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Mazda Protege 2005 Repair Service Manual

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The 2005 Mazda Protege, chassis code BJ, represents a refined iteration of Mazda's commitment to engaging driving dynamics, embodying the 'Jinba-Ittai' philosophy. As a compact car, it was designed to...
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Mazda Protege 2005 Repair Service ManualMazda Protege 2005 Repair Service ManualMazda Protege 2005 Repair Service ManualMazda Protege 2005 Repair Service Manual
The 2005 Mazda Protege, chassis code BJ, represents a refined iteration of Mazda's commitment to engaging driving dynamics, embodying the 'Jinba-Ittai' philosophy. As a compact car, it was designed to appeal to value-conscious consumers, commuters, and younger drivers, often competing with models like the Honda Civic and Toyota Corolla. Offered with a choice of a 2.0L FS-DE engine producing 130 hp or a less common 1.6L FP-DE engine, and available with either a 5-speed manual or a 4-speed automatic transmission, the Protege provided a balanced blend of performance and efficiency. Notable features included a focus on handling, with a suspension system designed for responsive road feel, and a comfortable interior with available premium audio and automatic climate control on higher trims. The vehicle also achieved strong safety ratings, including 5-star NHTSA front impact scores and a 'Good' IIHS front offset crash rating. This comprehensive factory service manual provides detailed information for the maintenance, repair, and diagnostics of the 2005 Mazda Protege. With over 1500 pages of factory-level content, it covers all major mechanical, electrical, and body systems, including engine assembly and diagnostics for both the 2.0L and 1.6L engines, manual and automatic transmission overhauls, drivetrain, suspension, steering, and braking systems. The manual also details body electrical components, HVAC systems, interior trim, and body panel work. Essential for owners and technicians alike, it includes step-by-step repair procedures, diagnostic guides with wiring diagrams, recommended maintenance schedules, fluid specifications, and identification of special tools. This resource is designed to ensure the proper upkeep and longevity of your Mazda Protege.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Year:
2005
Codes
Chassis Code:
BJ
👋 Introduction
Market Position
Segment:
Compact Car
Target Audience:
Value-conscious consumers, commuters, young drivers.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Nissan Sentra.
Key Features
Design Philosophy:
Jinba-Ittai ('horse and rider as one') driving dynamics.
Trim Levels:
Typically includes DX, ES, and MP3 trims.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive; covers all major mechanical, electrical, and body systems.
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, lubrication system, cooling system, fuel system, emission control systems.
Engine Electrical:
Ignition system, starting and charging systems, engine control module (ECM) diagnostics, sensors, actuators.
Transmission Manual:
Manual transmission (M5) overhaul, clutch, gear shift mechanism.
Transmission Automatic:
Automatic transmission (FS5A-EL) overhaul, hydraulic control, torque converter, electronic controls.
Drivetrain:
Front-wheel drive axle shafts, differentials, drive shafts.
Suspension:
Front and rear suspension systems, shock absorbers, struts, control arms, springs, bushings.
Steering
Steering System:
Power steering system, steering rack, tie rods, steering column.
Brakes
Brake System:
Front and rear disc brakes, hydraulic system, ABS system (if equipped), parking brake.
Electrical System
Body Electrical:
Lighting systems (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, fuses, relays.
Instrumentation Gauges:
Instrument cluster, warning lights, diagnostic trouble codes (DTCs).
Body And Trim
Body Panels:
Body panel removal and installation, doors, hood, trunk lid, bumpers, glass replacement.
Interior Trim:
Dashboard, door panels, seating systems, headliner.
Hvac
HVAC System:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, diagnostics.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, belt replacement, tire rotation.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, wiring diagrams, component testing.
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul.
Special Tools:
Identification and usage of specific tools required for various repairs.
Technical Depth
Depth Of Information:
Factory-level detail; suitable for professional technicians and advanced DIYers.
