TRAINING MANUAL Mazda5
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.
Contents Title Section General Information 00 Engine 01 Suspension 02 Driveline / Axle 03 Brakes 04 Transmission / Transaxle 05 Steering 06 Heater, Ventilation & Air Conditioning (HVAC) 07 Restraints 08 Body & Accessories 09 Service Training Mazda5
Service Training Mazda5
00 General Information
00 General Information General Information ............................................................................................1 Product Concept .............................................................................................1 Jacking and Lifting ..........................................................................................2 Towing ............................................................................................................3 Vehicle Identification Number .....
General Information General Information Product Concept • When Mazda began developing its next-generation MAV (Multi Activity Vehicle), it set its sights on creating a new global standard. It goes without saying that a MAV is intended to carry a lot of people and a lot of luggage. From this basic premise, we characterized our MAV as a ‘lifestyle partner’ that enables people to enjoy activities together with relatives and friends.
General Information Jacking and Lifting • The front of the vehicle can be lifted with a jack near the center of the front crossmember. M5_00002 1 2 Front crossmember Jack up position 3 Front NOTE: To prevent obstruction between the jack body and front bumper when the jack body is inserted, use a low floor type jack (frame height is 170 mm or less). • The rear of the vehicle can be lifted with a jack at the center of the rear crossmember.
General Information • The vehicle can be lifted with a lift at the indicated positions on the side sill. M5_00004 Towing • When towing the vehicle, remove the towing eylet from the storage box in the rear cargo area, open the cap located on the front bumper and install the towing eyelet.
General Information • A towing eyelet and tie down hook are provided at the rear of the vehicle. M5_00006 1 Tie down hook 2 Towing eyelet Vehicle Identification Number • The VIN (Vehicle Identification Number) is located on the cowl plate in the engine compartment.
General Information • The VIN key is shown as below: JMZ CR 1 9 8 2 5 # 1 2 3 4 5 6 Serial No. 0 = Hiroshima Plant 1 = Hofu For Europe-RHD : Dummy 0 For Europe-LHD : Dummy 5 to 9 (Same as model year-Israel etc.) For Others : Model year 5 = 2005 2 = 5MTX 5 = 4ATX Transmission 6 = 6MTX 8 = L8 (1.8 L) F = LF (2.0 L) T = RF-Turbo-Standard power (2.0 L) Engine Type R = RF-Turbo-High power (2.
General Information Engine Identification Number • The engine identification number is located on the cylinder block as shown below: L8/LF M5_00008 MZR-CD M5_00009 1 00-6 Front Service Training Mazda5
General Information Technical Data 1.8 L MZR Engine 3 Displacement 1798 cm Bore x Stroke 83 x 83.1 mm 10.8:1 Compression Ratio Maximum Power 85 kW {115 PS} at 5,300 rpm Maximum Torque 165 Nm at 4,000 rpm Euro 4 Emission Standard 2.0 L MZR Engine 3 Displacement 1999 cm Bore x Stroke 87.5 x 83.1 mm 10.8:1 Compression Ratio Maximum Power 107kW {145 PS} at 6,000 rpm Maximum Torque 185 Nm at 4,500 rpm Euro 4 Emission Standard 2.
General Information Maintenance Schedule Maintenance Interval (Number of months or km (miles), whichever comes first) Months x1000 km x1000 miles Maintenance Item 12 20 12.5 24 40 25 36 60 37.5 48 80 50 60 100 62.5 72 120 75 84 140 87.5 96 108 160 180 100 112.5 GASOLINE ENGINE Audible inspection every 120,000 km (75,000 miles), if noisy, adjust.
General Information I R C D • : Inspect and clean, repair, adjust, or replace if necessary. : Replace : Clean : Drain Refer below for a description of items marked * in the maintenance chart. – *1: If the vehicle is operated under hard conditions (dusty road, extended periods of idling or low speed operation, cold temperature or short driving distances), change the engine oil and oil filter every 10,000 km (6,250 miles) or less.
General Information NOTES: 00-10 Service Training Mazda5
01 Engines
01 Engines Table of Contents L8/LF Engines Mechanical System .............................................................................................1 Features..........................................................................................................1 Specifications..................................................................................................1 Overview .........................................................................................................
01 Engines Table of Contents (continued) Emission System...............................................................................................20 Features........................................................................................................20 Parts Location ...............................................................................................20 Charging System...............................................................................................22 Features.........
01 Engines Table of Contents (continued) Cooling System .................................................................................................40 Features........................................................................................................41 Specifications................................................................................................41 Parts Location ...............................................................................................
01 Engines Table of Contents (continued) Charging System...............................................................................................80 Features........................................................................................................80 Specifications................................................................................................80 Parts Location ...............................................................................................
NOTES: Table of Contents 01 Service Training Mazda5
L8/LF Engines Mechanical System Mechanical System Features • The mechanical system of the L8/LF engines is essentially the same as the Mazda6 (GG/GY) with L8/LF engines except for the following: – A new engine support hanger SST (49C0175AO) has been introduced.
Mechanical System L8/LF Engines Engine Performance Curve M501T066 1 2 3 01-2 L8 engine LF engine Engine speed 4 5 Output Torque Service Training Mazda5
L8/LF Engines Lubrication System Lubrication System Features • The lubrication system is essentially the same as that on the Mazda6 (GG/GY). It has the following features: – – Spin-on type oil filter. Water-cooled type oil cooler. Specifications Item Specification Force-fed type Type Oil pressure [oil temperature: 100°C {212°F}] (kPa {kgf/cm2, psi} [rpm]) 234—521 {2.39—5.31, 33.9—75.
Lubrication System L8/LF Engines Parts Location M5_01001 1 2 3 4 5 6 7 8 01-4 Oil pump chain tensioner Oil pump chain guide Oil pump chain Oil pump sprocket Oil pump O-ring Oil strainer Oil drain plug 9 10 11 12 13 14 15 16 Washer Oil pan Oil jet valve Oil filter adapter Oil pressure switch Oil filter Gasket Oil cooler Service Training Mazda5
L8/LF Engines Cooling System Cooling System Features • The cooling system has the following features: – Cooling system pressure cap has been moved from the coolant reserve tank to the cooling system filler neck. – – – A long-life engine coolant has been introduced. Separate cooling system filler neck has been introduced. Stepless cooling fan controlled by a fan control module has been introduced. Specifications Item Type Coolant capacity (approx.
Cooling System L8/LF Engines Parts Location M5_01002 1 2 3 4 5 6 01-6 Cooling system cap Coolant reserve tank Cooling system filler neck Radiator Thermostat Water pump 7 8 9 10 11 Cooling fan assembly Cooling fan Radiator cowling Cooling fan motor Fan control module Service Training Mazda5
L8/LF Engines Cooling System System Overview M5_01003 1 2 3 4 5 6 Coolant reserve tank Cooling system filler neck Radiator Thermostat Water pump Cylinder block 7 8 9 10 11 12 Cylinder head EGR valve Heater Oil cooler (AT) Oil cooler Coolant flow Long Life Coolant • The use of long life coolant means that coolant life is extended to 200,000 km (125,000 miles) or 11 years.
Cooling System L8/LF Engines Cooling Fan • The cooling fan assembly consists of the radiator cowling, cooling fan, cooling fan motor, and the fan control module. • The fan control module drives the fan motor based on a duty signal received from the PCM. This allows variable control of the fan motor speed, reducing fan operation noise and electrical load, and improving engine warm up time.
L8/LF Engines Cooling System Control • The cooling fan is controlled according to the engine coolant temperature as follows : Conditions Duty ratio • Engine coolant temperature is less than 100 ° C {212 ° F}. 0% • Engine coolant temperature is 106—108 ° C {223—226 ° F}. 75% • Engine coolant temperature is 108 ° C {226 ° F} or more.
Cooling System L8/LF Engines Fail-safe Function Over-current Failsafe • If current to the fan motor exceeds a specified value, the fan control module stops the fan motor for a specified amount of time. Overheat Failsafe • If the internal temperature of the fan module exceeds a specified value, the fan control module operates the cooling fan at high speed.
L8/LF Engines Intake-air System Intake-air System Features • The intake-air system is essentially the same as that on the current Mazda3 (BK) with LF engine. It has the following features: – – – Variable intake air system is used (LF engines only). – Plastic intake manifold is used. Variable tumble control system is used. Two resonance chambers, one near the fresh-air duct and one near the air cleaner are used.
Intake-air System L8/LF Engines Parts Location M5_01070 1 2 Fresh-air duct Resonance chamber (fresh-air duct side) 8 9 3 4 5 6 7 Air cleaner Resonance chamber (air cleaner side) Throttle body IAC valve Variable intake air solenoid valve (LF engine) 10 11 12 13 01-12 Variable tumble solenoid valve Variable intake air shutter valve actuator (LF engine) Variable tumble shutter valve actuator Intake manifold Accelerator cable Accelerator pedal Service Training Mazda5
L8/LF Engines Intake-air System System Overview M5_01071 1 Air cleaner 9 2 Resonance chamber (fresh-air duct side) 10 3 4 5 6 7 8 Resonance chamber (air cleaner side) IAC valve Throttle body Vacuum chamber Check valve Variable intake air solenoid valve (LF engine) 11 12 13 14 15 Service Training Mazda5 Variable intake air shutter valve actuator (LF engine) Variable intake air shutter valve (LF engine) Variable tumble solenoid valve Variable tumble shutter valve actuator Variable tumble shutter
Fuel System L8/LF Engines Fuel System Features • The fuel system is essentially the same as that used on the current Mazda3 (BK) except for the following: – – – Steel fuel tank is used. – – Quick connectors attaching the fuel hoses to the fuel tank have been changed. Fuel pump unit can be removed through access hole under second row seats. Fuel pump unit can be disassembled and individual components replaced (fuel pump motor, fuel gauge sender, low pressure filter, pressure regulator).
L8/LF Engines Fuel System Parts Location M5_01007 1 2 Fuel injector Quick release connectors Service Training Mazda5 3 4 Main fuse block Fuel pump relay 01-15
Fuel System L8/LF Engines M5_01008 1 2 Fuel tank Fuel pump unit 01-16 3 Quick release connector Service Training Mazda5
L8/LF Engines Fuel System Fuel Line Removal • A new SST has been introduced to enable the disconnection of the fuel line quick connector used at the fuel pump unit.. • The quick release connector can be disconnected by pinching the retainer tab with the SST and pulling the connector. M5_01009 1 • SST 49 E042 001 The quick release connectors are fitted with a checker tab that prevents improper fit. This checker tab cannot normally be removed.
Fuel System L8/LF Engines Fuel Pump Control • When the ignition is switched ON, the PCM turns the fuel pump relay on for one second. • When a crankshaft position sensor signal is detected during cranking, the fuel pump relay is turned ON. • The fuel pump relay remains ON for approximately two seconds after the ignition has been switched OFF, to improve engine starting.
L8/LF Engines Exhaust System Exhaust System Features • The exhaust system has the following features: – An exhaust system that can be replaced in sections has been utilized.
Emission System L8/LF Engines Emission System Features • The emission system on the Mazda5 is the same as that of the current Mazda3 (BK) with LF engine. It has the following features: – – Exhaust gas recirculation system is used. Three-way catalytic converter with warm-up converter is used.
L8/LF Engines Emission System Fuel Tank M5_01068 1 2 3 Fuel filler cap Charcoal canister Evaporative chamber Service Training Mazda5 4 5 Check valve (two-way) Rollover valve 01-21
Ignition System L8/LF Engines Charging System Features • The charging system on the Mazda5 is the same as that of the current Mazda3 (BK) with LF engine. It has the following features: – – A non-regulator type generator with built-in power transistor is used. Cooling duct is provided for the battery.
L8/LF Engines Charging System Ignition System Features • The ignition system has the following features: – An ignition system with direct ignition coils and independent ignition control has been adopted. – Iridium type spark plugs are used.
Ignition System L8/LF Engines Ignition Coils • Ignition coils installed directly to each spark plug have been adopted. • The direct ignition coil consists of an ignition coil with integrated power transistor, ignition coil connector, and rubber boot. • Construction of the ignition coils is essentially the same as those on the current Mazda3 (BK) with ZJ/Z6 engine. M5_01014 1 2 3 4 5 6 Ignition coil external view Ignition coil Ignition coil electrical circuit PCM Cylinder number No.
L8/LF Engines Control System Control System Features • The engine control system is essentially the same as that of the Mazda3 (BK) with LF engine.
