🏷️ 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 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: PDF 📖 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: PDF 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 ABS: 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...