TroubleAtlas Score
MAZDA NAVAJO (1991–1994): Technical Data, DTC & Service Schedule
Built 1991–1994 · all production years covered on this single page
4.0L V6 • Gasoline
© Wikimedia Commons CC BY-SA
TroubleAtlas Score
An independent value score for the Mazda Navajo (1991–1994) — reliability, safety, cost, parts, upkeep and documentation. Owing nothing to the manufacturer.
Scorecard · each voice 0–10
Reliabilityn/a
Safety & recallsn/a
Repair cost7.7
Parts & repairability7.3
Maintenance & durabilityn/a
Documentation & support6.2
Independent · Verified · Never for sale
Every figure on this Mazda Navajo (1991–1994) page is aggregated and cross-checked against more than 6.6 million real workshop operations, NHTSA records and OEM technical sources — and updated continuously. No invented estimates.
The Mazda Navajo (1991–1994) is powered by a 4.0L V6 engine. Use the sections below for verified fluids, battery, OEM tyres, the maintenance schedule, recommended parts and the most commonly reported OBD2 fault codes for this vehicle.
Common problems
Common repairs
Fluids & lubricants
Battery
Fault codes (OBD2)
Dashboard lights
Parts comparator
Accessories & tools
Tyres
Recalls & TSB
Complaints
Workshops nearby
COMMON PROBLEMS
Transmission fault signal (TCM)MODERATE
The transmission module detected a fault — check separate transmission codes.
Related codes: P0700
Misfire / Loss of cylinderMODERATE
Rough running, idle vibration, power loss.
Related codes: P0300
Thermostat: coolant temperature lowLOW
Thermostat stuck open — engine does not reach operating temperature.
Related codes: P0128
Battery/system voltage lowLOW
System voltage below 10V — check alternator, battery or wiring.
Related codes: P0562
P0011LOW
Check with an OBD2 scanner.
Related codes: P0011
COMMON REPAIRS
Front brake pads
Difficulty: Easy
0.8h
€56 – €72
Rear brake pads
Difficulty: Easy
0.9h
€63 – €81
Engine oil change
Difficulty: Easy
0.3h
€21 – €27
ABS Module
Difficulty: Medium
2.0h
€140 – €180
AVERAGE INDICATIVE COSTS
Prices may vary by area and workshop.
Full service
€ 120 – € 200
Full brake service
€ 180 – € 300
Spark plug replacement
€ 80 – € 140
Electronic diagnosis
€ 40 – € 70
OFFICIAL LABOUR TIMES (OLP)
Standard labour hours from a database of 6.6M+ real shop operations, with an indicative labour-cost estimate for your country.
Brakes8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| ABS Module | 2.0h | € 90–€ 150 |
| ABS Pump | 2.5h | € 112–€ 187 |
| ABS Tone Ring | 1.5h | € 67–€ 112 |
| ABS Wheel Speed Sensor - Front | 0.8h | € 36–€ 60 |
| ABS Wheel Speed Sensor - Rear | 0.8h | € 36–€ 60 |
| Brake Bleed - All Four | 1.0h | € 45–€ 75 |
| Brake Booster | 2.5h | € 112–€ 187 |
| Brake Booster Check Valve | 0.3h | € 13–€ 22 |
Cooling8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Coolant Bypass Pipe | 1.5h | € 67–€ 112 |
| Coolant Flush | 1.0h | € 45–€ 75 |
| Coolant Reservoir | 0.5h | € 22–€ 37 |
| Coolant Temperature Sensor | 0.5h | € 22–€ 37 |
| Cooling Fan Assembly | 1.0h | € 45–€ 75 |
| Cooling Fan Motor | 1.5h | € 67–€ 112 |
| Cooling Fan Relay | 0.3h | € 13–€ 22 |
| Engine Oil Cooler | 2.0h | € 90–€ 150 |
Electrical8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Airbag - Driver | 1.0h | € 45–€ 75 |