Control System L8/LF Engines Parts Location M5_01015 1 2 3 4 5 6 7 8 9 10 MAF/IAT sensor TP sensor IAC valve MAP sensor CKP sensor KS Fuel injector CMP sensor VIS solenoid valve (LF engine) VTCS solenoid valve 01-26 11 12 13 14 15 16 17 18 19 PCM Purge solenoid valve EGR valve Neutral switch (MT) TR switch (AT) HO2S (front, rear) ECT sensor Brake switch CPP switch (MT) Service Training Mazda5
L8/LF Engines Control System System Overview M5_01016 1 2 3 4 5 6 7 8 9 10 Air cleaner MAF/IAT sensor TP sensor MAP sensor CMP sensor ECT sensor CKP sensor Front H O2S Rear HO2S Purge solenoid valve Service Training Mazda5 11 12 13 14 15 16 17 18 19 20 EGR valve VIS solenoid valve (LF engine) VTCS solenoid valve IAC valve Fuel pump unit KS Fuel injector BARO sensor PCM To PCM 01-27
Control System L8/LF Engines Refrigerant pressure switch (medium pressure) Battery voltage Generator (terminal P: stator coil) Vehicle speed signal Instrument cluster Output IAC valve VIS solenoid valve VTCS solenoid valve Fuel injectors Fuel pump relay Ignition coil EGR valve Purge solenoid valve Front HO2S heater Rear HO2S heater A/C relay Fan control module Starter relay Generator (terminal D: field coil) 01-28 x x x x x x x x x x x x x x x x x x x x x x x x x Generator control x x Immob
2.0 MZR-CD Engine Mechanical System Mechanical System Features • The mechanical system of the vehicles with 2.0 MZR-CD engine has the following features: – – Pistons with a modified combustion chamber have been introduced. Cylinder head with integrated injector leak-off lines has been introduced.
Mechanical System 2.
2.
Mechanical System 2.0 MZR-CD Engine Pistons • Pistons with a modified combustion chamber have been introduced to achieve a lower compression ratio of ε = 16.7 . This leads to lower pumping losses and optimized thermal efficiency at middle and high engine load, reducing the fuel consumption.
2.0 MZR-CD Engine Mechanical System Cylinder Head • A cylinder head with integrated leak-off lines for the injectors has been introduced.
Lubrication System 2.0 MZR-CD Engine Lubrication System Features • The lubrication system of the vehicles with 2.0 MZR-CD engine has the following features: – – – An engine oil with reduced ash content has been introduced. An oil dipstick with an additional “X” mark has been introduced. Oil cooler and oil filter located at the rear of the engine have been introduced.
2.
Lubrication System 2.0 MZR-CD Engine Engine Oil • In order to limit the ash amount accumulated in the diesel particulate filter, an engine oil with reduced ash content is required. This oil must meet the specification ACEA C1 (equivalent to the Japanese specification JASO DL-1) and is also termed as low SAPS (Sulphate Ash, Phosphor, Sulphur) oil, since it has a reduced proportion of these components.
2.0 MZR-CD Engine Lubrication System Oil Dipstick • Since the fuel post-injections required to regenerate the DPF can lead to an excessively high engine oil dilution, an “X” mark has been added to the oil dipstick to make the customer aware of this condition. If the oil level is close to or exceeds the “X” mark, the engine oil must be replaced.
Lubrication System 2.0 MZR-CD Engine Oil Dilution Calculation • The PCM calculates the oil dilution amount based on the duration of the regeneration process and the regeneration intervals. • If the engine oil level reaches a certain limit due to oil dilution, DTC P252F is stored in the PCM but no warning light is illuminated.
2.0 MZR-CD Engine • Lubrication System The different conditions of the oil dilution are described in the following table. Engine oil dilution Item Engine oil level DPF indicator light — — Flashes every 0.4 s MIL — — — Output restriction — — Max.
Lubrication System 2.0 MZR-CD Engine Oil Cooler and Oil Filter • An oil cooler and oil filter located at the rear of the engine have been introduced.
2.0 MZR-CD Engine Cooling System Cooling System Features • The cooling system of the vehicles with 2.0 MZR-CD engine has the following features: – – A long-life engine coolant has been introduced (similar to that of the L8/LF engines). – Stepless cooling fan controlled by a fan control module has been introduced (similar to that of the L8/LF engines). Separate cooling system filler neck has been introduced (similar to that of the L8/LF engines). Specifications Item Type Coolant capacity (approx.
Cooling System 2.
2.0 MZR-CD Engine Intake-air System Intake-air System Features • The intake-air system of the vehicles with 2.0 MZR-CD engine has the following features: – – MAF learning function has been cancelled. – Manifold absolute pressure sensor located above the intake manifold has been introduced. – Variable swirl control valves have been cancelled. Turbocharger with variable geometry turbine and reduced turbine diameter has been introduced.
Intake-air System 2.0 MZR-CD Engine Turbocharger • A turbocharger with variable geometry turbine and reduced turbine diameter has been introduced. This leads to a lower inertia moment of the turbine, improving the response of the engine during acceleration.
2.0 MZR-CD Engine Intake-air System Manifold Absolute Pressure Sensor • A MAP (Manifold Absolute Pressure) sensor located above the intake manifold has been introduced.
Fuel System 2.0 MZR-CD Engine Fuel System Features • The fuel system of the vehicles with 2.0 MZR-CD engine has the following features: – – – – Common rail located above the intake manifold has been introduced. Solenoid valve-type injectors with injector correction factors have been introduced. Injector driver module has been cancelled. Injection amount learning function has been modified.
2.0 MZR-CD Engine Fuel System Common Rail • A common rail located above the intake manifold has been introduced.
Fuel System 2.0 MZR-CD Engine Injectors • Solenoid valve-type injectors with lower power consumption and better response have been introduced. M5_01072 1 2 From common rail Connector 3 To fuel tank NOTE: Since the size of the injector connector is relatively big compared to the diameter of the injector head, there might be an interference between the connector and the injector seal during removal and installation of the cylinder head cover.
2.0 MZR-CD Engine • Fuel System The injectors are directly driven by the PCM. The module has a high-voltage generator inside, which amplifies the battery voltage into a high voltage of approx. 90 V and stores it in a capacitor. A control circuit outputs the high voltage to the injectors as a drive signal. M5_01073 1 2 3 4 • From PCM control relay High voltage generator PCM Injector no.1 5 6 7 8 Injector no 2 Injector no 3 Injector no.4 Control circuit All injectors are connected in parallel, i.e.
Fuel System 2.0 MZR-CD Engine • When the required injection amount is small, the PCM outputs a short drive signal to the injectors. As a result, the opening time of the injectors is short, resulting in a small injection amount. • When the required injection amount is large, the PCM outputs a long drive signal to the injectors. As a result, the opening time of the injectors is long, resulting in a large injection amount.
2.0 MZR-CD Engine Fuel System NOTE: When re-installing the injectors after a repair, they must be matched to the cylinders they were removed from. Therefore make a note of the injector correction factors and the allocated cylinders before removing the injectors. Failure to follow this instruction may cause irregular idling, increased combustion noise and/or increased black smoke emissions. Injection Amount Learning Function • The injection amount learning function has been modified.
Emission System 2.
2.0 MZR-CD Engine Emission System Exhaust System Features • The exhaust system of the vehicles with 2.0 MZR-CD engine has the following features: – – Warm-up oxidation catalytic converter has been cancelled. Diesel particulate filter integrated in the housing of the oxidation catalytic converter has been introduced.
Emission System 2.0 MZR-CD Engine Exhaust Gas Recirculation System Features • The exhaust gas recirculation system of the vehicles with 2.0 MZR-CD engine has the following features: – – – EGR valve with direct current motor and position sensor has been introduced. EGR cooler located at the transmission-side of the engine has been introduced. Intake shutter valve with direct current motor and position sensor has been introduced.
2.0 MZR-CD Engine • Emission System The position of the EGR valve is controlled by the PCM, which activates the DC motor via a duty signal. M5_01033 1 2 DC motor PCM 3 Current detection circuit • At low engine speeds the PCM controls the DC motor with a large duty cycle, so that the EGR valve opens and exhaust gas is recirculated. • At high engine speeds the PCM controls the DC motor with a small duty cycle, so that the EGR valve closes and no exhaust gas is recirculated.
Emission System • 2.0 MZR-CD Engine The EGRVP (EGR Valve Position) sensor is integrated in the DC motor and detects its position by a sliding contact potentiometer. When the EGR valve opens the resistance of the potentiometer rises. The sensor supplies the PCM with an analogue voltage signal between 0…5 V. NOTE: After the EGR valve is replaced, its adaptation values in the PCM must be reset and the EGRVP sensor initialized (refer to the section “Control System, Maintenance and Repair”).
2.0 MZR-CD Engine Emission System EGR Cooler • An EGR cooler located at the transmission-side of the engine has been introduced.
Emission System 2.0 MZR-CD Engine Intake Shutter Valve • An ISV (Intake Shutter Valve) with DC motor and position sensor has been introduced. A reduction gear ensures, that a large rotation angle of the motor results in a small rotation angle of the valve. • The valve body is connected to the engine coolant circuit to prevent icing of the ISV at low ambient temperatures.
2.0 MZR-CD Engine • Emission System The position of the ISV is controlled by the PCM, which activates the DC motor via a duty signal. M5_01033 1 2 DC motor PCM 3 Current detection circuit • When the required EGR rate is high the PCM controls the DC motor with a large duty cycle. As a result, the ISV closes halfway, reducing the cross-section of the intake pipe. Thus a vacuum is generated in the intake manifold and a large amount of exhaust gas can be recirculated.
Emission System 2.0 MZR-CD Engine • In order to remove any deposits from the ISV a cleaning mode is activated each time the engine is shut off. Therefore, the PCM actuates the ISV so that it is moved from the fully open position to the fully closed position several times. This process takes approx. 10 s. • The PCM controls the DC motor by a duty signal 0 V/12 V. NOTE: If the ISV system fails, the ISV adopts in the open position in which no vacuum is produced.
2.0 MZR-CD Engine Emission System Diesel Particulate Filter System Features • The diesel particulate filter system of the vehicles with 2.0 MZR-CD engine has the following features: – Diesel particulate filter with differential pressure sensor and three exhaust gas temperature sensors (upper/middle/lower) has been introduced. – Heated oxygen sensor located behind the diesel particulate filter has been introduced.
Emission System 2.0 MZR-CD Engine • In comparison to the particulate matter limit for Euro 3 vehicles (0.05 g/km), the limit for Euro 4 vehicles (0.025 g/km) has been lowered by 50 %. In order to comply with the strict Euro 4 emission legislation, the Mazda5 CR with 2.0 MZR-CD engine is equipped with a diesel particulate filter system.
2.0 MZR-CD Engine • Emission System The DPF is a monolith made of silicon carbide ceramics, which features a high resistance against temperature fluctuations. The individual channels of the filter have porous dividing walls and are closed at alternative ends. As a result, the exhaust gas is forced to flow through the dividing walls, which retain the soot particles and allow gaseous components to pass. The accumulation of particles in the filter increases the filtration effect still further.
Emission System 2.0 MZR-CD Engine • The channels of the DPF are coated with platinum. This catalytic coating facilitates the regeneration of the filter by significantly lowering the light-off temperature of the soot and by accelerating the combustion of the particles. Without coating the burn-off of the particles takes place above a temperature of approx. 600 °C. Due to the effect of the platinum coating the light-off temperature of the soot is lowered to 500 °C.
2.0 MZR-CD Engine Emission System DPF Differential Pressure Sensor • The DPF differential pressure sensor detects the pressure difference in the exhaust gas flow upstream and downstream of the DPF. The pressure difference is a measure for the soot amount accumulated in the filter (i.e. the higher the pressure difference, the higher the soot amount).
Emission System 2.0 MZR-CD Engine M5_01041 1 2 DPF Measuring points for DPF differential pressure sensor 3 Oxidation catalytic converter • The signal of the DPF differential pressure sensor is used to determine, whether the soot amount requires regeneration of the filter. In addition, the signal serves to monitor the regeneration process. • The DPF differential pressure sensor supplies the PCM with an analogue voltage signal between 0…5 V.
2.0 MZR-CD Engine Emission System • In addition, the DPF differential pressure sensor features a temperature correction sensor, which is located on the bracket of the differential pressure sensor and detects the temperature in the engine compartment. The sensor is a temperature-resistive resistor with NTC (Negative Temperature Coefficient), i.e. its resistance becomes smaller when the temperature rises. The temperature correction sensor supplies the PCM with an analogue voltage signal between 0…5 V.
Emission System 2.0 MZR-CD Engine Diagnostics • Since the filter itself creates a certain resistance in the exhaust gas flow, the signal of the DPF differential pressure sensor is also used to determine the filter condition.
2.0 MZR-CD Engine Emission System • If the value measured by the DPF differential pressure sensor is below a certain limit, the DPF is recognized as being damaged. Then the PCM stores a corresponding DTC, illuminates the MIL and activates the limp home mode. • In this case, the DPF differential pressure sensor should be checked first. Call up the Datalogger of the PCM and select the PID EXHPRESS_DIF (Press).
