Training Manual Powertrain (NTOM) CT-L1001.
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. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
Powertrain Table of Contents Introduction .......................................................................................00-1 Engines ..............................................................................................01-1 MESI for Engine Service and Repairs.......................................................................01-1 Petrol Engines ............................................................................................................01-5 L-type Engines................
Table of Contents Powertrain Overview.......................................................................................................01-31 Cylinder Block...............................................................................................01-32 Pistons..........................................................................................................01-33 Crankshaft ....................................................................................................01-34 Camshafts ...
Powertrain Table of Contents Diesel Engines ..........................................................................................................01-61 RF-T Engine ..............................................................................................................01-61 Mechanical ..........................................................................................................01-61 Features ..............................................................................................
Table of Contents Powertrain Y-type Engines..........................................................................................................01-93 Mechanical (Y4 Engine) ......................................................................................01-93 Features .......................................................................................................01-93 Overview.......................................................................................................
Powertrain Table of Contents Transmissions ...................................................................................02-1 Drive Train...................................................................................................................02-1 Transmission Code ....................................................................................................02-2 Manual Transmissions...............................................................................................
Table of Contents Powertrain Notes: Curriculum Training
Powertrain Introduction Introduction • The training course “Powertrain” introduces the various engines and transmissions of the current Mazda models with the main focus on the mechanical system. • It is one part of the NTOM (New-To-Mazda) course, which is addressed to entry-level Mazda technicians. Successful attendance of the NTOM course is a prerequisite for participation in any technical courses of the Mazda Masters program.
Introduction Powertrain Notes: 00-2 Curriculum Training
Powertrain Engine MESI for Engine Service and Repairs • For engine service and repairs MESI provides two different types of information within the Service Contents menu. • The chapter “Engine” of the workshop manual contains information about the various engine systems such as cooling system, exhaust system etc. but also about certain mechanical repairs on the engine. • The “Engine Workshop Manual” contains detailed information about mechanical overhauling of the engine.
Engine • Powertrain Clicking a Hyperlink (e.g. compression inspection) provides the technician with additional information, which is essential for the repair in question. L1001.
Powertrain • Engine The Engine Workshop Manual can be found by choosing “Engine WM” of the Service Contents menu and then selecting “Engine). See example below. If you have to inspect a cylinder head for example, select “Mechanical” and then “Cylinder Head Inspection” to get information about the procedure. L1001.
Engine Powertrain Notes: 01-4 Curriculum Training
Powertrain Engines Petrol Engines • The following petrol engine types are fitted in the current Mazda models: Model / Engine Mazda2 (DY) 1.25 MZI 1.4 MZI 1.6 MZI X X X Mazda3 ZJ Z6 X X L8 LF L3 L3-T X Mazda3 MPS X Mazda5 X X Mazda6 X X X Mazda6 MPS X Mazda CX-7 X Mazda MX-5 X X L1001.4_T01001a L-type Engines • In the L-type engine line-up the following engines are available: – – – – L8 engine with 1.8 L displacement (also termed as 1.8 L MZR engine) LF engine with 2.
Engines Powertrain Mechanical (L8, LF, L3 Engine) Features • The mechanical system of the L8, LF and L3 engine has the following features: – – – – – Chain driven 16 valve DOHC (Double Overhead Camshaft) engine Balancer shafts (only L3 engine) Valve train with automatic timing chain tensioner and mechanical bucket tappets Variable valve timing system for the intake camshaft (except L8 engine) V-ribbed belt drive with automatic tensioner Overview L1001.
Powertrain Engines Cylinder Block • The cylinder block features a bearing support frame, in which the main bearing caps are integrated. Cylinder block and bearing support frame are matched to each other, i.e. they cannot be replaced separately. If one of the components exceeds the specification, the cylinder block must be replaced as a complete unit. • The main bearing cap bolts are torque-to-yield bolts, which must be tightened in several stages (refer to the workshop manual for details). L1001.
Engines Powertrain Pistons • The piston skirt is coated to reduce friction between the piston and the cylinder. • Piston, piston pin and connecting rod are shrinkage fitted and cannot be disassembled. If one of the components exceeds the specification, the piston/ connecting rod assembly has to be replaced as a complete unit. L1001.
Powertrain Engines Crankshaft • The crankshaft for the L8 and LF engine has four counterweights, while the crankshaft for the L3 engine has eight counterweights. • In addition, the crankshaft for the L3 engine is equipped with a drive gear for the balancer shafts. • The crankshaft features no key for the installation of the crankshaft sprocket and the crankshaft pulley, i.e. solely the clamping force of the lock bolt secures both components on the crankshaft.
Engines • Powertrain There is no positioning tab for locating the upper and lower bearing in the main journal. For installing the main bearing shells (upper and lower), they have to be measured and attached so that they are positioned in the center of the main bearing cap (refer to the workshop manual for details). L1001.
Powertrain Engines Balancer Shaft Unit • The balancer shafts minimize the engine vibrations by rotating at twice the speed of the crankshaft. • The balancer shaft unit features a two-piece housing, which is fixed to the cylinder block by four bolts. NOTE: The balancer shaft unit cannot be repaired due to its precise interior construction, i.e. it must be replaced as a complete unit.
Engines Powertrain Cylinder Head • The cylinder head is a conventional construction with separate camshaft bearing caps. • The cylinder head bolts are torque-to-yield bolts, which must be tightened in several stages (refer to the workshop manual for details). NOTE: The cylinder head bolts must not be re-used if their length exceeds the specification (refer to the workshop manual for details). L1001.
