Mazda Protege 2000-2004 Workshop Repair Service Manual
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Basic Information Identification Make: Mazda Model: Protege Model Years Covered: 2000, 2001, 2002, 2003, 2004 Codes Chassis Codes: BJ Introduction Market Position Segment: Compact car, known for its sporty handling and reliable performance, positioned as an affordable and engaging option. Competitive Analysis Competitors: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra. Key Features Vehicle Strengths: Responsive handling, stylish (for its time) design, good fuel economy, availability of sportier trims like Mazdaspeed. Manual Value Proposition Utility For Owners: Empowers owners and independent mechanics with the detailed knowledge to perform maintenance, diagnostics, and repairs, saving on labor costs and ensuring proper upkeep. Manual Details Coverage Areas Coverage: All models and trims within the specified years, potentially including sedan, hatchback (Protege5), and Mazdaspeed Protege variants. Specific engine and transmission options are detailed. Page Count Estimated Pages: Over 1500 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Mechanical Systems: Engine mechanicals (including disassembly, assembly, inspection, and repair), cooling system, lubrication system, fuel system (injection, components), exhaust system, ignition system, starting and charging systems. Drivetrain Systems: Manual and automatic transmission overhaul, clutch system, drive axles, differential, propeller shaft (if applicable), wheel bearings. Suspension And Steering: Front and rear suspension components (struts, springs, control arms, bushings), steering gear, power steering system, alignment specifications. Braking Systems: Front and rear disc brakes, anti-lock braking system (ABS) components and diagnosis, parking brake, brake fluid specifications. Electrical Systems: Wiring diagrams for all circuits, lighting system, instrument cluster, power windows, door locks, wipers, horn, battery, alternator, starter motor, fuses, relays. Body And Chassis: Body panel removal/installation, interior trim, door mechanisms, hood, trunk, glass, bumpers, chassis component torque specifications. HVAC System: Air conditioning system diagnosis, repair, refrigerant types, blower motor, climate control panels. Procedures Included Maintenance Procedures: Oil change, filter replacement, coolant flush and replacement, spark plug replacement, air filter replacement, fuel filter replacement, brake pad/rotor replacement, belt inspection/replacement, battery maintenance. Diagnostic Procedures: Troubleshooting charts, fault code interpretation (OBD-II), symptom-based diagnostics for engine, transmission, ABS, and other systems. Repair Procedures: Step-by-step instructions for engine component repair, transmission overhaul, suspension component replacement, brake system repair, electrical component replacement, bodywork repairs. Technical Specifications: Torque values for all fasteners, engine timing specifications, valve clearances, fluid capacities and types, electrical component resistance and voltage readings, diagnostic specifications. Technical Depth Depth: Comprehensive, from basic scheduled maintenance to complete engine and transmission rebuilds, including in-depth electrical system diagnostics and troubleshooting. Manual Specifications File Format PDF Features: Searchable text, high-resolution diagrams, printable pages, bookmark navigation. Print Quality Diagram Resolution: Clear, detailed, and easy-to-understand technical drawings and schematics. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) Engine Specifications Primary Engine Engine 1 Code: FS-DE (2.0L DOHC) Engine 1 Displacement: 1991 cc Engine 1 Horsepower: 130 hp @ 5600 rpm (US Spec, may vary by year/market) Engine 1 Torque: 135 lb-ft @ 4400 rpm (US Spec, may vary by year/market) Engine 1 Bore X Stroke: 83.1 mm x 92.0 mm Engine 1 Compression Ratio: 9.1:1 Engine 2 Code Engine 2 Code: FS-ZE (2.0L DOHC - Mazdaspeed, higher output) Engine 2 Engine 2 Horsepower: 170 hp (Mazdaspeed Protege) Engine 2 Torque: 170 lb-ft (Mazdaspeed Protege) Engine 2 Induction: Turbocharged (Mazdaspeed Protege) Engine 3 Code Engine 3 Code: FP-DE (1.8L SOHC - some early models/markets) Engine 3 Engine 3 Displacement: 1839 cc Engine 3 Horsepower: 122 hp @ 6000 rpm Performance 0 60 Mph: Approx. 8.5-9.5 seconds (2.0L) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Recommended Octane: 87 (for FS-DE), 91+ (recommended for Mazdaspeed Turbo) Transmission Standard Transmission Type 1: 5-speed Manual Transmission Optional Transmission Type 2: 4-speed Automatic Transmission Features Transmission Fluid Type Auto: Mazda ATF M-III or equivalent (check manual for specific part number) Transmission Fluid Capacity Auto: Approx. 7.4 liters (total fill) Transmission Fluid Type Manual: API GL-4 or GL-5, SAE 75W-90 (check manual for specific part number) Transmission Fluid Capacity Manual: Approx. 2.2 liters Dimensions Exterior Length: Approx. 4425 mm (Sedan), 4350 mm (Hatchback) Width: Approx. 1705 mm Height: Approx. 1415 mm (Sedan), 1445 mm (Hatchback) Wheelbase: Approx. 2610 mm Ground Clearance: Approx. 150 mm Weights Curb Weight: Approx. 1200-1300 kg (depending on trim and transmission) Gross Vehicle Weight Rating Gvwr: Refer to VIN plate/manual for specific model Towing Capacity: Not typically recommended or specified for this class of vehicle Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (for certain model years/configurations) NHTSA Front Impact Passenger: 4 Stars (for certain model years/configurations) IIHS Frontal Offset Driver: Acceptable/Good (depending on specific year/test) Active Features ABS: Available on most trims, standard on higher trims Traction Control: Available on some later models/trims Passive Features Airbags Front: Driver and passenger front airbags standard Airbags Side: Optional or standard on higher trims...
