Mazda Protege 2002 2003 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Model Years: 2002, 2003 Codes Chassis Codes: BJ Platform: Mazda BJ platform 👋 Introduction Market Position Segment: Compact Car Target Audience: Economy-conscious...

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标签: 2002 2003 Car Cars Mazda Misc Protege

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Model Years:

2002, 2003

Codes

Chassis Codes:

Platform:

Mazda BJ platform

👋 Introduction

Market Position

Segment:

Compact Car

Target Audience:

Economy-conscious buyers, young drivers, small families.

Competitive Analysis

Key Competitors:

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

Key Features

Reliability:

Generally considered reliable and affordable to maintain.

Driving Dynamics:

Praised for good handling and a responsive chassis, especially the Mazdaspeed Protege variant.

Fuel Economy:

Good fuel efficiency for its class.

📋 Manual Details

Coverage Areas

Main Coverage:

Comprehensive service, repair, and maintenance information for 2002-2003 Mazda Protege.

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, component inspection, timing belt/chain, piston rings, bearings, cylinder head, block, cooling system, lubrication system.

Fuel System:

Fuel pump, injectors, fuel rail, fuel filter, evaporative emission control (EVAP) system, fuel tank.

Ignition System:

Spark plugs, ignition coils, ignition timing, coil-on-plug (COP) system.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, oxygen sensors.

Transmission Manual:

Clutch system, transmission disassembly/assembly, gear ratios, internal components, shift mechanism.

Transmission Automatic:

Torque converter, transmission disassembly/assembly, hydraulic control, solenoids, internal components, valve body.

Drivetrain:

Front-wheel drive (FWD) system, half-shafts, CV joints, differential (in transaxle).

Suspension:

Front struts/shocks, rear shocks, control arms, ball joints, bushings, stabilizer bars, wheel bearings, alignment specifications.

Steering:

Power steering system, steering rack, tie rods, steering column, alignment.

Brakes:

Front disc brakes, rear drum brakes (or disc on some trims), brake calipers, master cylinder, power booster, ABS system (if equipped), brake bleeding procedures.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), wiring diagrams, fuses, relays.

Engine Control System ECU:

Engine Control Unit (ECU) diagnostics, sensors (MAP, TPS, O2, CKP, CMP), actuators, fuel injection control, idle control.

Climate Control HVAC:

Air conditioning system (compressor, refrigerant, evaporator, condenser), heater core, blower motor, climate controls, ducting.

Body Interior:

Door panels, dashboard removal, seats, headliner, carpet, trim pieces.

Body Exterior:

Bumpers, fenders, hood, trunk lid, doors, windows, mirrors, seals, body panel alignment.

Safety Systems:

Airbag system (SRS), seat belt pretensioners, diagnostics for safety systems.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation.

Repair Procedures:

Detailed step-by-step instructions for component removal, installation, and repair.

Overhaul Procedures:

Complete engine and transmission overhaul instructions, including torque specifications and critical measurements.

Diagnostics:

On-board diagnostics (OBD-II), sensor testing, actuator testing, circuit testing using multimeters and oscilloscopes.

Calibration:

Throttle body cleaning and adaptation, idle speed control adjustment.

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine/transmission rebuilds and advanced electrical diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Yes (typically, depending on scan quality)

Print Quality

Quality:

Professional (designed for digital viewing, printable)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

FS-DE (2.0L DOHC)

Engine Displacement 1:

1991 cc

Engine Configuration 1:

Inline 4-cylinder

Engine Bore X Stroke 1:

83.0 mm x 92.0 mm

Engine Compression Ratio 1:

9.1:1

Engine Horsepower 1:

130 hp @ 6000 rpm (approx.)

Engine Torque 1:

135 lb-ft @ 4000 rpm (approx.)

Engine Fuel Delivery 1:

Electronic Fuel Injection (EFI)

Engine Valve Train 1:

DOHC (Dual Overhead Camshafts), 4 valves per cylinder

Engine Timing Belt Tensioner Spec:

Requires periodic inspection and replacement, critical for engine longevity.

Secondary Engine

Engine Code 2:

Z5-DE (1.5L SOHC) - less common in North America for these years, but possible.

Engine Displacement 2:

1498 cc

Engine Horsepower 2:

105 hp @ 6000 rpm (approx.)

Engine Torque 2:

99 lb-ft @ 4000 rpm (approx.)

