🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 1996 Codes Chassis Code: BJ platform (This generation is often referred to as BJ, though the manual focuses on specific year) Engine Codes Covered: Z5, BP 👋 Introduction Market Position Market Position: The 1996 Mazda Protege was a compact car positioned in a highly competitive segment against vehicles like the Honda Civic, Toyota Corolla, Ford Escort, and Nissan Sentra. It offered a balance of economy, reliability, and engaging driving dynamics, appealing to a broad audience seeking practical transportation. Competitive Analysis Competitive Analysis: Compared to its peers, the Protege often stood out for its sharper handling characteristics, a testament to Mazda's 'Zoom-Zoom' philosophy even in this era. Its interior design was generally well-received, offering a functional and comfortable cabin. Key Features Key Features: This workshop manual is presented as the most complete service repair manual ever compiled for the 1996 Mazda Protege. Its comprehensive nature, with 952 pages of high-quality diagrams and instructions, makes it an invaluable resource for anyone looking to maintain, diagnose, or repair their vehicle. 📋 Manual Details Coverage Areas Systems Covered: General Information, Engine (Z5 & BP), Lubrication System, Cooling System, Fuel and Emission Control Systems (Z5 & BP), Engine Electrical System, Clutch, Manual Transaxle (F25M-R), Automatic Transaxle (FA4A-EL), Front and Rear Axles, Steering System, Braking System, Wheels and Tires, Suspension, Body (4-Door Sedan), Body Electrical System (4-Door Sedan), Heater and Air Conditioner Systems Page Count Page Count: 952 Manual Type Manual Type: Workshop Manual / Service Repair Manual Language Language: English Format Format: PDF (.rar archive containing .pdf) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed engine overhaul procedures for Z5 and BP engines, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, bearings, crankshaft, camshafts, valvetrain, etc.). Engine Performance: Covers engine tuning, diagnostics, and performance adjustments related to fuel, ignition, and emissions systems. Fuel System: Comprehensive coverage of fuel delivery, injection systems (likely multi-point), fuel pumps, filters, injectors, and fuel pressure regulators for both Z5 and BP engines. Emission Control: Detailed procedures for emission control systems, including catalytic converters, EGR systems, PCV systems, and evaporative emission control (EVAP). Lubrication: Information on the lubrication system, including oil pump, oil pan, oil filter, oil passages, and recommended oil specifications and capacities. Cooling System: Detailed coverage of the cooling system, including radiator, water pump, thermostat, coolant hoses, fan, and coolant specifications. Engine Electrical: Extensive coverage of the engine's electrical system, including ignition system (spark plugs, coils, wires), starter motor, alternator, battery, ECU, sensors (crankshaft position, camshaft position, MAF, O2), and wiring diagrams. Clutch System: Procedures for clutch inspection, adjustment, replacement (clutch disc, pressure plate, release bearing), and hydraulic clutch system service. Manual Transmission: Detailed service and repair procedures for the F25M-R manual transaxle, including disassembly, assembly, gear inspection, bearing replacement, and clutch interface. Automatic Transmission: Comprehensive service and repair information for the FA4A-EL automatic transaxle, covering internal components, hydraulic systems, torque converter, valve body, and electronic controls. Drivetrain Axles: Information on front and rear axles, including CV joints, drive shafts, differential components, and bearing services. Steering System: Covers power steering system (pump, rack and pinion, hoses, fluid), steering column, and alignment procedures. Braking System: Detailed coverage of front and rear brakes (disc/drum configurations), hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), parking brake, and ABS system if equipped. Wheels Tires: Information on wheel specifications, tire pressure recommendations, and tire rotation procedures. May also cover wheel bearing service. Suspension System: Detailed coverage of front and rear suspension components, including struts, shock absorbers, control arms, ball joints, bushings, and wheel alignment specifications. Body Exterior 4Sd: Repair and service information specific to the 4-door sedan body style, potentially including body panel removal/installation, door mechanisms, and trim. Body Electrical 4Sd: Comprehensive coverage of the vehicle's electrical system beyond the engine, including lighting (headlights, taillights, interior), power windows, locks, mirrors, wipers, horn, and body control modules. Includes detailed wiring diagrams. HVAC System: Service and repair procedures for the heating, ventilation, and air conditioning (HVAC) system, including the climate control unit, blower motor, evaporator, condenser, refrigerant handling, and ducts. Procedures Included Maintenance Procedures: Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, belt inspections, spark plug replacement, and brake pad replacement. Diagnostic Procedures: Troubleshooting guides and diagnostic steps for identifying and resolving common and complex issues across all covered systems, often including symptom-based diagnosis. Repair Procedures: Step-by-step instructions for the repair and replacement of virtually all mechanical, electrical, and body components. Engine Rebuild: Complete engine overhaul instructions, from initial disassembly to final assembly and break-in procedures. Transmission Overhaul: Detailed instructions for the overhaul and repair of both manual and automatic transmissions. Electrical Troubleshooting: In-depth troubleshooting for electrical faults, utilizing wiring diagrams and diagnostic tests for sensors, actuators, and control modules. Technical Depth Depth: Comprehensive, covering everything from...