Mazda MX5 MX-5 1999-2002 Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: MX-5 Generation: NB Codes Model Code: NB Series 👋 Introduction Market Position Segment: Lightweight Two-Seater Sports Car (Roadster) Philosophy: Jinba Ittai (Horse and...

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Art.-Nr: 370087

Stichworte: 1999 2000 2001 2002 Car Cars Mazda Misc MX-5 MX5

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Beschreibung

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Generation:

Codes

Model Code:

NB Series

👋 Introduction

Market Position

Segment:

Lightweight Two-Seater Sports Car (Roadster)

Philosophy:

Jinba Ittai (Horse and Rider as One)

Competitive Analysis

Competitors:

Porsche Boxster, BMW Z3, Honda S2000, Nissan 300ZX (though older)

Key Features

Design Era:

Second Generation (NB) - Evolution of the iconic NA Miata design

Performance Focus:

Rear-wheel drive, balanced chassis, responsive handling, driver engagement

Convertible:

Soft-top manual convertible roof standard, optional power-retractable hardtop (PRHT) introduced later in NB generation

📋 Manual Details

Coverage Areas

Years Covered:

1999, 2000, 2001, 2002

Regions Covered:

Global (primarily North American market specifications unless otherwise noted)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

1.8L BP-VE / BP-YV (DOHC 16-valve)

Fuel System:

Fuel Injection (EFI), Fuel Pump, Injectors, Fuel Lines, Evaporative Emission Control (EVAP)

Ignition System:

Electronic Ignition (Coil-on-Plug for some models/years, Distributor type for earlier NB)

Exhaust System:

Catalytic Converter, Muffler, Exhaust Manifold, O2 Sensors

Cooling System:

Radiator, Water Pump, Thermostat, Hoses, Fan System

Lubrication System:

Oil Pan, Oil Pump, Oil Filter, Oil Cooler (if equipped)

Transmission Manual:

5-Speed (FS5W71C) and 6-Speed (MZR-based, later NB)

Transmission Automatic:

4-Speed Automatic (optional)

Clutch System:

Hydraulic Clutch System, Clutch Master Cylinder, Slave Cylinder, Clutch Disc, Pressure Plate

Drivetrain:

Rear Wheel Drive (RWD), Differential, Driveshafts, Axles

Suspension Front:

Double Wishbone, Shock Absorbers, Springs, Stabilizer Bar

Suspension Rear:

Multi-link, Shock Absorbers, Springs, Stabilizer Bar

Steering System:

Power Rack and Pinion, Steering Column, U-Joints

Brakes Front:

Ventilated Discs, Calipers

Brakes Rear:

Solid Discs, Calipers

Brake Control:

ABS (Anti-lock Braking System), Brake Booster, Master Cylinder, Parking Brake

Wheels Tires:

Wheel Bearings, Tire Pressures, Wheel Alignment

Body Structure:

Chassis, Body Panels, Unibody Construction

Exterior:

Doors, Hood, Trunk, Bumpers, Glass, Convertible Top Mechanism

Interior:

Seats, Dashboard, Trim Panels, Carpets, Seat Belts

HVAC:

Heating, Ventilation, Air Conditioning (A/C) System, Blower Motor, Evaporator, Condenser

Electrical System:

Battery, Alternator, Starter Motor, Wiring Diagrams, Fuses, Relays

Lighting System:

Headlights, Taillights, Turn Signals, Interior Lighting

Instrumentation:

Instrument Cluster, Gauges, Warning Lights

Audio Visual:

Radio, Speaker Installation/Removal

Security System:

Immobilizer System (if equipped)

Driver Assistance:

Cruise Control (if equipped)

Procedures Included

Maintenance:

Scheduled Maintenance, Fluid Changes, Filter Replacements, Spark Plug Service, Brake Pad/Rotor Replacement

Diagnostics:

Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Fault Finding Procedures

Engine Repair:

Engine Overhaul, Head Gasket Replacement, Piston/Ring Replacement, Valve Stem Seals

Transmission Repair:

Transmission Overhaul, Clutch Replacement, Gearbox Rebuilding

Suspension Steering Repair:

Ball Joint Replacement, Bushing Replacement, Tie Rod End Replacement, Wheel Bearing Replacement

Brake System Repair:

Brake Fluid Flush, Caliper Rebuild, Rotor Resurfacing/Replacement, ABS Module Diagnostics

Electrical Diagnostics:

Wiring Harness Repair, Component Testing, Sensor Diagnostics

Body Repair:

Panel Replacement, Dent Repair, Convertible Top Repair/Replacement

HVAC Repair:

Refrigerant Charging, Blower Motor Replacement, A/C Compressor Replacement

Specification Data:

Torque Specifications, Tolerances, Electrical Schematics

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds)

Audience Level:

Professional Technicians and Advanced DIY Enthusiasts

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Printability:

Printable (all pages)

