Mazda B Series Training Manual
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Mazda B Series Training Manual

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Mazda BT-50
NMT-009

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  • Page 1 Training Manual Mazda BT-50 NMT-009...
  • Page 2 No part of this hardcopy may be reproduced in any form without prior permission of Mazda Motor Europe GmbH. The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of going to print.

  • Page 3: Table Of Contents

    Table of Contents General Information ................00-1 Product Concept....................00-1 Vehicle Identification Number................00-7 Engine Identification Number ................00-8 Other Vehicle Information Labels ................00-9 Model Plate.....................00-9 Tyre Pressure Label ..................00-9 Technical Data.....................00-10 Jacking and Lifting....................00-11 Towing .........................00-12 Scheduled Maintenance Table ................00-13 Remarks .......................00-15 WL-C Engine ..................01-1 Engine Performance Curve ...................01-1 Overview........................01-2 Mechanical ........................01-3...
  • Page 4 Table of Contents Fuel System ......................01-25 Features ......................01-25 Specifications ......................01-25 Parts Location......................01-26 System Overview....................01-28 High-Pressure Pump ...................01-29 Common Rail.......................01-29 Fuel Injectors .......................01-30 Exhaust System......................01-31 Features ......................01-31 Parts Location......................01-31 Warm up system....................01-32 Wiring Diagram.....................01-32 Exhaust Shutter Valve Solenoid Valve ............01-33 Exhaust Shutter Valve Unit................01-33 Operating Conditions..................01-33 Emission System......................01-34 Features ......................01-34...
  • Page 5 Table of Contents Suspension ..................02-1 Features ........................02-1 Specifications ......................02-1 Parts Location......................02-2 Front Suspension 2WD ..................02-2 Front Suspension 4WD ..................02-2 Rear Suspension ....................02-3 Wheels and Tyres .......................02-4 Specifications ......................02-5 Driveline / Axle...................03-1 Features ........................03-1 Specifications ......................03-1 RFW System ......................03-2 Parts Location....................03-2 System Overview....................03-3 On-Board Diagnostic System .................03-4 Transmission ..................05-1...
  • Page 6 Table of Contents Restraints...................08-1 Airbag System ......................08-1 Features ........................08-1 Parts Location......................08-2 Wiring Diagram......................08-3 SAS Control Module ....................08-4 Side Airbag Sensors....................08-5 Side Airbags ......................08-5 Seat Belt Pretensioners..................08-6 On-Board Diagnostic System ................08-7 Features ......................08-7 Self Test ......................08-7 PID Monitor.....................08-8 Body & Accessories................09-1 Body Panels ........................09-1 Cabin ........................09-1 Ladder Frame ......................09-2...
  • Page 7 Table of Contents Audio System......................09-16 Features ......................09-16 Specifications ......................09-16 Audio Unit .....................09-16 Speakers ......................09-16 Parts Location......................09-17 System Overview....................09-18 On-Board Diagnostic System ................09-20 Self-Test Function ..................09-20 Diagnostic Assist Function ................09-20 Power Systems ......................09-21 Parts Location......................09-21 Instrumentation / Driver Information System ............09-22 Features ......................09-22 Specifications ......................09-22 Instrument Cluster Overview ................09-23...
  • Page 8 Table of Contents Notes: Service Training BT-50...

  • Page 9: General Information

    Product Concept • The new Mazda BT-50 supersedes the B-Series, Mazda’s present pick-up truck. The aim of the BT-50 development team was to create a new pickup model in line with the current model range delivering Mazda’s Zoom-Zoom spirit in its individual and distinctive way.
  • Page 10 General Information • Plane body panels without the formerly used swage lines and other new styling elements contribute to a more brawny, but clear and modern overall styling impression. BT-50_00002 BT-50_00022 00-2 Service Training BT-50...
  • Page 11 General Information • The design and material quality of the interior has been improved and now reminds more of a passenger car than of a pick-up truck. BT-50_00003 • Beside the clearly arranged instrument panel the completely new T-shaped dashboard contains a centre stack panel incorporating the latest modular audio system and the climate control panel, both with easy to operate control elements.
  • Page 12 General Information • New features of the powertrain, such as the 16-valve DOHC-diesel engine with common rail direct injection and Euro 4 emission standard, the dual-mass flywheel or the 5-speed transmission S15M(X)-D contribute to a driving performance and emission output that are comparable to passenger cars.
  • Page 13 General Information • Other well-proven components, which are adopted from the B-Series as e.g. the chassis with the ladder frame and the suspension, are refined by major or minor changes in material, form, and/or dimension. BT-50_00006 • The supplemental restraint system is now enhanced by combined head / side airbags as used on the MX-5 (NC).
  • Page 14 General Information • The BT-50 is basically offered in three different body versions: – REG (REGular) Cabin, available in 2WD or 4WD layout BT-50_00008 – RAP (Rear Access Panel) Cabin (marketing name is ‘Freestyle Cab’), available in 4WD layout BT-50_00009 –...

  • Page 15: Vehicle Identification Number

    F = DBL cab (E)* 2 = RAP cab (1)* Body style 1 = 2WD 8 = 4WD Drive axle Vehicle type UN = Mazda BT-50 World manufacturer indication JMZ = European (L.H.D., U.K.) BT-50_T00001 * without cargo box Service Training BT-50 00-7...

  • Page 16: Engine Identification Number

    General Information Engine Identification Number • The engine identification number of the WL-C engine is located on the timing gear-side of the cylinder block. BT-50_00012 00-8 Service Training BT-50...

  • Page 17: Other Vehicle Information Labels

    General Information Other Vehicle Information Labels Model Plate • The model plate is located on the right side of the bulkhead in the engine compartment. BT-50_00013 Driving direction Tyre Pressure Label • The tyre pressure label is located on the driver’s door as shown below. BT-50_00014 Service Training BT-50 00-9...

