Mazda Protege 2005 Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Year: 2005 Codes Chassis Code: BJ 👋 Introduction Market Position Segment: Compact Car Target Audience: Value-conscious consumers, commuters, young drivers. Competitive Analysis...

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Type: Car

Vendor:

Sku: 57523

Tags: 2005 Car Cars Mazda Misc Protege

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Car

Target Audience:

Value-conscious consumers, commuters, young drivers.

Competitive Analysis

Key Competitors:

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

Key Features

Design Philosophy:

Jinba-Ittai ('horse and rider as one') driving dynamics.

Trim Levels:

Typically includes DX, ES, and MP3 trims.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive; covers all major mechanical, electrical, and body systems.

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, pistons, crankshaft, lubrication system, cooling system, fuel system, emission control systems.

Engine Electrical:

Ignition system, starting and charging systems, engine control module (ECM) diagnostics, sensors, actuators.

Transmission Manual:

Manual transmission (M5) overhaul, clutch, gear shift mechanism.

Transmission Automatic:

Automatic transmission (FS5A-EL) overhaul, hydraulic control, torque converter, electronic controls.

Drivetrain:

Front-wheel drive axle shafts, differentials, drive shafts.

Suspension:

Front and rear suspension systems, shock absorbers, struts, control arms, springs, bushings.

Steering

Steering System:

Power steering system, steering rack, tie rods, steering column.

Brakes

Brake System:

Front and rear disc brakes, hydraulic system, ABS system (if equipped), parking brake.

Electrical System

Body Electrical:

Lighting systems (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, fuses, relays.

Instrumentation Gauges:

Instrument cluster, warning lights, diagnostic trouble codes (DTCs).

Body And Trim

Body Panels:

Body panel removal and installation, doors, hood, trunk lid, bumpers, glass replacement.

Interior Trim:

Dashboard, door panels, seating systems, headliner.

HVAC System:

Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, diagnostics.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, belt replacement, tire rotation.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, wiring diagrams, component testing.

Repair Procedures:

Step-by-step instructions for component removal, installation, and overhaul.

Special Tools:

Identification and usage of specific tools required for various repairs.

Technical Depth

Depth Of Information:

Factory-level detail; suitable for professional technicians and advanced DIYers.

Diagnostic Codes:

Includes diagnostic trouble codes (DTCs) for engine, transmission, ABS, and other systems.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for easy navigation and information retrieval.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding:

Not Applicable (Digital PDF)

Paper Type

Paper Quality:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

FS-DE

Engine Type 1:

2.0L Inline-4 DOHC 16-valve

Horsepower 1:

130 hp @ 6000 rpm

Torque 1:

135 lb-ft @ 4300 rpm

Secondary Engine

Engine Code 2:

FP-DE (less common in North America for 2005)

Engine Type 2:

1.6L Inline-4 SOHC 16-valve

Horsepower 2:

100 hp

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI).

Fuel Type:

Unleaded gasoline, 87 octane recommended.

Cooling System

Coolant Type:

Mazda FL22 Extended Life Antifreeze (Green) or equivalent silicate-free, extended-life coolant.

Coolant Capacity:

Approx. 5.7 US quarts (5.4 liters).

🔧 Transmission

Standard

Transmission Type Std:

5-speed manual transmission (M5)

Optional

Transmission Type Opt:

4-speed automatic transmission (FS5A-EL)

Features

Automatic Transmission Features:

Electronic control, torque converter lock-up.

Fluid Specs

Manual Transmission Fluid Type:

API GL-4, SAE 75W-90 synthetic gear oil.

Automatic Transmission Fluid Type:

Mazda ATF-MV (Type M-V) or equivalent.

📐 Dimensions

Exterior

Length:

173.7 inches (4412 mm)

Width:

67.1 inches (1704 mm)

Height:

55.3 inches (1405 mm)

Wheelbase:

102.8 inches (2611 mm)

Weights

Curb Weight:

Approx. 2750-2950 lbs (1247-1338 kg) depending on trim and transmission.

Gross Vehicle Weight Rating:

Approx. 3700-3850 lbs (1678-1746 kg).

Cargo

Trunk Volume:

Approx. 12.0 cubic feet (sedan).

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

★★★★★

NHTSA Front Impact Passenger:

★★★★★

IIHS Front Offset Crash Rating:

Active Features

Anti Lock Braking System:

Available ABS on all wheels.

Traction Control:

Available Traction Control System (TCS).

Passive Features

Airbags:

Front dual-stage airbags, optional side-impact airbags.

Seatbelts:

Three-point seatbelts in all seating positions, pretensioners and load limiters for front seats.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional Bose premium audio system, MP3 player input (on MP3 trim).

Climate Control:

Manual climate control, available automatic climate control on higher trims.

Driver Assistance

Cruise Control:

Standard on most trims.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement:

Every 60,000 miles (96,000 km) with NGK Iridium plugs (PFR5A-11).

Engine Coolant Replacement:

Initial: 5 years or 100,000 miles (160,000 km), then every 2 years or 50,000 miles (80,000 km).

Fluid Specifications

Engine Oil Spec:

API SN/SP, ILSAC GF-6A or higher, SAE 5W-20 synthetic blend or full synthetic.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Issue 1:

Intake manifold gaskets can develop leaks (vacuum leaks).

Common Issue 2:

Exhaust manifold cracks can occur.

Common Issue 3:

Automatic transmission shift solenoid issues leading to harsh shifting or limp mode.

Common Issue 4:

Power steering pump whine or leaks.

Common Issue 5:

Rust development in wheel wells and rocker panels, especially in rust-belt regions.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Focus on driving enjoyment and innovative engineering.

Model Evolution

Protege Generation:

Third generation (2001-2003), facelifted for 2004-2005.

Facelift Details:

Revised front and rear styling, updated interior features.

Production

Manufacturing Locations:

Japan (Mazda's main production), Mexico (for North American market).

Production Years:

1990-2003 (global), 2001-2003 (North America), with the 2005 model year representing the final iteration of the BJ generation.

🏆 Awards & Recognition

Recognitions

Award 1:

Car and Driver's 10 Best Trucks list for the Protege5 wagon (related model).

Ratings

Kbb Consumer Rating:

Generally well-regarded for reliability and value by consumers.