Mazda Protege 5 Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Generation: First Generation (BK) Codes Chassis Code: BK Engine Codes Covered: FS-DE, ZM-DE 👋 Introduction Market Position Market Segment: Compact hatchback/station wagon. Target Audience: Families, young professionals, individuals seeking practical and versatile transportation with a sporty edge. Competitive Analysis Key Competitors: Honda Civic Hatchback/Wagon, Toyota Corolla Hatchback/Wagon, Ford Focus Wagon, Subaru Impreza Wagon, Volkswagen Golf. Distinguishing Factors: Unique sporty styling, practical cargo space in the wagon variant, engaging driving dynamics for its class, Mazda's reputation for reliability and driver engagement. Key Features Body Styles: Five-door hatchback. Design Philosophy: Sporty and youthful design, often referred to as a 'hot hatch' or 'sport wagon'. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission, Drive Axles, Suspension (Front and Rear), Steering System, Brakes (Front and Rear), ABS, SRS Airbag System, Body Electrical System, HVAC, Body Panels, Interior Trim, Exterior Trim, Diagnostic Procedures, Wiring Diagrams Page Count Page Count: Approx. 1500-2000 pages (Estimated for comprehensive service manual) Manual Type Manual Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital (PDF) / Print 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures for FS-DE (2.0L) and ZM-DE (1.5L) engines, including cylinder head, block assembly, pistons, crankshaft, camshafts, timing belt/chain, oil pump, lubrication system, cooling system. Fuel And Emissions: Fuel injection system (MPI), fuel pump, fuel filter, fuel lines, EVAP system, catalytic converter, oxygen sensors, emissions control systems, diagnostic trouble codes (DTCs) related to fuel and emissions. Ignition System Ignition System: Ignition coil testing, spark plug replacement, ignition timing, crankshaft position sensor, camshaft position sensor, ignition module testing. Transmission Manual Transmission Manual: Clutch inspection and replacement, manual transmission (FS5W71G and others) disassembly, inspection, reassembly, gear oil specifications, shift linkage adjustment. Transmission Automatic Transmission Automatic: Automatic transmission (e.g., FN4A-EL) operation, fluid type and capacity, torque converter service, valve body diagnosis, shift control solenoid testing, transmission control module (TCM) diagnostics. Suspension Steering Suspension Steering: Front and rear suspension component inspection (struts, shocks, control arms, ball joints, tie rods), wheel alignment specifications, power steering system diagnosis and repair, steering rack service. Brakes Abs Brakes ABS: Brake system inspection, pad and rotor replacement, caliper service, brake fluid specifications and bleeding procedures, Anti-lock Braking System (ABS) component testing (wheel speed sensors, hydraulic control unit), ABS warning light diagnosis. Electrical Body Electrical Body: 12V battery service, charging system (alternator, regulator), starting system (starter motor), lighting systems, wipers, horn, power windows, power locks, interior and exterior lighting circuits, fuse box layout, relay locations. Hvac HVAC: Air conditioning system components (compressor, condenser, evaporator), refrigerant type and charge, HVAC blower motor, climate control module, heater core service, cabin air filter replacement. Body Exterior Body Exterior: Body panel repair, door hinge service, tailgate operation, bumper replacement, glass replacement, exterior trim installation, paint touch-up procedures. Body Interior Body Interior: Seat removal and installation, dashboard disassembly, interior trim panel replacement, headliner service, carpeting, safety belt operation and inspection. Procedures Included Maintenance Procedures: Scheduled maintenance intervals, oil and filter change, air filter replacement, fuel filter replacement, spark plug replacement, coolant flush and fill, brake fluid flush, transmission fluid change, differential fluid change (if applicable), power steering fluid change. Troubleshooting Diagnostics: Systematic troubleshooting guides for common and uncommon issues, diagnostic trouble code (DTC) interpretation, live data analysis, component testing procedures, wiring diagram interpretation. Repair Replacement: Step-by-step instructions for replacing virtually every component on the vehicle, from major assemblies like engines and transmissions to smaller parts like sensors and switches. Wiring Diagrams: Detailed wiring diagrams for all vehicle systems, including power distribution, grounds, sensor inputs, actuator outputs, and communication buses. Technical Depth Technical Depth: Comprehensive - Covers basic maintenance, routine service, in-depth diagnostics, component-level repair, and complete system overhauls. Suitable for DIY mechanics and professional technicians. 📊 Manual Specifications File Format File Format: PDF Searchability: Fully searchable text for quick access to information. Printability: Printable pages for convenient on-the-go reference. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding Type: If printed: Spiral-bound or perfect-bound for durability. Paper Type Paper Type: If printed: Heavy-duty, coated paper to withstand shop environments. ⚙️ 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: 9.5:1 Performance Horsepower: 125 hp @ 6000 rpm (approx.) Torque: 130 lb-ft @ 4300 rpm (approx.) Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Recommended Fuel: 87 Octane Unleaded Gasoline Maintenance Items Timing Belt Replacement Interval: 60,000 miles or 5 years (whichever comes first) - CRITICAL MAINTENANCE ITEM Spark Plug Part Number: NGK BKR5E-11 (or equivalent) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Type: 4-Speed Automatic Transmission Features Clutch Type: Dry single plate, hydraulically actuated Manual Transmission Fluid Spec:...

