Mazda Protege 2002 All Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2002 Generation Generation Name: BJ (Second Generation) Codes Chassis Code: BJ 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair...

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Taper: Car

Distributeur:

UGS: 105329

Mots clés: 2002 Car Cars Mazda Misc Protege

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Generation

Generation Name:

BJ (Second Generation)

Codes

Chassis Code:

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts, independent repair shops, and Mazda Protege owners seeking to maintain or repair their vehicles

Competitive Analysis

Manual Value Proposition:

Offers extensive, dealership-level repair information at a fraction of the cost of professional labor, enabling users to perform a wide range of maintenance and repairs with confidence.

Key Features

User Friendliness:

Organized logically with clear headings, step-by-step instructions, and detailed illustrations/diagrams

Comprehensive Coverage:

Covers all major systems, including engine, transmission, brakes, electrical, and bodywork

📋 Manual Details

Coverage Areas

Coverage Scope:

All service and repair procedures for the 2002 Mazda Protege

Page Count

Estimated Page Count:

Approximately 1500-2000 pages (typical for a comprehensive service manual)

Manual Type

Manual Type:

Service and Repair Manual

Manual Format Type:

Digital Service and Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshaft, valve train, timing belt/chain, lubrication system, cooling system

Engine Performance:

Fuel injection system, ignition system, emissions control, engine diagnostics, performance tuning

Transmission Manual:

Manual transmission assembly, clutch system, gear shift mechanism, bearings, seals

Transmission Automatic:

Automatic transmission assembly, torque converter, valve body, planetary gears, shift control, transmission fluid cooler

Drivetrain:

Front-wheel drive system, axles, CV joints, differentials

Suspension:

Front suspension (struts, control arms, sway bar), rear suspension (independent or semi-independent, depending on model), shock absorbers, springs, bushings

Steering:

Power steering system (pump, rack and pinion, hoses), steering column, wheel alignment specifications

Brakes:

Front and rear brake systems (disc or drum, depending on trim), hydraulic system, brake pads, rotors, calipers, master cylinder, ABS system (if equipped)

Electrical System:

Battery, charging system (alternator), starting system (starter motor), ignition switch, wiring diagrams, fuses, relays

Lighting System:

Headlights, taillights, interior lights, turn signals, hazard lights, bulb types and replacement

Instrument Panel:

Gauges, warning lights, instrument cluster removal and repair

HVAC System:

Heating, ventilation, and air conditioning (AC) system, compressor, refrigerant, blower motor, climate controls

Body Interior:

Interior trim panels, seats, dashboard, door panels, carpets, headliner, seat belts

Body Exterior:

Body panels, doors, hood, trunk, bumpers, glass, mirrors, weather stripping, rust prevention

Chassis And Frame:

Frame structure, body mounting points, corrosion protection

Body Electronics:

Power windows, power locks, central locking system, remote keyless entry, sunroof operation

Audio System:

Factory radio, speaker replacement, antenna

Diagnostic Troubleshooting:

OBD-II diagnostic codes, troubleshooting flowcharts, symptom-based diagnostics

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, tire rotations, spark plug replacement, brake service, coolant flushes

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major systems

Troubleshooting Guides:

Detailed guides for diagnosing and fixing common problems with clear symptoms and solutions

Component Rebuilds:

Information on rebuilding major components like engines, transmissions, and brake calipers

Electrical Diagnostics:

Use of multimeters, interpreting wiring diagrams, tracing electrical faults

Special Tools:

Identification and usage of specialized tools required for specific repairs

Technical Depth

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine and transmission overhauls, including electrical system diagnostics and body repair

Diagnostic Capabilities:

Includes OBD-II scanner code interpretations and symptom-based troubleshooting for advanced diagnostics

Repair Specificity:

Detailed torque specifications, clearances, alignment procedures, and component tolerances

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval

Printability:

Printable pages for on-hand reference

Print Quality

Image Resolution:

High-resolution diagrams and images for clarity

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

FP-DE

Engine Displacement 1:

1.8 Liters (1839 cc)

Engine Configuration 1:

Inline 4-cylinder, DOHC, 16-valve

Horsepower 1:

122 hp @ 5500 rpm (approx.)

Torque 1:

114 lb-ft @ 3000 rpm (approx.)

Secondary Engine Optional

Engine Code 2:

FS-DE (Available on some higher trims/regions)

Engine Displacement 2:

2.0 Liters (1995 cc)

Engine Configuration 2:

Inline 4-cylinder, DOHC, 16-valve

Horsepower 2:

130 hp @ 5200 rpm (approx.)

