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Mazda Protege 2001-2003 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Model Years Covered: 2001, 2002, 2003 Generation Generation: BJ (Second Generation) Codes Chassis Codes: BJ3P (Sedan), BJ5W (Wagon) 👋 Introduction Market Position Segment: Compact Car Target Audience: Economy-minded buyers seeking reliable and practical transportation Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra Key Features Design Philosophy: Mazda's 'Zoom-Zoom' driving dynamics, practical interior, fuel efficiency Value Proposition Offering: Excellent value for money with a good balance of features, performance, and reliability 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for all aspects of the vehicle Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, cooling system, lubrication system, ignition system, exhaust system Transmission: Manual and automatic transmission service, repair, and diagnostics Drivetrain: Front-wheel drive, CV joints, drive axles, differentials Suspension: Front and rear suspension components, alignment, shock absorbers, springs Steering: Steering system components, power steering, steering column Brakes: Front and rear brakes (disc/drum), ABS system, parking brake Electrical: Battery, charging system, starting system, lighting, instruments, power accessories, body control modules HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Body And Trim: Exterior body panels, interior trim, doors, glass, seats Diagnostics: OBD-II diagnostics, trouble code (DTC) interpretation, symptom-based troubleshooting Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes, filter replacements, inspections Repair: Component removal and installation, adjustments, internal component repair Troubleshooting: Step-by-step diagnostic procedures for common and uncommon problems Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values Wiring Diagrams: Complete electrical system wiring diagrams for all major components and circuits Technical Depth Depth: Factory-level detail, suitable for professional technicians and advanced DIYers Diagnostic Tools: Includes information on required diagnostic tools and equipment Rebuild Procedures: Detailed procedures for engine and transmission rebuilding 📊 Manual Specifications File Format Compatibility: Compatible with all Windows versions, Linux, and macOS Print Quality Image Resolution: High-resolution, clear text and diagrams suitable for printing Binding Type Binding Type: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) File Features Searchability: Fully searchable text for quick information retrieval Distribution Delivery Method: Free Digital Download, No Shipping Costs ⚙️ Engine Specifications Primary Engine Engine Code 1: FS-DE (2.0L DOHC Inline-4) Displacement 1: 1991 cc Bore X Stroke 1: 83.0 mm x 92.0 mm Compression Ratio 1: 9.1:1 Horsepower 1: 130 hp @ 5500 rpm (approx.) Torque 1: 135 lb-ft @ 4000 rpm (approx.) Secondary Engine Engine Code 2: Z5-DE (1.5L DOHC Inline-4) - Primarily for base models/specific markets Displacement 2: 1498 cc Horsepower 2: 105 hp @ 6000 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline, 87 octane minimum Ignition System Ignition Type: Distributorless Ignition System (DIS) with coil-on-plug or coil pack 🔧 Transmission Standard Transmission Type 1: 5-Speed Manual Optional Transmission Type 2: 4-Speed Automatic (with Lock-up Torque Converter) Features Automatic Features: Electronically controlled, power/normal shift modes Fluid Spec Manual Transmission Fluid: API GL-4, SAE 75W-90 gear oil (check manual for exact specification) Automatic Transmission Fluid: Mazda ATF JWS3317 or equivalent (check manual for exact specification) 📐 Dimensions Exterior Length Sedan: 4425 mm / 174.2 in Width: 1705 mm / 67.1 in Height: 1410 mm / 55.5 in Wheelbase: 2610 mm / 102.8 in Interior Passenger Volume: Approx. 98 cu ft Cargo Trunk Volume Sedan: Approx. 12.9 cu ft Weights Curb Weight Manual: Approx. 2650 lbs (1200 kg) Curb Weight Automatic: Approx. 2750 lbs (1250 kg) Wheels And Tires Standard Tire Size: 185/65R14 or 195/55R15 (depending on trim) Wheel Bolt Pattern: 4x100 🛡️ Safety Features Ratings NHTSA Driver Front Impact: 4-Star (2001 models) NHTSA Passenger Front Impact: 4-Star (2001 models) IIHS Offset Frontal Crash: Good (for models equipped with side airbags, depending on year) Active Features ABS: Available Anti-lock Braking System (ABS) on most models Passive Features Airbags: Driver and front passenger airbags, optional side-impact airbags Seatbelts: Front 3-point height-adjustable seatbelts with pretensioners, rear 3-point seatbelts 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional cassette player, 4 or 6 speaker system Climate Control: Manual or automatic climate control system Driver Assistance Cruise Control: Standard on LX and ES trims, optional on DX Connectivity Connectivity Features: Limited to basic audio inputs, no Bluetooth or USB for this era 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first Air Filter Replacement Interval: Every 15,000 miles (24,000 km) or 12 months Spark Plug Replacement Interval: Every 60,000 miles (96,000 km) (iridium or platinum type) Coolant Flush Interval: Every 30,000 miles (48,000 km) or 24 months Fluid Specifications Engine Oil Specification: API SJ or SL, ILSAC GF-3, SAE 5W-30 synthetic blend or full synthetic recommended Engine Oil...