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🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege 5

Generation:

First Generation (BK)

Codes

Chassis Code:

Engine Codes Covered:

FS-DE, ZM-DE

👋 Introduction

Market Position

Market Segment:

Compact hatchback/station wagon.

Target Audience:

Families, young professionals, individuals seeking practical and versatile transportation with a sporty edge.

Competitive Analysis

Key Competitors:

Honda Civic Hatchback/Wagon, Toyota Corolla Hatchback/Wagon, Ford Focus Wagon, Subaru Impreza Wagon, Volkswagen Golf.

Distinguishing Factors:

Unique sporty styling, practical cargo space in the wagon variant, engaging driving dynamics for its class, Mazda's reputation for reliability and driver engagement.

Key Features

Body Styles:

Five-door hatchback.

Design Philosophy:

Sporty and youthful design, often referred to as a 'hot hatch' or 'sport wagon'.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Fuel System, Ignition System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission, Drive Axles, Suspension (Front and Rear), Steering System, Brakes (Front and Rear), ABS, SRS Airbag System, Body Electrical System, HVAC, Body Panels, Interior Trim, Exterior Trim, Diagnostic Procedures, Wiring Diagrams

Page Count

Page Count:

Approx. 1500-2000 pages (Estimated for comprehensive service manual)

Manual Type

Manual Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF) / Print

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures for FS-DE (2.0L) and ZM-DE (1.5L) engines, including cylinder head, block assembly, pistons, crankshaft, camshafts, timing belt/chain, oil pump, lubrication system, cooling system.

Fuel And Emissions:

Fuel injection system (MPI), fuel pump, fuel filter, fuel lines, EVAP system, catalytic converter, oxygen sensors, emissions control systems, diagnostic trouble codes (DTCs) related to fuel and emissions.

Ignition System

Ignition System:

Ignition coil testing, spark plug replacement, ignition timing, crankshaft position sensor, camshaft position sensor, ignition module testing.

Transmission Manual

Transmission Manual:

Clutch inspection and replacement, manual transmission (FS5W71G and others) disassembly, inspection, reassembly, gear oil specifications, shift linkage adjustment.

Transmission Automatic

Transmission Automatic:

Automatic transmission (e.g., FN4A-EL) operation, fluid type and capacity, torque converter service, valve body diagnosis, shift control solenoid testing, transmission control module (TCM) diagnostics.

Suspension Steering

Suspension Steering:

Front and rear suspension component inspection (struts, shocks, control arms, ball joints, tie rods), wheel alignment specifications, power steering system diagnosis and repair, steering rack service.