Powertrain Engines Camshafts • The camshafts feature no key for the installation of the camshaft sprockets, i.e. solely the clamping force of the lock bolt secures the sprocket on the camshaft. • The intake camshaft of the LF and L3 engine is equipped with an oil line supplying oil to the camshaft actuator of the variable valve timing system. • The intake camshaft has a pulse wheel for the CMP (Camshaft Position) sensor signals. L1001.
Engines Powertrain Valve Actuation • The camshafts actuate the valves via mechanical bucket tappets without adjustment shims. • The valve clearance is adjusted by the different thickness of the bucket tappets. The tappet thickness can be determined by the engraved number (e.g. number “402” means a thickness of 3.402 mm). In order to replace the tappets the camshafts have to be removed (refer to the workshop manual for details).
Powertrain Engines Valve Train • The camshafts are driven by a maintenance-free pinned link timing chain. L1001.
Engines Powertrain Timing Chain Tensioner • An automatic timing chain tensioner is fitted to ensure optimum chain tension over the service life of the engine. • The timing chain tensioner operates using engine oil pressure. The ratchet and the rack hold the piston in place when the engine is started. L1001.
Powertrain • Engines The timing chain tension can be released as following (refer to the workshop manual for details): 1. Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet. 2. Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon, and loosen the timing chain. 3. Placing a bolt (M6 x 1.0) in the engine front cover upper blind plug hole, secure the chain tensioner arm in the position where the tension is released. L1001.
Engines Powertrain Variable Valve Timing System • The variable valve timing system continuously varies the valve timing of the intake valves, controlling the cylinder charge. • The camshaft actuator is attached to the camshaft sprocket and varies the position of the intake camshaft in relation to the sprocket. The intake camshaft position is controlled by the oil control valve using engine oil pressure. NOTE: The camshaft actuator cannot be repaired due to its precise interior construction, i.e.
Powertrain Engines Valve Timing • For verifying or adjusting the valve timing a timing peg (SST) has to be installed in the blind plug hole, which is located at the rear of the cylinder block. Then turn the crankshaft clockwise until the crankshaft counterweight of cylinder no. 1 touches the timing peg (refer to the workshop manual for details). NOTE: To prevent damage to the timing peg do not use it to lock the crankshaft in position. L1001.
Engines • Powertrain For verifying or adjusting the valve timing a timing plate (SST) has to be installed in the camshafts. NOTE: Never use the timing plate to hold the camshafts while loosening or tightening the camshaft pulleys. Hold the camshafts using a wrench on the camshaft´s cast hexagon. NOTE: From a certain build date on specially coated washers are installed between the camshaft sprockets and the camshaft to increase the friction.
Powertrain Engines Accessory Drive Belt • A V-ribbed drive belt is fitted to drive the engine accessories. • An automatic tensioner provides constant drive belt tension. L1001.4_01015 1 2 3 4 • Generator pulley Idler pulley Drive belt Power steering pump pulley 5 6 7 8 Water pump pulley A/C compressor pulley Crankshaft pulley Drive belt tensioner pulley In order to check the drive belt for wear, verify that the automatic tensioner indicator mark does not exceed the specification. L1001.
Engines Powertrain Mechanical (L3-T Engine) Features • The mechanical system of the L3-T engine has the following features: – – – – – Chain driven 16 valve DOHC engine Balancer shaft unit Valve train with automatic timing chain tensioner and mechanical bucket tappets Variable valve timing system for the intake camshaft V-ribbed belt drive with automatic tensioner Overview L1001.
Powertrain Engines Pistons • The shape of the pistons has been adapted to the requirements of the direct injection system, i.e. the piston top is recessed to improve the mixture formation. • The piston skirt is redesigned due to the modified oil jet valves. In addition, it features a coating to reduce friction between the piston and the cylinder. • Piston, piston pin and connecting rod are not shrinkage fitted, i.e. the components can be replaced separately. L1001.
Engines Powertrain Camshafts • The intake camshaft features a trochoid shaped cam, which drives the high-pressure pump of the direct injection system. L1001.
Powertrain Engines Valve Train • The valve train is equipped with a roller chain and respective sprockets to improve durability. L1001.4_01021 1 2 3 4 Camshaft sprockets Timing chain Pitch size Pin 5 6 7 8 Chain guide Crankshaft sprocket Chain tensioner Chain tensioner arm Timing Chain Tensioner • The L3-T engine features a modified automatic timing chain tensioner. However, the operating principle is the same as on the L3 engine. L1001.
Engines Powertrain Valve Timing • Due to the modified intake camshaft a different timing plate (SST) is required to verify or adjust the valve timing. L1001.
Powertrain Engines Lubrication Features • The lubrication system of the L-type engines has the following features: – – – – Chain driven trochoid gear type oil pump Water-cooled type oil cooler (L8 engine only if equipped) Spin-on type or cartridge type oil filter Oil jet valves Parts Location L1001.
Engines Powertrain Cooling System Features • The cooling system of the L-type engines has the following features: – – – – Water pump driven by the accessory drive belt Unpressurized or pressurized type coolant reserve tank (depending on model) FL22 longlife engine coolant Cooling fan controlled by relays or by a fan control module (depending on model) Parts Location L1001.4_01025 Mazda6 GG/GY 1 2 3 4 5 6 Cooling system cap Radiator Thermostat Water pump Coolant reserve tank Cooling fan motor no.
Powertrain Engines Engine Coolant • For all current Mazda vehicles except for Mazda2 (DY) Mazda has developed a special engine coolant called ‘FL22’. This coolant has a significantly longer replacement interval than conventional coolant. Whereas conventional coolant must replaced at first every 100,000 km or 4 years (whichever occurs first) and after that every 2 years, FL22 coolant must be replaced every 200,000 km or 11 years (whichever occurs first).
