Mazda Protege 5 2000-2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Model Years Covered: 2000, 2001, 2002, 2003, 2004 Codes Chassis Code: BJFW Platform: Mazda Familia/Protege platform (BJ) 👋 Introduction Market Position...

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Type: Car

Vendor:

Sku: 354732

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

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege 5

Model Years Covered:

2000, 2001, 2002, 2003, 2004

Codes

Chassis Code:

Platform:

Mazda Familia/Protege platform (BJ)

👋 Introduction

Market Position

Positioning:

The Mazda Protege 5 (2000-2004) was positioned as a sporty and practical compact wagon, offering versatility and engaging driving dynamics within its segment.

Competitive Analysis

Competitors:

Competed against vehicles like the Honda Civic Si Wagon, Subaru Impreza Outback Sport, and Volkswagen Golf.

Key Features

Features:

Known for its distinctive styling, agile handling, available manual transmission, and practical cargo space.

Manual Value

Value Proposition:

This service manual provides essential technical information for owners and technicians to maintain and repair the Protege 5, ensuring its longevity and optimal performance.

📋 Manual Details

Coverage Areas

Coverage:

Complete factory service and repair

Page Count

Page Count:

Detailed page count unavailable without full manual access, but typically over 1500 pages for full coverage.

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, repair, overhaul, timing belt, lubrication system, cooling system, fuel delivery, emission controls.

Engine Performance:

Ignition system, fuel injection system (DFI), electronic engine controls (ECM/ECU), diagnostics, sensors, actuators, performance tuning basics.

Transmission:

Manual transmission (FS-DE, FP-DE), automatic transmission (FS5A-EL), clutch system, torque converter, transmission control.

Drivetrain:

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

Suspension:

Front and rear suspension systems, struts, shocks, control arms, ball joints, bushings, alignment procedures.

Steering:

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

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), brake lines, calipers, rotors, pads, master cylinder, brake fluid specifications.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system, accessories, wiring diagrams, fuses, relays.

HVAC:

Heating, ventilation, and air conditioning system, refrigerant handling, blower motor, compressor, A/C diagnosis.

Body And Trim:

Exterior body panels, interior trim components, doors, windows, glass, body hardware, trim removal and installation.

Chassis And Frame:

Frame structure, unibody construction, body repair basics.

Safety Systems:

Airbag system (SRS), seat belts, safety restraints.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad replacement, tire rotation.

Diagnostics:

Troubleshooting common symptoms, diagnostic trouble codes (DTCs), symptom-based diagnostics, component testing.

Repair:

Detailed step-by-step repair procedures for all major systems, including engine, transmission, brakes, suspension, steering, electrical.

Rebuilds:

Engine and transmission overhaul procedures, including component specifications and tolerances.

Calibration:

Wheel alignment specifications and procedures, headlight aiming.

Diagnosis Specific:

Diagnostic flowcharts for specific issues (e.g., no-start, poor performance, charging system faults).

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls, with detailed diagnostic procedures.

Detail Level:

Factory-level detail with torque specifications, clearances, and diagnostic parameters.

Diagrams:

Includes detailed wiring diagrams, system schematics, and exploded views for disassembly/reassembly.

📊 Manual Specifications

File Format

Format:

Digital Download (PDF is standard for this type of product).

Searchability:

Typically text-searchable PDF for quick information retrieval.

Printability:

Printable pages for physical reference.

Print Quality

Quality:

High-resolution images and diagrams for clarity.

Binding Type

Binding:

N/A (Digital download; if printed, typically bound or in loose-leaf binder).

Paper Type

Paper:

N/A (Digital download; if printed, likely heavy-duty paper for workshop use).

Completeness

Content:

Complete factory service information, covering all aspects of maintenance and repair.

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE (2.0L DOHC)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

1991 cc (2.0 Liters)

Performance

Horsepower:

Approx. 130-135 hp @ 6000 rpm (depending on market and specific tune)

Torque:

Approx. 135-137 lb-ft @ 4000 rpm (depending on market and specific tune)

Fuel System

Fuel Delivery:

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

Fuel Type:

Unleaded gasoline

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or coil pack setup.

Cooling System

Coolant Type:

Ethylene glycol-based coolant (e.g., Mazda FL22 or equivalent).

Lubrication System

Oil Type:

SAE 5W-30 or 10W-30 API SJ or higher (refer to owner's manual for exact spec).

Timing Belt

Belt Replacement Interval:

Typically 60,000-70,000 miles or 5-7 years, whichever comes first (highly recommended to follow manual or known service history).