Compact car, known for its sporty handling and reliable performance, positioned as an affordable and engaging option.
Competitive Analysis
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra.
Key Features
Vehicle Strengths:
Responsive handling, stylish (for its time) design, good fuel economy, availability of sportier trims like Mazdaspeed.
Manual Value Proposition
Utility For Owners:
Empowers owners and independent mechanics with the detailed knowledge to perform maintenance, diagnostics, and repairs, saving on labor costs and ensuring proper upkeep.
Manual Details
Coverage Areas
Coverage:
All models and trims within the specified years, potentially including sedan, hatchback (Protege5), and Mazdaspeed Protege variants. Specific engine and transmission options are detailed.
Page Count
Estimated Pages:
Over 1500 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
Manual Coverage
Systems Covered
Mechanical Systems:
Engine mechanicals (including disassembly, assembly, inspection, and repair), cooling system, lubrication system, fuel system (injection, components), exhaust system, ignition system, starting and charging systems.
Front and rear suspension components (struts, springs, control arms, bushings), steering gear, power steering system, alignment specifications.
Braking Systems:
Front and rear disc brakes, anti-lock braking system (ABS) components and diagnosis, parking brake, brake fluid specifications.
Electrical Systems:
Wiring diagrams for all circuits, lighting system, instrument cluster, power windows, door locks, wipers, horn, battery, alternator, starter motor, fuses, relays.
Body And Chassis:
Body panel removal/installation, interior trim, door mechanisms, hood, trunk, glass, bumpers, chassis component torque specifications.
HVAC System:
Air conditioning system diagnosis, repair, refrigerant types, blower motor, climate control panels.
Procedures Included
Maintenance Procedures:
Oil change, filter replacement, coolant flush and replacement, spark plug replacement, air filter replacement, fuel filter replacement, brake pad/rotor replacement, belt inspection/replacement, battery maintenance.
Diagnostic Procedures:
Troubleshooting charts, fault code interpretation (OBD-II), symptom-based diagnostics for engine, transmission, ABS, and other systems.
Repair Procedures:
Step-by-step instructions for engine component repair, transmission overhaul, suspension component replacement, brake system repair, electrical component replacement, bodywork repairs.
Technical Specifications:
Torque values for all fasteners, engine timing specifications, valve clearances, fluid capacities and types, electrical component resistance and voltage readings, diagnostic specifications.
Technical Depth
Depth:
Comprehensive, from basic scheduled maintenance to complete engine and transmission rebuilds, including in-depth electrical system diagnostics and troubleshooting.
Clear, detailed, and easy-to-understand technical drawings and schematics.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
Engine Specifications
Primary Engine
Engine 1 Code:
FS-DE (2.0L DOHC)
Engine 1 Displacement:
1991 cc
Engine 1 Horsepower:
130 hp @ 5600 rpm (US Spec, may vary by year/market)
Engine 1 Torque:
135 lb-ft @ 4400 rpm (US Spec, may vary by year/market)
Engine 1 Bore X Stroke:
83.1 mm x 92.0 mm
Engine 1 Compression Ratio:
9.1:1
Engine 2 Code
Engine 2 Code:
FS-ZE (2.0L DOHC - Mazdaspeed, higher output)
Engine 2
Engine 2 Horsepower:
170 hp (Mazdaspeed Protege)
Engine 2 Torque:
170 lb-ft (Mazdaspeed Protege)
Engine 2 Induction:
Turbocharged (Mazdaspeed Protege)
Engine 3 Code
Engine 3 Code:
FP-DE (1.8L SOHC - some early models/markets)
Engine 3
Engine 3 Displacement:
1839 cc
Engine 3 Horsepower:
122 hp @ 6000 rpm
Performance
0 60 Mph:
Approx. 8.5-9.5 seconds (2.0L)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Recommended Octane:
87 (for FS-DE), 91+ (recommended for Mazdaspeed Turbo)
Transmission
Standard
Transmission Type 1:
5-speed Manual Transmission
Optional
Transmission Type 2:
4-speed Automatic Transmission
Features
Transmission Fluid Type Auto:
Mazda ATF M-III or equivalent (check manual for specific part number)
Transmission Fluid Capacity Auto:
Approx. 7.4 liters (total fill)
Transmission Fluid Type Manual:
API GL-4 or GL-5, SAE 75W-90 (check manual for specific part number)
Transmission Fluid Capacity Manual:
Approx. 2.2 liters
Dimensions
Exterior
Length:
Approx. 4425 mm (Sedan), 4350 mm (Hatchback)
Width:
