2002 Mazda Protege Workshop Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2002 Generation Generation Code: BJ (Second Generation) Codes Chassis Code: BJ3P (sedan), BJ5P (hatchback) 👋 Introduction Market Position Market Segment: Compact...

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类型: Car

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标签: 2002 Car Cars Mazda Protege

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Generation

Generation Code:

BJ (Second Generation)

Codes

Chassis Code:

BJ3P (sedan), BJ5P (hatchback)

👋 Introduction

Market Position

Market Segment:

Compact Car / Economy Car

Competitive Analysis

Key Competitors:

• Honda Civic

• Toyota Corolla

• Nissan Sentra

• Ford Focus

• Chevrolet Cavalier/Cobalt

Key Features

Vehicle Strengths:

Reliability (generally), engaging driving dynamics for its class, practical interior space, fuel efficiency.

Manual Value Proposition

User Benefits:

Empowers owners with knowledge for DIY maintenance and repairs, aids in understanding vehicle systems, facilitates informed decisions with mechanics, helps diagnose issues efficiently, saves money on labor costs.

📋 Manual Details

Coverage Areas

Systems Covered:

• General Information

• Special Tools

• Specifications

• Maintenance

• Engine

• Cooling System

• Fuel System and Emissions Control

• Transaxle (Manual & Automatic)

• Steering System

• Suspension System

• Brake System

• Body and Frame

• Heater, Ventilation, and Air Conditioning (HVAC)

• Electrical System (including wiring diagrams)

Page Count

Estimated Page Count:

Comprehensive (exact page count not provided in product info, but typical for a full workshop manual exceeds 1000 pages)

Manual Type

Manual Type:

Workshop Repair Manual / Service Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanicals (cylinder head, block, pistons, crankshaft), lubrication, timing (belt/chain), ignition, fuel delivery, emissions control systems (catalytic converter, O2 sensors, EVAP), engine management (ECU diagnostics).

Drivetrain Systems:

Manual transaxle (clutch, gears, synchronizers, bearings), automatic transaxle (torque converter, planetary gears, valve body, solenoids), differential, CV joints, driveshafts.

Chassis Systems:

Front and rear suspension components (shocks, struts, control arms, bushings), steering rack, power steering pump, steering column, brake system (master cylinder, calipers, rotors, pads, lines, ABS components).

Body And Comfort Systems:

Body panel removal/installation, interior trim, door mechanisms, glass, HVAC system components (compressor, evaporator, heater core, blower motor, controls), seat mechanisms.

Electrical Systems:

Battery, starting and charging system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams for all vehicle systems, power windows, mirrors, central locking, instrument cluster, audio system.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes, drive belt inspection/replacement, tire rotation, air filter replacement, cabin air filter replacement.

Repair Procedures:

Engine overhaul, head gasket replacement, transmission rebuild, clutch replacement, brake component replacement, suspension part replacement, power steering pump replacement, alternator replacement, starter motor replacement, radiator replacement.

Diagnostic Procedures:

Troubleshooting guides for common drivability issues, diagnostic trouble codes (DTCs) interpretation, electrical system fault finding, fuel system pressure testing, emissions system diagnostics.

Special Tool Instructions:

Identification and usage instructions for specialized tools required for specific repair or maintenance tasks.

Technical Depth

Depth Of Coverage:

Comprehensive from basic maintenance to complex engine and transmission overhauls. Includes detailed diagnostic procedures and specifications for professional technicians and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

PDF Features:

Likely searchable text, printable pages, bookmarked chapters for easy navigation.

Print Quality

Print Quality Description:

Digital PDF format allows for high-resolution display of diagrams and text. Print quality depends on user's printer.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Options 2002:

• 1.6L (1598cc) 4-cylinder DOHC (Z5-DE)

• 2.0L (1991cc) 4-cylinder DOHC (FS-DE)

Performance

1.6L Engine Performance:

Approx. 106 hp @ 6000 rpm, 103 lb-ft torque @ 4000 rpm

2.0L Engine Performance:

Approx. 130 hp @ 5800 rpm, 135 lb-ft torque @ 4300 rpm

Fuel System

Fuel Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Emission Controls

Emission System Components:

Catalytic converter, Oxygen (O2) sensors, Exhaust Gas Recirculation (EGR) system, Evaporative Emission Control (EVAP) system.

