position Segment: Compact Sedan/Hatchback (Subcompact in some markets). Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Hyundai Elantra. Key Features Vehicle Strengths: Affordability, reliability, sporty handling (especially certain trims), good fuel economy, practical interior. Manual Purpose Target User: DIY mechanics, professional technicians, vehicle owners seeking in-depth knowledge. 📋 Manual Details Coverage Areas Engine Variants Covered: All engines for the specified production years Trim Levels Covered: All trim levels for the specified production years Page Count Estimated Pages: Extensive (Official Factory Service Manual, typically 1500+ pages) Manual Type Type: Complete Official Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, internal components (pistons, rings, bearings, crankshaft, camshafts), cylinder head, valve train, timing components, lubrication system, cooling system, fuel injection system, emissions control systems. Engine Performance: Engine specifications, diagnostics, troubleshooting, performance tuning basics. Transmission Manual: Manual transmission removal/installation, internal components, clutch system, shift linkage, maintenance, diagnostics. Transmission Automatic: Automatic transmission removal/installation, torque converter, internal components, transmission control system, maintenance, diagnostics, fluid specifications. Drivetrain: Front-wheel drive system, CV joints, drive axles, differential components, wheel bearings, hub assemblies. Suspension: Front suspension (struts, control arms, ball joints, sway bar), rear suspension (shock absorbers, springs, trailing arms, bushings), wheel alignment specifications, troubleshooting. Steering: Steering rack, power steering pump, steering column, tie rods, troubleshooting. Brakes: Front and rear brake systems (discs, calipers, pads, rotors), parking brake, ABS system (if equipped), brake fluid specifications, troubleshooting, bleeding procedures. Electrical System: Battery, starting system, charging system (alternator), ignition system, lighting systems (headlights, taillights, interior), horn, wipers, power windows, power locks. Engine Control Module ECM: ECM diagnostics, sensor inputs/outputs, wiring diagrams, troubleshooting strategies for engine performance issues. Body And Interior: Body panel removal/installation, door mechanisms, interior trim, seats, dashboard, weatherstripping, body repair basics. Heating Ventilation And Air Conditioning HVAC: HVAC system components (compressor, condenser, evaporator, blower motor), refrigerant specifications, troubleshooting, component testing. Safety Systems: Airbag system (SRS) components, diagnostics, disabling/enabling procedures, seatbelt systems. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotation, brake inspection. Diagnostic Procedures: Step-by-step troubleshooting guides for common and uncommon issues, diagnostic trouble code (DTC) interpretation and resolution. Repair Procedures: Detailed instructions for component removal, replacement, and reassembly for all major systems. Overhaul Procedures: Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly with specifications. Wiring Diagrams: Comprehensive electrical system wiring diagrams for all circuits, including component locations. Torque Specifications: Detailed torque specifications for all critical fasteners and components. Special Tools: Identification and usage instructions for any specialized tools required for specific procedures. Technical Depth Depth: Comprehensive: Covers everything from basic scheduled maintenance and fluid checks to complete engine and transmission rebuilds, complex electrical diagnostics, and body repair. 📊 Manual Specifications File Format Quality: High-resolution PDF, typically searchable and printable. Print Quality Printability: Designed for printing specific sections or the entire manual, often with booklet printing options. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code Common: FS-DE (2.0L Inline-4 DOHC) Displacement Common: 1991 cc (2.0 Liters) Performance Horsepower 2003 2003 Fs-De: 130 hp @ 5400 rpm Torque 2003 2003 Fs-De: 135 lb-ft @ 4000 rpm Engine Code Mp3 Mazdaspeed: FS-DET (2.0L Turbocharged Inline-4 DOHC) Horsepower Mp3 Mazdaspeed: 170 hp @ 5500 rpm (MP3), 170 hp @ 5500 rpm (Mazdaspeed) Torque Mp3 Mazdaspeed: 170 lb-ft @ 3000 rpm (MP3), 170 lb-ft @ 3000 rpm (Mazdaspeed) Fuel System Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 Octane recommended for naturally aspirated) 🔧 Transmission Standard Type: 5-Speed Manual Transmission Optional Type: 4-Speed Automatic Transmission Features Automatic Features: Electronically controlled, Lock-up torque converter. 📐 Dimensions Exterior Wheelbase Approx: 102.8 inches (2611 mm) Length Approx: 172.0 - 174.0 inches (4369 - 4420 mm) Width Approx: 67.5 - 68.3 inches (1715 - 1735 mm) Height Approx: 55.1 - 56.3 inches (1400 - 1430 mm) Weights Curb Weight Approx: 2600 - 2900 lbs (1180 - 1315 kg), varies by trim and transmission 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (for comparable models of the era) NHTSA Front Impact Passenger: Good (for comparable models of the era) IIHS Side Impact: Acceptable/Good (depending on specific year and equipment) Active Features ABS: Available on higher trims, standard on some later models. Passive Features Airbags: Driver and passenger front airbags standard. Side airbags optional on some trims. Seatbelts: 3-point front seatbelts with pretensioners, 3-point rear seatbelts. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM stereo with CD player and cassette (early models), premium sound system optional on some trims. Climate Control: Manual or automatic climate control systems depending on trim level. Driver Assistance Cruise Control: Standard or...
