2002 Mazda Protege Service Manual Instant Download 02 PDF
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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2002 Generation Generation Code: BJ Codes Chassis Code: BJ3P, BJ5P, BJ8P 👋 Introduction Market Position Segment: Compact Car / Economy Car Target Audience: DIY mechanics, car enthusiasts, owners seeking to reduce maintenance costs. Competitive Analysis Competitors: Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra, Chevrolet Cavalier. Key Features Manual Value Proposition: Cost savings on repairs and maintenance, empowerment for vehicle owners to perform their own services, accessibility via instant download. Vehicle Appeal: Known for its sporty handling, affordable pricing, and reliability in its class. 📋 Manual Details Coverage Areas Main Coverage: All Service and Repair Specific Coverage: Routine Maintenance, Tune-up Procedures, Engine, Transmission, Brakes, Suspension, Steering, Electrical Systems, Body, HVAC Page Count Estimated Page Count: Varies by specific manual version, but comprehensive manuals often exceed 1000 pages. Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF - Instant Download) 📖 Manual Coverage Systems Covered Powertrain: Engine lubrication, cooling, fuel, emissions, intake/exhaust, ignition, transaxle, clutch, manual transmission, automatic transmission, differential. Chassis: Suspension (front/rear), steering system, braking system (including ABS), wheel alignment. Electrical: Basic electrical, charging system, starting system, lighting, instrumentation, SRS (Supplemental Restraint System), wiring diagrams. Body And Interior: Body panels, interior trim, seats, HVAC (heating, ventilation, air conditioning), climate control (automatic). Procedures Included Maintenance: Oil changes, fluid checks/changes, filter replacements, spark plug replacement, tire rotation, brake pad replacement. Repair And Rebuild: Engine removal/installation, cylinder head overhaul, transmission rebuild, brake caliper service, suspension component replacement, HVAC system repair. Diagnostics: Troubleshooting guides, diagnostic fault codes (OBD-II), identification of common issues. Technical Depth Depth: Comprehensive: Covers everything from basic fluid services to complete engine and transmission overhauls. Includes detailed illustrations and step-by-step instructions. Special Procedures: Valve timing procedures, chain/gear replacement, tensioner adjustments/release/reset, timing marks, chain routing. 📊 Manual Specifications File Format Format: PDF Searchable: Typically searchable text within the PDF for efficient information retrieval. Print Quality Quality: High-resolution, suitable for printing individual pages or sections as needed. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: FS-DE (2.0L DOHC) Displacement: 1991 cc (2.0 Liters) Configuration: Inline 4-cylinder, DOHC (Double Overhead Camshaft) Bore X Stroke: 83.1 mm x 92.0 mm Compression Ratio: 9.1:1 (typical for FS-DE) Performance Horsepower: Approx. 130 hp @ 5200 rpm (FS-DE) Torque: Approx. 135 lb-ft @ 4000 rpm (FS-DE) Fuel System Fuel Delivery: Electronic Fuel Injection (MPI - Multi-Point Injection) Fuel Type: Unleaded Gasoline (87 octane recommended) Engine Variants Other Engines: FP-DE (1.8L DOHC, ~122 hp), Z5-DE (1.6L SOHC, ~98 hp - less common in North America for this year) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Automatic Transmission Features Manual Gear Ratios: Specific ratios vary by model and transmission, detailed in the manual. Automatic Features: Electronically controlled for optimal shift points. Fluid Specifications Manual Fluid: API GL-4 SAE 75W-90 Gear Oil (check manual for exact specification and capacity, e.g., Mazda JWS3309) Automatic Fluid: Dexron III or equivalent ATF (check manual for exact specification and capacity, e.g., Mazda ATF M-III) 📐 Dimensions Exterior Length: Approx. 168.1 inches (Sedan) Width: Approx. 67.7 inches Height: Approx. 55.5 inches (Sedan) Wheelbase: Approx. 102.7 inches Weights Curb Weight: Approx. 2700-2900 lbs (depending on trim and transmission) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4-star (for 2002 model, specific details may vary by test) NHTSA Front Impact Passenger: 4-star (for 2002 model, specific details may vary by test) Active Features ABS: Available Anti-lock Braking System (ABS) on some trims. Traction Control: Limited availability on higher trims or optional. Passive Features Airbags: Driver and front passenger airbags standard. Side airbags available on some trims. Seatbelts: Front seat pretensioners and load limiters. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with standard speaker configuration. Optional premium audio systems were available. Climate Control: Manual HVAC controls standard. Automatic Climate Control available on higher trims. Driver Assistance Cruise Control: Available on most trims. Connectivity Aux Input: Not typically equipped with standard aux input; aftermarket solutions may be available. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 to 7,500 miles or 6 months, whichever comes first (consult manual for exact specification based on driving conditions). Air Filter Replacement: Every 15,000 to 30,000 miles (consult manual). Spark Plug Replacement: Every 60,000 to 100,000 miles (depending on spark plug type - platinum/iridium recommended). Coolant Flush: Every 30,000 to 60,000 miles or 2-4 years (consult manual for coolant type and capacity). Fluid Specifications Engine Oil: API Service SG, SH, SJ or ILSAC GF-2. Viscosity: 5W-30 recommended for most climates. Capacity: Approx. 4.2 quarts with filter (FS-DE engine, check manual for exact capacity). Coolant: Ethylene Glycol based, Mazda FL22 Long Life Coolant or equivalent. Mix 50/50 with distilled water. Capacity: Approx. 6.1 quarts (FS-DE engine, check manual). Brake Fluid:...