Brakes Abs

Brakes ABS:

Brake system inspection, pad and rotor replacement, caliper service, brake fluid specifications and bleeding procedures, Anti-lock Braking System (ABS) component testing (wheel speed sensors, hydraulic control unit), ABS warning light diagnosis.

Electrical Body

Electrical Body:

12V battery service, charging system (alternator, regulator), starting system (starter motor), lighting systems, wipers, horn, power windows, power locks, interior and exterior lighting circuits, fuse box layout, relay locations.

HVAC:

Air conditioning system components (compressor, condenser, evaporator), refrigerant type and charge, HVAC blower motor, climate control module, heater core service, cabin air filter replacement.

Body Exterior

Body Exterior:

Body panel repair, door hinge service, tailgate operation, bumper replacement, glass replacement, exterior trim installation, paint touch-up procedures.

Body Interior

Body Interior:

Seat removal and installation, dashboard disassembly, interior trim panel replacement, headliner service, carpeting, safety belt operation and inspection.

Procedures Included

Maintenance Procedures:

Scheduled maintenance intervals, oil and filter change, air filter replacement, fuel filter replacement, spark plug replacement, coolant flush and fill, brake fluid flush, transmission fluid change, differential fluid change (if applicable), power steering fluid change.

Troubleshooting Diagnostics:

Systematic troubleshooting guides for common and uncommon issues, diagnostic trouble code (DTC) interpretation, live data analysis, component testing procedures, wiring diagram interpretation.

Repair Replacement:

Step-by-step instructions for replacing virtually every component on the vehicle, from major assemblies like engines and transmissions to smaller parts like sensors and switches.

Wiring Diagrams:

Detailed wiring diagrams for all vehicle systems, including power distribution, grounds, sensor inputs, actuator outputs, and communication buses.

Technical Depth

Technical Depth:

Comprehensive - Covers basic maintenance, routine service, in-depth diagnostics, component-level repair, and complete system overhauls. Suitable for DIY mechanics and professional technicians.

📊 Manual Specifications

File Format

File Format:

Searchability:

Fully searchable text for quick access to information.

Printability:

Printable pages for convenient on-the-go reference.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Type:

If printed: Spiral-bound or perfect-bound for durability.

Paper Type

Paper Type:

If printed: Heavy-duty, coated paper to withstand shop environments.

⚙️ 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:

9.5:1

Performance

Horsepower:

125 hp @ 6000 rpm (approx.)

Torque:

130 lb-ft @ 4300 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Maintenance Items

Timing Belt Replacement Interval:

60,000 miles or 5 years (whichever comes first) - CRITICAL MAINTENANCE ITEM

Spark Plug Part Number:

NGK BKR5E-11 (or equivalent)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission

Optional

Transmission Type:

4-Speed Automatic Transmission

Features

Clutch Type:

Dry single plate, hydraulically actuated

Manual Transmission Fluid Spec:

API GL-4 SAE 75W-90 Gear Oil

Automatic Transmission Fluid Spec:

Mazda ATF JWS3317 or equivalent

Transmission Fluid Capacity Manual:

Approx. 2.1 liters

Transmission Fluid Capacity Automatic:

Approx. 3.5 liters (dry fill)

📐 Dimensions

Exterior

Length:

166.9 inches (4239 mm)

Width:

67.7 inches (1720 mm)

Height:

60.4 inches (1534 mm)

Wheelbase:

102.8 inches (2610 mm)

Ground Clearance:

Approx. 5.7 inches (145 mm)

Weights

Curb Weight:

2900 - 3100 lbs (approx., depending on transmission and trim)

Gross Vehicle Weight Rating:

Approx. 4000 lbs

Wheel Bolt Pattern:

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

Wheel Size:

15-inch or 16-inch alloy wheels

Tire Size Standard:

P195/60R15 (typical)

Tire Size Optional:

P205/50R16 (typical)

Cargo

Cargo Volume Behind Rear Seats:

Approx. 22.6 cubic feet

Cargo Volume With Rear Seats Folded:

Approx. 44.0 cubic feet

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Rating:

4-star driver, 4-star passenger (for early models, specific year dependent)

IIHS Side Impact Rating:

Good (for models tested)

Active Features

Standard on most trims.

