Mazda MPV 1999 2000 2001 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: MPV Model Generation: LW (Second Generation) Model Years Covered: 1999, 2000, 2001, 2002 Codes Chassis Code: LW3W, LWFW 👋 Introduction Market Position Vehicle Segment: Compact Minivan / Multi-Purpose Vehicle (MPV) Target Audience: Families, individuals needing flexible cargo and passenger space. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Chrysler Town & Country/Dodge Caravan, Ford Windstar, Mercury Villager. Key Features Unique Selling Points: Sporty handling for its class, sliding rear doors, flexible seating configurations, available all-wheel drive (AWD on some models/markets). Manual Value Proposition: Empowers owners and independent technicians with the detailed knowledge required for accurate diagnosis and repair, reducing reliance on dealership service and potentially saving significant costs. 📋 Manual Details Coverage Areas Primary Regions Covered: North America, Europe, Asia (specific market variations may apply) Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system (belts/chains), lubrication, cooling system. Engine Fuel And Emissions: Fuel delivery, injection system (MPI), evaporative emission control (EVAP), exhaust system, catalytic converter, EGR system. Engine Electrical: Ignition system, starter motor, alternator, battery, engine control module (ECM/PCM) diagnostics and wiring. Transmission Automatic: Internal components, valve body, torque converter, external controls, fluid and filter service, troubleshooting. Drivetrain: Front-wheel drive (FWD) system, drive axles, CV joints, differential. Suspension: Front and rear suspension components (struts, shocks, control arms, bushings), alignment specifications. Steering: Power steering system (pump, rack and pinion, hoses), steering column, wheel alignment. Brakes: Front and rear disc brakes, hydraulic system, ABS (Anti-lock Braking System) components and diagnostics, parking brake. Electrical System: 12V power supply, battery, charging system, lighting (headlights, taillights, interior), horn, wipers, washers, power windows, power locks, mirrors. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system operation, components (compressor, condenser, evaporator, blower motor), refrigerant, troubleshooting. Body And Frame: Body panel removal and installation, interior trim, doors, hood, tailgate, glass, structural components, rust prevention. Chassis Electrical: Instrument cluster, dashboard indicators, audio system, remote keyless entry, security system. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and top-offs, tire rotation. Component Removal And Installation: Detailed step-by-step guides for major component replacement (e.g., alternator, starter, water pump, fuel pump, brake calipers). Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues across all systems. Engine Rebuild Procedures: Torque specifications for engine fasteners, clearance measurements, piston ring gap, bearing clearances, valve adjustments. Transmission Service: Fluid capacity, fluid type, filter replacement, torque converter drain and fill, shift linkage adjustment. Brake System Service: Brake pad/shoe replacement, rotor resurfacing/replacement, brake fluid flush, ABS bleeding procedures. Electrical Diagnostics: Wiring diagrams for all circuits, fuse and relay locations, diagnostic trouble codes (DTCs) and their meanings, component testing. HVAC Service: Refrigerant charging procedures, leak detection, component replacement (compressor, evaporator), cabin air filter replacement. Bodywork And Trim: Removal and installation of interior panels, door panels, exterior trim pieces, bumper covers, tailgate components. Technical Depth Depth Of Coverage: Comprehensive, covering from basic maintenance to in-depth mechanical and electrical diagnostics and repair. Diagnostic Tools Required: General hand tools, specialized engine tools, diagnostic scan tool (OBD-II), multimeter, pressure gauges. Rebuild Instructions: Detailed instructions for engine and transmission rebuilds with specifications. Specifications Provided: All torque values, clearances, fluid capacities, electrical specifications, and diagnostic parameters. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text content. Print Quality Print Readability: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code 1: FS-DE (2.0L DOHC I4) Engine Displacement 1: 1991 cc (2.0 Liters) Engine Configuration 1: Inline 4-Cylinder, DOHC, 16 Valves Horsepower 1: Approx. 120-130 hp (varies by market and year) Torque 1: Approx. 135-145 lb-ft (varies by market and year) Engine Variants Engine Code 2: G6 (2.5L V6 - optional on later models/markets) Engine Displacement 2: 2490 cc (2.5 Liters) Engine Configuration 2: V6, DOHC, 24 Valves Horsepower 2: Approx. 160-170 hp Torque 2: Approx. 160-170 lb-ft Fuel System Fuel Injection: Multi-Point Fuel Injection (MPI) Recommended Fuel: 87 Octane Unleaded Gasoline (check manual for specific requirements) Engine Features Timing Drive: Timing Belt (FS-DE), Timing Chain (G6 V6) 🔧 Transmission Standard Transmission Type Standard: 4-Speed Automatic (FWD) Optional Transmission Type Optional: 4-Speed Automatic with AWD (available on select models/markets) Features Transmission Fluid Type: Mazda ATF-Type T-IV or equivalent (verify with manual) Transmission Fluid Capacity: Approx. 3.5 - 4.0 Liters (for drain and refill, check manual) 📐 Dimensions Exterior Length: Approx. 179.7 inches (4564 mm) Width: Approx. 71.7 inches (1821 mm) Height: Approx. 67.1 inches (1704 mm) Wheelbase: Approx. 106.5 inches (2705 mm) Interior Seating Capacity: 7 passengers (2-3-2 configuration) Cargo Cargo Volume Behind 3Rd Row: Approx. 15.7 cu...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Model Generation:

LW (Second Generation)

Model Years Covered:

1999, 2000, 2001, 2002

Codes

Chassis Code:

LW3W, LWFW

👋 Introduction

Market Position

Vehicle Segment:

Compact Minivan / Multi-Purpose Vehicle (MPV)

Target Audience:

Families, individuals needing flexible cargo and passenger space.

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Chrysler Town & Country/Dodge Caravan, Ford Windstar, Mercury Villager.

Key Features

Unique Selling Points:

Sporty handling for its class, sliding rear doors, flexible seating configurations, available all-wheel drive (AWD on some models/markets).

Manual Value Proposition:

Empowers owners and independent technicians with the detailed knowledge required for accurate diagnosis and repair, reducing reliance on dealership service and potentially saving significant costs.

📋 Manual Details

Coverage Areas

Primary Regions Covered:

North America, Europe, Asia (specific market variations may apply)

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system (belts/chains), lubrication, cooling system.

Engine Fuel And Emissions:

Fuel delivery, injection system (MPI), evaporative emission control (EVAP), exhaust system, catalytic converter, EGR system.

Engine Electrical:

Ignition system, starter motor, alternator, battery, engine control module (ECM/PCM) diagnostics and wiring.

Transmission Automatic:

Internal components, valve body, torque converter, external controls, fluid and filter service, troubleshooting.

Drivetrain:

Front-wheel drive (FWD) system, drive axles, CV joints, differential.

Suspension:

Front and rear suspension components (struts, shocks, control arms, bushings), alignment specifications.

Steering:

Power steering system (pump, rack and pinion, hoses), steering column, wheel alignment.

Brakes:

Front and rear disc brakes, hydraulic system, ABS (Anti-lock Braking System) components and diagnostics, parking brake.

Electrical System:

12V power supply, battery, charging system, lighting (headlights, taillights, interior), horn, wipers, washers, power windows, power locks, mirrors.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system operation, components (compressor, condenser, evaporator, blower motor), refrigerant, troubleshooting.

Body And Frame:

Body panel removal and installation, interior trim, doors, hood, tailgate, glass, structural components, rust prevention.

Chassis Electrical:

Instrument cluster, dashboard indicators, audio system, remote keyless entry, security system.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and top-offs, tire rotation.

Component Removal And Installation:

Detailed step-by-step guides for major component replacement (e.g., alternator, starter, water pump, fuel pump, brake calipers).

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues across all systems.

Engine Rebuild Procedures:

Torque specifications for engine fasteners, clearance measurements, piston ring gap, bearing clearances, valve adjustments.

Transmission Service:

Fluid capacity, fluid type, filter replacement, torque converter drain and fill, shift linkage adjustment.

Brake System Service:

Brake pad/shoe replacement, rotor resurfacing/replacement, brake fluid flush, ABS bleeding procedures.

Electrical Diagnostics:

Wiring diagrams for all circuits, fuse and relay locations, diagnostic trouble codes (DTCs) and their meanings, component testing.

HVAC Service:

Refrigerant charging procedures, leak detection, component replacement (compressor, evaporator), cabin air filter replacement.

Bodywork And Trim:

Removal and installation of interior panels, door panels, exterior trim pieces, bumper covers, tailgate components.

Technical Depth

Depth Of Coverage:

Comprehensive, covering from basic maintenance to in-depth mechanical and electrical diagnostics and repair.

Diagnostic Tools Required:

General hand tools, specialized engine tools, diagnostic scan tool (OBD-II), multimeter, pressure gauges.

Rebuild Instructions:

Detailed instructions for engine and transmission rebuilds with specifications.

Specifications Provided:

All torque values, clearances, fluid capacities, electrical specifications, and diagnostic parameters.

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text content.

