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Mazda Protege 5 2000-2004 Online Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Model Code: BJ Series Body Style: 5-door hatchback/wagon Generation Generation Designation: Second Generation (BJ) Production Years Generation: 1998-2003 (Globally), 2000-2003 (North America for Protege 5) Codes Vin Character Engine: F (for FS-DE engine) 👋 Introduction Market Position Segment: Compact wagon/hatchback, sporty alternative to sedans Target Audience: Younger buyers, small families, enthusiasts looking for practicality with a sporty flair Competitive Analysis Key Competitors: Subaru Outback, Honda CR-V (early models), Toyota Matrix, Ford Focus Wagon Key Features Driving Dynamics: Known for responsive handling and engaging driving experience, a Mazda hallmark Practicality: Versatile cargo space due to hatchback design, folding rear seats Styling: Distinctive, sporty exterior styling for its class 📋 Manual Details Coverage Areas Covered Model Years: 2000, 2001, 2002, 2003 Covered Engine Options: FS-DE 2.0L DOHC (Naturally Aspirated) Covered Markets: North America (implies specific regional variations if any) Page Count Estimated Page Count: 1500-2500+ pages (typical for comprehensive service manuals) Manual Type Type: Online Service and Repair Manual Scope: Factory-level repair and maintenance information Language Language: English Format Format: Digital (likely PDF or web-based access) Searchability: Likely text-searchable 📖 Manual Coverage Systems Covered Powertrain: Engine, fuel system, ignition system, exhaust system, cooling system, lubrication system Drivetrain: Transmission (manual and automatic), clutch, driveshafts, differentials, AWD system (if applicable) Chassis: Suspension (front and rear), steering system, brakes (front and rear), wheels and tires Electrical: Battery, charging system, starting system, lighting system, instrument cluster, body electricals, power accessories Body And Frame: Body panels, doors, windows, interior trim, structural components, paint and finish HVAC: Heating, Ventilation, and Air Conditioning system Safety Systems: Airbags, seatbelts, ABS (Anti-lock Braking System) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Troubleshooting: Diagnostic procedures, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation Repair: Component removal and installation, adjustments, replacements, rebuilds Diagnostics: ECM/PCM diagnosis, sensor testing, actuator testing, electrical circuit tracing Specifications: Torque specifications, clearances, fluid capacities, electrical values Technical Depth Depth: Comprehensive, covering basic maintenance to major overhauls and complex diagnostics Diagnostic Tools: Information on using diagnostic scan tools and specialized equipment Wiring Diagrams: Includes detailed electrical wiring diagrams for all systems Special Tools: Identifies and describes any special tools required for specific procedures 📊 Manual Specifications File Format Digital Format: PDF (most common for online service manuals) Print Quality Readability: High resolution for clear viewing of text and diagrams Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Code: FS-DE Engine Type: Inline 4-cylinder, DOHC (Dual Overhead Camshafts), 16 valves Displacement: 1991 cc (2.0 Liters) Bore X Stroke: 83.0 mm x 92.0 mm Compression Ratio: 9.0:1 Performance Horsepower: 130 hp @ 6000 rpm (approx.) Torque: 135 lb-ft @ 4000 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential port injection Fuel Type: Unleaded gasoline, 87 octane recommended Emission Control: California/Federal emissions standards, Catalytic Converter, EGR system 🔧 Transmission Standard Transmission Type: 5-speed manual transmission Optional Transmission Type: 4-speed automatic transmission (with lock-up torque converter) Features Manual Gear Ratios: Refer to manual for specific ratios (e.g., 1st: 3.45, 2nd: 1.94, 3rd: 1.33, 4th: 0.97, 5th: 0.76, Rev: 3.33) Automatic Gear Ratios: Refer to manual for specific ratios (e.g., 1st: 2.80, 2nd: 1.50, 3rd: 1.00, 4th: 0.70, Rev: 2.20) Clutch Type: Dry single plate, hydraulically actuated Transmission Fluid Manual: API GL-4, SAE 75W-90 synthetic gear oil (check manual for specific part numbers, e.g., Mazda Genuine Gear Oil JWS3309) Transmission Fluid Automatic: Dexron III or equivalent (check manual for specific part numbers, e.g., Mazda ATF-III) 📐 Dimensions Exterior Length: 4320 mm (170.1 in) Width: 1705 mm (67.1 in) Height: 1545 mm (60.8 in) Wheelbase: 2615 mm (103.0 in) Front Track: 1475 mm (58.1 in) Rear Track: 1470 mm (57.9 in) Ground Clearance: 150 mm (5.9 in) approx. Wheel Bolt Pattern: 5 x 114.3 mm (5 x 4.5 inches) Wheel Size: 15-inch or 16-inch alloy wheels Tire Size: 195/60R15, 205/50R16 (depending on trim) Interior Passenger Volume: Approx. 96.0 cu ft Cargo Cargo Volume Seats Up: Approx. 19.1 cu ft Cargo Volume Seats Down: Approx. 42.4 cu ft Weights Curb Weight: 1310-1370 kg (2888-3019 lbs) approx. Gross Vehicle Weight Rating Gvwr: Refer to vehicle compliance plate or manual 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: ★★★★ (4 Stars - 2001 Model Year) NHTSA Frontal Impact Passenger: ★★★★ (4 Stars - 2001 Model Year) IIHS Moderate Overlap Frontal Offset: Good (for Protege sedan, presumed similar for hatchback) Active Features ABS: Standard on most trims, optional on others Traction Control: Available on some higher trims/later models Electronic Brakeforce Distribution Ebd: Often paired with ABS Passive Features Airbags: Front dual airbags standard Side Airbags: Optional front side-impact airbags on some trims Seatbelts: 3-point front and rear seatbelts, pretensioners and load limiters for front seats Child Seat Anchors: LATCH (Lower Anchors and Tethers...
