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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...
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Mazda Protege 1998-2003 Workshop Service Repair Manual
🏷️ 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 Bearings:
Can wear out and produce humming or grinding noises
Rust:
Susceptible to rust, especially in areas with harsh winters, on rocker panels, rear wheel arches, and frame components
📚 Vehicle History
Brand Heritage
Manufacturer:
Mazda Motor Corporation
Model Evolution
Generation:
Third Generation (BJ)
Previous Generation:
Mazda Protegé (BG) 1990-1994
Successor Generation:
Mazda3 (BK) 2003-2008
Production
Production Years:
1998-2003
Assembly Locations:
Japan, Mexico, Thailand (varies by market)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Protegé LX named to Car and Driver's 10Best list for 1999
Ratings
Ieda Crash Test:
Good rating in frontal offset crash tests by IIHS for some configurations
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