Mazda Protege 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2002 Generation Generation Designation: Third Generation (BJ) Codes Chassis Code: BJ 👋 Introduction Market Position Market Segment: Compact car, known for...

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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 Designation:

Third Generation (BJ)

Codes

Chassis Code:

👋 Introduction

Market Position

Market Segment:

Compact car, known for sporty handling and reliability.

Competitive Analysis

Key Competitors:

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

Key Features

Vehicle Selling Points:

Agile handling, good fuel economy, affordable pricing, available performance variants (e.g., Mazdaspeed Protege).

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair

Secondary Coverage:

Maintenance, Diagnosis, and Troubleshooting

Page Count

Estimated Page Count:

Extensive (Exact count not provided, but typical for full service manuals)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full coverage including disassembly, inspection, assembly, and specifications.

Engine Lubrication:

Oil pump, oil filter, oil cooler, oil passages, and lubrication system troubleshooting.

Engine Cooling:

Radiator, water pump, thermostat, coolant passages, cooling fan, and system diagnostics.

Engine Control:

ECU, sensors (e.g., crankshaft position, camshaft position, O2, MAP, TPS), actuators, ignition system, and emission controls.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel rail, pressure regulator, and EVAP system.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, hangers, and O2 sensor mounting.

Accelerator Control:

Throttle body, accelerator cable/linkage, cruise control integration.

Clutch:

Clutch disc, pressure plate, release bearing, clutch hydraulics (master and slave cylinders), and adjustment.

Manual Transmission:

Gearbox disassembly, inspection, assembly, shifting mechanisms, clutch operation, and fluid specifications.

Automatic Transmission:

Transmission operation, hydraulic control, valve body, torque converter, planetary gear sets, and fluid specifications.

Propeller Shaft:

Driveshaft components, universal joints, and differential coupling.

Rear Final Drive:

Differential housing, gears, bearings, seals, and lubrication.

Front Axle:

CV joints, axleshafts, wheel bearings, and hub assemblies.

Rear Axle:

Rear axle housing, bearings, seals, and hub assemblies.

Front Suspension:

MacPherson struts, control arms, ball joints, stabilizer bars, bushings, and wheel alignment.

Rear Suspension:

Independent rear suspension (e.g., multi-link or trailing arm), shock absorbers, springs, bushings, and wheel alignment.

Brake System:

Front and rear disc/drum brakes, calipers, rotors, pads, shoes, brake lines, master cylinder, and bleeding procedures.

Parking Brake:

Parking brake mechanism, cables, adjustment, and related components.

Brake Control System:

ABS (Anti-lock Braking System) components, sensors, hydraulic modulator, and diagnostic procedures.

Steering Control System:

Steering wheel, steering column, power steering pump, rack and pinion, tie rods, and steering linkage.

Seat Belts:

Seat belt retractors, anchors, buckles, and pre-tensioner systems.

Airbag system components, control module, sensors, and diagnostic procedures.

Body Lock Security:

Door locks, latches, handles, ignition switch, central locking system, and alarm system.

Glasses Window Mirrors:

Window regulators (manual and power), seals, glass replacement, and mirror adjustments.

Exterior Interior:

Bumpers, fenders, doors, hood, trunk lid, trim pieces, interior panels, and upholstery.

Instrument Panel:

Gauge cluster, warning lights, switches, climate controls, and dash panel removal/installation.

Seat:

Seat construction, adjustment mechanisms, and upholstery.

Automatic Air Conditioner:

A/C system components (compressor, condenser, evaporator, receiver-drier), refrigerant, charge procedures, diagnostics, and climate control unit.

Starting Charging:

Starter motor, battery, alternator, voltage regulator, and wiring diagrams.

Lighting System:

Headlights, taillights, turn signals, interior lighting, fuses, relays, and wiring.

Driver Information System:

On-board computer functions, trip computer, and other driver displays.

Wiper Washer Horn:

Wiper motor, linkage, blades, washer pump, reservoir, and horn operation.

Body Control System:

Integration of various body electronic modules.

Lan System:

Local Area Network (CAN bus) communication between modules, diagnostic access.

Audio Visual Navigation Telephone:

Radio, CD player, speaker systems, optional navigation, and telephone integration.

Auto Cruise Control:

Cruise control system components, operation, and troubleshooting.

Power Supply Ground Circuit Elements:

Battery, grounds, fuses, relays, and electrical component connections.

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, and general upkeep.

Procedures Included

Diagnostic Procedures:

Detailed troubleshooting guides, symptom-based diagnostics, and DTC (Diagnostic Trouble Code) explanations.

Repair Procedures:

Step-by-step instructions for component removal, installation, and overhaul.

Maintenance Procedures:

Oil changes, filter replacements, tune-ups, brake fluid flushes, coolant changes, and belt replacements.

