Mazda Protege 5 2000-2004 Online Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Model Code: BJ Series Body Style: 5-door hatchback/wagon Generation Generation Designation: Second Generation (BJ) Production Years Generation: 1998-2003 (Globally), 2000-2003 (North...

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Type: Car

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Sku: 366016

Tags: 2000 2001 2002 2003 2004 Car Cars Mazda Misc Protege 5

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege 5

Model Code:

BJ Series

Body Style:

5-door hatchback/wagon

Generation

Generation Designation:

Second Generation (BJ)

Production Years Generation:

1998-2003 (Globally), 2000-2003 (North America for Protege 5)

Codes

Vin Character Engine:

F (for FS-DE engine)

👋 Introduction

Market Position

Segment:

Compact wagon/hatchback, sporty alternative to sedans

Target Audience:

Younger buyers, small families, enthusiasts looking for practicality with a sporty flair

Competitive Analysis

Key Competitors:

Subaru Outback, Honda CR-V (early models), Toyota Matrix, Ford Focus Wagon

Key Features

Driving Dynamics:

Known for responsive handling and engaging driving experience, a Mazda hallmark

Practicality:

Versatile cargo space due to hatchback design, folding rear seats

Styling:

Distinctive, sporty exterior styling for its class

📋 Manual Details

Coverage Areas

Covered Model Years:

2000, 2001, 2002, 2003

Covered Engine Options:

FS-DE 2.0L DOHC (Naturally Aspirated)

Covered Markets:

North America (implies specific regional variations if any)

Page Count

Estimated Page Count:

1500-2500+ pages (typical for comprehensive service manuals)

Manual Type

Type:

Online Service and Repair Manual

Scope:

Factory-level repair and maintenance information

Language

Language:

English

Format

Format:

Digital (likely PDF or web-based access)

Searchability:

Likely text-searchable

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, fuel system, ignition system, exhaust system, cooling system, lubrication system

Drivetrain:

Transmission (manual and automatic), clutch, driveshafts, differentials, AWD system (if applicable)

Chassis:

Suspension (front and rear), steering system, brakes (front and rear), wheels and tires

Electrical:

Battery, charging system, starting system, lighting system, instrument cluster, body electricals, power accessories

Body And Frame:

Body panels, doors, windows, interior trim, structural components, paint and finish

HVAC:

Heating, Ventilation, and Air Conditioning system

Safety Systems:

Airbags, seatbelts, ABS (Anti-lock Braking System)

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation

Repair:

Component removal and installation, adjustments, replacements, rebuilds

Diagnostics:

ECM/PCM diagnosis, sensor testing, actuator testing, electrical circuit tracing

Specifications:

Torque specifications, clearances, fluid capacities, electrical values

Technical Depth

Depth:

Comprehensive, covering basic maintenance to major overhauls and complex diagnostics

Diagnostic Tools:

Information on using diagnostic scan tools and specialized equipment

Wiring Diagrams:

Includes detailed electrical wiring diagrams for all systems

Special Tools:

Identifies and describes any special tools required for specific procedures

📊 Manual Specifications

File Format

Digital Format:

PDF (most common for online service manuals)

Print Quality

Readability:

High resolution for clear viewing of text and diagrams

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Quality:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE

Engine Type:

Inline 4-cylinder, DOHC (Dual Overhead Camshafts), 16 valves

Displacement:

1991 cc (2.0 Liters)

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

9.0:1

Performance

Horsepower:

130 hp @ 6000 rpm (approx.)

Torque:

135 lb-ft @ 4000 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with sequential port injection

Fuel Type:

Unleaded gasoline, 87 octane recommended

Emission Control:

California/Federal emissions standards, Catalytic Converter, EGR system

🔧 Transmission

Standard

Transmission Type:

5-speed manual transmission

Optional

Transmission Type:

4-speed automatic transmission (with lock-up torque converter)

Features

Manual Gear Ratios:

Refer to manual for specific ratios (e.g., 1st: 3.45, 2nd: 1.94, 3rd: 1.33, 4th: 0.97, 5th: 0.76, Rev: 3.33)

Automatic Gear Ratios:

Refer to manual for specific ratios (e.g., 1st: 2.80, 2nd: 1.50, 3rd: 1.00, 4th: 0.70, Rev: 2.20)

