Mazda PROTEGE Service Repair Manual 02-ON

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🏷️ Basic Information Identification Make: Mazda Model: Protegé Model Years Covered: 2002 onwards Generation Generation: Third Generation (BJ) Codes Chassis Code Primary: BJ 👋 Introduction Market Position Market Segment: Compact...

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UGS: 267216

Mots clés: 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 Car Cars Mazda Misc Protege

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protegé

Model Years Covered:

2002 onwards

Generation

Generation:

Third Generation (BJ)

Codes

Chassis Code Primary:

👋 Introduction

Market Position

Market Segment:

Compact Car / Small Family Sedan/Hatchback

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Hyundai Elantra.

Key Features

Reputation:

Known for reliability, sporty handling, and value for money, especially with the performance-oriented Mazdaspeed variants.

Target Audience:

Individuals and families seeking an economical and engaging driving experience, DIY mechanics.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Page Count

Page Count:

Hundreds of Pages (estimated 1500+ pages based on typical comprehensive manuals)

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Detailed disassembly, inspection, repair, and reassembly procedures for all engine variants.

Fuel System:

Fuel injection systems (MPI/GDI), fuel pump, injectors, pressure regulator, evaporative emission control (EVAP).

Ignition System:

Spark plugs, ignition coils, ECU control, timing.

Cooling System:

Radiator, thermostat, water pump, hoses, fan operation, coolant specifications.

Exhaust System:

Catalytic converter, mufflers, oxygen sensors, emissions control.

Transmission Manual:

Clutch operation, gearbox disassembly, internal component replacement, shift linkage.

Transmission Automatic:

Torque converter, valve body, planetary gear sets, hydraulic control, transmission control module (TCM).

Drivetrain:

Front-wheel drive (FWD), all-wheel drive (AWD) system (if applicable), driveshafts, CV joints, differential.

Suspension Front:

MacPherson struts, control arms, ball joints, stabilizer bars, bushings, alignment specifications.

Suspension Rear:

Independent suspension (e.g., multi-link), shock absorbers, springs, bushings, alignment.

Steering System:

Power steering pump, rack and pinion, steering column, tie rods, alignment.

Brake System:

Front disc brakes, rear drum or disc brakes, ABS (Anti-lock Braking System) components, hydraulic lines, master cylinder, brake bleeding procedures.

Electrical System Dc:

Battery, alternator, starter motor, wiring diagrams, fuses, relays.

Lighting System:

Headlights, taillights, interior lighting, bulb replacement, aiming procedures.

Instrument Panel:

Gauges, warning lights, sensor inputs, cluster diagnostics.

Body Exterior:

Body panel removal/installation, door mechanisms, hood, trunk lid, bumpers, glass replacement.

Body Interior:

Seat removal/installation, dashboard trim, headliner, carpet, door panels.

HVAC System:

Air conditioning (A/C) system, heater core, blower motor, climate controls, refrigerant charging.

Safety Systems:

Airbag system (SRS) removal/installation, seatbelt mechanisms, crash sensor locations.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, fluid checks and top-offs.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, identification of common faults.

Component Replacement:

Step-by-step instructions for replacing major and minor components across all systems.

Diagnosis:

OBD-II (On-Board Diagnostics) code retrieval, interpretation, and diagnostic procedures for sensor failures.

Rebuilds:

Complete engine and transmission rebuild procedures with detailed specifications.

Adjustment Procedures:

Valve lash adjustment, throttle body synchronization, idle speed adjustment.

Calibration:

ECU/PCM relearn procedures, sensor calibration (e.g., throttle position sensor).

Technical Depth

Diagnostic Tools:

Guidance on using scan tools, multimeters, and specialized diagnostic equipment.

Torque Specifications:

Precise torque values for all critical fasteners (engine, chassis, body).

Electrical Schematics:

Comprehensive and detailed wiring diagrams for all vehicle systems.

