Mazda 3 Axela 2002 Car Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: 3 / Axela Year: 2002 Codes Chassis Code: BK Series (First Generation) Engine Codes: Z6 (1.6L), LF-VE (2.0L), MZR-CD (2.0L Diesel) 👋 Introduction Market Position Market Segment: Compact family car / hatchback. Target Audience: DIY enthusiasts, independent repair shops, fleet maintenance. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Volkswagen Golf. Key Features Driving Dynamics: Renowned for its sporty handling and engaging driving experience. Design Philosophy: Stylish and modern exterior and interior design. Reliability: Generally good reliability record, reflecting Mazda's engineering. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for Mazda 3 / Axela (BK Series, 2002 onwards). Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: Downloadable PDF File Format File Format: PDF Print Quality Print Quality: High-resolution, printable pages. Binding Type Binding Type: Digital Download (N/A for physical binding) Paper Type Paper Type: Digital (N/A for physical paper type) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, rebuild procedures, cylinder head, pistons, crankshaft, camshafts, timing belt/chain, oil pump, lubrication system. Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, EVAP system, fuel lines. Ignition System: Spark plugs, ignition coils, ignition control module (if applicable), wiring diagrams. Cooling System: Radiator, coolant hoses, thermostat, water pump, cooling fan, coolant specifications and capacity. Exhaust System: Exhaust manifold, catalytic converter, mufflers, exhaust pipes, O2 sensors. Transmission Manual: Clutch system, gearbox assembly, gear selection, input/output shafts, bearings, seals, transmission fluid specifications and capacity. Transmission Automatic: Torque converter, planetary gear sets, valve body, transmission control module (TCM), hydraulic system, transmission fluid specifications and capacity. Drivetrain: Front-wheel drive system, drive axles, CV joints, differential. Suspension Front: MacPherson struts, control arms, ball joints, sway bar, bushings, alignment specifications. Suspension Rear: Multi-link or independent rear suspension components, shock absorbers, springs, bushings, alignment specifications. Steering System: Power steering pump, steering rack, tie rod ends, steering column, steering fluid specifications. Brake System: Front and rear brake calipers, rotors, brake pads, master cylinder, brake booster, ABS system, parking brake, brake fluid specifications and bleeding procedures. Wheels And Tires: Wheel specifications, tire pressure recommendations, lug nut torque specifications. Electrical System: Battery, alternator, starter motor, lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams. Engine Control Module: ECM/ECU operation, sensors (crankshaft position, camshaft position, MAF, MAP, O2, coolant temperature), actuators. Body And Interior: Body panels, doors, hood, trunk, bumpers, interior trim, seats, dashboard, HVAC system (controls, ducting, blower motor). Heating Ventilation Air Conditioning: A/C compressor, condenser, evaporator, refrigerant, HVAC control panel, blower motor, cabin air filter. Safety Systems: Airbag system (SRS components, diagnostic procedures), seat belt pre-tensioners. Diagnostic Troubleshooting: General troubleshooting steps, symptom-based diagnostics, fault code interpretation (OBD-II). Procedures Included Scheduled Maintenance: Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, fluid level checks and top-offs. Major Engine Repairs: Engine overhaul, head gasket replacement, piston ring replacement, bearing replacement. Transmission Repair: Clutch replacement, transmission rebuild (manual and automatic), torque converter replacement. Brake System Repair: Brake pad and rotor replacement, caliper rebuild, master cylinder replacement, brake bleeding. Suspension Component Replacement: Strut and shock absorber replacement, control arm replacement, ball joint replacement. Steering System Repair: Power steering pump replacement, steering rack replacement, tie rod end replacement. Electrical Diagnostics: Troubleshooting electrical circuits, component testing, wiring repair. HVAC System Repair: A/C system recharge, component replacement (compressor, condenser), blower motor replacement. Body Panel Repair And Replacement: Door panel removal, fender replacement, bumper repair. Interior Component Removal And Installation: Dashboard disassembly, seat removal, center console removal. Airbag System Diagnostics And Replacement: Safely handling SRS components, diagnostic procedures. Technical Depth Depth Of Coverage: Full factory-level repair information. Diagnostic Capabilities: Detailed diagnostic procedures, sensor data interpretation, troubleshooting flowcharts. Rebuild Procedures: Complete engine and transmission rebuild instructions with torque specifications. Special Tools: Identification of required special tools and their usage. ⚙️ Engine Specifications Primary Engine Engine 1 Code: Z6-VE Engine 1 Type: Inline-4 Cylinder, DOHC, 16-valve Engine 1 Displacement: 1.6 Liters (1598 cc) Engine 1 Bore X Stroke: 78.0 mm x 83.6 mm Engine 1 Compression Ratio: 9.7:1 Engine 1 Horsepower Approx: 103 hp @ 6000 rpm Engine 1 Torque Approx: 146 Nm (108 lb-ft) @ 4000 rpm Optional Engine 1 Engine 2 Code: LF-VE Engine 2 Type: Inline-4 Cylinder, DOHC, 16-valve, Variable Valve Timing (VVT) Engine 2 Displacement: 2.0 Liters (1999 cc) Engine 2 Bore X Stroke: 87.5 mm x 94.0 mm Engine 2 Compression Ratio: 9.7:1 Engine 2 Horsepower Approx: 138 hp @ 6000 rpm Engine 2 Torque Approx: 180 Nm (133 lb-ft) @ 4500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Recommended Fuel: Unleaded gasoline, Octane rating 91 or higher. 🔧 Transmission Standard Manual Transmission: 5-speed manual transmission. Optional Automatic Transmission: 4-speed automatic transmission. Features Transmission Fluid Type Manual: API GL-4, SAE...

