🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Year: 2002 Codes Chassis Code: BJ Platform: Mazda Familia BJ platform 👋 Introduction Market Position Segment: Compact Wagon / Sport Compact Key Selling Points: Practicality, sporty handling, unique styling, versatile cargo space. Competitive Analysis Competitors: Subaru Outback, Honda CR-V (early models), Toyota Matrix, Ford Focus Wagon. Key Features Distinctive Features: Hatchback utility, characteristic roof rails, sporty suspension tuning. Target Audience Target Demographic: Young professionals, active individuals, small families seeking a balance of sportiness and practicality. 📋 Manual Details Coverage Areas Coverage Scope: Complete repair and maintenance for the 2002 Mazda Protege 5. Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Downloadable PDF File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair procedures, component identification for the 2.0L DOHC (FS-DE) engine. Transmission: Repair and maintenance for both the 4-speed automatic (FN4A-EL) and 5-speed manual (G5M-P) transmissions. Brakes: Front disc (ventilated), rear disc brake system, ABS, EBD, and parking brake. Suspension: Front strut suspension, rear multi-link independent suspension, alignment specifications. Steering: Power assisted rack and pinion steering, steering column, components. Electrical: Complete wiring diagrams, fuse box layouts, component testing, diagnostic trouble codes (DTCs) for all electrical systems. Body And Trim: Body panel removal and installation, interior trim, bumpers, glass replacement. HVAC: Air conditioning system, heater core, blower motor, climate control diagnostics. Fuel System: Fuel pump, injectors, fuel filter, evaporative emission control (EVAP) system. Cooling System: Radiator, thermostat, water pump, coolant types and capacities. Exhaust System: Catalytic converter, muffler, exhaust manifold, pipe replacement. Safety Systems: Airbag system diagnostics and replacement, seatbelt mechanisms. Procedures Included General Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Troubleshooting: Systematic diagnostic procedures for common and complex issues, guided by symptoms and DTCs. Engine Repair: Head gasket replacement, piston and ring service, valve adjustments, timing belt replacement. Transmission Repair: Clutch replacement (manual), transmission fluid service, valve body diagnostics (automatic). Brake Service: Brake pad and rotor replacement, caliper service, brake fluid flush. Suspension Repair: Strut replacement, ball joint replacement, bushing service. Electrical Diagnostics: Testing sensors, actuators, control modules (ECU, TCU), starter, alternator. Bodywork Procedures: Door panel removal, fender replacement, headlight/taillight replacement. HVAC Service: Refrigerant recharge, cabin air filter replacement, blower motor replacement. Timing Belt Replacement: Critical procedure with detailed steps and torque specifications. Wheel Alignment: Specifications for camber, caster, and toe angles. Technical Depth Depth Of Information: Factory-level detail, including torque specifications, component clearances, electrical schematics, and diagnostic procedures. Diagnostic Tools: Reference to use of OBD-II scanner and specific Mazda diagnostic equipment (e.g., MS3 or equivalent). Repair Instructions: Step-by-step instructions with accompanying diagrams and illustrations for all repair tasks. Schematics: Comprehensive electrical and vacuum schematics for all vehicle systems. ⚙️ Engine Specifications Primary Engine Engine Code: FS-DE Engine Type: Inline 4-cylinder, DOHC, 16-valve Displacement: 1991 cc (2.0 Liters) Performance Horsepower: 130 hp @ 6000 rpm Torque: 135 lb-ft @ 4000 rpm Bore X Stroke: 83.0 mm x 92.0 mm Compression Ratio: 9.7:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (87 octane recommended) Engine Management ECU Type: Engine Control Unit (ECU) with OBD-II diagnostics Ignition System: Electronic ignition with distributorless ignition system (DIS) 🔧 Transmission Standard Transmission Type: 5-speed Manual Optional Transmission Type: 4-speed Automatic (FWD only) Features Manual Gear Ratios: Provided in manual, typically close-ratio for sporty feel. Automatic Transmission Code: FN4A-EL Automatic Transmission Modes: Typically 'Normal' and 'Sport' modes. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 Automatic Transmission Fluid: Mazda ATF M-III or equivalent (Mercon V often compatible) 📐 Dimensions Exterior Length: 4435 mm (174.6 in) Width: 1705 mm (67.1 in) Height: 1535 mm (60.4 in) Wheelbase: 2610 mm (102.8 in) Front Track: 1470 mm (57.9 in) Rear Track: 1475 mm (58.1 in) Cargo Cargo Volume Seats Up: Approx. 28.0 cu ft (with rear seats up) Cargo Volume Seats Down: Approx. 57.0 cu ft (with rear seats folded) Weights Curb Weight Manual: Approx. 1330 kg (2932 lbs) Curb Weight Automatic: Approx. 1350 kg (2976 lbs) Gross Vehicle Weight Rating: Provided in manual, vehicle-specific. Towing Capacity: Not typically recommended or specified for this model. Wheels And Tires Standard Wheel Size: 15-inch alloy wheels Optional Wheel Size: 16-inch alloy wheels (available on some trims/markets) Standard Tire Size: P205/50R16 (common for 16-inch wheels) Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Lug Nut Torque: 103 Nm (76 lb-ft) 🛡️ Safety Features Ratings NHTSA Front Impact: 4 stars (driver and passenger) NHTSA Side Impact: 4 stars (front and rear passengers) IIHS Ratings: Good (Head Restraints & Seats, Roof Strength - 2007 update). Active Features ABS: Standard Anti-lock Braking System (ABS)...