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Mazda PROTEGE PROTEGE5 Full Service & Repair Manual 2001-2003

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🏷️ Basic Information Identification Make: Mazda Model: Protege Submodel: Protege5 Year Range: 2001-2003 Codes Platform Code: BJ Series 👋 Introduction Market Position Vehicle Segment: Compact hatchback, known for sporty handling and practical utility. Competitive Analysis Competitors: Honda Civic Hatchback, Toyota Corolla Hatchback, Ford Focus Hatchback, Subaru Impreza Hatchback. Key Features Protege5 Distinction: Sporty styling, versatile cargo space, engaging driving dynamics, and affordability. Manual Value Proposition Target Audience: Owners seeking to perform DIY maintenance and repairs, independent repair shops, automotive enthusiasts. Benefits: Cost savings on repairs, extended vehicle lifespan, in-depth understanding of vehicle systems. 📋 Manual Details Coverage Areas Manual Type: Factory Service & Repair Workshop Manual Language: English Format: Digital Download (Computer, Tablet, Smartphone) Licensing: No Expiry Dates, No Extra Fees 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, assembly, and torque specifications for all internal and external engine components. Engine Management: Fuel injection, ignition system, emission control systems, sensors, actuators, ECM diagnosis and troubleshooting. Transmission Manual: Repair, overhaul, clutch service, shift mechanism, and fluid specifications. Transmission Automatic: Component identification, hydraulic system, torque converter, electronic controls, diagnostic procedures, and fluid maintenance. Drivetrain Front Wheel Drive: CV joints, axles, differential, and front suspension mounting. Suspension Front: MacPherson struts, control arms, stabilizer bar, bushings, and alignment specifications. Suspension Rear: Multi-link independent suspension, shock absorbers, springs, control arms, bushings, and alignment specifications. Steering System: Power steering pump, rack and pinion, steering column, linkages, and hydraulic system service. Braking System: Front and rear disc brakes, ABS system, brake lines, calipers, master cylinder, and bleeding procedures. Electrical System General: Battery, charging system, starter motor, lighting circuits, and accessory power. Electrical System Harness: Wiring diagrams for all vehicle systems, connector identification, and troubleshooting continuity. Climate Control System: HVAC unit, refrigerant system, blower motor, actuators, and troubleshooting. Body And Interior: Body panel removal, interior trim, seats, glass replacement, door mechanisms, and hardware. Safety Systems Airbags: Airbag module location, SRS system diagnosis, and component replacement procedures. Procedures Included Routine Maintenance: Oil and filter changes, fluid checks and top-offs, spark plug replacement, air filter replacement, tire rotation. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls. Troubleshooting Diagnostics: Systematic diagnosis of common and uncommon faults using diagnostic codes and symptom analysis. Component Replacement: Step-by-step instructions for replacing individual parts and assemblies. Torque Specifications: Detailed torque values for all critical fasteners across all systems. Wiring Diagrams: Complete and comprehensive wiring schematics for electrical systems. Technical Depth Depth Level: Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. Diagnostic Procedures: Advanced diagnostic flowcharts and explanations for various fault conditions. Rebuild Procedures: Detailed instructions for rebuilding major components like engines and transmissions. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval. Printability: Printable pages for hands-on use. Print Quality Image Resolution: High-resolution images, diagrams, and schematics. Binding Type Digital Binding: N/A (Digital Format) Paper Type Digital Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: FS-DE (2.0L DOHC) Engine Type: Naturally Aspirated Inline-4 Displacement: 1991 cc (2.0 Liters) Bore X Stroke: 83.0 mm x 92.0 mm Compression Ratio: 9.7:1 Performance Horsepower: 130 hp @ 6000 rpm Torque: 135 lb-ft @ 4300 rpm Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Recommended Fuel: 87 Octane Unleaded Gasoline Ignition System Ignition Type: Distributorless Electronic Ignition System (E.D.I.S.) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission (with Overdrive) Features Clutch Type: Hydraulically Actuated Dry Single Plate Clutch (Manual) Fluid Specifications Manual Transmission Fluid: API GL-4 SAE 75W-90 Gear Oil (Check manual for specific Mazda PN) Automatic Transmission Fluid: Dexron III or equivalent (Check manual for specific Mazda PN) 📐 Dimensions Exterior Length: Approx. 165.7 inches (4209 mm) Width: Approx. 67.7 inches (1720 mm) Height: Approx. 56.9 inches (1445 mm) Wheelbase: Approx. 102.8 inches (2611 mm) Interior Passenger Volume: Approx. 91.0 cu ft Cargo Cargo Volume Seats Up: Approx. 18.9 cu ft Cargo Volume Seats Down: Approx. 36.0 cu ft Weights Curb Weight Manual: Approx. 2750 lbs (1247 kg) Curb Weight Automatic: Approx. 2840 lbs (1288 kg) Gross Vehicle Weight Rating: Approx. 3750 lbs (1701 kg) Towing Capacity: Not Recommended/Specified by Manufacturer Wheels Tires Wheel Bolt Pattern: 4x100 Standard Wheel Size: 15 inch alloy Standard Tire Size: 195/55R15 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars NHTSA Front Impact Passenger: 4 Stars NHTSA Side Impact Front Driver: 4 Stars NHTSA Side Impact Front Passenger: 4 Stars NHTSA Side Impact Rear Passenger: 4 Stars IIHS Frontal Offset: Good Active Features ABS: Standard Anti-lock Braking System Traction Control: Optional Traction Control System Passive Features Airbags Front: Driver and Front Passenger Airbags Airbags Side: Optional Side-Impact Airbags Seatbelts: 3-point front and rear seatbelts 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio with amplifier and subwoofer (depending...
