engine MAZDA MODEL PROTÉGÉ 2003 (in English) Repair Manual

8-40
Maintenance and Care
Owner Maintenance
Form No. 8Q94-EA-02G

Fuse Panel Description
Fuse block (Engine compartment)
DESCRIPTIONFUSE
RATINGPROTECTED
COMPONENT
1HEATER 40 A Heater
2 ABS 60 AAntilock brake
system, For
protection of
various circuits
3 IG KEY 60 AFor protection of
various circuits
4 PTC 30 A—
5GLOW 40 A—
6—— —
7COOLING
FA N30 A Cooling fan
8 BTN 40 AInterior lights,
Power door lock
9 AD FAN 30 AAdditional
cooling fan for air
conditioner
10INJ OR
FIP30 AEngine control
unit
11 A/C 10 A Air conditionerDESCRIPTIONFUSE
RATINGPROTECTED
COMPONENT
12 ST.SIG 10 A Starter signal
13 HORN 15 A Horn
14 HAZARD 15 AHazard warning
flashers
15 TAIL 15 A Taillights
16HEAD
C/U7.5 AFor protection of
various circuits
17 FOG 15 A—
18 FOG 15 A Fog lights
19 STOP 15 A Brake lights
20 HEAD-R 15 A Headlight-right
21 HEAD-L 15 A Headlight-left
22—— —
23 HEAD HI 15 A—
24 MAIN 100 AFor protection of
all circuits
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8-41
Maintenance and Care
Owner Maintenance
Form No. 8Q94-EA-02G
Fuse panel (Driver’s side)
DESCRIPTIONFUSE
RATINGPROTECTED
COMPONENT
1 S/WRM 15 AFor protection of
various circuits
2 H/CLN 20 AFor protection of
various circuits
3 RADIO 15 A Audio system
4 A/C 15 A Air conditioner
5 R.WIPER 10 AFor protection of
various circuits
6—— —
7—— —
8 ROOM 10 AInterior lights,
Trunk light,
Luggage
compartment light
9MIRR DEF 10 A—
10—— —
11DOOR
LOCK30 A Power door lock
12 P/WIND 30 A—DESCRIPTIONFUSE
RATINGPROTECTED
COMPONENT
13 WIPER 20 AWindshield wiper
and washer
14 ENGINE 10 AEngine control
unit
15 METER 10 A Instrument cluster
16—— —
17 P/WIND 30 A Power windows
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9-9
Customer Information
Wa r r a n t y
Form No. 8Q94-EA-02G
Government regulations in the United States and Canada require that automobiles meet
specific emission regulations and safety standards. Therefore, vehicles built for use in the
United States, its territories, and Canada may differ from those sold in other countries.
The differences may make it difficult or even impossible for your vehicle to receive
satisfactory servicing in other countries. We strongly recommend that you NOT take your
Mazda outside these areas.
You may have these problems if you do:
•Recommended fuel may be unavailable. Any kind of leaded fuel or low-octane fuel will
affect vehicle performance and damage the emission controls and engine.
•Proper repair facilities, tools, testing equipment, and replacement parts may not be
available.
The Mazda warranty applies only to Mazda vehicles registered and normally operated in
the United States, its territories, and Canada.
Outside the United States and Canada
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9-10
Customer Information
Wa r r a n t y
Form No. 8Q94-EA-02G
Non-genuine parts and accessories for Mazda vehicles can be found in stores.
These may fit your vehicle, but they are not approved by Mazda for use with Mazda
vehicles. When you install non-genuine parts or accessories, they could affect your
vehicle’s performance or safety system; the Mazda warranty doesn’t cover this. Before you
install any non-genuine parts or accessories, consult an Authorized Mazda Dealer.
Mazda assumes no responsibility for death, injury, or expenses that may result from the
installation of add-on non-genuine parts or accessories.
Add-On Non-Genuine Parts and Accessories
Installation of Non-Genuine Parts or Accessories:
Installation of non-genuine parts or accessories is dangerous. Improperly designed
parts or accessories could seriously affect your vehicle’s performance or safety system.
This could cause you to have an accident or increase your chances of injuries in an
accident. Always consult an Authorized Mazda Dealer before you install non-genuine
parts or accessories.
Add-On Electrical and Electronic Equipment:
Incorrectly choosing or installing improper add-on equipment or choosing an
improper installer is dangerous. Essential systems could damaged, causing engine
stalling, air-bag (SRS) activation, ABS inactivation, or a fire in the vehicle.
Be very careful in choosing and installing add-on electrical equipment, such as
mobile telephones, two-way radios, stereo systems, and car alarm systems.
WARNING
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10-3
Identification Numbers
Form No. 8Q94-EA-02G

Engine Number
Front 1.6-liter engine
2.0-liter engine
Front
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10-4
Form No. 8Q94-EA-02G
Specifications

