Mazda MPV (1st & 2nd Gen) 1990-2012 OEM Factory Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: MPV Model Nickname: Mazda MPV Generation Generation Covered: 1st Gen (LW series) & 2nd Gen (LW series) Codes Product Code: OEM Factory Service...

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Type: Car

Vendor:

Sku: 464333

Tags: 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 Car Cars Mazda Misc MPV

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Model Nickname:

Mazda MPV

Generation

Generation Covered:

1st Gen (LW series) & 2nd Gen (LW series)

Codes

Product Code:

OEM Factory Service Repair Workshop Manual

👋 Introduction

Market Position

Vehicle Type:

Compact MPV (Multi-Purpose Vehicle)

Target Audience:

Families, individuals seeking versatile and practical transportation.

Competitive Analysis

Competitors:

Toyota Sienna, Honda Odyssey, Dodge Caravan/Voyager, Chrysler Town & Country, Ford Windstar.

Key Features

Versatility:

Flexible seating arrangements, ample cargo space, sliding doors (2nd Gen) for easy access.

Handling:

Often praised for car-like handling dynamics compared to other MPVs.

Reliability:

Generally good reliability, especially with proper maintenance.

📋 Manual Details

Coverage Areas

Coverage Years:

1990-2012

Page Count

Estimated Pages:

Extensive (typically 1000+ pages for comprehensive factory manuals)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

All engine variants, diagnostics, repair, rebuild, tuning, emissions control

Transmission:

Automatic transmission (AT), manual transmission (MT) if applicable, diagnostics, repair, rebuild, fluid service

Drivetrain:

Front-wheel drive (FWD), All-wheel drive (AWD) systems, differentials, CV joints, driveshafts

Brakes:

Hydraulic system, ABS, EBD, brake discs, pads, calipers, lines, parking brake

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications

Steering:

Power steering system, steering rack, tie rods, linkage

Electrical:

Battery, charging system, starting system, lighting, ignition, fuses, relays, wiring diagrams

Body And Frame:

Chassis, body panels, doors, windows, interior trim, exterior trim, rust repair

HVAC:

Heating, ventilation, air conditioning system, components, refrigerants, service

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel lines, evaporative emission control

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, pipes, emission control

Cooling System:

Radiator, water pump, thermostat, hoses, coolant specifications

Safety Systems:

Airbag systems, seatbelt mechanisms, SRS (Supplemental Restraint System) diagnostics

Diagnostics:

OBD-II (On-Board Diagnostics) procedures, diagnostic trouble codes (DTCs), diagnostic tools

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, lubrication, tire rotations, spark plug replacement

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults

Repair:

Step-by-step instructions for component replacement and repair

Rebuild:

Complete engine and transmission rebuild procedures, including torque specifications and clearances

Installation:

Instructions for installing aftermarket parts and OEM components

Adjustment:

Component adjustments (e.g., parking brake, clutch, throttle linkage)

Technical Depth

Depth:

Comprehensive factory-level detail, from basic maintenance to complete engine and transmission overhauls.

Diagnostic Scope:

In-depth diagnostic trees, component testing procedures, and electrical troubleshooting guides.

Wiring Diagrams:

Detailed, color-coded wiring diagrams for all electrical systems.

Torque Specs:

Extensive list of all torque specifications for engine, chassis, and body fasteners.

Tolerances:

Precision measurement tolerances for critical engine and transmission components.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text for quick information retrieval.

Print Quality

Quality:

High-resolution digital reproduction of original factory manuals.

Illustrations:

Clear diagrams, schematics, and photographic illustrations.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1 Variant:

2.5L V6 (BP-ZE/AJ) - 1st Gen

Engine 1 Displacement:

2.5 liters

Engine 1 Cylinders:

Engine 1 Configuration:

Engine 1 Fuel Delivery:

Electronic Fuel Injection (EFI)

Engine 1 Horsepower Range:

Approx. 160-170 hp

Engine 1 Torque Range:

Approx. 160-175 lb-ft

Engine 2 Variant:

3.0L V6 (3.0L Ford "Vulcan" engine, later Mazda "J") - 2nd Gen

Engine 2 Displacement:

3.0 liters

Engine 2 Cylinders:

Engine 2 Configuration:

Engine 2 Fuel Delivery:

Electronic Fuel Injection (EFI)

Engine 2 Horsepower Range:

Approx. 190-200 hp

Engine 2 Torque Range:

Approx. 200-210 lb-ft

Performance

Emissions Standard:

Meets applicable federal and state emissions standards for respective model years.

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Typically around 17-18 gallons

🔧 Transmission

Standard

Transmission Type:

4-speed automatic (FWD models)

Optional

Transmission Type AWD:

4-speed automatic (AWD models)

Features

Transmission Control:

Electronic control with adaptive shift logic.