Engine removal/installation, cylinder head overhaul, transmission rebuild, brake caliper service, suspension component replacement, HVAC system repair.
Diagnostics:
Troubleshooting guides, diagnostic fault codes (OBD-II), identification of common issues.
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid services to complete engine and transmission overhauls. Includes detailed illustrations and step-by-step instructions.
FP-DE (1.8L DOHC, ~122 hp), Z5-DE (1.6L SOHC, ~98 hp - less common in North America for this year)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
4-speed Automatic Transmission
Features
Manual Gear Ratios:
Specific ratios vary by model and transmission, detailed in the manual.
Automatic Features:
Electronically controlled for optimal shift points.
Fluid Specifications
Manual Fluid:
API GL-4 SAE 75W-90 Gear Oil (check manual for exact specification and capacity, e.g., Mazda JWS3309)
Automatic Fluid:
Dexron III or equivalent ATF (check manual for exact specification and capacity, e.g., Mazda ATF M-III)
📐 Dimensions
Exterior
Length:
Approx. 168.1 inches (Sedan)
Width:
Approx. 67.7 inches
Height:
Approx. 55.5 inches (Sedan)
Wheelbase:
Approx. 102.7 inches
Weights
Curb Weight:
Approx. 2700-2900 lbs (depending on trim and transmission)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4-star (for 2002 model, specific details may vary by test)
NHTSA Front Impact Passenger:
4-star (for 2002 model, specific details may vary by test)
Active Features
ABS:
Available Anti-lock Braking System (ABS) on some trims.
Traction Control:
Limited availability on higher trims or optional.
Passive Features
Airbags:
Driver and front passenger airbags standard. Side airbags available on some trims.
Seatbelts:
Front seat pretensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with standard speaker configuration. Optional premium audio systems were available.
Climate Control:
Manual HVAC controls standard. Automatic Climate Control available on higher trims.
Driver Assistance
Cruise Control:
Available on most trims.
Connectivity
Aux Input:
Not typically equipped with standard aux input; aftermarket solutions may be available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 to 7,500 miles or 6 months, whichever comes first (consult manual for exact specification based on driving conditions).
Air Filter Replacement:
Every 15,000 to 30,000 miles (consult manual).
Spark Plug Replacement:
Every 60,000 to 100,000 miles (depending on spark plug type - platinum/iridium recommended).
Coolant Flush:
Every 30,000 to 60,000 miles or 2-4 years (consult manual for coolant type and capacity).
Fluid Specifications
Engine Oil:
API Service SG, SH, SJ or ILSAC GF-2. Viscosity: 5W-30 recommended for most climates. Capacity: Approx. 4.2 quarts with filter (FS-DE engine, check manual for exact capacity).
Coolant:
Ethylene Glycol based, Mazda FL22 Long Life Coolant or equivalent. Mix 50/50 with distilled water. Capacity: Approx. 6.1 quarts (FS-DE engine, check manual).
Brake Fluid:
DOT 3 or DOT 4. Check manual for specific recommendations and capacity.
Known Issues
Engine:
Occasional intake manifold gasket leaks, oil leaks from valve cover or oil pan. Some reports of oil consumption with higher mileage. Timing belt inspection/replacement is critical (if applicable to specific engine variant, FS-DE is timing chain).
Suspension Steering:
Worn control arm bushings, ball joints, and tie rod ends can lead to premature tire wear and sloppy handling. Strut mounts can also wear out.
Electrical:
Alternator failures, power window motor issues, and faulty ignition coils can occur.
Exhaust:
Corrosion and leaks in the exhaust system, especially in rust-prone areas.
📚 Vehicle History
Brand Heritage
Brand:
Mazda has a long history of producing reliable and engaging vehicles, often known for their 'Zoom-Zoom' driving dynamics.
Model Evolution
Generation Bj:
The BJ generation (1998-2003) saw significant updates, including improved styling, chassis dynamics, and powertrain options. The 2002 model year falls within this generation.
Production
Manufacturing Location:
Primarily Japan (Hofu Plant).
Production Years:
1998-2003 (for the BJ generation).
🏆 Awards & Recognition
Recognitions
Model Reputation:
Consistently praised for its driving dynamics, value for money, and sporty appeal within the compact car segment.
Safety Ratings General:
Generally received good safety ratings for its time, but specific performance varies by test and year. The manual would detail how to maintain safety systems like SRS.