Approx. 1705 mm
Height:
Approx. 1415 mm (Sedan), 1445 mm (Hatchback)
Wheelbase:
Approx. 2610 mm
Ground Clearance:
Approx. 150 mm
Weights
Curb Weight:
Approx. 1200-1300 kg (depending on trim and transmission)
Gross Vehicle Weight Rating Gvwr:
Refer to VIN plate/manual for specific model
Towing Capacity:
Not typically recommended or specified for this class of vehicle
Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (for certain model years/configurations)
NHTSA Front Impact Passenger:
4 Stars (for certain model years/configurations)
IIHS Frontal Offset Driver:
Acceptable/Good (depending on specific year/test)
Active Features
ABS:
Available on most trims, standard on higher trims
Traction Control:
Available on some later models/trims
Passive Features
Airbags Front:
Driver and passenger front airbags standard
Airbags Side:
Optional or standard on higher trims
Seatbelts:
Three-point seatbelts with pretensioners for front occupants
Technology Features
Infotainment
Head Unit:
Factory AM/FM/CD or Cassette player, with optional premium audio systems (e.g., Bose on some trims).
Speakers:
Typically 4-6 speakers, depending on trim level.
Driver Assistance
Cruise Control:
Available on most trims.
Instrument Cluster:
Analog gauges for speedometer, tachometer, fuel, and temperature. Some models feature digital odometers and trip computers.
Connectivity
Auxiliary Input:
Not standard; requires aftermarket modification.
Bluetooth:
Not available on factory systems; requires aftermarket integration.
Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe conditions may require shorter intervals.
Engine Oil Filter Replacement:
With every oil change
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Approx. 30,000-60,000 miles (48,000-96,000 km) depending on plug type (standard vs. platinum/iridium).
Coolant Replacement:
Initial replacement at 60,000 miles (96,000 km) or 5 years, then every 30,000 miles (48,000 km) or 2-3 years thereafter.
Timing Belt Replacement:
Crucial! This engine uses a timing belt. Recommended replacement at 60,000-100,000 miles (96,000-160,000 km) or 7-10 years. Failure can cause catastrophic engine damage (interference engine).
Fluid Specifications
Engine Oil Viscosity:
5W-30 (most common, check owner's manual for specific climate recommendations and part numbers)
Engine Oil Capacity:
Approx. 4.3 liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze (Mazda FL22 or equivalent blue/green coolant)
Brake Fluid Type:
DOT 3 or DOT 4 (check manual)
Power Steering Fluid Type:
Dexron II or equivalent ATF (check manual for exact specification)
Known Issues
Engine Mounts:
Can wear out over time, leading to increased vibration, especially at idle.
Automatic Transmission:
Some models may experience delayed shifting or harsh engagement; fluid and filter changes are critical. Transmission control module (TCM) issues are also possible.
Suspension Bushings:
Front and rear control arm bushings can degrade, causing clunking noises and poor handling.
Wheel Bearings:
Front wheel bearings can be a point of failure, leading to humming or grinding noises.
Exhaust Manifold:
Cracking in the exhaust manifold can lead to exhaust leaks and a ticking noise.
Ac Compressor:
AC compressors can fail over time; proper system maintenance is key.
Interior Trim Wear:
Plastic interior components can become brittle or faded with age.
Vehicle History
Brand Heritage
Mazda Philosophy:
Known for 'Zoom-Zoom' driving dynamics, focusing on driver engagement and sporty feel even in mainstream vehicles.
Model Evolution
Generation Code:
Third Generation (BJ Platform, 1998-2004 globally, 2000-2004 in North America)
Key Changes 2000 2004:
Introduction of the Protege5 hatchback variant (2002), introduction of the Mazdaspeed Protege performance variant (2003), subtle styling updates and feature enhancements throughout the model run.
Production
Manufacturing Locations:
Primarily Japan, but also Mexico and other global locations for various markets.
Awards & Recognition
Recognitions
Automotive Journal Awards:
While specific awards vary by year and region, the Protege was generally well-regarded for its handling and value.
Ratings
Consumer Reports Reliability:
Mixed to average reliability ratings for this generation, with common issues noted in transmissions and suspension components. The manual helps address these proactively.
Certifications
Emissions Standards:
Designed to meet prevailing emissions standards of its era (e.g., EPA in the US).