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SKU: 366016
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Mazda Protege 5 2000-2004 Online Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Protege 5
Model Code:
BJ Series
Body Style:
5-door hatchback/wagon
Generation
Generation Designation:
Second Generation (BJ)
Production Years Generation:
1998-2003 (Globally), 2000-2003 (North America for Protege 5)
Codes
Vin Character Engine:
F (for FS-DE engine)
👋 Introduction
Market Position
Segment:
Compact wagon/hatchback, sporty alternative to sedans
Target Audience:
Younger buyers, small families, enthusiasts looking for practicality with a sporty flair
Competitive Analysis
Key Competitors:
Subaru Outback, Honda CR-V (early models), Toyota Matrix, Ford Focus Wagon
Key Features
Driving Dynamics:
Known for responsive handling and engaging driving experience, a Mazda hallmark
Practicality:
Versatile cargo space due to hatchback design, folding rear seats
Styling:
Distinctive, sporty exterior styling for its class
📋 Manual Details
Coverage Areas
Covered Model Years:
2000, 2001, 2002, 2003
Covered Engine Options:
FS-DE 2.0L DOHC (Naturally Aspirated)
Covered Markets:
North America (implies specific regional variations if any)
Page Count
Estimated Page Count:
1500-2500+ pages (typical for comprehensive service manuals)
Manual Type
Type:
Online Service and Repair Manual
Scope:
Factory-level repair and maintenance information
Language
Language:
English
Format
Format:
Digital (likely PDF or web-based access)
Searchability:
Likely text-searchable
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
Transmission (manual and automatic), clutch, driveshafts, differentials, AWD system (if applicable)
Chassis:
Suspension (front and rear), steering system, brakes (front and rear), wheels and tires
Electrical:
Battery, charging system, starting system, lighting system, instrument cluster, body electricals, power accessories
Body And Frame:
Body panels, doors, windows, interior trim, structural components, paint and finish
HVAC:
Heating, Ventilation, and Air Conditioning system
Safety Systems:
Airbags, seatbelts, ABS (Anti-lock Braking System)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation
Repair:
Component removal and installation, adjustments, replacements, rebuilds
Diagnostics:
ECM/PCM diagnosis, sensor testing, actuator testing, electrical circuit tracing
Specifications:
Torque specifications, clearances, fluid capacities, electrical values
Technical Depth
Depth:
Comprehensive, covering basic maintenance to major overhauls and complex diagnostics
Diagnostic Tools:
Information on using diagnostic scan tools and specialized equipment
Wiring Diagrams:
Includes detailed electrical wiring diagrams for all systems
Special Tools:
Identifies and describes any special tools required for specific procedures
📊 Manual Specifications
File Format
Digital Format:
PDF (most common for online service manuals)
Print Quality
Readability:
High resolution for clear viewing of text and diagrams
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
FS-DE
Engine Type:
Inline 4-cylinder, DOHC (Dual Overhead Camshafts), 16 valves
Displacement:
1991 cc (2.0 Liters)
Bore X Stroke:
83.0 mm x 92.0 mm
Compression Ratio:
9.0:1
Performance
Horsepower:
130 hp @ 6000 rpm (approx.)