Emission System 2.0 MZR-CD Engine Exhaust Gas Temperature Sensors • The three exhaust gas temperature sensors (upper/middle/lower) are located in the combined housing of the oxidation catalytic converter/DPF and detect the temperature of the exhaust gas upstream of the oxidation catalytic converter, as well as upstream and downstream of the DPF. Each sensor is a temperature-resistive resistor with NTC, i.e. its resistance becomes smaller when the temperature rises.
2.0 MZR-CD Engine Emission System • The signal of the upper exhaust gas temperature sensor allows to check, whether the exhaust gas temperature required for operation of the oxidation catalytic converter is reached. • The signal of the middle exhaust gas temperature sensor is used to determine, whether the exhaust gas temperature required for regeneration of the filter is reached.
Emission System 2.0 MZR-CD Engine Heated Oxygen Sensor • The HO2S (Heated O2 Sensor) is located behind the DPF and detects the oxygen concentration in the exhaust gas. The HO2S is a broad-band type sensor, i.e. it generates a clear electrical signal in a wide range from λ = 0.7…∞ (∞ = air with 21 % oxygen). As a result, the sensor is also capable of detecting the oxygen concentration in the exhaust gas of a diesel engine, which generally works with an excess-air factor of λ ∼ 1.4 (at full load) to λ ∼ 3.
2.0 MZR-CD Engine • Emission System If the exhaust gas is lean, the pump cell pumps oxygen out of the diffusion gap back into the exhaust gas, resulting in a positive pump current. Conversely, if the exhaust gas is rich, oxygen is pumped from the exhaust gas into the diffusion gap, leading to a negative pump current. If the composition of gas in the diffusion gap is λ = 1, no pumping takes place and the pump current is zero.
Emission System • 2.0 MZR-CD Engine The HO2S supplies the PCM with a current between -1.8…+1.8 mA. M5_01047 X • Excess-air factor λ Y Current Since the HO2S only generates a usable signal above a certain temperature, it features an integral heater element. The temperature of the HO2S is controlled by the PCM, which activates the heater element via a duty signal.
2.0 MZR-CD Engine Emission System • At low exhaust gas temperatures the PCM controls the heater element by a large duty cycle, so that the required operating temperature is reached quickly. • At high exhaust gas temperatures the PCM controls the heater element by a small duty cycle, so that no heating takes place. • The PCM controls the heater element by a duty signal 0 V/12 V.
Emission System 2.0 MZR-CD Engine Regeneration Control • The regeneration control determines the soot amount accumulated in the DPF and starts the regeneration process accordingly. The regeneration control is integrated in the PCM. Soot Amount Calculation • The PCM receives information about the soot amount accumulated in the filter from the DPF differential pressure sensor.
2.0 MZR-CD Engine Emission System NOTE: Do NOT perform automatic regeneration when the soot accumulation rate in the DPF is 100 % or more, since this may cause damage to the filter or the engine. • If the soot accumulation rate in the DPF reaches 140 % or more, the MIL also illuminates and DTC P242F is stored in the PCM. In addition, the PCM further reduces the fuel injection amount and hence the soot emission of the engine, resulting in a lower soot amount accumulated in the filter.
Emission System 2.0 MZR-CD Engine Regeneration Process • Due to the effect of the catalytic coating the diesel particles are burnt off above a temperature of 500 °C. Since the exhaust gas temperature during normal driving is between 150…400 °C (depending on the engine operating conditions), it must be increased artificially by external intervention from the engine management system to start the regeneration process.
2.0 MZR-CD Engine Emission System Regeneration Intervals • Depending on the operating conditions of the vehicle the DPF is regenerated every 100…300 km. Due to the ash residues that have formed from the engine oil and diesel fuel the usable filter volume is reduced. Since the ash amount accumulated in the DPF increases with every regeneration process, the regeneration intervals become shorter with rising mileage.
Charging System 2.0 MZR-CD Engine Charging System Features • The charging system of the vehicles with 2.0 MZR-CD engine has the following features: – Smart charging system has been introduced.
2.0 MZR-CD Engine Charging System Smart Charging System • A so-called "Smart Charging System” has been introduced to improve battery charging and durability. The exciting current of the field coil and hence the charging voltage is controlled by the PCM, which actuates the generator by a duty signal. In addition, the generator sends a feedback signal to the PCM, which hereby monitors the generator load.
Charging System 2.0 MZR-CD Engine • When the battery voltage/battery electrolyte temperature is high and/or the generator load is low, the PCM controls the generator with a small duty cycle. As a result, a low exciting current flows through the field coil and the generator outputs a low charging voltage. • When the battery voltage/battery electrolyte temperature is low and/or the generator load is high, the PCM controls the generator with a large duty cycle.
2.0 MZR-CD Engine Control System Control System Features • The control system of the vehicles with 2.0 MZR-CD engine has the following features: – – Powertrain control module with FEEPROM has been introduced. – – – Hall-type accelerator pedal position sensor has been introduced. Magneto resistive-type crankshaft and camshaft position sensor have been introduced. Idle switch has been cancelled. Power steering pressure switch has been introduced.
Control System A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LHD Exhaust gas temperature sensor Park neutral position switch Intake air temperature sensor no.2 Crankshaft position sensor MAF/IAT sensor ISV with DC motor and position sensor EGR valve with DC motor and position sensor Engine coolant temperature sensor Fuel temperature sensor Fuel metering valve Generator (stator coil and field coil) Fuel pressure sensor Glow plug MAP sensor Fuel injector Refrigerant pressure switch 01-84 2.
2.0 MZR-CD Engine Control System Relationship Chart Output Input Refrigerant pressure switch Cruise control switches Accelerator pedal position sensor MAF/IAT sensor IAT sensor no.
Control System 2.0 MZR-CD Engine Powertrain Control Module • The PCM (Powertrain Control Module) is located behind a cover in the passenger footwell and features a 121-pin (two-block) connector. NOTE: When replacing the PCM, several steps must be performed to ensure its proper function (refer to the section “Control System, Maintenance and Repair”).
2.0 MZR-CD Engine Control System Crankshaft Position Sensor • An magneto resistive-type CKP (Crankshaft Position) sensor has been introduced, which is located at the rear side of the clutch housing. The sensor consists of two magneto resistive elements and a magnet, which scan a rotor with 56 teeth, missing five teeth in one location. The rotor is integrated in the flywheel. M5_01053 1 2 3 4 Clutch housing CKP sensor Output signal 5V Service Training Mazda5 5 6 7 8 0.
Control System • 2.0 MZR-CD Engine The magneto resistive elements have the characteristics that their resistance changes depending on the magnetic flux. When the rotor passes the sensor, an alternating magnetic field is generated that changes the resistance of the magneto resistive elements. An integrated circuit converts the output voltage of the magneto resistive elements into a rectangular wave signal, which is then input to the PCM.
2.0 MZR-CD Engine Control System Camshaft Position Sensor • An magneto resistive-type CMP (Camshaft Position) sensor has been introduced, which is located at the vacuum pump. The sensor consists of two magneto resistive elements and a magnet, which scan a rotor with five teeth. The rotor is attached to the drive gear of the power steering oil pump. M5_01055 1 2 3 4 Cylinder head CMP sensor Output signal 5V Service Training Mazda5 5 6 7 8 0.
Control System • 2.0 MZR-CD Engine The magneto resistive elements have the characteristics that their resistance changes depending on the magnetic flux. When the rotor passes the sensor, an alternating magnetic field is generated that changes the resistance of the magneto resistive elements. An integrated circuit converts the output voltage of the magneto resistive elements into a rectangular wave signal, which is then input to the PCM.
2.0 MZR-CD Engine Control System Accelerator Pedal Position Sensor • A hall-type APP (Accelerator Pedal Position) sensor has been introduced. For safety reasons the APP sensor consists of two hall elements integrated in the stator and a magnetic rotor joint to the accelerator pedal. NOTE: If one hall-type sensor fails, the PCM uses the signal from the other sensor to detect the driver’s acceleration demand. As a result, the engine speed is limited to approx. 2500 min-1.
Control System • 2.0 MZR-CD Engine When the magnetic rotor rotates, a voltage is generated in the hall elements. As the hall voltage is very low, it is amplified in the sensor and input to the PCM.
2.0 MZR-CD Engine • Control System Each hall-type sensor supplies the PCM with an analogue voltage signal between 0…5 V. In order to facilitate failure detection there is a voltage offset of 0.5 V between both signals.
Control System 2.0 MZR-CD Engine Power Steering Pressure Switch • A PSP (Power Steering Pressure) switch located at the power steering oil pump has been introduced to detect the load condition of the power steering. If the power steering oil pressure exceeds a given value, the switch closes and supplies the PCM with a voltage signal of 0 V.
2.0 MZR-CD Engine Control System Maintenance and Repair 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 WDS. Therefore, select the option ToolboxÆ PowertrainÆData ResetÆEngine Oil. Manual regeneration • If the DPF is blocked due to an excessive soot amount accumulated, it must be regenerated manually with the aid of WDS. Therefore, select the option ToolboxÆ PowertrainÆDPFÆDPF Regeneration.
Control System 2.0 MZR-CD Engine NOTE: If the exhaust gas temperature during manual regeneration exceeds a certain limit, the PCM stops the regeneration process and increases the engine speed to 2500 min-1 to cool the DPF. NOTE: Depending on the amount of soot accumulated the PCM performs normal and long regeneration mode one after another, i.e. the regeneration process may take up to 94 min.
2.0 MZR-CD Engine Control System Replacing the EGR valve or the ISV • After replacing the EGR valve or the ISV, its adaptation values in the PCM must be reset with the aid of the WDS. Therefore, select the option ToolboxÆPowertrainÆ Data ResetÆETB/EGR. Then the EGRVP sensor or the ISV position sensor must be initialized using the option ToolboxÆPowertrainÆETB/EGR Initialization. Replacing the DPF • After replacing the DPF, the following steps must be performed: 1.
Control System 2.0 MZR-CD Engine Replacing the HO2S • After replacing the HO2S, its adaptation values in the PCM must be reset with the aid of the WDS. Therefore, select the option ToolboxÆPowertrainÆData ResetÆ O2 Sensor. Replacing the PCM • After replacing the PCM, the following steps must be performed: 1. The PCM must be configured using the option ToolboxÆModule ProgrammingÆ Programmable Module InstallationÆPCM. 2. The keys must be programmed via the option ToolboxÆBodyÆSecurityÆPATS Functions. 3.
2.0 MZR-CD Engine On-board Diagnostic System On-board Diagnostic System Features • The On-board diagnostic system consists of the following functions: – – – Self-test function PID monitor function Simulation test function Self Test • The self-test function allows to read out the CMDTCs of the PCM with the aid of WDS. Therefore, select the option ToolboxÆSelf TestÆModulesÆPCMÆRetrieve CMDTCs.
On-board Diagnostic System 2.0 MZR-CD Engine PID Monitor • The PID monitor function allows to monitor the PIDs of the PCM with the aid of WDS. Therefore, select the option ToolboxÆDataloggerÆModulesÆPCM. Item AC_REQ ACCS ALTF ALTT V APP APP_LRN Definition A/C ON request A/C compressor cycling switch Generator field current control duty cycle Generator output voltage Accelerator pedal position APP learning value - closed APP1 APP sensor no.1 APP2 APP sensor no.
2.
On-board Diagnostic System Item 2.
2.0 MZR-CD Engine On-board Diagnostic System Simulation Test • The simulation test function allows to activate certain PIDs of the PCM with the aid of WDS. Therefore, select the option ToolboxÆDataloggerÆModulesÆPCM. Item ACCS EGRP GENVDSD GP_LMP GPC INJ_1 INJ_2 INJ_3 INJ_4 VBCV Definition A/C compressor cycling switch EGR valve position sensor Generator voltage desired Glow plug indicator light Glow plug relay Fuel injector no.1 Fuel injector no.2 Fuel injector no.3 Fuel injector no.
On-board Diagnostic System 2.
02 Suspension
02 Suspension Wheels and Tires.................................................................................................1 Specifications..................................................................................................1 Standard Tire ............................................................................................1 Temporary Spare Tire...............................................................................1 Front Suspension............................................
Suspension Wheels and Tires Wheels and Tires • Wheel and tire sizes are the same as the current Mazda3 (BK), but tire speed ratings have changed. Specifications Standard Tire Item Tire Specifications Size 195/65R15 91V 205/55R 16 91V 205/50R 17 93V Size 15 X 6J 16 X 6 1/2J 17 X 6 1/2J Material Steel Wheel Aluminium alloy Aluminium alloy Offset (mm {in}) 52.5 (2.07) Pitch circle diameter (mm {in}) 114.3 (4.
