2002 Mazda MX-5 (2nd gen NB) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: MX-5 Year: 2002 Codes Generation: 2nd Generation (NB) Chassis Code: NB 👋 Introduction Market Position Vehicle Segment: Lightweight, two-seater, rear-wheel-drive sports car Philosophy:...

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Stichworte: 2002 Car Cars Mazda Misc MX-5

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🏷️ Basic Information

Identification

Make:

Mazda

Model:

Year:

Codes

Generation:

2nd Generation (NB)

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Lightweight, two-seater, rear-wheel-drive sports car

Philosophy:

Affordable, pure, driver-focused sports car experience

Competitive Analysis

Key Competitors Era:

Porsche Boxster, BMW Z3, Honda S2000 (though typically higher price point), Nissan 300ZX (older model)

Key Features

Driving Dynamics:

Renowned for excellent handling, balanced chassis, and direct steering feedback

Convertible Top:

Available with manual soft-top or optional power-operated soft-top

Lightweight Construction:

Emphasis on reducing weight for enhanced performance and agility

📋 Manual Details

Coverage Areas

Coverage Summary:

All models & All repairs A-Z

Page Count

Estimated Page Count:

Over 1500 pages (typical for full service manuals)

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF - inferred from common industry practice for digital manuals)

Digital Searchability:

Likely searchable text content (if PDF)

Illustrations And Diagrams:

Includes detailed diagrams, illustrations, and exploded views

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system, exhaust system, timing belt/chain, engine performance diagnostics.

Engine Management:

ECU, ignition system, fuel injection system, emissions control, sensor diagnostics, EVAP system.

Transmission Manual:

Clutch system, gearbox overhaul, gear shift mechanism, maintenance, troubleshooting.

Transmission Automatic:

If applicable to specific 2002 models (NB generation primarily offered manual), transmission overhaul, fluid, torque converter, maintenance.

Drivetrain:

Driveshafts, differential, axle bearings, wheel hubs, maintenance.

Suspension:

Front suspension, rear suspension, shock absorbers, springs, bushings, alignment specifications, diagnostics.

Steering:

Power steering system, steering column, tie rods, power steering pump, rack and pinion, troubleshooting.

Brakes:

Front and rear brake systems (discs), ABS system, hydraulic lines, master cylinder, brake fluid specifications, bleeding procedures, caliper overhaul.

Electrical System:

Battery, charging system (alternator, starter), lighting system, horn, wipers, power windows, power locks, fuses, relays, wiring diagrams.

HVAC System:

Air conditioning system, heater core, blower motor, refrigerant types, service procedures.

Body And Trim:

Body panel removal and installation, interior trim, seats, doors, convertible top mechanism, bumpers, hoods, trunks.

Chassis And Frame:

Frame construction, corrosion protection, jacking points, towing information.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement, tire rotation.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for all major systems, common problems and solutions.

Repair:

Detailed step-by-step repair procedures for every component and system, including complete engine and transmission rebuilds.

Diagnostics:

OBD-II system diagnostics, specific diagnostic trouble codes (DTCs), sensor testing, actuator testing, using diagnostic tools.

Specifications And Data:

Torque specifications, clearances, fluid capacities, electrical specifications, engine data, alignment settings.

Wiring Diagrams:

Comprehensive electrical wiring schematics for all vehicle systems.

Technical Depth

Depth Of Coverage:

Full Factory Diagnostic and Repair Procedures

Target Audience:

Professional Technicians and Serious DIY Enthusiasts

📊 Manual Specifications

File Format

File Format Standard:

Print Quality

Print Quality Standard:

High-resolution scans suitable for printing

Binding Type

Binding Type Physical:

N/A (Digital Format)

Paper Type

Paper Type Physical:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

BP-Z3 (common for 2002 NB)

Engine Type:

Naturally aspirated, inline 4-cylinder, DOHC, 16-valve

Displacement:

1.8 Liters (1839 cc)

Bore X Stroke:

83.0 mm x 85.0 mm

Compression Ratio:

9.5:1

Horsepower Peak:

140-145 hp @ 6500 rpm (varies slightly by market and specific tune)

Torque Peak:

119-120 lb-ft @ 5000 rpm

Performance

Redline:

7000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Port Injection

Fuel Type:

Unleaded gasoline (Premium recommended)

Fuel Tank Capacity:

50 Liters (13.2 US Gallons)

Engine Management

ECU Type:

Mazda branded ECU (specific model number would be in manual)

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil-Near-Plug (CNP) depending on exact build date.

