2002 Mazda Protege 5 Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Year: 2002 Codes Chassis Code: BJ Platform: Mazda Familia BJ platform 👋 Introduction Market Position Segment: Compact Wagon / Sport Compact...

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标签: 2002 Car Cars Mazda Misc Protege 5

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege 5

Year:

Codes

Chassis Code:

Platform:

Mazda Familia BJ platform

👋 Introduction

Market Position

Segment:

Compact Wagon / Sport Compact

Key Selling Points:

Practicality, sporty handling, unique styling, versatile cargo space.

Competitive Analysis

Competitors:

Subaru Outback, Honda CR-V (early models), Toyota Matrix, Ford Focus Wagon.

Key Features

Distinctive Features:

Hatchback utility, characteristic roof rails, sporty suspension tuning.

Target Audience

Target Demographic:

Young professionals, active individuals, small families seeking a balance of sportiness and practicality.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete repair and maintenance for the 2002 Mazda Protege 5.

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

File Format

File Format:

Print Quality

Print Quality:

High-resolution, suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair procedures, component identification for the 2.0L DOHC (FS-DE) engine.

Transmission:

Repair and maintenance for both the 4-speed automatic (FN4A-EL) and 5-speed manual (G5M-P) transmissions.

Brakes:

Front disc (ventilated), rear disc brake system, ABS, EBD, and parking brake.

Suspension:

Front strut suspension, rear multi-link independent suspension, alignment specifications.

Steering:

Power assisted rack and pinion steering, steering column, components.

Electrical:

Complete wiring diagrams, fuse box layouts, component testing, diagnostic trouble codes (DTCs) for all electrical systems.

Body And Trim:

Body panel removal and installation, interior trim, bumpers, glass replacement.

HVAC:

Air conditioning system, heater core, blower motor, climate control diagnostics.

Fuel System:

Fuel pump, injectors, fuel filter, evaporative emission control (EVAP) system.

Cooling System:

Radiator, thermostat, water pump, coolant types and capacities.

Exhaust System:

Catalytic converter, muffler, exhaust manifold, pipe replacement.

Safety Systems:

Airbag system diagnostics and replacement, seatbelt mechanisms.

Procedures Included

General Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.

Troubleshooting:

Systematic diagnostic procedures for common and complex issues, guided by symptoms and DTCs.

Engine Repair:

Head gasket replacement, piston and ring service, valve adjustments, timing belt replacement.

Transmission Repair:

Clutch replacement (manual), transmission fluid service, valve body diagnostics (automatic).

Brake Service:

Brake pad and rotor replacement, caliper service, brake fluid flush.

Suspension Repair:

Strut replacement, ball joint replacement, bushing service.

Electrical Diagnostics:

Testing sensors, actuators, control modules (ECU, TCU), starter, alternator.

Bodywork Procedures:

Door panel removal, fender replacement, headlight/taillight replacement.

HVAC Service:

Refrigerant recharge, cabin air filter replacement, blower motor replacement.

Timing Belt Replacement:

Critical procedure with detailed steps and torque specifications.

Wheel Alignment:

Specifications for camber, caster, and toe angles.

Technical Depth

Depth Of Information:

Factory-level detail, including torque specifications, component clearances, electrical schematics, and diagnostic procedures.

Diagnostic Tools:

Reference to use of OBD-II scanner and specific Mazda diagnostic equipment (e.g., MS3 or equivalent).

Repair Instructions:

Step-by-step instructions with accompanying diagrams and illustrations for all repair tasks.

Schematics:

Comprehensive electrical and vacuum schematics for all vehicle systems.

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

1991 cc (2.0 Liters)

Performance

Horsepower:

130 hp @ 6000 rpm

Torque:

135 lb-ft @ 4000 rpm

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

9.7:1

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Engine Management

ECU Type:

Engine Control Unit (ECU) with OBD-II diagnostics

Ignition System:

Electronic ignition with distributorless ignition system (DIS)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual

Optional

Transmission Type:

4-speed Automatic (FWD only)

Features

Manual Gear Ratios:

Provided in manual, typically close-ratio for sporty feel.

Automatic Transmission Code:

FN4A-EL

Automatic Transmission Modes:

Typically 'Normal' and 'Sport' modes.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90

Automatic Transmission Fluid:

Mazda ATF M-III or equivalent (Mercon V often compatible)

📐 Dimensions

Exterior

Length:

4435 mm (174.6 in)

Width:

1705 mm (67.1 in)

Height:

1535 mm (60.4 in)

Wheelbase:

2610 mm (102.8 in)

Front Track:

1470 mm (57.9 in)

Rear Track:

1475 mm (58.1 in)

Cargo

Cargo Volume Seats Up:

Approx. 28.0 cu ft (with rear seats up)

Cargo Volume Seats Down:

Approx. 57.0 cu ft (with rear seats folded)

Weights

Curb Weight Manual:

Approx. 1330 kg (2932 lbs)

Curb Weight Automatic:

Approx. 1350 kg (2976 lbs)

Gross Vehicle Weight Rating:

Provided in manual, vehicle-specific.

