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2002 Mazda PROTEGE/PROTEGE 5 Service & Repair Manual-PDF

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🏷️ Basic Information Identification Make: Mazda Model: Protege / Protege5 Model Years Covered: 2002 Production Years Context: This manual specifically covers the 2002 model year. Codes Chassis Codes: BJ (for North American market, chassis designation for the third generation Protege) 👋 Introduction Market Position Market Segment: Compact car (Protege sedan/hatchback) and compact wagon (Protege5). Competitors: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Hyundai Elantra, Subaru Impreza. Competitive Analysis Protege Strengths: Sporty handling (especially with the Protege5), good value proposition, distinctive styling for the Protege5. Key Features Protege5 Distinction: The Protege5 variant offered a more practical wagon body style with sportier suspension tuning and unique styling cues, appealing to a more lifestyle-oriented buyer. Manual Value Proposition: Provides in-depth technical knowledge crucial for maintaining and repairing the vehicle, enabling cost savings and ensuring proper vehicle function. 📋 Manual Details Coverage Areas Coverage Scope: Complete official service and repair information for all models and engines of the 2002 Mazda Protege and Protege5. Page Count Estimated Page Count: Likely in the range of 1500-2500 pages (typical for comprehensive official service manuals of this era, though exact count not specified). Manual Type Manual Type: Official Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed repair and diagnostic procedures for all engine variants (e.g., 1.6L DOHC, 2.0L DOHC, potentially 2.0L DOHC SPI for specific markets). Transmission: Coverage for both manual (e.g., FS5A-EL) and automatic transmissions (e.g., GF4AX-EL), including overhaul, diagnostics, and fluid specifications. Drivetrain: Front-wheel drive (FWD) system, including clutch, differential, driveshafts, and CV joints. Suspension: Front (MacPherson strut) and rear (multi-link) suspension systems, including shock absorbers, springs, control arms, alignment procedures, and specifications. Steering: Power steering system, steering rack, linkage, and diagnostic procedures. Brakes: Front and rear brake systems (disc brakes), including hydraulic components, ABS (if equipped), pad/rotor replacement, bleeding procedures, and specifications. Electrical System: Comprehensive coverage of the vehicle's electrical system, including battery, charging system, starting system, lighting, wipers, horn, power accessories, and wiring diagrams. Engine Control System: ECU, sensors (e.g., MAF, O2, TPS, crank/cam position), actuators, fuel injection, ignition system, and emissions control systems. Body And Interior: Body panel removal/installation, door mechanisms, interior trim, seats, airbags, and body repair information. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, including compressor, condenser, evaporator, refrigerant, blower motor, and controls. Procedures Included Maintenance Procedures: Oil and filter changes, fluid level checks and top-offs, spark plug replacement, air filter replacement, coolant flush, brake fluid flush, belt inspections and replacement. Diagnostic Procedures: Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation and resolution, component testing procedures. Repair Procedures: Step-by-step instructions for major component removal, overhaul, and installation (engine, transmission, suspension components, brakes, etc.). Torque Specifications: Precise torque values for all critical fasteners across all vehicle systems. Wiring Diagrams: Detailed electrical wiring diagrams for all circuits, aiding in troubleshooting and repair. Special Tools: Identification of required special tools and procedures for their use. Technical Depth Depth Of Information: Comprehensive, covering everything from basic preventative maintenance to complete engine and transmission overhauls and complex electrical diagnostics. Target Audience: Professional technicians and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text (assuming a properly created PDF). Print Quality Print Quality: High-resolution, suitable for clear printing of diagrams, schematics, and text. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options 2002: Common engines include 1.6L BP-DE DOHC (16-valve) and 2.0L FS-DE DOHC (16-valve). Specific engine code variants may exist. Engine Displacement 1.6L: 1598 cc Engine Displacement 2.0L: 1991 cc Engine Type: Inline-4, DOHC, 16-valve (per cylinder bank) Performance Horsepower 1.6L Approx: 105-110 hp @ 6000 rpm (approximate, market dependent) Torque 1.6L Approx: 105-110 lb-ft @ 4000 rpm (approximate, market dependent) Horsepower 2.0L Approx: 120-130 hp @ 6000 rpm (approximate, market dependent) Torque 2.0L Approx: 135-140 lb-ft @ 4000 rpm (approximate, market dependent) Fuel System Fuel Injection: Electronic Fuel Injection (EFI) / Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline (Octane rating typically 87 or higher recommended, check manual for specifics). 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission (e.g., G5M-P) Optional Optional Transmission: 4-speed automatic transmission (e.g., GF4AX-EL) Features Automatic Transmission Features: Electronically controlled, potentially with 'Sport' or 'Comfort' modes. Fluid Specifications Manual Transmission Fluid: Refer to manual for specific GL-4 or GL-5 gear oil specification (e.g., SAE 75W-90). Automatic Transmission Fluid: Mazda Genuine ATF JWS 3314 or equivalent (e.g., Dexron III/Mercon equivalent, but always verify with manual). 📐 Dimensions Exterior Protege Sedan Length Approx: 174.5 inches (approximate) Protege5 Length Approx: 167.9 inches (approximate) Protege Wheelbase Approx: 102.7 inches (approximate) Cargo Protege5 Cargo Volume Approx: 29.3 cubic feet with rear seats up (approximate) Weights Curb Weight Approx: 2600 - 2900 lbs (depending on body style and equipment) Wheel Bolt Pattern: 4x100mm Wheel...