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Sku: 261179
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Mazda Protege 2001-2003 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Model Years Covered:
2001, 2002, 2003
Generation
Generation:
BJ (Second Generation)
Codes
Chassis Codes:
BJ3P (Sedan), BJ5W (Wagon)
👋 Introduction
Market Position
Segment:
Compact Car
Target Audience:
Economy-minded buyers seeking reliable and practical transportation
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra
Key Features
Design Philosophy:
Mazda's 'Zoom-Zoom' driving dynamics, practical interior, fuel efficiency
Value Proposition
Offering:
Excellent value for money with a good balance of features, performance, and reliability
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for all aspects of the vehicle
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, cooling system, lubrication system, ignition system, exhaust system
Transmission:
Manual and automatic transmission service, repair, and diagnostics
Drivetrain:
Front-wheel drive, CV joints, drive axles, differentials
Suspension:
Front and rear suspension components, alignment, shock absorbers, springs
Steering:
Steering system components, power steering, steering column
Brakes:
Front and rear brakes (disc/drum), ABS system, parking brake
Electrical:
Battery, charging system, starting system, lighting, instruments, power accessories, body control modules
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair
Body And Trim:
Exterior body panels, interior trim, doors, glass, seats
Diagnostics:
OBD-II diagnostics, trouble code (DTC) interpretation, symptom-based troubleshooting
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes, filter replacements, inspections
Repair:
Component removal and installation, adjustments, internal component repair
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon problems
Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values
Wiring Diagrams:
Complete electrical system wiring diagrams for all major components and circuits
Technical Depth
Depth:
Factory-level detail, suitable for professional technicians and advanced DIYers
Diagnostic Tools:
Includes information on required diagnostic tools and equipment
Rebuild Procedures:
Detailed procedures for engine and transmission rebuilding
📊 Manual Specifications
File Format
Compatibility:
Compatible with all Windows versions, Linux, and macOS
Print Quality
Image Resolution:
High-resolution, clear text and diagrams suitable for printing
Binding Type
Binding Type:
Not Applicable (Digital PDF)
Paper Type
Paper Type:
Not Applicable (Digital PDF)
File Features
Searchability:
Fully searchable text for quick information retrieval
Distribution
Delivery Method:
Free Digital Download, No Shipping Costs
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
FS-DE (2.0L DOHC Inline-4)
Displacement 1:
1991 cc
Bore X Stroke 1:
83.0 mm x 92.0 mm
Compression Ratio 1:
9.1:1
Horsepower 1:
130 hp @ 5500 rpm (approx.)
Torque 1:
135 lb-ft @ 4000 rpm (approx.)
Secondary Engine
Engine Code 2:
Z5-DE (1.5L DOHC Inline-4) - Primarily for base models/specific markets
Displacement 2:
1498 cc
Horsepower 2:
105 hp @ 6000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with coil-on-plug or coil pack
🔧 Transmission
Standard
Transmission Type 1:
5-Speed Manual
Optional
Transmission Type 2:
4-Speed Automatic (with Lock-up Torque Converter)
Features
Automatic Features:
Electronically controlled, power/normal shift modes
Fluid Spec
Manual Transmission Fluid:
API GL-4, SAE 75W-90 gear oil (check manual for exact specification)
Automatic Transmission Fluid:
Mazda ATF JWS3317 or equivalent (check manual for exact specification)
📐 Dimensions
Exterior
Length Sedan:
4425 mm / 174.2 in
Width:
1705 mm / 67.1 in
Height:
1410 mm / 55.5 in
Wheelbase:
2610 mm / 102.8 in
Interior
Passenger Volume:
Approx. 98 cu ft
Cargo
Trunk Volume Sedan:
Approx. 12.9 cu ft
Weights
Curb Weight Manual:
Approx. 2650 lbs (1200 kg)
Curb Weight Automatic:
Approx. 2750 lbs (1250 kg)
Wheels And Tires
Standard Tire Size:
185/65R14 or 195/55R15 (depending on trim)
Wheel Bolt Pattern:
4x100
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
4-Star (2001 models)
NHTSA Passenger Front Impact:
4-Star (2001 models)
IIHS Offset Frontal Crash:
Good (for models equipped with side airbags, depending on year)
Active Features
ABS:
Available Anti-lock Braking System (ABS) on most models
Passive Features
Airbags:
Driver and front passenger airbags, optional side-impact airbags
Seatbelts:
Front 3-point height-adjustable seatbelts with pretensioners, rear 3-point seatbelts
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional cassette player, 4 or 6 speaker system
Climate Control:
Manual or automatic climate control system
Driver Assistance
Cruise Control:
Standard on LX and ES trims, optional on DX
Connectivity
Connectivity Features:
Limited to basic audio inputs, no Bluetooth or USB for this era
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first
Air Filter Replacement Interval:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement Interval:
Every 60,000 miles (96,000 km) (iridium or platinum type)
Coolant Flush Interval:
Every 30,000 miles (48,000 km) or 24 months
Fluid Specifications
Engine Oil Specification:
API SJ or SL, ILSAC GF-3, SAE 5W-30 synthetic blend or full synthetic recommended
Engine Oil Capacity:
4.5 US quarts (4.3 liters) with filter change (FS-DE engine)
Coolant Specification:
Mazda Super Long Life Coolant (Blue) or equivalent HOAT coolant
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid
Known Issues
Common Issue 1:
Premature wear of front control arm bushings
Common Issue 2:
Ignition coil failure (especially on older models)
Common Issue 3:
Catalytic converter failure due to engine misfires or oil consumption
Common Issue 4:
Power steering pump leaks or noise
Common Repairs
Tune Up Components:
Spark plugs (NGK PFR5N-11 or equivalent), ignition wires/coils, air filter, fuel filter
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Mazda's reputation for building engaging and reliable vehicles
Model Evolution
Bj Generation Introduction:
The BJ generation Protege was introduced for the 1999 model year, with significant updates for the 2001 model year, including revised styling and powertrain options.
Trim Levels:
DX, LX, ES, Mazdaspeed Protege (later models, not covered by this manual)
Production
Manufacturing Location:
Japan (Mazda Hofu Plant)
Production Years
Model Production Run:
1999-2003 (BJ generation)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Protege family often cited for value and driving dynamics, though not always making the 10Best list for this specific generation.
Ratings
Konsumen Reports Reliability:
Generally good to average reliability ratings for the period, with some model years showing better performance than others.
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