🔧 Transmission

Standard Transmission

Standard Transmission Type:

5-speed Manual

Optional Transmission

Optional Transmission Type:

4-speed Automatic (with overdrive)

Features

Automatic Transmission Features:

Electronically controlled with lock-up torque converter.

📐 Dimensions

Exterior Sedan

Length Sedan:

Approx. 174.8 inches (4440 mm)

Exterior Hatchback

Length Hatchback:

Approx. 164.9 inches (4188 mm)

Exterior Width

Width:

Approx. 67.7 inches (1720 mm)

Exterior Height

Height:

Approx. 55.5 inches (1410 mm)

Wheelbase

Wheelbase:

Approx. 102.7 inches (2606 mm)

Weights

Curb Weight Range:

Approx. 2600 - 2800 lbs (1179 - 1270 kg), depending on trim and transmission.

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Rating Driver:

4 out of 5 stars (for 2002 model year, specific testing varied by body style and equipment)

NHTSA Frontal Crash Rating Passenger:

4 out of 5 stars (for 2002 model year)

Active Features

Active Safety Features:

Front disc brakes, Rear drum brakes (some trims may have rear discs), Optional Anti-lock Braking System (ABS).

Passive Features

Passive Safety Features:

Dual front airbags, Seatbelt pretensioners, Crumple zones.

💡 Technology Features

Infotainment

Audio System Features:

Factory AM/FM stereo with CD player, cassette player (optional), and speaker system. Basic radio controls, potentially steering wheel audio controls on higher trims.

Driver Assistance

Driver Assistance Features:

Limited by 2002 standards; primarily ABS on certain models, and basic cruise control.

Connectivity

Connectivity Features:

Minimal by modern standards. May include power outlets for charging devices.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first. Check owner's manual for specific recommendations based on driving conditions.

Engine Oil Type Viscosity:

Typically SAE 5W-30 or 5W-20 for gasoline engines. Consult manual for exact specification.

Engine Oil Capacity:

Approx. 4.0-4.5 quarts (3.8-4.3 liters) with filter for 1.6L and 2.0L engines. Check manual for precise capacity.

Coolant Replacement Interval:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years. Mazda typically uses Long Life Coolant (LLC) – consult manual for specification.

Spark Plug Replacement Interval:

Around 60,000-100,000 miles (96,000-160,000 km), depending on spark plug type (e.g., iridium plugs last longer). Check manual for specific recommendations.

Transmission Fluid Change Interval:

Manual: Inspect regularly, change as needed. Automatic: Every 30,000-60,000 miles (48,000-96,000 km) under normal conditions. Check manual for specific fluid type (e.g., Mazda ATF JWS3309 or equivalent).

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4. Always use fresh, sealed fluid.

Power Steering Fluid Type:

Refer to manual; typically a specific ATF or power steering fluid.

Known Issues

Common Protege Issues:

• Rear wheel bearing noise/failure

• Catalytic converter failure (especially on higher mileage vehicles)

• Rust on rocker panels, wheel wells, and rear quarter panels

• Front suspension component wear (ball joints, bushings)

• Transmission issues (clutch wear on manuals, solenoid issues on automatics)

• Power steering leaks

• Ignition coil failure (leading to misfires)

📚 Vehicle History

Brand Heritage

Mazda Heritage:

Mazda Motor Corporation, a Japanese automaker known for its driver-focused vehicles and innovative technologies like the Wankel rotary engine.

Model Evolution

Protege Generations:

The 2002 model belongs to the second generation (BJ series, 1998-2003), which offered improved styling, safety, and refinement over its predecessor.

Production

Production Plants:

Primary production in Hofu, Yamaguchi, Japan, and potentially other global facilities depending on market.

🏆 Awards & Recognition

Recognitions

Past Awards Or Accolades:

While specific awards for the 2002 model are not widely publicized, the Protege line generally received praise for its value, reliability, and sporty driving characteristics for its class during its production run.