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission (e.g., G25M-R)

Optional

Transmission Type:

4-speed Automatic Transmission (e.g., FS5A-EL)

Features

Manual Features:

Clutch operation, gear ratios, shift linkage.

Automatic Features:

Torque converter lock-up, electronic control unit (TCU), gear ratios.

Fluid Specifications

Manual Transmission Fluid:

GL-4 gear oil (e.g., SAE 75W-90).

Automatic Transmission Fluid:

Mercon V or equivalent ( Mazda M-V ATF).

📐 Dimensions

Exterior

Length:

Approx. 170.0 inches

Width:

Approx. 67.7 inches

Height:

Approx. 59.4 inches

Wheelbase:

Approx. 102.8 inches

Cargo

Cargo Volume:

Approx. 28.0 cubic feet (with rear seats up); Approx. 58.0 cubic feet (with rear seats folded).

Weights

Curb Weight:

Approx. 2800-3000 lbs (depending on transmission and trim).

Gross Vehicle Weight Rating:

Varies by model, consult specific vehicle sticker.

Wheel And Tire

Wheel Size:

15-inch or 16-inch alloy wheels.

Tire Size:

Typically 195/55R15 or 205/50R16.

Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Lug Nut Torque:

Typically 80-100 ft-lbs (consult manual for exact spec).

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Good (for 2003 model year, actual ratings may vary by year and test parameters).

IIHS Front Offset:

Acceptable to Good (for 2003 model year).

Active Features

Available Anti-lock Braking System (ABS).

Traction Control:

Not typically standard, may be available on some higher trims or specific markets.

Passive Features

Airbags:

Front airbags, optional side airbags.

Seatbelts:

Three-point front and rear seat belts, pretensioners for front seats.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional cassette player, and premium sound system with amplifier on some trims.

Climate Control:

Manual or automatic climate control systems.

Driver Assistance

Cruise Control:

Standard on most trims.

Power Features:

Power windows, power door locks, power mirrors.

Connectivity

Auxiliary Input:

Not standard; aftermarket solutions may be available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Air Filter Replacement:

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

Cabin Air Filter Replacement:

Every 15,000-20,000 miles or annually.

Brake Fluid Flush:

Every 24-36 months or as recommended by the service interval chart.

Coolant Flush:

Every 30,000 miles or 3 years, whichever comes first.

Transmission Fluid Change:

Manual: every 60,000 miles. Automatic: every 30,000-50,000 miles (severe conditions may require more frequent changes).

Fluid Specifications

Engine Oil Capacity:

Approx. 4.3 U.S. quarts (with filter) for the 2.0L engine.

Coolant Capacity:

Approx. 6.0-6.5 U.S. quarts.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Engine Issues:

Oil leaks from valve cover gasket and oil pan gasket are relatively common. Occasional issues with oil pressure sending unit or intake manifold gaskets.

Suspension Issues:

Worn front control arm bushings, worn sway bar links, and premature strut wear can occur, especially on higher mileage vehicles.

Electrical Issues:

Corrosion on battery terminals, minor dashboard electrical glitches, and occasional power window regulator failures.

Exhaust Issues:

Rust and corrosion on exhaust components, particularly the muffler and catalytic converter, especially in areas with harsh winters.

📚 Vehicle History

Brand Heritage

Mazda Heritage:

Mazda has a long history of producing reliable and engaging vehicles, often emphasizing driving enjoyment and innovative design.

Model Evolution

Protege Family:

The Protege 5 is part of the third generation of the Mazda Protege family (BJ platform), which also included sedan and hatchback variants.

Protege 5 Introduction:

The Protege 5 was introduced for the 2002 model year as a stylish and more practical alternative to the standard Protege hatchback.

Production

Manufacturing Location:

Primarily manufactured in Japan and Mexico.

Production Years

Production Period:

2000-2003 (for the BJ generation Protege line), with the Protege 5 specifically introduced for 2002-2003 model years before being replaced by the Mazdaspeed3/Mazda3 hatchback.

🏆 Awards & Recognition

Recognitions

Initial Reception:

The Protege 5 was generally well-received for its styling, handling, and practicality, though sales volumes were not as high as some competitors.

Ratings

Consumer Reports:

Consumer Reports ratings varied by year, but often highlighted its good handling and fuel economy, while noting average reliability in some areas.

Certifications

Emission Standards:

Meets Federal EPA emission standards for the respective model years.