Diagnostic Codes:
Includes diagnostic trouble codes (DTCs) for engine, transmission, ABS, and other systems.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for easy navigation and information retrieval.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding:
Not Applicable (Digital PDF)
Paper Type
Paper Quality:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
FS-DE
Engine Type 1:
2.0L Inline-4 DOHC 16-valve
Horsepower 1:
130 hp @ 6000 rpm
Torque 1:
135 lb-ft @ 4300 rpm
Secondary Engine
Engine Code 2:
FP-DE (less common in North America for 2005)
Engine Type 2:
1.6L Inline-4 SOHC 16-valve
Horsepower 2:
100 hp
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI).
Fuel Type:
Unleaded gasoline, 87 octane recommended.
Cooling System
Coolant Type:
Mazda FL22 Extended Life Antifreeze (Green) or equivalent silicate-free, extended-life coolant.
Coolant Capacity:
Approx. 5.7 US quarts (5.4 liters).
🔧 Transmission
Standard
Transmission Type Std:
5-speed manual transmission (M5)
Optional
Transmission Type Opt:
4-speed automatic transmission (FS5A-EL)
Features
Automatic Transmission Features:
Electronic control, torque converter lock-up.
Fluid Specs
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 synthetic gear oil.
Automatic Transmission Fluid Type:
Mazda ATF-MV (Type M-V) or equivalent.
📐 Dimensions
Exterior
Length:
173.7 inches (4412 mm)
Width:
67.1 inches (1704 mm)
Height:
55.3 inches (1405 mm)
Wheelbase:
102.8 inches (2611 mm)
Weights
Curb Weight:
Approx. 2750-2950 lbs (1247-1338 kg) depending on trim and transmission.
Gross Vehicle Weight Rating:
Approx. 3700-3850 lbs (1678-1746 kg).
Cargo
Trunk Volume:
Approx. 12.0 cubic feet (sedan).
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
★★★★★
NHTSA Front Impact Passenger:
★★★★★
IIHS Front Offset Crash Rating:
Good
Active Features
Anti Lock Braking System:
Available ABS on all wheels.
Traction Control:
Available Traction Control System (TCS).
Passive Features
Airbags:
Front dual-stage airbags, optional side-impact airbags.
Seatbelts:
Three-point seatbelts in all seating positions, pretensioners and load limiters for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional Bose premium audio system, MP3 player input (on MP3 trim).
Climate Control:
Manual climate control, available automatic climate control on higher trims.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) with NGK Iridium plugs (PFR5A-11).
Engine Coolant Replacement:
Initial: 5 years or 100,000 miles (160,000 km), then every 2 years or 50,000 miles (80,000 km).
Fluid Specifications
Engine Oil Spec:
API SN/SP, ILSAC GF-6A or higher, SAE 5W-20 synthetic blend or full synthetic.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Issue 1:
Intake manifold gaskets can develop leaks (vacuum leaks).
Common Issue 2:
Exhaust manifold cracks can occur.
Common Issue 3:
Automatic transmission shift solenoid issues leading to harsh shifting or limp mode.
Common Issue 4:
Power steering pump whine or leaks.
Common Issue 5:
Rust development in wheel wells and rocker panels, especially in rust-belt regions.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Focus on driving enjoyment and innovative engineering.
Model Evolution
Protege Generation:
Third generation (2001-2003), facelifted for 2004-2005.
Facelift Details:
Revised front and rear styling, updated interior features.
Production
Manufacturing Locations:
Japan (Mazda's main production), Mexico (for North American market).
Production Years:
1990-2003 (global), 2001-2003 (North America), with the 2005 model year representing the final iteration of the BJ generation.
🏆 Awards & Recognition
Recognitions
Award 1:
Car and Driver's 10 Best Trucks list for the Protege5 wagon (related model).
Ratings
Kbb Consumer Rating:
Generally well-regarded for reliability and value by consumers.
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