Engines Powertrain Z-type Engines • In the Z-type engine line-up the following engines are available: – – • ZJ engine with 1.3 L displacement (also termed as 1.3 MZR engine) Z6 engine with 1.6 L displacement (also termed as 1.6 MZR engine) Both engines are fitted in the Mazda3 models. They are equipped with a multipoint manifold injection system and a distributorless ignition system (direct ignition coils).
Powertrain Engines Overview L1001.4_01026 NOTE: Some of the components of the Z-type engine are very similar in construction and operation to those of the L-type engines. Therefore, this section only describes the components which are new or differ from those of the L-type engines.
Engines Powertrain Cylinder Block • The cylinder block is equipped with cylinder liners, the coolant jackets of which are open towards the top. • The cylinder block is composed of an upper and a lower part, in which the main bearing caps are integrated. Upper and lower cylinder block are matched to each other, i.e. they cannot be replaced separately. If one of the components exceeds the specification, the cylinder block must be replaced as a complete unit. L1001.
Powertrain Engines Pistons • The pistons of the ZJ engine only have valve recesses on the intake side, whereas the pistons of the Z6 engine have valve recesses on the intake and exhaust side. • Piston, piston pin and connecting rod are not shrinkage fitted, i.e. the components can be replaced separately. L1001.
Engines Powertrain Crankshaft • The crankshaft is equipped with a key for the installation of the crankshaft sprocket and the crankshaft pulley. • The installation procedure for the main bearing shells is the same as on the L-type engines. L1001.
Powertrain Engines Camshafts • The camshafts are equipped with a pin for the installation of the camshaft pulleys. • The intake camshaft is equipped with an oil line supplying oil to the camshaft actuator of the variable valve timing system. • The intake camshaft has a pulse wheel for the CMP sensor signals. Valve Train • The valve train is similar to that of the L-type engines. In addition, the procedure for releasing the timing chain tension is the same as on the L-type engines. L1001.
Engines Powertrain Valve Timing • For verifying or adjusting the valve timing, the crankshaft sprocket key has to be aligned with the timing mark on the oil pump housing. L1001.4_01034 1 • Timing mark 2 Crankshaft sprocket key For verifying or adjusting the valve timing, the timing marks on the camshaft sprockets have to be aligned, so that they form a straight line with the upper horizontal surface of the cylinder head. L1001.
Powertrain Engines Lubrication Features • The lubrication system of the Z-type engines has the following features: – – – – Trochoid gear type oil pump, directly driven by the crankshaft Water-cooled type oil cooler (depending on model) Spin-on type oil filter Oil jet valves Parts Location L1001.
Engines Powertrain Cooling System Features • The cooling system of the Z-type engines has the following features: – – – – Water pump driven by the accessory drive belt Pressurized type coolant reserve tank FL22 longlife engine coolant Cooling fan with cooling fan motor and integrated fan control module Parts Location L1001.
Powertrain Engines Service Procedures Adjusting the Idle Speed • On the Mazda3 with ZJ and Z6 engine the idle speed must be adjusted at specified service intervals using M-MDS. To perform the procedure select the PIDs RPM (Rpm) and test# (Mode) in the M-MDS Datalogger, and set the PID test# to ON. Now the PCM (Powertrain Control Module) uses a fixed value for the ignition timing control, so that the idle speed can be adjusted on the air adjusting screw of the throttle body.
Engines Powertrain MZI-type Engines • In the MZI engine line-up the following engines are available: – – – • 1.25 MZI engine with 1.25 L displacement 1.4 MZI engine with 1.4 L displacement 1.6 MZI engine with 1.6 L displacement The MZI-type engines are fitted in the Mazda2 (DY) models. They are equipped with a multipoint manifold injection system and a distributorless ignition system (ignition coil unit).
Powertrain Engines Overview L1001.4_01040 NOTE: Some of the components of the MZI-type engine are very similar in construction and operation to those of the L-type engines. Therefore, this section only describes the components which are new or differ from those of the L-type engines.
Engines Powertrain Cylinder Block • The cylinder block features a bearing support frame, in which the main bearing caps are integrated. The bearing support frame is matched to the cylinder block and is not located by means of guide sleeves, i.e. the components of the crank train (crankshaft, connecting rod and piston) cannot be replaced separately. If one of the components exceeds the specification, the cylinder block must be replaced as a complete unit.
Powertrain Engines Valve Train • The camshafts are driven by a timing belt, which has to be replaced every 160,000 km or 10 years (whichever occurs first). In addition, the valve clearance must be inspected (and if necessary adjusted) at the same service interval. • The procedure for verifying or adjusting the valve timing is the same as on the L-type engines.
Engines Powertrain Timing Belt Tensioner • Depending on the build date of the vehicle different manual or automatic timing belt tensioners are fitted (refer to the workshop manual for details). NOTE: On vehicles with automatic tensioner do not remove the locking pin (SST), until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or damage to the timing belt tensioner. L1001.4_01044 Manual timing belt tensioner with eccentric cam L1001.
Powertrain Engines L1001.4_01046 Automatic timing belt tensioner (vehicles built from 09/2003 onwards) 1 Locking pin (SST) L1001.
Engines Powertrain Accessory Drive Belts • A V-ribbed drive belt is fitted to drive the engine accessories. There are two variants of the accessory belt drive: – – • Vehicles without A/C have one drive belt Vehicles with A/C have two drive belts Both variants have elastic drive belts (also termed as stretchy belt), i.e. they do not need a tensioner. Since retensioning is not possible, the drive belt must not be re-used. L1001.