Front Suspension Suspension Front Suspension Features • The front suspension of the Mazda5 is essentially the same as the current Mazda3 (BK). It has the following features: – – – Strut-type design. Front crossmember rubber mounted to the body at four points. Oil filled bushes used for the front lower arms.
Suspension Front Suspension Specifications Item Engine type Type Spring type Shock absorber type Stabilizer Front suspension Wheel alignment (unloaded) Specification L8,LF MZR-CD Strut type Coil spring Low-pressure gas charged, cylindrical, double-acting Type Diameter (mm {in}) Tire [Tolerance ±4 (mm {in}) Total {0.15}] toe-in Rim inner Degree Maximum steering Inner angle Outer [Tolerance ±3 °] Torsion bar 23 {0.90} 2 {0.08} 1 ± 3 {0.04 ± 0.
Front Suspension Suspension Front Shock Absorber • A shock absorber with an internal rebound spring is used to control wheel-lift* during hard cornering. The rebound spring allows a limited amount of movement of the shock absorber when it is fully extended. Without the spring the shock absorber would top-out, making the suspension ineffective and causing wheel hop or wheel lift. *Wheel-lift: Tendency for wheels on the inside of a curve to lift off the ground during cornering.
Suspension Rear Suspension Rear Suspension Features • The rear suspension is essentially the same as the current Mazda3 (BK). It has the following features: – – E-type design layout. Separate shock absorber and springs.
Rear Suspension Suspension Specifications Item Type Spring type Shock absorber type Stabilizer Rear suspension Wheel alignment (unloaded) Type Diameter Tire [Tolerance ±4 Total {0.15}] toe-in Rim inner (mm {in}) (mm {in}) Degree Camber angle [Tolerance ± 1° ] Specification Multi-link Coil spring High-pressure gas charged, cylindrical, double-acting Torsion bar 20 {0.79} 2 {0.08} 1 ± 3 {0.04 ± 0.
03 Driveline/ Axle
03 Driveline/Axle Front Axle.............................................................................................................1 Features..........................................................................................................1 Overview .........................................................................................................1 Rear Axle..............................................................................................................2 Features............
Driveline/Axle Front Axle Front Axle Features • The front axle on the Mazda5 is essentially the same design as that of the current Mazda3 (BK). It has the following features: – Unit-design angular ball bearings are used.
Rear Axle Driveline/Axle Rear Axle Features • The rear axle on the Mazda5 is essentially the same design as that of the current Mazda3 (BK). It has the following features: – Unit-design angular ball bearings are used.
Driveline/Axle Drive Shaft Drive Shaft Features • The drive shafts on the Mazda5 are essentially the same design as those on the current Mazda3 (BK). They have the following features: – – A bell joint is used for the wheel-side constant velocity joints. A tripod joint is used for the transaxle-side constant velocity joint. Specifications Item Specifications LF Bell joint Double offset joint Tripod joint 26.0 {1.
Driveline/Axle NOTES: 03-4 Service Training Mazda5
04 Brakes
04 Brakes Conventional Brake System ...............................................................................1 Features..........................................................................................................1 Specifications..................................................................................................1 Master Cylinder...............................................................................................2 Antilock Brake System ...............................
Brakes Conventional Brake System Conventional Brake System Features • The construction and operation of the brake system is essentially the same as the current Mazda3 (BK). It has the following features: – – – An intrusion minimizing brake pedal is used. Mechanical brake assist is included in the power brake unit. A remote master cylinder reservoir tank has been added. Specifications Item Type Brake pedal Pedal lever ratio Max.
Conventional Brake System Brakes Master Cylinder • The master cylinder remote reservoir is attached to the vehicle body under the cowl panel, and connected to the master cylinder via a rubber hose. NOTE: The remote reservoir and connecting hoses can be replaced separately, but the master cylinder and main reservoir cannot. If a fault exists in the master cylinder or main reservoir, they must be replaced as an assembly.
Brakes Antilock Brake System Antilock Brake System Features • The construction and operation of the ABS (Antilock Brake System) is essentially the same as the current Mazda3 (BK). It has the following features: – A TEVES MK7 hydraulic unit/control module is used to control ABS and Electronic Brake force Distribution operation (vehicles without DSC). – – Giant Magneto Resistance element type ABS wheel speed sensors are used.
Dynamic Stability Control Brakes Dynamic Stability Control • The construction and operation of the DSC (Dynamic Stability Control) is essentially the same as the current Mazda3 (BK). It has the following features: – A TEVES MK6 DSC hydraulic unit/control module, controlling DSC/TCS/ABS/EBD is used. – – A combine sensor, integrating both the yaw rate sensor and lateral-G sensor is used.
Brakes Dynamic Stability Control Combine Sensor • The combine sensor is located on the cross member under the front right seat, and detects the vehicle yaw rate and lateral-G force. The combine sensor transmits yaw and lateral acceleration information to the DSC HU/CM via a dedicated CAN bus (independent of the MS-CAN/HS-CAN). NOTE: When replacing the combine sensor, the new sensor has to be initialized.
Dynamic Stability Control Brakes NOTES: 04-6 Service Training Mazda5
05 Transmission/ Transaxle
05 Transmission/ Transaxle Manual Transaxle ................................................................................................1 Features..........................................................................................................1 G35M-R Transmission ........................................................................................2 Specifications..................................................................................................2 Overview .....................
Transmission/Transaxle Manual Transaxle Features • The transmission/transaxle has the following features: – – – – – Cable operated shift mechanism. – – – 6-speed A26M-R manual transmission for diesel engine models. Shift lever located at centre of dashboard. Hydraulically operated clutch (same as Mazda3 (BK)). Quick connector clutch pipes (same as Mazda3 (BK)). 5-speed G35M-R manual transmission for gasoline engine models (similar to Mazda3 (BK)).
G35M-R Transmission/Transaxle G35M-R Transmission • The G35M-R manual transaxle is essentially the same as that used on the current Mazda3 (BK) with LF engine, except for the following: – – Triple-cone synchronizer is used for first and second gears. Double-cone synchronizer is used for third and fourth gears.
Transmission/Transaxle Overview M5_05016 1 2 3 4 5 6 7 8 First gear Reverse idler gear Reverse gear Second gear Third gear Fourth gear Fifth gear Secondary shaft fifth gear Service Training Mazda5 9 10 11 12 13 14 15 16 Secondary shaft fourth gear Secondary shaft third gear Secondary shaft second gear Secondary shaft first gear Secondary shaft Clutch hub sleeve (reverse gear) Primary shaft Differential gear 05-3
G35M-R Transmission/Transaxle Triple Cone Synchronizer • A triple-cone synchronizer mechanism is used for the first and second gears. • The construction of the triple-cone synchronizer is essentially the same as a double-cone synchronizer, except that the inner surface of the inner ring is used as a friction surface on the triple-cone synchronizer.
Transmission/Transaxle Shift Mechanism • A cable operated shift mechanism similar to the current Mazda3 (BK) is used. • The main selector cable is adjusted by unclipping it from the selector mechanism and then reattaching it to achieve the correct cable length, the same as on the Mazda3.
A26M-R Transmission/Transaxle A26M-R Transmission • The A26M-R 6-speed manual transaxle is manufactured by Aisin, and designed for frontwheel-drive vehicles with a transversely mounted powertrain. Specifications Item Viscosity All season Above 10°C{50°F} Specifications MZR-CD A26M-R Cable Synchromesh Synchromesh (lever type) 3,538 1,913 1,218 0,880 0,809 0,673 3,166 1GR, 2GR, 3GR, 4GR: 3.611 5GR, 6GR, Reverse: 3.
Transmission/Transaxle A26M-R Construction • The A26M-R manual transaxle is a three-shaft design; one primary (input) shaft and two secondary (output) shafts. • The three-shaft design allows for a more compact construction due to the fact that each output shaft needs only to carry three or four gears, so can thus be made shorter. • As a result of the three shaft construction there are two final gear ratios; one for the first to fourth gears and a different one for the fifth, sixth and reverse gears.
A26M-R Transmission/Transaxle Cross-sectional View M5_05007 1 2 3 4 5 6 7 05-8 Primary shaft Final gear No. 2 Reverse gear Reverse idler gear Secondary shaft No. 2 Secondary shaft No. 1 Differential ring gear 8 9 10 11 12 13 14 Final gear No.
Transmission/Transaxle A26M-R Power Flow First to Sixth Gear M5_05008 1 2 3 First gear Second gear Third gear Service Training Mazda5 4 5 6 Fourth gear Fifth gear Sixth gear 05-9
A26M-R Transmission/Transaxle Reverse Gear M5_05009 1 Reverse gear 05-10 Service Training Mazda5
Transmission/Transaxle A26M-R Synchronizer Clutch Hub • A ball-type detent mechanism is used in each clutch hub to reduce the overall dimensions of the hub. • The ball-type detent mechanism consists of a coil-type synchronizer key spring, synchronizer key, and ball. Its function is essentially the same as the radial-type spring found in other transaxles.
A26M-R Transmission/Transaxle Shift Interlock Mechanism • The shift interlock mechanism prevents two gears being engaged at the same time. During shifting, the shift forks and control rod, except for the one in operation, are locked in the neutral position by the interlock plate.
Transmission/Transaxle 1 2 3 4 5 6 7 8 Reverse shift fork Inner lever Fifth/sixth gear shift fork Interlock plate First/second gear shift fork Third/fourth gear control rod A-A sectional view Neutral Service Training Mazda5 A26M-R 9 10 11 12 13 14 15 First gear Second gear Third gear Fourth gear Fifth gear Sixth gear Reverse gear 05-13
A26M-R Transmission/Transaxle Shift Mechanism • A cable operated shift mechanism similar to the current Mazda3 (BK) is used. • The main selector cable is adjusted the same way as on the Mazda3.
Transmission/Transaxle A26M-R Reverse Lockout Mechanism • The reverse lockout mechanism consists of a guide plate attached to the shift lever assembly, which restricts the movement of the shift lever to prevent accidentally selecting reverse when shifting into first gear. • Under normal conditions, movement of the shift lever is restricted by the guide plate.
A26M-R Transmission/Transaxle Oil Level Inspection • The A26M-R manual transaxle is filled with 2.55 litres of manual transaxle oil which complies with the specification API Service GL-4 or GL-5 (grade) and SAE 75W-90 (viscosity). • To check the transaxle oil level, verify that the oil level is near the brim of the filler plug hole. If the oil level is low, add the specified amount and type of oil through the plug hole.
06 Steering
06 Steering Steering ................................................................................................................1 Features..........................................................................................................1 Specifications..................................................................................................1 Power Steering ....................................................................................................2 Features......................
Steering Steering Features • The steering system has the following features: – Steering column with tilt and telescopic adjustment, as well as bending sheet and telescopic energy absorption mechanism (same as current Mazda3 (BK)).
Power Steering Steering Power Steering Features • Electro-hydraulic power steering for vehicles with L8/LF engine (similar to Mazda3 (BK) with LF engine). • Hydraulic power steering for vehicles with MZR-CD engine (similar to Mazda6 (GG/GY) with MZR-CD engine.
Steering 1 2 3 4 5 6 Steering wheel Steering column and shaft Steering gear and linkage Power steering oil pump Electric power steering oil pump EHPAS control module ( built into electric power steering oil pump Service Training Mazda5 Power Steering 7 8 9 10 11 12 Steering angle sensor Instrument cluster EHPAS warning light PCM L8, LF MZR-CD 06-3
Power Steering Steering Electro Hydraulic Power Assist Steering (L8/LF engines) Features • The same EHPAS as that utilized on the current Mazda3 (BK) with LF engine is used on the Mazda5 with L8/LF engines, with the following changes: – Steering angle sensor built into steering gear has been discontinued.
Steering Power Steering Wiring Diagram M5_06003 1 2 3 4 5 6 7 EHPAS control module Battery EHPAS 80 A fuse Ignition switch EHPAS 5 A fuse Instrument cluster EHPAS warning light 8 9 10 11 12 13 14 CAN driver CAN_L CAN_H Steering angle sensor DLC-2 DSC HU/CM PCM Steering Angle Sensor • Instead of using a steering angle sensor located on the steering gear as on the Mazda3, the Mazda5 EHPAS uses the DSC steering angle sensor (fitted to the steering column) to detect steering rotation speed.
Steering NOTES: 06-6 Service Training Mazda5
07 Heating, Ventilation& Air Conditioning
07 HVAC Basic System .......................................................................................................1 Features..........................................................................................................1 Specifications..................................................................................................1 Control System....................................................................................................2 Manual Air Conditioning ................
HVAC Basic System Basic System Features • The construction and operation of the HVAC (Heater/Ventilator/Air Conditioning) is essentially the same as the current Mazda3 (BK). – – – – Sirocco blower motor is used. Pollen filter is used. Triple-type refrigerant pressure switch is used. Sub-cooling type condenser is used. Specifications Item Specification Heating capacity (kW {kcal/h}) 4.550 {3,913}: LF, L8 5.200 {4.472}: MZR-CD Cooling capacity (kW {kcal/h}) 3.
