Positioning:
The Mazda Protegé (BJ chassis) was positioned as a compact/subcompact car known for its sporty handling, reliability, and value, often competing with vehicles like the Honda Civic, Toyota Corolla, and Ford Focus.
Competition:
This manual provides detailed factory-level information that surpasses generic Haynes or Chilton manuals, offering precise torque specifications, diagnostic procedures, and factory-approved repair methods essential for maintaining the vehicle's original performance and longevity.
Features:
Comprehensive coverage, factory accuracy, no subscription or expiry fees, instant digital access, essential for DIY mechanics and professional workshops alike.
Coverage:
All repairs, servicing, diagnostics, maintenance, troubleshooting, wiring diagrams, technical specifications, exploded views, component identification.
Page Count:
Estimated 2500+ pages (typical for full factory service manuals of this era).
Type:
Factory Service Manual / Workshop Manual
Format:
Digital Download (PDF or similar compatible format)
Powertrain:
Engine mechanical, engine management (ECU), fuel system, ignition system, exhaust system, cooling system.
Drivetrain:
Transmission (manual and automatic), clutch, driveshafts, differentials, axles, hubs.
Chassis:
Suspension (front and rear), steering system, brakes (hydraulic, ABS, parking brake).
Electrical:
Battery, charging system, starting system, lighting, instrument cluster, power windows, locks, wipers, horns, audio system, body control modules, wiring diagrams.
Body:
Body exterior, interior trim, doors, hood, trunk, bumpers, glass, seats, airbags.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, tire rotation.
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting charts, fault code explanations.
Repair:
Component removal and installation, overhaul procedures, adjustments, component testing.
Diagnostics:
OBD-II diagnostics, sensor testing, actuator testing, ECU diagnostics.
Depth:
Comprehensive from basic fluid checks and filter changes to complete engine and transmission rebuilds, including detailed electrical diagnostics and wiring schematics.
File Type:
PDF (Portable Document Format) or similar, ensuring compatibility across devices.
Quality:
High-resolution scans or digital originals, suitable for printing individual pages or the entire manual.
Binding:
N/A (Digital format - no physical binding).
Paper:
N/A (Digital format - no physical paper).
Engine Codes:
Z5-DE (1.5L I4), FS-DE (2.0L I4), FS-Z (2.0L DOHC I4 with VVT).
Displacements:
1.5 Liters (1498 cc), 2.0 Liters (1991 cc).
Horsepower Range:
Approximately 105 hp (1.5L) to 130 hp (2.0L FS-DE) and 140 hp (2.0L FS-Z with VVT).
Torque Range:
Approximately 95 lb-ft (1.5L) to 135 lb-ft (2.0L).
Injection Type:
Electronic Fuel Injection (EFI) with multi-point injection (MPI).
Fuel Requirement:
Unleaded gasoline, typically 87 octane (87 AKI).
Type:
Distributorless Ignition System (DIS) with coil-on-plug technology on some models.
ECU:
Mazda Engine Control Unit (ECU) with OBD-II diagnostics.
Coolant Type:
Mazda Genuine Long Life Antifreeze/Coolant (Blue) or equivalent HOAT coolant.
Manual:
5-speed manual transmission.
Automatic:
4-speed automatic transmission.
Manual Fluid:
API GL-4 SAE 75W-90 or SAE 75W-85 gear oil.
Automatic Fluid:
Mazda Genuine ATF J3 or equivalent Mercon V specification.
Clutch Type:
Dry single plate, hydraulically actuated diaphragm spring clutch.
Length:
Approx. 166.1 - 172.8 inches (depending on body style).
Width:
Approx. 67.7 inches.
Height:
Approx. 55.7 - 57.1 inches (depending on body style).
Wheelbase:
Approx. 102.8 inches.
Curb Weight:
Approx. 2500 - 2700 lbs (depending on model and trim).
Wheel Bolt Pattern:
4x100mm (common for many trims).
Wheel Size:
14-inch or 15-inch alloy or steel wheels.
Tire Size:
185/65R14, 195/55R15 (typical).
NHTSA Front Impact:
Likely 4-star driver and 4-star passenger (based on general BJ Protegé ratings).
IIHS Side Impact:
Varies by year and configuration; some Protegé models received 'Good' ratings.
ABS:
Available Anti-lock Braking System (ABS) on certain trims and as an option.
Traction Control:
Limited availability on specific performance models or as an option.
Airbags:
Driver and passenger front airbags. Side airbags available on some higher trims.
Seatbelts:
3-point seatbelts with pretensioners and load limiters for front occupants.
Audio System:
Factory AM/FM/CD player, often with 4 or 6 speakers. Some premium systems may have an amplifier.
Climate Control:
Manual or automatic climate control systems depending on trim level.
Cruise Control:
Available cruise control system on most models.
Keyless Entry:
Available as an option or on higher trim levels.
OBD Ii:
Equipped with OBD-II diagnostic port for emissions and engine diagnostics.
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first, under normal driving conditions. Severe driving may require more frequent changes.
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving environment.
Spark Plug Replacement:
Every 60,000 - 100,000 miles for platinum or iridium plugs, depending on type installed.
Timing Belt Replacement:
Every 60,000 - 90,000 miles for FS-DE/FS-Z engines (interference engines, critical replacement).
Engine Oil Capacity:
Approx. 4.2 quarts (4.0L) for 1.5L and 2.0L engines with filter change.
Engine Oil Viscosity:
5W-30 is typically recommended for most ambient temperatures.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Engine Mounts:
Degradation and failure of engine and transmission mounts, leading to vibration and noise.
Oxygen Sensors:
Premature failure of oxygen sensors, affecting fuel economy and emissions.
Idle Control Valve:
Clogging or failure of the Idle Air Control (IAC) valve, causing rough idle or stalling.
Exhaust Manifold:
Cracking of the exhaust manifold on some 2.0L models, leading to exhaust leaks.
Power Steering:
Leaking power steering hoses or pumps.
Mazda Heritage:
Mazda has a long history of producing reliable and often driver-focused vehicles, with a reputation for engineering innovation and value.
Protege Evolution:
The 2002-2003 models represent the later years of the third generation (BJ) Protegé, which saw significant updates in styling, safety, and powertrain compared to earlier generations. This generation was also available as a sedan, hatchback (ES), and wagon (also named Protegé5).
Manufacturing Locations:
Primarily manufactured in Japan and Mexico.
