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...

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标签: 1999 Car Cars Mazda Misc MPV

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Year:

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

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.