Engine

Electrical System
*Only for MAZDASPEED Protegé

Lubricant Quality
*Refer to the recommended SAE viscosity numbers on page 8-9.
Specifications
ItemModel
1.6-liter engine 2.0-liter engine
Type DOHC-16V in-line, 4-cylinder
Bore×Stroke 78.0 × 83.6 mm (3.07 × 3.29 in) 83.0 × 92.0 mm (3.27 × 3.62 in)
Displacement 1,598 ml (1,598 cc, 97.5 cu in) 1,991 ml (1,991 cc, 121.5 cu in)
Compression ratio 9.0 9.1
ItemModel
1.6-liter engine 2.0-liter engine
Battery 12V-40AH/5HR12V-40AH/5HR
12V-52AH/5HR
Alternator 12 V-70 A 12 V-80 A
Starter 12 V - 1.0 kW 12 V - 1.0 kW
Spark-plug numberMAZDA—BP13 18 110, BP14 18 110
NGK ZFR5F-11, ZFR6F-11
BKR5E-11, BKR6E-11, PZFR6F
*
DENSO KJ16CR11, KJ20CR11 K16PR-U11, K20PR-U11
CHAMPION—RC8YC4, RC10YC4
Spark-plug gap
1.0—1.1 mm (0.040—0.043 in), 0.7—0.8 mm (0.028—0.031 in)
*
LubricantClassification
API Service ILSAC
Engine oil
*
SG (Energy Conserving II) —
SH (Energy Conserving II) GF-I
SJ GF-II
SL GF-III
Lubricant Classification
Manual transaxle oilAny temperatureAPI Service GL-4 or GL-5
SAE 75W-90
Above 10°C (50°F) API Service GL-4 or GL-5
SAE 80W-90
Automatic transaxle fluid ATF M-V
Power steering fluid ATF M-III or equivalent (e.g. Dexron® III)
Brake/Clutch fluid SAEJ1703 or FMVSS116 DOT-3
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10-5
Specifications
Form No. 8Q94-EA-02G

Capacities
(Approximate Quantities)
Check oil and fluid levels with dipsticks or reservoir gauges.

Dimensions
*Only for MAZDASPEED Protegé
ItemUnit
L US qt Imp qt
Engine oil1.6-liter engineWith oil filter replacement 3.2 3.4 2.8
Without oil filter replacement 3.0 3.2 2.6
2.0-liter engineWith oil filter replacement 3.5 3.7 3.1
Without oil filter replacement 3.3 3.5 2.9
Coolant1.6-liter engineWith heater 6.0 6.3 5.3
Without heater 5.5 5.8 4.8
2.0-liter engineWith heater 7.5 7.9 6.6
Without heater 6.9 7.3 6.1
Transaxle oilManual transaxle 2.7 2.9 2.4
Automatic transaxle 7.2 7.6 6.3
Fuel tank1.6-liter engine 50 13.2 (US gal) 11.0 (Imp gal)
2.0-liter engine 55 14.5 (US gal) 12.1 (Imp gal)
ItemModel
Sedan Hatchback
Overall length
4,450 mm (175.2 in), 4,445 mm
*(175.0 in)4,331 mm (170.5 in)
Overall width 1,705 mm (67.1 in) 1,705 mm (67.1 in)
Overall height 1,410 mm (55.5 in) 1,410 mm (55.5 in)
Front tread
1,470 mm (57.9 in), 1,455 mm
*(57.2 in)1,465 mm (57.7 in)
Rear tread
1,470 mm (57.9 in), 1,460 mm*(57.4 in)1,470 mm (57.9 in)
Wheelbase 2,610 mm (102.8 in) 2,610 mm (102.8 in)
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10-6
Specifications
Form No. 8Q94-EA-02G