| Airbag - Passenger | 1.5h | € 67–€ 112 |
| Airbag - Side | 2.0h | € 90–€ 150 |
| Airbag Module/Computer | 1.0h | € 45–€ 75 |
| Alternator | 1.5h | € 67–€ 112 |
| Alternator Belt | 0.5h | € 22–€ 37 |
| Amplifier | 1.5h | € 67–€ 112 |
| Antenna | 0.5h | € 22–€ 37 |
Engine8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Camshaft Position Sensor | 1.0h | € 45–€ 75 |
| Camshaft R&R | 8.0h | € 360–€ 600 |
| Connecting Rod Bearings | 15.0h | € 675–€ 1125 |
| Crankshaft Position Sensor | 1.0h | € 45–€ 75 |
| Crankshaft R&R | 20.0h | € 900–€ 1500 |
| Cylinder Head R&R | 6.0h | € 270–€ 450 |
| Cylinder Head Resurface | 8.0h | € 360–€ 600 |
| Engine Mount - Front | 1.5h | € 67–€ 112 |
Exhaust8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Air Injection Check Valve | 0.8h | € 36–€ 60 |
| Catalytic Converter - California | 1.5h | € 67–€ 112 |
| Catalytic Converter - Direct Fit | 1.5h | € 67–€ 112 |
| Catalytic Converter - Universal | 2.0h | € 90–€ 150 |
| Downpipe | 2.0h | € 90–€ 150 |
| EGR Cooler | 3.0h | € 135–€ 225 |
| EGR Tube | 1.5h | € 67–€ 112 |
| EGR Valve | 1.0h | € 45–€ 75 |
Fuel system8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Charcoal Canister | 1.0h | € 45–€ 75 |
| EVAP Purge Valve | 0.8h | € 36–€ 60 |
| EVAP Vent Valve | 0.8h | € 36–€ 60 |
| Fuel Cap | 0.1h | € 4–€ 7 |
| Fuel Filler Neck | 1.5h | € 67–€ 112 |
| Fuel Filter | 0.5h | € 22–€ 37 |
| Fuel Filter - In-Tank | 2.0h | € 90–€ 150 |
| Fuel Injector - Single | 1.0h | € 45–€ 75 |
HVAC8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| AC Accumulator | 1.5h | € 67–€ 112 |
| AC Clutch Coil | 1.5h | € 67–€ 112 |
| AC Compressor | 2.5h | € 112–€ 187 |
| AC Compressor Clutch | 2.0h | € 90–€ 150 |
| AC Compressor Oil Add | 0.5h | € 22–€ 37 |
| AC Condenser | 2.5h | € 112–€ 187 |
| AC Evaporator | 6.0h | € 270–€ 450 |
| AC Expansion Valve (TXV) | 4.0h | € 180–€ 300 |
Steering8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Center Link/Drag Link | 1.5h | € 67–€ 112 |
| Electric Power Steering Module | 1.5h | € 67–€ 112 |
| Electric Power Steering Motor | 2.5h | € 112–€ 187 |
| Idler Arm | 1.0h | € 45–€ 75 |
| Pitman Arm | 1.2h | € 54–€ 90 |
| Power Steering Fluid Flush | 0.5h | € 22–€ 37 |
| Power Steering Gear Box | 3.5h | € 157–€ 262 |
| Power Steering Hose - High Pressure | 1.0h | € 45–€ 75 |
Suspension8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Air Line | 1.0h | € 45–€ 75 |
| Air Spring/Air Bag | 1.5h | € 67–€ 112 |
| Air Suspension Compressor | 1.5h | € 67–€ 112 |
| Air Suspension Height Sensor | 1.0h | € 45–€ 75 |
| Air Suspension Valve Block | 2.0h | € 90–€ 150 |
| Ball Joint - Lower | 1.8h | € 81–€ 135 |
| Ball Joint - Upper | 1.5h | € 67–€ 112 |
| Ball Joints - Upper and Lower | 3.0h | € 135–€ 225 |
Transmission8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Kickdown Cable | 0.8h | € 36–€ 60 |
| Neutral Safety Switch | 1.0h | € 45–€ 75 |
| Overdrive Solenoid | 2.0h | € 90–€ 150 |
| Shift Cable | 1.5h | € 67–€ 112 |
| Shift Linkage | 1.0h | € 45–€ 75 |
| Transmission Control Module | 1.0h | € 45–€ 75 |
| Transmission Cooler Lines | 1.0h | € 45–€ 75 |
| Transmission Filter | 1.0h | € 45–€ 75 |
WORKSHOP LABOUR RATES BY COUNTRY
Average independent-workshop hourly labour rates, to estimate repair costs in your country.