Traction Control:

Available on some higher trims or as part of a package.

Electronic Brakeforce Distribution Ebd:

Often integrated with ABS.

Passive Features

Airbags:

Front dual-stage airbags (driver and passenger) standard. Side-impact airbags and curtain airbags available on select trims.

Seat Belts:

3-point seat belts with pretensioners and load limiters in front, 3-point seat belts in rear.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

Rollover Protection:

Reinforced body structure.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM CD player with 4 or 6 speakers. Optional premium audio systems available on higher trims.

Climate Control:

Manual climate control or optional automatic climate control depending on trim level.

Dashboard Instruments:

Includes tachometer, speedometer, fuel gauge, engine temperature gauge, and warning lights.

Driver Assistance

Cruise Control:

Available on most models.

Keyless Entry:

Available on select trims.

Connectivity

Power Outlets:

12V power outlet in the center console.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (with conventional oil); 7,500 miles or 12 months (with synthetic oil).

Tire Rotation Interval:

Every 7,500 miles.

Engine Air Filter Replacement Interval:

Every 15,000 miles or 12 months.

Cabin Air Filter Replacement Interval:

Every 15,000 miles or 12 months.

Coolant Replacement Interval:

First at 60,000 miles or 5 years, then every 30,000 miles or 2 years thereafter.

Brake Fluid Replacement Interval:

Every 24 months or 30,000 miles.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API SN or higher)

Engine Oil Capacity:

4.0 U.S. quarts (3.8 liters) with filter change.

Coolant Type:

Mazda Super Long Life Coolant (Blue) or equivalent ethylene glycol-based coolant.

Power Steering Fluid Type:

Dexron III ATF or equivalent.

Known Issues

Timing Belt Failure:

While not as prone as some older Mazda engines, timing belt failure due to age or infrequent replacement can cause catastrophic engine damage. This manual emphasizes its critical replacement interval.

Catalytic Converter Issues:

Early models can experience premature catalytic converter failure, often linked to exhaust leaks or engine misfires.

Suspension Wear:

Worn ball joints, tie rod ends, and struts can lead to steering looseness and premature tire wear. Manual details inspection points.

Evaporative Emissions System Faults:

Faulty purge valves or vent solenoids can trigger check engine lights and emissions-related DTCs.

Window Regulator Failures:

Power window regulators can sometimes fail, requiring replacement of the regulator assembly.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Known for 'Zoom-Zoom' driving dynamics and driver-focused engineering.

Model Evolution

Mazda Familia Lineage:

The Protege line (including Protege 5) is part of Mazda's long-standing Familia compact car series, which dates back to the 1960s.

Protege 5 Introduction:

Introduced for the 2002 model year in North America, based on the third-generation Protege platform (BG/BJ series).

Protege 5 Design Intent:

Designed as a sporty and practical alternative to traditional compact sedans and wagons, emphasizing style and versatility.

Production

Production Years:

2002-2003 (North America, as the Protege 5, a variant of the BJ chassis Protege).

Manufacturing Locations:

Primarily manufactured in Japan (Mazda's Hofu Plant).

Model Discontinuation:

The Protege line was replaced by the Mazda3 for the 2004 model year, which continued the sporty compact ethos.

🏆 Awards & Recognition

Recognitions

Car And Driver Best List:

The Protege line (including the Protege 5) was often lauded by automotive critics for its value and driving dynamics, though specific 'awards' for the Protege 5 model itself are less commonly cited than general praise for the Protege family.

Ratings

Consumer Reports Reliability:

Generally received average to above-average reliability ratings from consumer organizations during its production run, though specific model year reliability can vary.