Control System HVAC Control System Manual Air Conditioning • Control of the manual air conditioning is essentially the same as that for the current Mazda3 (BK).
HVAC Control System Climate Control Unit • A wire operated climate control unit is used with the manual air conditioning. • The airflow mode dial features an additional microswitch to turn the air intake mode to fresh when the airflow mode is set to the defrost position. NOTE: The illumination bulbs can be replaced separately.
Control System HVAC Operation • When the A/C is switched on, the climate control unit sends an “A/C on request” signal via cable to the BCM (Body Control Module). The BCM forwards this information via the MS-CAN (Middle-Speed CAN) bus to the instrument cluster. From there the signal is transmitted via the HS-CAN (High-Speed CAN) bus to the PCM, which operates the A/C relay and the fan control module accordingly.
HVAC Control System Wiring Diagram M5_07005 1 2 3 4 5 6 7 Blower relay Blower motor Resistor Air intake actuator Evaporator temperature sensor A/C relay Magnetic clutch Service Training Mazda5 8 9 10 11 12 13 14 Refrigerant pressure switch Fan switch Climate control unit TNS relay PCM BCM To CPU 07-5
Control System HVAC Full-auto Air Conditioning • Control of the full-auto air conditioning is essentially the same as that for the current Mazda3 (BK).
HVAC Control System Wiring Diagram M5_07012 Service Training Mazda5 07-7
Control System 1 2 3 4 5 6 7 8 9 10 07-8 Ambient temperature sensor Cabin temperature sensor Evaporator temperature sensor Solar radiation sensor Magnetic clutch Refrigerant pressure switch Air mix actuator Airflow mode actuator Air intake actuator Blower motor HVAC 11 12 13 14 15 16 17 18 19 Blower relay Power MOS-FET Climate control unit A/C relay TNS relay Climate control unit switches CPU BCM PCM Service Training Mazda5
HVAC Control System Climate Control Unit • A logic-type climate control unit is used. It is connected via the MS-CAN to the BCM. • The current status of the full-auto A/C system is displayed on the information display (refer to section 09, “Instrumentation/Driver Info”). NOTE: The illumination bulbs can be replaced separately.
Control System HVAC M5_07008 07-10 Service Training Mazda5
HVAC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Ambient temperature sensor ECT sensor Cabin temperature sensor Evaporator temperature sensor Solar radiation sensor Climate control unit Airflow temperature control Airflow volume control Airflow mode control Air intake control A/C compressor control Air mix actuator Power MOS-FET Blower motor Service Training Mazda5 Control System 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Airflow mode actuator Air intake actuator Refrigerant pressure switch High/Low pressure signal
Control System HVAC On-board Diagnostic System • The on-board diagnostic system is essentially the same as the current Mazda3 (BK) except for the following: – Simulation test function for climate control unit has been added to WDS. Simulation Test • The simulation test function allows the respective components controlled by the climate control unit to be operated manually. To do this, connect the WDS to the vehicle and select the option Toolbox→Datalogger→Modules→EATC.
HVAC Water Heater System Water Heater System (MZR-CD engine) • To improve heating capability directly after cold start, an additional water heater system has been adopted. • The heater mainly consists of a combustion chamber, heat exchanger, fresh air blower and electronic control module. The unit used on the Mazda5 (CR) is supplied by Eberspächer. • Fuel is combusted within the water heater unit and used to heat the engine coolant.
Water Heater System HVAC Operation • The water heater control module outputs a signal to the blower fan and the fuel pump, which then deliver air and fuel to the unit. • Within the unit, fuel is vaporized and mixed with air, and then sent to the combustion chamber. • The mixture is ignited by the glow plug in the combustion chamber. • Engine coolant temperature is raised as it circulates along the outside of the combustion chamber.
HVAC Water Heater System Starting Conditions • The water heater system will start to operate when all of the following conditions are met: – – Ambient temperature less than 5 °C {41 °F}. Water temperature less than 70 °C {158 °F}. Full/half Switching • Depending on the engine coolant temperature, the water heater control module sets the heater output to either full or half strength settings.
Water Heater System HVAC On-board Diagnostics • The on-board diagnostic system consists of the following functions: – – – Self-test PID monitor Simulation test function Self Test • The self-test function allows water heater DTCs to be displayed. To view these connect the WDS to the vehicle and select the option Toolbox→Self Test→ Electrical→ Supplemental Heater. PID Monitor • The PID monitor function allows the PIDs of the water heater to be monitored.
HVAC Water Heater System Start Heater Utility • The operation of the water heater can be tested by using the FFH Start Heater Utility. To do this first verify that the coolant temperature is low, then connect the WDS to the vehicle and select the option Toolbox→Electrical→Supplemental Heater→FFH→FFH Start Heater Utility. NOTE: The Start Heater Utility will operate the water heater for a predetermined length of time, after which the heater will automatically switch off.
HVAC NOTES: 07-18 Service Training Mazda5
08 Restraint System
08 Restraint System Airbag System ....................................................................................................1 Features..........................................................................................................1 Parts Location.................................................................................................2 Wiring Diagram ...............................................................................................3 SAS Control Module ................
Restraints Airbag System Airbag System Features • The airbag system has the following features: – – – – – Single-stage front airbags are used. Side airbags are fitted. Stored gas-type curtain airbags are used. Dual side airbag sensors are fitted. Rack-operated belt pretensioners are used.
Airbag System Restraints Parts Location M5_08001 1 2 3 4 5 6 7 08-2 Airbag system warning light Driver-side airbag Clock spring PAD switch Passenger-side airbag SAS control module PAD indicator light 8 9 10 11 12 13 Side airbag Curtain airbag Crash zone sensor Side airbag sensor No. 1 Side airbag sensor No.
Restraints Airbag System Wiring Diagram M5_08002 Service Training Mazda5 08-3
Airbag System 1 2 3 4 5 6 7 8 9 10 11 12 13 08-4 SAS control module Instrument cluster Airbag system warning light DLC-2 PAD indicator light PAD switch PASS AIRBAG ON PASS AIRBAG OFF Crash zone sensor Twisted pair Driver-side side airbag sensor No. 1 Passenger-side side airbag sensor No. 1 Driver-side side airbag sensor No. 2 Restraints 14 15 16 17 18 19 20 21 22 23 24 25 Passenger-side side airbag sensor No.
Restraints Airbag System SAS Control Module • The SAS (Sophisticated Airbag Sensor) control module is located on the centre tunnel, near to the gear lever. • A micromechanical crash sensor is incorporated into the SAS control module, which measures the acceleration/deceleration of the vehicle in a crash. • The SAS control module processes the signals it receives from the crash zone sensor, the side airbag sensors and the internal micromechanical sensor.
Airbag System Restraints Side Airbag Sensors • Two side airbag sensors are installed to each side of the vehicle, one at the base of the B-pillar and one near the rear wheelhouse. • Side airbag sensor No. 1 and No. 2 are different part numbers, so are not interchangeable. • The sensor initialisation procedure is the same as that for the Mazda3 (BK) (turn ignition switch to ON and confirm that the airbag warning light illuminates for approximately six seconds, then goes out.
Restraints Airbag System Curtain Airbags • Instead of using propellants to inflate the curtain airbags, the curtain airbags of the Mazda5 utilize gas stored inside the inflator.
Airbag System Restraints Seatbelt Pretensioners • Rack-type seatbelt pretensioners similar to those used in the Mazda2 have been adopted for the front seats. • When a deployment signal is received from the SAS module during a frontal or offset collision, the pretensioners operate, tightening the seat belt webbing thus restraining the driver and front seat passenger.
Restraints Airbag System Operation • Under normal conditions, the clutch rollers that are installed around the circumference of the spindle roll freely in the space between the gear and spindle, without resistance being applied to the spindle. • Because the spindle and gear are free to move separately, only the spindle rotates when the seatbelt webbing is extended/retracted, while the gear remains stationary.
Airbag System Restraints • When a deployment signal is received from the SAS module, gas is produced by the gas generator (gas is generated in the same way as in airbag inflators). The pressure of this gas pushes the rack up in the cylinder. • As the rack moves upwards, it causes the gear to rotate. • The rotation of the gear pushes the clutch rollers against the spindle, locking the gear and spindle together. • As the gear is rotated, so is the spindle, and the seat belt webbing is retracted.
Restraints Airbag System On-board Diagnostic System • The main functions of the on-board diagnostic system are: – – Self-test PID monitor Self Test • The self-test function allows airbag system DTCs to be displayed. To do this, connect the WDS to the vehicle and select the option Toolbox→Self Test→Modules→RCM.
Airbag System Restraints PID Monitor • The PID monitor function allows airbag system PIDs to be monitored. To do this, connect the WDS to the vehicle and select the option Toolbox→Datalogger→Modules→RCM. Item Definition Unit/Condition CCNT_RCM Number of continuous DTCs — CR2D_Comm Driver-side side airbag sensor No. 2 system communication data error OK/FAULT CR2D_Inter Driver-side side airbag sensor No. 2 system internal circuit disabled OK/FAULT CR2D_Mount Driver-side side airbag sensor No.
Restraints Seat Belts Seat Belts Features • The seatbelts of the Mazda5 have the following features: – – Seatbelts with pretensioners, load limiter, and ELR are used for the front seats. – Isofix and tether strap child restraint seat anchors are provided for the two outer second row seats. Seatbelts with ELR are used for the two outer second row seats and the third row seats.
Seat Belts Restraints Child Restraint Anchors M5_08011 1 2 Top tether belt ISOFIX anchor 08-14 3 Second-row seat Service Training Mazda5
09 Body & Accessories
09 Body & Accessories Table of Contents Body Panels.........................................................................................................1 Features..........................................................................................................1 Cabin ....................................................................................................................1 Doors and Liftgate...............................................................................................
09 Body & Accessories Table of Contents (continued) Keyless Start Function .................................................................................27 Guidance Function ........................................................................................29 Customization ...............................................................................................30 Service and Repair .......................................................................................
09 Body & Accessories Table of Contents (continued) Front Combination Light...................................................................................56 Headlight Auto Leveling System......................................................................57 Parts Location ...............................................................................................57 Wiring Diagram .............................................................................................58 Operation ..............
09 Body & Accessories Table of Contents (continued) LCD Unit .......................................................................................................76 Automatic Mode......................................................................................76 Day Mode ...............................................................................................76 Night Mode .............................................................................................76 Split Screen ...............
09 Body & Accessories Table of Contents (continued) Instrument Cluster ..........................................................................................105 Input/Output Check Mode ...........................................................................107 Configuring Instrument Cluster ...................................................................108 Seat Belt Warning .......................................................................................109 Driver’s Seat Belt Warning.......
Body & Accessories Body Panels Body Panels Features • The body shell of the Mazda5 has the following features: – – Triple H-construction is used. Front bumper and rear bumper reinforcements used. Cabin • The cabin utilizes the same MAIDAS (Mazda Advanced Impact Distribution and Absorption System) concept as the Mazda3. The three fork structure at the back of each front side frame directs frontal impact energy toward the A-pillar, crossmember No.
Body Panels • Body & Accessories In the event of a side collision, the triple-H frame structure effectively distributes force in an H-pattern along the floor, the side and the roof of the vehicle. This structure not only improves the safety of the cabin, but also helps it resist body twisting and improves steering performance. M5_09002 1 2 3 09-2 Crossmember No.2 Crossmember No.
Body & Accessories Doors and Liftgate Doors and Liftgate Features • The doors on the Mazda5 have the following features: – Door units integrating power window motor and regulator, inner door handle and speaker (front doors only) are used. – – – Side impact bars are utilized. Plastic liftgate has been utilized. Sliding doors are used on both sides of vehicle.
Doors and Liftgate Body & Accessories Sliding Doors • To allow easier entry and exiting of the vehicle, sliding doors are provided on both sides. • The sliding doors incorporate a side impact bar, and catcher pins to increase safety in the event of a side collision.
Body & Accessories Doors and Liftgate Sliding Door Open Lock Actuator • The sliding door open lock actuator holds the sliding door in the fully open position to prevent the door closing unexpectedly. • When the inner or outer sliding door handle is operated, a cable releases the open lock actuator, allowing the door to be closed.
Doors and Liftgate Body & Accessories Liftgate • The liftgate consists of an outer skin made of polycarbonate ABS (AcrylonitrileButadiene-Styrene) plastic, and an inner made of glass fibre reinforced polypropylene bonded together. The liftgate harness is incorporated into the liftgate assembly and cannot be replaced separately. • Liftgate dampers that allow the liftgate to be opened to two heights are used.
