Mazda PROTEGE Full Service & Repair Manual 2002

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🏷️ Basic Information Identification Make: Mazda Model: Protegé Year: 2002 Generation Generation Name: Third Generation (BJ Series) Generation Years: 1998-2003 Codes Chassis Code: BJ 👋 Introduction Market Position Segment: Compact...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protegé

Year:

Generation

Generation Name:

Third Generation (BJ Series)

Generation Years:

1998-2003

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact car, known for affordability, reliability, and sporty handling, particularly in performance trims.

Competitive Analysis

Competitors 2002:

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

Key Features

Platform Heritage:

Shared platform with Ford Focus and Volvo S40/V40 in some international markets, but primarily Mazda's own development for North America.

Design Philosophy:

Jinba Ittai ('horse and rider as one') driving dynamics, emphasizing driver engagement and responsive handling.

Availability Trims:

Available in sedan and hatchback body styles, with various trim levels like DX, LX, ES, and the performance-oriented Mazdaspeed Protegé.

📋 Manual Details

Coverage Areas

Regions Covered:

Likely global, with specific emphasis on North American specifications for 2002 model year.

Page Count

Estimated Page Count:

1500-2500+ pages (typical for comprehensive factory service manuals)

Manual Type

Type:

Factory Service and Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed diagrams, disassembly, assembly, overhaul, lubrication, cooling, exhaust, emissions control.

Engine Performance:

Fuel injection systems, ignition systems, engine management, diagnostics, tuning.

Transmission Manual:

Disassembly, assembly, clutch operation, gear shift mechanisms, lubrication.

Transmission Automatic:

Operation, removal, installation, overhaul, hydraulic control, torque converter, fluid specifications.

Drivetrain:

Axles, CV joints, differential (if applicable), drive shafts, wheel bearings.

Suspension:

Front and rear suspension components, alignment procedures, shock absorbers, springs, bushings.

Steering:

Power steering system, steering rack/gearbox, tie rod ends, steering column.

Brakes:

Front and rear brake systems (disc/drum), hydraulic lines, master cylinder, ABS (if equipped), brake fluid specifications.

Electrical System:

Battery, charging system (alternator, starter), lighting system, power windows, locks, mirrors, wipers.

Body And Interior:

Body panels, doors, hood, trunk, bumpers, interior trim, seats, HVAC controls.

Heating Ventilation Air Conditioning HVAC:

AC system components, refrigerant handling, heater core, blower motor, climate control.

Safety Systems:

Airbag system (SRS), seatbelt pre-tensioners, safety component diagnostics.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug service, fluid level checks, tire rotation.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, fault code interpretation (OBD-II).

Component Replacement:

Step-by-step instructions for replacing major and minor components.

Overhaul Rebuild:

Detailed procedures for complete engine, transmission, and other major component rebuilds.

Diagnostic Testing:

Procedures for testing various electrical and mechanical systems using multimeters, scan tools, and specialized equipment.

Alignment Specifications:

Front and rear wheel alignment angles, adjustments, and procedures.

Torque Specifications:

Precise torque values for all critical fasteners and components.

Technical Depth

Depth:

Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts.

Diagnostics Level:

Advanced diagnostics, including wiring diagrams, component testing, and signal tracing.

Rebuild Level:

Full engine and transmission rebuild procedures, including clearances and tolerances.

📊 Manual Specifications

File Format

Format:

Digital (PDF expected)

Searchability:

Likely text-searchable if professionally generated PDF.

Print Quality

Quality:

High resolution for diagrams and text, suitable for printing.

Binding Type

Binding:

Not applicable for digital download (printable pages).

Paper Type

Paper Type:

Not applicable for digital download (printable pages).

Software Requirements

Software:

PDF Reader software (e.g., Adobe Acrobat Reader).

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

FS-DE (2.0L DOHC 16-valve Inline-4)

Engine Displacement Primary:

1991 cc (2.0 Liters)

Bore X Stroke Primary:

83.0 mm x 92.0 mm

Compression Ratio Primary:

9.1:1 or 9.5:1 (depending on specific variant)

Horsepower Primary:

Approx. 125-130 hp @ 5500-6000 rpm

Torque Primary:

Approx. 130-135 lb-ft @ 4000-4500 rpm

Engine Variants

Other Engine Options:

Z5-DE (1.5L SOHC 16-valve Inline-4) in some markets, FS-ZE (2.0L DOHC Turbocharged) for Mazdaspeed Protegé.

