Mazda PROTEGE 5 Digital Workshop Repair Manual 2001-2003
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🏷️ Basic Information Identification Make: Mazda Model: Protege 5 Year: 2001-2003 Codes Chassis Code: BJ (Third Generation Protege) 👋 Introduction Market Position Vehicle Segment: Compact Station Wagon (Wagon variant of the Protege sedan/hatchback line). Target Audience: DIY mechanics, automotive enthusiasts, repair shops seeking detailed service information. Competitive Analysis Competitors: Honda Civic Wagon, Toyota Corolla Wagon, Subaru Impreza Outback Sport, Nissan Sentra Wagon. Key Features Practicality: Known for its practicality, engaging driving dynamics, and sporty styling within the compact wagon segment. Manual Value: Provides in-depth, factory-level repair and maintenance information, crucial for preserving and repairing these vehicles. 📋 Manual Details Coverage Areas Manual Type: Digital Workshop Repair Manual Language: English Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, tuning, cooling system, lubrication system, fuel injection, emissions control. Transmission: Manual and Automatic transmission repair, overhaul, diagnostics, clutch, drivetrain components. Brakes: Hydraulic system, ABS (Anti-lock Braking System), disc and drum brake repair, parking brake. Electrical: Wiring diagrams, lighting system, ignition system, charging system, starting system, battery, fuses, relays, power accessories, diagnostic trouble codes (DTCs). Suspension Steering: Front and rear suspension, power steering system, steering rack, wheel alignment specifications. Body Chassis: Body repair, panel replacement, interior trim, exterior trim, chassis maintenance, rust prevention. HVAC: Heating, Ventilation, and Air Conditioning system diagnosis and repair, refrigerant handling. Procedures Included Maintenance: Regular service intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, belt replacement. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. Repair: Step-by-step instructions for component removal, installation, and overhaul of all major vehicle systems. Rebuilding: Detailed procedures for engine and transmission rebuilding, including specifications and tolerances. Restoration: Guidance on refurbishing and restoring various vehicle components and systems. Technical Depth Depth: Comprehensive, covering all diagnostic and repair procedures from basic maintenance to advanced rebuilds. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) with searchable text and printable pages. Print Quality Resolution: High-resolution, suitable for on-screen viewing and printing. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: FS-DE (2.0L DOHC Inline-4) Displacement: 1991 cc (2.0 Liters) Configuration: Inline 4-cylinder, DOHC (Double Overhead Camshafts), 16 valves Bore X Stroke: 83.0 mm x 92.0 mm Compression Ratio: 9.1:1 (typical) Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (MPI) Performance Horsepower: 110-115 hp @ 5500-5700 rpm (approximate) Torque: 125-130 lb-ft @ 4000-4500 rpm (approximate) Fuel System Fuel Type: Unleaded gasoline (87 octane or higher recommended) Fuel Tank Capacity: 50 Liters (13.2 US Gallons) 🔧 Transmission Standard Transmission Type Standard: 5-speed manual transmission Optional Transmission Type Optional: 4-speed automatic transmission Features Clutch Type: Hydraulically actuated, dry single-plate (for manual transmission) Transmission Fluid Manual: API GL-4, SAE 75W-90 (check specific manual for exact specification and quantity) Transmission Fluid Automatic: Mazda ATF-III or equivalent (check specific manual for exact specification and quantity) 📐 Dimensions Exterior Length: 4410 mm (173.6 in) Width: 1720 mm (67.7 in) Height: 1460 mm (57.5 in) Wheelbase: 2610 mm (102.8 in) Front Track: 1480 mm (58.3 in) Rear Track: 1470 mm (57.9 in) Interior Seating Capacity: 5 occupants Cargo Cargo Volume: Approx. 18.5 cubic feet (with rear seats up) Weights Curb Weight: 1260-1310 kg (2778-2888 lbs) depending on configuration Gross Vehicle Weight Rating: Approximately 1740 kg (3836 lbs) 🛡️ Safety Features Ratings NHTSA Front Driver: Good (2003 model year) - Source: IIHS (Insurance Institute for Highway Safety) NHTSA Front Passenger: Good (2003 model year) - Source: IIHS (Insurance Institute for Highway Safety) Active Features ABS: Standard on most models (4-wheel Anti-lock Braking System) Traction Control: Optional on some trims. Passive Features Airbags Front: Driver and front passenger airbags (standard) Airbags Side: Optional front side-impact airbags on some trims. Seatbelts: Three-point seatbelts with pretensioners and load limiters in the front, three-point seatbelts in the rear. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM stereo with CD player and 4 or 6 speakers. Premium audio options available on higher trims. Climate Control: Manual or automatic climate control systems depending on trim level. Driver Assistance Cruise Control: Standard or optional depending on trim level. Connectivity Power Windows Locks: Standard on most trims, with driver's auto-down feature. Remote Keyless Entry: Available on higher trim levels. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first (synthetic oil recommended). Air Filter Replacement: Every 30,000 miles (48,000 km) or as needed based on driving conditions. Spark Plug Replacement: Every 75,000 miles (120,000 km) using Iridium-tipped spark plugs. Coolant Replacement: Every 75,000 miles (120,000 km) or 5 years, whichever comes first. Fluid Specifications Engine Oil: SAE 5W-30 API SG or SH or SJ, ILSAC GF-2 (refer to manual for specific viscosity under different temperature ranges) Engine Oil Capacity: 4.2 Liters (4.4 US Quarts) with filter change...
