Mazda Protege / Mazda Protege 5 since 2002, repair e-manual

Contents

General information

• How to use this manual
• Fundamental procedures
• Installation of radio system
• Electrical system
• Jacking positions
• Vehicle lift (2 supports) and safety Stand (rigid rack) position
• Towing
• SAE standards
• Abbreviations
• Pre-delivery inspection
• Scheduled maintenance

On-board diagnostic (engine control system)

• Control system wiring diagram
• Control system device and control Relationship chart
• Foreword
• OBD-II pending trouble codes
• OBD-II freeze frame data
• OBD-II on-board system readiness test
• OBD-II diagnostic monitoring test results
• OBD-II read / clear diagnostic test results
• OBD-II parameter identification (PID) access
• On-board diagnostic test
• After repair procedure
• OBD-II drive mode
• Diagnostic monitoring test Results

Mechanical ZM

• Mechanical location index
• Drive belt inspection
• Drive belt adjustment
• Valve clearance inspection
• Valve clearance adjustment
• Compression inspection
• Timing belt
• Cylinder head gasket replacement
• Front oil seal replacement
• Rear oil seal replacement
• Engine removal / installation
• Engine disassembly / assembly
• Engine tune-up

Mechanical FS

• Mechanical location index
• Drive belt inspection
• Drive belt adjustment
• Valve clearance inspection
• Valve clearance adjustment
• Compression inspection
• Timing belt removal / installation
• Cylinder head gasket replacement
• Front oil seal replacement
• Rear oil seal replacement
• Engine removal / installation
• Engine disassembly / assembly
• Engine tune-up

Lubrication

• Oil pressure inspection
• Engine oil inspection
• Engine oil replacement
• Oil filter replacement
• Oil pan removal / installation
• Oil pump removal / installation
• Oil pump disassembly / assembly
• Oil pump inspection

Cooling system

• Cooling system location index
• Cooling system service warnings
• Engine coolant level inspection
• Engine coolant protection inspection
• Engine coolant replacement
• Engine coolant leakage inspection
• Radiator cap inspection
• Radiator removal / installation
• Thermostat removal / installation
• Thermostat inspection
• Water pump removal / installation
• Cooling fan motor inspection
• Cooling fan motor removal / installation

Intake-air system

• Intake-air system location index
• Intake-air system flow diagram
• Vacuum hose routing diagram
• Intake-air system removal / installation
• Idle air control (iac) valve removal / installation
• Idle air control (iac) valve inspection
• Variable tumble control system (VTCS) diagram
• Variable tumble control system (VTCS) check valve (one-way) removal / installation
• Variable tumble control system (VTCS) check valve (one-way) inspection
• Variable tumble control system (VTCS) shutter valve actuator removal / installation
• Variable tumble control system (VTCS) shutter valve actuator inspection
• Variable tumble control system (VTCS) delay valve removal / installation
• Variable tumble control system (VTCS) delay valve inspection
• Variable tumble control system (VTCS) solenoid valve inspection
• Accelerator cable removal / installation
• Accelerator cable inspection / adjustment

Fuel system

• Fuel system location index
• Fuel system diagram
• Before repair procedure
• After repair procedure
• Fuel pressure inspection
• Fuel tank removal / installation
• Fuel tank inspection
• Fuel shut-off valve inspection
• Nonreturn valve inspection
• Fuel pump unit removal / installation
• Fuel pump unit disassembly / assembly
• Fuel pump unit inspection
• Fuel filter (high-pressure) removal / installation
• Fuel injector removal / installation
• Fuel injector inspection
• Pressure regulator removal / installation
• Pressure regulator inspection
• Pulsation damper removal / installation
• Pulsation damper inspection
• PRC solenoid valve removal / installation
• PRC solenoid valve inspection

Emission system

• Emission system location index
• Evaporative emission (EVAP) control system diagram
• Evaporative emission (EVAP) control system (fuel tank side) component removal / installation
• Evaporative gas check valve (two-way) inspection
• Air filter inspection
• Charcoal canister inspection
• Canister drain cut valve (CDCV) removal / installation
• Canister drain cut valve (CDCV) Inspection
• Catch tank inspection
• Purge solenoid valve removal / installation
• Purge solenoid valve inspection
• Fuel-filler cap inspection
• EGR system diagram
• EGR valve removal / installation
• EGR valve inspection
• EGR boost sensor solenoid valve inspection
• Positive crankcase ventilation (PCV) system flow diagram
• Positive crankcase ventilation (PCV) valve inspection
• Warm up three-way catalytic converter (WU-TWC) Inspection