  • Page 18: Technical Data

    General Information Technical Data Item Unit 5,075 Overall length (w/o rear step bumper) 1,805 Overall width (AWD models with Overfenders) 1,715 1,745 1,755 Overall height (unladen) 1,620 1,750 * 1,760 * 1,445 Front track 1,445 1,495 1,440 Rear track 1,450 1,470 3,000 Wheelbase...

  • Page 19: Jacking And Lifting

    General Information Jacking and Lifting • The front of the vehicle can be lifted with a jack near the centre of the front crossmember. NOTE: The jacking point on the front axle for the 2WD is different to the 4WD model. BT-50_00023 only 2WD 2WD and 4WD...

  • Page 20: Towing

    General Information Towing • The towing hooks on the 2WD model are different from the 4WD model. BT-50_00020 Towing hooks • The 4WD model has two tie-down hooks that may not be used for towing. The towing hook is located on the left side. BT-50_00021 Tie-down hooks Towing hook...

  • Page 21: Scheduled Maintenance Table

    General Information Scheduled Maintenance Table Number of months or kilometers (miles), whichever comes first Months Maintenance Interval x1000 km x1000 miles 12.5 37.5 62.5 87.5 112.5 ENGINE Engine valve clearance Replace every 120,000 km (75,000 miles) Engine timing belt Replace every 120,000 km (75,000 miles) Engine timing belt auto tensioner* Engine oil Engine oil filter...
  • Page 22 General Information Number of months or kilometers (miles), whichever comes first Months Maintenance Interval x1000 km x1000 miles 12.5 37.5 62.5 87.5 112.5 CHASSIS and BODY Brake lines, hoses and connections Brake fluid Parking brake Brake booster and hoses Inspect every 200,000 km (125,000 miles) Disc brakes Drum brakes Power steering fluid, lines, hoses and...

  • Page 23: Remarks

    General Information Remarks • Refer below for a description of items marked with * in the maintenance chart. – *1: Replacement of the engine timing belt and auto tensioner is required at every 120,000 km (75,000 miles). Failure to replace the timing belt and the auto tensioner may result in damage to the engine.
  • Page 24 General Information Notes: 00-16 Service Training BT-50...

  • Page 25: Wl-C Engine

    Engine WL-C Engine WL-C Engine • The BT-50 is offered with the 2.5 L common rail diesel engine, which has the identification code WL-C. • The design and operation of the WL-C engine are essentially carried over from that of the B-Series with WLT-3 engine, except for the new features described in the respective sections.

  • Page 26: Overview

    WL-C Engine Engine Overview BT-50_01002 01-2 Service Training BT-50...

  • Page 27: Mechanical

    WL-C Engine Mechanical Mechanical Features • The mechanical system of the WL-C engine has the following new features: – Pistons with integrated combustion chamber – Coated piston skirt – Reduced compression ratio – Newly constructed aluminium alloy cylinder head – Double overhead camshafts (driven by a timing belt) –...

  • Page 28: Piston

    Mechanical WL-C Engine Piston • In accordance with the adoption of the common rail injection system, the piston head shape now incorporates the combustion chamber. Due to the modified piston shape the compression ratio is reduced from 21.6: 1 on the WLT-3 engine to 18.0: 1. •...

  • Page 29: Cylinder Head

    WL-C Engine Mechanical Cylinder Head Parts Location BT-50_01007 Cylinder head cover Cylinder head gasket Upper camshaft bearing caps Seal plate Lower camshaft bearing case with Camshaft pulley injector sealing rings Cylinder head Camshaft Service Training BT-50 01-5...
  • Page 30 Mechanical WL-C Engine • The cylinder head and the full floating cylinder head cover are made of aluminium alloy. • The steel laminated cylinder head gasket is available in three different thicknesses depending on the piston protrusion. The gasket is marked respectively (refer to Engine W/M).

  • Page 31: Valve Gear

    WL-C Engine Mechanical Valve Gear • The valve gear comprises helical gears and a timing belt • The timing belt drives two camshafts and is adjusted by an auto tensioner. • Adjustable roller type rocker arms have been adopted to lower the friction between camshaft lobe and rocker arm, reducing the engine’s mechanical loss.

  • Page 32: Valve-Clearance Adjustment

    Mechanical WL-C Engine Valve-Clearance Adjustment • The valve clearance is measured between roller and cam lobe. CAUTION: For loosening the locknut of the adjusting screw the cam lobe must push down the rocker arm firmly as shown in the figure below. Otherwise the claw of the rocker arm might be damaged.

  • Page 33: Timing Belt Auto Tensioner

    WL-C Engine Mechanical Timing Belt Auto Tensioner • A timing belt auto tensioner has been adopted to maintain timing belt tension constant. The timing belt tension is released by turning the auto tensioner counterclockwise with the aid of an Allen wrench (with max. 39 Nm apply force). The turned back tensioner is secured by inserting a fixing pin with 6 mm diameter into the appropriate bore (No.

  • Page 34: Engine Timing

    Mechanical WL-C Engine Engine Timing • When replacing the timing belt the timing marks must be positioned as shown in the figure below. BT-50_01013 Intake camshaft pulley Timing mark Exhaust camshaft pulley High-pressure pump pulley 01-10 Service Training BT-50...

  • Page 35: Features

    Full-flow paper element, spin-on type Oil filter Bypass pressure 80-120 Total (dry engine) Oil capacity Oil replacement (approx. Oil and oil filter quantity) replacement Grade API CF or ACEA B1/B3/B5 Viscosity (SAE) 5W-30 Remarks e.g. Mazda genuine Dexelia oil BT-50_T01003 Service Training BT-50 01-11...

  • Page 36: Parts Location

    Lubrication System WL-C Engine Parts Location BT-50_01044 Oil jet valve Oil cooler and oil filter body component Oil pressure switch Oil pan Oil dipstick Oil drain plug Oil cooler Oil strainer Oil filter body Oil outlet pipe Oil filter Oil pump 01-12 Service Training BT-50...

