🏷️ Basic Information

Make:

Mazda

Model:

Protege 5

Years Covered:

2001, 2002, 2003

Chassis Code:

BJ5W

Engine Code Primary:

FS-DE

👋 Introduction

Target Audience:

DIY enthusiasts, independent repair shops, Mazda owners seeking in-depth repair knowledge.

Advantage:

Provides professional-grade information that rivals dealership service manuals, enabling significant cost savings on repairs and maintenance.

Accessibility:

Instant download allows immediate access to repair information, empowering users to start repairs quickly.

Comprehensiveness:

Covers virtually every aspect of vehicle service and repair, making it an indispensable resource.

📋 Manual Details

Manual Type:

Service and Repair Workshop Manual

Manual Scope:

Comprehensive factory-type coverage for all service and repair jobs.

Language:

English

Format:

PDF

Estimated Page Count:

1500-2000+ pages (typical for this era and scope)

📖 Manual Coverage

Engine Mechanical:

Disassembly, inspection, assembly, timing belt, seals, gaskets, cooling system, lubrication system, fuel delivery system, emission control system, intake manifold, exhaust manifold.

Engine Management:

Ignition system, fuel injection system (MPI), ECU operation, sensors (MAF, O2, TPS, ECT, CKP, CMP), actuators, diagnostic trouble codes (DTCs), OBD-II diagnostics.

Transmission:

4-speed Automatic (FS5A-EL) and 5-speed Manual transmissions: disassembly, inspection, assembly, torque converter, clutch, gearsets, shift control, linkages, fluid specifications.

Drivetrain:

Front-wheel drive (FWD), axles, CV joints, differential, wheel bearings.

Suspension:

Front suspension (MacPherson struts, control arms, sway bar), Rear suspension (multi-link independent), shock absorbers, springs, bushings, alignment specifications.

Brakes:

Front disc brakes (vented), Rear disc brakes, ABS (Anti-lock Braking System), brake hydraulics, master cylinder, calipers, rotors, pads, parking brake system, bleeding procedures.

Steering:

Power steering system, steering rack and pinion, steering column, tie rod ends, power steering pump, fluid specifications.

Electrical System:

Battery, alternator, starter motor, wiring diagrams (schematics), fuses, relays, lighting systems (headlights, taillights, interior), horn, wipers, power windows, mirrors, door locks.

HVAC:

Air conditioning system, heater core, blower motor, climate controls, refrigerant charging, leak detection.

Body And Chassis:

Body panel removal and installation, doors, hood, liftgate, bumpers, interior trim, structural components, rust prevention.

Safety Systems:

Airbag system (SRS), seat belts, passive restraint systems, lighting safety.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, ignition system checks, brake fluid flush, coolant flush, drive belt replacement.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, common problems and solutions, electrical system diagnostics, engine performance issues.

Repair:

Component removal, installation, overhaul, rebuilding of engine, transmission, suspension, brakes, steering, electrical components.

Diagnostics:

OBD-II scanning, live data interpretation, sensor testing, actuator testing, wiring continuity tests.

Specifications:

Torque specifications for all fasteners, clearances, tolerances, fluid capacities, electrical component resistance values.

Depth:

Expertly detailed, factory-level technical information covering everything from basic maintenance to complete engine and transmission overhauls. Includes step-by-step instructions with diagrams and illustrations.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable (OCR processed), enabling quick access to specific topics.

Resolution:

High-resolution digital scans suitable for printing individual pages or the entire manual.

Digital Format:

N/A (Digital Download)

Digital Format:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Name:

FS-DE (Mazda MZR Engine Family)

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Camshaft), 16-valve

Displacement:

2.0 Liters (1991 cc)

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

9.1:1

Horsepower:

110-130 PS (approx. 108-128 hp) depending on market and emissions tuning (US spec typically around 110-116 hp)

Torque:

137-148 Nm (approx. 101-109 lb-ft) depending on market and emissions tuning (US spec typically around 118-121 lb-ft)

Fuel Delivery:

Electronic Fuel Injection (MPI - Multi-Point Injection)

Fuel Type:

Unleaded gasoline (Octane rating as per owner's manual recommendation, typically 87 AKI in North America)

Ignition Timing:

Electronically controlled (ECU)

Emission Controls:

Catalytic converter, EGR (Exhaust Gas Recirculation), PCV (Positive Crankcase Ventilation), EVAP (Evaporative Emission Control).