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Mazda PROTEGE PROTEGE5 Full Service & Repair Manual 2001-2003
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege
Submodel:
Protege5
Year Range:
2001-2003
Codes
Platform Code:
BJ Series
👋 Introduction
Market Position
Vehicle Segment:
Compact hatchback, known for sporty handling and practical utility.
Competitive Analysis
Competitors:
Honda Civic Hatchback, Toyota Corolla Hatchback, Ford Focus Hatchback, Subaru Impreza Hatchback.
Key Features
Protege5 Distinction:
Sporty styling, versatile cargo space, engaging driving dynamics, and affordability.
Manual Value Proposition
Target Audience:
Owners seeking to perform DIY maintenance and repairs, independent repair shops, automotive enthusiasts.
Benefits:
Cost savings on repairs, extended vehicle lifespan, in-depth understanding of vehicle systems.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service & Repair Workshop Manual
Language:
English
Format:
Digital Download (Computer, Tablet, Smartphone)
Licensing:
No Expiry Dates, No Extra Fees
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, assembly, and torque specifications for all internal and external engine components.
Engine Management:
Fuel injection, ignition system, emission control systems, sensors, actuators, ECM diagnosis and troubleshooting.
Transmission Manual:
Repair, overhaul, clutch service, shift mechanism, and fluid specifications.
Transmission Automatic:
Component identification, hydraulic system, torque converter, electronic controls, diagnostic procedures, and fluid maintenance.
Drivetrain Front Wheel Drive:
CV joints, axles, differential, and front suspension mounting.
Suspension Front:
MacPherson struts, control arms, stabilizer bar, bushings, and alignment specifications.
Suspension Rear:
Multi-link independent suspension, shock absorbers, springs, control arms, bushings, and alignment specifications.
Steering System:
Power steering pump, rack and pinion, steering column, linkages, and hydraulic system service.
Braking System:
Front and rear disc brakes, ABS system, brake lines, calipers, master cylinder, and bleeding procedures.
Electrical System General:
Battery, charging system, starter motor, lighting circuits, and accessory power.
Electrical System Harness:
Wiring diagrams for all vehicle systems, connector identification, and troubleshooting continuity.
Climate Control System:
HVAC unit, refrigerant system, blower motor, actuators, and troubleshooting.
Body And Interior:
Body panel removal, interior trim, seats, glass replacement, door mechanisms, and hardware.
Safety Systems Airbags:
Airbag module location, SRS system diagnosis, and component replacement procedures.
Procedures Included
Routine Maintenance:
Oil and filter changes, fluid checks and top-offs, spark plug replacement, air filter replacement, tire rotation.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls.
Troubleshooting Diagnostics:
Systematic diagnosis of common and uncommon faults using diagnostic codes and symptom analysis.
Component Replacement:
Step-by-step instructions for replacing individual parts and assemblies.
Torque Specifications:
Detailed torque values for all critical fasteners across all systems.
Wiring Diagrams:
Complete and comprehensive wiring schematics for electrical systems.
Technical Depth
Depth Level:
Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts.
Diagnostic Procedures:
Advanced diagnostic flowcharts and explanations for various fault conditions.
Rebuild Procedures:
Detailed instructions for rebuilding major components like engines and transmissions.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Searchable text for quick information retrieval.
Printability:
Printable pages for hands-on use.
Print Quality
Image Resolution:
High-resolution images, diagrams, and schematics.