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Mazda PROTEGE Service & Repair Manual (2000 2001 2002 2003 2004)-PDF
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protegé
Codes
Production Years Covered:
2000, 2001, 2002, 2003, 2004
👋 Introduction
Market Position
Segment:
Compact Sedan/Hatchback (Subcompact in some markets).
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Hyundai Elantra.
Key Features
Vehicle Strengths:
Affordability, reliability, sporty handling (especially certain trims), good fuel economy, practical interior.
Manual Purpose
Target User:
DIY mechanics, professional technicians, vehicle owners seeking in-depth knowledge.
📋 Manual Details
Coverage Areas
Engine Variants Covered:
All engines for the specified production years
Trim Levels Covered:
All trim levels for the specified production years
Page Count
Estimated Pages:
Extensive (Official Factory Service Manual, typically 1500+ pages)
Manual Type
Type:
Complete Official Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine removal/installation, internal components (pistons, rings, bearings, crankshaft, camshafts), cylinder head, valve train, timing components, lubrication system, cooling system, fuel injection system, emissions control systems.
Engine Performance:
Engine specifications, diagnostics, troubleshooting, performance tuning basics.
Transmission Manual:
Manual transmission removal/installation, internal components, clutch system, shift linkage, maintenance, diagnostics.
Transmission Automatic:
Automatic transmission removal/installation, torque converter, internal components, transmission control system, maintenance, diagnostics, fluid specifications.
Drivetrain:
Front-wheel drive system, CV joints, drive axles, differential components, wheel bearings, hub assemblies.
Suspension:
Front suspension (struts, control arms, ball joints, sway bar), rear suspension (shock absorbers, springs, trailing arms, bushings), wheel alignment specifications, troubleshooting.
Steering:
Steering rack, power steering pump, steering column, tie rods, troubleshooting.
Brakes:
Front and rear brake systems (discs, calipers, pads, rotors), parking brake, ABS system (if equipped), brake fluid specifications, troubleshooting, bleeding procedures.
Electrical System:
Battery, starting system, charging system (alternator), ignition system, lighting systems (headlights, taillights, interior), horn, wipers, power windows, power locks.
Engine Control Module ECM:
ECM diagnostics, sensor inputs/outputs, wiring diagrams, troubleshooting strategies for engine performance issues.
Body And Interior:
Body panel removal/installation, door mechanisms, interior trim, seats, dashboard, weatherstripping, body repair basics.
Heating Ventilation And Air Conditioning HVAC:
HVAC system components (compressor, condenser, evaporator, blower motor), refrigerant specifications, troubleshooting, component testing.
Safety Systems:
Airbag system (SRS) components, diagnostics, disabling/enabling procedures, seatbelt systems.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotation, brake inspection.
Diagnostic Procedures:
Step-by-step troubleshooting guides for common and uncommon issues, diagnostic trouble code (DTC) interpretation and resolution.
Repair Procedures:
Detailed instructions for component removal, replacement, and reassembly for all major systems.
Overhaul Procedures:
Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly with specifications.
Wiring Diagrams:
Comprehensive electrical system wiring diagrams for all circuits, including component locations.
Torque Specifications:
Detailed torque specifications for all critical fasteners and components.
Special Tools:
Identification and usage instructions for any specialized tools required for specific procedures.
Technical Depth
Depth:
Comprehensive: Covers everything from basic scheduled maintenance and fluid checks to complete engine and transmission rebuilds, complex electrical diagnostics, and body repair.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, typically searchable and printable.