Powertrain • Engines In order to remove the drive belt cut it through with a knife. New drive belts are supplied in a service kit, which also contains the SSTs (installation tool and guide tool) required for installation (refer to the workshop manual for details). NOTE: The SSTs in the service kit are designed for single use only. L1001.
Engines Powertrain Lubrication Features • The lubrication system of the MZI-type engines has the following features: – – – G-rotor type oil pump, directly driven by the crankshaft Spin-on type oil filter No oil jet valves Cooling System Features • The cooling system of the MZI-type engines has the following features: – – – 01-48 Water pump driven by the accessory drive belt Pressurized type coolant reserve tank Cooling fan controlled by relays Curriculum Training
Powertrain Engines 13B-MSP Rotary Engine • The 13B-MSP (Multi Side Port) rotary engine is fitted in the Mazda RX-8 models, and is available as a standard and a high-power version. It is equipped with a manifold injection system (two injectors per rotor on the standard power engine, and three injectors per rotor on the high-power engine) and a distributorless ignition system (two direct ignition coils per rotor).
Engines Powertrain Construction • The main components of the rotary engine are the rotors, the eccentric shaft, the rotor housings, the front, rear and intermediate housings. • The rotor rotates within the rotor housing, which is sandwiched between the intermediate housing on one side, and the front or rear housing on the other, forming a sealed chamber. • The eccentric shaft transfers the rotational force of the rotors to the transmission.
Powertrain • Engines Due to the large bathub shaped combustion chambers the rotary engine is equipped with two spark plugs per rotor housing, improving combustion efficiency and exhaust emissions NOTE: Two different spark plugs (leading and trailing) with different lengths are mounted in each rotor housing. If a wrong spark plug is used the engine may be damaged (e.g. a spark plug which is too long may contact the rotor).
Engines Powertrain Operating Principle • In the rotary engine, each of the three faces of the rotor forms a chamber. These three chambers are not interconnected and their combustion cycles vary as described below. • In much the same way as the four-stroke reciprocating engine, the air/fuel mixture in a rotary engine is subjected to combustion and expansion within the engine, thus converting heat energy to output power.
Powertrain Engines Intake Stroke • The volume of the operating chamber in position 1 is at its minimum, thus corresponding with intake TDC (Top Dead Center) of a reciprocating engine. As the rotor continues to turn from 2 through to 4, the intake ports become increasingly larger and draw in the air/fuel mixture as the intake stroke begins. At the same time, the intake operating chamber increases in capacity, reaching its maximum at 5.
Engines Powertrain • The above is a description for only one chamber; the other two operate in exactly the same way. As a result of these actions by only one chamber, the rotor makes one rotation (during which the eccentric shaft turns three times), resulting in an intake of the gas mixture followed by compression, combustion and exhaust. Also, because there are three chambers on one rotor, there are three combustion (output) cycles for each revolution of the rotor.
Powertrain Engines Lubrication Features • The lubrication system of the 13B-MSP engine has the following features: – – – – – Chain driven trochoid gear type oil pump Air-cooled type oil cooler Spin-on type oil filter Metering oil pump with oil nozzles Mazda Dexelia Ultra engine oil Parts Location L1001.
Engines Powertrain Engine Oil • For the rotary engine, Mazda specifies the use of mineral engine oil. If synthetic or semisynthetic engine oil is used for the rotary engine, carbon deposits may get accumulated in the intake ports and in the combustion chamber. This can cause misfire, knocking and/or power loss as a long-term effect.
Powertrain Engines Cooling System Features • The cooling system of the 13B-MSP engine has the following features: – – – – Water pump driven by the accessory drive belt Pressurized type coolant reserve tank FL22 longlife engine coolant Cooling fan controlled by relays Parts Location L1001.
Engines Powertrain Service Procedures Compression Test • Since the operation of the rotary engine is different to that of a reciprocating engine, a compression test cannot be performed using a conventional compression tester. For this reason, WDS (Worldwide Diagnostic System) or a special rotary engine compression tester (SST) in conjunction with an adapter (SST) must be used (refer to the workshop manual for details). L1001.
Powertrain Engines L1001.4_01118 1 2 Vehicle battery Rotary engine compression tester (SST) 3 Adapter (SST) NOTE: If the cranking speed during the compression test differs from the specification, the indicated pressure values must be evaluated using the diagram below. L1001.
Engines Powertrain Notes: 01-60 Curriculum Training
Powertrain Engines Diesel Engines • The following diesel engine types are fitted in the current Mazda models: Model / Engine Mazda2 (DY) Mazda3 Y4 Y6 RF-T X X WL-C X Mazda5 X Mazda6 X Mazda BT-50 X L1001.4_T01001b RF-T Engine • The RF-T engine with 2.0 L displacement (also termed as 2.0 MZR-CD engine) is fitted in the Mazda3 F/L, the Mazda5 and the Mazda6 models, and is available as a standard and a high-power version.
Engines Powertrain Overview L1001.
Powertrain Engines Cylinder Block • The cylinder block is a conventional construction with separate main bearing caps. L1001.4_01061 Pistons • The piston shape meets the requirements of the common rail direct injection system, i.e. the combustion chamber is integrated in the piston head. • The piston skirt is coated to reduce friction between the piston and the cylinder. L1001.
Engines Powertrain Crankshaft • The crankshaft is equipped with a key for the installation of the crankshaft timing pulley and the crankshaft pulley. • In addition, the crankshaft features a drive gear for the oil pump. L1001.