  • Page 37: System Overview

    WL-C Engine Lubrication System System Overview BT-50_01015 Oil pressure switch Main bearing Vacuum pump Crankshaft Turbocharger Connecting rod bearing Timing gears Oil pump Oil Strainer Piston Oil filter Oil jet valve Oil cooler Oil pan Oil cooler and oil filter body component Oil passage Camshaft Oil relief passage...

  • Page 38: Oil Filter

    Lubrication System WL-C Engine Oil Filter • The spin-on type oil filter consists of one full flow element. The bypass element that has been additionally used on the filter WLT-3 engine has been dropped. BT-50_01017 Full-flow paper element 01-14 Service Training BT-50...

  • Page 39: Cooling System

    WL-C Engine Cooling System Cooling System Features • The cooling system of the WL-C engine has the following new features: – Longlife engine coolant FL-22 – Asymmetric positioned radiator fan blades for noise reduction (thermo-modulated fan-type) Specifications Specification Item WL-C Type Water-cooled, forced circulation Without heater: 8.8...

  • Page 40: Parts Location

    Cooling System WL-C Engine Parts Location BT-50_01045 Radiator cowling Cooling fan Water pump pulley Coolant reserve tank Thermostat Radiator Water pump Cooling system cap NOTE: To bleed the cooling system follow the instructions of the W/M. 01-16 Service Training BT-50...

  • Page 41: System Overview

    WL-C Engine Cooling System System Overview BT-50_01018 Coolant reserve tank Heater EGR cooler Water pump Cylinder head Thermostat Turbocharger Radiator Cylinder block Coolant flow direction Oil cooler Service Training BT-50 01-17...
  • Page 42 Intake-Air System WL-C Engine Intake-Air System Features • The intake-air system of the WL-C engine has the following new features: – Newly designed air cleaner housing with dry filter element – MAF (Mass Air Flow) sensor with integrated IAT (Intake Air Temperature) sensor no.2 * and MAF learning function –...

  • Page 43: Intake-Air System

    WL-C Engine Intake-Air System Parts Location BT-50_01021 Glow plug Fresh-air duct Glow plug cord Check valve Charge-air cooler VBC solenoid valve VSC solenoid valve Vacuum chamber Glow plug relay VBC vacuum actuator MAP / IAT no.1 sensor Air cleaner VSC vacuum actuator MAF / IAT no.2 sensor Intake manifold Service Training BT-50...

  • Page 44: System Overview

    Intake-Air System WL-C Engine System Overview BT-50_01020 Charge-air cooler Glow plug Check valve Vacuum pump Vacuum chamber VSC vacuum actuator VBC solenoid valve VSC solenoid valve MAF / IAT no.2 sensor VSC shutter valves Air cleaner MAP / IAT no.1 sensor Intake manifold VBC vacuum actuator To PCM...

  • Page 45: Maf Sensor

    WL-C Engine Intake-Air System MAF Sensor • The MAF sensor with integrated IAT sensor no.2 is installed on the air filter. MAF Learning Function • The MAF learning function is used to compensate any deterioration of the MAF sensor. It should be carried out at each service interval by means of M-MDS (refer to chapter ‘Maintenance and Repair’).

  • Page 46: Variable Geometry Turbocharger

    Intake-Air System WL-C Engine Variable Geometry Turbocharger • The BT-50 uses a VGT, which controls the boost pressure by adjusting guide blades. The operation is similar to that of the VGT used on the Mazda6 (2.0 MZR-CD). BT-50_01046 VBC vacuum actuator Exhaust-gas flow Intake-air flow 01-22...

  • Page 47: Intake Manifold

    WL-C Engine Intake-Air System Intake Manifold • The intake manifold features two helical intake ports per cylinder for optimal swirl of intake air. The 2 and 3 cylinder share a common secondary intake port to minimise the required space. BT-50_01024 Secondary intake port VSC vacuum actuator Primary intake port...

  • Page 48: Variable Swirl Control Shutter Valves

    Intake-Air System WL-C Engine Variable Swirl Control Shutter Valves • The BT-50 uses VSC shutter valves, which reduce the exhaust emissions at low engine speeds. The operation is similar to that of the VSC shutter valves used on the Mazda6 pre F/L with 2.0 MZR-CD engine.

  • Page 49: Fuel System

    WL-C Engine Fuel System Fuel System Features • The fuel system of the WL-C engine has the following new features: – High-pressure pump incorporating gear-type feed pump with overflow valve, three element-type radial piston pump, fuel metering valve, and fuel temperature sensor –...

  • Page 50: Parts Location

    Fuel System WL-C Engine Parts Location BT-50_01027 Fuel gauge sender unit Vehicles with cargo box Fuel tank (4WD) Vehicles without cargo box 01-26 Service Training BT-50...
  • Page 51 WL-C Engine Fuel System BT-50_01028 Check valve in fuel return line Sedimentor switch Fuel injectors Fuel filter (incl. fuel warmer for cold regions) Fuel pressure sensor Common rail High-pressure pump Pressure limiter valve Fuel metering valve Service Training BT-50 01-27...

  • Page 52: System Overview

    Fuel System WL-C Engine System Overview BT-50_01029 Pressure limiter valve High-pressure pump Check valve Fuel filter Fuel injector Sedimentor switch Common rail Fuel tank Fuel pressure sensor To PCM Fuel metering valve Fuel flow Fuel temperature sensor 01-28 Service Training BT-50...

  • Page 53: High-Pressure Pump

    WL-C Engine Fuel System High-Pressure Pump • The BT-50 uses the high-pressure pump (CP3S3) with three pumping elements offset by 120°. The operation is similar to the high-pressure pump (CP3.2) used on the Mazda3 (1.6 MZ-CD), which is also manufactured by Bosch. BT-50_01030 Fuel return High-pressure pump...