Torque 2:

135 lb-ft @ 4000 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

🔧 Transmission

Standard

Transmission Type 1:

5-Speed Manual

Optional

Transmission Type 2:

4-Speed Automatic

Features

Drive Type:

Front-Wheel Drive (FWD)

📐 Dimensions

Exterior

Length:

167.2 - 170.4 inches (depending on body style)

Width:

67.1 inches

Height:

55.3 - 56.3 inches (depending on body style)

Wheelbase:

102.0 inches

Front Track:

58.3 inches

Rear Track:

57.7 inches

Cargo

Trunk Volume Sedan:

Approx. 12.0 cu ft

Weights

Curb Weight Est:

2600 - 2800 lbs (depending on configuration)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

★★★★ (4-star)

NHTSA Front Impact Passenger:

★★★★ (4-star)

IIHS Side Impact:

Acceptable (Rating varies by year and specific test)

Active Features

Available on most models (standard on higher trims)

Traction Control:

Rarely standard, might be available on specific performance trims

Passive Features

Airbags Front:

Driver and front passenger airbags

Seat Belts:

3-point front seat belts with pretensioners, 3-point rear seat belts

Child Seat Anchors:

LATCH system (Lower Anchors and Tethers for Children)

💡 Technology Features

Infotainment

Audio System Standard:

AM/FM stereo with cassette player and optional CD player, 4 speakers.

Audio System Upgrades:

Higher trims may have better audio systems or more speakers.

Driver Assistance

Anti-lock Braking System (ABS) was an available option, enhancing braking control.

Connectivity

Remote Keyless Entry:

Available on higher trim levels for convenience.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 to 7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for exact recommendations).

Engine Air Filter:

Replace every 15,000-30,000 miles or as needed based on inspection.

Cabin Air Filter:

Replace every 15,000-30,000 miles or annually for optimal air quality.

Spark Plugs:

Replace every 60,000-100,000 miles, depending on plug type (e.g., iridium plugs offer longer life).

Timing Belt:

Crucial! Replace every 60,000 to 90,000 miles or 5-7 years. Failure can cause severe engine damage (interference engine).

Fluid Specifications

Engine Oil Type 1 8L:

API SG or higher, SAE 5W-30 or 5W-40 (consult manual for precise recommendation).

Engine Oil Capacity 1 8L:

Approx. 3.8 U.S. quarts (with filter change).

Coolant Type:

Ethylene glycol based, Mazda specific coolant or compatible universal coolant. Typically a 50/50 mix with distilled water.

Transmission Fluid Manual:

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

Transmission Fluid Automatic:

Mazda Genuine ATF MV or equivalent Dexron III/Mercon. Consult manual for exact specification.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid:

Dexron II or III type automatic transmission fluid.

Known Issues

Engine Mounts:

Worn engine and transmission mounts can lead to excessive vibration and clunking noises.

Rear Main Seal Leaks:

The crankshaft rear main seal can develop leaks.

Evaporative Emissions System:

Issues with the EVAP system, such as a faulty vent solenoid or canister, can trigger check engine lights.

Power Steering Pump Noise:

The power steering pump can become noisy over time, especially when turning.

ABS Sensor Failure:

ABS wheel speed sensors can fail, leading to ABS warning lights and loss of ABS function.

Catalytic Converter:

The catalytic converter can become clogged or fail, affecting engine performance and emissions.

Window Regulators:

Power window regulators can fail, causing windows to become inoperable.

📚 Vehicle History

Brand Heritage

Mazda Brand Focus:

Mazda has a history of producing well-engineered, sporty, and reliable vehicles, often with a focus on driver engagement.

Model Evolution

Protege Lineage:

The Protege was Mazda's compact car offering, known for its value and good driving dynamics. The 2002 model is part of the second generation (BJ), which debuted in 1998/1999.

Trim Levels 2002:

Common trims included DX, LX, ES, and MP3 (performance variant). Body styles typically included sedan and hatchback (Protege5).

Production

Production Years Bj Gen:

1998-2003

Manufacturing Locations:

Primarily Japan, with some production potentially in other Mazda facilities globally.

🏆 Awards & Recognition

Recognitions

Automotive Press Recognition:

The Protege generally received positive reviews for its handling, fuel economy, and value proposition during its production run.

Ratings

Consumer Reports Reliability:

Reliability ratings varied by year and specific components, but many owners found them dependable with proper maintenance.