Mazda Protege 5 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Year: 2002 Codes Chassis Code: BJ 👋 Introduction Market Position Segment: Compact Wagon/Hatchback Competitive Analysis Competitors: Subaru Outback, Honda CR-V, Toyota...

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标签: 2002 Car Cars Mazda Protege Protege 5

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege 5

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Wagon/Hatchback

Competitive Analysis

Competitors:

Subaru Outback, Honda CR-V, Toyota RAV4, Ford Focus Wagon.

Key Features

Design Philosophy:

Sporty handling, practical cargo space, driver-focused interior.

Target Audience:

Young families, active individuals, those seeking versatile utility.

📋 Manual Details

Coverage Areas

Systems:

Engine, Suspension, Driveline, Brakes, Transaxle, Steering, HVAC, Restraints, Body, Wiring Diagrams, Service Index

Page Count

Estimated Pages:

N/A (Digital Download)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, assembly, troubleshooting, and repair of the engine.

Engine Electrical:

Ignition system, fuel injection system, starting and charging system, sensor diagnostics.

Driveline:

Front-wheel drive system, CV joints, driveshafts, differential.

Transaxle:

Automatic and manual transaxle service, repair, and overhaul.

Suspension:

Front and rear suspension components, alignment procedures, shock absorber and strut replacement.

Steering:

Power steering system, steering gear, steering column, wheel alignment.

Brakes:

Front and rear brake systems (disc/drum), ABS system diagnostics and repair, brake fluid service.

HVAC:

Air conditioning system, heating system, climate control operation, component diagnosis.

Restraints:

Airbag system components, SRS module, seatbelt service.

Body:

Body panel removal/installation, interior trim, doors, windows, locks, exterior lighting.

Electrical Wiring:

Comprehensive wiring diagrams for all vehicle systems, electrical component location.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacement, lubrication.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting.

Repair:

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

Diagnostics:

OBD-II diagnostic trouble codes (DTCs) and diagnostic procedures.

Specifications:

Torque specifications, clearances, fluid capacities, electrical values.

Technical Depth

Depth:

Comprehensive, covering routine maintenance to complete engine and transaxle rebuilds.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text within the PDF document.

Print Quality

Printability:

Printable

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Compatibility

Operating Systems:

Windows and Mac

Requirements

Software:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE (also known as Z5-DE in some markets)

Engine Type:

2.0L Inline 4-Cylinder, DOHC, 16-Valve

Performance

Horsepower:

130 hp @ 6,000 rpm

Torque:

135 lb-ft @ 4,000 rpm

Fuel System

Injection Type:

Electronic Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Cooling System

Coolant Capacity:

Approximately 5.5 US quarts (5.2 Liters)

Lubrication System

Oil Capacity:

Approximately 4.0 US quarts (3.8 Liters) with filter change

Recommended Oil Viscosity:

SAE 5W-30

Ignition System

Spark Plugs:

NGK PFR5A-11 (or equivalent)

Engine Mounts

Engine Mount Torque Specs:

Refer to manual for specific values (critical for vibration control)

🔧 Transmission

Standard

Type:

5-speed Manual Transaxle

Optional

Type:

4-speed Automatic Transaxle

Features

Manual Fluid Type:

GL-4 Manual Transmission Fluid

Automatic Fluid Type:

Mazda ATF J (or equivalent Dexron III/Mercon)

Automatic Fluid Capacity

Capacity:

Approximately 6.8 US quarts (6.4 Liters) for refill, 9.1 US quarts (8.6 Liters) for overhaul

📐 Dimensions

Exterior

Length:

173.4 inches (4,405 mm)

Width:

67.7 inches (1,720 mm)

Height:

59.1 inches (1,500 mm)

Wheelbase:

102.8 inches (2,610 mm)

Weights

Curb Weight:

Approx. 3,000-3,100 lbs (1,360-1,405 kg) depending on transmission and trim

Cargo

Cargo Volume Seats Up:

Approx. 28.9 cubic feet (818 Liters)

Cargo Volume Seats Down:

Approx. 59.1 cubic feet (1,674 Liters)

Wheels Tires

Standard Wheel Size:

15-inch alloy

Optional Wheel Size:

16-inch alloy

Standard Tire Size:

205/50R16 (often fitted on 16-inch wheels)

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inches)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-star driver, 4-star passenger (for the Protege sedan/hatchback platform it shares)

IIHS Front Offset Crash Test:

Good (for the Protege sedan/hatchback platform)

Active Features

Available ABS (Anti-lock Braking System)

Passive Features

Airbags:

Driver and front passenger airbags, available side airbags.

Seatbelts:

Pretensioner front seatbelts.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, available premium audio system with amplifier.

Speaker Configuration:

Typically 4 or 6 speakers.

Driver Assistance

Cruise Control:

Standard on most trims.

Connectivity

Auxiliary Input:

Not typically equipped with factory auxiliary input; aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (using synthetic blend or full synthetic).

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement:

Every 75,000 miles (120,000 km).

Transmission Fluid Change Auto:

Every 45,000 miles (72,000 km) or 36 months.

Transmission Fluid Change Manual:

Every 60,000 miles (96,000 km) or 48 months.

Coolant Flush Replacement:

Every 60,000 miles (96,000 km) or 48 months.

Brake Fluid Replacement:

Every 24 months, regardless of mileage.

Fluid Specifications

Power Steering Fluid:

ATF Type T-III or equivalent (refer to manual for exact spec)

Brake Fluid:

DOT 3

Known Issues

Engine Mounts:

Worn engine mounts can lead to excessive vibration, especially at idle.

Ignition Coils:

Premature failure of ignition coils can cause misfires and rough running.

Catalytic Converter:

Early models may experience premature catalytic converter failure, often indicated by P0420 code.

Rear Wheel Bearings:

Can become noisy and require replacement.

Power Window Motors:

May fail over time, causing windows to not operate.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Jinba-Ittai ('horse and rider as one') - focus on driving dynamics.

Model Evolution

Generation:

Second Generation Mazda Protege (BJ chassis)

Protege 5 Introduction:

Introduced for the 2002 model year as a distinct variant of the Protege line.

Protege 5 Positioning:

Designed to offer a sportier, more versatile alternative to traditional compact sedans.

Production

Production Years:

2002-2003 (North America)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver Alist:

Named to Car and Driver's 10Best list in 2002 for its value, driving dynamics, and practicality.