🇩🇪Germany€95/h
🇪🇸Spain€55/h
🇫🇷France€75/h
🇮🇹Italy€45/h
🇬🇧UK£80/h
🇺🇸USA$120/h
Reference rate
€45/h
Source: Eurostat 2024
📋 RECALLS & TSB (9)
NHTSA 94V169002
Parking Brake › Conventional
Date: 31/10/1994
THE PARKING BRAKE CONTROL SELF-ADJUST PAWL DOES NOT LINE UP PROPERLY WITH THE SELF-ADJUST RACHET CAUSING THE PAWL TO SLIP OVER ONE OR MORE TEETH IN THE RACHET.
NHTSA 95V164002
Structure › Body › Hatchback/Liftgate › Support Device/Strut
Date: 28/08/1995
THE HYDRAULIC LIFT CYLINDERS ARE ATTACHED TO BRACKETS THAT ARE WELDED TO THE LIFTGATE. THE BRACKET WELDS CAN FRACTURE.
NHTSA 96V024002
Service Brakes, Hydraulic › Power Assist › Hydraulic
Date: 28/02/1996
THE STUDS WHICH ATTACH THE BRAKE MASTER CYLINDER TO THE POWER BRAKE VACUUM BOOSTER ASSEMBLY CAN DEVELOP STRESS CORROSION CRACKING AFTER BEING OPERATED FOR AN EXTENDED PERIOD OF TIME IN THE SOUTHERN CALIFORNIA LOCATION.
NHTSA 97V235002
Structure › Body › Roof And Pillars
Date: 25/02/1998
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES EQUIPPED WITH FACTORY INSTALLED SUNROOF. THE SUNROOF GLASS PANEL ASSEMBLY CAN SEPARATE WHILE THE VEHICLE IS MOVING DUE TO INCORRECT HINGE ENGAGEMENT. THIS WAS CAUSED BY IMPROPER SUNROOF INSTALLATION OF THE GLASS PANEL.
NHTSA 99V310002
Structure › Body › Hatchback/Liftgate › Support Device/Strut
Date: 24/11/1999
VEHICLE DESCRIPTION: ON CERTAIN SPORT UTILITY VEHICLES, THE HYDRAULIC LIFT CYLINDER BRACKET WELDS COULD FRACTURE.
NHTSA 00T005000
Tires › Tread/Belt
Date: 21/08/2000
TIRE DESCRIPTION: FIRESTONE WILDERNESS AT, SIZE P235/75R15, PRODUCED AT THE DECATUR, ILLINOIS TIRE PLANT AND ALL FIRESTONE RADIAL ATX AND RADIAL ATX II TIRES, SIZE P235/75R15. OPERATION OF THESE TIRES AT LOW INFLATION PRESSURES, HIGH SPEED, AND IN HOT WEATHER, CAN CONTRIBUTE TO…
NHTSA 91V028000
Structure › Body › Bumpers
Date: 13/02/1991
REAR BUMPER MAY BE SUSCEPTIBLE TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER MOUNTED TRAILER HITCH.
NHTSA 91V020000
Fuel System, Gasoline › Storage › Tank Assembly
Date: 05/01/1991
FRONT HEAT SHIELD EXTENSION MAY CONTACT THE UPPER FRONT CORNER OF PLASTIC FUEL TANK DAMAGING OR PUNCTURING THE FUEL TANK.
NHTSA 91V189001
Power Train › Automatic Transmission
Date: 04/11/1991
WHEN THE AUTOMATIC TRANSMISSION SHIFT LEVER IS PLACED IN THE PARK POSITION, THE PARK PAWL DOES NOT ALWAYS ABUT OR ENGAGE THE PARK GEAR.
COMMON OBD2 CODES TO CHECK
P0420
P0420
Powertrain
P0171
P0171
Powertrain
P0300
P0300
Powertrain
P0128
P0128
Powertrain
P0455
P0455
Powertrain
P0700
P0700
Transmission
P0442
P0442
Powertrain
P0172
P0172
Powertrain
P0401
P0401
Powertrain
All documented fault codes for this vehicle
The most documented diagnostic codes for this model, by system and severity. Tap a code for the full guide.
