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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Tags: 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

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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.