Mazda PROTEGE Service Repair Manual 1999 2000 2001 2002 2003

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🏷️ Basic Information Identification Make: Mazda Model: Protege Product Name: Mazda Protege Service Repair Manual 1999-2003 Codes Platform Code: BJ (third generation) 👋 Introduction Market Position Segment: Compact Car Competitors: Honda Civic, Toyota Corolla, Nissan Sentra, Ford Focus, Chevrolet Cavalier. Key Features Vehicle Appeal: Known for its sporty handling, reliable engines, and good value for money, particularly in its sportier trims. Manual Value: Essential for owners and mechanics to maintain, diagnose, and repair the vehicle effectively, covering all aspects of its operation and construction. 📋 Manual Details Coverage Areas Years Covered: 1999, 2000, 2001, 2002, 2003 Models Covered: All Protege models (e.g., DX, LX, ES, MP3, Mazdaspeed Protege) Engines Covered: All engine variants offered during these model years Page Count Estimated Page Count: Extensive (typically 1000+ pages for a complete factory service manual) Manual Type Type: Complete Service and Repair Manual Language Language: English Format Format: Downloadable Digital Format (e.g., PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system, intake and exhaust systems. Engine Performance: Fuel injection system (EFI), ignition system, engine control module (ECM) operations, emissions control systems (EGR, catalytic converter). Transmission Manual: Clutch system, gearshift mechanism, transmission case, gears, bearings, seals, maintenance, and repair procedures. Transmission Automatic: Automatic transmission assembly, torque converter, valve body, planetary gear sets, hydraulic control system, maintenance, and repair procedures. Drivetrain: Front-wheel drive system, drive shafts, CV joints, differential, hubs, wheel bearings. Suspension: Front suspension (MacPherson struts, control arms, sway bars), rear suspension (independent multi-link), shock absorbers, springs, bushings, alignment specifications. Steering: Power steering system (pump, rack and pinion, hoses), steering column, linkages, steering angle sensor (if applicable). Brakes: Front and rear brake systems (disc/drum configurations), hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), parking brake, ABS system operation and components. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams. Body And Chassis: Body panels, doors, hood, trunk, glass, interior trim, chassis structure, corrosion protection, body repair procedures. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, blower motor, climate controls. Safety Systems: Airbag system operation, SRS module, seat belts, child seat anchorages (LATCH). Interior: Seats, dashboard, instrument cluster, door panels, center console, headliner, floor covering, seat belt mechanisms. Exterior: Bumpers, grille, fenders, hood, trunk lid, doors, windows, mirrors, exterior trim, weatherstripping. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, air filter replacement, battery maintenance, wiper blade replacement. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) for engine and other systems, step-by-step diagnostic procedures for common and uncommon faults. Repair Procedures: Detailed step-by-step instructions for component removal, installation, and overhaul for all major vehicle systems. Component Overhaul: Engine rebuild procedures, transmission overhaul, brake caliper rebuilding, suspension component replacement. Electrical Diagnostics And Repair: Fuse and relay identification, troubleshooting electrical circuits using wiring diagrams, repair of wiring harness issues, component testing. Body And Frame Repair: Body panel alignment, dent repair, rust repair, glass replacement, interior trim reassembly. HVAC System Repair: Refrigerant charging, component replacement (compressor, condenser, heater core), leak detection, blower motor repair. Technical Depth Depth: Comprehensive factory-level detail, suitable for professional technicians and experienced DIY enthusiasts. Detail Level: Includes torque specifications, clearances, diagnostic flowcharts, wiring diagrams, exploded views, and part identification. Diagnostic Tools: References to required diagnostic tools and equipment (e.g., scan tools, multimeters, specialized wrenches). 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval. Printability: Printable pages for on-site reference. Print Quality Image Quality: High-resolution images, diagrams, and schematics. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 1999-2000 Engine Code: FS-DE Configuration: 2.0L Inline-4, DOHC, 16-valve Horsepower: 125-130 hp @ 6000 rpm (varies slightly by year/trim) Torque: 128-132 lb-ft @ 4500 rpm (varies slightly by year/trim) Primary Engine 2001-2003 Engine Code: FS-DE (updated), FS-Z (Mazdaspeed) Configuration: 2.0L Inline-4, DOHC, 16-valve (Standard), 2.0L DOHC Turbocharged (Mazdaspeed) Horsepower: 125-130 hp @ 6000 rpm (Standard), 170 hp @ 5500 rpm (Mazdaspeed) Torque: 128-132 lb-ft @ 4500 rpm (Standard), 170 lb-ft @ 3500 rpm (Mazdaspeed) Fuel System Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 octane recommended, higher for Mazdaspeed) Engine Management ECU: Engine Control Unit (ECU) manages fuel, ignition, and emissions. 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Automatic Control: Electronically controlled automatic transmission with overdrive. Fluid Specification Manual Fluid: API GL-4, SAE 75W-90 Gear Oil (Consult manual for exact spec/brand) Automatic Fluid: Mazda ATF MV Type or equivalent (Consult manual for exact spec/brand) 📐 Dimensions Exterior Sedan Length: Approx. 172.8 - 174.0 inches Width: Approx. 67.7 inches Height: Approx. 55.7 - 56.1 inches Wheelbase: Approx. 102.4 inches Exterior...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Product Name:

Mazda Protege Service Repair Manual 1999-2003

Codes

Platform Code:

BJ (third generation)

👋 Introduction

Market Position

Segment:

Compact Car

Competitors:

Honda Civic, Toyota Corolla, Nissan Sentra, Ford Focus, Chevrolet Cavalier.

Key Features

Vehicle Appeal:

Known for its sporty handling, reliable engines, and good value for money, particularly in its sportier trims.

Manual Value:

Essential for owners and mechanics to maintain, diagnose, and repair the vehicle effectively, covering all aspects of its operation and construction.

📋 Manual Details

Coverage Areas

Years Covered:

1999, 2000, 2001, 2002, 2003

Models Covered:

All Protege models (e.g., DX, LX, ES, MP3, Mazdaspeed Protege)

Engines Covered:

All engine variants offered during these model years

Page Count

Estimated Page Count:

Extensive (typically 1000+ pages for a complete factory service manual)

Manual Type

Type:

Complete Service and Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (e.g., PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system, intake and exhaust systems.

Engine Performance:

Fuel injection system (EFI), ignition system, engine control module (ECM) operations, emissions control systems (EGR, catalytic converter).

Transmission Manual:

Clutch system, gearshift mechanism, transmission case, gears, bearings, seals, maintenance, and repair procedures.

Transmission Automatic:

Automatic transmission assembly, torque converter, valve body, planetary gear sets, hydraulic control system, maintenance, and repair procedures.

Drivetrain:

Front-wheel drive system, drive shafts, CV joints, differential, hubs, wheel bearings.

Suspension:

Front suspension (MacPherson struts, control arms, sway bars), rear suspension (independent multi-link), shock absorbers, springs, bushings, alignment specifications.

Steering:

Power steering system (pump, rack and pinion, hoses), steering column, linkages, steering angle sensor (if applicable).

Brakes:

Front and rear brake systems (disc/drum configurations), hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), parking brake, ABS system operation and components.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams.

Body And Chassis:

Body panels, doors, hood, trunk, glass, interior trim, chassis structure, corrosion protection, body repair procedures.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, blower motor, climate controls.

Safety Systems:

Airbag system operation, SRS module, seat belts, child seat anchorages (LATCH).

Interior:

Seats, dashboard, instrument cluster, door panels, center console, headliner, floor covering, seat belt mechanisms.

Exterior:

Bumpers, grille, fenders, hood, trunk lid, doors, windows, mirrors, exterior trim, weatherstripping.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, air filter replacement, battery maintenance, wiper blade replacement.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs) for engine and other systems, step-by-step diagnostic procedures for common and uncommon faults.