P0455
powertrain
LOW⏱ 0.62h avgP0442
powertrain
LOW⏱ 0.62h avgP0440
powertrain
LOW⏱ 0.78h avgP0420
powertrain
MEDIUM⏱ 1.24h avgP0300
powertrain
HIGH⏱ 1.22h avgP0172
powertrain
MEDIUM⏱ 1.13h avgP0171
powertrain
MEDIUM⏱ 0.95h avgP0730
transmission
MEDIUM⏱ 1.25h avgP0700
transmission
HIGH⏱ 1.25h avgP0401
powertrain
MEDIUM⏱ 1.25h avgP0011
powertrain
MEDIUM⏱ 5.4h avgU0100
network
HIGHP0562
electrical
MEDIUM⏱ 0.58h avgP0128
powertrain
MEDIUM⏱ 0.88h avg
DASHBOARD WARNING LIGHTS — UNIVERSAL GUIDE
56 warning lights classified by urgency. Appears on your vehicle? Check the urgency level.
Show all dashboard warning lights
🔴 IMMEDIATE STOP — pull over
Oil Pressure WarningEngine
Engine Temperature WarningCooling
Brake System WarningBrakes
Immobilizer / Key FaultSecurity
🟠 WARNING — check soon
Malfunction Indicator Light (MIL) / Check EngineEngine
Diesel Particulate Filter (DPF)Emissions
Battery / Charging SystemElectrical
Low Fuel WarningFuel
ABS WarningBrakes
Brake Pad Wear IndicatorBrakes
Electronic Parking Brake (EPB)Brakes
Power Steering WarningSteering
ESC / Stability Control FaultChassis
Tire Pressure Warning (TPMS)Chassis
Transmission Temperature WarningTransmission
Transmission / Gearbox FaultTransmission
Airbag / SRS WarningActive safety
EGR / Exhaust Gas Recirculation FaultEmissions
Catalytic Converter / Emissions FaultEmissions
AdBlue / DEF Level LowEmissions
Coolant Level LowCooling
Hybrid / EV System WarningHybrid
EV Charge System FaultHybrid
12V Battery (Hybrid/EV Auxiliary)Hybrid
Suspension Fault / Air SuspensionSuspension
CAN Bus / Network Communication FaultNetwork
Water in Fuel FilterFuel
Diesel Injector FaultFuel
Steering Angle Sensor FaultSteering
Turbo / Boost Pressure FaultEngine
Regenerative Braking Fault (Hybrid/EV)Hybrid
i-ACTIVSENSE Fault (Mazda)ADAS
MRCC Fault (Mazda)ADAS
🟡 MONITOR
Fuel Cap / Evap SystemEmissions
4WD / AWD SystemDrivetrain
Bulb Failure WarningLighting
Headlight Range / Leveling FaultLighting
Service / Maintenance DueMaintenance
A/C System FaultHvac
Clutch Wear WarningTransmission
Cruise Control / ACC FaultADAS
🔵 INFORMATION
Engine Temperature Low (Blue)Cooling
Glow Plug / Diesel PreheatEngine
Traction Control / ESC OffChassis
Seatbelt ReminderActive safety
Rear Fog Light IndicatorLighting
Lane Departure / LDWS WarningADAS
Forward Collision Warning (FCW/AEB)ADAS
Blind Spot Monitor FaultADAS
Rear Parking Sensor / Camera FaultADAS
Windshield Washer Fluid LowMaintenance
Door Open WarningBody
Hood / Trunk Open WarningBody
Gear Shift Indicator (Manual)Transmission
Sport / Performance Mode ActiveTransmission
i-stop (Mazda)Engine
REPORTED COMPLAINTS & PROBLEMS (NHTSA)
123 owner complaints filed with the U.S. National Highway Traffic Safety Administration (NHTSA) for the Mazda Navajo across model years 1991–1994. These are real, verified reports submitted by vehicle owners.