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type:

4-speed Automatic Transmission (less common on MX-5)

Features

Gear Ratios Manual 5Speed:

Specific ratios vary, but typically close-ratio for sporty feel.

Clutch Type:

Hydraulically operated, single dry plate

Maintenance

Manual Transmission Fluid Type:

GL-4 Manual Transmission Fluid (e.g., 75W-90)

Automatic Transmission Fluid Type:

Dexron III (or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 3955 mm (155.7 inches)

Width:

Approx. 1675 mm (65.9 inches)

Height:

Approx. 1230 mm (48.4 inches)

Wheelbase:

Approx. 2265 mm (89.2 inches)

Ground Clearance:

Approx. 120 mm (4.7 inches)

Interior

Seating Capacity:

Cargo

Trunk Volume:

Approx. 150 Liters (5.3 cubic feet)

Weights

Curb Weight Manual:

Approx. 1070 - 1100 kg (2359 - 2425 lbs)

Wheelbase Measurement:

Center to center of front and rear wheels

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Good (for NB generation, specific model year testing varies)

NHTSA Side Impact Driver:

Acceptable (for NB generation)

IIHS Front Offset:

Good (for NB generation)

Active Features

Anti-lock Braking System (standard on most trims)

Traction Control:

Traction Control System (TCS) available on some models/trims

Passive Features

Airbags:

Driver and Passenger Frontal Airbags

Rollover Protection:

Pop-up roll bar behind seats (structural reinforcement)

Seatbelts:

Three-point inertia-reel seatbelts with pre-tensioners

💡 Technology Features

Infotainment

Audio System:

Factory fitted AM/FM/CD player, often with optional premium sound system and amplifier.

Navigation:

Not typically factory installed on the 2002 model. Aftermarket options common.

Driver Assistance

Cruise Control:

Available as an option or standard on higher trims.

Connectivity

Auxiliary Input:

Not standard. Aftermarket solutions for AUX/USB/Bluetooth connectivity are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Engine Air Filter Replacement:

Every 15,000 miles or 12 months

Cabin Air Filter Replacement:

Every 15,000 miles or 12 months (if equipped)

Spark Plug Replacement:

Every 30,000 miles (standard plugs) or 60,000 miles (long-life plugs like Iridium)

Transmission Fluid Change:

Manual: 60,000 miles; Automatic: 30,000-50,000 miles

Coolant Flush:

Every 30,000 miles or 24 months

Fluid Specifications

Engine Oil Type:

API SG/SH or ILSAC GF-2, SAE 5W-30 (recommended)

Engine Oil Capacity:

Approx. 3.7 Liters (3.9 US Quarts) with filter change

Coolant Type:

Mazda Genuine Long Life Coolant or equivalent (Ethylene Glycol based, typically green or blue)

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Oil Consumption:

Some engines may develop increased oil consumption with age, requiring monitoring and top-offs. Ring sealing issues are a potential cause addressed in detailed repair sections.

Radiator Plastic Tanks:

Plastic end tanks on the original radiator can become brittle and crack over time, leading to leaks.

Rear Main Seal Leak:

Potential for rear main crankshaft seal leaks, particularly on higher-mileage vehicles.

Clutch Actuator Seal:

Leaking slave cylinder seals can affect clutch operation.

Exhaust Manifold Cracks:

Older exhaust manifolds can develop hairline cracks, leading to exhaust leaks and a ticking sound.

📚 Vehicle History

Brand Heritage

Mazda Brand Philosophy:

Jinba Ittai ('horse and rider as one') - emphasizing driver connection and control

Model Evolution

Mx-5 Legacy:

Successor to the groundbreaking NA generation, continuing the lightweight roadster formula.

Nb Generation Introduction:

Introduced in late 1998 for the 1999 model year, running until 2005.

Nb Facelift:

Facelifted in 2000 for the 2001 model year with updated styling, improved aerodynamics, and minor mechanical tweaks. The 2002 model falls within this facelifted NB generation.

Production

Manufacturing Location:

Mazda's Ujina Plant in Hiroshima, Japan

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The MX-5 (Miata) has frequently appeared on Car and Driver's 10Best lists in previous generations, setting a high standard for the brand's sports cars.

Overall Reputation:

Consistently praised for its handling, reliability (when maintained), and pure driving experience, cementing its status as a modern classic.