Mazda MPV Complete Workshop Service Repair Manual 2002
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🏷️ Basic Information Identification Make: Mazda Model: MPV Year: 2002 Codes Chassis Code: LW (Second Generation) 👋 Introduction Market Position Segment: Compact/Mid-size Minivan Target Audience: Families seeking practical and versatile transportation Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Chrysler Town & Country, Ford Windstar Key Features Vehicle Strengths: Unique sliding rear doors for easy access, flexible seating configurations, available AWD (in some markets), refined handling for its class, distinctive styling. Manual Value Proposition: Empowers owners and technicians with detailed, accurate information for efficient and correct servicing, reducing repair costs and downtime. 📋 Manual Details Coverage Areas Regions Covered: North America, Europe, Asia (specific markets may vary) Page Count Estimated Page Count: 1500+ Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Digital Downloadable (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, lubrication, cooling system Engine Management: Fuel injection, ignition system, emissions control, sensor diagnostics, ECU operation Transmission Automatic: Transmission assembly, torque converter, valve body, clutch packs, gear sets, hydraulic control, cooling, removal/installation Drivetrain: Front-wheel drive (FWD), axles, CV joints, differential (transaxle) maintenance and repair Suspension: Front suspension (struts, control arms, ball joints), rear suspension (multi-link design), shock absorbers, springs, anti-roll bars Steering: Power steering system, pump, rack and pinion, steering column, alignment procedures Brakes: Front disc brakes, rear drum or disc brakes (depending on market/trim), ABS system, hydraulic lines, calipers, master cylinder, parking brake Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting, horn, power windows, locks, mirrors, wipers, accessories Body And Chassis: Body panels, doors, hinges, latches, interior trim, underbody, chassis components, rust prevention HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, diagnostics, repair Safety Systems: Airbag system (SRS), seat belt mechanisms, diagnostics and servicing Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical schematics interpretation Repair Procedures: Component removal, installation, and overhaul for all major systems Engine Overhaul: Engine rebuilds, head gasket replacement, timing belt/chain service Transmission Service: Fluid and filter changes, seal replacement, complete transmission rebuild Brake Service: Pad and rotor replacement, caliper service, bleeding procedures, ABS component replacement Electrical Diagnostics: Wiring diagrams, component testing, circuit analysis Body Repair: Dent repair, panel replacement, glass replacement, interior component fitting Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and torque specifications. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Text-searchable, allowing for quick location of specific information Print Quality Print Readability: High-resolution diagrams and text, suitable for professional printing Binding Type Binding: Not applicable (Digital Download) Paper Type Paper Quality: Not applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code And Type: FS-DE (2.0L DOHC I4) and AJ-DE (2.5L DOHC V6) - Note: Specific engine availability varies by market and trim. Performance 2.5L V6 (Aj-De) Horsepower: Approx. 170-175 hp @ 6000 rpm (varies by market) 2.5L V6 (Aj-De) Torque: Approx. 175-180 lb-ft @ 4000-4500 rpm (varies by market) 2.0L I4 (Fs-De) Horsepower: Approx. 120-130 hp (less common in North America for 2002) 2.0L I4 (Fs-De) Torque: Approx. 130-140 lb-ft Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), sequential multi-port Fuel Type: Unleaded gasoline (87 octane recommended for V6) Maintenance Timing Belt Replacement Interval: Refer to specific vehicle maintenance schedule; typically 60,000-90,000 miles or 5-7 years for the V6 AJ-DE. The 2.0L may have a timing chain. 🔧 Transmission Standard Type: 4-speed Automatic Transmission (4EAT or similar) Optional Drivetrain: All-Wheel Drive (AWD) availability on select models Features Transmission Fluid Type: Mazda ATF-MV (or equivalent Dexron III/Mercon compatible fluid, always verify) 📐 Dimensions Exterior Length: Approx. 177.4 inches (4505 mm) Width: Approx. 71.7 inches (1820 mm) Height: Approx. 66.5 inches (1690 mm) Wheelbase: Approx. 105.1 inches (2670 mm) Weights Curb Weight: Approx. 3500-3800 lbs (1588-1724 kg) depending on configuration Gross Vehicle Weight Rating Gvwr: Typically around 4800-5000 lbs 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: 4-star (driver), 5-star (passenger) - reflects general safety for the era IIHS Offset Front Crash Test Rating: Good (for models tested) Active Features ABS: Standard Anti-lock Braking System Traction Control: Available on AWD models, potentially optional on FWD Passive Features Airbags: Front driver and passenger airbags, optional side airbags Seat Belts: 3-point seat belts in all seating positions, pretensioners for front seats 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio systems with more speakers and subwoofer. Navigation: Optional factory navigation system available on higher trims. Driver Assistance Cruise Control: Standard cruise control system. Connectivity Auxiliary Input: Generally not standard; aftermarket solutions for AUX or USB connectivity are common. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles or 6-12 months with synthetic oil, or as per...