Body & Accessories Seats Seats Features • The seats on the Mazda5 have the following features: – – The Mazda5 is available in two seating layouts, a five seater and a seven seater. – The right-hand second row seat features a storage box under the seat cushion,as well as a stowable tray that can be unfolded and positioned between the second row seats. – The seat cushion and seat back of the second row seats fold separately, allowing a nearly flat floor surface for storage.
Security and Locks Body & Accessories Security and Locks Features • The security and lock system on the Mazda5 (CR) has the following features: – – – – – Advanced Keyless Entry and Starting System has been adopted (depends on grade). Power door lock system controlled by the BCM is used. Double-locking function is used. Auto re-lock function is used. Theft deterrent system controlled by BCM is used.
Body & Accessories Security and Locks Standard Keyless Entry system • The standard Keyless Entry system is similar to that on the Mazda3, with the following exceptions: – Switchblade type retractable key has been adopted.
Security and Locks Body & Accessories Wiring Diagram M5_09026 09-10 Service Training Mazda5
Body & Accessories 1 2 3 4 5 6 7 8 9 10 11 Cargo compartment light Liftgate latch switch Door lock-link switch Front door latch switch (LH) Front door latch switch (RH) Sliding door switch (LH) Sliding door switch (RH) To CAN bus Keyless receiver Front door lock actuator (driver side) Front door lock actuator (passenger side) Security and Locks 12 13 14 15 16 17 18 19 20 21 Sliding door lock actuator (LH) Sliding door lock actuator (RH) Liftgate lock actuator Front turn signal (LH) Side turn signal (LH)
Security and Locks Body & Accessories M5_09028 1 Release tab 09-12 Service Training Mazda5
Body & Accessories Security and Locks Advanced Keyless Entry and Start System • The Advanced Keyless Entry and Start System allows the vehicle to be unlocked and started without using a key. As long as the driver has an advanced keyless entry card key in their possession, operation of the doorlocks and start knob (to start the engine) can be achieved without actually removing the card key from their pocket or bag.
Security and Locks 1 2 3 4 5 6 7 8 9 10 11 12 13 Start knob (ignition switch) Security light Coil antenna Steering lock unit Keyless warning light (red) Keyless indicator light (green) Keyless buzzer Keyless antenna (driver side) Request switch (driver side) Front door key cylinder Keyless antenna (passenger side) Request switch (liftgate) Front door latch and lock actuator 09-14 Body & Accessories 14 15 16 17 18 19 20 21 22 23 24 25 26 Rear door lock actuator Rear door latch Liftgate latch and lock act
Body & Accessories Security and Locks Wiring Diagram M5_09012 Service Training Mazda5 09-15
Security and Locks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Keyless control module Keyless receiver Coil antenna PCM Steering lock unit Start knob push switch Key reminder switch Request switch (liftgate) Request switch (driver side) Request switch (passenger side) Brake light switch Brake light Selector lever Key interlock solenoid Keyless antenna (driver side) Keyless antenna (passenger side) Keyless antenna (liftgate) 09-16 Body & Accessories 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Keyles
Body & Accessories Security and Locks Card Key • A thin, card type transmitter has been adopted. • The card key incorporates buttons to lock and unlock the doors and to disable the intrusion sensor (when theft-deterrent system fitted), a button type battery (CR2025), an auxiliary key, and an indicator light. • When the LOCK or UNLOCK buttons are operated or a request signal is received from the vehicle, the indicator light illuminates.
Security and Locks Body & Accessories Request Switch • Request switches are installed to driver’s door, passenger’s door, and liftgate respectively. When the request switch is pressed, the Keyless Control Module sends a request signal to the card key.
Body & Accessories Security and Locks Keyless Antennas • A total of six antennas send request signals to card keys, and relay card key ID’s to the Keyless Control Module. • The antennas in the front doors and the liftgate are used to detect card keys outside the vehicle, and those in the rear interior panels and behind the glovebox detect card keys inside the vehicle.
Security and Locks Body & Accessories Keyless Control Module • The Keyless Control Module is located behind the driver’s side kick panel. It confirms the identification of the card keys and transmits this information to the PCM and BCM. • The Keyless Control Module is connected to the HS-CAN bus. NOTE: When replacing the Keyless Control Module, the new module has to be configured.
Body & Accessories Security and Locks Steering Lock Unit • The steering lock unit consists of the steering lock and the start knob. When the start knob is pushed in a request signal is sent by the Keyless Control Module via the keyless antennas. If the Keyless Control Module successfully identifies a valid card key, it sends a signal to the steering lock unit, allowing the steering to be unlocked and the start knob to be turned to the ON position.
Security and Locks Body & Accessories Keyless Entry Function • Unlocking and locking of doors can be achieved either by using the auxiliary key, by pushing the buttons on the transmitter (card key), or simply by pressing the request switches on each of the front doors or liftgate. • An answer-back function is provided for visual and audible confirmation of door lock operation.
Body & Accessories Security and Locks Locking/Unlocking Using Transmitter • When either of the buttons on the transmitter is pushed, the transmitter ID (Identification) and a rolling code are transmitted as radio waves. The signal is detected by the keyless receiver and communicated to the Keyless Control Module. The Keyless Control Module verifies that the ID of the key is valid, and sends a signal to the BCM to operate the door lock actuators.
Security and Locks Body & Accessories Locking/Unlocking Using Request Switches • Whenever one of the request switches is pressed, the Keyless Control Module transmits an ID request signal via the keyless antennas to the card key (a). If the driver’s door request switch is operated, for example, the ID request signal will only be transmitted to the area outside the driver’s door. The same occurs respectively for the other request switches.
Body & Accessories • The doors will only lock when a request switch is pushed if the following conditions are all met: – – – – – • Security and Locks There is no card key inside the vehicle. All doors and liftgate are closed. Auxiliary key is not in the ignition. Start knob is in the LOCK position. A card key is within the reception range of the keyless antennas in the front doors/liftgate.
Security and Locks Body & Accessories Auto Re-lock Function • The doors will automatically re-lock 30 seconds after being unlocked unless any of the following conditions are met: – – – – Any of the doors or liftgate are opened. – Any of the request switches are pushed. The auxiliary key is inserted in the ignition. The start knob is pressed. Any of the buttons of the transmitter are operated (the auto re-lock timer will be reset to ‘0’ if the UNLOCK button is pressed).
Body & Accessories Security and Locks Keyless Start Function • If the driver has a card key with them when they enter the car, it is not necessary to insert a key in the ignition switch to start the engine. The ignition can be switched ON and the engine started simply by turning the start knob. • When the start knob is pressed the Keyless Control Module transmits an ID request signal inside the vehicle, via the interior keyless antennas (a).
Security and Locks Body & Accessories M5_09016 1 2 3 4 5 ID verification NG Red keyless indicator light (flashing) ID verification OK Green keyless indicator light (illuminated) Keyless receiver 09-28 6 7 8 9 10 Keyless control module Steering lock unit Transmitter (card key) Keyless antenna Reception range (interior) Service Training Mazda5
Body & Accessories Security and Locks Guidance Function • The driver is informed of faults or misuse of the system via the warning light and the internal buzzer in the instrument cluster, or the external keyless buzzer. Item Start knob not in LOCK position Operation condition Interior buzzer Keyless Keyless warning indicator light light (green) (red) - Sounds (approx.
Security and Locks Item Start knob operable Start knob Guidance inoperable Lock/unlock answer back *3 Operation condition Start knob is operable (lock released) when it is pressed Start knob is inoperable (locked) when it is pressed Doors are locked/unlocked with normal/advanced keyless entry function Body & Accessories Keyless buzzer (outside the vehicle) Instrument cluster Keyless Keyless Buzzer warning indicator (Interior) light light (red) (green) - - - On (Max.
Body & Accessories Security and Locks Service and Repair Programming Additional Card Keys With Two or More Card Keys • If two or more registered card keys are available, additional keys can be programmed without the use of WDS. A maximum of six card keys can be programmed. NOTE: Steps 3 to 6 below must be completed within 30 seconds of inserting the auxiliary key in the ignition. NOTE: Do not program card keys while WDS or any other computer devices are in the vehicle.
Security and Locks Body & Accessories Erasing Registered Card Keys 1. Establish communication between WDS and the vehicle. 2. Select the option Toolbox→Body→Security→PATS Functions. 3. Carry out the security access procedure (read out the WDS outcode, and input corresponding incode). 4. Select the option “Card Key Clearing”. 5. Complete procedure by programming at least one new card keys. NOTE: Only one registered card key is necessary for the system to function correctly.
Body & Accessories Security and Locks On-board Diagnostic System • The on-board diagnostic system consists of the following functions: – – – Self-test PID monitor Simulation test function Self Test • The self-test function allows the Advanced Keyless Entry system DTCs to be displayed. To view these, connect WDS to the vehicle and select the option Toolbox→Self Test→Modules→RKE. PID Monitor • The PID monitor function allows the PIDs for the Advanced Keyless Entry system to be monitored.
Security and Locks Body & Accessories Simulation Test • The simulation test function allows certain PIDs for the Advanced Keyless Entry system to be activated. To do this, connect WDS to the vehicle and select the option Toolbox→Datalogger→Modules→RKE.
Body & Accessories Security and Locks Immobilizer System (vehicles with standard Keyless Entry system) • The immobilizer system is basically the same as that in the Mazda3 (BK). Control of the immobilizer is carried out by the instrument cluster.
Security and Locks Body & Accessories The ignition switch is turned from the LOCK (ACC) to the ON (START) position. (Security light illuminates.) 1. The instrument cluster sends data A* to the key (transponder) via the coil. 2. The key (transponder) calculates data B from received data A and sends its specific key ID number and data B to the instrument cluster via the coil. 3. The instrument cluster verifies consistency between the received key ID number and the previously registered key ID numbers.
Body & Accessories Security and Locks Immobilizer System (vehicles with Advanced Keyless Entry system) • A D-PATS (Distributed Passive Anti-Theft System) type immobilizer system is used. The system consists of the auxiliary key (with integrated transponder), coil antenna, Keyless Control Module, instrument cluster and PCM. • A maximum of eight keys can be programmed.
Security and Locks Body & Accessories Operation • Control of the immobilizer system on the Mazda5 with Advanced Keyless Entry system is carried out by the instrument cluster. The keys contain a unique ID number that is programmed into the instrument cluster, PCM and Keyless Control Module.
Body & Accessories Security and Locks The start knob is pressed and the ignition switch is turned to the ON position. 1. The instrument cluster transmits data A* to the key (transponder) via the keyless control module and coil antenna. 2. The key (transponder) calculates data B from received data A, and transmits unique key ID number and data B to the instrument cluster via the coil antenna and keyless control module. 3.
Security and Locks Body & Accessories Immobilizer System Component Replacement Operation Necessary Preparation Adding keys/card keys (two or more programmed keys/card keys available) • Two or more programmed keys/card keys. • One ore more keys/card keys to be programmed. Adding keys/card keys (one • One or more keys/card or no programmed key/card keys to be programmed. key available) Required Action • Can be performed without WDS, providing "Customer spare key programming" function is enabled.
Body & Accessories Security and Locks This page is intentionally left blank! Service Training Mazda5 09-41
Security and Locks Body & Accessories On-board Diagnostic System • The on-board diagnostic system consists of the following: – Self-test Self Test • The self-test function allows immobilizer system DTCs to be displayed. To do this, connect the WDS to the vehicle and select the option Toolbox→Self Test→ Modules→IC, PCM and/or RKE. • The security light displays stored DTCs by flashing on and off. The on/off pattern will differ depending on which DTC is stored.
Body & Accessories Security and Locks Theft Deterrent System • The construction and operation of the theft deterrent system on the Mazda5 is essentially the same as that on the current Mazda3 (BK), except for the following: – An additional intruder sensor is installed near the rear of the passenger compartment.
Security and Locks 1 2 3 4 5 6 7 09-44 Front intruder sensor (vehicles with sunroof) Front intruder sensor (vehicles without sunroof) Key reminder switch Keyless control module BCM Front door latch and lock actuator (driver side) Front door latch and lock actuator (passenger side) Body & Accessories 8 Rear door switch 9 Bonnet latch switch 10 11 12 13 Theft-deterrent siren Liftgate latch and lock actuator Rear intruder sensor Transmitter Service Training Mazda5
Body & Accessories Security and Locks Wiring Diagram M5_09032 1 2 3 4 5 6 7 Cargo compartment light switch Liftgate latch switch Front door latch switch (LH) Front door latch switch (RH) Sliding door switch (LH) Sliding door switch (RH) Theft-deterrent siren Service Training Mazda5 8 9 10 11 12 13 Intruder sensor (front) Intruder sensor (rear) Door lock-link switch Door key cylinder switch (driver side) Bonnet switch BCM 09-45
Glass/Windows/Mirrors Body & Accessories Glass/Windows/Mirrors Features • The glass/windows/mirrors have the following features: – – Rear defroster controlled by the Body Control Module is used (same as Mazda3). Power window system with auto-open/close function available on all windows. Power Window System Features • The power window system is essentially the same as that on the current Mazda3 (BK), and has the following features: – – – – – – – – 09-46 Manual open/close function on all windows.