  • Page 54: Fuel Injectors

    Fuel System WL-C Engine Fuel Injectors • The WL-C engine uses solenoid valve-type fuel injectors, which are directly controlled by the PCM. The operation is similar to the Mazda3 (1.6 MZ-CD). • The fuel injectors are mounted with brackets to the cylinder head. •...

  • Page 55: Exhaust System

    WL-C Engine Exhaust System Exhaust System Features • The exhaust system has the following new features: – Modified exhaust manifold – Warm up system with exhaust shutter valve (if equipped) Parts Location BT-50_01034 Exhaust manifold Warm up switch Joint pipe With exhaust shutter valve Oxidation catalytic converter Front pipe...

  • Page 56: Warm Up System

    Exhaust System Engine Warm-Up System • Since the common-rail diesel engines do not provide enough residual heat for the heating system of the vehicle, a warm-up system has been adopted to heat up the passenger compartment quickly at low ambient temperatures. It consists of: –...

  • Page 57: Exhaust Shutter Valve Unit

    WL-C Engine Exhaust System Exhaust Shutter Valve Solenoid Valve • The exhaust shutter valve solenoid valve (ON/OFF-type) is located above the vacuum chamber in the engine compartment. Exhaust Shutter Valve Unit • The exhaust shutter valve unit consists of exhaust shutter valve, exhaust flange, transfer lever, stop screw, actuation rod, and vacuum actuator.
  • Page 58 Emission System WL-C Engine Emission System Features • The emission system of the WL-C engine has the following features: – One EGR solenoid valve to control EGR valve position instead of two solenoid valves as used on the B-series * –...
  • Page 59 WL-C Engine Emission System BT-50_01033 Oxidation catalytic converter EGR control solenoid valve EGR cooler ISV solenoid valve (full) EGR solenoid valve ISV solenoid valve (half) MAF sensor EGR valve Air filter Service Training BT-50 01-35...

  • Page 60: System Overview

    Emission System WL-C Engine System Overview BT-50_01035 Air filter EGR solenoid valve EGR control solenoid valve EGR valve position sensor Fuel tank EGR valve Rollover valves MAF sensor Check valve (two-way) (without cargo box) Oxidation catalytic converter Evaporative chamber (without cargo box) ISV solenoid valve (full) To PCM ISV solenoid valve (half)

  • Page 61: Egr Solenoid Valve

    WL-C Engine Emission System EGR Solenoid Valve BT-50_01047 To EGR valve EGR solenoid valve To vacuum chamber EGR Control • The PCM controls the position of the EGR valve by means of the EGR solenoid valve (via duty signal) and the EGR control solenoid valve (via ON/OFF signal). –...

  • Page 62: Intake Shutter Valve

    Emission System WL-C Engine Intake Shutter Valve • The WL-C engine uses a three-step ISV, which increases the EGR rate at low engine speeds and prevents bucking movements of the engine during shut-off. The operation is similar to the ISV used on the Mazda6 pre F/L (2.0 MZR-CD). BT-50_01026 Fully opened at normal driving (for low First vacuum actuator operates for high...

  • Page 63: Charging And Starting System

    WL-C Engine Charging and Starting System Charging and Starting System • A modified generator has been adopted for the charging system, while the starting system is identical to that used on the B-Series. Specification Item WL-C Voltage Battery Type and capacity (Ah) 95D31R (64) (5-hour rate)

  • Page 64: Control System

    Control System WL-C Engine Control System Features • The control system of the WL-C engine has the following new features: – CKP (CranKshaft Position) sensor located at the flywheel – CMP (CaMshaft Position) sensor – PCM (Powertrain Control Module) with extended control strategies Specifications Specification Item...

  • Page 65: Parts Location

    WL-C Engine Control System Parts Location BT-50_01036 MIL (Malfunction Indicator Lamp) CMP sensor Glow indicator light Fuel pressure sensor APP sensor High-pressure pump Main relay Fuel temperature sensor Idle switch Fuel metering valve Brake switch ECT sensor (Data Link Connector) MAP sensor / IAT sensor no.1 DLC-2 CPP switch...

  • Page 66: System Overview

    Control System WL-C Engine System Overview BT-50_01037 01-42 Service Training BT-50...
  • Page 67 WL-C Engine Control System EGR valve position sensor Idle switch VBC solenoid valve APP sensor MAF sensor / IAT sensor no.2 Main relay Exhaust shutter valve Engine switch Exhaust shutter solenoid valve Neutral switch Oxidation catalytic converter A/C switch CMP sensor DLC-1 / DLC-2 ECT sensor Vehicle speed signal...

  • Page 68: Block Diagram

    Control System WL-C Engine Block Diagram PCM Control Input Output Strategies Battery CPP switch Neutral switch Idle speed control APP sensor Fuel metering valve Glow control Idle switch Fuel injectors Variable boost control MAF sensor / IAT sensor no.2 VBC solenoid valve Variable swirl control ECT sensor VSC solenoid valve...

  • Page 69: Relationship Chart

    WL-C Engine Control System Relationship Chart x: Applicable Control Item Item Input device Battery CPP switch Neutral switch APP sensor Idle switch MAF sensor IAT sensor no.2 IAT sensor no.1 ECT sensor Fuel temperature sensor BARO sensor MAP sensor Fuel pressure sensor CMP sensor CKP sensor Vehicle speed signal...

  • Page 70: Crankshaft Position Sensor

    Control System WL-C Engine Crankshaft Position Sensor • The inductive type CKP sensor is located at the upper part of clutch housing. The pulse wheel is installed to the primary mass of the flywheel, and has 58 projections with a space of 6°crank angle between each projection.

  • Page 71: Camshaft Position Sensor

    WL-C Engine Control System Camshaft Position Sensor • The Hall-type CMP sensor is installed at the right front side of the cylinder head. A projection on the intake camshaft pulley covers 26° camshaft rotation angle. BT-50_01051 CMP sensor Pulse wheel Intake camshaft pulley Gap (1,4 mm) NOTE: When the CMP signal fails during engine operation, the engine continues to run and...

