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2002-2005 Mazda MPV Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: MPV Model Years Covered: 2002, 2003, 2004, 2005 Generation Generation Designation: LW Series (Second Generation) Codes Chassis Code: LW3W 👋 Introduction Market Position...
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2002-2005 Mazda MPV Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
MPV
Model Years Covered:
2002, 2003, 2004, 2005
Generation
Generation Designation:
LW Series (Second Generation)
Codes
Chassis Code:
LW3W
👋 Introduction
Market Position
Vehicle Segment:
Compact/Mid-size Minivan
Target Demographic:
Families, active individuals requiring versatile cargo and passenger space
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Dodge Grand Caravan, Ford Windstar
Key Features
Unique Selling Points:
Sportier driving dynamics for a minivan, practical sliding doors, flexible seating configurations, available AWD.
Manual Value Proposition:
Empowers owners and independent mechanics with factory-level diagnostic and repair information, reducing reliance on costly dealership services.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Secondary Coverage:
Global markets with similar configurations
Page Count
Estimated Page Count:
2500-3500
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Drivetrain, Exhaust System
Chassis:
Suspension, Steering, Brakes, Wheels and Tires
Electrical:
Ignition System, Charging System, Starting System, Lighting, Instrumentation, Body Electrical, Powertrain Control Module (PCM) and related components
Body:
Body Panels, Doors, Glass, Seats, Interior Trim, HVAC System
Safety Systems:
Airbags, Seatbelts, ABS (Anti-lock Braking System), Traction Control (if equipped)
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad inspection and replacement
Diagnostic Procedures:
Troubleshooting guides for common and uncommon issues, diagnostic trouble codes (DTCs) explanation and resolution
Repair And Overhaul:
Engine component removal and installation, transmission overhaul, brake caliper and rotor replacement, suspension component replacement, electrical component diagnosis and repair
Component Replacement:
Alternator, starter motor, fuel pump, water pump, radiators, AC compressor, power steering pump, CV axles, exhaust components
Special Tools:
Identification and usage of specialized Mazda tools required for specific repairs
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and bodywork repairs.
Audience:
Professional technicians and knowledgeable DIY enthusiasts
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Fully searchable text content for quick information retrieval
Print Quality
Print Readability:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
FS-DE (North America), AJ (Japan)
Engine Type:
2.5L DOHC 24-Valve V6 (FS-DE/AJ)
Bore X Stroke:
84.5 mm x 74.2 mm
Displacement:
2497 cc (2.5 Liters)
Performance
Horsepower Hp:
170 hp @ 6000 RPM (approx.)
Torque Lb Ft:
173 lb-ft @ 4500 RPM (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Regular (87 Octane recommended)
Cooling System
Coolant Capacity Liters:
7.1 L (approx.)
Lubrication
Oil Capacity Quarts:
4.5 US Quarts (with filter)
Recommended Oil Viscosity:
SAE 5W-30
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic
Optional
Optional Transmission:
All-Wheel Drive (AWD) system
Features
Transmission Control:
Electronic Control Unit (ECU) controlled, with adaptive shift logic
Fluid Specifications
Transmission Fluid Type:
Mazda ATF-MV or equivalent DEXRON III/MERCON
Fluid Capacity
Transmission Fluid Capacity Liters:
3.1 L (approx. for dry fill)
📐 Dimensions
Exterior
Length Inches:
186.8 in
Width Inches:
71.7 in
Height Inches:
65.7 in
Wheelbase Inches:
112.4 in
Interior
Passenger Volume Cubic Feet:
123.1 cu ft (approx.)
Cargo
Cargo Volume Behind 3Rd Row Cubic Feet:
18.0 cu ft (approx.)
Cargo Volume Behind 2Nd Row Cubic Feet:
44.0 cu ft (approx.)
Cargo Volume Behind 1St Row Cubic Feet:
87.8 cu ft (approx.)
Weights
Curb Weight Lbs:
3700 - 3900 lbs (depending on configuration)
Gross Vehicle Weight Rating Gvwr Lbs:
5200 lbs (approx.)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test Driver:
4/5 Stars (for 2004 model)
NHTSA Frontal Crash Test Passenger:
4/5 Stars (for 2004 model)
IIHS Front Offset Crash Test:
Good (for comparable models in its class)
Active Features
Braking System:
4-Wheel Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS) on some trims
Passive Features
Airbags:
Driver and front passenger airbags, optional side-impact airbags
Seatbelts:
3-point seatbelts in all seating positions, front pretensioners
Child Safety:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional Bose premium sound system
Navigation:
Optional factory GPS navigation system
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assistance:
Optional rear parking sensors on some trims
Connectivity
Auxiliary Input:
Optional auxiliary audio input jack on later models or aftermarket
🔧 Maintenance
Service Intervals
Oil Change Interval Miles:
Every 7,500 miles or 6 months (synthetic oil recommended)
Engine Air Filter Replacement Miles:
Every 30,000 miles
Cabin Air Filter Replacement Miles:
Every 15,000 miles or annually
Spark Plug Replacement Miles:
Every 100,000 miles (if Iridium type)
Transmission Fluid Change Miles:
Every 45,000 - 60,000 miles
Fluid Specifications
Power Steering Fluid:
Mazda Genuine ATF or Dexron II/III
Brake Fluid:
DOT 3
Coolant:
Mazda Genuine Long Life Antifreeze/Coolant (Blue) or equivalent (50/50 mix with distilled water)
Known Issues
Common Problem 1:
Ignition coil failure (leading to misfires)
Common Problem 2:
Transmission shifting issues or shuddering (fluid and filter changes can help)
Common Problem 3:
CV axle boot wear and tear
Common Problem 4:
Power window regulator failure
Common Problem 5:
Rear liftgate strut failure
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Zoom-Zoom - Emphasizing driving enjoyment and responsiveness.
Model Evolution
First Generation Introduction:
1990
Second Generation Introduction:
1999
Lw Series Redesign:
Significant redesign for the second generation, featuring a more aerodynamic profile and a larger V6 engine.
Production
Manufacturing Location:
Japan (and potentially other Mazda global facilities)
Production End For Model:
2005 (in North America, replaced by larger Mazda CX-9 or other models in the lineup).
🏆 Awards & Recognition
Recognitions
Car And Driver Ranking:
Often listed on Car and Driver's '10 Best Trucks/Vans' lists during its production run for its blend of practicality and driving dynamics.
Ratings
Jd Power Initial Quality:
Generally received average to above-average ratings for initial quality within its segment.
Certifications
Safety Certifications:
Meets or exceeds all applicable federal motor vehicle safety standards (FMVSS).
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