Powertrain Engines Cylinder Head • The cylinder head is a conventional construction with separate camshaft bearing caps. • The cylinder head bolts are torque-to-yield bolts, which must be tightened in several stages (refer to the workshop manual for details). NOTE: The cylinder head bolts must not be re-used if their length exceeds the specification (refer to the workshop manual for details). • The leak-off lines for the fuel injectors are integrated in the cylinder head.
Engines Powertrain Camshaft • The camshaft is equipped with a key for the installation of the camshaft pulley. • The camshaft drives the vacuum pump directly, and the power steering oil pump via a helical gear. Valve Actuation • The camshaft actuates the valves via roller rocker arms and rocker bridges.
Powertrain Engines Valve Train • The camshaft is driven by a timing belt, which has to be replaced every 120,000 km. L1001.
Engines Powertrain Timing Belt Tensioner • An automatic timing belt tensioner is fitted to ensure optimum belt tension over the service life of the engine. • The timing chain tensioner operates using a hydraulic mechanism, which also compensates the increased belt tension due to heat expansion of the engine components. L1001.
Powertrain • Engines When replacing the timing belt, the timing belt tensioner has to be checked as following (refer to the workshop manual for details): – – – Measure the tensioner rod projection length. Inspect the tensioner for oil leakage. Verify the thrust/resistance of the tensioner. NOTE: If the tensioner rod projection length and/or tensioner thrust/resistance exceeds the specification and/or there is an oil leakage, replace the timing belt tensioner.
Engines Powertrain Valve Timing • For verifying or adjusting the valve timing the timing marks have to be aligned as shown below (refer to the workshop manual for details). • Before installing the timing belt the camshaft pulley must be fixed to the cylinder head using a bolt (M8 x 1.25). In addition, the fuel high-pressure pump pulley has to be locked against rotation with the aid of the FIP (Fuel Injection Pump) repair kit (part no. RFY1-13SMO).
Powertrain Engines Accessory Drive Belt • A V-ribbed drive belt is fitted to drive the engine accessories. • An automatic tensioner provides constant drive belt tension. L1001.4_01069 1 2 3 • Generator pulley Drive belt Drive belt tensioner pulley 4 5 6 A/C compressor pulley Idler pulley Crankshaft pulley In order to check the drive belt for wear, verify that the automatic tensioner indicator mark does not exceed the specification. L1001.
Engines Powertrain Lubrication Features • The lubrication system of the RF-T engine has the following features: – – – – – Trochoid gear type oil pump, directly driven by the crankshaft Water-cooled type oil cooler Spin-on type oil filter Oil jet valves Mazda Dexelia DPF engine oil Parts Location L1001.
Powertrain Engines Engine Oil • For vehicles with RF-T engine and DPF (Diesel Particulate Filter), Mazda has developed special engine oil called ‘Mazda Dexelia DPF’. This oil meets the specification ACEA C1, and has a significantly lower ash formation than normal engine oil. As a result of its very low ash formation in comparison to other engine oils, ‘Mazda Dexelia DPF’ guarantees lifetime performance of the DPF.
Engines Powertrain Cooling System Features • The cooling system of the RF-T engine has the following features: – – – – Timing belt driven water pump Unpressurized or pressurized type coolant reserve tank (depending on model) FL22 longlife engine coolant Cooling fan controlled by relays or by a fan control module (depending on model) Parts Location L1001.
Powertrain Engines Diesel Particulate Filter System • The DPF is a honeycomb structure with many channels closed off at alternate ends. The soot particulates contained in the exhaust gas accumulate at the porous dividing walls, while gaseous components such as CO and HC pass through the filter with no problem. • To prevent the filter becoming blocked with soot particulates, it must be ‘regenerated’ at certain intervals, i.e. the collected soot particulates are burnt off.
Engines Powertrain Service Procedures Replacing the Engine Oil • Every time the engine oil is replaced, the parameter “Calculated oil dilution” in the PCM must be reset with the aid of M-MDS (Mazda-Modular Diagnostic System). To perform the procedure select the option ToolboxÆPowertrainÆData ResetÆEngine Oil and follow the instructions of M-MDS.
Powertrain Engines DPF Manual Regeneration • If the DPF indicator light is illuminated and the DPF is blocked due to an excessive soot amount accumulated, it must be manually regenerated with the aid of M-MDS. To perform the procedure select the option ToolboxÆPowertrainÆDPFÆDPF Regeneration and follow the instructions of M-MDS. • Depending on the amount of soot accumulated in the DPF the PCM automatically selects normal regeneration mode (34 min) or long regeneration mode (60 min).
Engines Powertrain WL-C Engine • The WL-C engine with 2.5 L displacement (also termed as 2.5 MZR-CD engine) is fitted in the BT-50 models. It is equipped with a common rail direct injection system and a VGT turbocharger.
Powertrain Engines Overview L1001.4_01073 NOTE: Some of the components of the WL-C engine are very similar in construction and operation to those of the RF-T engine. Therefore, this section only describes the components which are new or differ from those of the RF-T engine.
Engines Powertrain Balancer Shafts • The balancer shafts are directly fitted into the cylinder block. The crankshaft drives the balancer shafts via helical gears. L1001.
Powertrain Engines Cylinder Head • The cylinder head features a bolted on camshaft bearing frame, which can be replaced separately. • The cylinder head gasket is available in three different thicknesses depending on the piston protrusion. The gasket is marked respectively (refer to the workshop manual for details). • The cylinder head bolts are torque-to-yield bolts, which must be tightened in several stages (refer to the workshop manual for details).
