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Mazda 323 Protege 1990 1991 Workshop Service Manual PDF Download
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Basic Information Identification Make: Mazda Model: 323 Protege Year: 1990-1991 Codes Chassis Codes: BG (for both 1990 and 1991 models) Introduction Market Position Segment: Compact/Subcompact car Target Audience: DIY mechanics,...
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| Basic Information | |
| Identification | |
| Make: | Mazda |
| Model: | 323 Protege |
| Year: | 1990-1991 |
| Codes | |
| Chassis Codes: | BG (for both 1990 and 1991 models) |
| Introduction | |
| Market Position | |
| Segment: | Compact/Subcompact car |
| Target Audience: | DIY mechanics, independent repair shops, Mazda owners seeking in-depth repair knowledge |
| Competitive Analysis | |
| Competitors: | Honda Civic, Toyota Corolla, Nissan Sentra, Ford Escort |
| Key Features | |
| Vehicle Strengths: | Reliability, fuel efficiency, sporty handling, distinctive styling for its era |
| Manual Value Proposition: | Provides comprehensive, manufacturer-level repair information, enabling cost-effective maintenance and repairs. |
| Manual Details | |
| Coverage Areas | |
| Scope: | Comprehensive workshop service and repair |
| Page Count | |
| Total Pages: | 728 |
| Manual Type | |
| Type: | Workshop Service Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Detailed diagnostics, repair, overhaul, and tuning for gasoline engines (e.g., 1.6L B6, 1.8L BP) |
| Transmission: | Manual and automatic transmission disassembly, assembly, repair, and adjustment |
| Drivetrain: | Front-wheel drive system, CV joints, differential inspection and repair |
| Suspension: | Front and rear suspension components, alignment specifications, shock absorber and strut replacement |
| Steering: | Power steering system diagnosis and repair, steering column and rack and pinion maintenance |
| Brakes: | Front and rear brake systems (disc and drum), hydraulic system diagnosis, caliper and rotor replacement, brake fluid specifications |
| Electrical: | Complete wiring diagrams, component testing, starter, alternator, ignition system, lighting, fuses, relays, sensors |
| Fuel System: | Fuel injection system (MPI/EFI), fuel pump, injectors, fuel pressure testing, fuel filter replacement |
| Cooling System: | Radiator, thermostat, water pump, coolant specifications, fan operation |
| Exhaust System: | Catalytic converter, muffler, exhaust manifold, gasket replacement |
| Body And Interior: | Body panel removal and installation, interior trim, door mechanisms, glass replacement, HVAC system |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs |
| Troubleshooting: | Diagnostic procedures for common and uncommon issues, symptom-based fault finding |
| Repair And Rebuild: | Detailed step-by-step instructions for component repair and complete overhaul |
| Inspection: | Visual inspections, diagnostic checks, wear and tear assessment |
| Specifications And Torques: | Tightening torques for critical fasteners, measurement specifications |
| Special Tools: | Identification and usage of specialized tools required for specific procedures |
| Diagnostics: | Systematic diagnostic procedures for electrical and mechanical faults. |
| Technical Depth | |
| Depth: | In-depth diagnostics, component-level repair, complete engine and transmission rebuilds |
| Manual Specifications | |
| File Format | |
| File Type: | Portable Document Format (PDF) |
| Searchability: | Searchable text for quick information retrieval |
| Print Quality | |
| Quality: | High-resolution for clarity of diagrams and text |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Completeness | |
| Completeness: | Designed to be a complete workshop manual, covering all major repair and maintenance aspects. |
| Engine Specifications | |
| Primary Engine | |
| Engine Code 1: | B6 (1.6L DOHC) |
| Engine Code 2: | BP (1.8L DOHC) |
| Performance | |
| 1.6L Horsepower: | Approx. 88-98 hp (depending on market and configuration) |
| 1.8L Horsepower: | Approx. 103-118 hp (depending on market and configuration) |