Body & Accessories Glass/Windows/Mirrors Power Window Main Switch M5_09006 1 2 3 4 5 6 7 8 Power window main switch Power window motor (driver side) Close Open Auto Power-cut switch Conjunction circuit Close relay Service Training Mazda5 9 10 11 12 13 14 15 Open relay Hall effect switch 1 Hall effect switch 2 To power mirror switch To power window subswitches BCM Power window control module 09-47
Glass/Windows/Mirrors Body & Accessories Power Window Subswitch M5_09007 1 2 3 4 5 6 Power window subswitch Power window motor Close Open Auto Close relay 09-48 7 8 9 10 11 Open relay Hall effect switch 1 Hall effect switch 2 Power window control module From power window main switch Service Training Mazda5
Body & Accessories Glass/Windows/Mirrors Exterior Opening/Closing Function • The exterior opening/closing function allows all of the windows to either be opened, or closed from outside the vehicle. • By pressing the driver’s door request switch, or the LOCK button on a card key or a retractable type key transmitter for approximately 1.5 seconds, all of the windows can be closed. • Conversely, by pressing the UNLOCK button on a card key or a retractable type key transmitter for approximately 1.
Glass/Windows/Mirrors Body & Accessories Operation Using Request Switch M5_09086 1 2 3 4 5 6 7 8 9 Transmitter Request switch (driver side) Keyless receiver Keyless control module Door latch switch Start knob/key reminder switch Cargo compartment light switch Power window main switch Input signal 09-50 10 11 12 13 14 15 16 17 18 Control signal Power window subswitch (RF) Power window subswitch (LR) Power window subswitch (RR) Power window motor (LF) Power window motor (RF) Power window motor (LR) Po
Body & Accessories Glass/Windows/Mirrors Using Transmitter M5_09008 1 2 3 4 5 6 7 8 9 Transmitter Keyless receiver Keyless control module Door latch switch Start knob/key reminder switch Cargo compartment light switch Power window main switch Input signal Control signal Service Training Mazda5 10 11 12 13 14 15 16 17 Power window subswitch (RF) Power window subswitch (LR) Power window subswitch (RR) Power window motor (LF) Power window motor (RF) Power window motor (LR) Power window motor (RR) BCM
Glass/Windows/Mirrors Body & Accessories Operation Prohibition • When the following conditions are met before, or during window operation, the exterior open/close function does not operate.
Body & Accessories Sunroof Sunroof • The construction and operation of the sunroof on the Mazda5 is essentially the same as that on the current Mazda3 (BK), except for the following: – Drive unit for sunroof is now available as a separate part. Specifications Item Specification Slide system Outer slide Opening measurement (mm {in}) Tilt-up amount (mm {in}) Opening/ closing time 202 x 722 {7.95 x 28.4} (s) 22 – 28 {0.9 – 1.1} Slide: 2.5 – 5.5, Tilt: 0.
Sunroof Body & Accessories M5_09033 1 2 3 4 5 Drip rail Drip guide Rear stopper Sunshade Deflector 09-54 6 7 8 9 Sunroof motor Guide and decoration trim Drive unit Frame Service Training Mazda5
Body & Accessories Lighting System Lighting System Features • The headlight system on the Mazda5 is essentially the same as the current Mazda3 (BK). It has the following features: – – – – – – Projector type headlights (low-beam). – Daytime running lights (depending on market). Discharge headlights with auto leveling system (depending on grade). Stepped reflectors in the rear combination lights. Light Emitting Diode type high-mount brake light. Auto headlight system (depending on grade).
Lighting System Body & Accessories Front Combination Light • Projector type headlights with built-in front turn signal light and parking light are used.
Body & Accessories Lighting System Headlight Auto Leveling System • The construction and operation of the headlight auto leveling system is essentially the same as that on the current Mazda3 (BK), except for the following: – – Conditions necessary before auto leveling control commences are different. The headlight auto leveling module requires initialization after related components are replaced.
Lighting System Body & Accessories Wiring Diagram M5_09036 09-58 Service Training Mazda5
Body & Accessories Lighting System Operation • If the auto leveling control module detects the vehicle is moving at a constant vehicle speed of 8 km/h or more for four seconds while the headlights are on, the average value of the vehicle attitude during this period is calculated and the optical axis is adjusted.
Lighting System Body & Accessories Rear Combination Light • A stepped reflector that diffuses and reflects the light of the rear combination lights is used. • A round reflector is incorporated in the lower part of the rear combination light.
Body & Accessories Wiper/Washer System Wiper/Washer System • The wiper/washer system is essentially the same as the current Mazda3 (BK). It has the following features: – – – – Front wiper/washer and headlight cleaner system controlled by the BCM. Auto wiper system (depending on grade). Rear wiper/washer controlled by the BCM. Washer fluid level sensor installed in the windshield washer tank (depending on grade).
Wiper/Washer System 1 2 3 4 5 6 7 8 9 Wiper and washer switch Rain sensor Windshield wiper arm and blade Windshield wiper motor Windshield washer hose Headlight cleaner actuator Headlight cleaner nozzle Headlight cleaner hose Windshield washer nozzle Body & Accessories 10 11 12 13 14 15 16 17 18 Rear washer hose Rear washer nozzle Rear wiper arm and blade Rear wiper motor Washer tank Rear washer motor Washer fluid-level sensor Windshield washer motor Headlight cleaner motor Rain Sensor Initialization •
Body & Accessories Entertainment Systems Entertainment Systems Audio System Features • The audio unit is of a modular construction, similar to the Mazda3. Three base audio unit combinations are available: Type A – – AM/FM tuner CD player Type B – – – AM/FM tuner CD player RDS (Radio Data System) Type C – – – – • AM/FM tuner CD player Hard Disc Drive RDS MD (Mini Disc) player, cassette deck, or 6-disc CD (Compact Disc) changer are available as options.
Entertainment Systems Body & Accessories Specifications Audio Unit Specification Item Type A Type B Without RDS Rated Voltage Frequency band 12 (V) AM FM Audio amplifier maximum output power Output impedance LW (kHz) – 153 – 279 MW (kHz) 530 – 1620 531 – 1629 87.5 – 108.
Body & Accessories Entertainment Systems Parts Location M5_09040 1 2 3 4 5 Rear speaker Front door speaker Front tweeter Information display Centre panel module Service Training Mazda5 6 7 8 9 Audio control switches Centre roof antenna Capacitor Remote control (with HDD) 09-65
Entertainment Systems Body & Accessories System Overview M5_09041 09-66 Service Training Mazda5
Body & Accessories 1 2 3 4 5 6 7 8 9 10 Centre panel module Information display Audio control switch TNS signal Audio control circuit Antenna Audio unit Base unit Lower module Front tweeter (right) Service Training Mazda5 Entertainment Systems 11 12 13 14 15 16 17 18 19 Front door speaker (right) Front tweeter (left) Front door speaker (left) Rear speaker (right) Rear speaker (left) Remote controller (with HDD) Infrared sensor Type A/Type B (without HDD) Type C (with HDD) 09-67
Entertainment Systems Body & Accessories Centre Panel Module • The centre panel module consists of the audio unit and switches, and the heater control unit. A lower module (cassette deck or MD player) may be added to type A or type B audio systems, but not to type C (with HDD). • The centre panel module is connected to the MS-CAN bus. NOTE: There is no mute connector provided on the audio unit.
Body & Accessories Entertainment Systems Music Hard Disc Drive • The HDD (Hard Disc Drive) unit allows albums to be recorded from the CD player, stored on the hard disc in MP3 format, and played back. • Music recorded on the HDD can be categorized by album name, artist, music style, or compiled into favourites lists to allow more convenient searching and playback.
Entertainment Systems Body & Accessories Secret Menu • The secret menu allows the following operations to be carried out: – – Format the hard disc. – Rebuild the HDD database. (If “DB ERROR” is displayed on the information display, it is possible that rebuilding the HDD database will restore the functionality of the unit.) – Scan the HDD disc for errors. Display or update the Firmware installed. (Firmware is the software that manages the HDD database.
Body & Accessories Entertainment Systems On-board Diagnostic System • The on-board diagnostic system is similar to the Mazda3 (BK), and consists of the following functions: – – Self-diagnostic function Diagnostic assist function Self Diagnostic Function • The self-diagnostic function allows DTCs in the audio unit to be displayed. It can be entered as follows: 1. Turn the ignition switch to the ACC or ON position. 2. Confirm that the audio unit is switched off.
Entertainment Systems Body & Accessories Car Navigation System Features • The Mazda5 is equipped with a new navigation system manufactured by Denso. The construction and operation of the navigation system is essentially carried over from that of the Mazda3 (BK), except for the following features: – – – The speed of operation has been improved. – A voice control system has been adopted to enable the customer to verbally control most functions of the navigation system.
Body & Accessories Entertainment Systems Parts Location M5_09054 1 2 3 4 5 6 Microphone Car-navigation unit Remote control (RHD) Car-navigation control panel (LHD) Back-up light switch (MTX) TR switch (ATX) Service Training Mazda5 7 8 9 10 11 Front door speaker Front tweeter Voice recognition switch GPS antenna LCD unit 09-73
Entertainment Systems Body & Accessories System Overview M5_09055 1 2 3 4 RDS-TMC tuner Gyro sensor DVD driver GPS receiver 13 14 15 16 5 6 7 8 CPU RDS-TMC antenna Front tweeter (driver side) Front door speaker (driver side) 17 18 19 20 9 10 11 12 Rear camera Rear view monitor control module Audio unit CPU 21 22 23 24 09-74 LCD GPS antenna Microphone with amplifier Car-navigation control panel or remote control Parking brake switch Parking brake signal LCD unit TR switch (ATX) or back-up light
Body & Accessories Entertainment Systems Car Navigation Unit • The car navigation unit is located in the glove compartment and incorporates the DVDROM drive and the gyro sensor.
Entertainment Systems Body & Accessories LCD Unit • The LCD unit is a pop-up type incorporated in the dashboard. It serves as a display for the navigation system during normal operation and as a display for the rear view camera when reverse gear is selected. • The LCD unit features a dedicated bidirectional serial bus to the navigation unit and the audio unit. All necessary video signals are separately sent as a RGB signal.
Body & Accessories Entertainment Systems Split Screen • Different display modes can be selected with the split screen function.
Entertainment Systems Body & Accessories Map and Turn Arrows M5_09061 Automatically Enlarged Illustration of a Nearby Intersection M5_09062 M5_09063 09-78 Service Training Mazda5
Body & Accessories Entertainment Systems Microphone • The microphone is located beside the LCD unit and recognizes verbal commands in order to control several functions of the navigation system. • The microphone incorporates an amplifier and is connected to the navigation unit. • To enable the recognition function, the voice recognition button on the steering wheel has to be pressed first.
Entertainment Systems Body & Accessories Voice Recognition Button • The voice recognition button is incorporated in the steering wheel. Its signal is forwarded on the serial bus from the audio unit via the LCD display unit to the navigation unit. • To activate the voice recognition, the driver has to press the button. This activates the microphone and mutes the audio unit for a specified time, during which the driver can input verbal commands.
Body & Accessories • Entertainment Systems The list of verbal commands that the navigation system will follow is shown below: M5_09083 Service Training Mazda5 09-81
Entertainment Systems Body & Accessories Control Panel • The navigation control panel is located on the centre console. RHD vehicles are equipped with a remote control instead of the control panel. M5_09067 • The layout of the control types is different, but the functions are the same, except for the fact that the remote control does not feature a DIM button.
Body & Accessories Entertainment Systems Traffic Message Channel • The TMC (Traffic Message Channel) function is a specific application of the RDS (Radio Data System), using a FM receiver that is incorporated in the navigation unit. It receives traffic messages and forwards the received information to the CPU. The messages can be displayed and the route can be automatically recalculated when there are traffic jams along the first selected route.
Entertainment Systems Body & Accessories • Traffic events received by the TMC receiver are shown as a symbol on the Navigation display in a scale of 50m…4km. Events within a 25km radius of the vehicle are monitored by the system in order to automatically select a detour if necessary. • The colour and type of the TMC symbol depends on the traffic information.
Body & Accessories • Entertainment Systems Each traffic event is indicated by one sign.
Entertainment Systems Body & Accessories TMC Availability • The map below shows the availability of TMC in Europe. NOTE: Even when the TMC displays traffic events on other road types (e.g. major roads), the DRGS (Dynamic Route Guidance System) recalculates the route only for traffic events on motorways. NOTE: TMC information about a large traffic jam does not necessarily mean that the navigation system will reroute the vehicle.