Performance

0-60 Mph Approx:

9-10 seconds

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Octane Rating:

87 Octane (minimum)

🔧 Transmission

Standard

Type Standard:

5-speed Manual

Optional

Type Optional:

4-speed Automatic

Features

Automatic Transmission Control:

Electronic control unit (ECU) for shifting logic.

Fluid Specification

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (check manual for exact spec)

Automatic Transmission Fluid:

Mazda ATF-MV (or equivalent Dexron-III/Mercon compatible)

📐 Dimensions

Exterior

Length:

Approx. 166.7 inches (4234 mm)

Width:

Approx. 67.5 inches (1715 mm)

Height:

Approx. 56.3 inches (1430 mm)

Wheelbase:

Approx. 102.8 inches (2611 mm)

Front Track:

Approx. 59.1 inches (1501 mm)

Rear Track:

Approx. 58.5 inches (1486 mm)

Ground Clearance:

Approx. 5.7 inches (145 mm)

Weights

Curb Weight:

Approx. 2500-2700 lbs (1134-1225 kg)

Gross Vehicle Weight Rating:

Varies by trim, typically around 3700 lbs

Towing Capacity:

Not typically recommended or specified for this vehicle.

Wheelbase Mazdaspeed:

Same as standard Protege, but suspension tuned for performance.

Cargo

Cargo Volume Sedan:

Approx. 12.0 cu ft

Cargo Volume Hatchback:

Approx. 18.2 cu ft (rear seats up)

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact 2002:

4 Stars

NHTSA Passenger Front Impact 2002:

4 Stars

IIHS Small Overlap Front Impact:

Not rated (vehicle predates rigorous testing in this specific area)

Active Features

Available on higher trims, optional on some models.

Traction Control:

Rarely equipped, not a common feature.

Passive Features

Airbags Front:

Standard driver and passenger front airbags.

Airbags Side:

Optional side-impact airbags on some models/trims.

Seatbelts:

3-point front seat belts with pretensioners, 3-point rear seat belts.

Child Seat Anchors:

LATCH system (Lower Anchors and Tethers for Children) in rear seats.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM/CD player, optional cassette player, speaker configuration varied by trim.

Display:

Analog gauges, basic digital clock, climate control displays.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Parking Sensors:

Not factory equipped.

Connectivity

Aux Input:

Not typically equipped with factory auxiliary input; aftermarket solutions required.

Bluetooth:

Not factory equipped.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Engine Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for standard plugs, 60,000 miles (96,000 km) for platinum/iridium.

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 4 years. Critical item to prevent catastrophic engine failure.

Coolant Flush:

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

Brake Fluid Flush:

Every 24,000 miles (38,000 km) or 2 years.

Fluid Specifications

Engine Oil Type:

SAE 5W-30, API SG or higher.

Engine Oil Capacity:

4.2 US quarts (4.0 liters) with filter change.

Coolant Type:

Mazda FL22 Long Life Antifreeze/Coolant (or equivalent HOAT).

Coolant Capacity:

Approx. 6.4 US quarts (6.1 liters)

Power Steering Fluid:

Mazda Genuine Power Steering Fluid (or equivalent Dexron II/III ATF).

Known Issues

Common Issues Engine:

Timing belt failure if not replaced on schedule, occasional oil leaks from valve cover or oil pan gasket.

Common Issues Suspension:

Worn front struts/shocks, rear shock leaks, worn bushings (control arm, sway bar).

Common Issues Electrical:

Faulty alternator, cooling fan issues, dashboard warning lights (ABS, Check Engine).

Common Issues HVAC:

Compressor clutch failure, evaporator core leaks (leading to poor AC performance).

Common Issues Brakes:

Rear brake drums sticking, premature wear on rear brake shoes.

Part Numbers

Timing Belt Kit Example:

Gates TCK245 (typical equivalent, verify with specific VIN)

Oil Filter Example:

Mazda B6Y1-14-302 (or equivalent like Wix 51358)

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Jinba Ittai - 'horse and rider as one', emphasizing driver engagement and connection.

Model Evolution

Generation:

Second Generation (BJ) Protege/Protege5.

Body Styles:

Sedan, 5-door Hatchback (Protege5).

Performance Variant:

Mazdaspeed Protege (2003 model year), featuring a turbocharged engine.

Production

Production Years:

1998-2003 (Second Generation)

Manufacturing Location:

Japan (primarily), Hofu, Yamaguchi

🏆 Awards & Recognition

Recognitions

Consumer Reports Ratings:

Generally received average to above-average ratings for predicted reliability in its class during its production years.

Motor Trend Car Of The Year Contender:

Protege models were often considered strong contenders or noteworthy in compact car comparisons.