Market Position:
The Mazda Protege (2002-2003) was a compact car positioned as a reliable, practical, and often sporty alternative in a highly competitive segment against rivals like the Honda Civic, Toyota Corolla, and Ford Focus.
Competitive Analysis:
The Protege stood out for its engaging driving dynamics, particularly in its sportier 'ES' and 'Mazdaspeed' variants, and offered a good balance of features and affordability. This workshop manual provides the detailed technical information necessary for owners and technicians to maintain and repair these vehicles effectively, ensuring their performance and longevity.
Key Features:
This manual is essential for anyone needing to perform diagnostics, maintenance, or repairs on the 2002-2003 Mazda Protege. Its comprehensive nature ensures that both common and complex tasks can be addressed with confidence.
Engine Systems:
Engine mechanical (assembly, disassembly, overhaul), engine management system (ECU, sensors, actuators), lubrication, cooling, fuel, ignition, emissions control.
Transmission Systems:
Manual and automatic transmission overhaul, clutch operation, gear shifting mechanisms, torque converter, transmission control.
Drivetrain Systems:
Front-wheel drive system, drive shafts, CV joints, differential.
Suspension And Steering:
Front and rear suspension (struts, shocks, bushings, control arms), power steering system, steering rack, steering column.
Brake Systems:
Front and rear disc brakes, ABS system, brake fluid, calipers, rotors, pads, parking brake.
Electrical Systems:
Battery, charging system, starting system, lighting system, interior/exterior lights, dashboard instruments, fuses, relays, wiring diagrams, body control module (BCM).
Body And Interior:
Exterior body panels, doors, hood, trunk, interior trim, seats, HVAC system, body sealing, paint repair.
Safety Systems:
Airbag system, seat belt mechanisms, ABS functionality related to safety.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement.
Diagnostic Procedures:
Troubleshooting guides for common issues, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation and clearing, electrical system diagnostics.
Repair Procedures:
Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs.
Specifications And Tolerances:
Precise torque specifications, clearances, measurements, and alignment data for all repair procedures.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems.
Technical Depth:
Extremely high. Covers everything from basic fluid checks to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical system tracing.
Engine Displacement And Type:
1.6L DOHC Inline-4 (Z5) and 2.0L DOHC Inline-4 (FS-DE)
Horsepower 1.6L:
105 hp @ 6000 rpm
Torque 1.6L:
105 lb-ft @ 4000 rpm
Horsepower 2.0L:
125 hp @ 6000 rpm
Torque 2.0L:
130 lb-ft @ 4000 rpm
Engine Displacement Mazdaspeed:
2.0L DOHC Turbocharged Inline-4 (FS-DET)
Horsepower Mazdaspeed:
170 hp @ 5500 rpm
Torque Mazdaspeed:
170 lb-ft @ 3000 rpm
Fuel System Type:
Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (SMPI), Turbocharged Sequential Fuel Injection (TSFI) for Mazdaspeed
Fuel Octane Rating:
87 Octane (for naturally aspirated engines); 91 Octane recommended for Mazdaspeed
ECU Type:
Denso or Hitachi ECU (specifics vary by market and engine variant)
Standard Transmission Type:
5-speed Manual Transmission
Optional Transmission Type:
4-speed Automatic Transmission
Clutch Type:
Hydraulically actuated, single dry plate clutch
Manual Transmission Fluid Spec:
API GL-4, SAE 75W-90 (or equivalent specified by Mazda)
Automatic Transmission Fluid Spec:
Mazda ATF J-M3 or equivalent ATF Dexron III/Mercon
Wheelbase:
Approx. 102.8 inches (2610 mm)
Length:
Approx. 170.9 inches (4341 mm)
Width:
Approx. 67.7 inches (1720 mm)
Height:
Approx. 55.7 inches (1415 mm)
Curb Weight:
Approx. 2600 - 2900 lbs (1180 - 1315 kg), depending on trim and equipment
Gross Vehicle Weight Rating:
Typically around 3700 lbs (1680 kg)
Trunk Volume:
Approx. 12.1 cubic feet (342 liters) for sedan, varies for hatchback
NHTSA Front Impact Driver:
★★★★ (4-Star)
NHTSA Front Impact Passenger:
★★★★ (4-Star)
IIHS Front Offset Crash Rating:
Good (for models equipped with side airbags)
ABS:
Available Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS) on some models
Airbags:
Dual front airbags, optional side-impact airbags
Seatbelts:
3-point front and rear seat belts, pre-tensioners for front seats
Infotainment System Description:
Basic infotainment systems for the era, typically including an AM/FM radio with CD player or cassette tape deck. Higher trims may offer premium audio systems from brands like Bose.
Driver Assistance Features:
Limited by modern standards. Features like ABS and Traction Control (on select models) were the primary driver assistance technologies available.
Connectivity Features:
Basic connectivity, typically through auxiliary audio inputs or aftermarket Bluetooth adapters. No integrated smartphone integration or advanced telematics.
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe driving conditions may require shorter intervals.
Air Filter Replacement Interval:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement Interval:
Every 60,000 miles (96,000 km) for conventional spark plugs; up to 100,000 miles (160,000 km) for platinum-tipped plugs (consult manual for exact type).
Timing Belt Replacement Interval:
75,000 miles (120,000 km) or 5 years (for FS-DE/FS-DET engines). Crucial to prevent catastrophic engine damage if the belt breaks.
Engine Oil Specification:
SAE 5W-30, API SJ or higher, ILSAC GF-3 certified
Coolant Specification:
Mazda Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid
Engine Oil Capacity:
Approx. 4.3 US quarts (4.1 liters) with filter, for 2.0L engines.
Cooling System Capacity:
Approx. 5.4 US quarts (5.1 liters).
Common Issues List:
Ignition coil failure, catalytic converter failure, wheel bearing wear, HVAC blower motor issues, power steering pump leaks, minor oil leaks from valve cover or oil pan gaskets.
Brand Heritage:
Mazda has a long history of producing reliable and driver-focused vehicles, often incorporating innovative technologies and unique styling cues. The Protege line benefited from this heritage, aiming to offer a compelling package in the compact car segment.
Third Generation Bj:
The 2002-2003 models represent the third generation (BJ) of the Protege, introduced for the 2001 model year. This generation saw significant styling updates, improved chassis dynamics, and the introduction of the high-performance Mazdaspeed variant.
Production Period:
The third-generation Protege (BJ) was produced from 1998/1999 (depending on market) through 2005, with significant facelifts and updates occurring during its lifecycle.
Manufacturing Locations:
Primary manufacturing was in Japan, with some assembly occurring in other global locations.