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2002 Mazda PROTEGE/PROTEGE 5 Service & Repair Manual-PDF
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege / Protege5
Model Years Covered:
2002
Production Years Context:
This manual specifically covers the 2002 model year.
Codes
Chassis Codes:
BJ (for North American market, chassis designation for the third generation Protege)
👋 Introduction
Market Position
Market Segment:
Compact car (Protege sedan/hatchback) and compact wagon (Protege5).
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Hyundai Elantra, Subaru Impreza.
Competitive Analysis
Protege Strengths:
Sporty handling (especially with the Protege5), good value proposition, distinctive styling for the Protege5.
Key Features
Protege5 Distinction:
The Protege5 variant offered a more practical wagon body style with sportier suspension tuning and unique styling cues, appealing to a more lifestyle-oriented buyer.
Manual Value Proposition:
Provides in-depth technical knowledge crucial for maintaining and repairing the vehicle, enabling cost savings and ensuring proper vehicle function.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete official service and repair information for all models and engines of the 2002 Mazda Protege and Protege5.
Page Count
Estimated Page Count:
Likely in the range of 1500-2500 pages (typical for comprehensive official service manuals of this era, though exact count not specified).
Manual Type
Manual Type:
Official Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed repair and diagnostic procedures for all engine variants (e.g., 1.6L DOHC, 2.0L DOHC, potentially 2.0L DOHC SPI for specific markets).
Transmission:
Coverage for both manual (e.g., FS5A-EL) and automatic transmissions (e.g., GF4AX-EL), including overhaul, diagnostics, and fluid specifications.
Drivetrain:
Front-wheel drive (FWD) system, including clutch, differential, driveshafts, and CV joints.
Suspension:
Front (MacPherson strut) and rear (multi-link) suspension systems, including shock absorbers, springs, control arms, alignment procedures, and specifications.
Steering:
Power steering system, steering rack, linkage, and diagnostic procedures.
Brakes:
Front and rear brake systems (disc brakes), including hydraulic components, ABS (if equipped), pad/rotor replacement, bleeding procedures, and specifications.
Electrical System:
Comprehensive coverage of the vehicle's electrical system, including battery, charging system, starting system, lighting, wipers, horn, power accessories, and wiring diagrams.
Engine Control System:
ECU, sensors (e.g., MAF, O2, TPS, crank/cam position), actuators, fuel injection, ignition system, and emissions control systems.
Body And Interior:
Body panel removal/installation, door mechanisms, interior trim, seats, airbags, and body repair information.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, including compressor, condenser, evaporator, refrigerant, blower motor, and controls.
Procedures Included
Maintenance Procedures:
Oil and filter changes, fluid level checks and top-offs, spark plug replacement, air filter replacement, coolant flush, brake fluid flush, belt inspections and replacement.
Diagnostic Procedures:
Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation and resolution, component testing procedures.
Repair Procedures:
Step-by-step instructions for major component removal, overhaul, and installation (engine, transmission, suspension components, brakes, etc.).
Torque Specifications:
Precise torque values for all critical fasteners across all vehicle systems.
Wiring Diagrams:
Detailed electrical wiring diagrams for all circuits, aiding in troubleshooting and repair.
Special Tools:
Identification of required special tools and procedures for their use.
Technical Depth
Depth Of Information:
Comprehensive, covering everything from basic preventative maintenance to complete engine and transmission overhauls and complex electrical diagnostics.
Target Audience:
Professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable text (assuming a properly created PDF).
Print Quality
Print Quality:
High-resolution, suitable for clear printing of diagrams, schematics, and text.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Options 2002:
Common engines include 1.6L BP-DE DOHC (16-valve) and 2.0L FS-DE DOHC (16-valve). Specific engine code variants may exist.