We i g h t s
Sedan
*Only for MAZDASPEED Protegé
Hatchback

Air Conditioner
ItemWe i g h t
1.6-liter engine 2.0-liter engine
GVWR (Gross Vehicle Weight Rating) 1,600 kg (3,527 lb)1,653 kg (3,644 lb),
1,674 kg
*(3,691 lb)
GAWR (Gross Axle Weight Rating)Front 850 kg (1,874 lb)883 kg (1,947 lb),
889 kg
*(1,960 lb)
Rear 760 kg (1,675 lb)780 kg (1,720 lb),
785 kg
*(1,731 lb)
CW (Curb Weight)*—1,273 kg (2,807 lb)
Item Weight
GVWR (Gross Vehicle Weight Rating)Manual transaxle 1,638 kg (3,611 lb)
Automatic transaxle 1,662 kg (3,664 lb)
GAWR (Gross Axle Weight Rating)FrontManual transaxle 863 kg (1,903 lb)
Automatic transaxle 887 kg (1,955 lb)
Rear 780 kg (1,720 lb)
CW (Curb Weight)Manual transaxle 1,232 kg (2,716 lb)
Automatic transaxle 1,247 kg (2,749 lb)
Gas complies with SAE J639 Maximum operating charge
HFC134a (R-134a) 0.525 kg (18.55 oz)
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11-2
Form No. 8Q94-EA-02G
Index
A
Add-On Non-Genuine Parts and
Accessories
...................................... 9-10
Air Bag Systems
.............................. 2-36
Air Filter
.......................................... 8-19
Antenna
............................................ 6-10
Anti-Lock Brake System (ABS)
........ 5-7
Warning light
.............................. 5-7
Appearance Care
.............................. 8-42
Ashtray
............................................. 6-38
Audio System
................................... 6-10
Audio set
................................... 6-17
Operating tips for
audio system
............................. 6-11
Safety certification
.................... 6-34
Automatic Transaxle
Driving tips
............................... 5-12
Fluid
.......................................... 8-16
Overdrive
.................................. 5-11
Shift-lock system
...................... 5-11
Transaxle ranges
....................... 5-10
Automatic Transaxle (Sport AT)
Driving tips
............................... 5-18
Indicators
.................................. 5-15
Manual shift mode
.................... 5-15
Shifting
..................................... 5-16
Shifting recommendation
......... 5-17
Shift-lock override
.................... 5-14
Shift-lock system
...................... 5-14
Transaxle ranges
....................... 5-13
B
Battery
Maintenance
............................. 8-23
Specifications
........................... 10-4
Beeps
Ignition key reminder
............... 5-35
Lights-on reminder
................... 5-35
B
Seat belt warning beep .............. 5-35
Before Starting the Engine
................. 4-5
After getting in
............................ 4-5
Before getting in
......................... 4-5
Body Lubrication
............................. 8-19
Brake/Clutch
Fluid
.......................................... 8-14
Brakes
Anti-lock brake system (ABS)
....5-7
Foot brake
................................... 5-4
Pad wear indicator
...................... 5-8
Parking brake
.............................. 5-5
Warning light
.............................. 5-5
Break-In Period
.................................. 4-6
Bulb Replacement
............................ 8-29
C
Capacities ......................................... 10-5
Carbon Monoxide
.............................. 4-4
Cargo Securing Loops
...................... 6-39
Catalytic Converter
............................ 4-3
Cell Phones
...................................... 9-11
Center Console
................................. 6-39
Child Restraint
Child restraint precautions
........ 2-22
Installing child-restraint
systems
...................................... 2-25
LATCH child-restraint
systems
...................................... 2-31
Child Safety Locks for Rear Door
..... 3-8
Cigarette Lighter
.............................. 6-37
Climate Control System
.....................6-2
Gas specifications
..................... 10-6
Cruise Control
.................................. 5-19
Cup Holder
....................................... 6-38
Customer Assistance
.......................... 9-2
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11-3
Index
Form No. 8Q94-EA-02G
D
Dashboard Illumination ................... 5-26
Daytime Running Lights
.................. 5-38
Defroster
Rear window
............................. 5-40
Dimensions
...................................... 10-5
Door Locks
......................................... 3-6
Driving In Flooded Area
.................. 4-10
Driving Tips
....................................... 4-6
Automatic transaxle
.................. 5-12
Automatic transaxle
(Sport AT)
................................. 5-18
Break-in period
........................... 4-6
Driving in flooded area
............. 4-10
Hazardous driving
....................... 4-7
Money-saving suggestions
.......... 4-6
Rocking the vehicle
.................... 4-7
Trailer towing
........................... 4-11
Winter driving
............................. 4-8
E
Emergency Starting .......................... 7-15
Flooded engine
.......................... 7-15
Jump-starting
............................ 7-15
Push-starting
............................. 7-17
Emergency Towing
.......................... 7-18
Emission Control System
................... 4-3
Engine
Coolant
...................................... 8-12
Exhaust gas
................................. 4-4
Hood release
............................. 3-18
Oil
............................................... 8-9
Overheating
............................... 7-13
Starting
........................................ 5-3
Engine Compartment Overview
........ 8-8
Engine Coolant
Overheating
............................... 7-13
E
Engine Coolant Temperature
Gauge
...............................................5-25
Exhaust Gas
........................................4-4
Exterior Care
....................................8-44
F
Flasher
Hazard warning
.........................5-41
Headlights
.................................5-36
Flat Tire
..............................................7-3
Changing
.....................................7-7
Spare tire and tool storage
...........7-3
Fluids
Classification
.............................10-4
Owner maintenance
.....................8-6
Fog Lights
........................................5-37
Foot Brake
..........................................5-4
Front Seats
..........................................2-2
Fuel
Filler lid and cap
.......................3-16
Gauge
........................................5-26
Requirements
..............................4-2
Tank capacity
............................10-5
Fuses
.................................................8-38
Panel description
.......................8-40
Replacement
..............................8-38
G
Gauges ..............................................5-23
Glove Box
........................................6-39
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