1999 Mazda MPV (2nd gen) Service and Repair Manual

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Basic Information Identification Make: Mazda Model: MPV Year: 1999 Generation Generation: 2nd Generation Codes Platform Code: LW (Global) Introduction Market Position Segment: Compact/Mid-size Minivan Target Audience: Families seeking a versatile...

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Description

Basic Information
Identification
Make:	Mazda
Model:	MPV
Year:	1999
Generation
Generation:	2nd Generation
Codes
Platform Code:	LW (Global)

Introduction
Market Position
Segment:	Compact/Mid-size Minivan
Target Audience:	Families seeking a versatile and practical vehicle.
Competitive Analysis
Key Competitors:	Honda Odyssey, Toyota Sienna, Chrysler Town & Country/Dodge Caravan, Ford Windstar.
Mpv Advantage:	Mazda MPV offered a more car-like driving experience and agile handling compared to some larger minivans, along with optional AWD.
Key Features
Seating Capacity:	Available in 7-passenger configurations.
Door Configuration:	Sliding rear passenger doors (typical for minivans).
Powertrain Options:	Optional All-Wheel Drive (AWD) was a distinguishing feature.

Manual Details
Coverage Areas
Coverage:	All models and all repairs A-Z
Page Count
Estimated Page Count:	1500+
Manual Type
Type:	Factory Service Manual (FSM)
Language
Language:	English
Format
Format:	Printed (assumed, based on typical FSMs)

Manual Coverage
Systems Covered
Engine:	Detailed diagnostics, repair procedures, component testing, and specifications for the 2.5L V6 engine.
Transmission:	In-depth coverage of the 5-speed automatic transmission, including diagnosis, overhaul, hydraulic control systems, and electronic controls.
Drivetrain:	Front-wheel drive and all-wheel drive (AWD) systems, including drive shafts, CV joints, differentials, and hub assemblies.
Suspension:	Front and rear suspension systems, including struts, shock absorbers, control arms, bushings, springs, and alignment procedures.
Brakes:	Disc brakes (front and rear), ABS system diagnosis and repair, brake fluid specifications, component replacement, and bleeding procedures.
Steering:	Power steering system diagnosis, pump, rack and pinion, steering column, and related components.
Cooling System:	Radiator, cooling fans, water pump, thermostat, hoses, and coolant specifications.
Fuel System:	Fuel pump, injectors, fuel filter, fuel lines, and evaporative emissions control (EVAP) system.
Exhaust System:	Exhaust manifolds, catalytic converter, mufflers, and pipes.
Electrical System:	Battery, charging system (alternator), starting system, ignition system, lighting, fuses, relays, and wiring diagrams.
Climate Control:	HVAC system, A/C compressor, refrigerant, heater core, blower motor, and climate control module.
Body And Interior:	Door mechanisms, power windows, locks, seats, interior trim, and body panel repair.
Safety Systems:	Airbag system diagnosis and service, seatbelt mechanisms.
Procedures Included
Maintenance:	Scheduled maintenance tasks, fluid changes, filter replacements, tune-ups, and lubrication.
Troubleshooting:	Diagnostic procedures for common and uncommon faults, using symptom-based troubleshooting guides and diagnostic trouble codes (DTCs).
Repair:	Step-by-step instructions for component removal, installation, and adjustment for all major systems.
Overhaul:	Complete overhaul procedures for the engine and transmission, including disassembly, inspection, measurement, and reassembly.
Diagnostics:	Detailed diagnostic flowcharts, testing procedures for sensors and actuators, and interpretation of diagnostic data.
Wiring Diagrams:	Comprehensive electrical wiring diagrams for all vehicle systems, including component locations and connector pinouts.
Technical Depth
Depth:	Factory-level technical information, suitable for professional technicians and advanced DIYers.
Diagnostics Focus:	Advanced diagnostic strategies and troubleshooting of complex electrical and mechanical issues.
Component Specs:	Precise torque specifications, clearances, tolerances, and wear limits for all critical components.

Manual Specifications
File Format
Digital Format:	PDF (if digital; otherwise, printed)
Print Quality
Quality:	High-resolution, clear text and diagrams (typical for FSMs).
Binding Type
Binding:	Professionally bound or comb-bound (if printed).
Paper Type
Paper:	Durable paper stock suitable for workshop use (if printed).

Engine Specifications
Primary Engine
Engine Code:	J5 (2.5L V6 DOHC)
Displacement:	2490 cc (2.5 Liters)
Configuration:	V6 (60-degree bank angle)
Bore X Stroke:	81.6 mm x 81.0 mm (approx.)
Compression Ratio:	9.2:1 (approx.)
Performance
Horsepower:	168 hp @ 6000 rpm (approx.)
Torque:	155 lb-ft @ 4500 rpm (approx.)
Fuel System
Fuel Delivery:	Electronic Fuel Injection (EFI)
Fuel Type:	Unleaded Gasoline (87 octane recommended)
Ignition System
Ignition Type:	Distributorless Ignition System (DIS)
Emission Control
Emission System:	Catalytic converter, EGR (Exhaust Gas Recirculation), PCV (Positive Crankcase Ventilation), EVAP (Evaporative Emission Control).

