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Mazda Protege5 Workshop Manual 2002

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🏷️ Basic Information Identification Make: Mazda Model: Protege5 Year: 2002 Codes Chassis Code: BJ Platform: Mazda BJ Platform 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair shops, and...
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Type: Car
Vendor:
Sku: 356084
Mazda Protege5 Workshop Manual 2002
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege5
Year:
2002
Codes
Chassis Code:
BJ
Platform:
Mazda BJ Platform
👋 Introduction
Market Position
Target Audience:
DIY mechanics, independent repair shops, and Mazda Protege5 owners seeking detailed repair and maintenance guidance.
Competitive Analysis
Value Proposition:
Offers comprehensive, factory-level repair information in a cost-effective and easily accessible digital format, eliminating the need for expensive physical manuals or CD-ROMs.
Key Features
Completeness:
Claims to cover 'every part of this car'.
Usability:
PDF format allows for selective printing and easy navigation.
📋 Manual Details
Coverage Areas
General:
Complete Workshop Service/Repair
Specific:
Lubrication & Maintenance, Suspension, Brakes, Cooling System, Electrical System, Engine, Fuel System, Exhaust System, Transmission, Heating and Air Conditioning, Emission Control Systems, Body, Wiring Diagrams
Page Count
Estimated:
Comprehensive (exact page count not specified, but described as complete)
Manual Type
Type:
Workshop Service / Repair Manual
Language
Primary:
English
Format
File Type:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (all aspects of repair and rebuilding), Fuel System (components, diagnosis, fuel injection), Exhaust System (components, emissions control integration), Transmission (likely manual and/or automatic, specific details depend on exact coverage)
Chassis:
Suspension (components, alignment, diagnosis), Brakes (hydraulic system, ABS, disc/drum components), Steering System (components, power steering)
Electrical:
Electrical System (wiring diagrams, component testing, diagnostics, battery, starting, charging, lighting, accessories, body electronics), HVAC (heating, ventilation, and air conditioning systems)
Body:
Body (construction, exterior panels, interior trim, glass, doors, locks, security systems)
Procedures Included
Maintenance:
Lubrication, fluid changes, filter replacements, basic inspections, scheduled maintenance
Diagnostics:
Troubleshooting guides, symptom-based diagnosis, electrical circuit testing, mechanical component diagnosis
Repair:
Component removal and installation, rebuilding procedures (e.g., engine, transmission), adjustments, part replacements
Specifications:
Torque specifications, clearances, fluid capacities, diagnostic data, wiring schematics
Technical Depth
Level:
Comprehensive factory-level detail, suitable for rebuilding and advanced diagnostics
📊 Manual Specifications
File Format
Accessibility:
Searchable text within PDF for quick information retrieval
Print Quality
Flexibility:
Printable in full or specific sections as needed by the user
Binding Type
Digital Format:
N/A (Digital PDF)
Paper Type
Digital Format:
N/A (Digital PDF)
Compatibility
Operating Systems:
Windows (all versions), Mac
Delivery
Method:
Email delivery (instant access, no shipping delay)
Comparison
Vs Factory Cdrom:
Equivalent to factory shop manual CD-ROMs, offering all the same technical repair information without the higher cost.
Content Richness
Visuals:
Contains numerous pictures and diagrams to aid in understanding procedures.
⚙️ Engine Specifications
Primary Engine
Engine Code:
FS-DE (commonly found in Protege5 for this year)
Engine Type:
2.0L Inline-4 DOHC 16-valve
Performance
Horsepower:
Approx. 130-134 hp @ 6000 rpm (specific to market and configuration)
Torque:
Approx. 135-137 lb-ft @ 4000 rpm (specific to market and configuration)
Fuel System
Induction:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (SMPI)
Fuel Type:
Unleaded Gasoline
Technical Details
Bore X Stroke:
83.0 mm x 92.0 mm (typical for FS-DE)
Compression Ratio:
9.7:1 (typical for FS-DE)
Engine Management:
ECU (Engine Control Unit) controlled ignition and fuel delivery
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (likely)
Optional
Type:
4-speed Automatic Transmission (likely)
Features
Manual Fluid Spec:
GL-4 SAE 75W-90 (typical specification, consult manual for exact)
Automatic Fluid Spec:
Mazda ATF J-M3 or equivalent (typical specification, consult manual for exact)
Manual Coverage
Procedures:
Clutch inspection and replacement, gearshift mechanism, transmission fluid changes, internal component repair (if specified).
📐 Dimensions
Exterior
Length:
Approx. 4410 mm (173.6 inches)
Width:
Approx. 1745 mm (68.7 inches)
Height:
Approx. 1530 mm (60.2 inches)
Wheelbase
Value:
Approx. 2615 mm (103.0 inches)
Weights
Curb Weight:
Approx. 1300-1350 kg (2866-2976 lbs) depending on transmission and trim
Gross Vehicle Weight Rating:
Consult vehicle specific documentation
Cargo
Cargo Volume:
Approx. 35.2 cubic feet with rear seats folded (wagon configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 stars (driver/passenger) for 2002 model year
IIHS Front Offset Impact:
Good (for 2002 model year)
Active Features
ABS:
Standard on most trims
Traction Control:
Optional on some trims
Passive Features
Airbags:
Front airbags standard, optional side airbags
Seatbelts:
Three-point front and rear seatbelts, pretensioners and load limiters for front seats
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio system with amplifier. Aux input or USB generally not standard.
Driver Assistance
Cruise Control:
Standard on most trims
Keyless Entry:
Optional on some trims
Connectivity
Bluetooth:
Not standard for this model year.
Convenience
Power Accessories:
Power windows, power door locks, power mirrors were common features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months (typical, consult manual for specific conditions and oil type)
Air Filter Replacement:
Every 30,000 miles or as needed based on inspection
Spark Plug Replacement:
Every 100,000 miles (for long-life iridium type)
Timing Belt Replacement:
N/A (FS-DE engine uses a timing chain)
Fluid Specifications
Engine Oil:
API SN/SP, ILSAC GF-6A or higher, SAE 5W-20 or 5W-30 (consult manual for specific viscosity and capacity)
Coolant:
Mazda Genuine Super Long Life Coolant (Blue) or equivalent HOAT coolant, 50/50 mix with distilled water
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine:
Occasional oil leaks from valve cover gasket, potential for carbon buildup in intake manifold.
Suspension:
Wear in front sway bar links and bushings, rear shock absorbers may degrade over time.
Electrical:
Alternator failures, power window motor issues, some sensor failures (e.g., crankshaft position sensor).
Body:
Rust in common areas (wheel wells, rocker panels) depending on climate and care.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Known for 'Zoom-Zoom' driving dynamics, sporty handling, and driver-focused design.
Model Evolution
Protege Lineage:
The Protege5 is the wagon variant of the third-generation Mazda Protege (BJ chassis) which ran from 1998 to 2003. It was introduced as a more practical and stylish alternative to the sedan.
Production
Manufacturing Location:
Japan
Production Years
Generation Bj:
1998-2003 (Protege5 specifically launched for 2002 model year)
🏆 Awards & Recognition
Recognitions
Car And Driver:
The Protege line, including variants like the Protege5, was often praised by automotive critics for its engaging driving dynamics and value for money.
Ratings
Consumer Reports:
Reliability ratings varied by year, but the Protege platform generally offered a good balance of features and value.
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