Mazda 323 Protegé BJ, 1998-2003 Workshop Manual
Detailed repair, maintenance and diagnostics manual for Mazda 323 Protegé BJ (1998-2003). Includes wiring diagrams, error codes (DTC), instructions for the engine, transmission, suspension, brake system and other vehicle components. Ideal for mechanics and owners who want to understand the structure of the car.
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| Mazda 323 Protegé BJ (1998-2003) General Information | Download |
| Mazda 323 Protegé BJ (1998-2003) Engine Repair Manual ZM, FS | Download |
| Mazda 323 Protegé BJ (1998-2003) Suspension | Download |
| Mazda 323 Protegé BJ (1998-2003) Driveline/Axle | Download |
| Mazda 323 Protegé BJ (1998-2003) Brakes, Parking Brake System | Download |
| Mazda 323 Protegé BJ (1998-2003) Transmission/Transaxle | Download |
| Mazda 323 Protegé BJ (1998-2003) Steering | Download |
| Mazda 323 Protegé BJ (1998-2003) HVAC | Download |
| Mazda 323 Protegé BJ (1998-2003) Restraints | Download |
| Mazda 323 Protegé BJ (1998-2003) Body and Accessories | Download |
| Mazda 323 Protegé BJ (1998-2003) Wiring Diagram Supplement | Download |
| Mazda 323 Protegé BJ (1998-2003) Service Index | Download |
Mazda 323 Protegé – Main Problems
1. Engine
Common faults:
⚠ Oil consumption (2.0 FS-DE, 1.6 ZM-DE) – sticking oil scraper rings and wear of valve seals.
⚠ Noise from hydraulic lifters – especially on 1.6 and 1.8 liters.
⚠ Problems with the cooling system – weak radiator, frequent antifreeze leaks.
✅ Solution:
Use high-quality oil (5W-30, 5W-40) and change it every 7,000 – 10,000 km.
Flush hydraulic lifters every 50,000 km.
Check the antifreeze level and the condition of the radiator.
2. Transmission (manual and automatic transmission)
Main problems:
⚠ Wear of manual transmission synchronizers – especially 2nd and 3rd gears.
⚠ Kicks and delays in automatic transmission (F4A-EL, FN4A-EL) – solenoids fail.
✅ Solution:
Change the oil in the gearbox every 40,000 km.
If kicks appear – clean the valve body and replace the solenoids.
3. Suspension and steering
Common faults:
⚠ Rapid wear of bushings and stabilizer struts.
⚠ Steering rack play after 120,000 km.
✅ Solution:
Change the stabilizer bushings every 40,000 km.
Check the steering rack and tighten the adjusting bolt if necessary.
4. Electrics and sensors
⚠ Failure of the ignition coils – especially on the 2.0 FS.
⚠ Malfunction of the MAF (mass air flow sensor) - causes floating revolutions.
⚠ Oxidation of the wiring and relay due to moisture.
✅ Solution:
Install original or reinforced ignition coils.
Clean the MAF every 20,000 km.
Check the wiring before winter.
5. Body corrosion
⚠ Sills, arches, rear fenders rot - especially in regions with reagents.
✅ Solution:
Do anti-corrosion treatment every 2-3 years.
Monitor the condition of the body before winter.