| 1.6L Torque: | Approx. 92-98 lb-ft |
| 1.8L Torque: | Approx. 106-110 lb-ft |
| Fuel System | |
| Injection Type: | Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPI) |
| Fuel Grade: | Unleaded gasoline (Octane rating as per owner's manual, typically 87 AKI or higher) |
| Engine Details | |
| Cylinder Layout: | Inline 4-cylinder |
| Valvetrain: | DOHC (Double Overhead Camshaft) |
| Transmission | |
| Standard | |
| Manual Transmission: | 5-speed manual (e.g., F5M33) |
| Optional | |
| Automatic Transmission: | 4-speed automatic (e.g., F4A21) |
| Features | |
| Clutch Type: | Hydraulic dry single plate clutch |
| Fluid Specifications | |
| Manual Fluid: | GL-4 gear oil (e.g., SAE 75W-90 or 80W-90) |
| Automatic Fluid: | Dexron-III or equivalent ATF (Automatic Transmission Fluid) |
| Dimensions | |
| Exterior | |
| Length: | Approx. 4,270 - 4,330 mm (varies by body style: sedan/hatchback) |
| Width: | Approx. 1,670 - 1,690 mm |
| Height: | Approx. 1,370 - 1,400 mm |
| Weights | |
| Curb Weight: | Approx. 1,050 - 1,150 kg (varies by model and options) |
| Gross Vehicle Weight: | Varies by model, consult manual for specific ratings |
| Safety Features | |
| Ratings | |
| Crash Test Results: | Data from this era is less standardized than modern ratings. Consult specific regional safety reports if available. |
| Active Features | |
| ABS: | Optional on some higher trim levels |
| Passive Features | |
| Airbags: | Driver airbag standard on later models, passenger airbag optional/unavailable on early models |
| Seat Belts: | 3-point front and rear seat belts |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory AM/FM stereo with cassette player, optional CD player on higher trims. |
| Controls: | Manual HVAC controls, basic dashboard instrumentation. |
| Driver Assistance | |
| Cruise Control: | Available on some models/trims. |
| Connectivity | |
| Connectivity Features: | N/A (No advanced connectivity or Bluetooth as standard for this era). |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Typically every 5,000-7,500 miles or 6 months, check manual for specific recommendation. |
| Timing Belt Replacement: | Crucial for BP and B6 engines. Typically every 60,000-90,000 miles or 5-7 years. Consult manual for exact interval and part numbers. |
| Spark Plug Replacement: | Varies by spark plug type (copper, platinum). Typically 30,000-60,000 miles. |
| Fluid Specifications | |
| Engine Oil Type: | API SG or higher, SAE 5W-30 or 10W-30 (check manual for precise recommendation based on climate). |
| Coolant Type: | Ethylene glycol based coolant, typically a 50/50 mix with distilled water. |
| Brake Fluid Type: | DOT 3 or DOT 4. |
| Known Issues | |
| Common Problem 1: | Timing belt failure (if not replaced on schedule, can cause catastrophic engine damage). |
| Common Problem 2: | Rust and corrosion, particularly in wheel wells, rocker panels, and around windows. |
| Common Problem 3: | Ignition system components (e.g., distributor, coil). |
| Common Problem 4: | CV joint wear and tear. |
| Common Problem 5: | Oil leaks from engine seals and gaskets over time. |
| Vehicle History | |
| Brand Heritage | |
| Mazda Philosophy: | Focus on driver engagement, innovation, and quality craftsmanship. |
| Model Evolution | |
| Generation: | This corresponds to the second generation of the Mazda 323 Protege (BG platform). |
| Market Introduction: | The BG generation was introduced globally in late 1989 for the 1990 model year, replacing the BF generation. |
| Production | |
| Production Years: | 1989-1994 (BG generation) |
| Manufacturing Locations: | Japan (e.g., Hofu Plant), and potentially other global Mazda assembly plants. |
| Awards & Recognition | |
| Recognitions | |
| Industry Awards: | While specific awards for the 1990-1991 models might be scarce in easily accessible records, the Mazda 323 and Protege lines generally received praise for value, reliability, and driving dynamics in their respective eras. |
| Ratings | |
| Reliability Reputation: | Generally good reliability for its time, with common wear items being the primary concern for well-maintained vehicles. |