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Sku: 494824

Collections: ALL Mazda

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Tags: 2002 3 Axela Car Cars Mazda Misc

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

3 / Axela

Year:

Codes

Chassis Code:

BK Series (First Generation)

Engine Codes:

Z6 (1.6L), LF-VE (2.0L), MZR-CD (2.0L Diesel)

👋 Introduction

Market Position

Market Segment:

Compact family car / hatchback.

Target Audience:

DIY enthusiasts, independent repair shops, fleet maintenance.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Volkswagen Golf.

Key Features

Driving Dynamics:

Renowned for its sporty handling and engaging driving experience.

Design Philosophy:

Stylish and modern exterior and interior design.

Reliability:

Generally good reliability record, reflecting Mazda's engineering.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service and repair for Mazda 3 / Axela (BK Series, 2002 onwards).

Page Count

Estimated Page Count:

1000+

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

Downloadable PDF

File Format

File Format:

Print Quality

Print Quality:

High-resolution, printable pages.

Binding Type

Binding Type:

Digital Download (N/A for physical binding)

Paper Type

Paper Type:

Digital (N/A for physical paper type)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, rebuild procedures, cylinder head, pistons, crankshaft, camshafts, timing belt/chain, oil pump, lubrication system.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, EVAP system, fuel lines.

Ignition System:

Spark plugs, ignition coils, ignition control module (if applicable), wiring diagrams.

Cooling System:

Radiator, coolant hoses, thermostat, water pump, cooling fan, coolant specifications and capacity.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, exhaust pipes, O2 sensors.

Transmission Manual:

Clutch system, gearbox assembly, gear selection, input/output shafts, bearings, seals, transmission fluid specifications and capacity.

Transmission Automatic:

Torque converter, planetary gear sets, valve body, transmission control module (TCM), hydraulic system, transmission fluid specifications and capacity.

Drivetrain:

Front-wheel drive system, drive axles, CV joints, differential.

Suspension Front:

MacPherson struts, control arms, ball joints, sway bar, bushings, alignment specifications.