Specifications Charts:

Detailed charts for engine clearances, component tolerances, fluid capacities, and wear limits.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution digital format optimized for clear viewing and printing of diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

Searchability

Searchability:

Likely text-searchable PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

FS-DE (2.0L DOHC)

Engine Displacement Liters:

Engine Configuration:

Inline 4-cylinder

Engine Aspiration:

Naturally Aspirated

Performance

Horsepower Approx 20L:

125-130 hp @ 6000 rpm

Torque Approx 20L:

135-140 lb-ft @ 4000 rpm

Mazdaspeed Engine Code:

FS-DET (2.0L DOHC Turbocharged)

Mazdaspeed Horsepower:

170 hp @ 5500 rpm

Mazdaspeed Torque:

170 lb-ft @ 3000 rpm

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type Std:

5-Speed Manual

Optional

Transmission Type Opt:

4-Speed Automatic

Features

AWD Availability:

Available on some models, often paired with specific trims or engines.

📐 Dimensions

Exterior

Wheelbase Inches:

102.8

Length Inches Sedan:

178.7

Width Inches:

Height Inches:

Weights

Curb Weight Lbs Typical:

2700-3000 lbs (varies by trim and drivetrain)

Gross Vehicle Weight Rating Gvwr Lbs:

Approx. 3800-4000 lbs

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Good (for 2003 model year, specific ratings may vary slightly by year/configuration)

NHTSA Front Impact Passenger:

Good (for 2003 model year)

IIHS Side Impact:

Acceptable or Good (depending on year and specific test parameters)

Active Features

ABS Standard Optional:

Optional on lower trims, standard on higher trims or later model years.

Traction Control:

Available on some models, particularly AWD or performance variants.

Passive Features

Airbags Standard:

Frontal airbags (driver and passenger) standard.

Airbags Optional:

Side airbags (curtain and/or torso) available on some trims.

Seatbelts:

Three-point seatbelts with pretensioners for front seats.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM CD player with optional premium audio systems (e.g., Bose).

Display:

Basic LCD screen for radio and clock functions; no integrated navigation or touchscreen on most models.

Driver Assistance

Cruise Control:

Available on most models, standard on higher trims.

Keyless Entry:

Available on higher trim levels.

Connectivity

Auxiliary Input:

Rarely standard; some later models might have an aftermarket or dealer-installed option.

🔧 Maintenance

Service Intervals

Oil Change Interval Miles:

Every 5,000 to 7,500 miles or 6 months, whichever comes first (depending on oil type and driving conditions).

Air Filter Replacement Miles:

Every 15,000 to 30,000 miles.

Spark Plug Replacement Miles:

Every 60,000 to 100,000 miles (depending on spark plug type - standard vs. iridium).

Transmission Fluid Change Miles:

Automatic: 60,000 miles (severe service), 100,000 miles (normal). Manual: inspect regularly, change as needed.

Fluid Specifications

Engine Oil Type Viscosity:

API SN/SP, ILSAC GF-5/GF-6A certified SAE 5W-20 or 5W-30 (check owner's manual for specific engine recommendations).

Coolant Type:

Mazda Super Long Life Coolant (Blue) or equivalent HOAT (Hybrid Organic Acid Technology) coolant.

Brake Fluid Type:

DOT 3 or DOT 4.

Transmission Fluid Type Auto:

Mazda ATF-FZ or equivalent Dexron-III/Mercon compatible fluid.

Transmission Fluid Type Manual:

API GL-4 SAE 75W-90 synthetic gear oil.

Known Issues

Engine Oil Consumption:

Some FS-DE engines can develop oil consumption issues due to worn piston rings or valve stem seals.

Rear Main Seal Leaks:

Rear crankshaft main seal leaks are a known issue on higher mileage vehicles.

Catalytic Converter Failure:

Premature failure can occur, often due to engine misfires or oil burning.

Suspension Components:

Worn ball joints, tie rods, and control arm bushings can lead to steering looseness and noise.

Power Steering Pump Noise:

Humming or whining noises from the power steering pump can indicate low fluid or a failing pump.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Jinba Ittai (Horse and Rider as One) - Focus on driving dynamics and connection.

Model Evolution

First Generation:

1990-1997 (GB/GC chassis)

Second Generation:

1998-2001 (BJ chassis, early models)

Third Generation Intro:

Introduced for the 2002 model year, featuring updated styling and technology.

Production

Production Location:

Hofu Plant, Yamaguchi Prefecture, Japan; also produced at plants in Mexico and Thailand for various markets.

Production End

Model Discontinuation North America:

Discontinued after the 2003 model year in North America, replaced by the Mazda3.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Previous generations of the Protegé were recognized by Car and Driver, indicating its solid market standing.

Ratings

Jd Power Dependability:

Generally scored well in dependability studies for its class during its production run.