Transmission
Standard
Type:	5-speed Automatic Transmission
Optional
Type:	All-Wheel Drive (AWD)
Features
Electronic Control:	Electronically controlled for optimal shift points and fuel economy.
Fluid Type
Transmission Fluid:	Mazda ATF-Type T-IV or equivalent (consult manual for specific part number and specifications).
Fluid Capacity
Transmission Fluid Capacity:	Approx. 3.7 Liters (for initial fill/drain and refill, total capacity higher).

Dimensions
Exterior
Length:	4745 mm (186.8 in)
Width:	1795 mm (70.7 in)
Height:	1680 mm (66.1 in)
Wheelbase:	2900 mm (114.2 in)
Front Track:	1515 mm (59.6 in)
Rear Track:	1510 mm (59.4 in)
Weights
Curb Weight FWD:	1725 kg (3803 lbs) - approx.
Curb Weight AWD:	1800 kg (3968 lbs) - approx.
Gross Vehicle Weight Rating:	2400 kg (5291 lbs) - approx.
Cargo
Cargo Volume Behind 3Rd Row:	16.9 cu ft
Cargo Volume Behind 2Nd Row:	41.1 cu ft
Cargo Volume Max:	113.9 cu ft
Towing
Towing Capacity:	2000 lbs (when properly equipped with trailer brake controller and hitch; consult manual for specifics).

Safety Features
Ratings
NHTSA Frontal Crash:	4-star driver, 4-star passenger (for 1999 model year, specific ratings may vary by test methodology).
IIHS Side Impact:	Acceptable (for models with side airbags, if equipped; specific ratings may vary).
Active Features
ABS:	Anti-lock Braking System (ABS) standard on most trims.
Traction Control:	Optional Traction Control System (TCS) available on some models, particularly AWD.
Passive Features
Airbags:	Driver and front passenger airbags standard. Side airbags optional on higher trims.
Seatbelts:	Three-point seatbelts for all outboard seating positions, with pretensioners for front seats. Lower Anchors and Tethers for Children (LATCH) system.
Rollover Protection:	Reinforced body structure designed to mitigate rollover risks.

Technology Features
Infotainment
Audio System:	Factory AM/FM stereo with CD player and optional cassette player. Speaker configurations varied by trim level.
Display:	Basic digital or analog climate control and radio displays.
Driver Assistance
Cruise Control:	Standard cruise control on most models.
Connectivity
Power Accessories:	Power windows, power door locks, power mirrors, and remote keyless entry (depending on trim).

Maintenance
Service Intervals
Oil Change Interval:	Every 5,000 miles or 6 months, whichever comes first (consult manual for exact recommendation based on driving conditions).
Air Filter Replacement:	Every 15,000 - 30,000 miles or as needed, based on inspection.
Spark Plug Replacement:	Approx. 60,000 - 100,000 miles (depending on spark plug type; iridium recommended for longer life).
Transmission Fluid Change:	Every 30,000 - 60,000 miles (depending on severity of use; drain and refill recommended over flush).
Coolant Replacement:	Every 30,000 - 50,000 miles or 2-3 years.
Fluid Specifications
Engine Oil:	SAE 5W-30 API SG or SH certified (consult manual for exact specification and API category).
Engine Oil Capacity:	4.5 Liters (4.8 US Quarts) with filter change.
Coolant:	Ethylene Glycol based coolant, typically a 50/50 mix with deionized water. Mazda Super Long Life Coolant (FL22) or equivalent.
Brake Fluid:	DOT 3 or DOT 4 (consult manual for specific recommendation).
Known Issues
Engine Mounts:	Wear and tear on engine mounts can lead to vibration and noise.
Exhaust Manifold:	Cracked exhaust manifolds can cause exhaust leaks and ticking noises.
Transmission Slipping:	Early signs of transmission wear or low fluid can lead to slipping.
Power Window Motors:	Failure of power window regulators or motors.
A C System:	Leaking refrigerant lines or failed compressor.

Vehicle History
Brand Heritage
Mazda Philosophy:	Mazda's focus on Jinba-Ittai ('horse and rider as one') driving dynamics, even applied to a minivan.
Model Evolution
1St Gen Mpv:	Original MPV (1988-1998) was more of a tall wagon/compact SUV, often rear-wheel drive.
2Nd Gen Introduction:	The 2nd generation MPV (1999-2006) was a complete redesign, adopting a more conventional minivan platform with front-wheel drive and optional AWD, and a larger overall footprint.
Production
Manufacturing Location:	Hofu, Yamaguchi Prefecture, Japan.
Production Years
Model Years Covered:	1999-2006 (2nd generation globally, specific manual covers 1999 models).

Awards & Recognition
Recognitions
Segment Performance:	Often praised for its driving dynamics and optional AWD compared to competitors.
Ratings
Consumer Reports:	Varied reviews; some model years and powertrains received better ratings than others. Manual would detail specific owner feedback insights.