Engines Powertrain Camshaft • The camshafts are equipped with a pin for the installation of the camshaft pulleys. • The camshaft pulleys for the intake and exhaust camshaft are identical. A letter (“I” for intake and “E” for exhaust) on the camshaft pulleys indicates the installation position, i.e. the letter on the camshaft pulley must be aligned with the pin on the camshaft. L1001.
Powertrain Engines Valve Actuation • The camshafts actuate the valves via roller cam followers. • The valve clearance has to be measured between the roller cam follower and the cam lobe, and is adjusted through the adjusting screw of the roller cam follower (refer to the workshop manual for details).
Engines Powertrain Valve Train • The camshafts are driven via a timing belt by the fuel high-pressure pump pulley/gear, which in turn is driven via helical gears by the crankshaft. • The timing belt and the timing belt tensioner have to be replaced every 120,000 km. L1001.4_01078 1 2 3 4 5 6 7 Camshaft pulley Intake camshaft Exhaust camshaft Roller cam follower Balancer shaft Balancer shaft gear Idler gear no.3 01-84 8 9 10 11 12 13 14 Crankshaft gear Idler gear no.1 Idler gear no.
Powertrain • Engines The crankshaft gear and the fuel high-pressure pump gear are equipped with friction gears. The spring-loaded friction gears eliminate the backlash between the meshing gears, reducing gear noise. NOTE: Before removing the fuel high-pressure pump gear, the friction gear must be fixed to the fuel high-pressure pump gear using a detent bolt (M6 x 1.0, length approx. 16 mm) to prevent it from rotating due to the spring force. L1001.
Engines Powertrain Timing Belt Tensioner • The WL-C engine features a modified automatic timing belt tensioner with integrated tensioner pulley. However, the operating principle is the same as on the RF-T engine. L1001.
Powertrain Engines Valve Timing • For verifying or adjusting the valve timing of the gear drive the timing marks have to be aligned as shown below (refer to the workshop manual for details). • All helical gears except for the fuel high-pressure pump gear have a punch mark as timing mark. However, the punch marks on the crankshaft gear and on the fuel-highpressure pump gear can only be seen when the friction gears are removed.
Engines • Powertrain For verifying or adjusting the valve timing of the belt drive, the timing marks have to be aligned as shown below (refer to the workshop manual for details). L1001.
Powertrain Engines Accessory Drive Belt • Three V-drive belts are fitted to drive the engine accessories, i.e. two belts drive the generator and one belt drives the A/C compressor. • The drive belt tension can be adjusted via two manual tensioners (refer to the workshop manual for details). NOTE: The belt deflection has to be checked when the engine is cold, or at least 30 minutes after the engine has been switched off. L1001.
Engines Powertrain Lubrication Features • The lubrication system of the WL-C engine has the following features: – – – – Gear type oil pump, directly driven by the crankshaft Water-cooled type oil cooler Spin-on type oil filter Oil jet valves Parts Location L1001.
Powertrain Engines Cooling System Features • The cooling system of the WL-C engine has the following features: – – – – Water pump driven by the accessory drive belts Unpressurized type coolant reserve tank FL22 longlife engine coolant Thermo-modulation type cooling fan Parts Location L1001.
Engines Powertrain Service Procedures MAF Sensor Learning Function • The MAF learning function is used to compensate the deviations of the amount due to measured intake air deterioration of the MAF sensor. It has to be carried out at specified service intervals by means of M-MDS. During this procedure the MAF learning function is performed at engine speeds of 750 min-1, 1850 min-1, and 2500 min-1.
Powertrain Engines Y-type Engines • In the Y-type engine line-up the following engines are available: – – Y4 type with 1.4 L displacement (also termed as 1.4 MZ-CD engine) Y6 type with 1.6 L displacement (also termed as 1.6 MZ-CD engine) • The Y4 engine is fitted in the Mazda2 (DY) models. It is equipped with a common rail direct injection system and a FGT turbocharger • The Y6 engine is fitted in the Mazda3 models, and is available as a standard and a highpower version.
Engines Powertrain Overview L1001.4_01086 NOTE: Some of the components of the Y4 engine are very similar in construction and operation to those of the RF-T engine. Therefore, this section only describes the components which are new or differ from those of the RF-T engine.
Powertrain Engines Cylinder Block • The cylinder block is equipped with cylinder liners, the coolant jackets of which are open towards the top. • The cylinder block is composed of an upper and a lower cylinder block, in which the main bearing caps are integrated. Upper and lower cylinder block are matched to each other, i.e. they cannot be replaced separately. If one of the components exceeds the specification, the cylinder block must be replaced as a complete unit.
Engines Powertrain Pistons • The pistons have valve recesses for the intake and exhaust valves. • The piston skirt is coated to reduce friction between the piston and the cylinder. • The connecting rods are fracture-split on the big end to ensure a perfect fit between connecting rod and connecting rod bearing cap. For this reason, the pairs of connecting rods and connecting rod bearing caps must be kept together during removal. L1001.
Powertrain Engines Crankshaft • The crankshaft is equipped with a key for the installation of the crankshaft timing pulley and the crankshaft pulley. • The crankshaft timing pulley has a magnetic pulse wheel for the CKP sensor signals. NOTE: When removing or installing the crankshaft timing pulley care must be taken, since scratches or impacts can de-magnetize the magnetic pulse wheel.
Engines Powertrain L1001.4_01090 1 • Diameter classes of the main journals 2 Diameter classes of the main bearings The correct tolerance class for the lower bearing shell of each main bearing can be determined by the diagram shown below. L1001.