Print Quality

Print Readability:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

FS-DE (2.0L DOHC I4)

Engine Displacement 1:

1991 cc (2.0 Liters)

Engine Configuration 1:

Inline 4-Cylinder, DOHC, 16 Valves

Horsepower 1:

Approx. 120-130 hp (varies by market and year)

Torque 1:

Approx. 135-145 lb-ft (varies by market and year)

Engine Variants

Engine Code 2:

G6 (2.5L V6 - optional on later models/markets)

Engine Displacement 2:

2490 cc (2.5 Liters)

Engine Configuration 2:

V6, DOHC, 24 Valves

Horsepower 2:

Approx. 160-170 hp

Torque 2:

Approx. 160-170 lb-ft

Fuel System

Fuel Injection:

Multi-Point Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline (check manual for specific requirements)

Engine Features

Timing Drive:

Timing Belt (FS-DE), Timing Chain (G6 V6)

🔧 Transmission

Standard

Transmission Type Standard:

4-Speed Automatic (FWD)

Optional

Transmission Type Optional:

4-Speed Automatic with AWD (available on select models/markets)

Features

Transmission Fluid Type:

Mazda ATF-Type T-IV or equivalent (verify with manual)

Transmission Fluid Capacity:

Approx. 3.5 - 4.0 Liters (for drain and refill, check manual)

📐 Dimensions

Exterior

Length:

Approx. 179.7 inches (4564 mm)

Width:

Approx. 71.7 inches (1821 mm)

Height:

Approx. 67.1 inches (1704 mm)

Wheelbase:

Approx. 106.5 inches (2705 mm)

Interior

Seating Capacity:

7 passengers (2-3-2 configuration)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 15.7 cu ft (445 Liters)

Cargo Volume Behind 2Nd Row:

Approx. 41.6 cu ft (1178 Liters)

Weights

Curb Weight:

Approx. 3500-3800 lbs (1588-1724 kg) depending on configuration

Gross Vehicle Weight Rating:

Varies by model (consult manual)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

Not rated or 4 stars (depending on year and specific tests)

NHTSA Frontal Impact Passenger:

Not rated or 4 stars (depending on year and specific tests)

IIHS Frontal Offset:

Acceptable or Good (depending on year and specific tests)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags (on some models)

Seatbelts:

3-point seatbelts in all seating positions, pretensioners for front seats.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD or Cassette player with optional premium sound system. Aftermarket head unit installation is common.

Navigation:

Not typically available from the factory on this generation.

Driver Assistance

Cruise Control:

Standard on most trims.

Parking Sensors:

Not typically available from the factory.

Connectivity

Auxiliary Input:

Not typically available from the factory.

Bluetooth:

Not available from the factory; requires aftermarket installation.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months (whichever comes first), using synthetic oil (check manual for exact intervals).

Engine Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions.

Engine Oil Filter Replacement:

Replace with every oil change.

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Transmission Fluid Change Interval:

Every 60,000 miles (96,000 km) or 4 years (severe service may require more frequent changes).

Timing Belt Replacement:

Every 90,000 miles (144,000 km) or 7 years for FS-DE engine (critical maintenance item).

Spark Plug Replacement:

Iridium spark plugs: 100,000 miles (160,000 km). Platinum spark plugs: 60,000 miles (96,000 km). (Verify type and interval).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 API SG/SH/SJ (Synthetic recommended) - Check manual for latest specifications.

Coolant Type:

Mazda Long Life Antifreeze/Coolant (Blue) or equivalent HOAT coolant. Mixture ratio: 50/50.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Engine Idle Roughness:

Can be caused by dirty throttle body, vacuum leaks, or faulty ignition components.

Automatic Transmission Slipping:

Often related to low fluid level, worn clutches, or issues with the valve body. Regular fluid changes are crucial.

Power Steering Pump Noise:

Can occur due to low fluid level or a failing pump.

Suspension Noise:

Worn ball joints, tie rod ends, or bushings can lead to clunking or rattling sounds.

HVAC Blower Motor Failure:

Blower motor resistor or the motor itself can fail, affecting cabin temperature control.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Zoom-Zoom (driving dynamics, spirited performance, Jinba Ittai - horse and rider as one).

Model Evolution

First Generation Mpv:

Introduced in 1988 as a smaller, car-based MPV with rear-wheel drive or optional all-wheel drive, often with a compact RWD platform.

Second Generation Lw Mpv:

Launched in 1999, adopting a dedicated FWD minivan platform, shared with the Ford Windstar. Larger dimensions and more car-like driving dynamics.

Third Generation Mpv:

Introduced in 2006, a more significantly restyled model with suicide rear doors and different powertrain options.

Production

Manufacturing Location:

Hofu, Yamaguchi Prefecture, Japan (for North American market variants)

Production Period:

1999-2006 for the LW generation.

🏆 Awards & Recognition

Recognitions

Car And Driver Best 10:

Mazda MPV has appeared on Car and Driver's 10Best list in previous generations, reflecting Mazda's emphasis on driving dynamics.

Ratings

Consumer Reports Reliability:

Variable; often rated average to below average for this generation, with specific models/years showing more issues than others. The manual is crucial for addressing common problems.