Mazda PROTEGE 5 Service Repair Manual 2001-2003

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Model Year Start: 2001 Model Year End: 2003 Codes Platform Code: BJ (G11P) 👋 Introduction Market Position Segment: Compact Wagon /...

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标签: 2001 2002 2003 Car Cars Mazda Misc PROTEGE 5

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege 5

Model Year Start:

Model Year End:

Codes

Platform Code:

BJ (G11P)

👋 Introduction

Market Position

Segment:

Compact Wagon / Sport Wagon

Target Audience:

DIY mechanics, independent repair shops, enthusiasts seeking in-depth knowledge.

Competitive Analysis

Competitors:

Subaru Outback Sport, Honda Civic Wagon (older generations), Ford Focus Wagon.

Key Features

Vehicle Appeal:

Sporty handling, versatile cargo space, reliable powertrain.

Manual Advantage:

Provides detailed, factory-level information crucial for accurate diagnosis and repair, preventing costly mistakes from incomplete sources.

📋 Manual Details

Coverage Areas

Engine Coverage:

2.0L DOHC (FS-DE)

Transmission Coverage:

4-Speed Automatic, 5-Speed Manual

Chassis Coverage:

Front-wheel drive (FWD)

Body Styles Covered:

5-Door Hatchback Wagon

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Service and Repair Manual

Comparison To Factory:

Factory-level detail (similar to FSM/CDROM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing components.

Engine Performance:

Fuel delivery, ignition system, emissions control, engine management (ECM/PCM).

Transmission Manual:

Clutch system, 5-speed transmission assembly, internal components, shifting mechanism.

Transmission Automatic:

4-speed automatic transmission assembly, torque converter, valve body, hydraulic control, electronic control.

Drivetrain:

Front drive axles, CV joints, differential.

Suspension:

Front struts, rear shock absorbers, springs, control arms, bushings, stabilizer bars.

Steering:

Power steering system, rack and pinion, steering column, steering wheel.

Brakes:

Front disc brakes, rear disc brakes, ABS (Anti-lock Braking System), parking brake, hydraulic system.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting, horn, wipers, power windows, mirrors, locks.

Body And Chassis:

Body panels, doors, windows, interior trim, bumpers, frame structure, weatherstripping.

HVAC:

Heating, Ventilation, and Air Conditioning system, climate control, refrigerant circuits.

Safety Systems:

Airbag system (SRS), seat belts, safety restraints.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement, brake pad replacement.

Diagnostics Troubleshooting:

Systematic fault finding, symptom-based diagnosis, diagnostic trouble codes (DTCs), wiring diagrams, component testing.

Repair Rebuild:

Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component repair.

Component Replacement:

Detailed instructions for replacing major and minor components across all systems.

Adjustments:

Valve clearance adjustment, parking brake adjustment, clutch pedal free play adjustment.

Calibration Settings:

Wheel alignment specifications, idle speed settings, ignition timing specifications.

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds).

Diagnostic Tools Required:

OBD-II scanner, multimeter, specialized tools (specified).

Torque Specifications:

Detailed torque values for all critical fasteners.

Wiring Diagrams:

Included for all major electrical systems.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable

Printability:

Printable

Print Quality

Image Resolution:

High resolution (clear diagrams and photos)

Binding Type

Binding:

Not applicable (Digital)

Paper Type

Paper Quality:

Not applicable (Digital)

⚙️ 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:

9.2:1

Performance

Horsepower:

125-130 hp @ 6000-6200 rpm (approx.)

Torque:

135-140 lb-ft @ 4000-4500 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Engine Management

Engine Control Module:

ECU/ECM

Cooling System

Coolant Type:

Ethylene Glycol-based (Mazda specific recommendation often found in manual)

Lubrication System

Oil Type:

5W-30 or 10W-30 (refer to manual for exact spec)

Oil Capacity:

4.2 US quarts (4.0 L) with filter change (approx.)

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual

Optional

Transmission Type Optional:

4-Speed Automatic

Features

Automatic Features:

Electronically controlled with overdrive

Fluid Specifications Manual

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (refer to manual for exact specification)

Fluid Specifications Automatic

Automatic Transmission Fluid:

Mazda ATF Type M-III or equivalent (refer to manual for exact specification)

📐 Dimensions

Exterior

Length:

171.1 inches (4346 mm)

Width:

67.7 inches (1720 mm)

Height:

58.9 inches (1496 mm)

Wheelbase:

102.8 inches (2611 mm)

Ground Clearance:

5.3 inches (135 mm) (approx.)

Cargo

Cargo Volume Behind Rear Seats:

27.1 cu ft (767 L)

Cargo Volume With Rear Seats Folded:

60.2 cu ft (1705 L)

Weights

Curb Weight Manual:

2822 lbs (1280 kg)

Curb Weight Automatic:

2866 lbs (1300 kg)

Gross Vehicle Weight Rating Gvwr:

3900 lbs (1769 kg) (approx.)

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

4 stars (driver), 4 stars (passenger)

IIHS Side Impact Rating:

Active Features

Standard (on most models)

Traction Control:

Optional

Passive Features

Airbags:

Front airbags standard, side airbags optional.

Seat Belts:

3-point front and rear seat belts, pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium audio.

Climate Control:

Manual climate control, optional automatic climate control on higher trims.

Driver Assistance

Cruise Control:

Standard on most models.

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 (refer to manual for severe conditions).

Air Filter Replacement:

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

Spark Plug Replacement:

Every 60,000 miles (96,000 km) (Long-life iridium plugs may have longer intervals, check manual).

Coolant Flush:

Every 30,000 miles (48,000 km) or 24 months.

Brake Fluid Change:

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

Fluid Specifications

Power Steering Fluid:

Dexron III or equivalent (refer to manual).

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual).

Known Issues

Engine Mounts:

Can wear out prematurely, leading to vibration and noise.

Suspension Components:

Worn sway bar links, ball joints, and strut mounts are common over time.

Automatic Transmission:

Some units may experience hard shifting or premature failure; regular fluid changes are critical.

Rust Corrosion:

Common in certain climates, especially around wheel wells and rocker panels.

Maintenance Importance

Preventative Maintenance:

Adhering to the factory maintenance schedule outlined in this manual is crucial for longevity and performance.

📚 Vehicle History

Brand Heritage

Mazda Focus:

Mazda's reputation for sporty driving dynamics and reliable engineering.

Model Evolution

Protege Lineage:

Part of the long-standing Protege lineup, the Protege 5 introduced a popular wagon variant.

Generation:

Second generation Protege (BJ platform), with the Protege 5 being a distinct body style for this generation.

Production

Production Start Year:

Production End Year:

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver 2002:

Listed on Car and Driver's Ten Best list for 2002.

Automotive Journalism:

Praised for its practicality, engaging driving dynamics, and value proposition within its class.