Repair Procedures:

Detailed step-by-step instructions for component removal, installation, and overhaul for all major vehicle systems.

Component Overhaul:

Engine rebuild procedures, transmission overhaul, brake caliper rebuilding, suspension component replacement.

Electrical Diagnostics And Repair:

Fuse and relay identification, troubleshooting electrical circuits using wiring diagrams, repair of wiring harness issues, component testing.

Body And Frame Repair:

Body panel alignment, dent repair, rust repair, glass replacement, interior trim reassembly.

HVAC System Repair:

Refrigerant charging, component replacement (compressor, condenser, heater core), leak detection, blower motor repair.

Technical Depth

Depth:

Comprehensive factory-level detail, suitable for professional technicians and experienced DIY enthusiasts.

Detail Level:

Includes torque specifications, clearances, diagnostic flowcharts, wiring diagrams, exploded views, and part identification.

Diagnostic Tools:

References to required diagnostic tools and equipment (e.g., scan tools, multimeters, specialized wrenches).

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable pages for on-site reference.

Print Quality

Image Quality:

High-resolution images, diagrams, and schematics.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine 1999-2000

Engine Code:

FS-DE

Configuration:

2.0L Inline-4, DOHC, 16-valve

Horsepower:

125-130 hp @ 6000 rpm (varies slightly by year/trim)

Torque:

128-132 lb-ft @ 4500 rpm (varies slightly by year/trim)

Primary Engine 2001-2003

Engine Code:

FS-DE (updated), FS-Z (Mazdaspeed)

Configuration:

2.0L Inline-4, DOHC, 16-valve (Standard), 2.0L DOHC Turbocharged (Mazdaspeed)

Horsepower:

125-130 hp @ 6000 rpm (Standard), 170 hp @ 5500 rpm (Mazdaspeed)

Torque:

128-132 lb-ft @ 4500 rpm (Standard), 170 lb-ft @ 3500 rpm (Mazdaspeed)

Fuel System

Type:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 octane recommended, higher for Mazdaspeed)

Engine Management

Engine Control Unit (ECU) manages fuel, ignition, and emissions.

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

4-speed Automatic Transmission

Features

Automatic Control:

Electronically controlled automatic transmission with overdrive.

Fluid Specification

Manual Fluid:

API GL-4, SAE 75W-90 Gear Oil (Consult manual for exact spec/brand)

Automatic Fluid:

Mazda ATF MV Type or equivalent (Consult manual for exact spec/brand)

📐 Dimensions

Exterior Sedan

Length:

Approx. 172.8 - 174.0 inches

Width:

Approx. 67.7 inches

Height:

Approx. 55.7 - 56.1 inches

Wheelbase:

Approx. 102.4 inches

Exterior Hatchback

Length:

Approx. 164.2 inches

Width:

Approx. 67.7 inches

Height:

Approx. 55.7 inches

Wheelbase:

Approx. 102.4 inches

Weights

Curb Weight:

Approx. 2700 - 3000 lbs (varies by model and equipment)

Gross Vehicle Weight Rating:

Varies by model, consult specific vehicle documentation.

Towing Capacity:

Not designed for significant towing; consult owner's manual for specific limitations.

Cargo

Trunk Volume Sedan:

Approx. 12.0 - 13.0 cu ft

Cargo Volume Hatchback:

Approx. 20.0 cu ft (with rear seats up), 39.0 cu ft (with rear seats folded)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Good (for models tested during these years, check specific year/model for exact ratings).

NHTSA Front Impact Passenger:

Good (for models tested during these years, check specific year/model for exact ratings).

IIHS Side Impact:

Good (for models tested during these years, check specific year/model for exact ratings).

Active Features

Anti-lock Braking System (ABS) available/standard on higher trims.

Traction Control:

Traction Control System (TCS) available on some models.