  • Page 72: Powertrain Control Module

    Control System WL-C Engine Powertrain Control Module Features • The PCM has the following new features: – Programmable module – Built in BARO sensor – A/C (Air Conditioning) cut-off control – Glow plug relay with feedback to PCM * – Integrated RFW (Remote Free Wheel) control on versions with 4WD (refer to chapter ‘Driveline / Axle’) –...

  • Page 73: A/C Cut-Off Control

    WL-C Engine Control System • The PCM has two connectors with 154 pins in total. BT-50_01041 • Similar to other current modules the PCM now allows to carry out the following programming functions by means of M-MDS: – Programmable module installation (to replace PCM) –...

  • Page 74: Glow Plug Relay

    Control System WL-C Engine Glow Plug Relay • The glow plug relay has a feedback line to the PCM to facilitate failure detection. The PCM operates the glow plug relay for max. 120 s at an engine coolant temperature below 32 °C. BT-50_01038 From main relay Glow plugs...

  • Page 75: On-Board Diagnostic System

    WL-C Engine Control System On-Board Diagnostic System Features • The OBD (On-Board Diagnostic) system has the following features: – – Self test – PID monitor – Simulation test Malfunction Indicator Lamp • The MIL is located in the IC. It illuminates when emission related malfunction have been detected by the OBD system.

  • Page 76: Pid Monitor

    Control System WL-C Engine PID Monitor • The PID monitor function allows monitoring the PIDs of the PCM. Therefore connect the M-MDS to the vehicle and select the option Toolbox Datalogger Modules PCM. Definition Unit/Condition Ambient air temperature °C AC_REQ A/C request signal OFF/ON ACCS...

  • Page 77: Simulation Test

    WL-C Engine Control System Definition Unit/Condition Mass airflow Manifold absolute pressure Malfunction indicator lamp OFF/ON MIL_DIS Distance travelled since the MIL was activated Engine speed SEGRP DSD Desired EGR valve position SELTESTDTC Diagnostic trouble codes — VBCV VBC solenoid valve VPWR Module supply voltage Vehicle speed...

  • Page 78: Maintenance And Repair

    Control System WL-C Engine Maintenance and Repair MAF Sensor Learning Function • The MAF learning procedure by means of M-MDS must be carried out at every service interval. During this procedure the MAF learning is performed at engine speeds of 750 min , 1850 min , and 2500 min...

  • Page 79: Pcm Replacement

    WL-C Engine Control System PCM Replacement • When the PCM has been replaced certain procedures have to be performed in the following order: 1. Perform PCM configuration procedure. 2. Perform IMMOBILISER SYSTEM programming. 3. Perform PCM data reset procedure to reset all adaptation values in the PCM with the aid of the M-MDS.
  • Page 80 Control System WL-C Engine Notes: 01-56 Service Training BT-50...

  • Page 81: Suspension

    Suspension Suspension Features • The front and rear suspension of the BT-50 have the following new features: – Enlarged diameter and modified damper valve tuning of the double acting low pressurised shock absorbers – Enlarged diameter of the front stabiliser –...

  • Page 82: Parts Location

    Suspension Parts Location Front Suspension 2WD BT-50_02002 Front shock absorber Lower arm Torsion bar spring Tension rod Upper arm Front stabiliser Front Suspension 4WD BT-50_02003 Shock absorber Lower arm Torsion bar spring Front stabiliser Upper arm 02-2 Service Training BT-50...

  • Page 83: Rear Suspension

    Suspension Rear Suspension BT-50_02004 Shock absorber Leaf spring Service Training BT-50 02-3...

  • Page 84: Wheels And Tyres

    Wheels and Tyres Suspension Wheels and Tyres • The wheels and tyres have the following new features: – Modified wheel and tyre sizes – Modified wheel offset – New designs for 15- and 16-inch aluminium alloy wheels and 15-inch steel wheels. BT-50_02001 15-inch standard steel rim (2WD) 15-inch aluminium alloy rim (2WD)

  • Page 85: Specifications

    Suspension Wheels and Tyres Specifications Item Specification Size 15 x 61/2J 15 x 61/2JJ 16 x 7J Offset Wheel Pitch circle diameter 139.7 Aluminium Aluminium Material Steel Steel alloy alloy 235/75R15 245/70R16 Size 215/70R15C 106/104S 109S 111S Up to four persons Front Tyre...
  • Page 86 Wheels and Tyres Suspension Notes: 02-6 Service Training BT-50...

  • Page 87: Driveline / Axle

    Driveline / Axle Driveline / Axle Features • The driveline / axle of the BT-50 has the following new features: – Modified transfer case due to increased engine torque and new transmission – RFW control with OBD function integrated in PCM (separate RFW module has been dropped) NOTE: Further information can be found in the Training Manuals ‘B-Series’...

  • Page 88: Rfw System

    RFW System Driveline / Axle RFW System • The RFW system is controlled by the PCM. The input and output components are the same as used for the B-Series with separate RFW control module. Parts Location BT-50_03001 RFW main switch RFW vacuum actuator Transfer neutral switch Joint shaft component...

  • Page 89: System Overview

    Driveline / Axle RFW System System Overview BT-50_03002 4WD indicator light One-way check valve RFW indicator light Lock solenoid valve To battery Free solenoid valve Front differential RFW main switch Lock Free Vehicle battery RFW vacuum actuator Engine switch RFW unit Selector lever RFW switch 4WD switch...

  • Page 90: On-Board Diagnostic System

    RFW System Driveline / Axle On-Board Diagnostic System • Detected malfunctions are stored as 4-digit DTCs in the PCM memory and can be retrieved by means of M-MDS. DTC Table Malfunction P1812 RFW lock solenoid valve circuit failure P1813 RFW lock solenoid valve open circuit P1814 RFW lock solenoid valve circuit/short to battery P1815...

