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Mazda Protege 5 2001-2003 Service Repair Shop Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Generation: First Generation (BJ Series) Codes Chassis Code: BJ5W 👋 Introduction Market Position Segment: Compact Wagon / Sport Wagon Target Audience:...
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Mazda Protege 5 2001-2003 Service Repair Shop Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege 5
Generation:
First Generation (BJ Series)
Codes
Chassis Code:
BJ5W
👋 Introduction
Market Position
Segment:
Compact Wagon / Sport Wagon
Target Audience:
Families, young professionals, enthusiasts seeking a practical and sporty vehicle.
Competitive Analysis
Key Competitors:
Subaru Outback, Honda CR-V, Toyota RAV4, Ford Focus Wagon
Key Features
Unique Selling Points:
Sporty handling, versatile cargo space, distinctive styling, reliable mechanicals.
Manual Value Proposition:
Empowers owners to perform essential maintenance and repairs, saving significant costs associated with dealership or independent mechanic services.
📋 Manual Details
Coverage Areas
Geographic Markets:
North America
Specific Regions:
USA, Canada
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Service and Repair Shop Manual
Language
Language:
English
Format
Digital Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical, Engine Control System (ECM), Fuel System, Ignition System, Exhaust System, Lubrication System
Drivetrain:
Automatic Transmission, Manual Transmission, Drivetrain Components (CV joints, driveshafts)
Chassis:
Suspension System (Front & Rear), Steering System, Brake System (ABS included)
Electrical:
Body Electrical System, Lighting, Instrumentation, Powertrain Control Module (PCM) Wiring Diagrams, Body Control Module (BCM) Wiring Diagrams
Body And Trim:
Body Exterior, Interior Trim, Body Sealing, Doors, Windows, Seats
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replenishments
Diagnostics:
Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Component Testing Procedures
Repair And Rebuild:
Engine Rebuild Procedures, Transmission Overhaul, Suspension Component Replacement, Brake Caliper Rebuild
Special Tools:
Identification of required special tools for specific repairs
Technical Depth
Depth:
Comprehensive: From basic fluid changes to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text Content
Print Quality
Resolution:
High-resolution scans suitable for printing
Binding Type
Binding Type Digital:
N/A (Downloadable)
Paper Type
Paper Type Digital:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
FS-DE
Engine Type:
Inline 4-Cylinder, DOHC (Dual Overhead Camshafts), 16 Valves
Displacement:
2.0 Liters (1991 cc)
Performance
Horsepower Net:
130 hp @ 5200 rpm (approx.)
Torque Net:
135 lb-ft @ 4000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Sequential multiport
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Engine Management
ECM Type:
Denso or similar, with OBD-II diagnostics
Cooling System
Coolant Type:
Ethylene Glycol based, typically 50/50 mix with distilled water (refer to manual for specific Mazda coolant type)
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission
Optional
Type:
4-Speed Automatic Transmission with Overdrive
Features
Automatic Features:
Electronically Controlled, Lock-up torque converter
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90 (refer to manual for exact specification and capacity)
Automatic Transmission Fluid:
Mazda ATF-Type T-IV or equivalent (refer to manual for exact specification and capacity)
📐 Dimensions
Exterior
Length:
4390 mm (172.8 inches)
Width:
1705 mm (67.1 inches)
Height:
1545 mm (60.8 inches)
Wheelbase:
2615 mm (103.0 inches)
Ground Clearance:
150 mm (5.9 inches)
Cargo
Cargo Volume Seats Up:
Approximately 29.7 cubic feet
Cargo Volume Seats Down:
Approximately 57.4 cubic feet
Weights
Curb Weight Manual:
Approx. 1370 kg (3020 lbs)
Curb Weight Automatic:
Approx. 1390 kg (3064 lbs)
Gross Vehicle Weight Rating:
Approx. 1870 kg (4123 lbs)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Rating:
4 Stars (Driver and Passenger)
IIHS Side Impact Rating:
Good (for models equipped with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional (TCS) on some models
Passive Features
Airbags:
Dual front airbags standard; optional side-impact airbags
Seatbelts:
Three-point height-adjustable front seat belts with pretensioners, rear three-point seat belts
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player with 4 or 6 speakers; optional premium audio with subwoofer.
Climate Control:
Manual climate control standard; optional automatic climate control on higher trims.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors standard or optional depending on trim.
Diagnostics
OBD Ii Support:
Full OBD-II compliance for engine diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (using synthetic or synthetic blend oil recommended for optimal performance)
Air Filter Replacement:
Every 15,000 miles or 12 months
Spark Plug Replacement:
Every 60,000 miles (iridium type recommended)
Coolant Flush:
Every 30,000 miles or 24 months
Fluid Specifications
Engine Oil Capacity:
4.2 Liters (4.4 US Quarts) with filter change (refer to manual for exact capacity and oil type recommendation)
Engine Oil Viscosity:
5W-30 or 5W-20 (refer to manual and climate conditions)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific requirement)
Power Steering Fluid Type:
Mazda Genuine Power Steering Fluid or Dexron III/Mercon equivalent (refer to manual)
Known Issues
Engine Mounts:
Can degrade over time leading to increased vibration and noise.
Exhaust Manifold:
Cracking can occur on the cast iron exhaust manifold.
Transmission Shifting:
Automatic transmission can sometimes exhibit rough shifting; fluid changes are critical.
Suspension Components:
Worn control arm bushings and sway bar links are common wear items.
Radiator Fan Motor:
Fan motor failure can lead to overheating.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Zoom-Zoom - Emphasizing driving dynamics and spirited performance.
Model Evolution
Protege Lineage:
The Protege 5 is a wagon variant of the third-generation Mazda Protege (BJ platform), launched globally in 2001.
Protege 5 Introduction:
Introduced to offer a more versatile and stylish alternative to traditional sedans and SUVs in the compact segment.
Production
Production Years:
2001-2003 (for this specific manual coverage)
Manufacturing Location:
Hofu, Yamaguchi, Japan
🏆 Awards & Recognition
Recognitions
Initial Reception:
Praised for its practicality, driving dynamics, and unique styling in the compact wagon segment.
Long Term Value:
Considered a solid value proposition for its reliability and utility, making it a sought-after used vehicle.
Certifications
Safety Certifications:
Met all federal motor vehicle safety standards (FMVSS) for its model years.
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