🏷️ Basic Information

Make:

Mazda

Model:

Protege 5

Year:

2003

Body Style:

Wagon

Generation Code:

BJ

👋 Introduction

Vehicle Segment:

Compact Wagon/Hatchback

Target Audience:

Families, individuals seeking practicality and sporty handling in a compact package.

Key Competitors:

Subaru Outback, Honda Civic Si Wagon, Volkswagen Golf.

Vehicle Highlights:

Sporty styling, engaging driving dynamics, practical cargo space, available all-wheel drive (though less common on the Protege 5).

Dealer Equivalence:

Contains the same information used by official Mazda dealers.

Ease Of Use:

Designed to be simple to use with step-by-step diagrams.

📋 Manual Details

Systems Covered:

General Information, Engine, Lubrication System, Cooling System, Fuel and Emission Control System, Engine Electrical System, Clutch, Manual Transaxle, Automatic Transaxle, Front and Rear Axles, Steering System, Braking System, Suspension, Body, Body Electrical System, Heater and Air Conditioner, Technical Data, Special Tools

Estimated Page Count:

Over 1500 pages (typical for comprehensive factory service manuals)

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for engine disassembly, inspection, repair, and reassembly, including cylinder head, pistons, connecting rods, crankshaft, and timing components.

Engine Performance:

Information on engine tuning, diagnostics, and performance optimization.

Lubrication System:

Oil pump, oil filter, oil passages, and lubrication system troubleshooting.

Cooling System:

Radiator, water pump, thermostat, cooling fan, hoses, and coolant capacity, along with troubleshooting for overheating.

Fuel And Emission Control:

Fuel injectors, fuel pump, fuel filter, EVAP system, oxygen sensors, catalytic converter, and emission control systems diagnostics.

Engine Electrical:

Ignition system, starting system, charging system (alternator, battery), ECU, sensors (crankshaft, camshaft), and wiring diagrams.

Clutch:

Clutch disc, pressure plate, release bearing, clutch hydraulics, and clutch pedal adjustment.

Manual Transaxle:

Gearbox disassembly, repair, inspection, gear ratios, shift linkage, and fluid specifications.

Automatic Transaxle:

Transmission operation, valve body, torque converter, planetary gear sets, clutch packs, solenoids, and transmission fluid requirements.

Front And Rear Axles:

CV joints, wheel bearings, differential (if applicable), axle shafts, and seals.

Steering System:

Power steering pump, steering rack, tie rods, steering column, and steering angle sensor.

Braking System:

Front and rear brake discs and pads, calipers, brake master cylinder, ABS system, hydraulic lines, and brake fluid specifications.

Suspension:

Front and rear suspension components (struts, shock absorbers, control arms, springs), alignment specifications, and wheel bearing replacement.

Body:

Body panel removal and installation, doors, hood, tailgate, interior trim, and chassis specifications.

Body Electrical:

Lighting systems, power windows, power locks, mirrors, wipers, horn, central locking, and body control module (BCM) diagnostics.

Heater And Air Conditioner:

HVAC system components, refrigerant, blower motor, controls, diagnostics, and cabin air filter replacement.

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, fluid checks and changes, spark plug replacement, and tune-ups.

Diagnostics:

Troubleshooting guides for common problems, diagnostic trouble codes (DTCs), and diagnostic procedures for various systems.

Repair:

Step-by-step repair instructions for all major mechanical and electrical components.

Wiring Diagrams:

Complete electrical schematics for all vehicle systems.

Torque Specifications:

Precise torque settings for all critical fasteners and bolts.

Fluid Capacities:

Detailed information on all fluid capacities and types (engine oil, coolant, brake fluid, transmission fluid, power steering fluid).

Depth:

Comprehensive, from basic maintenance to complete engine and transmission overhauls, including electrical system diagnostics and body repair.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text within the PDF for quick information retrieval.

Zoom Functionality:

Yes, allows for detailed examination of diagrams and text.

Compatibility:

Compatible with all versions of Windows and Mac.

Required Software:

Adobe PDF Reader & WinZip (for extraction if in a compressed archive).