Print Quality

Image Resolution:

High-resolution, clear diagrams and photographs

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

BP-VE / BP-YV

Configuration:

Inline 4-Cylinder, DOHC, 16 Valves

Displacement:

1839 cc (1.8 Liters)

Performance

Horsepower:

140-145 HP @ 6500 RPM (varies slightly by market and year)

Torque:

119-121 lb-ft @ 5000 RPM (varies slightly by market and year)

Redline:

7000 RPM

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (91 Octane or higher recommended)

Compression Ratio:

9.5:1

🔧 Transmission

Standard

Type Standard:

5-Speed Manual (FS5W71C)

Optional

Type Optional:

4-Speed Automatic

Features

Drive Layout:

Rear Wheel Drive (RWD)

Clutch Type:

Hydraulically Actuated, Dry Single Plate

📐 Dimensions

Exterior

Length:

3955 mm (155.7 in)

Width:

1690 mm (66.5 in)

Height:

1245 mm (49.0 in)

Wheelbase:

2265 mm (89.2 in)

Front Track:

1455 mm (57.3 in)

Rear Track:

1465 mm (57.7 in)

Weights

Curb Weight:

~1060-1120 kg (2337-2469 lbs) - Varies by transmission and options

Gross Vehicle Weight Rating:

Approx. 1400 kg (3086 lbs)

Cargo

Trunk Volume:

Approx. 150 Liters (5.3 cu ft)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4 Stars (Driver & Passenger)

NHTSA Side Impact:

5 Stars (Driver & Passenger)

Active Features

Standard on most models within this range

Traction Control:

Optional on some higher trims

Passive Features

Airbags Front:

Driver and Passenger Frontal Airbags

Seat Belts:

3-Point ELR Seatbelts with Pretensioners

Rollover Protection:

Reinforced A-pillars and windshield frame, pop-up hoop behind headrests (on some models)

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with 4-6 speakers depending on trim level.

Display:

Simple digital or analog displays for climate control and radio.

Driver Assistance

Cruise Control:

Available on higher trim levels, mechanical linkage operated.

Connectivity

Bluetooth:

Not available from the factory on this generation.

Not available from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months (whichever comes first) under normal driving conditions.

Air Filter Replacement:

Every 15,000 miles or 12 months.

Spark Plug Replacement:

Every 60,000 miles (Platinum or Iridium recommended).

Coolant Flush:

Every 30,000 miles or 24 months.

Brake Fluid Flush:

Every 24,000 miles or 24 months.

Transmission Fluid Change:

Manual: Every 60,000 miles. Automatic: Every 30,000 miles.

Fluid Specifications

Engine Oil Spec:

API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity recommendation based on climate).

Coolant Type:

Mazda Long Life Antifreeze/Coolant (or equivalent ethylene glycol-based coolant with deionized water).

Brake Fluid Type:

DOT 3 or DOT 4.

Transmission Fluid Manual:

API GL-4 SAE 75W-90 Gear Oil.

Transmission Fluid Automatic:

Dexron III (or equivalent ATF).

Power Steering Fluid:

Mazda Genuine Power Steering Fluid (or DEXRON II/III compatible ATF).

Known Issues

Engine Oil Consumption:

Some 1.8L engines can consume oil if not maintained properly. Regular checks are advised.

Cooling Fan Failure:

Electric cooling fan motor failure can lead to overheating, especially in traffic.

Window Regulator Failure:

Manual window regulators can become stiff or fail over time.

Clutch Wear:

Clutch wear is normal, but premature failure can occur with aggressive driving or poor maintenance.

Radiator Leaks:

Plastic end tanks on radiators can crack and leak over time.

Power Steering Pump Noise:

Whining noise from the power steering pump can indicate low fluid or pump wear.

📚 Vehicle History

Brand Heritage

Brand Focus:

Mazda's long history of producing engaging and reliable vehicles, with a strong emphasis on driving dynamics.

Model Evolution

Nb Introduction:

The NB generation replaced the NA Miata in 1998 for the 1999 model year. It retained the core principles but featured a stiffer chassis, updated styling (including pop-up headlight elimination), and improved aerodynamics.

Facelift:

A significant facelift occurred for the 2001 model year, introducing revised bumpers, headlights, taillights, and a power increase for the 1.8L engine to 145 HP (BP-YV). The 6-speed manual transmission became available.

Production

Production Period:

1998-2005 (for the NB generation)

Manufacturing Plant:

Mazda Hiroshima Plant, Japan

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Mazda MX-5 (Miata) has a strong legacy, with earlier generations frequently appearing on Car and Driver's 10Best list. The NB generation continued this reputation for driving excellence.

Motor Trend Car Of The Year:

While not winning 'Car of the Year', the MX-5 is consistently praised for its value and driving dynamics.

Ratings

Overall Enthusiast Rating:

Consistently high ratings from automotive journalists and owners for pure driving enjoyment.