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Mazda MPV 1999 2000 2001 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: MPV Model Generation: LW (Second Generation) Model Years Covered: 1999, 2000, 2001, 2002 Codes Chassis Code: LW3W, LWFW 👋 Introduction Market Position Vehicle...
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Mazda MPV 1999 2000 2001 2002 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
MPV
Model Generation:
LW (Second Generation)
Model Years Covered:
1999, 2000, 2001, 2002
Codes
Chassis Code:
LW3W, LWFW
👋 Introduction
Market Position
Vehicle Segment:
Compact Minivan / Multi-Purpose Vehicle (MPV)
Target Audience:
Families, individuals needing flexible cargo and passenger space.
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Chrysler Town & Country/Dodge Caravan, Ford Windstar, Mercury Villager.
Key Features
Unique Selling Points:
Sporty handling for its class, sliding rear doors, flexible seating configurations, available all-wheel drive (AWD on some models/markets).
Manual Value Proposition:
Empowers owners and independent technicians with the detailed knowledge required for accurate diagnosis and repair, reducing reliance on dealership service and potentially saving significant costs.
📋 Manual Details
Coverage Areas
Primary Regions Covered:
North America, Europe, Asia (specific market variations may apply)
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system (belts/chains), lubrication, cooling system.
Engine Fuel And Emissions:
Fuel delivery, injection system (MPI), evaporative emission control (EVAP), exhaust system, catalytic converter, EGR system.
Engine Electrical:
Ignition system, starter motor, alternator, battery, engine control module (ECM/PCM) diagnostics and wiring.
Transmission Automatic:
Internal components, valve body, torque converter, external controls, fluid and filter service, troubleshooting.
Drivetrain:
Front-wheel drive (FWD) system, drive axles, CV joints, differential.
Suspension:
Front and rear suspension components (struts, shocks, control arms, bushings), alignment specifications.
Steering:
Power steering system (pump, rack and pinion, hoses), steering column, wheel alignment.
Brakes:
Front and rear disc brakes, hydraulic system, ABS (Anti-lock Braking System) components and diagnostics, parking brake.
Electrical System:
12V power supply, battery, charging system, lighting (headlights, taillights, interior), horn, wipers, washers, power windows, power locks, mirrors.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system operation, components (compressor, condenser, evaporator, blower motor), refrigerant, troubleshooting.
Body And Frame:
Body panel removal and installation, interior trim, doors, hood, tailgate, glass, structural components, rust prevention.
Chassis Electrical:
Instrument cluster, dashboard indicators, audio system, remote keyless entry, security system.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and top-offs, tire rotation.
Component Removal And Installation:
Detailed step-by-step guides for major component replacement (e.g., alternator, starter, water pump, fuel pump, brake calipers).
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues across all systems.
Engine Rebuild Procedures:
Torque specifications for engine fasteners, clearance measurements, piston ring gap, bearing clearances, valve adjustments.
Transmission Service:
Fluid capacity, fluid type, filter replacement, torque converter drain and fill, shift linkage adjustment.
Brake System Service:
Brake pad/shoe replacement, rotor resurfacing/replacement, brake fluid flush, ABS bleeding procedures.
Electrical Diagnostics:
Wiring diagrams for all circuits, fuse and relay locations, diagnostic trouble codes (DTCs) and their meanings, component testing.
HVAC Service:
Refrigerant charging procedures, leak detection, component replacement (compressor, evaporator), cabin air filter replacement.
Bodywork And Trim:
Removal and installation of interior panels, door panels, exterior trim pieces, bumper covers, tailgate components.
Technical Depth
Depth Of Coverage:
Comprehensive, covering from basic maintenance to in-depth mechanical and electrical diagnostics and repair.
Diagnostic Tools Required:
General hand tools, specialized engine tools, diagnostic scan tool (OBD-II), multimeter, pressure gauges.
Rebuild Instructions:
Detailed instructions for engine and transmission rebuilds with specifications.
Specifications Provided:
All torque values, clearances, fluid capacities, electrical specifications, and diagnostic parameters.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text content.