Cruise control system

• Location index
• Cruise control module removal / installation
• Cruise control module Inspection
• Cruise actuator removal / installation
• Cruise actuator inspection
• Actuator cable removal
• Actuator cable installation
• Cruise control switch removal / installation
• Cruise control switch inspection

Control system

• Control system component location index
• Control system diagram
• Control system wiring diagram
• PCM removal / installation
• Inspection using an oscilloscope (reference)
• Mass air flow (MAF) / intake air temperature (IAT) sensor inspection
• Throttle position (TP) sensor inspection
• Throttle position (TP) sensor removal / installation
• Engine coolant temperature (ECT) sensor removal / installation
• Engine coolant temperature (ECT) sensor inspection
• Crankshaft position (CKP) sensor inspection
• Crankshaft position (CKP) sensor adjustment
• Crankshaft position (CKP) sensor removal / installation
• Plate removal / installation
• Camshaft position (CMP) sensor removal / installation
• Camshaft position (CMP) sensor inspection
• Heated oxygen sensor (HO2S) Inspection
• Egr boost sensor inspection
• Fuel tank pressure sensor inspection
• Clutch switch inspection
• Neutral switch inspection
• Power steering pressure (PSP) switch inspection

Suspension

• Precaution (suspension)

Front suspension

• Front suspension location Index
• Front shock absorber and coil spring removal / installation
• Front shock absorber inspection
• Front shock absorber disposal
• Front lower arm removal / installation
• Front lower arm inspection
• Front stabilizer removal / installation
• Stabilizer control link (front) inspection
• Front crossmember removal / installation
• Transverse member (ZM (ATX), FS) removal / installation
• Front strut bar removal / installation

Rear suspension

• Rear suspension location index
• Rear shock absorber and spring removal / installation
• Rear shock absorber inspection
• Rear shock absorber disposal
• Rear stabilizer removal / installation
• Stabilizer control link (rear) inspection
• Lateral link and trailing link removal / installation

Driveline / axle

• Precaution (driveline / axle)

Front axle

• Front axle location index
• Wheel hub, steering knuckle pre-inspection
• Wheel hub bolt replacement
• Wheel hub, steering knuckle removal / installation

Rear axle

• Rear axle location index
• Wheel hub, hub spindle pre-inspection
• Wheel hub, hub spindle (drum brake type) removal / installation
• Wheel hub, hub spindle (disc brake type) removal / installation

Rear axle

• Rear axle location index
• Wheel hub, hub spindle pre-inspection
• Wheel hub, hub spindle (drum brake type) removal / installation
• Wheel hub, hub spindle (disc brake type) removal / installation

Drive shaft

• Drive shaft location index
• Joint shaft pre-inspection
• Joint shaft removal / installation
• Joint shaft disassembly / assembly
• Drive shaft pre-inspection
• Drive shaft removal / installation
• Drive shaft (ZM, FS ATX, FS MTX right side) disassembly / assembly
• Drive shaft (FS MTX LEFT SIDE) disassembly / assembly

Brakes

• Symptom troubleshooting
• General procedures

Conventional brake system

• Conventional brake system location index
• Air bleeding
• Vacuum hose check valve Inspection (power brake unit)
• Brake pedal inspection
• Brake pedal removal / installation
• Brake switch inspection
• Master cylinder removal / installation
• Fluid level sensor inspection
• Master cylinder disassembly / assembly
• Power brake unit inspection
• Power brake unit removal / installation
• Dual proportioning valve (without ABS) inspection
• Dual proportioning valve (without ABS) and brake pipe joint (with ABS) replacement
• Front brake (disc) inspection
• Front brake (disc) removal / installation
• Disc pad (front) replacement
• Caliper (front) disassembly / assembly
• Rear brake (disc) inspection
• Rear brake (disc) removal / installation
• Disc pad (rear) replacement
• Caliper (rear) disassembly / assembly
• Rear brake (drum) inspection
• Rear brake (drum) removal / installation
• Wheel cylinder disassembly / assembly

