This workshop repair service manual covers the Protege models produced for the 2002 and 2003 model years, identified by the chassis code BJ. As part of a reputation for sporty driving dynamics and reliable engineering, the Protege offered practical and economical transportation, available in sedan and hatchback body styles. Notable for its class, it featured a 2.0L DOHC engine producing approximately 125-130 horsepower, paired with either a 5-speed manual or a 4-speed automatic transmission. The vehicle was designed with a focus on driver engagement and was manufactured in locations including Japan and the United States. This comprehensive English-language manual provides detailed information for maintaining and repairing your Protege. It covers all major systems, including engines (1.6L and 2.0L DOHC), transmissions (manual and automatic), drivetrain, brakes, suspension, steering, and the complete electrical system. You will find step-by-step procedures for scheduled maintenance, component replacement, troubleshooting, diagnostics, and complete engine and transmission overhauls. Technical specifications, such as torque values, fluid capacities, and wiring diagrams, are also included to ensure accurate and effective service. 🏷️ Basic Information Identification Make: Mazda Model: Protege Model Years: 2002, 2003 Codes Chassis Code: BJ 👋 Introduction Market Position Segment: Compact car, aimed at the affordable and reliable segment. Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra Key Features Design Philosophy: Practical, reliable, and economical transportation with a focus on driver engagement for its class. Body Styles: Sedan, hatchback (5-door), and station wagon (Mazda Familia Van in some markets). 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English Format: PDF Download Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for this era's comprehensive manuals) 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, overhaul procedures for all gasoline engines (e.g., 1.6L, 2.0L DOHC) Transmission: Manual and automatic transmission diagnosis, repair, and rebuilding Drivetrain: Front-wheel drive, clutch system, drive shafts, differential Brakes: Front disc, rear drum/disc (depending on trim), ABS system diagnosis and repair Suspension: Front MacPherson strut, rear multi-link, alignment specifications, component replacement Steering: Power steering system diagnosis and repair, steering linkage Electrical System: Complete wiring diagrams, charging system, starting system, lighting, accessories, ECU diagnosis Body And Interior: Body panel repair, door mechanisms, interior trim removal, HVAC system Cooling System: Radiator, cooling fan, thermostat, water pump replacement and diagnosis Fuel System: Fuel pump, injectors, fuel filter, emissions control systems Exhaust System: Catalytic converter, mufflers, exhaust manifold repair and replacement Safety Systems: Airbag system diagnosis and repair, seat belt mechanisms Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, tune-ups Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides Repair: Step-by-step instructions for component removal, installation, and adjustment Overhaul: Complete engine and transmission rebuilding procedures Diagnostics: OBD-II diagnostic codes, sensor testing, component testing Specifications: Torque specifications, clearances, fluid capacities, and critical measurements Technical Depth Depth Level: Comprehensive: Covers from basic maintenance to in-depth engine and transmission overhaul, including electrical system diagnostics and body repair. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable for efficient information retrieval. Print Quality Print Recommendation: Designed for digital viewing but printable for workshop use. High-resolution diagrams and text. Binding Type Binding Type: Not applicable for PDF format, but if printed, typically a comb or spiral binding for lay-flat use. Paper Type Paper Type: Not applicable for PDF format, but original manuals often used durable paper stock for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code Common: FS-DE (2.0L DOHC) Engine Displacement: 1991 cc (2.0 Liters) Engine Configuration: Inline 4-cylinder, DOHC, 16-valve Performance Horsepower: Approximately 125-130 hp @ 6000 RPM (varies slightly by market/tune) Torque: Approximately 135-140 lb-ft @ 4300 RPM (varies slightly by market/tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), multi-point injection (MPI) Fuel Type: Unleaded gasoline (87 octane recommended, higher may improve performance) Other Ignition System: Electronic ignition with distributor or distributorless ignition system (DIS) Engine Oil Type: API SG, SH, SJ or ILSAC GF-2 or GF-3 certified SAE 5W-30 or 5W-40 Engine Oil Capacity: Approximately 4.5 liters (4.8 US quarts) with filter change 🔧 Transmission Standard Transmission Type Std: 5-speed manual transmission Optional Transmission Type Opt: 4-speed automatic transmission Features Automatic Transmission Features: Electronically controlled, potentially with overdrive and lock-up torque converter. Fluid Specifications Manual Transmission Fluid: API GL-4 SAE 75W-90 gear oil Automatic Transmission Fluid: Mercon/Dexron III (or equivalent) 📐 Dimensions Exterior Length: Approx. 4405-4570 mm (173.4-179.9 in), depending on body style Width: Approx. 1705-1720 mm (67.1-67.7 in) Height: Approx. 1405-1445 mm (55.3-56.9 in), depending on body style Weights Curb Weight: Approx. 1170-1350 kg (2580-2976 lbs), depending on trim and equipment 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: Good (for 2003 sedan models) IIHS Offset Front Crash Test Rating: Acceptable (for 2003 sedan models) Active Features ABS: Available, typically optional on lower trims, standard on higher trims. Passive Features Airbags: Driver and front passenger airbags standard....