Mazda Protege 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2002 Generation Generation Code: BJ Codes Platform: Mazda B-platform 👋 Introduction Market Position Vehicle Segment: Compact Car Target Audience: DIY mechanics,...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Generation

Generation Code:

Codes

Platform:

Mazda B-platform

👋 Introduction

Market Position

Vehicle Segment:

Compact Car

Target Audience:

DIY mechanics, aspiring technicians, Mazda Protege owners seeking in-depth repair knowledge

Competitive Analysis

Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra

Key Features

Manual Advantage:

Provides dealership-level repair information, simplifying complex procedures with diagrams and step-by-step instructions.

Ease Of Use:

Designed to be user-friendly for a wide range of technical skill levels.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete workshop repair and service

Page Count

Estimated Page Count:

Varies by specific edition, typically 1000+ pages for comprehensive coverage

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Yes, including internal components, timing, fuel injection, ignition, and emissions

Lubrication System:

Yes, oil pump, oil filter, oil passages, oil pressure

Cooling System:

Yes, radiator, water pump, thermostat, hoses, coolant specifications

Fuel And Emission Control:

Yes, fuel pump, injectors, evaporative emission control (EVAP), catalytic converter, EGR

Engine Electrical:

Yes, starter, alternator, battery, ignition system, sensors (MAF, O2, CKP, CMP), engine control module (ECM)

Clutch:

Yes, clutch disc, pressure plate, release bearing, hydraulic system

Manual Transaxle:

Yes, gears, bearings, seals, shift mechanism, fluid specifications

Automatic Transaxle:

Yes, torque converter, planetary gears, hydraulic control, valve body, fluid specifications

Front And Rear Axles:

Yes, CV joints, wheel bearings, axle shafts, differential (if applicable)

Steering System:

Yes, power steering pump, rack and pinion, steering column, linkage

Braking System:

Yes, hydraulic system, brake lines, master cylinder, ABS, calipers, pads, rotors, parking brake

Suspension:

Yes, struts, springs, control arms, ball joints, bushings, alignment specifications

Body:

Yes, body panel repair, doors, windows, trim, bumpers, chassis structure

Body Electrical System:

Yes, lighting, wipers, horn, power windows, locks, mirrors, horn, body control module (BCM)

Heater And Air Conditioner:

Yes, HVAC system, blower motor, compressor, refrigerant, climate controls

Procedures Included

Maintenance:

Yes, oil changes, filter replacements, spark plugs, coolant flush, brake fluid service

Troubleshooting:

Yes, diagnostic charts, symptom analysis, common fault finding

Repair:

Yes, detailed step-by-step repair procedures for all major components

Diagnostics:

Yes, includes wiring diagrams, component testing, and OBD-II diagnostic trouble codes (DTCs)

Installation:

Yes, for specific components and accessories

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds

Electrical Diagrams:

Yes, detailed wiring schematics for all vehicle systems

Torque Specifications:

Yes, for critical fasteners throughout the vehicle

Fluid Capacities:

Yes, all fluid types and capacities for engine, transmission, cooling, etc.

Special Tools:

Yes, lists and descriptions of special tools required for specific procedures

📊 Manual Specifications

File Format

Format:

Searchable:

Yes (dependent on original scan quality/OCR)

Zoom Functionality:

Compatibility:

Windows & Mac OS

Required Software:

Adobe PDF Reader, WinZip (for extraction)

Print Quality

Printability:

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Z5-DE (1.5L) or FS-DE (2.0L - common in ES, GT trims)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Performance

Displacement 1 5L:

1498 cc (91.4 cu in)

Horsepower 1 5L:

Approx. 105 hp @ 6000 rpm

Torque 1 5L:

Approx. 100 lb-ft @ 4000 rpm

Displacement 2 0L:

1991 cc (121.5 cu in)

Horsepower 2 0L:

Approx. 126-130 hp @ 6000 rpm

Torque 2 0L:

Approx. 132-135 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transaxle

Optional

Transmission Type Optional:

4-speed Automatic Transaxle

Features

Manual Transaxle Fluid:

API GL-4, SAE 75W-90 Gear Oil (e.g., Mazda Manual Transmission Fluid JWS 3317 or equivalent)

Automatic Transaxle Fluid:

Dexron III/Mercon equivalent (e.g., Mazda ATF-III or equivalent)

📐 Dimensions

Exterior

Wheelbase:

102.7 inches (2606 mm)

Length:

170.5 inches (4330 mm)

Width:

67.1 inches (1704 mm)

Height:

55.1 inches (1400 mm)

Weights

Curb Weight:

Approx. 2600-2800 lbs (1180-1270 kg) depending on trim and transmission

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (1998-2002 models)

NHTSA Front Impact Passenger:

4 Stars (1998-2002 models)

IIHS Side Impact:

Acceptable (for some model years in this generation)

Active Features

Available on certain trims (e.g., ES, GT)

Passive Features

Airbags:

Driver and passenger front airbags standard

Seatbelts:

Front seat pretensioners

💡 Technology Features

Infotainment

Audio System:

Optional premium audio systems, CD player, AM/FM radio

Driver Assistance

Cruise Control:

Available on higher trims

Connectivity

Auxiliary Input:

Not typically factory standard; aftermarket solutions common

🔧 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)

Spark Plug Replacement:

Approx. 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium plugs, less for standard

Timing Belt Replacement:

60,000 - 90,000 miles (96,000 - 145,000 km) – CRITICAL for Z5-DE and FS-DE engines as they are interference engines.

Fluid Specifications

Engine Oil:

API SG or SH, SAE 5W-30 or 5W-40 (check owner's manual for specific recommendations based on climate)

Coolant:

Ethylene Glycol based antifreeze/coolant (Mazda FL22 or equivalent blue coolant recommended)

Fluid Capacities

Engine Oil Capacity:

Approx. 3.7 - 4.2 US quarts (3.5 - 4.0 liters) with filter change

Cooling System Capacity:

Approx. 5.5 - 6.0 US quarts (5.2 - 5.7 liters)

Known Issues

Common Problems:

Ignition coil failure, O2 sensor failure, catalytic converter issues, rust on rocker panels and wheel wells, worn suspension bushings, sticky throttle body

Transmission Issues:

Automatic transmission shift solenoid failures, manual clutch wear

📚 Vehicle History

Brand Heritage

Mazda Focus:

Known for sporty handling and reliable engineering

Model Evolution

Generation:

Third Generation (BJ, 1998-2003)

Trim Levels:

DX, LX, ES, GT, MP3 (sportier variants)

Production

Production Years Bj Generation:

1998-2003

🏆 Awards & Recognition

Recognitions

Car And Driver Ranking:

Often featured on Car and Driver's 10Best list in earlier generations, continued to be praised for handling.

Ratings

Fuel Economy Rating:

Good for its class, typically in the mid-20s to low-30s MPG highway depending on engine and transmission.