Transmission Fluid Type:

Refer to manual for specific ATF (Automatic Transmission Fluid) specification (e.g., Mazda ATF J).

📐 Dimensions

Exterior

Length:

Varies by generation, approx. 180-184 inches

Width:

Varies by generation, approx. 70-71 inches

Height:

Varies by generation, approx. 67-69 inches

Wheelbase:

Varies by generation, approx. 106-108 inches

Ground Clearance:

Approximately 5.5-6 inches

Interior

Seating Capacity:

7-passenger configuration standard (2-2-3 or 2-3-2 layout)

Cargo

Cargo Volume Behind 3Rd Row:

Significant, designed for family utility.

Cargo Volume With 3Rd Row Folded:

Substantially increased, maximizing utility.

Weights

Curb Weight:

Approx. 3,700 - 4,200 lbs (depending on configuration and drivetrain)

Gross Vehicle Weight Rating:

Refer to vehicle's VIN plate for specific GVWR.

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

Varies by year and testing; consult NHTSA records for specific ratings.

IIHS Side Impact:

Varies by year and testing; consult IIHS records for specific ratings.

Active Features

Anti-lock Braking System standard on most models.

Traction Control:

Available on some AWD models and later trims.

Passive Features

Airbags:

Front airbags standard; side airbags available on later models/trims.

Seat Belts:

Three-point seat belts in all seating positions, pretensioners with force limiters for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system on designated rear seats.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, cassette tape player (early models), available premium sound systems.

Display:

Basic digital or analog displays for radio and climate control.

Driver Assistance

Cruise Control:

Standard on most trims.

Parking Sensors:

Rarely available, not a common feature.

Connectivity

Aux Input:

Not standard, may be added aftermarket.

Bluetooth:

Not available from factory, aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000 - 7,500 miles or 6-12 months, depending on oil type and driving conditions.

Air Filter Replacement:

Every 15,000 - 30,000 miles or as needed based on inspection.

Cabin Air Filter Replacement:

Every 15,000 - 30,000 miles or annually.

Spark Plug Replacement:

Varies by plug type: ~30,000 miles for standard, ~60,000-100,000 miles for iridium/platinum.

Transmission Fluid Service:

Every 30,000 - 60,000 miles, depending on driving conditions.

Coolant Flush:

Every 30,000 - 50,000 miles or 2-4 years.

Fluid Specifications

Engine Oil Type:

Refer to manual for specific API classification and viscosity (e.g., 5W-30, 10W-30).

Engine Oil Capacity:

Approx. 4.5 - 5.5 quarts (with filter change), depending on engine.

Coolant Type:

Ethylene glycol-based coolant (e.g., Mazda FL22 Long Life Coolant or equivalent).

Power Steering Fluid:

Refer to manual for specific type (often ATF or dedicated PS fluid).

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Engine Oil Leaks:

Common on higher mileage V6 engines, particularly valve cover gaskets and oil pan seals.

Transmission Hard Shifting:

Can occur with age and fluid degradation; regular fluid service is critical.

Exhaust Manifold Cracks:

Some V6 engines may develop cracks in exhaust manifolds, leading to ticking noises.

Suspension Wear:

Ball joints, control arm bushings, and sway bar links can wear over time, affecting ride and handling.

Power Window Motors:

Occasional failure of power window regulators and motors.

HVAC Blower Motor Failure:

Blower motor resistor or motor itself can fail, impacting cabin climate control.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Focus on driving dynamics ('Jinba Ittai' - horse and rider as one), even in utility vehicles.

Model Evolution

Generation 1 Launch:

Generation 1 Design:

Distinctive 'cab-forward' design, front-wheel drive platform, available all-wheel drive.

Generation 2 Launch:

1999 (for model year 2000 in North America)

Generation 2 Redesign:

Major redesign, increased dimensions, improved styling, longer wheelbase, sliding rear doors introduced.

Engine Change 2Nd Gen:

Shift to 3.0L V6 (Ford-derived, later re-engineered by Mazda) for improved power.

Production

Production Years:

1990-2005 (North America); continued in other markets until 2012.

Manufacturing Location:

Primarily Japan (Hofu Plant) for most models sold globally.

🏆 Awards & Recognition

Recognitions

Car And Driver Best Car List:

Often cited in automotive reviews for its practicality and driving characteristics during its production run.

Ratings

Consumer Reports Reliability:

Varied by year, but generally considered average to above average when properly maintained.

Certifications

Safety Certifications:

Complied with all applicable FMVSS (Federal Motor Vehicle Safety Standards).