  • Page 91: Transmission

    Transmission Clutch Clutch Features • The clutch system of the BT-50 has the following new features: – Clutch master cylinder with one-way valve and pulsation damper – Dual mass flywheel Specifications Item Specification Manual transmission type S15M-D, S15MX-D Clutch control Hydraulic Spring type Diaphragm...

  • Page 92: Parts Location

    Clutch Transmission Parts Location BT-50_05013 Dual-mass flywheel Clutch release cylinder Clutch disc Clutch release collar Clutch cover Clutch pedal Clutch release fork Clutch master cylinder 05-2 Service Training BT-50...

  • Page 93: Clutch Master Cylinder

    Transmission Clutch Clutch Master Cylinder • The one-way valve prevents harsh clutch engagement by a throttle, which prevents too quick back flowing of the fluid when the clutch is engaged thus ensuring smooth driving off. • The pulsation damper reduces pressure fluctuations in the hydraulic line during clutch operation, minimizing operation noise and vibration transmission to the clutch pedal.

  • Page 94: Dual Mass Flywheel

    Clutch Transmission Dual Mass Flywheel • The dual mass flywheel compensates torque fluctuations thus reducing rattle noises of the transmission gears. BT-50_05014 Torsional-vibration damping spring Primary flywheel Secondary flywheel 05-4 Service Training BT-50...

  • Page 95: S15M(X)-D Manual Transmission

    Transmission S15M(X)-D Manual Transmission S15M(X)-D Manual Transmission • Due to the increased engine torque the newly developed three-shaft 5-speed manual transmission S15M-D has been adopted for the 2WD version, while the S15MX-D transmission with an additional transfer case has been adopted for the 4WD version. •...

  • Page 96: Specifications

    S15M(X)-D Manual Transmission Transmission Specifications Item Specification Transmission type S15M-D, S15MX-D Transmission/Transfer control Floor-shift Shift assist Synchromesh 3.905 2.248 1.491 Gear ratio 1.000 0.800 Reverse 3.391 Type Manual Transmission fluid type A Transmission case oil Capacity 3.55 (approx.quantity) Type Manual Transmission fluid type A Shift control case oil Capacity [S15M-D]...

  • Page 97: Overview

    Transmission S15M(X)-D Manual Transmission Overview BT-50_05002 Extension housing (S15M-D) Reverse idler gear Transfer case (S15MX-D) Reverse gear Output shaft gear gear Counter shaft gear Input shaft gear Service Training BT-50 05-7...

  • Page 98: Power Flow

    S15M(X)-D Manual Transmission Transmission Power Flow BT-50_05003 Gear BT-50_05004 Gear BT-50_05005 Gear 05-8 Service Training BT-50...
  • Page 99 Transmission S15M(X)-D Manual Transmission BT-50_05006 Gear BT-50_05007 Gear BT-50_05008 Reverse Gear Service Training BT-50 05-9...

  • Page 100: Shift Mechanism

    S15M(X)-D Manual Transmission Transmission Shift Mechanism • Most of the shift mechanism components are accommodated in the shift mechanism unit. Due to its five speed layout the S15M(X)-D transmission requires four shift rods in total (three in the shift mechanism unit and one in the transmission housing). BT-50_05009 Section A-A Control rod...

  • Page 101: Shift Mechanism Unit

    Transmission S15M(X)-D Manual Transmission Shift Mechanism Unit BT-50_05010 Transmission breather Interlock pin Spring shift rod Plastic spring seat shift rod Detent ball Retaining ring Oil baffle plate Plain washer Retaining bolt Push pin shift fork /reverse shift rod end Stopper block Rubber plug shift fork shift rod end...

  • Page 102: Th / Reverse Gear Mechanism

    S15M(X)-D Manual Transmission Transmission / Reverse Gear Mechanism • The shift fork for the 5 / reverse gear is mounted on an additional shift rod inside the gearbox. It is operated by the 5 / reverse shift rod in the shift mechanism unit via the counter lever.
  • Page 103 Transmission S15M(X)-D Manual Transmission Counter lever Reverse gear Washer Countershaft rear bearing Retaining ring Locknut /reverse clutch hub and shift fork Synchronizer key spring component Steel ball Clutch hub sleeve gear bearing inner race Detent spring Needle bearing Detent ball gear /reverse shift rod Synchronizer ring...

  • Page 104: Reverse Gear Lockout Mechanism

    S15M(X)-D Manual Transmission Transmission Reverse Gear Lockout Mechanism • To prevent accidental shifting into reverse gear while downshifting from the 5 to the 4 gear a cam-type lockout mechanism is installed in the extension housing (2WD) or in the transfer case (4WD). The figure below shows the variant of the 4WD version. BT-50_05012 Shifting directly from 5 to reverse gear...

  • Page 105: Hvac

    HVAC Basic System Basic System Features • The HVAC (Heating, Ventilation, Air Conditioning) basic system of the BT-50 has the following new features: – Modified blower unit to reduce fan noise – Condenser with sub-cooling function and integrated receiver / drier Specifications Item Specification...

  • Page 106: Parts Location

    Basic System HVAC Parts Location BT-50_07001 Heater / air distribution unit High pressure charging valve Cooling unit Condenser Blower unit Receiver / drier Low pressure charging valve Compressor Refrigerant pressure switch 07-2 Service Training BT-50...

  • Page 107: Refrigerant System

    HVAC Basic System Refrigerant System BT-50_07006 Low-pressure charging valve Condenser Expansion valve Evaporator High-pressure charging valve A/C Compressor Receiver / drier Service Training BT-50 07-3...

  • Page 108: Control System

    Control System HVAC Control System Features • The HVAC control of the BT-50 has the following new features: – Newly designed control panel with larger dials Parts Location BT-50_07003 A/C relay Blower motor Climate control unit Refrigerant pressure switch Evaporator temperature sensor Magnetic clutch Blower resistor 07-4...

