2002 Mazda Protege Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2002 Codes Chassis Code: BJ (Third Generation) Engine Codes: FP-DE (1.8L), FS-DE (2.0L DOHC) 👋 Introduction Market Position Vehicle Segment: Compact...

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Type: Car

Vendor:

Sku: 236442

Tags: 2002 Car Cars Mazda Misc Protege

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Codes

Chassis Code:

BJ (Third Generation)

Engine Codes:

FP-DE (1.8L), FS-DE (2.0L DOHC)

👋 Introduction

Market Position

Vehicle Segment:

Compact Car

Target Audience:

Budget-conscious buyers, first-time car owners, enthusiasts seeking reliable transportation.

Competitive Analysis

Key Competitors:

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

Key Features

Vehicle Strengths:

Reliability, fuel efficiency, sporty handling (especially GT models), affordable maintenance.

Manual Value Proposition:

Provides essential technical information for DIY maintenance and repair, saving on labor costs and empowering owners.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Manual / Service Manual

Language:

English

Format:

Digital Download (PDF)

Page Count

Estimated Page Count:

1500+

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, repair, timing belt, oil pump, pistons, crankshaft, cylinder head.

Engine Performance:

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

Transmission Manual:

Clutch system, gearshift linkage, manual transmission disassembly, assembly, inspection, repair.

Transmission Automatic:

Automatic transmission operation, disassembly, assembly, hydraulic control, electronic control unit (ECU) integration.

Drivetrain:

Front-wheel drive (FWD), driveshafts, CV joints, differential, transaxle.

Suspension:

Front struts, rear shock absorbers, control arms, bushings, coil springs, sway bars, alignment specifications.

Steering:

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

Brakes:

Front disc brakes, rear drum/disc brakes, ABS system, hydraulic lines, brake fluid specifications, bleeding procedures.

Electrical System:

Battery, alternator, starter motor, charging system, fuses, relays, wiring diagrams, lighting systems.

Engine Control Module ECM:

ECM operation, sensor inputs, actuator outputs, diagnostic trouble codes (DTCs), reprogramming information.

Body And Interior:

Body panel removal/installation, door mechanisms, interior trim, seats, dashboard, HVAC system.

Heating Ventilation Air Conditioning HVAC:

AC system components, refrigerant types, charging procedures, blower motor, climate controls.

Safety Systems:

Airbag system, seatbelt pre-tensioners, SRS component replacement.

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, tire rotation.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, fault code explanations.

Repair:

Step-by-step instructions for component removal, installation, and adjustment for all major vehicle systems.

Diagnostics:

On-board diagnostics (OBD-II) scan tool usage, sensor data analysis, diagnostic connector locations.

Wiring Diagrams:

Detailed electrical wiring schematics for all circuits, including component locations and pinouts.

Specifications Data:

Torque specifications, clearances, fluid capacities, and other critical data for repairs and maintenance.

Technical Depth

Depth Level:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Detail:

Advanced diagnostic procedures, including oscilloscope use for sensor analysis and signal tracing.

Component Rebuilds:

Detailed instructions for rebuilding engines, transmissions, and other major components.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Format:

N/A (Digital Download)

Paper Type

Paper Format:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

1.8L (1839 cc)

Engine 1 Type:

DOHC Inline-4, 16-valve

Engine 1 Power:

120-125 hp @ 6000 rpm (approx.)

Engine 1 Torque:

117-120 lb-ft @ 4000 rpm (approx.)

Engine 2 Displacement:

2.0L (1991 cc)

Engine 2 Type:

DOHC Inline-4, 16-valve (FS-DE)

Engine 2 Power:

140 hp @ 6000 rpm (approx.)

Engine 2 Torque:

135 lb-ft @ 4000 rpm (approx.)