Families seeking practical and versatile transportation
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Chrysler Town & Country, Ford Windstar
Key Features
Vehicle Strengths:
Unique sliding rear doors for easy access, flexible seating configurations, available AWD (in some markets), refined handling for its class, distinctive styling.
Manual Value Proposition:
Empowers owners and technicians with detailed, accurate information for efficient and correct servicing, reducing repair costs and downtime.
📋 Manual Details
Coverage Areas
Regions Covered:
North America, Europe, Asia (specific markets may vary)
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and torque specifications.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Text-searchable, allowing for quick location of specific information
Print Quality
Print Readability:
High-resolution diagrams and text, suitable for professional printing
Binding Type
Binding:
Not applicable (Digital Download)
Paper Type
Paper Quality:
Not applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
FS-DE (2.0L DOHC I4) and AJ-DE (2.5L DOHC V6) - Note: Specific engine availability varies by market and trim.
Performance
2.5L V6 (Aj-De) Horsepower:
Approx. 170-175 hp @ 6000 rpm (varies by market)
2.5L V6 (Aj-De) Torque:
Approx. 175-180 lb-ft @ 4000-4500 rpm (varies by market)
2.0L I4 (Fs-De) Horsepower:
Approx. 120-130 hp (less common in North America for 2002)
Approx. 3500-3800 lbs (1588-1724 kg) depending on configuration
Gross Vehicle Weight Rating Gvwr:
Typically around 4800-5000 lbs
🛡️ Safety Features
Ratings
NHTSA Front Crash Test Rating:
4-star (driver), 5-star (passenger) - reflects general safety for the era
IIHS Offset Front Crash Test Rating:
Good (for models tested)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Available on AWD models, potentially optional on FWD
Passive Features
Airbags:
Front driver and passenger airbags, optional side airbags
Seat Belts:
3-point seat belts in all seating positions, pretensioners for front seats
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio systems with more speakers and subwoofer.
Navigation:
Optional factory navigation system available on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Auxiliary Input:
Generally not standard; aftermarket solutions for AUX or USB connectivity are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles or 6-12 months with synthetic oil, or as per owner's manual recommendations.
Air Filter Replacement Interval:
Every 15,000-30,000 miles or as needed based on driving conditions.
Cabin Air Filter Replacement Interval:
Typically every 15,000-20,000 miles or annually.
Fluid Specifications
Engine Oil Type And Viscosity:
API SG or SH, ILSAC GF-II or GF-III. Viscosity typically SAE 5W-30 or 10W-30 depending on ambient temperature (refer to manual for exact specification).
Engine Oil Capacity:
Approx. 4.5 quarts (4.3L) for 2.5L V6 with filter.
DOT 3 or DOT 4, depending on specific model requirements.
Known Issues
Common Wear Item:
Front struts and bushings, rear suspension components (especially for AWD models), CV joints, and exhaust system components can experience wear over time.
Engine Vibration:
Some V6 engines might exhibit minor vibrations at idle if engine mounts are worn or due to carbon buildup. Ensure proper engine mount inspection and cleaning of intake manifold/throttle body.
Transmission Shifting:
Erratic shifting or slipping can indicate low fluid, worn clutch packs, or issues with the valve body. Regular fluid and filter changes are crucial.
Power Sliding Doors:
The motors and mechanisms for the power sliding doors can require lubrication or adjustment over time to ensure smooth operation.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Mazda is known for its Jinba Ittai philosophy ('horse and rider as one'), emphasizing driving dynamics and driver engagement, even in practical vehicles like the MPV.
Model Evolution
Generation Designation:
The 2002 model year marks the second generation of the Mazda MPV (LW platform), introduced for the 1999 model year in Japan and later globally. It moved from a body-on-frame construction to a unibody platform, transitioning from a rear-wheel-drive truck-based van to a front-wheel-drive minivan.
Facelift Notes:
The second generation received a significant refresh for the 2002 model year, including updated styling (grille, headlights, taillights), interior enhancements, and the introduction of the more powerful 2.5L V6 engine and optional AWD in North America.
Production
Manufacturing Locations:
Primarily Hofu, Yamaguchi Prefecture, Japan
🏆 Awards & Recognition
Recognitions
Family Car Awards:
While specific awards for the 2002 model are not widely publicized, the MPV line has historically been recognized for its practicality and value as a family vehicle.