Body & Accessories Entertainment Systems Activation of TMC and DRGS • To switch on the TMC and DRGS first select “RDS-TMC” from the main menu. A new menu will be displayed where several options can be selected.
Entertainment Systems Body & Accessories On-board Diagnostic System • The on-board diagnostic system has the following functions: – – – – Vehicle Signal Check Navigation Check Product Version Error Code • To access the OBD function, press the “Menu” button and select Navigation Set Up Æ Calibration Æ Map Version. Then push the joystick up two times and down two times. Now, the “Diagnosis Check” screen is displayed. After selecting “Menu” the OBD main menu is displayed on the screen.
Body & Accessories Entertainment Systems Vehicle Signal Check • The “Vehicle Signal Check” allows several input signals of the navigation system to be checked.
Entertainment Systems Body & Accessories GPS Information • The option “GPS Information” allows the data received from GPS satellites to be checked. M5_09076 1 No.
Body & Accessories Entertainment Systems Microphone Check • The “Microphone Check” allows to check the input signals of the microphone.
Entertainment Systems Body & Accessories Vehicle Sensors • The option “Vehicle Sensors” allows the sensor signals of the navigation system to be checked.
Body & Accessories Entertainment Systems History • The option “History” allows the usage of the navigation system in the past to be checked.
Entertainment Systems Body & Accessories Remote Control Test • The “Remote Control Test” allows the buttons of the control panel/remote control to be checked. The display informs the technician how to proceed after the test has been selected. M5_09080 Product Version • The option “Products Version” allows the hardware and software version of the navigation system to be checked.
Body & Accessories Entertainment Systems Error Code • The option “Error Code” allows DTCs stored in the navigation system to be inspected.
Entertainment Systems Body & Accessories Rear Entertainment System Features • The RES (Rear Entertainment System) unit consists of a DVD/CD player and built in display. • In addition, an input for external devices (such as video games) is provided behind the second row seats. • Audio from the RES can be played back through the vehicle audio system, or listened to using infrared type wireless headphones (purchased separately). • An infrared remote control is provided to operate the RES.
Body & Accessories Entertainment Systems Parts Location M5_09043 1 2 3 4 Remote control Rear speaker RES unit Front door speaker 5 6 7 Tweeter Auxiliary terminal unit Audio unit DVD/CD Playback • The below DVD/CD formats can be played back: – – – – 12 cm or 8 cm DVD-VIDEO (PAL format, Region Code ‘2’ or ‘ALL’) 12 cm or 8 cm Video-CD (PAL format) CD-R (CD-AUDIO, MP3) CD-RW (CD-AUDIO, MP3) Service Training Mazda5 09-97
Entertainment Systems Body & Accessories Customisation • The following DVD preset and playback settings can be changed using the remote control: – – – – – – Language (menu language, subtitle/spoken language) Parent lock setting (when available on DVD) DVD movie camera angle (when available on DVD) DVD movie screen size Picture quality Sound output balance (left, right, or both) Overheat Protection Function • If the internal temperature of the DVD/CD player or display exceeds the threshold, operation
Body & Accessories Entertainment Systems Rear View Monitor • The rear view monitor consists of the rear view monitor control module, the rear camera, the steering angle sensor, the LCD (Liquid Crystal Display) unit (integrated with the car navigation system) and the reverse light switch. • When the driver selects reverse gear while the ignition is in the ON position, the rear camera switches on and displays the area behind the vehicle on the car navigation display.
Entertainment Systems Body & Accessories Parts Location M5_09044 1 2 3 Steering angle sensor LCD unit Rear view monitor control module 4 5 Car-navigation unit Rear camera System Overview M5_09045 1 2 3 Car-navigation unit LCD unit Rear view monitor control module 09-100 4 5 6 Steering angle sensor Rear camera Back-up light switch (MTX) Service Training Mazda5
Body & Accessories Entertainment Systems Reference Lines • The following reference lines are superimposed on the image provided by the back camera, to assist the driver when reversing into a parking space: M5_09046 No. Line Color Red • This line indicates about 0.5 m {1.64 ft} from the end of rear bumper. • It moves according to steering operation. Yellow • This line indicates about 1 m {3.28 ft} from the end of rear bumper. • It moves according to steering operation.
Entertainment Systems Body & Accessories Rear View Monitor Control Module Initialization • When replacing the rear view monitor control module, rear camera or liftgate, the rear view monitor control module must be initialized. The initialization mode can be entered by conducting the following procedure: 1. Turn the audio unit off and turn the ignition switch to the LOCK position. 2.
Body & Accessories Control System Instrumentation/Driver Information System Features • The construction and operation of the instrumentation/driver information system is essentially the same as that on the Mazda3 (BK) except for the following: – – – – Mileage data is uploaded into new instrument cluster during configuration procedure. Code numbers for instrument cluster input/output check mode have been changed. Information display is now connected to the MS-CAN bus.
Instrumentation/Driver Information Body & Accessories Specifications Item Specification Meter type Indication range Stepper motor type (mph {km/h}) 0—143 {0—230} Speedometer Input signal communication system CAN system Input signal source PCM Rated voltage (V) Meter type Tachometer Indication range (rpm) 0—8,000 (L8, LF), 0—6,000 (MZR-CD) Red zone (rpm) 6,500—8,000 (L8, LF) 5,000—6,000 (MZR-CD) Input signal communication system CAN system Input signal source Rated voltage PCM (V) Me
Body & Accessories Control System Instrument Cluster • The instrument cluster features LEDs for the warning and indicator lights. It is connected to the HS- and the MS-CAN bus.
Instrumentation/Driver Information No.
Body & Accessories Control System Input/Output Check Mode 1. To enter the input/output check mode, turn the ignition switch to ON while pushing the odometer/ tripmeter switch. Keep pressing the odometer/tripmeter switch until “test” is displayed on the odomoter/tripmeter display. 2. Press the odometer/tripmeter switch to move from one check mode to the next.
Instrumentation/Driver Information Body & Accessories Configuring Instrument Cluster • When replacing the instrument cluster, the new cluster has to be configured. To do this, connect the WDS to the vehicle and select the option Toolbox→Module Programming→Programmable Module Installation→IC. During this procedure the mileage is uploaded into the new instrument cluster. NOTE: Configuring of the instrument cluster can only be conducted once.
Body & Accessories Control System Seat Belt Warning • Seat belt warnings are provided for both the driver’s seat and the passenger’s seat. The operation of the seat belt warning light and warning chime is controlled by the instrument cluster.
Instrumentation/Driver Information Body & Accessories Passenger’s Seat Belt Warning • For the control of the passenger’s seat belt warning, the signal from the passenger’s seat belt buckle switch and an additional seat occupancy sensor is used. The occupancy sensor is located on the seat cushion, and informs the instrument cluster whether the seat is occupied or not.
Body & Accessories Control System Information Display • The information display indicates information for the audio system, climate control system, and driver information such as fuel economy data. • Information between the information display and other modules is exchanged via the MS-CAN bus. Input/Output Check Mode • An input/output check mode is provided to allow diagnostics of the information display.
Instrumentation/Driver Information Body & Accessories Wiring Diagram M5_09049 09-112 Service Training Mazda5
Body & Accessories Control System Control System Features • With the introduction of the Mazda5 (CR) a new control system for body electrics has been adopted. It has the following features: – – A Body Control Module has been adopted. – Controller Area Network with HS-CAN and MS-CAN bus communication. An interior fuse box separate to the Body Control Module (at end of instrument panel on passenger’s side). Body Control Module • The BCM is installed on the passenger’s side underneath the dashboard.
Control System Body & Accessories BCM Location M5_09050 1 BCM NOTE: The BCM does not require configuring when it is replaced. NOTE: Directly after switching off the ignition a current draw of approximately 180 mA for 30 minutes is normal, after which it drops to approximately 20 mA.
Body & Accessories Control System On-board Diagnostic System • The on-board diagnostic system consists of the following functions: – – Self test PID monitor Self Test • The self test function allows BCM DTCs to be displayed on WDS. To do this, connect WDS to the vehicle and select the option Toolbox→Self Test→Modules→GEM. • When the ignition is switched off, DTCs stored by the self test will be deleted.
Control System Body & Accessories PID Monitor • The PID monitor function allows BCM PIDs to be displayed. To do this, connect WDS to the vehicle and select the option Toolbox→Datalogger→Modules→GEM.
Body & Accessories Control System Controller Area Network • The Mazda5 uses an MS-CAN (Middle Speed-Controller Area Network) and an HS-CAN (High Speed-Controller Area Network) for transmission of multiplex input/output signals between electrical modules, similar to the Mazda3. The instrument cluster is connected to both networks and operates as portal, allowing information exchange between the MS-CAN and the HS-CAN.
Control System Body & Accessories M5_09051 1 2 3 4 5 6 7 8 9 PCM (MZR-CD) PCM (L8, LF) DSC HU/CM (with DSC) ABS HU/CM (with ABS) Rear view monitor control module Keyless control module (with Advanced Keyless Entry system) EHPAS control module (with L8/LF engine) Instrument cluster Twisted pair 09-118 10 11 12 13 14 15 Climate control unit (with full-auto A/C) Information display Water heater unit (with MZR-CD engine) Audio unit (base module) DLC-2 BCM 16 CAN-H 17 CAN-L Service Training Mazda5
Body & Accessories Control System HS-CAN Signal Chart • The following signals are transmitted via the HS-CAN bus.
Control System Body & Accessories Multiplex module Signal PCM EHPAS control module (L8, LF) DSC HU/CM Keyless control module Instrument cluster ABS HU/CM Rear view monitor control module DSC indicator light on request – – OUT – – IN DSC OFF light on request – – OUT – – IN Keyless warning/indicator light on request – – – – OUT IN Keyless warning buzzer on request – – – – OUT IN Fuel tank level IN – – – – OUT A/C on request IN – – – – OUT Transaxle in revers
Body & Accessories Control System MS-CAN Signal Chart • The following signals are transmitted via the MS-CAN bus.
Control System Body & Accessories On-board Diagnostic System • The on-board diagnostic system is essentially the same as the Mazda3, except for the following: – CAN related DTCs can now be stored in the information display and Keyless Control Module as these modules are now connected to the area network.
List of Abbreviations ABS ABS ABDC A/C ALC Acrylonitrile-ButadieneStyrene Compact Disc CKP Crankshaft Position CMDTC Continuous Memory DTC CMP Camshaft Position CPP Clutch Pedal Position CPU Central Processing Unit CRS Child Restraint Seat DC Direct Current DLC Data Link Connector DSC Dynamic Stability Control D-PATS Distributed-PATS DPF Diesel Particulate Filter DRGS Dynamic Route Guidance System DTC Diagnostic Trouble Code Air Conditioning Auto Level Control AT Automati
List of Abbreviations DVD Digital Versatile Disc HDD Hard Disc Drive EBD Electronic Brake Force Distribution HI High HO2S Heated O2 Sensor ECT Engine Coolant Temperature HS-CAN High-Speed CAN HU/CM Hydraulic Unit/Control Module HVAC Heater, Ventilation & Air Conditioning IAC Idle Air Control IAT Intake Air Temperature IC Instrument Cluster ID Identification IG Ignition ISV Intake Shutter Valve KOEO Key On Engine Off KOER Key On Engine Running EGR Exhaust Gas Recirculation
List of Abbreviations KS Knock Sensor LCD Liquid Crystal Display LED LF LH LO MOS-FET Metal Oxide Semiconductor Field Effect Transistor MP3 Moving Picture Experts Group Layer-3 MS-CAN Middle-Speed CAN MTX Manual Transaxle NOx Nitrous Oxide NTC Negative Temperature Coefficient NVH Noise, Vibration & Harshness OBD On Board Diagnostics OCV Oil Control Valve PAD Passenger Airbag Deactivation PATS Passive Anti-Theft System PCM Powertrain Control Module PCV Positive Crankcase Vent
List of Abbreviations PID Parameter Identification PJB Passenger Junction Box SAS Sophisticated Airbag Sensor SST Special Service Tool TCC Torque Converter Clutch TCS Traction Control System Power Window Control Module TDC Top Dead Center RDS Radio Data System TFT Transmission Fluid Temperature RES Rear Entertainment System TMC Traffic Message Channel TNS Tail, Number & Side lights TP Throttle Position TR Transmission Range Tx Transmitter (line) VBC Variable Boost Control VIN
List of Abbreviations VSS Vehicle Speed Sensor VTCS Variable Tumble Control System WDS Worldwide Diagnostic System WU-TWC Warm Up Three-Way Catalyst Service Training Mazda5
List of Abbreviations Service Training Mazda5
