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2002 Mazda Protege Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2002 Codes Chassis Code: BJ 👋 Introduction Market Position Segment: Compact car Target Audience: Economy-minded buyers, first-time car owners, enthusiasts Competitive...
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2002 Mazda Protege Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Year:
2002
Codes
Chassis Code:
BJ
👋 Introduction
Market Position
Segment:
Compact car
Target Audience:
Economy-minded buyers, first-time car owners, enthusiasts
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra
Key Features
Vehicle Strengths:
Reliability, affordability, good handling (especially Mazdaspeed versions), practical interior
Manual Value:
Enables DIY repairs, reduces labor costs, ensures correct procedures are followed
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete repair and service procedures
Secondary Coverage:
Maintenance, diagnostics, electrical systems, chassis, body
Page Count
Estimated Pages:
Approximately 1500-2000 (typical for a comprehensive factory service manual of this era)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, and repair for all variants
Engine Performance:
Engine tuning, fuel injection, ignition system, emission control
Transmission Manual:
Manual transmission repair, clutch, gearbox
Transmission Automatic:
Automatic transmission repair, torque converter, shift control
Drivetrain:
Front-wheel drive, axles, CV joints, differential
Suspension:
Front and rear suspension, shock absorbers, springs, control arms, bushings
Steering:
Power steering system, steering gear, steering column, tie rods
Brakes:
Front and rear disc brakes, ABS, brake lines, master cylinder, calipers
Electrical System Powertrain:
Engine control module (ECM), sensors, actuators, wiring diagrams for powertrain
Electrical System Body:
Lighting, wipers, power windows, door locks, interior electronics, wiring diagrams for body
HVAC:
Heating, ventilation, air conditioning system diagnosis and repair
Body And Frame:
Body panels, doors, bumpers, chassis structure, repair procedures
Procedures Included
Fundamental Procedures:
Basic maintenance, fluid changes, filter replacements, lubrication
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), diagnostic flowcharts
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair
Scheduled Maintenance:
Recommended service intervals and procedures
Electrical Troubleshooting:
Detailed wiring diagrams, component testing, circuit analysis
Pre Delivery Inspection:
Inspection checklist for new vehicles
Jacking And Towing:
Correct jacking points, lifting procedures, towing guidelines
Technical Depth
Depth:
Comprehensive: from routine maintenance to complete engine and transmission overhauls, advanced diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text (if properly created PDF)
Print Quality
Quality:
Digital copy, print quality depends on user's printer
Binding Type
Binding:
N/A (Digital Delivery)
Paper Type
Paper:
N/A (Digital Delivery)
⚙️ Engine Specifications
Primary Engine
Engine Code:
FS-DE (2.0L DOHC)
Displacement:
1991 cc (2.0 Liters)
Configuration:
Inline 4-cylinder
Valvetrain:
DOHC, 16 valves
Performance
Horsepower:
130 hp @ 6000 rpm (approximate for non-Mazdaspeed)
Torque:
135 lb-ft @ 4000 rpm (approximate for non-Mazdaspeed)
Compression Ratio:
9.1:1 (typical for FS-DE)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Engine Code
Alternative Engine Code:
FP-DE (1.8L SOHC - less common in North America for 2002, but possible)
🔧 Transmission
Standard
Type:
5-speed Manual
Optional
Type:
4-speed Automatic
Features
Clutch Type:
Dry, single-plate (Manual)
Transmission Fluid Manual:
API GL-4, SAE 75W-90 (typically)
Transmission Fluid Automatic:
Dexron III or equivalent (typically)
📐 Dimensions
Exterior
Length:
Approximately 173.8 inches
Width:
Approximately 67.3 inches
Height:
Approximately 55.5 inches
Wheelbase:
Approximately 102.8 inches
Weights
Curb Weight:
Approximately 2600-2800 lbs (depending on trim and transmission)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-star driver, 4-star passenger (for sedan, typical for the era)
IIHS Side Impact:
Good (for models equipped with side airbags)
Active Features
ABS:
Available (standard on higher trims, optional on some)
Traction Control:
Less common, potentially available on specific trims or Mazdaspeed models
Passive Features
Airbags Front:
Standard dual front airbags
Airbags Side:
Optional front side-impact airbags
Seatbelts:
3-point front and rear seatbelts
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player (optional premium audio)
Climate Control:
Manual or automatic climate control (depending on trim)
Driver Assistance
Cruise Control:
Available on most trims
Connectivity
Aux Input:
Not standard, aftermarket solutions are common
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 miles or 6 months (typical recommendation)
Air Filter Replacement:
Every 30,000 miles or 24 months (typical)
Spark Plug Replacement:
Every 60,000 - 100,000 miles (depending on spark plug type)
Timing Belt Replacement:
This model uses a timing chain, not a belt, which generally does not require periodic replacement.
Fluid Specifications
Engine Oil:
API SN/SP, ILSAC GF-6A, SAE 5W-20 or 5W-30 (check manual for specific engine variant)
Coolant:
Mazda FL22 Long Life Coolant (or equivalent G12/G12+ type, pre-diluted)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine Oil Consumption:
Some FS-DE engines can experience increased oil consumption with age and mileage; proper maintenance is key.
Exhaust Manifold:
Cracking on the exhaust manifold can occur due to thermal stress.
Cv Boots:
Front CV axle boots can wear and tear, leading to lubrication loss and joint damage.
Ac Compressor:
AC compressor clutch or the unit itself can fail over time.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Jinba Ittai - unity of horse and rider, emphasizing driver engagement and responsiveness
Model Evolution
Generation:
Second Generation (BJ, 1998-2003)
Facelift:
Minor facelift for 2001 model year, continuing into 2002
Production
Manufacturing Location:
Hofu, Yamaguchi, Japan; AutoAlliance International, Flat Rock, Michigan, USA (for some markets)
🏆 Awards & Recognition
Recognitions
Car Of The Year:
While the Protege as a whole did not win major 'Car of the Year' awards in 2002, it was consistently praised for its value and driving dynamics in its class.
Ratings
Consumer Reports:
Typically rated average to above average for reliability for its era, with some specific components showing higher failure rates as documented in owner surveys.
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