Torque:
135 lb-ft @ 4000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential port injection
Fuel Type:
Unleaded gasoline, 87 octane recommended
Emission Control:
California/Federal emissions standards, Catalytic Converter, EGR system
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission
Optional
Transmission Type:
4-speed automatic transmission (with lock-up torque converter)
Features
Manual Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 3.45, 2nd: 1.94, 3rd: 1.33, 4th: 0.97, 5th: 0.76, Rev: 3.33)
Automatic Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 2.80, 2nd: 1.50, 3rd: 1.00, 4th: 0.70, Rev: 2.20)
Clutch Type:
Dry single plate, hydraulically actuated
Transmission Fluid Manual:
API GL-4, SAE 75W-90 synthetic gear oil (check manual for specific part numbers, e.g., Mazda Genuine Gear Oil JWS3309)
Transmission Fluid Automatic:
Dexron III or equivalent (check manual for specific part numbers, e.g., Mazda ATF-III)
📐 Dimensions
Exterior
Length:
4320 mm (170.1 in)
Width:
1705 mm (67.1 in)
Height:
1545 mm (60.8 in)
Wheelbase:
2615 mm (103.0 in)
Front Track:
1475 mm (58.1 in)
Rear Track:
1470 mm (57.9 in)
Ground Clearance:
150 mm (5.9 in) approx.
Wheel Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
Wheel Size:
15-inch or 16-inch alloy wheels
Tire Size:
195/60R15, 205/50R16 (depending on trim)
Interior
Passenger Volume:
Approx. 96.0 cu ft
Cargo
Cargo Volume Seats Up:
Approx. 19.1 cu ft
Cargo Volume Seats Down:
Approx. 42.4 cu ft
Weights
Curb Weight:
1310-1370 kg (2888-3019 lbs) approx.
Gross Vehicle Weight Rating Gvwr:
Refer to vehicle compliance plate or manual
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
★★★★ (4 Stars - 2001 Model Year)
NHTSA Frontal Impact Passenger:
★★★★ (4 Stars - 2001 Model Year)
IIHS Moderate Overlap Frontal Offset:
Good (for Protege sedan, presumed similar for hatchback)
Active Features
ABS:
Standard on most trims, optional on others
Traction Control:
Available on some higher trims/later models
Electronic Brakeforce Distribution Ebd:
Often paired with ABS
Passive Features
Airbags:
Front dual airbags standard
Side Airbags:
Optional front side-impact airbags on some trims
Seatbelts:
3-point front and rear seatbelts, 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, optional premium audio systems with more speakers
Speakers:
Typically 4-6 speakers depending on trim level
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Auxiliary Input:
Not typically standard; aftermarket solutions available
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions)
Oil Filter Replacement:
With every oil change
Engine 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 (if equipped)
Spark Plug Replacement:
Every 60,000 miles (96,000 km) (Iridium or Platinum plugs recommended)
Transmission Fluid Change Manual:
Every 60,000 miles (96,000 km) or as needed
Transmission Fluid Change Automatic:
Every 45,000 miles (72,000 km) or as needed
Coolant Flush Replacement:
Every 50,000 miles (80,000 km) or 3 years
Brake Fluid Replacement:
Every 2 years or 30,000 miles (48,000 km)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic (API SJ or SL, ILSAC GF-3)
Engine Oil Capacity:
4.2 L (4.4 US qt) with filter change
Coolant Type:
Mazda Genuine Long Life Antifreeze/Coolant (Blue) or equivalent (ethylene glycol based, 50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Known Issues
Engine Mounts:
Can degrade over time, leading to vibration
Ignition Coils:
Can fail, causing misfires and rough running
Rear Wheel Bearings:
Can develop noise and wear out, especially on higher mileage vehicles
Catalytic Converter:
Can become clogged or fail, affecting performance and emissions
Suspension Components:
Control arm bushings, sway bar links can wear and require replacement
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Zoom-Zoom driving dynamics, Jinba Ittai (horse and rider as one)
Model Evolution
Protege Lineage:
Part of Mazda's long-standing compact car lineage, succeeding models like the 323
Protege 5 Introduction:
Introduced for the 2002 model year in North America, based on the BJ platform, offering a unique wagon/hatchback variant of the Protege sedan
Production
Manufacturing Location:
Japan (primarily)
End Of Production Line:
The Protege line was replaced by the Mazda3 (Mazda3 MPS in some markets) starting with the 2004 model year.
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
The Protege sedan was recognized by Car and Driver in the past, indicating a competitive chassis and driving feel that likely carried over to the Protege 5.
Consumer Reports:
General reliability ratings varied by year, but the platform was generally considered decent for its class, though some specific issues are noted.
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