8 crash reports 3 fires 7 injuries
Complaints by model year (most reported first)
Model year 199450
Model year 199139
Model year 199322
Model year 199212
Most reported components (all years)
Tires19
Service Brakes19
Hydraulic19
Power Train13
Visibility11
Engine And Engine Cooling11
Sample reports
WHILE DRIVING THE TRUCK THE SUN ROOF ALL OF A SUDDEN SEPARATED WHILE THE TRUCK WAS IN MOTION. *AK (MY 1992)
CONSUMER HAS BEEN EXPERIENCING PROBLEMS WITH SUNROOF. WHILE DRIVING SUNROOF GLASS FLEW OFF. THE MANUFACTURER HAS BEEN CONTACTED. IS IN ACCORDANCE WITH RECALL NUMBER 97V235002.*AK (MY 1991)
THE HEADS WERE SEVERLY CRACKED. THE MECHANIC SAID THAT THIS SHOULD HAVE BEEN RECALLED BECAUSE THERE HAVE , NOT ONLY BEEN SO MANY INSTANCES BUT MANY TIMES, AS WITH THIS CASE THE HEADS WERE SO SEVERLY CRACKED THAT ONLY COMPLETE REPLACEMENT… (MY 1993)
ON NEW OCCASION THE BATTERY EXPLODED . TT (MY 1991)
Source: NHTSA complaints database (U.S. data.gov). Figures cover production years 1991–1994.
Frequently Asked Questions
Does the Mazda Navajo have any safety recalls?
Yes — 9 official NHTSA recall campaign(s) affect this model, mainly: TIRES:TREAD/BELT, STRUCTURE:BODY:BUMPERS, FUEL SYSTEM. Check the recalls section for your exact year/VIN.
What does fault code P0300 mean on the Mazda Navajo?
Random/Multiple Cylinder Misfire Detected This code is among the most documented for this model — tap it in the OBD2 section for the full step-by-step guide.
What does fault code P0128 mean on the Mazda Navajo?
Coolant temperature below thermostat regulating temperature — thermostat stuck open or faulty This code is among the most documented for this model — tap it in the OBD2 section for the full step-by-step guide.
What does fault code P0011 mean on the Mazda Navajo?
A Camshaft Position Timing Over-Advanced or System Performance (Bank 1) This code is among the most documented for this model — tap it in the OBD2 section for the full step-by-step guide.
Are electrical problems common on the Mazda Navajo?
Yes — 8 of 91 real owner reports filed with NHTSA mention the electrical. One owner reported: “A SHORT OCCURRED AT THE JUNCTION OF THE ELECTRICAL CONNECTION TO THE FUEL TANK. THE SHORT MELTED THE PLASTIC CONNECTION AND BURNED THROUGH THE ASSEMBLY TO THE INSIDE OF THE GAS TANK. THERE WAS EVIDE…” See the owner-reported complaints section below for more.
Are steering problems common on the Mazda Navajo?
Yes — 11 of 91 real owner reports filed with NHTSA mention the steering. One owner reported: “BRAKE ROTORS NEEDED TO BE REPLACED, AS WELL AS U JOINTS/ POWER STEERING/BUSHINGS AND WHEEL BEARINGS. DEALE HAS HAD CAR FOR FOUR MONTHS. *AK…” See the owner-reported complaints section below for more.
Are brakes problems common on the Mazda Navajo?
Yes — 20 of 91 real owner reports filed with NHTSA mention the brakes. One owner reported: “BRAKE ROTORS NEEDED TO BE REPLACED, AS WELL AS U JOINTS/ POWER STEERING/BUSHINGS AND WHEEL BEARINGS. DEALE HAS HAD CAR FOR FOUR MONTHS. *AK…” See the owner-reported complaints section below for more.
Which OBD2 fault codes are commonly documented for the Mazda Navajo (1991–1994)?
Commonly documented OBD2 codes across many vehicles include: P0420, P0300, P0171. Find the full description, likely causes and estimated repair costs in the OBD2 Codes section on this page.
How often should the Mazda Navajo (1991–1994) be serviced?
Routine maintenance for the Mazda Navajo (1991–1994) typically includes an oil change every 6,000–9,000 miles (10,000–15,000 km), an air filter every 12,000–18,000 miles (20,000–30,000 km) and a brake inspection every 12,000 miles (20,000 km). Check the full plan with specific intervals in the Scheduled Maintenance section on this page.
Bookmark this page to consult it at the workshop or when buying parts. TroubleAtlas updates its technical data continuously — check back for new information on the Mazda Navajo (1991–1994).