2002 Mazda Protege/Protege 5 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege / Protege5 Model Years Covered: 2002 Codes Platform Code: BJ (Third Generation) 👋 Introduction Market Position Segment: Compact Car / Affordable Compact...

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标签: 2002 Car Cars Mazda Misc Protege Protege 5

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege / Protege5

Model Years Covered:

Codes

Platform Code:

BJ (Third Generation)

👋 Introduction

Market Position

Segment:

Compact Car / Affordable Compact

Target Audience:

Young drivers, families seeking fuel-efficient and practical transportation.

Competitive Analysis

Key Rivals 2002:

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

Key Features

Protege Strengths:

Responsive handling, good value for money, reliable powertrains, practical interior space (especially Protege5).

Protege5 Distinction:

Sporty styling, versatile cargo capacity, sport-tuned suspension.

📋 Manual Details

Coverage Areas

Engine Coverage:

All engines for the 2002 model year

Drivetrain Coverage:

Front-wheel drive (FWD), all-wheel drive (AWD) where applicable

Body Style Coverage:

Sedan (Protege), Wagon (Protege5)

Page Count

Estimated Page Count:

Extensive (typical factory service manuals are 1000+ pages)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanicals, fuel system, ignition system, exhaust system, emissions control.

Transmission Drivetrain:

Manual and automatic transmissions, transaxle, CV joints, axles, differentials.

Suspension Steering:

Front and rear suspension components, steering gear, power steering system, wheel alignment.

Brakes:

Front and rear brakes (disc/drum), parking brake, ABS system, hydraulic components.

Electrical Electronics:

Wiring diagrams, battery, charging system, starting system, lighting, instruments, body electrical, power accessories.

HVAC:

Heating, ventilation, and air conditioning system components and operation.

Body Chassis:

Body panels, doors, windows, interior trim, frame, corrosion protection.

Procedures Included

Maintenance:

Scheduled maintenance checks, fluid changes, filter replacements, lubrication points.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics.

Repair:

Detailed step-by-step repair procedures for all major vehicle components.

Specifications:

Torque specifications, clearances, fluid capacities, electrical values.

Rebuild:

Engine and transmission rebuild procedures, component overhaul.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid checks to complete engine/transmission overhauls and advanced electrical diagnostics.

📊 Manual Specifications

File Format

Compatibility:

Compatible with most PDF readers, searchable text.

Print Quality

Printability:

Printable for workshop use, high-resolution diagrams.

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code Usdm:

FS-DE (2.0L DOHC)

Engine Displacement:

1991 cc (2.0 Liters)

Engine Configuration:

Inline 4-cylinder, DOHC, 16 valves

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

9.0:1

Performance

Horsepower Ps:

130 PS @ 6000 rpm

Torque Lb Ft:

135 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) / Sequential Electronic Fuel Injection (S-EFI)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Engine Variants

Protege Other Engines:

Z5-DE (1.5L SOHC, less common in North America for 2002)

Protege Es Gx Gt Engines:

FS-DE (2.0L DOHC) standard on higher trims.

🔧 Transmission

Standard

Protege Standard Transmission:

5-speed manual transmission

Optional

Protege Optional Transmission:

4-speed automatic transmission

Features

Automatic Transmission Control:

Electronic control unit (ECU) for shift timing and logic.

Manual Transmission Gear Ratios:

Detailed in manual; typically a close-ratio setup for sporty feel.

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (consult manual for exact specification).

Automatic Transmission Fluid:

Dexron III or equivalent (consult manual for exact specification).

📐 Dimensions

Exterior

Protege Sedan Length:

Approx. 174.6 inches (4435 mm)

Protege5 Length:

Approx. 167.3 inches (4250 mm)

Protege Width:

Approx. 67.9 inches (1725 mm)

Protege Height:

Approx. 55.3 inches (1405 mm) / Protege5: Approx. 57.7 inches (1465 mm)

Wheelbase:

Approx. 102.7 inches (2605 mm)

Cargo

Protege5 Cargo Volume:

Significant for its class, especially with rear seats folded (specific cu. ft. in manual).

Weights

Curb Weight Approx:

2600 - 2800 lbs (1180 - 1270 kg), varies by model and trim.

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Tire Size Standard:

195/60R15, 205/50R16 (depending on trim)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

Likely 4-star (check specific report for exact rating)

NHTSA Frontal Impact Passenger:

Likely 4-star (check specific report for exact rating)

IIHS Crash Test Performance:

Generally good for its class, manual will detail specific test results if available.

Active Features

Available on higher trims (4-wheel disc brakes with ABS).

Traction Control:

Optional on some models.

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags optional on some models.

Seatbelts:

3-point front and rear seatbelts, pretensioners on front seats.

Child Seat Anchors:

LATCH system (Lower Anchors and Tethers for Children).

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium sound system (Bose on some trims). Aux input typically not standard.

Climate Control:

Manual HVAC controls, optional automatic climate control on higher trims.

Driver Assistance

Cruise Control:

Standard on most trims.

Connectivity

Oem Connectivity Features:

Limited by modern standards. May include power windows, locks, mirrors. Keyless entry optional.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first (check manual for specific recommendation).

Engine Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Typically around 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium-tipped plugs, 30,000 miles for standard.

Timing Belt Replacement:

Crucial! Check manual. Typically 60,000 - 90,000 miles (96,000 - 144,000 km) for interference engines like the FS-DE. Failure can cause severe engine damage.

Fluid Specifications

Engine Oil Type Capacity:

5W-30 viscosity, approximately 4.2 US quarts (4.0 liters) with filter. Consult manual.

Coolant Type Capacity:

Mazda Super Long Life Coolant (or equivalent HOAT), approximately 7.0 US quarts (6.6 liters). Consult manual.

Brake Fluid Type:

DOT 3 or DOT 4 (check manual).

Power Steering Fluid Type:

ATF Dexron II/III compatible (consult manual).

Known Issues

Common Protege Issues:

EGR valve clogging, front control arm bushings wear, catalytic converter failure (especially on higher mileage vehicles), rear wheel bearings wear, power steering pump leaks.

Protege5 Specific Issues:

Similar to Protege, potential for exhaust system rust due to wagon design, occasional AC compressor issues.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

'Zoom-Zoom' driving dynamics, focus on driver engagement.

Model Evolution

Protege Generations:

First introduced in the 1970s, the 2002 model represents the third generation (BJ platform).

Protege5 Introduction:

Introduced for the 2002 model year, offering a more versatile and sportier wagon variant.

Production

Production Location:

Mazda's Hofu Plant in Japan, and potentially U.S. assembly for some variants.

Production Years Bj Platform:

1998-2003 (globally), with some regional variations.

🏆 Awards & Recognition

Recognitions

Automotive Journal Accolades:

The Protege platform generally received positive reviews for its driving dynamics and value during its production run. Specific awards for the 2002 model may vary.