Performance

Compression Ratio Fp:

9.2:1

Compression Ratio Fs:

9.1:1

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 Octane recommended)

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug

Engine Management

Engine Control Unit:

Mazda Electronic Control Unit (ECU)

🔧 Transmission

Standard

Transmission Type 1:

5-Speed Manual Transmission

Optional

Transmission Type 2:

4-Speed Automatic Transmission

Features

Clutch Type:

Hydraulically actuated dry single-plate clutch

Automatic Transmission Features:

Electronically controlled, lock-up torque converter.

📐 Dimensions

Exterior

Length:

169.4 inches (Sedan) / 170.5 inches (Hatchback)

Width:

67.1 inches

Height:

55.5 inches (Sedan) / 56.1 inches (Hatchback)

Wheelbase:

102.8 inches

Front Track:

58.1 inches

Rear Track:

57.7 inches

Weights

Curb Weight Min:

2600 lbs (approx.)

Curb Weight Max:

2800 lbs (approx.)

Gross Vehicle Weight Rating Gvw:

3700 lbs (approx.)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Rating:

★★★★☆ (4-star)

NHTSA Frontal Passenger Rating:

★★★★☆ (4-star)

IIHS Frontal Offset Rating:

Active Features

Anti Lock Brakes ABS:

Standard on most trims

Traction Control TCS:

Optional on some trims

Passive Features

Airbags Front:

Dual front airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

3-point front and rear seatbelts, front seatbelt pre-tensioners.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player; optional premium audio systems available on higher trims.

Display:

Basic digital clock and radio display. No advanced touchscreen or navigation available for 2002.

Driver Assistance

Cruise Control:

Available on most trims.

Connectivity

Auxiliary Input:

Not typically standard; aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first.

Engine Air Filter Interval:

Every 15,000 miles or 12 months.

Cabin Air Filter Interval:

Every 15,000 miles or 12 months (if equipped).

Spark Plug Replacement Interval:

Every 60,000-100,000 miles (depending on plug type, e.g., iridium).

Timing Belt Replacement Interval:

Every 60,000 miles or 5 years (critical for interference engines).

Fluid Specifications

Engine Oil Type:

API Service SG, SH, or SJ category; SAE 5W-30 or 5W-20 (check owner's manual for exact specification)

Engine Oil Capacity:

3.7 - 4.2 quarts (4.0 - 4.4 liters) with filter change (Varies by engine)

Coolant Type:

Mazda Long Life Coolant (or equivalent ethylene glycol-based coolant with deionized water)

Transmission Fluid Manual:

API GL-4 SAE 75W-90 gear oil

Transmission Fluid Automatic:

Mazda ATF JWS 3317 or equivalent Dexron III/Mercon

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Power Steering Fluid Type:

Mazda Genuine ATF or equivalent Dexron II/III

Known Issues

Common Concern 1:

Timing belt failure (especially if not replaced at recommended intervals, as engines are typically interference).

Common Concern 2:

Sagging headliner (common in older vehicles due to adhesive degradation).

Common Concern 3:

Front suspension components (e.g., control arm bushings, sway bar links) wear.

Common Concern 4:

Catalytic converter issues or emissions control problems.

Common Concern 5:

Power window regulators can fail.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Mazda is known for its 'Jinba Ittai' (horse and rider as one) philosophy, emphasizing driving dynamics and driver connection.

Model Evolution

Generation Introduction:

The third generation Protege (BJ) debuted for the 1999 model year, with significant updates for 2001 and continuing into 2002.

Body Styles Offered:

Sedan, 5-door hatchback (MP3, Mazdaspeed Protege variants were often hatchback).

Production

Production Years:

1998-2003 (for the BJ generation)

Manufacturing Locations:

Japan, Mexico, Taiwan, Thailand, China.

🏆 Awards & Recognition

Recognitions

Car And Driver 2002 Alist:

The Protege 5 (a variant) was recognized by Car and Driver on its '10Best' list for value and practicality.

General Reputation:

Praised for its value, sporty handling (especially GT and MP3/Mazdaspeed models), and overall reliability within its class.