Adjustment Procedures:

Clutch adjustment, parking brake adjustment, idle speed adjustment, and alignment procedures.

Specification Data:

Torque specifications, clearances, fluid capacities, and electrical resistance values.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams for all major systems.

Technical Depth

Depth:

Comprehensive, dealer-level technical information suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format:

PDF (.pdf)

Compression:

.rar/.zip (Requires decompression software like WinRAR, WinZip, or 7-Zip)

Print Quality

Printability:

Yes, printable pages

Binding Type

Binding Type:

Digital (PDF) - No physical binding

Paper Type

Paper Type:

N/A (Digital file)

Reader Requirements

Reader Software:

Adobe Acrobat Reader or compatible PDF viewer required.

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

FS-DE (2.0L DOHC Inline-4)

Engine Displacement:

1991 cc (2.0 Liters)

Performance

Horsepower Typical:

Approximately 120-130 hp @ 5800-6000 rpm (varies slightly by market and specific tune)

Torque Typical:

Approximately 127-135 lb-ft @ 4000-4500 rpm (varies slightly)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline

Engine Mechanical

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

9.1:1 to 9.7:1 (depending on specific FS-DE variant)

Valvetrain:

DOHC (Dual Overhead Camshafts), 16 valves (4 per cylinder), with VVT-i equivalent (Variable Valve Timing - Mazda's system, S-VT)

🔧 Transmission

Standard

Transmission Type Std:

5-Speed Manual Transmission

Optional

Transmission Type Opt:

4-Speed Automatic Transmission

Features

Automatic Transmission Features:

Electronically controlled, likely with torque converter lock-up for improved efficiency.

📐 Dimensions

Exterior

Wheelbase:

Approximately 102.8 inches (2610 mm)

Overall Length:

Approximately 174.8 inches (4440 mm)

Overall Width:

Approximately 67.7 inches (1720 mm)

Overall Height:

Approximately 55.7 inches (1415 mm)

Weights

Curb Weight Approx:

2700 - 2900 lbs (1225 - 1315 kg) depending on body style and transmission

Gross Vehicle Weight Rating:

Approximately 3700 - 3900 lbs (1680 - 1770 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

Likely 4-star (based on typical ratings for vehicles of this era and class)

NHTSA Frontal Impact Passenger:

Likely 4-star (based on typical ratings for vehicles of this era and class)

Active Features

Available Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and front passenger airbags (SRS).

Seat Belts:

3-point front seatbelts with pretensioners, 3-point rear seatbelts.

💡 Technology Features

Infotainment

Audio System Features:

AM/FM stereo with CD player, and optional cassette player. Speaker configurations vary by trim level.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Connectivity

Telematics:

Basic connectivity for optional phone systems, but no advanced telematics suites common in modern vehicles.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type.

Transmission Fluid Interval:

Manual: Check for leaks, replace as needed (often around 60,000-100,000 miles). Automatic: Typically 50,000-75,000 miles (100,000 km) under normal driving.

Coolant Replacement Interval:

Typically every 30,000 - 50,000 miles (48,000 - 80,000 km) or 2-4 years.

Spark Plug Replacement:

Typically 60,000 - 100,000 miles for iridium or platinum plugs, or 30,000 miles for standard plugs.

Fluid Specifications

Engine Oil Type Common:

API SJ or higher, SAE 5W-30 or 5W-40. Check manual for specific recommendations.

Engine Oil Capacity:

Approximately 4.2 US quarts (4.0 Liters) with filter change for the 2.0L engine.

Coolant Type:

Ethylene Glycol based, typically requiring a 50/50 mix with distilled water. Refer to Mazda's specific coolant specification.

Transmission Fluid Manual:

API GL-4, SAE 75W-90 gear oil.

Transmission Fluid Automatic:

Mazda ATF JWS3317 or equivalent DEXRON III/MERCON.

Power Steering Fluid:

ATF Dexron III or specific Mazda power steering fluid.

Known Issues

Common Problems:

Potential for oil leaks from valve cover gaskets and oil pan gaskets. Transmission synchromesh wear (manual). AC compressor failures. Suspension component wear (bushings, ball joints).

Engine Performance Issues:

Minor power loss over time due to carbon buildup, spark plug wear. Clogged fuel injectors.

📚 Vehicle History

Brand Heritage

Mazda Reputation:

Known for 'Zoom-Zoom' driving dynamics and reliable engineering.

Model Evolution

Protege Lineage:

Part of Mazda's popular compact sedan and hatchback line, evolving through multiple generations.

Production

Production Years:

The third generation (BJ) was produced from 1998-2003. The 2002 model year falls within this generation.

Manufacturing Locations:

Primarily Japan, with some production in other global facilities.

🏆 Awards & Recognition

Recognitions

Past Awards:

The Protege line often received praise for its driving dynamics and value for money, making it a consistent competitor in its segment.