🔧 Transmission

Type:

5-speed Manual Transmission

Type:

4-speed Automatic Transmission (FS5A-EL)

Manual Transmission Gears:

1st, 2nd, 3rd, 4th, 5th, Reverse

Automatic Transmission Modes:

Drive (D), Neutral (N), Reverse (R), Park (P), sometimes a "2" or "L" range for lower gears.

Manual Transmission Fluid:

API GL-4 Gear Oil (e.g., SAE 75W-90)

Automatic Transmission Fluid:

Mazda ATF-Type T-IV or equivalent.

📐 Dimensions

Body Style:

5-door compact hatchback wagon

Wheelbase:

2615 mm (103.0 inches)

Overall Length:

4430 mm (174.4 inches)

Overall Width:

1745 mm (68.7 inches)

Overall Height:

1540 mm (60.6 inches)

Ground Clearance:

Approx. 150 mm (5.9 inches)

Cargo Volume Seats Up:

Approx. 30.3 cu ft (858 Liters)

Cargo Volume Seats Down:

Approx. 60.1 cu ft (1702 Liters) with rear seats folded

Curb Weight:

Approx. 1300-1350 kg (2866-2976 lbs) depending on transmission and options.

🛡️ Safety Features

NHTSA Front Driver:

Good (Tested on sedan variant, often similar for wagon)

NHTSA Front Passenger:

Good (Tested on sedan variant, often similar for wagon)

IIHS Offset Frontal:

Acceptable (Tested on sedan variant, often similar for wagon)

ABS:

Standard on most models/trims (4-wheel disc brakes with ABS)

Traction Control:

Optional on some trims.

Airbags:

Frontal airbags for driver and front passenger. Side airbags optional or standard on higher trims.

Seatbelts:

3-point seatbelts with pre-tensioners and load limiters for front occupants, 3-point seatbelts for rear occupants.

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with CD player. Cassette player may be present on earlier builds. Optional premium sound system available.

Climate Control:

Manual or automatic climate control depending on trim level.

Cruise Control:

Standard on most trims.

Power Accessories:

Power windows, power door locks, power mirrors standard on most trims.

🔧 Maintenance

Oil Change Interval:

Typically 5,000 miles (8,000 km) or 6 months, whichever comes first. Consult manual for specific conditions.

Engine Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plug Replacement:

Platinum-tipped spark plugs: typically 60,000-100,000 miles (96,000-160,000 km). Consult manual for exact type and interval.

Timing Belt Replacement:

Crucial! High-interference engine. Typically 60,000 miles (96,000 km) or 4-5 years. Failure can cause severe engine damage.

Engine Oil Type:

API SG or SH, SAE 5W-30 is common. Check manual for exact specifications.

Engine Oil Capacity:

Approx. 4.2 Liters (4.4 US quarts) with filter change.

Coolant Type:

Mazda Genuine Super Long Life Coolant (Blue) or equivalent HOAT coolant (50/50 mix with distilled water).

Coolant Capacity:

Approx. 7.0 Liters (7.4 US quarts).

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid Type:

Dexron II/III or equivalent ATF.

Engine:

Timing belt failure if not replaced on schedule, occasional oil leaks from valve cover or oil pan gaskets, carbon buildup on intake valves.

Suspension:

Worn sway bar links and bushings, premature wear of front struts/shocks.

Electrical:

Alternator failure, power window motor issues, occasional corrosion on electrical connectors.

Body:

Rust on rear wheel arches, rocker panels, and around the liftgate hinges.

📚 Vehicle History

Mazda Philosophy:

Mazda is known for its focus on driving dynamics ('Zoom-Zoom'), innovative engineering, and stylish design.

Protege Lineage:

The Protege line has a long history, evolving through several generations of compact sedans and hatchbacks. The Protege 5 represents the sporty, wagon variant of the third generation (BJ chassis).

Protege 5 Introduction:

The Protege 5 was introduced for the 2002 model year, offering a more versatile and stylish alternative to the traditional Protege sedan, directly competing with models like the Subaru Outback Sport and the Volkswagen Golf/Jetta Wagon.

Production Plant:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Initial Reception:

The Protege 5 was generally well-received for its practicality, sporty handling, and distinctive styling, offering good value for its segment.

Consumer Reports Ratings:

Often rated average to above average for predicted reliability, with some specific model years receiving higher marks.