Suspension Rear:

Multi-link or independent rear suspension components, shock absorbers, springs, bushings, alignment specifications.

Steering System:

Power steering pump, steering rack, tie rod ends, steering column, steering fluid specifications.

Brake System:

Front and rear brake calipers, rotors, brake pads, master cylinder, brake booster, ABS system, parking brake, brake fluid specifications and bleeding procedures.

Wheels And Tires:

Wheel specifications, tire pressure recommendations, lug nut torque specifications.

Electrical System:

Battery, alternator, starter motor, lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams.

Engine Control Module:

ECM/ECU operation, sensors (crankshaft position, camshaft position, MAF, MAP, O2, coolant temperature), actuators.

Body And Interior:

Body panels, doors, hood, trunk, bumpers, interior trim, seats, dashboard, HVAC system (controls, ducting, blower motor).

Heating Ventilation Air Conditioning:

A/C compressor, condenser, evaporator, refrigerant, HVAC control panel, blower motor, cabin air filter.

Safety Systems:

Airbag system (SRS components, diagnostic procedures), seat belt pre-tensioners.

Diagnostic Troubleshooting:

General troubleshooting steps, symptom-based diagnostics, fault code interpretation (OBD-II).

Procedures Included

Scheduled Maintenance:

Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, fluid level checks and top-offs.

Major Engine Repairs:

Engine overhaul, head gasket replacement, piston ring replacement, bearing replacement.

Transmission Repair:

Clutch replacement, transmission rebuild (manual and automatic), torque converter replacement.

Brake System Repair:

Brake pad and rotor replacement, caliper rebuild, master cylinder replacement, brake bleeding.

Suspension Component Replacement:

Strut and shock absorber replacement, control arm replacement, ball joint replacement.

Steering System Repair:

Power steering pump replacement, steering rack replacement, tie rod end replacement.

Electrical Diagnostics:

Troubleshooting electrical circuits, component testing, wiring repair.

HVAC System Repair:

A/C system recharge, component replacement (compressor, condenser), blower motor replacement.

Body Panel Repair And Replacement:

Door panel removal, fender replacement, bumper repair.

Interior Component Removal And Installation:

Dashboard disassembly, seat removal, center console removal.

Airbag System Diagnostics And Replacement:

Safely handling SRS components, diagnostic procedures.

Technical Depth

Depth Of Coverage:

Full factory-level repair information.

Diagnostic Capabilities:

Detailed diagnostic procedures, sensor data interpretation, troubleshooting flowcharts.

Rebuild Procedures:

Complete engine and transmission rebuild instructions with torque specifications.

Special Tools:

Identification of required special tools and their usage.

⚙️ Engine Specifications

Primary Engine

Engine 1 Code:

Z6-VE

Engine 1 Type:

Inline-4 Cylinder, DOHC, 16-valve

Engine 1 Displacement:

1.6 Liters (1598 cc)

Engine 1 Bore X Stroke:

78.0 mm x 83.6 mm

Engine 1 Compression Ratio:

9.7:1

Engine 1 Horsepower Approx:

103 hp @ 6000 rpm

Engine 1 Torque Approx:

146 Nm (108 lb-ft) @ 4000 rpm

Optional Engine 1

Engine 2 Code:

LF-VE

Engine 2 Type:

Inline-4 Cylinder, DOHC, 16-valve, Variable Valve Timing (VVT)

Engine 2 Displacement:

2.0 Liters (1999 cc)

Engine 2 Bore X Stroke:

87.5 mm x 94.0 mm

Engine 2 Compression Ratio:

9.7:1

Engine 2 Horsepower Approx:

138 hp @ 6000 rpm

Engine 2 Torque Approx:

180 Nm (133 lb-ft) @ 4500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

Unleaded gasoline, Octane rating 91 or higher.

🔧 Transmission

Standard

Manual Transmission:

5-speed manual transmission.

