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Mazda Protege 5 2001-2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Model Alias: Familia Model Years Covered: 2001, 2002, 2003 Codes Chassis Code: BJ 👋 Introduction Market Position Segment: Compact Wagon /...
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Mazda Protege 5 2001-2003 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege 5
Model Alias:
Familia
Model Years Covered:
2001, 2002, 2003
Codes
Chassis Code:
BJ
👋 Introduction
Market Position
Segment:
Compact Wagon / Sport Compact
Target Audience:
Enthusiast owners, DIY mechanics, independent repair shops
Competitive Analysis
Key Competitors:
Subaru Outback, Honda CR-V, Toyota RAV4 (though Protege 5 leaned more towards sport compact)
Key Features Vehicle
Design Philosophy:
Sporty handling, practical cargo space, distinctive styling
Key Features Manual
Value Proposition:
Authentic dealer-level information for comprehensive servicing and repair
Benefits To Owner:
Enables DIY maintenance, accurate diagnostics, reduces repair costs, preserves vehicle value
📋 Manual Details
Coverage Areas
Engine Coverage:
2.0L DOHC 16-valve (FS-DE)
Transmission Coverage:
4-speed Automatic, 5-speed Manual
Body Style Coverage:
Wagon
Page Count
Estimated Page Count:
2000+
Manual Type
Manual Classification:
Factory Service Workshop Manual
Language
Language Of Manual:
English
Format
Digital Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine Management:
Fuel injection, ignition system, emissions control, engine mechanicals
Powertrain:
Engine, transmission, clutch, drive axles, differential
Chassis:
Suspension (front and rear), steering, brakes (front and rear, ABS)
Electrical:
Wiring diagrams, lighting, instruments, power distribution, comfort systems
Body And Interior:
Body panels, doors, windows, seats, trim, HVAC system
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug service
Diagnostic Procedures:
Troubleshooting charts, fault code interpretation, system diagnostics
Repair And Rebuild:
Engine overhaul, transmission rebuild, suspension component replacement, brake caliper service
Component Removal And Installation:
Detailed steps for removing and installing all major components
Specifications And Tolerances:
Torque values, clearances, fluid capacities, diagnostic parameters
Technical Depth
Depth Of Information:
Comprehensive, from basic maintenance to in-depth diagnostics and component overhaul
Diagnostic Tools Required:
References to Mazda-specific diagnostic tools (e.g., OBD-II scanner, specific test equipment)
📊 Manual Specifications
File Format
Digital File Type:
PDF
Searchability:
Text-searchable for quick information retrieval
Print Quality
Digital Resolution:
High resolution, suitable for printing individual pages or sections
Binding Type
Binding Type Physical Manual:
N/A (Digital Download)
Paper Type
Paper Type Physical Manual:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
FS-DE
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
2.0 Liters (1991 cc)
Bore X Stroke:
83.0 mm x 92.0 mm
Compression Ratio:
9.1:1
Performance
Horsepower:
130 hp @ 5200 rpm
Torque:
135 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Fuel Type Recommended:
87 Octane Regular Unleaded Gasoline
Engine Cooling
Cooling System Type:
Pressurized Liquid Cooling
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
4-speed Automatic (with Overdrive)
Features
Automatic Transmission Modes:
Normal, Sport (likely)
Fluid Type
Manual Transmission Fluid:
API GL-4, SAE 75W-90
Automatic Transmission Fluid:
Mazda ATF-Type T-IV or equivalent
📐 Dimensions
Exterior
Length:
Approx. 174.8 inches (4440 mm)
Width:
Approx. 67.9 inches (1725 mm)
Height:
Approx. 59.1 inches (1500 mm)
Wheelbase:
Approx. 102.4 inches (2600 mm)
Ground Clearance:
Approx. 5.9 inches (150 mm)
Weights
Curb Weight:
Approx. 2900-3050 lbs (1315-1383 kg) depending on transmission
Gross Vehicle Weight Rating Gvwr:
Typically around 4000 lbs (1814 kg)
Cargo
Cargo Volume Seats Up:
Approx. 34.0 cubic feet
Cargo Volume Seats Down:
Approx. 60.0 cubic feet
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4-star (2002 model)
NHTSA Front Impact Passenger:
4-star (2002 model)
IIHS Moderate Overlap Frontal Offset:
Good (2002 model)
Active Features
ABS Availability:
Optional on most trims
Traction Control Availability:
Rarely equipped, likely not a common factory option
Passive Features
Airbags Standard:
Driver and Passenger Frontal Airbags
Side Impact Airbags Availability:
Optional on some trims
Seatbelt Pretensioners:
Standard on front seats
💡 Technology Features
Infotainment
Audio System:
AM/FM Stereo with CD Player, optional Premium Bose Audio System
Speaker Count:
4 or 6 speakers
Climate Control:
Manual Air Conditioning, optional Automatic Climate Control
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Auxiliary Input:
Not typically factory equipped, aftermarket solutions common
Lighting
Headlight Type:
Halogen, projector style for some models
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months (whichever comes first)
Air Filter Replacement Interval:
Every 15,000 miles or 12 months
Spark Plug Replacement Interval:
Every 60,000 miles (iridium plugs)
Coolant Flush Interval:
Every 30,000 miles or 24 months
Fluid Specifications
Engine Oil Capacity:
4.3 US quarts (4.1 Liters) with filter change
Engine Oil Viscosity:
5W-30 (Synthetic Recommended)
Coolant Type:
Mazda Long Life Antifreeze (Blue) or equivalent (Ethylene Glycol-based)
Brake Fluid Type:
DOT 3
Power Steering Fluid Type:
ATF Dexron II or III (or equivalent)
Windshield Washer Fluid Type:
Water-based washer fluid, appropriate for climate
Known Issues
Common Wear Item 1:
Front wheel bearings (can be prone to premature failure)
Common Wear Item 2:
Rear strut mounts (can develop knocking noises)
Common Wear Item 3:
Catalytic converter (can fail due to age or engine issues)
Common Wear Item 4:
Ignition coils (can fail, leading to misfires)
Common Wear Item 5:
Power steering pump leaks (seals can deteriorate)
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Zoom-Zoom - emphasizing a sporty and engaging driving experience
Model Evolution
Protege Lineage:
Part of Mazda's long-standing compact car family, known for offering a sportier alternative
Protege 5 Introduction:
Introduced for the 2002 model year as a sportier, more stylish variant of the Protege sedan and hatchback.
Production
Production Location:
Japan (Hofu Plant)
Production Years Global:
2001/2002 - 2003
🏆 Awards & Recognition
Recognitions
Motor Trend Car Of The Year Nominee:
Protege line often a contender, though Protege 5 specifically not a standout winner in this era.
Ratings
Consumer Reports Reliability:
Mixed to Average for the era, specific model years and common issues addressed in the manual are critical.
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