Binding Type
Digital Binding:
N/A (Digital Format)
Paper Type
Digital Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
FS-DE (2.0L DOHC)
Engine Type:
Naturally Aspirated Inline-4
Displacement:
1991 cc (2.0 Liters)
Bore X Stroke:
83.0 mm x 92.0 mm
Compression Ratio:
9.7:1
Performance
Horsepower:
130 hp @ 6000 rpm
Torque:
135 lb-ft @ 4300 rpm
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Recommended Fuel:
87 Octane Unleaded Gasoline
Ignition System
Ignition Type:
Distributorless Electronic Ignition System (E.D.I.S.)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission (with Overdrive)
Features
Clutch Type:
Hydraulically Actuated Dry Single Plate Clutch (Manual)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 SAE 75W-90 Gear Oil (Check manual for specific Mazda PN)
Automatic Transmission Fluid:
Dexron III or equivalent (Check manual for specific Mazda PN)
📐 Dimensions
Exterior
Length:
Approx. 165.7 inches (4209 mm)
Width:
Approx. 67.7 inches (1720 mm)
Height:
Approx. 56.9 inches (1445 mm)
Wheelbase:
Approx. 102.8 inches (2611 mm)
Interior
Passenger Volume:
Approx. 91.0 cu ft
Cargo
Cargo Volume Seats Up:
Approx. 18.9 cu ft
Cargo Volume Seats Down:
Approx. 36.0 cu ft
Weights
Curb Weight Manual:
Approx. 2750 lbs (1247 kg)
Curb Weight Automatic:
Approx. 2840 lbs (1288 kg)
Gross Vehicle Weight Rating:
Approx. 3750 lbs (1701 kg)
Towing Capacity:
Not Recommended/Specified by Manufacturer
Wheels Tires
Wheel Bolt Pattern:
4x100
Standard Wheel Size:
15 inch alloy
Standard Tire Size:
195/55R15
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars
NHTSA Front Impact Passenger:
4 Stars
NHTSA Side Impact Front Driver:
4 Stars
NHTSA Side Impact Front Passenger:
4 Stars
NHTSA Side Impact Rear Passenger:
4 Stars
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Optional Traction Control System
Passive Features
Airbags Front:
Driver and Front Passenger Airbags
Airbags Side:
Optional Side-Impact Airbags
Seatbelts:
3-point front and rear seatbelts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio with amplifier and subwoofer (depending on trim).
Display Type:
Basic LCD display for audio and clock functions.
Driver Assistance
Cruise Control:
Available cruise control system.
Keyless Entry:
Available keyless entry system.
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (using conventional oil). 7,500 miles with synthetic oil.
Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plug Replacement:
Every 60,000 miles (Iridium spark plugs).
Coolant Flush:
Every 30,000 miles or 24 months.
Fluid Specifications
Engine Oil Capacity:
4.2 US quarts (4.0 Liters) with filter, SAE 5W-30 (See manual for climate variations and synthetic recommendations).
Coolant Type:
Mazda Genuine Long Life Antifreeze/Coolant (Blue) or equivalent ethylene glycol-based coolant with silicate inhibitors.
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Mazda Genuine ATF (Automatic Transmission Fluid) or equivalent Dexron III
Known Issues
Engine Oil Consumption:
Some 2.0L engines may experience higher than normal oil consumption; regular oil level checks are crucial. See manual for potential causes and remedies.
Rear Wheel Bearing Noise:
Premature wear or noise from rear wheel bearings can occur. Manual covers replacement procedures.
ABS Sensor Failure:
ABS wheel speed sensor failures can trigger ABS warning lights. Manual provides diagnostic steps.
Exhaust Manifold Cracks:
Cracks in the exhaust manifold are known to occur, leading to exhaust leaks and ticking noises. Manual details replacement.
📚 Vehicle History
Brand Heritage
Mazda Identity:
Mazda is a Japanese automaker renowned for its 'Zoom-Zoom' driving philosophy, emphasizing sporty handling and driver engagement across its product line.
Model Evolution
First Generation Protege:
Introduced globally in 1990 as a replacement for the Mazda 323/Familia. Offered in sedan and hatchback variants.
Second Generation Protege Bj:
Launched in 1998 globally, with North American debut for the 2000 model year. This generation saw the introduction of the Protege5 hatchback. Known for improved chassis dynamics and modern styling.
Production
Manufacturing Location:
Primary assembly in Hofu, Yamaguchi Prefecture, Japan.
Production Years Protege5:
2001-2003 (North America)
🏆 Awards & Recognition
Recognitions
Car And Driver 2003:
Car and Driver's 10Best Trucks and Utilities list for 2003 (referring to the Mazda B-Series Truck, but reflecting Mazda's overall reputation for sporty design and utility at the time).
Ratings
Consumers Digest Best Buy:
The Mazda Protege line often received 'Best Buy' recommendations from automotive publications for its value and performance.
Certifications
Emisiones Compliance:
Compliant with EPA and CARB emission standards for its model years.
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