  • Page 109: Wiring Diagram

    HVAC Control System Wiring Diagram BT-50_07004 A/C switch A/C relay Fan switch Refrigerant pressure switch Blower resistor Magnetic clutch Blower motor Climate control unit Blower relay A/C Amplifier / Thermoswitch (incl. evaporator temperature sensor) Service Training BT-50 07-5...

  • Page 110: Climate Control Unit

    Control System HVAC Climate Control Unit • A new designed cable operated climate control unit has been adopted. BT-50_07005 A/C switch Fan switch Rear window defroster switch Rec/Fresh lever Airflow mode selector dial Temperature control dial Climate control unit 07-6 Service Training BT-50...
  • Page 111 Restraints Airbag System Airbag System Features • The airbag system of the BT-50 has the following new features: – Side airbags integrated in the backrests of the front seats (depending on grade) * – Side airbag sensors installed on the door sills –...

  • Page 112: Restraints

    Airbag System Restraints Parts Location BT-50_08001 Airbag system warning light Side airbag sensor Clock spring Side airbag module Seat belt pretensioner SAS control module Driver-side airbag module Passenger-side airbag module 08-2 Service Training BT-50...

  • Page 113: Wiring Diagram

    Restraints Airbag System Wiring Diagram BT-50_08002 Clock spring SAS control module Driver-side airbag module Twisted pair wire Passenger-side airbag module Passenger-side side airbag sensor Driver-side seat belt pretensioner Driver-side side airbag sensor Driver-side side airbag module Passenger-side seat belt pretensioner Airbag system warning light Passenger-side side airbag module DLC-2...

  • Page 114: Sas Control Module

    Airbag System Restraints SAS Control Module • The SAS control module is located on the centre tunnel, in front of the shift lever. • The SAS control module processes the signals it receives from the internal micro- mechanical sensor and the side airbag sensors. If the acceleration/deceleration caused by a frontal or side impact exceeds a predetermined threshold, the SAS control module triggers the airbags / pre-tensioners or only the side airbags with a DC signal.

  • Page 115: Side Airbag Sensors

    Restraints Airbag System Side Airbag Sensors • The side airbag sensors are installed under the vehicle on the door sills, close to the B- pillar. A rigid metal cover protects the sensors against any damage during off-road driving. • The side airbag sensor measures the acceleration / deceleration of the vehicle during a side impact and transmits this information to the SAS control module.

  • Page 116: Seat Belt Pretensioners

    Airbag System Restraints Seat Belt Pretensioners • The BT-50 is equipped with rack-type seat belt pretensioners, which remove the excess slack from the seat belt in case of an accident. The operation is similar to that of the MX- 5 (NC) seat belt pretensioners. BT-50_08006 Spindle Clutch roller...

  • Page 117: On-Board Diagnostic System

    Restraints Airbag System On-Board Diagnostic System Features • The OBD system of the airbag system allows bi-directional communication with M-MDS, enabling a quicker and more precise diagnosis. It has the following new features: – Selftest (retrieving four digit DTCs stored for present and past malfunctions) –...
  • Page 118 Airbag System Restraints PID Monitor • The PID monitor function allows monitoring the PIDs of the SAS control module. Therefore, connect the M-MDS to the vehicle and select the option Toolbox Datalogger Modules RCM. Definition Unit/Condition CONT_RCM Number of continuous DTCs CRSH_ST_D1 Driver-side airbag sensor communication state OK/FAULT...

  • Page 119: Body & Accessories

    Body & Accessories Body Panels Body Panels Cabin • The cabin structure of the BT-50 (DBL cab version) with its triple-H structure, the side- door beams, and the use of high-tensile steel, provide a class top level of passive safety in conjunction with the rigid ladder frame satisfying stringent European collision-safety standards.

  • Page 120: Ladder Frame

    Body Panels Body & Accessories Ladder Frame • The cross-braced ladder frame of the BT-50 is essentially carried over from the B-Series, just as four cabin mounts, which minimise lateral movement, but allow for compliance in vertical movement providing comfortable driving. BT-50_09003 DBL Cab Frame 09-2...

  • Page 121: Cargo Box

    Body & Accessories Body Panels Cargo Box • The cargo box of the BT-50 has the following new features allowing a more versatile usage of the cargo box: – Taller cargo box walls to increase the load capacity. – New structure of the inner cargo box walls with one horizontal and several vertical guiding grooves that allow splitting up the cargo space with boards.

  • Page 122: Glass/Windows/Mirrors

    Glass/Windows/Mirrors Body & Accessories Glass/Windows/Mirrors • The glass/windows/mirrors of the BT-50 have following new features: – Rear window defroster switch installed in centre panel – Power outer mirror switch installed in driver door trim – Enlarged power outer mirrors BT-50_09006 Rear window defroster switch BT-50_09007 Power outer mirror switch...

  • Page 123: Security And Locks

    Power door lock system (without double lock) – Keyless entry system (keyless transmitter with retractable key) – Mazda immobiliser system with separate immobiliser module – Theft-deterrent system (for vehicles with U.K. specification) NOTE: Further information can be found in the Training Manuals of the ‘B-Series’ (NMT-005) and ‘Immobiliser System’...

  • Page 124: Wiring Diagram

    Security and Locks Body & Accessories Wiring Diagram BT-50_09009 Instrument cluster Theft-deterrent horn Door ajar warning light Theft-deterrent control module Security light Door key cylinder switches Door switches Door lock control module Driver’s door lock-link switch Keyless control module Rear door lock-link switches Hazard warning switch Bonnet switch Flasher control module...

  • Page 125: Exterior Trim

    Body & Accessories Exterior Trim Exterior Trim Features • The exterior trim of the BT-50 has the following new features (depending on grade): – Painted front bumper with integrated front grille – New designed chrome door handles – Larger wheel arch extensions –...

  • Page 126: Front And Rear Bumper

    Exterior Trim Body & Accessories Front and Rear Bumper • The front bumper is completely new designed, while the rear bumper is the same as used on the B-Series. • The plastic front bumper is installed on a steel reinforcement. The bumper also accommodates the front grille, newly designed front fog lights and the lower wheel arch extensions (if equipped).