Powertrain • Engines There is no positioning tab for locating the lower bearings in the main journals. For installing the lower main bearing shells a guide (SST) and two guide studs (SST) are required (refer to the workshop manual for details). L1001.
Engines Powertrain Cylinder Head • The cylinder head features a bolted on camshaft housing, which comprises an upper and a lower part. Upper and lower camshaft housing as well as the cylinder head are matched to each other, i.e. they cannot be replaced separately. If one of the components exceeds the specification, the cylinder head must be replaced as a complete unit. • There are no guide sleeves for locating the camshaft housing on the cylinder head.
Powertrain Engines Valve Actuation • The camshaft actuates the valves via roller cam followers. • The adjustment of the valve clearance is performed via maintenance-free hydraulic tappets. L1001.
Engines Powertrain Valve Train • The camshaft is driven by a timing belt, which has to be replaced every 240,000 km or 10 years (whichever occurs first). NOTE: The timing belt must not be re-used. NOTE: The timing belt has to be installed with the arrows pointing in the direction of engine rotation. L1001.
Powertrain Engines Timing Belt Tensioner • An automatic timing belt tensioner is fitted to ensure optimum belt tension over the service life of the engine. • For tensioning the timing belt, turn the tensioner with an Allen key until the pointer is aligned with the corresponding mark on the housing, and tighten the bolt (refer to the workshop manual for details). L1001.
Engines Powertrain Valve Timing • For verifying or adjusting the valve timing, the crankshaft timing peg (SST) has to be installed in the cylinder block, and the camshaft timing peg (SST) in the cylinder head. • Depending on whether or not there is a hole for the crankshaft timing peg (SST) in the bracket of the fuel high-pressure pump, the fuel high-pressure pump pulley must be aligned in either of the two ways shown below (refer to the workshop manual for details). L1001.
Powertrain Engines Mechanical (Y6 Engine) Features • The mechanical system of the Y6 engine has the following features: – – Belt and chain driven 16 valve DOHC engine – – Vacuum pump driven by the exhaust camshaft Valve train with automatic timing belt tensioner, roller cam followers and hydraulic tappets V-ribbed belt drive with automatic tensioner Overview L1001.4_01101 NOTE: Some of the components of the Y6 engine are very similar in construction and operation to those of the Y4 engine.
Engines Powertrain Cylinder Head • The cylinder head is composed of an upper and a lower part. Upper and lower cylinder head are matched to each other, i.e. they cannot be replaced separately. If one of the components exceeds the specification, the cylinder head must be replaced as a complete unit. • There are no guide sleeves for locating the cylinder head upper part on the lower part.
Powertrain Engines Camshafts • The camshafts are mounted hanging in the upper part of the cylinder head. • The intake camshaft drives the exhaust camshaft by a timing chain. • The intake camshaft is equipped with a key for the installation of the camshaft pulley. • The exhaust camshaft drives the vacuum pump directly. L1001.
Engines Powertrain • An automatic timing chain tensioner is fitted to ensure optimum chain tension over the service life of the engine. • The timing chain tensioner operates using engine oil pressure. NOTE: The timing chain tensioner must be inserted together with the timing chain and the camshafts into the cylinder head upper part, as it is impossible to fit it afterwards. L1001.
Powertrain Engines Valve Train • The valve train is similar to that of the Y4 engine except for the additional chain drive of the exhaust camshaft. For this reason, the procedure for verifying or adjusting the valve timing is the same as on the Y4 engine. L1001.
Engines Powertrain Lubrication Features • The lubrication system of the Y-type engines has the following features: – – – – Trochoid gear type oil pump, directly driven by the crankshaft Water-cooled type oil cooler Cartridge type oil filter Oil jet valves Parts Location L1001.
Powertrain Engines Cooling System Features • The cooling system of the Y-type engines has the following features: – – – – Timing belt driven water pump Pressurized type coolant reserve tank FL22 longlife engine coolant (only Y6 engine) Cooling fan controlled by relays or by a fan control module (depending on model) Parts Location L1001.
Engines Powertrain Diesel Particulate Filter System • The Mazda3 with Y6 high-power engine features a DPF with a honeycomb structure, which must be regenerated at certain intervals. In order to facilitate the regeneration process, the Mazda3 uses a special fuel additive that is automatically injected into the fuel tank. During the combustion process the additive attaches itself to the soot particulates, which then accumulate in the filter.
Powertrain Engines Service Procedures Bleeding the Fuel System • Since the Mazda3 with Y6 engine features no priming pump for the low-pressure fuel system, a hand pump (SST) must be used to bleed the system when the fuel filter has been replaced (refer to the workshop manual for details). L1001.
Engines Powertrain Refilling the Fuel Additive Tank • The fuel additive tank must be refilled every 60,000 km. Due to its installation position at the crossmember behind the fuel tank, a special fuel additive refill kit is available, which consists of the fuel additive container, filler hose with valve, overflow hose and overflow bottle (refer to the workshop manual for details).
Powertrain Engines Installing a New DPF • The DPF must be replaced every 120,000 km Thereafter, the parameters for the regeneration control in the PCM and the parameter“ Total additive injection amount” in the FACM must be reset with the aid of M-MDS. To perform the procedure select the option ToolboxÆPowertrainÆService FunctionsÆDPF Component/Parameter CommandsÆReset Particulate Filter Learned Values and follow the instructions of M-MDS.