API GL-4, SAE 75W-90 (check specific manual for exact specification and quantity)
Transmission Fluid Automatic:
Mazda ATF-III or equivalent (check specific manual for exact specification and quantity)
📐 Dimensions
Exterior
Length:
4410 mm (173.6 in)
Width:
1720 mm (67.7 in)
Height:
1460 mm (57.5 in)
Wheelbase:
2610 mm (102.8 in)
Front Track:
1480 mm (58.3 in)
Rear Track:
1470 mm (57.9 in)
Interior
Seating Capacity:
5 occupants
Cargo
Cargo Volume:
Approx. 18.5 cubic feet (with rear seats up)
Weights
Curb Weight:
1260-1310 kg (2778-2888 lbs) depending on configuration
Gross Vehicle Weight Rating:
Approximately 1740 kg (3836 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Driver:
Good (2003 model year) - Source: IIHS (Insurance Institute for Highway Safety)
NHTSA Front Passenger:
Good (2003 model year) - Source: IIHS (Insurance Institute for Highway Safety)
Active Features
ABS:
Standard on most models (4-wheel Anti-lock Braking System)
Traction Control:
Optional on some trims.
Passive Features
Airbags Front:
Driver and front passenger airbags (standard)
Airbags Side:
Optional front side-impact airbags on some trims.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters in the front, three-point seatbelts in the rear.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player and 4 or 6 speakers. Premium audio options available on higher trims.
Climate Control:
Manual or automatic climate control systems depending on trim level.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Connectivity
Power Windows Locks:
Standard on most trims, with driver's auto-down feature.
Remote Keyless Entry:
Available on higher trim levels.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (synthetic oil recommended).
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Every 75,000 miles (120,000 km) using Iridium-tipped spark plugs.
Coolant Replacement:
Every 75,000 miles (120,000 km) or 5 years, whichever comes first.
Fluid Specifications
Engine Oil:
SAE 5W-30 API SG or SH or SJ, ILSAC GF-2 (refer to manual for specific viscosity under different temperature ranges)
Engine Oil Capacity:
4.2 Liters (4.4 US Quarts) with filter change
Coolant Type:
Mazda Long Life Coolant (Blue) or equivalent ethylene glycol-based coolant with silicate inhibitors.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Mounts:
Premature wear of engine and transmission mounts, leading to vibration.
Ignition Coils:
Failure of ignition coils can cause misfires and rough running.
Power Steering Pump:
Occasional leaks or failure of the power steering pump.
Catalytic Converter:
Can be prone to clogging or failure over time, especially with high mileage or poor maintenance.
📚 Vehicle History
Brand Heritage
Mazda Heritage:
Mazda has a long history of producing reliable and engaging vehicles, often focusing on driving dynamics and innovative design.
Model Evolution
Protege Lineage:
The Protege 5 is part of the third generation (BJ) of the Mazda Protege, which ran from 1998 to 2005. It was introduced as a sportier, more practical wagon variant.
Production
Production Location:
Assembled in Japan and other Mazda facilities globally.
Production Years:
2001-2003 for the Protege 5 model
🏆 Awards & Recognition
Recognitions
IIHS Ratings:
Often received 'Good' ratings in IIHS crash tests for frontal impact, indicating good occupant protection.
Consumer Reports:
Generally received average to above-average reliability ratings from sources like Consumer Reports for its segment.