Mazda Protege 5 Workshop Manual 2002

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Year: 2002 Codes Chassis Code: BJ 👋 Introduction Market Position Target Audience: DIY enthusiasts and professional mechanics Value Proposition: Inexpensive way...

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Type: Car

Vendor:

Sku: 285126

Tags: 2002 Car Cars Mazda Protege Protege 5

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege 5

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts and professional mechanics

Value Proposition:

Inexpensive way to maintain and repair vehicle, dealer-level information

Competitive Analysis

Comparison:

Provides same detail as dealer-used manuals, offering significant cost savings over dealership service.

Key Features

Feature 1:

Step-by-step instructions

Feature 2:

Detailed illustrations and photos

Feature 3:

Printable pages for garage use

Feature 4:

Comprehensive system coverage

📋 Manual Details

Coverage Areas

Coverage Type:

Complete Service and Repair

Page Count

Total Pages:

1600+

Manual Type

Manual Format Type:

Workshop Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Yes (2.0L DOHC FS-DE)

Transmission:

Yes (Manual & Automatic)

Brakes:

Yes (ABS, Disc/Drum)

Suspension:

Yes (Front MacPherson Strut, Rear Multi-link)

Steering:

Yes (Power Rack & Pinion)

Electrical:

Yes (Wiring Diagrams, ECUs, Lighting)

Bodywork:

Yes (Body Panel Repair, Doors, Glass)

HVAC:

Fuel System:

Yes (Injection, Pump, Tank)

Exhaust System:

Cooling System:

Yes (Radiator, Fan, Thermostat)

Ignition System:

Procedures Included

General Maintenance:

Yes (Oil changes, filter replacements, inspections)

Engine Repair:

Yes (Top-end, bottom-end, timing belt/chain, seals)

Transmission Repair:

Yes (Clutch replacement, internal component repair)

Brake Service:

Yes (Pad/rotor replacement, caliper service, bleeding)

Suspension Repair:

Yes (Shocks, struts, bushings, control arms)

Steering Component Service:

Yes (Tie rods, power steering pump)

Electrical Diagnostics:

Yes (Troubleshooting procedures, component testing)

Body Panel Replacement:

HVAC System Repair:

Yes (Compressor, condenser, evaporator service)

Fuel System Diagnostics:

Yes (Injector cleaning, pressure testing)

Exhaust System Repair:

Cooling System Service:

Yes (Flushing, component replacement)

Ignition System Troubleshooting:

Yes (Spark plugs, coils, sensors)

Tire And Wheel Service:

Yes (Mounting, balancing, rotation)

Diagnostic Trouble Codes:

Yes (OBD-II codes and explanations)

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds)

Diagnostic Capabilities:

Advanced diagnostics with detailed troubleshooting flowcharts

Rebuild Procedures:

Complete disassembly and reassembly instructions for major components

Illustrations:

Hundreds of detailed illustrations and diagrams

Specifications:

Includes torque specifications, clearances, tolerances, and diagnostic values

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Printable without restriction

Resolution:

High (Scanned: No implies digitally created/sourced, ensuring clarity)

Binding Type

Binding:

Digital (PDF - no physical binding)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE

Engine Type:

2.0L Inline 4-Cylinder DOHC (16-Valve)

Displacement:

1991 cc (121.5 cu. in.)

Performance

Horsepower:

130 hp @ 6000 rpm (approx.)

Torque:

135 lb-ft @ 4000 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with coil-on-plug

Cooling System

Coolant Type:

Mazda specific Long Life Coolant (Ethylene Glycol based, typically green)

Timing Drive

Timing Mechanism:

Timing Belt (Service Interval: 60,000 miles or 5 years)

🔧 Transmission

Standard

Transmission Type Std:

5-Speed Manual

Optional

Transmission Type Opt:

4-Speed Automatic

Features

Clutch Type:

Hydraulic Dry Single Plate Clutch (Manual)

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 Gear Oil (e.g., Mazda Manual Transmission Fluid JWS 3309 compatible)

Automatic Transmission Fluid:

Mazda Genuine ATF JWS 3309 or equivalent Dexron III/Mercon

📐 Dimensions

Exterior

Wheelbase:

102.8 inches (2610 mm)

Length:

173.8 inches (4415 mm)

Width:

67.7 inches (1720 mm)

Height:

60.8 inches (1545 mm)

Cargo

Cargo Volume:

30.4 cu ft (with rear seats up) / 60.2 cu ft (with rear seats down)

Weights

Curb Weight Manual:

3,000 lbs (approx.)

Curb Weight Automatic:

3,050 lbs (approx.)

Gross Vehicle Weight Rating:

4,100 lbs (approx.)

Wheels And Tires

Wheel Size:

15-inch or 16-inch alloy wheels

Tire Size Std:

205/50R16 (common for GT/Sport trims)

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inches)

Lug Nut Torque:

80-100 lb-ft (108-136 Nm)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Good (for 2002 models, based on similar Protege sedan data)

NHTSA Front Impact Passenger:

Good (for 2002 models, based on similar Protege sedan data)

IIHS Front Offset:

Good (for 2002 models, based on similar Protege sedan data)

Active Features

Standard on most trims

Traction Control:

Optional on some trims

Passive Features

Airbags Front:

Driver and Passenger Frontal Airbags

Airbags Side:

Optional Side-Impact Airbags (in front seats)

Seatbelts:

3-point front and rear seatbelts, pretensioners

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium audio system

Display:

Digital clock, basic radio display

Driver Assistance

Cruise Control:

Available on higher trims

Connectivity

Auxiliary Input:

Not standard, aftermarket solutions available

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Engine Oil Filter Replacement:

At every oil change

Air Filter Replacement:

Every 30,000 miles or 2 years

Spark Plug Replacement:

Approx. 60,000 miles (use specified iridium or platinum plugs)

Timing Belt Replacement:

Every 60,000 miles or 5 years (critical interval)

Coolant Flush:

Every 30,000 miles or 2 years

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil Capacity:

4.5 US quarts (4.3 L) with filter change (for FS-DE 2.0L engine)

Engine Oil Viscosity:

5W-30 is recommended by Mazda for most conditions.

Coolant Capacity:

6.4 US quarts (6.0 L)

Power Steering Fluid:

ATF Dexron II or equivalent

Known Issues

Common Issue 1:

Timing belt failure (if not replaced on schedule, can cause severe engine damage)

Common Issue 2:

Cracked exhaust manifold (can cause exhaust leaks and loss of power)

Common Issue 3:

Front strut mount wear (can cause clunking noises)

Common Issue 4:

Power window regulator failure

Common Issue 5:

EGR valve clogging (can lead to rough idle and CEL)

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

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

Model Evolution

Protege Generation:

BJ Platform (Second Generation Protege, 1998-2003)

Protege 5 Introduction:

Introduced for the 2002 model year as a sport compact wagon variant of the Protege line.

Protege 5 Design:

Characterized by its distinctive 'smiley face' grille and sporty wagon styling.

Production

Manufacturing Location:

Hofu, Japan

🏆 Awards & Recognition

Recognitions

Award 1:

Automotive Journalists Association of Canada (AJAC) - Best New Design 2002 (Protege 5)

Award 2:

Edmunds.com - Recommended by consumers for practicality and value.