🏷️ Basic Information

Make:

Mazda

Model:

Protege

Year:

2002

Platform:

BJ (Second Generation)

Chassis Code:

BJ3P, BJ5P, BJ8W

👋 Introduction

Vehicle Segment:

Compact Car / Small Family Car

Target Audience:

Budget-conscious buyers, young drivers, families seeking reliable and economical transportation.

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra

Design Philosophy:

Mazda's 'Zoom-Zoom' driving dynamics, practical and functional interior, reliable mechanicals.

Utility For Owners:

Empowers DIY enthusiasts and independent mechanics with comprehensive diagnostic and repair information.

Professional Use:

Provides essential data for professional automotive technicians to efficiently diagnose and repair the vehicle.

📋 Manual Details

Primary Focus:

ZM and FS engine families, mechanical and electrical systems

Estimated Pages:

1000+

Type:

Workshop Manual / Service Manual

Language:

English

Format:

Digital (likely PDF), potentially Printable

📖 Manual Coverage

Engine Management:

On-Board Diagnostics (OBD) for ZM & FS engines, Engine Control Systems, Cruise Control System, Fuel System, Ignition System, Starting System, Charging System, Intake Air System (ZM & FS), Exhaust System, Emission System

Drivetrain:

Manual Transaxle (F25M-R, G15M-R, Shift Mechanism), Automatic Transaxle (Shift Mechanism), Driveline/Axle (Front Axle, Rear Axle, Drive Shaft), Clutch

Suspension Steering:

Front Suspension, Rear Suspension, Wheel Alignment, Power Steering, Engine Speed Sensing

Brakes:

Conventional Brake System, Parking Brake System, Antilock Brake System (ABS), OBD, Symptom Troubleshooting

HVAC:

Refrigerant System, Basic System, Control System, Symptom Troubleshooting

Electrical Body:

Lighting Systems, Wiper/Washer System, Instrumentation/Driver Info, Power Door Lock System, Audio System, Body Panels, Doors and Liftgate, Glass/Windows/Mirrors, Seats, Sunroof, Exterior Trim, Interior Trim, Entertainment Systems, Security and Locks

Safety Restraints:

Air Bag System, Seat Belt Service

General Maintenance:

Lubrication, Cooling System Maintenance, Fluid Changes

Troubleshooting:

Symptom Troubleshooting for Engine Control Systems (ZM & FS), HVAC, Brakes, Restraints

Diagnostic Procedures:

On-Board Diagnostics (OBD) codes and interpretation for Engine Control and Power Door Locks, Audio systems

Repair Procedures:

Detailed mechanical repair procedures for all covered systems, including engine, transmission, suspension, brakes, steering, body, and HVAC

Special Tools:

Listing and usage of specialized service tools required for specific repairs and diagnostics

Diagnostic Capability:

Comprehensive diagnostic procedures covering OBD interpretation, symptom-based troubleshooting, and specific system checks.

Mechanical Depth:

Detailed step-by-step repair instructions, including disassembly, inspection, repair, and reassembly of all major mechanical components.

Electrical Depth:

Wiring diagrams, component locations, testing procedures for electrical systems, including ECU diagnostics.

📊 Manual Specifications

Digital Features:

Searchable text, hyperlinked table of contents, high-resolution diagrams.

Diagram Clarity:

High-quality, clear, and detailed diagrams, schematics, and illustrations.

Physical Manual Potential:

If printed, likely spiral-bound or perfect-bound for ease of use on a workbench.

Physical Manual Potential:

Durable paper stock suitable for workshop environments, resistant to grease and wear.

⚙️ Engine Specifications

Engine Code:

ZM-DE

Configuration:

DOHC I4 (Inline 4-Cylinder)

Displacement:

1.5 Liters (1498 cc)

Horsepower Est:

103 hp @ 6000 rpm

Torque Est:

102 lb-ft @ 4000 rpm

Engine Code:

FS-DE

Configuration:

DOHC I4 (Inline 4-Cylinder)

Displacement:

2.0 Liters (1991 cc)

Horsepower Est:

118-125 hp @ 5000-5400 rpm

Torque Est:

123-125 lb-ft @ 4000-4300 rpm

Injection:

Multi-port Fuel Injection (MPI)

Engine Variations Covered:

Specifically ZM (1.5L) and FS (2.0L) engine families.

🔧 Transmission

Transmission Type Manual:

5-speed Manual Transaxle (F25M-R or G15M-R)

Transmission Type Automatic:

4-speed Automatic Transaxle (F4E-AT or 4F27E)

Manual Transaxle Codes:

F25M-R, G15M-R

Automatic Transaxle Codes:

F4E-AT, 4F27E

Clutch Type:

Dry single-plate clutch (manual transmission)

📐 Dimensions

Length Est:

167.7 - 173.3 inches

Width Est:

67.7 inches

Height Est:

55.7 - 56.7 inches

Curb Weight Est:

2600 - 2850 lbs

🛡️ Safety Features

NHTSA Frontal Impact Driver:

4-star (for the 2002 model year)

NHTSA Frontal Impact Passenger:

4-star (for the 2002 model year)

IIHS Moderate Overlap Frontal Offset:

Good (for the 1999-2003 generation)

ABS:

Available Antilock Brake System (ABS)

Traction Control:

Not commonly available on this generation

Airbags:

Frontal airbags (driver and passenger), available side airbags.

Seatbelts:

3-point front and rear seat belts, pretensioners and load limiters for front seats.

💡 Technology Features

Audio System:

Factory-installed AM/FM/CD player with basic speaker system. Optional premium audio available on higher trims.

Cruise Control:

Electronically controlled cruise control system, detailed in the manual.

Usb Aux:

Not typically equipped from factory; aftermarket solutions common.

🔧 Maintenance

Oil Change Interval:

Typically 5,000 - 7,500 miles or 6-12 months, depending on driving conditions and oil type.

Engine Coolant Flush:

Every 2-3 years or 30,000-45,000 miles.

Timing Belt Replacement:

For FS engine: Typically 60,000 miles (check specific model for exact interval as it might be a belt or chain).

Engine Oil:

API SN/SP or ILSAC GF-5/GF-6A. Viscosity: 5W-30 is common. Consult manual for exact spec based on climate.

Engine Coolant:

Mazda FL22 Long Life Coolant (or equivalent OAT/HOAT coolant). Mix 50/50 with distilled water.

Transmission Fluid Manual:

API GL-4 SAE 75W-90 Gear Oil.

Transmission Fluid Automatic:

Mazda ATF (or equivalent Dexron III/Mercon compatible fluid).

Engine Common Problems:

Oil leaks from valve cover or oil pan gasket, occasional ignition coil failure, carbon buildup on intake valves (especially with direct injection variants not covered here).

Suspension Common Problems:

Worn sway bar end links, strut mounts, and control arm bushings leading to knocking or rattling noises.

Transmission Common Problems:

Manual clutch wear, automatic transmission shifting issues (less common for this era but possible).

Electrical Common Problems:

Window regulator failures, power lock actuator issues, dashboard warning light intermittency.

📚 Vehicle History

Manufacturer:

Mazda Motor Corporation

Global Names:

Mazda Familia, Mazda 323

Generation Designation:

BJ (Second Generation)

Production Years:

1999-2003 (for the BJ generation)

Manufacturing Locations:

Japan (primary), also produced in other Mazda plants globally.

🏆 Awards & Recognition

Jd Power Initial Quality:

Mazda Protege generally received good ratings for initial quality and reliability in its segment during its production years.