Mazda MPV 2002 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: MPV Year: 2002 Codes Chassis Code: LW Series 👋 Introduction Market Position Segment: Compact MPV (Multi-Purpose Vehicle) / Minivan Competitive Analysis Competitors 2002:...

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Type: Car

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Sku: 468770

Tags: 2002 Car Cars Mazda Misc MPV

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Year:

Codes

Chassis Code:

LW Series

👋 Introduction

Market Position

Segment:

Compact MPV (Multi-Purpose Vehicle) / Minivan

Competitive Analysis

Competitors 2002:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Dodge Caravan/Grand Caravan.

Key Features

Body Style:

Front-engine, front-wheel drive (FWD) or optional all-wheel drive (AWD) compact minivan.

Seating Capacity:

Typically seats 6 or 7 passengers with 2-3 rows of seating.

Value Proposition

Manual Value:

Enables DIY maintenance and repairs, saving on labor costs and extending vehicle lifespan.

📋 Manual Details

Coverage Areas

General Coverage:

Complete factory service, repair, and workshop information for the 2002 Mazda MPV.

Page Count

Estimated Pages:

Over 1500 pages (typical for a comprehensive factory service manual of this era).

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, repair, cylinder head, pistons, crankshaft, camshaft, timing system, lubrication system.

Engine Management:

Fuel injection system, ignition system, emission control systems (EGR, EVAP), engine control module (ECM) diagnostics and repair.

Transmission Automatic:

Automatic transmission (e.g., FNR5) repair, overhaul, diagnosis, control systems, fluid specifications, torque converter.

Transmission Manual:

Manual transmission (if applicable to specific trims) repair, overhaul, clutch system.

Drivetrain:

Front-wheel drive (FWD) system, drive shafts, CV joints, differentials, rear differential (for AWD if applicable).

Suspension:

Front suspension (struts, control arms, stabilizer bar), rear suspension (multi-link, shock absorbers, springs), alignment specifications.

Brakes:

Front disc brakes, rear drum/disc brakes (depending on configuration), ABS system, hydraulic system, parking brake.

Steering:

Power steering system (hydraulic pump, rack and pinion), steering column, linkage.

Electrical System:

Battery, charging system (alternator), starting system, lighting system, power windows, locks, mirrors, wipers, horn.

Body And Chassis:

Body panel removal and installation, interior trim, exterior trim, glass replacement, chassis components.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant handling.

Safety Systems:

Airbag system diagnosis and service, seatbelt mechanisms.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad replacement, belt inspection and replacement.

Diagnostics:

Troubleshooting charts, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical schematic interpretation.

Repair:

Step-by-step repair procedures for all major vehicle systems, component replacement, assembly and disassembly instructions.

Overhaul:

Detailed instructions for complete overhaul of engine and transmission components.

Specifications:

Torque specifications for all fasteners, clearances, measurements, alignment data, diagnostic parameters.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems.

Technical Depth

Depth:

Factory-level detail, covering everything from basic maintenance and troubleshooting to complex component overhauls and electrical system diagnostics.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution, clear text and graphics suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Text Search:

Yes (fully searchable text within the PDF document).

Usability

Device Compatibility:

Compatible with computers, tablets, and smartphones.

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE

Engine Type:

2.0L DOHC 16-valve Inline-4 (I4)

Displacement:

1991 cc

Performance

Horsepower:

Approx. 125-130 hp @ 6000 rpm (depending on market and specific tuning)

Torque:

Approx. 135-140 lb-ft @ 4300 rpm (depending on market and specific tuning)

Fuel System

Induction:

Electronic Fuel Injection (EFI), Multi-point Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Engine Management

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil Packs.

Cooling System

Coolant Capacity:

Approx. 7.0-7.5 Liters (including heater core and reservoir).

🔧 Transmission

Standard

Type:

4-Speed Automatic Transmission

Optional

Type:

All-Wheel Drive (AWD) System (optional on select trims).

Features

Automatic Transmission Code:

Likely a variant of the Mazda FNR5 or similar 4-speed automatic.

Fluid Specifications

Atf Type:

Mazda ATF-III or equivalent Dexron III/Mercon compatible fluid. Consult manual for exact specification.

Fluid Capacity

Transmission Fluid Capacity:

Approx. 7.5 - 8.5 Liters (dry fill, service refill will be less).

📐 Dimensions

Exterior

Length:

Approx. 4685 mm (184.4 inches)

Width:

Approx. 1750 mm (68.9 inches)

Height:

Approx. 1655 mm (65.2 inches)

Wheelbase:

Approx. 2805 mm (110.4 inches)

Weights

Curb Weight:

Approx. 1600-1750 kg (3527-3858 lbs) depending on configuration.

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 470 Liters (16.6 cubic feet)

Cargo Volume With 3Rd Row Folded:

Approx. 1590 Liters (56.2 cubic feet)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

Likely 4-star rating for driver and passenger based on 2002 standards (requires specific NHTSA data).

IIHS Side Crash Test:

Good rating typical for vehicles of this class and era designed with side impact protection (requires specific IIHS data).

Active Features

Standard Anti-lock Braking System (ABS) on most trims.

Traction Control:

Optional Traction Control System (TCS) on some models.

Passive Features

Airbags:

Front dual airbags (driver and passenger), available side-impact airbags for front occupants.

Seatbelts:

3-point seatbelts with pre-tensioners for front occupants, 3-point seatbelts for rear passengers.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium audio system with amplifier and subwoofer.

Display:

Basic digital or analog climate controls, often a simple digital clock and radio display.

Driver Assistance

Cruise Control:

Standard cruise control on most trims.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors were common features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe driving conditions may require more frequent changes.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement:

Every 60,000 miles (96,000 km) for standard spark plugs, or 100,000 miles (160,000 km) for platinum-tipped plugs (check manual for specific type).

Transmission Fluid Change:

Every 30,000 miles (48,000 km) or 24 months, especially for vehicles used for towing or in severe conditions.

Fluid Specifications

Engine Oil Viscosity:

5W-30 or 10W-30 (API SG/SH/SJ rated).

Engine Coolant:

Mazda FL22 Long Life Coolant or equivalent (pre-diluted ethylene glycol based, green color).

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Known Issues

Ignition Coils:

Premature failure of ignition coils can lead to misfires and rough idling.

Automatic Transmission:

Some units may experience delayed engagement or rough shifting, often related to fluid degradation or solenoid issues.

Front Suspension Components:

Wear in ball joints, tie rod ends, and bushings can lead to clunking noises and steering looseness.

Cv Axles:

Damaged CV boots can lead to joint failure and clicking noises during turns.

HVAC Blower Motor:

Blower motor resistors can fail, leading to loss of fan speeds.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Mazda is known for its 'Zoom-Zoom' philosophy emphasizing driving enjoyment and sporty handling, even in practical vehicles.

Model Evolution

First Generation:

The MPV was first introduced in 1988, pioneering the compact minivan segment.

Second Generation:

The 2002 model belongs to the second generation (LW, 1999-2006), which saw a significant redesign with a more car-like unibody construction, improved styling, and enhanced safety features.

Production

Manufacturing Location:

Japan (primarily Hofu Plant).

Market Focus:

Global market, including North America, Europe, and Asia.

🏆 Awards & Recognition

Recognitions

Car And Driver Best:

While not directly winning major awards in 2002, the MPV consistently received positive reviews for its practicality and driving dynamics within its segment.

Ratings

Consumer Reports:

Consumer Reports often rated the MPV favorably for reliability and practicality in its class during this period, though specific model year ratings vary.