  • Page 127: Interior Trim

    Body & Accessories Interior Trim Interior Trim Features • The interior trim of the BT-50 has the following new features: – Newly designed dashboard installed on a steel crossmember – Front door pockets with bottle holder – Sliding upper glove compartment –...

  • Page 128: Lighting System

    Lighting System Body & Accessories Lighting System Features • The lighting system of the BT-50 has the following new features: – Front combination light with multi-reflector headlight type, turn and parking light – Rear combination light with stepped reflector – Front and rear fog light switch incorporated in light switch –...

  • Page 129: Rear Combination Light

    Body & Accessories Lighting System Rear Combination Light BT-50_09013 Brake/taillight bulb Section A-A Turn light bulb Rear combination light Back-up light bulb (LH) Rear fog light bulb (RH) Service Training BT-50 09-11...

  • Page 130: Overview

    Lighting System Body & Accessories Overview BT-50_09014 Combination switch Centre console illumination Light switch Glove compartment light Panel light control switch Hazard warning switch Headlight levelling switch Interior light Daytime Running Light • Since some countries outlaw driving vehicles without switched on headlights during daytime, a DRL system is available for these markets.

  • Page 131: Wiring Diagram

    Body & Accessories Lighting System Wiring Diagram BT-50_09028 Service Training BT-50 09-13...

  • Page 132: Wiper / Washer System

    Wiper / Washer System Body & Accessories Wiper / Washer System Features • The wiper / washer system of the BT-50 has the following new features: – Intermittent wiper function with adjustable interval Parts Location BT-50_09016 Wiper and washer switch Wiper arm and blade Washer nozzle Washer motor...

  • Page 133: Wiring Diagram

    Body & Accessories Wiper / Washer System Wiring Diagram BT-50_09024 Wiper switch Auto-stop switch Washer switch Interval relay Washer motor Interval control switch Wiper motor One-touch switch Service Training BT-50 09-15...

  • Page 134: Audio System

    Entertainment Body & Accessories Audio System Features • The modular audio system of the BT-50 is available in two different variants: Radio with CD player or with 6-CD changer. It has the following features: – AM/FM tuner with RDS (Radio Data System) and ALC (Audio Level Control) –...

  • Page 135: Parts Location

    Body & Accessories Entertainment Parts Location BT-50_09017 Roof antenna Audio unit Tweeter LH Antenna cable Rear speaker RH Front speaker RH Rear speaker LH Tweeter RH Front speaker LH Service Training BT-50 09-17...

  • Page 136: System Overview

    Front speaker (LH) TNS signal Tweeter (LH) Centre panel unit Rear speaker (RH) NOTE: A telephone mute function is only available by using an appropriate connector adapter, which is provided as accessory part by Mazda Motor Europe. 09-18 Service Training BT-50...
  • Page 137 Body & Accessories Entertainment • The modular audio system consists of the base unit, the lower module (if equipped) and the centre panel. The base unit with CD player is different from the one with 6-CD changer. BT-50_09018 Base unit Cover Audio unit Centre panel...

  • Page 138: On-Board Diagnostic System

    Entertainment Body & Accessories On-Board Diagnostic System • The OBD system of the modular audio system comprises a self-test and a diagnostic assist function. Self-Test Function • The fault memory of the audio module can store up to three DTCs. If a fourth fault is detected when three DTCs are already stored, the oldest DTC is deleted and the new one stored.

  • Page 139: Power Systems

    Body & Accessories Power Systems Power Systems Parts Location BT-50_09020 Main fuse block Fuse block Service Training BT-50 09-21...

  • Page 140: Instrumentation / Driver Information System

    Instrumentation / Driver Info Body & Accessories Instrumentation / Driver Information System Features • The instrumentation / driver information system of the BT-50 has the following new features: – LED-type warning and indicator lights – Front and rear fog light indicator lights incorporated in the IC –...

  • Page 141: Instrument Cluster Overview

    Body & Accessories Instrumentation / Driver Info Instrument Cluster Overview BT-50_09023 Item Input signal source RFW indicator light 4x4 indicator light RFW main switch Red Zone Turn indicator light Flasher control module Speedometer gauge Water temperature gauge ECT sensor High-beam indicator light Headlight switch Front fog light indicator light Front fog light relay...

  • Page 142: Key Reminder Warning Alarm

    Instrumentation / Driver Info Body & Accessories Key Reminder Warning Alarm • This function warns with an intermittent sound from the buzzer in the IC that the key is in the steering lock in position ACC or LOCK when any door is opened. Additionally a permanent sound warns when a door is opened and the lights are switched on.

  • Page 143: Control System

    Body & Accessories Control System Control System Features • The control system of the BT-50 has the following new features: – DLC-2 – HS-CAN connection between PCM and DLC-2 for communication with M-MDS Data Link Connector • The DLC-2 is located under the dashboard next to the centre panel. •...

  • Page 144: Wiring Diagram

    Control System Body & Accessories Wiring Diagram BT-50_09027 09-26 Service Training BT-50...
  • Page 145 Mass Air Flow Daytime Running Light Manifold Absolute Pressure Diagnostic Trouble Code Malfunction Indicator Lamp Engine Coolant Temperature Music Cassette Exhaust Gas Recirculation Mini Disc Fault ENgine M-MDS Mazda-Modular Diagnostic HVAC Heating, Ventilation, Air System Conditioning Service Training Mazda BT-50...
  • Page 146 Vehicle Speed Sensor Parameter IDentification Vehicle Identification Number Random Access Panel REGular Remote FreeWheel Rear Wheel Drive Sophisticated Airbag Sensor Supplemental Restraint System Special Service Tool Test ENgine Wiring Diagram Workshop Manual Variable Boost Control Variable Geometry Turbocharger Service Training Mazda BT-50...

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