Optional

Automatic Transmission:

4-speed automatic transmission.

Features

Transmission Fluid Type Manual:

API GL-4, SAE 75W-90 (Manual)

Transmission Fluid Type Automatic:

Mazda ATF JWS3317 or equivalent (Automatic)

📐 Dimensions

Exterior

Length:

Approx. 4415 mm (Hatchback), 4460 mm (Sedan)

Width:

Approx. 1745 mm

Height:

Approx. 1465 mm (Hatchback), 1435 mm (Sedan)

Wheelbase:

Approx. 2640 mm

Weights

Curb Weight Approx:

1250 kg - 1350 kg (depending on engine and trim)

Gross Vehicle Weight Rating:

Approx. 1750 kg

🛡️ Safety Features

Ratings

NHTSA Rating:

Information not readily available for 2002 models for specific NHTSA ratings. Typically scored well in frontal and side impacts for its era.

Active Features

Standard on most models, Anti-lock Braking System.

Traction Control:

Optional on some higher trims.

Passive Features

Airbags:

Frontal airbags for driver and passenger. Side airbags and curtain airbags available on select trims.

Seatbelts:

Three-point seatbelts with pre-tensioners and force limiters.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM CD player, optional premium audio systems available on higher trims.

Display:

Basic digital display for clock, radio, and climate settings. No integrated navigation on base models.

Driver Assistance

Cruise Control:

Available on most models.

Connectivity

Auxiliary Input:

Not standard; may be an aftermarket addition.

Bluetooth:

Not available on 2002 models; typically introduced in later generations.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Check manual for specific conditions.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Typically around 60,000 - 75,000 miles (96,000 - 120,000 km) for platinum or iridium plugs. Refer to manual for exact interval.

Timing Belt Replacement:

The Z6 and LF-VE engines utilize a timing chain, which generally does not require periodic replacement under normal maintenance. However, the manual will specify any inspection intervals or replacement procedures if wear is detected.

Fluid Specifications

Engine Oil Specification:

SAE 5W-20 or 5W-30, API SN/SP, ILSAC GF-5 or higher.

Engine Oil Capacity:

Approx. 4.0 - 4.5 Liters (4.2 - 4.8 US Quarts) with filter change, depending on engine.

Coolant Specification:

Mazda Super Long Life Coolant (Blue) or equivalent (Ethylene Glycol based, Phosphate-free).

Brake Fluid Specification:

DOT 3 or DOT 4.

Power Steering Fluid Specification:

Mazda Genuine Power Steering Fluid or Dexron III/Mercon compatible ATF.

Known Issues

Common Issues Engine:

Oil leaks from valve cover gasket, minor oil consumption on high-mileage engines, occasional carbon buildup on intake valves.

Common Issues Suspension:

Worn sway bar links, noisy front struts/shocks, worn control arm bushings.

Common Issues Electrical:

Failing power window motors, occasional issues with climate control modules, SRS warning light illumination (often due to wiring or seat occupancy sensor).

Common Issues Exhaust:

Corrosion of exhaust components, particularly in areas with harsh winters.

📚 Vehicle History

Brand Heritage

Mazda History:

Mazda, a Japanese automaker known for its innovative technology and driver-focused vehicles, has a long history of producing reliable and engaging cars.

Model Evolution

Mazda3 First Generation:

The Mazda 3 (also known as Mazda Axela in Japan and other markets) was introduced in 2003 as a 2004 model year vehicle, replacing the Mazda Familia/323. The 2002 model information in the product name likely refers to early production or market introduction timelines for this generation.

Production

Production Locations:

Primarily manufactured in Japan (Hofu) and later in other global locations.

🏆 Awards & Recognition

Recognitions

Car And Driver Awards:

The Mazda 3 (first generation) was frequently featured on Car and Driver's '10Best' lists in subsequent years for its engaging driving dynamics, solidifying its reputation.