Performance

Mazdaspeed Protege Engine:

FS-DET (2.0L DOHC 16-valve Turbocharged Inline-4)

Mazdaspeed Protege Horsepower:

Approx. 170 hp @ 5500 rpm

Mazdaspeed Protege Torque:

Approx. 170 lb-ft @ 3000 rpm

Fuel System

Fuel Induction:

Electronic Fuel Injection (EFI), Sequential Multiport Fuel Injection (SMPI)

Fuel Type:

Unleaded gasoline, 87 octane recommended (higher for Mazdaspeed)

Fuel Tank Capacity:

Approx. 13.0 US gallons (49 Liters)

🔧 Transmission

Standard

Transmission Type Standard:

5-speed manual transmission

Optional

Transmission Type Optional:

4-speed automatic transmission (F4A-EL or equivalent)

Features

Clutch Type:

Hydraulically actuated single dry plate (manual transmission)

Differential:

Open differential, standard

Gear Ratios:

Specific ratios for manual and automatic transmissions will be detailed in the manual.

📐 Dimensions

Exterior

Length:

Sedan: ~175.0 inches (4445 mm); Hatchback: ~165.0 inches (4190 mm)

Width:

Approx. 67.9 inches (1725 mm)

Height:

Sedan: ~55.7 inches (1415 mm); Hatchback: ~55.7 inches (1415 mm)

Wheelbase:

Approx. 102.7 inches (2606 mm)

Front Track:

Approx. 58.1 inches (1475 mm)

Rear Track:

Approx. 57.7 inches (1465 mm)

Weights

Curb Weight:

Approx. 2600-2900 lbs (1180-1315 kg), varies by trim and body style.

Gross Vehicle Weight Rating Gvwr:

Specific GVWRs will be listed in the manual.

Cargo

Trunk Volume Sedan:

Approx. 12.0-14.0 cubic feet

Cargo Volume Hatchback:

Significantly more with rear seats folded, details in manual.

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Likely 4-star rating (typical for vehicles of this era, requires manual confirmation).

NHTSA Front Impact Passenger:

Likely 4-star rating (typical for vehicles of this era, requires manual confirmation).

IIHS Moderate Overlap Frontal Offset:

Results vary by model year and specific tests, manual may reference IIHS data.

Active Features

Available on higher trim levels (ES, Mazdaspeed).

Traction Control:

May be available on select models, especially Mazdaspeed.

Electronic Brake Force Distribution Ebdf:

Often integrated with ABS systems.

Passive Features

Airbags:

Driver and passenger front airbags standard; side airbags available on some trims.

Seatbelts:

Three-point seatbelts with pre-tensioners for front occupants.

Crumple Zones:

Designed with energy-absorbing zones for crash protection.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player or cassette player, optional premium sound system.

Climate Control:

Manual or automatic climate control systems.

Driver Assistance

Cruise Control:

Standard on many trims, optional on base models.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors available on most trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (refer to manual for exact recommendation).

Engine Air Filter:

Replace every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Spark Plugs:

Replace every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (e.g., standard vs. platinum/iridium).

Transmission Fluid Change:

Manual: Inspect periodically, change if evidence of contamination. Automatic: Every 30,000-50,000 miles (48,000-80,000 km), check manual.

Coolant Flush:

Every 30,000-50,000 miles (48,000-80,000 km).

Brake Fluid Flush:

Every 2-3 years or 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil Type:

API Service SG, SH, SJ or ILSAC GF-2, GF-3. Viscosity: SAE 5W-30 recommended for most conditions. Refer to manual for exact specification.

Engine Oil Capacity:

Approx. 4.0-4.5 US quarts (3.8-4.3 Liters) with filter change.

Coolant Type:

Mazda Long Life Coolant (or equivalent ethylene glycol based coolant with de-ionized water).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Automatic:

Dexron III/Mercon (or equivalent ATF).

Transmission Fluid Manual:

GL-4 SAE 75W-90 or SAE 80W-90 gear oil.

Known Issues

Engine Mounts:

Can degrade over time leading to vibration.

Ignition Coils:

Can fail prematurely, causing misfires.

Catalytic Converter:

Can become clogged, affecting performance.

Power Steering Pump:

Potential for leaks or noise.

Rear Wheel Bearings:

Can develop noise and wear, especially on higher mileage vehicles.

Evaporative Emission Control System Evap:

Faulty purge valve or vent solenoid can trigger check engine light.

📚 Vehicle History

Brand Heritage

Mazda Reputation:

Known for sporty driving dynamics, reliable engineering, and innovative design.

Model Evolution

Protege Lineage:

The Protegé was Mazda's entry-level compact car, evolving from earlier models like the 323 (Familia in Japan). The BJ generation represented a significant redesign.

Bj Generation Updates:

The 2002 model year would likely feature minor cosmetic updates or feature additions as part of a mid-cycle refresh if applicable, though the core BJ platform remained consistent.

Production

Production Locations:

Primarily manufactured in Japan and Mexico.

Production Years Model:

1998-2003 (BJ Generation)

🏆 Awards & Recognition

Recognitions

Intellichoice Award:

The Protegé (BJ generation) received several 'Best Value' awards from IntelliChoice in its segment for its low ownership costs and reliability.

Ratings

Consumer Reports Reliability:

Generally rated as average to above average in reliability by consumer organizations for its era.