Engines Powertrain Notes: 01-116 Curriculum Training
Powertrain Transmissions Drive Train • The following drive train types are used on the current Mazda models: – – – FWD (Front Wheel Drive) RWD (Rear Wheel Drive) 4WD (4 Wheel Drive) Model / Drive train FWD Mazda2 (DY) X Mazda3 X Mazda3 MPS X Mazda5 X Mazda6 X RWD 4WD Mazda6 MPS X Mazda CX-7 X Mazda MX-5 X Mazda RX-8 X Mazda BT-50 X X L1001.
Transmissions Powertrain Transmission Code • The transmissions of the current Mazda models except for Mazda2 (DY) have a 5- or 6-digit alphanumerical code, which contains the information shown below.
Powertrain Transmissions Manual Transmissions • Depending on the installation position of the engine different types of manual transmissions are used. Vehicles with transversally installed engine feature a MTX (Manual Transaxle) and vehicles with longitudinally installed engine a MT (Manual Transmission). The basic difference between MTX and MT is that the MTX has a differential integrated in the transmission housing, while the MT has an external differential at the rear axle.
Transmissions Powertrain F35M-R Transmission • The F35M-R transmission is a two-shaft five-speed MTX, which is operated via cables. It is only fitted in the Mazda3 models with Z-type engine. Overview L1001.
Powertrain Transmissions Service Procedures Transmission Oil Inspection • For transmission oil inspection on the F35M-R transmission the distance between upper edge of the hole in the transmission housing and oil level must be measured as shown below (refer to the workshop manual for details).
Transmissions Powertrain A26M(X)-R Transmission • The A26M(X)-R transmission is a three-shaft (non-coaxial arranged) six-speed MTX, which is operated via cables. • The A26M-R transmission is fitted in the Mazda3, Mazda5 and Mazda6 models with RF-T engine, and in the Mazda3 MPS models. The A26MX-R transmission with boltedon transfer case is fitted in the Mazda6 MPS and Mazda CX-7 models.
Powertrain Transmissions • The three shaft design with one input shaft and two output shafts allows for a more compact construction, since each output shaft only carries three or four gears. • As a result of this construction there are two different final gear ratios available, i.e. one for the first to fourth gear and another one for the fifth, sixth and reverse gear. L1001.4_02003 1 2 Differential Output shaft no. 1 Curriculum Training 3 4 Output shaft no.
Transmissions Powertrain S15M(X)-D Transmission • The S15M(X)-D is a three-shaft (coaxial arranged) five-speed MT, which is directly operated by the shift lever. • The S15M-D transmission is fitted in the RWD version of the Mazda BT-50, while the S15MX-D transmission with bolted-on transfer case is fitted in the 4WD version.
Powertrain Transmissions Automated Shift Manual Transmission • The automated shift manual transmission is based on the two-shaft five-speed MTX iB5. Compared to the cable operated version of the iB5 transmission the automated shift manual transmission features a bolted-on shift actuator, and a separate clutch actuator with integrated TCM (Transmission Control Module).
Transmissions Powertrain Service Procedures Bleeding the Clutch System • The hydraulic fluid of the clutch system should be replaced every two years, together with the hydraulic fluid of the brake system. Since the clutch system can only be bled in a certain position of the clutch master cylinder, the clutch actuator first needs to be driven to this position with the aid of M-MDS.
Powertrain Transmissions Automatic Transmissions • Depending on the installation position of the engine different types of automatic transmissions are used. Vehicles with transversally installed engine feature an ATX (Automatic Transaxle) and vehicles with longitudinally installed engine an AT (Automatic Transmission). The basic difference between ATX and AT is that the ATX has a differential integrated in the transmission housing, while the AT has an external differential at the rear axle.
Transmissions Powertrain FS5A-EL Transmission • The FS5A-EL transmission is a five-speed ATX, which is controlled electronically by a TCM. It is only fitted in the Mazda6 models with LF and L3 engine. NOTE: When replacing or refilling the ATF (Automatic Transmission Fluid) and/or the separate transfer oil only use the specified type of oil (refer to the workshop manual for details). Overview L1001.
Powertrain Transmissions Limited Slip Differential • For the current Mazda models a taper ring type LSD (Limited Slip Differential) is used (also termed as “Super LSD”). It is fitted to the rear axle of the Mazda6 MPS, Mazda MX-5, Mazda RX-8, Mazda BT-50, and to the MTX of the Mazda3 MPS. Overview L1001.
Transmissions Powertrain Service Procedures Rear Differential Oil Inspection and Oil Replacement • There are two different rear differentials (type A and type B) for the Mazda BT-50. The difference is the position of the oil filler hole due to a revised oil capacity. On the type A rear differential the oil level is higher than the oil filler hole, i.e. special measures are required for rear differential oil inspection and oil replacement.
Powertrain List of Abbreviations A/C Air Conditioning F/L Facelift ACEA Association des Constructeurs Européens d'Automobiles FWD Front Wheel Drive HC Hydro Carbon API American Petroleum Institute LCD Liquid Crystal Display AT Automatic Transmission LF Left Front ATF Automatic Transmission Fluid LSD Limited Slip Differential ATX Automatic Transaxle MAF Mass Air Flow AWD All Wheel Drive MESI BDC Bottom Dead Center Mazda Electronic Service Information CKP Crankshaft Position M-M
List of Abbreviations SAE Society of Automotive Engineers SOHC Single Overhead Camshaft SST Special Service Tool TCM Transmission Control Module TEN Test ENgine TCM Transmission Control Module TDC Top Dead Center VGT Variable Geometry Turbocharger WDS Worldwide Diagnostic System W/M Workshop Manual 2WD 2 Wheel Drive 4WD 4 Wheel Drive 03-2 Powertrain Curriculum Training