Antilock brake system

• ABS location index
• ABS system diagram
• ABS hydraulic unit (HU) / control module (CM) System inspection
• ABS hydraulic unit (HU) / control module (CM) Removal/installation
• ABS hydraulic unit (HU) / control module (CM) Inspection
• Front ABS wheel-speed sensor removal / installation
• Front / rear ABS wheel-speed Sensor inspection
• Rear ABS wheel-speed sensor Removal / installation

Transmission / transaxle

• On-board diagnostic
• Symptom troubleshooting

Clutch

• Clutch component location index
• General procedures
• Clutch fluid replacement / air bleeding
• Clutch pedal inspection
• Clutch pedal adjustment
• Clutch pedal removal / installation
• Clutch master cylinder removal / installation
• Clutch master cylinder disassembly / assembly
• Clutch release cylinder removal / installation
• Clutch release cylinder disassembly / assembly
• Clutch unit removal / installation
• Clutch cover inspection
• Clutch disc inspection
• Clutch release collar inspection
• Pilot bearing inspection
• Flywheel inspection

Manual transaxle F25M-R

• Manual transaxle F25M-R location index
• Transaxle oil inspection F25M-R
• Transaxle oil replacement F25M-R
• Oil seal (differential) replacement F25M-R
• Manual transaxle (MTX) removal / installation F25M-R

Manual transaxle G15M-R

• Manual transaxle G15M-R location index
• Transaxle oil inspection G15M-R
• Transaxle oil replacement G15M-R
• Oil seal (differential) replacement G15M-R
• Manual transaxle (MTX) removal / installation G15M-R

Manual transaxle shift mechanism

Automatic transaxle

• Automatic transaxle location index
• Automatic transaxle (ATX) cross-sectional view
• System wiring diagram
• Automatic transaxle (ATX) powertrain structural view
• Mechanical system test
• Road test
• Automatic transaxle fluid (ATF) inspection
• Automatic transaxle fluid (ATF) replacement
• O/D off switch inspection
• O/D off switch removal / installation
• Transaxle range (TR) switch inspection
• Transaxle range (TR) switch removal / installation
• Transaxle range (TR) switch adjustment
• Transaxle fluid temperature (TFT) sensor inspection
• Transaxle fluid temperature (TFT) sensor removal / installation
• Input / turbine speed sensor inspection
• Input / turbine speed sensor removal / installation
• Vehicle speedometer sensor (VSS) inspection ATX
• Vehicle speedometer sensor (VSS) removal / installation ATX
• Solenoid valves inspection
• Solenoid valves removal / installation
• O/D off indicator light Inspection
• PCM inspection
• PCM removal / installation
• Automatic transaxle (ATX) removal / installation
• Oil seal (transaxle) replacement
• Control valve body removal / installation
• Oil cooler flushing
• Oil cooler removal / installation
• Drive plate removal / installation

Automatic transaxle shift mechanism

• Automatic transmission shift mechanism location index
• Interlock cable inspection
• Selector lever inspection
• Selector lever adjustment
• Selector lever removal / installation
• Selector lever disassembly / assembly

Steering

• On-board diagnostic
• Engine speed sensing power steering
• Technical data
• Service tools

Heater, ventilation and air conditioning

• Symptom troubleshooting
• Refrigerant system
• Basic system
• Control system
• Technical data
• Service tools

Restraints

• On-board diagnostic
• Symptom troubleshooting
• Air bag system
• Seat belt
• Service tools

Body and accessories

• On-board diagnostic
• Body panels
• Doors and liftgate
• Glass / windows / mirrors
• Seats
• Security and locks
• Sunroof
• Exterior trim
• Interior trim
• Lighting systems
• Wiper / washer system
• Entertainment
• Power systems
• Instrumentation / driver info
• Technical data
• Service tools

Electrical wiring schematic

System circuit diagram / connector locations

Common connectors

Joint box

Complete wiring system

Fuse block complete wiring system

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