Clutch Type:

Dry single plate, hydraulically actuated

Transmission Fluid Manual:

API GL-4, SAE 75W-90 synthetic gear oil (check manual for specific part numbers, e.g., Mazda Genuine Gear Oil JWS3309)

Transmission Fluid Automatic:

Dexron III or equivalent (check manual for specific part numbers, e.g., Mazda ATF-III)

📐 Dimensions

Exterior

Length:

4320 mm (170.1 in)

Width:

1705 mm (67.1 in)

Height:

1545 mm (60.8 in)

Wheelbase:

2615 mm (103.0 in)

Front Track:

1475 mm (58.1 in)

Rear Track:

1470 mm (57.9 in)

Ground Clearance:

150 mm (5.9 in) approx.

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Wheel Size:

15-inch or 16-inch alloy wheels

Tire Size:

195/60R15, 205/50R16 (depending on trim)

Interior

Passenger Volume:

Approx. 96.0 cu ft

Cargo

Cargo Volume Seats Up:

Approx. 19.1 cu ft

Cargo Volume Seats Down:

Approx. 42.4 cu ft

Weights

Curb Weight:

1310-1370 kg (2888-3019 lbs) approx.

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle compliance plate or manual

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

★★★★ (4 Stars - 2001 Model Year)

NHTSA Frontal Impact Passenger:

★★★★ (4 Stars - 2001 Model Year)

IIHS Moderate Overlap Frontal Offset:

Good (for Protege sedan, presumed similar for hatchback)

Active Features

Standard on most trims, optional on others

Traction Control:

Available on some higher trims/later models

Electronic Brakeforce Distribution Ebd:

Often paired with ABS

Passive Features

Airbags:

Front dual airbags standard

Side Airbags:

Optional front side-impact airbags on some trims

Seatbelts:

3-point front and rear seatbelts, pretensioners and load limiters for front seats

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium audio systems with more speakers

Speakers:

Typically 4-6 speakers depending on trim level

Driver Assistance

Cruise Control:

Standard on most trims

Connectivity

Auxiliary Input:

Not typically standard; aftermarket solutions available

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions)

Oil Filter Replacement:

With every oil change

Engine Air Filter Replacement:

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

Cabin Air Filter Replacement:

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

Spark Plug Replacement:

Every 60,000 miles (96,000 km) (Iridium or Platinum plugs recommended)

Transmission Fluid Change Manual:

Every 60,000 miles (96,000 km) or as needed

Transmission Fluid Change Automatic:

Every 45,000 miles (72,000 km) or as needed

Coolant Flush Replacement:

Every 50,000 miles (80,000 km) or 3 years

Brake Fluid Replacement:

Every 2 years or 30,000 miles (48,000 km)

Fluid Specifications

Engine Oil Type:

SAE 5W-30 Synthetic (API SJ or SL, ILSAC GF-3)

Engine Oil Capacity:

4.2 L (4.4 US qt) with filter change

Coolant Type:

Mazda Genuine Long Life Antifreeze/Coolant (Blue) or equivalent (ethylene glycol based, 50/50 mix with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Known Issues

Engine Mounts:

Can degrade over time, leading to vibration

Ignition Coils:

Can fail, causing misfires and rough running

Rear Wheel Bearings:

Can develop noise and wear out, especially on higher mileage vehicles

Catalytic Converter:

Can become clogged or fail, affecting performance and emissions

Suspension Components:

Control arm bushings, sway bar links can wear and require replacement

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Zoom-Zoom driving dynamics, Jinba Ittai (horse and rider as one)

Model Evolution

Protege Lineage:

Part of Mazda's long-standing compact car lineage, succeeding models like the 323

Protege 5 Introduction:

Introduced for the 2002 model year in North America, based on the BJ platform, offering a unique wagon/hatchback variant of the Protege sedan

Production

Manufacturing Location:

Japan (primarily)

End Of Production Line:

The Protege line was replaced by the Mazda3 (Mazda3 MPS in some markets) starting with the 2004 model year.

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

The Protege sedan was recognized by Car and Driver in the past, indicating a competitive chassis and driving feel that likely carried over to the Protege 5.

Consumer Reports:

General reliability ratings varied by year, but the platform was generally considered decent for its class, though some specific issues are noted.