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags available on some trims.

Seat Belts:

Three-point front and rear seat belts, pretensioners and load limiters on front belts.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM radio with CD player or cassette player. Optional premium audio systems available on higher trims.

Display:

Basic dashboard cluster with analog gauges for speedometer, tachometer, fuel, and temperature. No central infotainment screen on most models.

Driver Assistance

Cruise Control:

Available on most models.

Keyless Entry:

Available on higher trim levels.

Connectivity

Power Windows Locks:

Power windows and door locks available on most trims, standard on higher trims.

🔧 Maintenance

Service Intervals General

Oil Change Interval:

Every 5,000 miles or 6 months (whichever comes first) under normal driving conditions; consult manual for severe conditions.

Engine Oil Filter Replacement:

Recommended with every oil change.

Air Filter Replacement:

Every 15,000 - 30,000 miles, or as needed based on inspection.

Cabin Air Filter Replacement:

Every 15,000 - 30,000 miles, or as needed based on inspection (if equipped).

Spark Plug Replacement:

Around 60,000 miles (for standard plugs) or 100,000 miles (for platinum/iridium plugs, consult manual).

Coolant Flush Replacement:

Every 30,000 - 50,000 miles or 2-3 years.

Brake Fluid Replacement:

Every 2-3 years, or as needed based on inspection and fluid condition.

Transmission Fluid Replacement Manual:

Consult manual, often less frequent but inspect for leaks.

Transmission Fluid Replacement Automatic:

Every 30,000 - 50,000 miles, or as specified by Mazda.

Timing Belt Replacement:

Around 60,000 - 90,000 miles (FS-DE engine uses a timing belt; critical to replace to avoid severe engine damage).

Fluid Specifications

Engine Oil:

SAE 5W-30, API SJ or ILSAC GF-2 certified (Consult manual for exact specification and capacity).

Coolant:

Mazda Genuine Long Life Antifreeze/Coolant (Blue) or equivalent ethylene glycol-based coolant with appropriate corrosion inhibitors. Capacity approx. 6.0-6.5 quarts.

Brake Fluid:

DOT 3 or DOT 4 Brake Fluid.

Power Steering Fluid:

Dexron II/III Automatic Transmission Fluid (ATF) or equivalent (Consult manual for exact spec).

Known Issues

Engine Mounts:

Worn engine and transmission mounts can lead to excessive vibration and clunking noises.

Alternator Failure:

Alternators can fail prematurely, leading to battery discharge and electrical system issues.

Cv Joints:

Front CV joints can wear out, causing clicking noises during turns.

Rear Wheel Bearings:

Rear wheel bearings may develop a humming or grinding noise as they wear.

Exhaust System:

Rust and corrosion can affect the exhaust system components, leading to leaks.

HVAC Blend Door Actuator:

Blend door actuators in the HVAC system can fail, causing incorrect temperature or air distribution.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Mazda is known for its 'Zoom-Zoom' philosophy, emphasizing driving enjoyment and innovative engineering.

Model Evolution

Generation:

This covers the third generation (BJ) of the Mazda Protege, launched in late 1998 for the 1999 model year.

Redesign:

The BJ generation featured a significant redesign with more aerodynamic styling and improved chassis dynamics.

Special Editions:

Included sport-oriented trims like the ES, MP3 (performance-tuned), and the high-performance Mazdaspeed Protege (turbocharged).

Production

Production Years:

1999-2003 (for the BJ generation covered by this manual).

Production Locations

Manufacturing:

Primarily manufactured in Japan and North America (e.g., Mazda's Flat Rock, Michigan plant).

🏆 Awards & Recognition

Recognitions

Car Of The Year:

Mazda Protege and its variants received positive reviews and some regional awards for value and performance during its production run.

Ratings

Consumer Reports:

Generally rated as average to above average for reliability by consumer organizations during its era, with some specific model years and components having better or worse tracked reliability.