Towing Capacity:

Not typically recommended or specified for this model.

Wheels And Tires

Standard Wheel Size:

15-inch alloy wheels

Optional Wheel Size:

16-inch alloy wheels (available on some trims/markets)

Standard Tire Size:

P205/50R16 (common for 16-inch wheels)

Wheel Bolt Pattern:

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

Lug Nut Torque:

103 Nm (76 lb-ft)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4 stars (driver and passenger)

NHTSA Side Impact:

4 stars (front and rear passengers)

IIHS Ratings:

Good (Head Restraints & Seats, Roof Strength - 2007 update).

Active Features

Standard Anti-lock Braking System (ABS) on most models.

Electronic Brake-force Distribution (EBD) often integrated with ABS.

Traction Control:

Optional on some models.

Passive Features

Airbags:

Front driver and passenger airbags. Side curtain airbags optional on some trims.

Seatbelts:

3-point front and rear seatbelts with pretensioners and load limiters for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium audio (Bose on some trims), speaker configuration (e.g., 4 or 6 speakers).

Dashboard Features:

Digital odometer, tachometer, temperature gauge, fuel gauge, warning lights.

Driver Assistance

Cruise Control:

Standard on most models.

Remote Keyless Entry:

Available on higher trims.

Connectivity

Auxiliary Input:

Not standard; aftermarket solutions available.

Lighting

Headlights:

Halogen headlights, manual adjustment.

Comfort Features

Power Windows Locks:

Standard on most models.

Sunroof:

Optional on certain trim levels.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (severe conditions may require sooner).

Engine Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

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

Cabin Air Filter Replacement:

Replace every 15,000 miles (24,000 km) or annually.

Spark Plug Replacement:

Typically every 60,000 miles (96,000 km) for platinum plugs.

Timing Belt Replacement:

Crucial: Every 60,000 miles (96,000 km) or 4 years, whichever comes first. Failure causes severe engine damage.

Brake Fluid Flush:

Every 2-3 years or 30,000 miles (48,000 km).

Coolant Flush:

Every 60,000 miles (96,000 km) or 4 years.

Fluid Specifications

Engine Oil Capacity:

4.4 Liters (4.7 US Quarts) with filter (FS-DE engine).

Engine Oil Viscosity:

5W-30 or 10W-30 (refer to manual for specific temperature ranges).

Coolant Type:

Mazda FL22 Long Life Coolant or equivalent (ethylene glycol based, silicate-free).

Power Steering Fluid:

Dexron II/III or equivalent ATF.

Known Issues

Common Problems Engine:

Oil leaks from valve cover gasket and rear main seal, occasional intake manifold gasket leaks, timing belt tensioner noise.

Common Problems Transmission:

Automatic transmission shift quality issues (solenoid related), clutch wear (manual).

Common Problems Suspension Steering:

Worn sway bar end links, sagging rear springs, tie rod end wear.

Common Problems Electrical:

Cracked dashboard (common for this era Mazda), alternator failure, window regulator issues, instrument cluster illumination failure.

Common Problems HVAC:

Blend door actuator failure, AC compressor clutch failure.

Technical Bulletins

Tbs Availability:

Manual provides access to common Technical Service Bulletins (TSBs) related to specific repairs or issues.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Jinba Ittai ('horse and rider as one'), emphasizing driving dynamics and connection.

Model Evolution

Protege Lineage:

The Protege 5 is the wagon variant of the third generation (BJ) Mazda Protege, succeeding the hatchback version of the previous generation.

Protege 5 Introduction:

Introduced for the 2002 model year, targeting the growing compact crossover and sporty wagon market.

Production

Manufacturing Location:

Hofu, Yamaguchi Prefecture, Japan (Primary)

Production Years For Gen Bj:

1998-2003 (North America)

🏆 Awards & Recognition

Recognitions

Car And Driver Awards:

Car and Driver magazine's '10Best' list for compact cars (previous generations of Protege contributed to brand reputation).

Safety Awards:

Achieved good safety ratings from IIHS and NHTSA for its time.

Certifications

Emissions Certification:

Meets EPA and CARB emissions standards for the year 2002.