Mazda Protege 5 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Year: 2004 Codes Chassis Code: BJ 👋 Introduction Market Position Vehicle Segment: Compact Wagon / Sport Wagon Target Audience: DIY enthusiasts,...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege 5

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact Wagon / Sport Wagon

Target Audience:

DIY enthusiasts, home mechanics, small repair shops

Competitive Analysis

Competitors:

Subaru Outback, Honda CR-V, Toyota RAV4 (in wagon/SUV crossover segment)

Key Features

Vehicle Appeal:

Practicality, sporty handling for its class, cargo versatility

Manual Value:

Provides dealer-level technical information, enabling complex repairs and maintenance

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Workshop Service and Repair

Diagnostic Coverage:

Extensive diagnostic procedures and troubleshooting guides

Repair Coverage:

Detailed step-by-step repair instructions for all major components

Maintenance Coverage:

Comprehensive routine maintenance schedules and procedures

Electrical Coverage:

Complete electrical diagrams and wiring schematics

Body Coverage:

Body repair, collision information, and adjustments

Technical Data Coverage:

Torque specifications, fluid capacities, and technical data

Special Tools Coverage:

Identification and usage of specialized tools for repairs

Page Count

Estimated Pages:

Likely 1000+ pages based on typical factory service manuals

Manual Type

Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language

Language:

English

Format

Format:

Accessibility:

Searchable text within PDF

Compatibility:

Windows and Mac Operating Systems

Software Requirements:

Adobe PDF Reader, WinZip (or equivalent unzipping software)

Viewing Features:

Zoom in/out capability

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, internal components, cylinder head, pistons, crankshaft, camshafts, timing system

Lubrication System:

Oil pump, oil filter, oil pan, oil cooler (if applicable), lubrication flow diagrams

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan, coolant specifications

Fuel System:

Fuel pump, fuel injectors, fuel filter, fuel pressure regulator, fuel tank, fuel lines

Emission Control:

Catalytic converter, oxygen sensors, EGR system, PCV system, evaporative emission control (EVAP)

Engine Electrical:

Ignition system (coils, spark plugs), starter motor, alternator, battery, engine control module (ECM) and sensors

Clutch:

Clutch disc, pressure plate, release bearing, clutch hydraulics (master and slave cylinders)

Manual Transaxle:

Gearbox assembly, shift mechanism, synchronizers, internal components, lubrication

Automatic Transaxle:

Transmission assembly, torque converter, valve body, solenoids, planetary gear sets, hydraulic circuits, fluid specifications

Front Axle:

CV joints, drive shafts, hub bearings

Rear Axle:

Rear suspension components, differential (if applicable), hub bearings

Steering System:

Power steering pump, steering rack, tie rods, steering column, linkage

Braking System:

Front and rear brake pads, rotors, calipers, brake lines, master cylinder, ABS system, parking brake

Suspension Front:

MacPherson struts, control arms, sway bar, bushings, springs

Suspension Rear:

Trailing arms, shocks, springs, sway bar, bushings

Body:

Body panels, doors, hood, tailgate, bumpers, glass, interior trim

Body Electrical:

Lighting (headlights, taillights, interior), power windows, power door locks, central locking, wipers, horn, mirrors

Heater And Air Conditioner:

HVAC system components, blower motor, evaporator, condenser, refrigerant system, heater core, controls

Procedures Included

Engine Overhaul:

Complete engine rebuild procedures

Transmission Service:

Fluid changes, seal replacements, internal component servicing

Brake System Repair:

Pad and rotor replacement, caliper service, bleeding procedures

Suspension Component Replacement:

Strut replacement, bushing replacement, alignment procedures

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks

Troubleshooting:

Identification and resolution of common vehicle problems

Body And Trim Repair:

Panel adjustments, trim removal and installation

HVAC Service:

Refrigerant recharging, component replacement

Technical Depth

Depth:

Comprehensive (from basic maintenance to full component rebuilds)

Detail Level:

Detailed step-by-step instructions with accompanying diagrams and illustrations

📊 Manual Specifications

File Format

Type:

Print Quality

Quality:

High-resolution scans for clarity of diagrams and text

Readability:

Designed for clear reading and printing of individual pages

Binding Type

Type:

Digital (PDF), no physical binding

Paper Type

Type:

Digital, not applicable

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE (most common for this model)

Configuration:

Inline 4-cylinder

Displacement:

2.0 Liters (1991 cc)

Performance

Horsepower:

Approx. 130 hp @ 5200-6000 rpm (depending on market and specific tune)

Torque:

Approx. 135 lb-ft @ 4000-4500 rpm (depending on market and specific tune)

Fuel System

Induction:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Technical Features

Valve Train:

DOHC, 16 valves, Variable Valve Timing (VVT) on some variants

🔧 Transmission

Standard

Type:

5-Speed Manual Transaxle

Optional

Type:

4-Speed Automatic Transaxle

Features

Drive Type:

Front-Wheel Drive (FWD)

📐 Dimensions

Exterior

Length:

Approx. 173.5 inches (4407 mm)

Width:

Approx. 67.7 inches (1720 mm)

Height:

Approx. 60.6 inches (1539 mm)

Weights

Curb Weight:

Approx. 3000-3200 lbs (1360-1450 kg) depending on transmission and options

Gross Vehicle Weight Rating:

Typically around 4000 lbs (1814 kg)

Cargo

Cargo Volume:

Approx. 28.0 - 34.0 cubic feet with rear seats up, expandable significantly when folded

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Likely 4/5 stars (check specific year/trim for exact ratings)

NHTSA Front Impact Passenger:

Likely 4/5 stars (check specific year/trim for exact ratings)

IIHS Frontal Offset:

Good (typically for this generation Protege)

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 Airbags (front)

Seatbelts:

3-point front and rear seatbelts, pretensioners

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, optional premium sound system with subwoofer

Display:

Basic digital display for clock, radio, and climate control

Driver Assistance

Cruise Control:

Available on most trims

Connectivity

Auxiliary Input:

Not standard, may have been an aftermarket addition

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (or as per severe service schedule)

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed

Spark Plug Replacement:

Every 60,000-100,000 miles (96,000-160,000 km) depending on spark plug type (Iridium recommended)

Timing Belt Replacement:

Not applicable; equipped with a timing chain

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 5W-30 or 5W-20 (check owner's manual for specific recommendation)

Engine Oil Capacity:

Approx. 4.2 US quarts (4.0 liters) with filter change

Coolant Type:

Ethylene glycol-based antifreeze, Mazda Genuine Super Long Life Coolant or equivalent (pre-mixed 50/50)

Transmission Fluid Manual:

GL-4 SAE 75W-90 gear oil (verify specific Mazda spec)

Transmission Fluid Automatic:

Mazda ATF M-III or equivalent (check owner's manual)

Power Steering Fluid:

Mazda Genuine Power Steering Fluid or Dexron II/III ATF (verify specific spec)

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Common Problem 1:

Rusting on rear wheel arches and rocker panels

Common Problem 2:

Front suspension clunking/rattling noises (often due to worn bushings or sway bar links)

Common Problem 3:

Check Engine Light due to EVAP system leaks or O2 sensor failures

Common Problem 4:

Automatic transmission issues (e.g., harsh shifting, slipping) can occur with high mileage

Common Problem 5:

Power steering pump whine or leaks

📚 Vehicle History

Brand Heritage

Brand:

Mazda

Philosophy:

Zoom-Zoom driving spirit, focus on stylish design and enjoyable driving dynamics

Model Evolution

Generation:

Second Generation Protege (BJ Platform)

Protege 5 Introduction:

Introduced for the 2002 model year, representing the wagon variant of the second-generation Protege sedan/hatchback

Production

Production Period:

2002-2003 (US Market, for the 2002-2003 model years); 2004 model year updates were part of the BJ platform lifecycle.

Manufacturing Location:

Hofu, Yamaguchi Prefecture, Japan

🏆 Awards & Recognition

Recognitions

Award 1:

Often praised for its driving dynamics and practicality within the compact segment