Printability:

Printable pages for physical reference.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code:

FS-DE

Engine Type:

Naturally Aspirated Inline-4

Displacement:

2.0 Liters (1991 cc)

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

9.1:1

Valve Train:

DOHC, 16 valves (4 valves per cylinder)

Horsepower:

130 hp @ 6000 rpm

Torque:

135 lb-ft @ 4300 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 Octane

🔧 Transmission

Transmission Type:

5-Speed Manual Transaxle

Transmission Type:

4-Speed Automatic Transaxle

Manual Transmission Gear Ratios:

Detailed in manual, typically includes ratios for 1st through 5th gear and reverse.

Automatic Transmission Features:

Electronic control, lock-up torque converter.

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 (Specific Mazda specification recommended in manual).

Automatic Transmission Fluid:

Mazda ATF M-III or equivalent (Refer to manual for exact specification).

📐 Dimensions

Length:

169.3 inches (4300 mm)

Width:

67.7 inches (1720 mm)

Height:

60.2 inches (1530 mm)

Wheelbase:

102.8 inches (2610 mm)

Front Track:

58.7 inches (1490 mm)

Rear Track:

58.3 inches (1480 mm)

Curb Weight:

Approx. 2850 - 3000 lbs (1293 - 1361 kg)

Gross Vehicle Weight Rating Gvwr:

Specific GVWR detailed in manual.

Towing Capacity:

Not typically recommended or specified for this vehicle.

Cargo Volume:

Approx. 32.1 cubic feet (behind rear seats), expandable with seats folded.

🛡️ Safety Features

NHTSA Front Impact Driver:

5-Star (for 2003 model year, typical for its class).

NHTSA Front Impact Passenger:

5-Star (for 2003 model year, typical for its class).

IIHS Frontal Offset:

Good (for 2003 model year).

ABS:

Standard Anti-lock Braking System

Traction Control:

Optional or standard on some trims.

Airbags:

Front airbags (driver and passenger), optional side-impact airbags.

Seatbelts:

3-point front and rear seatbelts with pretensioners and load limiters.

Child Safety Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Audio System:

Factory AM/FM/CD stereo system, often with optional premium audio.

Display:

Basic digital or analog display for radio and clock.

Cruise Control:

Standard on many trims.

Auxiliary Input:

Not typically standard, aftermarket solutions available.

🔧 Maintenance

Oil Change Interval:

Every 5,000 - 7,500 miles or 6 months (refer to manual for specific conditions).

Air Filter Replacement:

Every 15,000 - 30,000 miles or as needed based on driving conditions.

Spark Plug Replacement:

Every 30,000 - 60,000 miles (depending on spark plug type).

Coolant Flush:

Every 30,000 - 50,000 miles or 2-3 years.

Timing Belt Replacement:

For the FS-DE engine, it uses a timing chain, not a belt, so no regular replacement is needed beyond inspection for wear.

Engine Oil:

5W-30 Synthetic Blend or Full Synthetic (API SN or higher).

Engine Oil Capacity:

Approx. 4.3 US Quarts (4.1 Liters) with filter change.

Coolant:

Mazda Super Long Life Coolant (FL22) or equivalent OAT/HOAT antifreeze.

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

Mazda Genuine Power Steering Fluid or Dexron II/III compatible fluid.

Common Problems:

Oil leaks from valve cover gasket and oil pan gasket, interior trim rattles, potential for catalytic converter failure, issues with certain power window regulators, wheel bearing wear.

Troubleshooting Guides:

The manual provides specific troubleshooting flowcharts and symptom-based diagnostics for these and other issues.

📚 Vehicle History

Mazda Philosophy:

Jinba Ittai (horse and rider as one), emphasizing driving feel and connection.

Protege Lineage:

Part of the larger Mazda Protege family, which ran for several generations.

Protege 5 Introduction:

Introduced for the 2002 model year as a sportier, more versatile variant of the Protege sedan.

Production Dates:

2002-2003 (US Market), part of the second generation (BJ) Protege.

Manufacturing Location:

Japan and Mexico

🏆 Awards & Recognition

Consumer Reports Rating:

Varies by year, generally received average to good ratings for reliability and performance in its class.

Safety Awards:

Achieved high safety ratings from NHTSA and IIHS, as detailed in the safety section.