Engine Displacement 1.6L:
1598 cc
Engine Displacement 2.0L:
1991 cc
Engine Type:
Inline-4, DOHC, 16-valve (per cylinder bank)
Performance
Horsepower 1.6L Approx:
105-110 hp @ 6000 rpm (approximate, market dependent)
Torque 1.6L Approx:
105-110 lb-ft @ 4000 rpm (approximate, market dependent)
Horsepower 2.0L Approx:
120-130 hp @ 6000 rpm (approximate, market dependent)
Torque 2.0L Approx:
135-140 lb-ft @ 4000 rpm (approximate, market dependent)
Fuel System
Fuel Injection:
Electronic Fuel Injection (EFI) / Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (Octane rating typically 87 or higher recommended, check manual for specifics).
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission (e.g., G5M-P)
Optional
Optional Transmission:
4-speed automatic transmission (e.g., GF4AX-EL)
Features
Automatic Transmission Features:
Electronically controlled, potentially with 'Sport' or 'Comfort' modes.
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific GL-4 or GL-5 gear oil specification (e.g., SAE 75W-90).
Automatic Transmission Fluid:
Mazda Genuine ATF JWS 3314 or equivalent (e.g., Dexron III/Mercon equivalent, but always verify with manual).
📐 Dimensions
Exterior
Protege Sedan Length Approx:
174.5 inches (approximate)
Protege5 Length Approx:
167.9 inches (approximate)
Protege Wheelbase Approx:
102.7 inches (approximate)
Cargo
Protege5 Cargo Volume Approx:
29.3 cubic feet with rear seats up (approximate)
Weights
Curb Weight Approx:
2600 - 2900 lbs (depending on body style and equipment)
Wheel Bolt Pattern:
4x100mm
Wheel Size:
Typically 15-inch or 16-inch alloy or steel wheels.
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating 2002:
Likely 4-star for driver and passenger in frontal crash (check specific vehicle configuration and official NHTSA reports for confirmation).
IIHS Rating 2002:
Good in frontal offset crash tests for some trims/configurations (check IIHS archives).
Active Features
ABS:
Available Anti-lock Braking System (ABS) on most models.
Passive Features
Airbags:
Dual front airbags standard. Side-impact airbags may be optional on some trims.
Seatbelts:
Front 3-point height-adjustable seatbelts with pretensioners, rear 3-point seatbelts.
💡 Technology Features
Infotainment
Infotainment System 2002:
Basic AM/FM/CD stereo system. Higher trims may have premium audio or cassette tape options. No integrated navigation or complex infotainment systems.
Driver Assistance
Traction Control:
Traction Control System (TCS) may have been optional on higher trims.
Connectivity
Connectivity Options:
Basic connectivity via power outlets for accessories. No Bluetooth or USB integration from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 to 7,500 miles or 6 months (whichever comes first), depending on driving conditions. Consult manual for exact OEM recommendation.
Timing Belt Interval:
The 2.0L FS-DE engine is a timing belt engine. Replacement is typically recommended around 90,000 to 105,000 miles or 7-10 years. Crucial to verify with manual and service history.
Fluid Specifications
Engine Oil Type:
Refer to manual for viscosity (e.g., 5W-30 or 10W-30 depending on temperature) and API service classification (e.g., SG, SH, SJ).
Coolant Type:
Ethylene glycol-based antifreeze, typically requiring a 50/50 mix with distilled water. Mazda Super Long Life Coolant (FL22) or equivalent specification.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Idle Roughness:
Can be caused by dirty throttle body, vacuum leaks, or faulty idle air control valve (IACV).
Exhuast Manifold Cracks:
Some reports of exhaust manifold cracks, particularly on the 2.0L engine.
Cv Joint Boots:
Wear and tear on front CV joint boots can lead to lubrication loss and premature failure if not addressed.
Rear Wheel Bearings:
Rear wheel bearings can sometimes develop noise and require replacement.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Mazda's philosophy often centers on 'Zoom-Zoom,' emphasizing driving enjoyment and sporty characteristics.
Model Evolution
Third Generation Protege:
The 2002 model year falls into the third generation (BJ) of the Mazda Protege, which ran from model year 1998 to 2003. This generation introduced the Protege5 wagon variant.
Production
Production Location:
Primarily manufactured in Japan and Mexico.
🏆 Awards & Recognition
Recognitions
Automotive Press Awards:
The third-generation Protege received positive reviews from automotive publications for its handling and value, often praised as a strong competitor in its segment.
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