Market Position:
The Mazda Protege (BJ generation) was a popular compact car, known for its sporty handling and good value, competing with vehicles like the Honda Civic, Toyota Corolla, and Ford Focus.
Competitive Analysis:
The 2002 Protege offered a blend of performance and practicality, often praised for its chassis dynamics derived from Mazda's 'Zoom-Zoom' philosophy. This service manual provides the in-depth technical data necessary to maintain and repair this engaging vehicle.
Key Features:
Comprehensive coverage of all major vehicle systems, detailed step-by-step repair procedures, extensive troubleshooting guides, precise torque specifications, and clear diagnostic information.
Systems Covered:
Engine Mechanical, Engine Control, Fuel System, Emissions Control, Intake/Exhaust, Cooling, Lubrication, Ignition, Starting, Charging, Manual Transmission, Automatic Transmission, Clutch, Drivetrain, Driveshaft, Differential, Steering, Suspension (Front/Rear), Brakes (including ABS), Body, HVAC, Electrical, SRS (Supplemental Restraint System), Wiring Diagrams, Body Controls, Climate Control
Estimated Page Count:
1500+
Manual Type:
Factory Service Manual (FSM)
Engine Mechanical:
Complete overhaul procedures, cylinder head, valve train, engine block, crankshaft, pistons, connecting rods, engine lubrication system, timing components (chain/gear), tensioners.
Engine Control:
ECM (Engine Control Module) diagnostics, sensor testing, actuator control, emission control systems (EVAP, EGR), ignition system, fuel injection system.
Transmission:
Manual transmission (clutch, gear engagement, overhaul), Automatic transmission (torque converter, planetary gearsets, hydraulic controls, overhaul).
Brakes:
Hydraulic system, brake pad/shoe replacement, caliper/wheel cylinder service, ABS system diagnosis and repair, bleeding procedures.
Electrical:
Battery, charging system, starting system, lighting, ignition, power accessories, body control modules, SRS (Supplemental Restraint System) components and diagnosis, detailed wiring diagrams.
Maintenance Procedures:
Routine tune-up, oil changes, filter replacements, spark plug service, coolant flush, brake fluid change, transmission fluid service.
Repair Procedures:
Engine removal/installation, cylinder head gasket replacement, piston ring replacement, transmission overhaul, clutch replacement, brake caliper rebuilding, suspension component replacement, HVAC system repair.
Diagnostic Procedures:
Troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation, live data analysis for engine control and other systems, component testing procedures.
Special Procedures:
Valve timing procedures (chain & gear replacement, tensioner adjustment/release/reset, timing mark alignment), engine torque specifications, fastener tightening sequences.
Technical Depth:
Comprehensive: Covers all aspects from basic maintenance and routine checks to complex diagnostics, component overhaul, and complete vehicle repair. Includes detailed specifications and procedures for factory-level servicing.
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
2.0 Liters (1991 cc)
Bore X Stroke:
83.1 mm x 92.0 mm
Horsepower:
Approx. 130 hp @ 6000 rpm (for FS-DE)
Torque:
Approx. 135 lb-ft @ 4000 rpm (for FS-DE)
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-Point Fuel Injection (MPFI)
Fuel Type:
Unleaded Gasoline
Valve Timing Chain Gear:
Detailed procedures for chain routing, sprocket alignment, tensioner release/reset, and timing mark identification.
Manual Transmission Type:
5-speed manual
Automatic Transmission Type:
4-speed automatic
Clutch Type:
Dry, single plate, diaphragm spring
Transmission Fluid Manual:
Refer to manual for specific type (e.g., API GL-4 for manual, ATF for automatic).
Wheelbase:
Approx. 102.8 inches (2611 mm)
Length:
Approx. 173.8 inches (4415 mm)
Width:
Approx. 67.7 inches (1720 mm)
Height:
Approx. 55.3 inches (1405 mm)
Curb Weight Manual:
Approx. 2700 - 2850 lbs (1225 - 1293 kg)
Curb Weight Automatic:
Approx. 2800 - 2950 lbs (1270 - 1338 kg)
Wheel Bolt Pattern:
4x100 mm
Standard Tire Size:
185/65R14 or 195/55R15 (depending on trim)
NHTSA Frontal Crash Rating:
4-star driver, 4-star passenger (for comparable models of the era, specific data for 2002 may vary)
Airbags:
Driver and front passenger airbags standard. Side airbags optional on some trims.
Seatbelts:
Three-point seatbelts with pretensioners.
ABS:
Anti-lock Braking System (ABS) available/standard on higher trims.
Srs Coverage:
Detailed diagnostics, component replacement, and system checks for the Supplemental Restraint System (SRS) airbags.
Infotainment System:
Basic AM/FM stereo with CD player or cassette player. Options for premium sound systems on higher trims.
Driver Assistance Features:
Limited by modern standards. ABS was available. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
Connectivity Features:
No integrated Bluetooth or USB connectivity; auxiliary input jacks might be present on some aftermarket or upgraded head units.
Oil Change Interval:
Typically 7,500 miles or 6 months, whichever comes first (refer to manual for exact recommendation based on driving conditions).
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or approximately every 30,000 miles.
Spark Plugs:
Typically replaced around 60,000 - 100,000 miles depending on type (iridium recommended).
Coolant Flush:
Every 30,000 - 50,000 miles or as recommended by the manual.
Engine Oil Type:
5W-20 or 5W-30 synthetic blend/full synthetic (API SN or higher).
Engine Oil Capacity:
Approx. 4.2 quarts (4.0 liters) with filter change.
Coolant Type:
Mazda Long Life Antifreeze/Coolant (or equivalent HOAT, blue color).
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
Mazda Genuine ATF or Dexron III/Mercon compatible ATF.
Common Issues:
Ignition coil failure, mass air flow (MAF) sensor issues, catalytic converter failure, minor oil leaks from valve cover gasket or oil pan, sometimes transmission issues on high-mileage automatics.
Maintenance Focus:
Regularly checking and replacing PCV valve, ensuring proper cooling system maintenance, and addressing any check engine lights promptly are key for longevity.
Brand Heritage:
Mazda has a long history of producing reliable and engaging vehicles, often emphasizing driving dynamics and sporty design. The Protege line has been a staple in the compact segment for decades.
Model Evolution:
The 2002 model year falls within the third generation (BJ) of the Mazda Protege, which was produced from 1998 to 2003. This generation saw significant updates in styling, technology, and platform compared to its predecessors.
Production Years:
1998-2003 (BJ generation)
Manufacturing Locations:
Primarily manufactured in Japan, with some production in other Mazda facilities globally.
