1991 Mazda Protege Service and Repair Manual

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Covers all 1991 Protege trims — DX Sedan 4-Door, GT Sedan 4-Door, 4WD Sedan 4-Door +1 more ·
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1991 Mazda Protege service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • DX Sedan 4-Door
  • GT Sedan 4-Door
  • 4WD Sedan 4-Door
  • LX Sedan 4-Door

Engines covered

  • 1.8L 1839CC l4 GAS SOHC Naturally Aspirated
  • 1.8L 1839CC l4 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
NHTSA #15V67400019/10/2015Component: ELECTRICAL SYSTEM:IGNITION:SWITCH

Mazda North American Operations (Mazda) is recalling certain model year 1989-1998 MPV, 1990-1995 323, 1990-1998 Protege, 1992-1993 MX-3, 1993-1995 929, 1993-1997 MX-6, and 1993-1998 626 vehicles. In

Consequence

If the ignition switch overheats there would be an increased risk of a fire.

Remedy

Mazda will notify owners, and dealers will replace the ignition switch, free of charge. The recall

TSB #10213425

Speedometer replacement procedure

TSB #10098367

IN ACCORDANCE WITH FEDERAL REGULATIONS, FOLLOW THE PROCEDURE LISTED BELOW WHEN REPLACING A SPEEDOMETER.NOTE:MAZDA VEHICLES ARE MANUFACTURED WITH TAMPER-PROOF SPEEDOMETERS.WHEN A SPEEDOMETER IS REPLACED, THE NEW SPEEDOMETER WILL READ ZERO (0

TSB #10009427

BATTERY TEST PROCEDURE REQUIREMENTS. *TT

TSB #10009424

SPEEDOMETER REPLACEMENT PROCEDURE. *TT

TSB #605988

EXPERIENCING POPPING NOISE FROM FRONT BRAKE CALIPER DURING SLOW SPEED BRAKING. *TT

TSB #603891

CONDITIONS WITH STEERING WHEEL SLIGHTLY OFF CENTER. *YC

TSB #603882

SUBJECT ON PASSIVE SEAT BELT RETRACTOR SWITCH. *YC

TSB #54318

SUBJECT PERTAINING TO MTX OVERHAUL INFORMATION. *YC

Showing the 8 most recent of 17 technical service bulletins on file with NHTSA.

20160108Component: AIR BAGSCrash reported1 injured

TL* THE CONTACT OWNS A 1991 MAZDA PROTEGE. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 45 MPH DURING RAIN WEATHER CONDITIONS, THE VEHICLE WENT OVER A POTHOLE CAUSING THE CONTACT TO LOSE CON

20160108Component: SEAT BELTSCrash reported1 injured

TL* THE CONTACT OWNS A 1991 MAZDA PROTEGE. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 45 MPH DURING RAIN WEATHER CONDITIONS, THE VEHICLE WENT OVER A POTHOLE CAUSING THE CONTACT TO LOSE CON

20001005Component: TIRESCrash reported1 injured

THIRD TIRE OF SET OF 4 THAT TREAD HAD SEPARATED - THIS ONE TOTALED THE CAR AND INJURED ONE PERSON. TIRE HAD 18,000 MILES WEAR. *AK (TIRESIZE: P185/60R14)( DOT NUMBER: TIRE SIZE: P185/60R14 )

19990323Component: VEHICLE SPEED CONTROLCrash reported1 injured

WENT TO STOP AT STOP LIGHT, ENGINE CONTINUED TO ACCELERATE, UNABLE TO STOP. REARENDED STATIONARY VEHICLE AT LIGHT. OUR VEHICLE TOTALED. DRIVER SUSTAINED INJURIES. *AK

19960715Component: SEAT BELTS:FRONT:RETRACTORCrash reported1 injured

DRIVING VEHICLE, ANOTHER VEHICLE DROVE OUT OF PARKING LOT & ORIGINAL VEHICLE HIT THE DRIVER'S SIDE, SEAT BELT DID NOT RESTRAIN THE DRIVER. *AK

Showing the 5 most serious of 60 complaints filed with NHTSA.

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