Print Quality
Printability:
Designed for printing specific sections or the entire manual, often with booklet printing options.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Quality:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
FS-DE (2.0L Inline-4 DOHC)
Displacement Common:
1991 cc (2.0 Liters)
Performance
Horsepower 2003 2003 Fs-De:
130 hp @ 5400 rpm
Torque 2003 2003 Fs-De:
135 lb-ft @ 4000 rpm
Engine Code Mp3 Mazdaspeed:
FS-DET (2.0L Turbocharged Inline-4 DOHC)
Horsepower Mp3 Mazdaspeed:
170 hp @ 5500 rpm (MP3), 170 hp @ 5500 rpm (Mazdaspeed)
Torque Mp3 Mazdaspeed:
170 lb-ft @ 3000 rpm (MP3), 170 lb-ft @ 3000 rpm (Mazdaspeed)
Fuel System
Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane recommended for naturally aspirated)
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission
Optional
Type:
4-Speed Automatic Transmission
Features
Automatic Features:
Electronically controlled, Lock-up torque converter.
📐 Dimensions
Exterior
Wheelbase Approx:
102.8 inches (2611 mm)
Length Approx:
172.0 - 174.0 inches (4369 - 4420 mm)
Width Approx:
67.5 - 68.3 inches (1715 - 1735 mm)
Height Approx:
55.1 - 56.3 inches (1400 - 1430 mm)
Weights
Curb Weight Approx:
2600 - 2900 lbs (1180 - 1315 kg), varies by trim and transmission
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for comparable models of the era)
NHTSA Front Impact Passenger:
Good (for comparable models of the era)
IIHS Side Impact:
Acceptable/Good (depending on specific year and equipment)
Active Features
ABS:
Available on higher trims, standard on some later models.
Passive Features
Airbags:
Driver and passenger front airbags standard. Side airbags optional on some trims.
Seatbelts:
3-point front seatbelts with pretensioners, 3-point rear seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player and cassette (early models), premium sound system optional on some trims.
Climate Control:
Manual or automatic climate control systems depending on trim level.
Driver Assistance
Cruise Control:
Standard or optional on most models.
Connectivity
Power Features:
Power windows, power door locks, power mirrors available on most trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first. Consult manual for exact recommendation based on driving conditions.
Spark Plug Replacement:
Approximately 60,000-100,000 miles (96,000-160,000 km) depending on spark plug type (copper vs. platinum/iridium).
Transmission Fluid Change Auto:
Every 30,000-50,000 miles (48,000-80,000 km), or more frequently under severe use. Crucial for longevity.
Transmission Fluid Change Manual:
Inspect and change as needed, typically around 60,000-100,000 miles (96,000-160,000 km) for longevity.
Fluid Specifications
Engine Oil Type:
API SJ or higher, SAE 5W-30 is common. Always check manual for specific viscosity and certification.
Engine Oil Capacity:
Approx. 4.0 - 4.5 US quarts (3.8 - 4.3 Liters) with filter. Check manual for exact capacity.
Coolant Type:
Mazda Genuine Super Long Life Coolant (Blue) or equivalent silicate-free, ethylene glycol-based coolant.
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid:
Dexron III ATF or equivalent is often specified, but check manual for precise specification.
Known Issues
Ignition Coils:
Premature failure of ignition coils can lead to misfires and poor performance.
Oxygen Sensors:
Can fail over time, impacting fuel economy and emissions.
Automatic Transmission Issues:
Can sometimes develop harsh shifting or slipping if not properly maintained.
Wheel Bearing Wear:
Front wheel bearings can wear out, causing humming or grinding noises.
Cv Joint Boots:
Torn CV joint boots can lead to premature failure of the joints due to loss of lubrication and ingress of dirt.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Focus on driving dynamics ('Jinba Ittai' - horse and rider as one), affordability, and innovative design.
Model Evolution
Generation Details:
This refers to the second generation (BJ chassis) of the Mazda Protegé, a significant redesign from the previous model.
Production
Manufacturing Locations:
Primary manufacturing in Hofu, Yamaguchi, Japan; some assembly may have occurred in other locations globally.
🏆 Awards & Recognition
Recognitions
Consumer Reports:
Generally rated as average to above-average for reliability during its production years, with some years excelling.
Ratings
Jdp Power Initial Quality:
Often performed well in J.D. Power and Associates Initial Quality studies for its segment.
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