Print Quality
Print Readability:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
FS-DE (2.0L DOHC I4)
Engine Displacement 1:
1991 cc (2.0 Liters)
Engine Configuration 1:
Inline 4-Cylinder, DOHC, 16 Valves
Horsepower 1:
Approx. 120-130 hp (varies by market and year)
Torque 1:
Approx. 135-145 lb-ft (varies by market and year)
Engine Variants
Engine Code 2:
G6 (2.5L V6 - optional on later models/markets)
Engine Displacement 2:
2490 cc (2.5 Liters)
Engine Configuration 2:
V6, DOHC, 24 Valves
Horsepower 2:
Approx. 160-170 hp
Torque 2:
Approx. 160-170 lb-ft
Fuel System
Fuel Injection:
Multi-Point Fuel Injection (MPI)
Recommended Fuel:
87 Octane Unleaded Gasoline (check manual for specific requirements)
Engine Features
Timing Drive:
Timing Belt (FS-DE), Timing Chain (G6 V6)
🔧 Transmission
Standard
Transmission Type Standard:
4-Speed Automatic (FWD)
Optional
Transmission Type Optional:
4-Speed Automatic with AWD (available on select models/markets)
Features
Transmission Fluid Type:
Mazda ATF-Type T-IV or equivalent (verify with manual)
Transmission Fluid Capacity:
Approx. 3.5 - 4.0 Liters (for drain and refill, check manual)
📐 Dimensions
Exterior
Length:
Approx. 179.7 inches (4564 mm)
Width:
Approx. 71.7 inches (1821 mm)
Height:
Approx. 67.1 inches (1704 mm)
Wheelbase:
Approx. 106.5 inches (2705 mm)
Interior
Seating Capacity:
7 passengers (2-3-2 configuration)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 15.7 cu ft (445 Liters)
Cargo Volume Behind 2Nd Row:
Approx. 41.6 cu ft (1178 Liters)
Weights
Curb Weight:
Approx. 3500-3800 lbs (1588-1724 kg) depending on configuration
Gross Vehicle Weight Rating:
Varies by model (consult manual)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Not rated or 4 stars (depending on year and specific tests)
NHTSA Frontal Impact Passenger:
Not rated or 4 stars (depending on year and specific tests)
IIHS Frontal Offset:
Acceptable or Good (depending on year and specific tests)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS) on some models
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front side-impact airbags (on some models)
Seatbelts:
3-point seatbelts in all seating positions, pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette player with optional premium sound system. Aftermarket head unit installation is common.
Navigation:
Not typically available from the factory on this generation.
Driver Assistance
Cruise Control:
Standard on most trims.
Parking Sensors:
Not typically available from the factory.
Connectivity
Auxiliary Input:
Not typically available from the factory.
Bluetooth:
Not available from the factory; requires aftermarket installation.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months (whichever comes first), using synthetic oil (check manual for exact intervals).
Engine Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on driving conditions.
Engine Oil Filter Replacement:
Replace with every oil change.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or annually.
Transmission Fluid Change Interval:
Every 60,000 miles (96,000 km) or 4 years (severe service may require more frequent changes).
Timing Belt Replacement:
Every 90,000 miles (144,000 km) or 7 years for FS-DE engine (critical maintenance item).
Spark Plug Replacement:
Iridium spark plugs: 100,000 miles (160,000 km). Platinum spark plugs: 60,000 miles (96,000 km). (Verify type and interval).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 API SG/SH/SJ (Synthetic recommended) - Check manual for latest specifications.
Coolant Type:
Mazda Long Life Antifreeze/Coolant (Blue) or equivalent HOAT coolant. Mixture ratio: 50/50.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Idle Roughness:
Can be caused by dirty throttle body, vacuum leaks, or faulty ignition components.
Automatic Transmission Slipping:
Often related to low fluid level, worn clutches, or issues with the valve body. Regular fluid changes are crucial.
Power Steering Pump Noise:
Can occur due to low fluid level or a failing pump.
Suspension Noise:
Worn ball joints, tie rod ends, or bushings can lead to clunking or rattling sounds.
HVAC Blower Motor Failure:
Blower motor resistor or the motor itself can fail, affecting cabin temperature control.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Zoom-Zoom (driving dynamics, spirited performance, Jinba Ittai - horse and rider as one).
Model Evolution
First Generation Mpv:
Introduced in 1988 as a smaller, car-based MPV with rear-wheel drive or optional all-wheel drive, often with a compact RWD platform.
Second Generation Lw Mpv:
Launched in 1999, adopting a dedicated FWD minivan platform, shared with the Ford Windstar. Larger dimensions and more car-like driving dynamics.
Third Generation Mpv:
Introduced in 2006, a more significantly restyled model with suicide rear doors and different powertrain options.
Production
Manufacturing Location:
Hofu, Yamaguchi Prefecture, Japan (for North American market variants)
Production Period:
1999-2006 for the LW generation.
🏆 Awards & Recognition
Recognitions
Car And Driver Best 10:
Mazda MPV has appeared on Car and Driver's 10Best list in previous generations, reflecting Mazda's emphasis on driving dynamics.
Ratings
Consumer Reports Reliability:
Variable; often rated average to below average for this generation, with specific models/years showing more issues than others. The manual is crucial for addressing common problems.
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