Mazda PROTEGE Service Repair Manual 2002-2003

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🏷️ Basic Information Identification Make: Mazda Model: Protege Model Variant: FS-DE, YD-DE, FP-DE (depending on market and trim) Year Range: 2002-2003 Codes Chassis Code: BJ (platform shared with Ford Focus...

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Type: Car

Vendor:

Sku: 360129

Tags: 2002 2003 Car Cars Mazda Misc PROTEGE

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Model Variant:

FS-DE, YD-DE, FP-DE (depending on market and trim)

Year Range:

2002-2003

Codes

Chassis Code:

BJ (platform shared with Ford Focus and Volvo S40/V40)

👋 Introduction

Market Position

Market Segment:

Compact sedan and hatchback, competing with vehicles like Honda Civic, Toyota Corolla, and Ford Focus.

Competitive Analysis

Key Strengths Of Protege:

Sporty handling (especially Mazdaspeed variants), good value proposition, reliable engines.

Key Features

Manual Value Proposition:

Provides professional-grade repair information, enabling owners to perform extensive maintenance and repairs, saving significant costs compared to dealership servicing.

Manual Completeness Claim:

Advertised as a complete service repair manual, equivalent to factory workshop manuals, offering comprehensive coverage.

📋 Manual Details

Coverage Areas

Coverage Summary:

Comprehensive service and repair for all major vehicle systems.

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Service and Repair Manual (Factory Workshop Manual equivalent)

Language

Language:

English

Format

Format:

Digital (PDF recommended for searchability and ease of use)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, crankshaft, timing system, lubrication, cooling system.

Engine Control:

Fuel injection, ignition system, emissions control, engine control module (ECM) diagnosis and programming.

Transmission Manual:

Manual transmission overhaul, clutch system, gear selection.

Transmission Automatic:

Automatic transmission overhaul, torque converter, shift control, hydraulic system.

Drivetrain:

Front-wheel drive system, axles, CV joints, driveshafts.

Suspension:

Front and rear suspension components, struts, shocks, springs, control arms, bushings, alignment specifications.

Steering:

Power steering system, steering rack, tie rods, steering column.

Brakes:

Front and rear disc brakes, anti-lock braking system (ABS), hydraulic system, parking brake.

Electrical System:

Battery, charging system, starting system, lighting, horn, wipers, power accessories.

HVAC:

Heating, Ventilation, and Air Conditioning system, refrigerant, compressor, evaporator, heater core.

Body And Chassis:

Body panels, doors, windows, interior trim, frame, rust prevention.

Safety Systems:

Airbag system, seat belts, SRS control unit.

Procedures Included

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for all systems, including symptom-based troubleshooting charts and diagnostic trouble codes (DTCs).

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.

Component Repair Rebuild:

Detailed instructions for disassembling, repairing, and reassembling all major mechanical and electrical components.

Electrical Component Replacement:

Wiring diagrams, component testing, and replacement procedures for sensors, actuators, control modules, and accessories.

Suspension Steering Alignment:

Component replacement, adjustment procedures, and detailed alignment specifications.

Brake System Service:

Brake pad and rotor replacement, caliper service, bleeding the brake system, ABS component replacement.

HVAC System Service:

Refrigerant handling, component replacement, leak detection, system evacuation and recharging.

Body Repair:

Panel replacement, door hinge and lock repair, glass replacement.

Technical Depth

Depth Of Coverage:

Factory-level technical detail, suitable for professional technicians and advanced DIY mechanics.

Diagnostics Level:

In-depth diagnostic strategies, including the use of scan tools and oscilloscopes.

Specifications Data:

Torque specifications, clearances, fluid capacities, electrical system schematics, and diagnostic data.

📊 Manual Specifications

File Format

File Format Typical:

Print Quality

Image Resolution:

High resolution, suitable for printing and clear viewing of diagrams.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Fs De:

2.0L DOHC 16-valve Inline-4 (FS-DE)

Engine Displacement Fs De:

1991 cc (121.5 cu in)

Horsepower Fs De Std:

130 hp @ 5500 rpm (estimated, may vary by market)

Torque Fs De Std:

135 lb-ft @ 4000 rpm (estimated, may vary by market)

Other Engines

Engine Code Yd De:

1.8L DOHC 16-valve Inline-4 (YD-DE)

Engine Code Fp De:

2.0L DOHC 16-valve Turbocharged Inline-4 (FP-DE - Mazdaspeed Protege)

Performance

0 60 Mph Std:

Approx. 9.0-9.5 seconds (depending on transmission and trim)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 Octane (Minimum)

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission

Optional

Optional Transmission:

4-speed Automatic Transmission

Features

Clutch Type:

Dry, single-plate (for manual transmission)

📐 Dimensions

Exterior

Wheelbase:

Approx. 102.8 inches (2611 mm)

Length:

Approx. 173.9 inches (4417 mm) - Sedan

Width:

Approx. 67.5 inches (1715 mm)

Height:

Approx. 55.7 inches (1415 mm) - Sedan

Weights

Curb Weight:

Approx. 2700-2900 lbs (1225-1315 kg) - depending on trim and powertrain

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

4-star (driver), 4-star (passenger) - for 2002 model year

IIHS Side Impact Rating:

Good (for models equipped with side airbags)

Active Features

Standard on most models, optional on some base trims.

Traction Control:

Optional on select higher trims.

Passive Features

Airbags:

Driver and front passenger airbags standard. Optional side airbags.

Seat Belts:

Three-point seatbelts with pretensioners for front seats.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium audio with amplifier.

Climate Control:

Manual or automatic climate control (depending on trim level).

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

Power Windows Locks:

Available, depending on trim level.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions).

Engine Oil Filter Replacement:

Replace at every oil change.

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on inspection.

Spark Plug Replacement:

Platinum-tipped plugs: 100,000 miles (160,000 km). Standard plugs: 30,000 miles (48,000 km).

Coolant Replacement:

Initial replacement at 60,000 miles (96,000 km) or 5 years, then every 30,000 miles (48,000 km) or 2.5 years thereafter.

Fluid Specifications

Engine Oil Type:

API SM or ILSAC GF-4 certified 5W-30 (or 5W-20 if specified for extreme cold).

Engine Oil Capacity:

Approx. 4.2 US quarts (4.0 liters) with filter change for 2.0L engine.

Transmission Fluid Manual:

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

Transmission Fluid Automatic:

Mazda ATF-J / ATF-III (Mercon compatible).

Coolant Type:

Mazda Genuine Super Long Life Coolant (or equivalent HOAT coolant).

Known Issues

Ignition Coil Packs:

Premature failure of coil packs can lead to misfires.

Catalytic Converter:

Can become clogged over time, especially if engine is burning oil.

Suspension Bushings:

Wear and tear on control arm bushings can lead to clunking noises and poor handling.

Power Steering Pump:

Occasional leaks or noisy operation.

Transmission Clutches Automatic:

Wear on clutch packs in the automatic transmission can lead to slipping or delayed shifts.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Jinba-Ittai (Horse and Rider as One) - focusing on driver engagement and responsive handling.

Model Evolution

Protege Generation:

This manual covers the third generation (BJ platform) of the Mazda Protege, which debuted for the 1999 model year and received a significant facelift for 2001.

Powertrain Updates 2002 2003:

Minor updates to emissions and potentially ECU tuning for compliance.

Production

Manufacturing Locations:

Primary production was in Japan, with some assembly in other global locations.