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Mazda Protege 2002 Full Service Repair Manual

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$16.99
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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2002 Codes Chassis Code: BJ 👋 Introduction Market Position Vehicle Segment: Compact Car Target Audience: DIY mechanics, automotive enthusiasts, repair shops....
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Mazda Protege 2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Year:
2002
Codes
Chassis Code:
BJ
👋 Introduction
Market Position
Vehicle Segment:
Compact Car
Target Audience:
DIY mechanics, automotive enthusiasts, repair shops.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra
Key Features
Vehicle Appeal:
Reliability, fuel efficiency, sporty handling (especially with SP2 trim), affordability.
Manual Value Proposition:
Empowers owners to maintain and repair their Mazda Protege, saving significant costs and extending vehicle lifespan.
📋 Manual Details
Coverage Areas
Manual Type:
Full Service & Repair Manual
Language:
English
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine Mechanical, Engine Control (ECU), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Emission Controls
Drivetrain Systems:
Manual Transmission, Automatic Transmission, Clutch, Driveshafts, Differentials, Axles
Suspension Steering:
Front Suspension, Rear Suspension, Steering System, Power Steering
Brake Systems:
Front Brakes, Rear Brakes, ABS (Anti-lock Braking System), Parking Brake
Electrical Systems:
Battery, Charging System, Starting System, Lighting System, Instrumentation, Wiper/Washer System, Horn, Power Accessories, Fuses and Relays, ECU Wiring Diagrams
Body Chassis:
Body Structure, Doors, Windows, Seats, Interior Trim, Exterior Trim, Bumpers, Hood, Trunk, Frame
Heating Ventilation Ac:
HVAC System, Air Conditioning, Heater, Ventilation
Procedures Included
Maintenance Procedures:
Oil Change, Filter Replacement, Fluid Checks and Replacements, Belt Inspection and Replacement, Spark Plug Replacement, Tune-up Procedures, Tire Rotation, Brake Pad/Rotor Service
Diagnostic Procedures:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs) Explanation, Component Testing Procedures, Fault Finding Charts
Repair Procedures:
Engine Overhaul, Transmission Overhaul, Suspension Component Replacement, Brake Caliper Rebuild, Electrical Component Replacement, Body Panel Repair, Interior Component Repair
Rebuild Refurbish:
Detailed instructions for rebuilding engine, transmission, and other major components.
Technical Depth
Depth Level:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds.
Diagnostics Focus:
In-depth diagnostic procedures with troubleshooting flowcharts and component testing specifications.
Diagrams Illustrations:
Detailed diagrams, exploded views, and step-by-step illustrations for all procedures.
📊 Manual Specifications
File Format
Format Details:
Searchable PDF
Print Quality:
High-resolution, printable pages
Binding Type
Binding Format:
Digital (PDF Download)
Paper Type
Paper Specification:
N/A (Digital Format)
Page Count
Estimated Page Count:
Over 1000 pages (estimated for a full service manual of this scope)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
FS-DE
Engine Type 1:
2.0L DOHC 16-valve Inline-4
Displacement 1:
1991 cc (121.5 cubic inches)
Bore X Stroke 1:
83.0 mm x 92.0 mm
Compression Ratio 1:
9.1:1
Horsepower 1:
122 hp @ 5500 rpm (standard models)
Torque 1:
127 lb-ft @ 4000 rpm (standard models)
Performance
Engine Code 2:
YF-DE (for SP2 trim - JDM spec, might vary)
Engine Type 2:
2.0L DOHC 16-valve Inline-4 (Variable Valve Timing - VVT)
Horsepower 2:
130 hp @ 6000 rpm (SP2 trim - typical output)
Torque 2:
135 lb-ft @ 4000 rpm (SP2 trim - typical output)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Recommended Octane:
87 AKI (or higher)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual
Optional
Transmission Type Optional:
4-Speed Automatic (with Overdrive)
Features
Automatic Transmission Features:
Electronically controlled, lock-up torque converter.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 gear oil (e.g., Mazda Genuine Gear Oil) - refer to manual for exact spec
Automatic Transmission Fluid:
Mazda ATF-SP II M or equivalent (e.g., Dexron III/Mercon)
📐 Dimensions
Exterior
Length:
Approx. 169.1 inches (4295 mm) for sedan, 167.9 inches (4265 mm) for hatchback
Width:
Approx. 67.3 inches (1709 mm)
Height:
Approx. 55.7 inches (1415 mm) for sedan, 55.9 inches (1420 mm) for hatchback
Wheelbase:
Approx. 102.7 inches (2606 mm)
Weights
Curb Weight:
Approx. 2600-2800 lbs (1180-1270 kg), varies by trim and transmission
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
4/5 Stars (for 2002 model, specific test results may vary)
NHTSA Passenger Front Impact:
4/5 Stars (for 2002 model, specific test results may vary)
Active Features
ABS:
Available on certain trims, standard on some higher trims.
Passive Features
Airbags:
Driver and passenger front airbags standard. Side airbags available on some trims.
Seatbelts:
3-point front seat belts with pretensioners and load limiters, 3-point rear seat belts.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player (optional cassette player on some models), 4 or 6 speakers.
Display:
Basic digital or analog climate controls and radio display.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Bluetooth Compatibility:
Not available from the factory.
Usb Ports:
Not available from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (severe conditions may require shorter intervals).
Engine Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for standard plugs, or 60,000-100,000 miles for platinum/iridium plugs (refer to manual).
Transmission Fluid Change:
Manual: Check every 30,000 miles. Automatic: Every 45,000 miles (90,000 km) under normal use, more frequently for severe use.
Fluid Specifications
Engine Oil Type:
API SJ or higher, SAE 5W-30 viscosity grade recommended (refer to manual for specific temperature ranges).
Coolant Type:
Mazda Super Long Life Coolant (Blue) or equivalent ethylene glycol-based coolant with demineralized water (50/50 mix).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Oil Consumption:
Some FS-DE engines can consume oil, especially at higher mileage. Regular checks are crucial.
Ignition Coils:
Coil-on-plug systems can be prone to failure, leading to misfires.
Rear Wheel Bearings:
Can develop noise and require replacement over time.
Rust Corrosion:
As with many vehicles of this era, check for rust, especially in wheel wells, rocker panels, and subframes.
Transmission Mounts:
Can degrade, leading to clunking noises during acceleration or shifting.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Jinba Ittai (horse and rider as one) - focus on driving dynamics and driver connection.
Model Evolution
Protege Generations:
The 2002 model is part of the third generation (BJ) Protege, produced from 1998-2003.
Bj Generation Updates:
Introduced in 1998, the BJ generation saw styling updates and powertrain improvements over its lifecycle. The 2002 model represents a later iteration of this platform.
Production
Manufacturing Location:
Primarily manufactured in Japan, with some production in other Mazda facilities globally.
🏆 Awards & Recognition
Recognitions
Automotive Journal Awards:
While specific 2002 awards are scarce, the Protege line generally received praise for value, handling, and reliability from automotive publications of the era. For instance, Motor Trend named the Protege ES a 'Best Buy' in its class in previous years.
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