Training Manual Mazda BT-50 NMT-009
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.
Table of Contents General Information ..........................................................................00-1 Product Concept....................................................................................................00-1 Vehicle Identification Number................................................................................00-7 Engine Identification Number ................................................................................00-8 Other Vehicle Information Labels ..............
Table of Contents Fuel System ..............................................................................................................01-25 Features ..............................................................................................................01-25 Specifications ......................................................................................................01-25 Parts Location......................................................................................................
Table of Contents Suspension ........................................................................................02-1 Features ................................................................................................................02-1 Specifications ........................................................................................................02-1 Parts Location........................................................................................................
Table of Contents Restraints...........................................................................................08-1 Airbag System ............................................................................................................08-1 Features ................................................................................................................08-1 Parts Location........................................................................................................
Table of Contents Audio System............................................................................................................09-16 Features ..............................................................................................................09-16 Specifications ......................................................................................................09-16 Audio Unit .....................................................................................................
Table of Contents Notes: Service Training BT-50
General Information General Information Product Concept • The new Mazda BT-50 supersedes the B-Series, Mazda’s present pick-up truck. The aim of the BT-50 development team was to create a new pickup model in line with the current model range delivering Mazda’s Zoom-Zoom spirit in its individual and distinctive way. • The BT-50 has inherited the tough and reliable commercial truck performance of the BSeries.
General Information • Plane body panels without the formerly used swage lines and other new styling elements contribute to a more brawny, but clear and modern overall styling impression.
General Information • The design and material quality of the interior has been improved and now reminds more of a passenger car than of a pick-up truck. BT-50_00003 • Beside the clearly arranged instrument panel the completely new T-shaped dashboard contains a centre stack panel incorporating the latest modular audio system and the climate control panel, both with easy to operate control elements.
General Information • New features of the powertrain, such as the 16-valve DOHC-diesel engine with common rail direct injection and Euro 4 emission standard, the dual-mass flywheel or the 5-speed transmission S15M(X)-D contribute to a driving performance and emission output that are comparable to passenger cars. • The noise level emitted by the engine has been significantly reduced by the common rail injection system and additionally dampened by broad use of insulation materials.
General Information • Other well-proven components, which are adopted from the B-Series as e.g. the chassis with the ladder frame and the suspension, are refined by major or minor changes in material, form, and/or dimension. BT-50_00006 • The supplemental restraint system is now enhanced by combined head / side airbags as used on the MX-5 (NC).
General Information • The BT-50 is basically offered in three different body versions: – REG (REGular) Cabin, available in 2WD or 4WD layout BT-50_00008 – RAP (Rear Access Panel) Cabin (marketing name is ‘Freestyle Cab’), available in 4WD layout BT-50_00009 – DBL (DouBLe) Cabin, available in 4WD layout BT-50_00010 00-6 Service Training BT-50
General Information Vehicle Identification Number • The VIN is located on the outside of the right chassis member (visible from the right front wheel arch). The model code of the BT-50 has remained ‘UN’, while the serial number starts at 600,001. BT-50_00011 JMZ UN 1 A 1 2 0 W 600001 Serial No. Plant W= Auto Alliance Thailand Dummy 0 Transmission 2 = 5 speed MTX Engine Type 1 = WL-C (2.
General Information Engine Identification Number • The engine identification number of the WL-C engine is located on the timing gear-side of the cylinder block.
General Information Other Vehicle Information Labels Model Plate • The model plate is located on the right side of the bulkhead in the engine compartment. BT-50_00013 1 Driving direction Tyre Pressure Label • The tyre pressure label is located on the driver’s door as shown below.
General Information Technical Data Item Unit REG 2WD Overall length (w/o rear step bumper) Overall width (AWD models with Overfenders) 1,715 Overall height (unladen) 1,620 Front track mm 1,450 Wheelbase Ground clearance (unladen) Maximum fording depth Angle of approach (unladen) Angle of departure (unladen) Minimum turning circle (wall-to-wall) 2,985 181 300 24 26 12 *1 P235/75R15 *2 m 5,075 1,805 *1 1,745 2 1,750 * *1 1,445 *2 1,495 *1 1,440 *2 1,470 3,000 207 450 32 27 12.
General Information Jacking and Lifting • The front of the vehicle can be lifted with a jack near the centre of the front crossmember. NOTE: The jacking point on the front axle for the 2WD is different to the 4WD model.
General Information Towing • The towing hooks on the 2WD model are different from the 4WD model. BT-50_00020 2WD 1 • Towing hooks The 4WD model has two tie-down hooks that may not be used for towing. The towing hook is located on the left side.
General Information Scheduled Maintenance Table Maintenance Interval Number of months or kilometers (miles), whichever comes first Months 12 24 36 48 60 72 84 96 108 x1000 km 20 40 60 80 100 120 140 160 180 x1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.
General Information Maintenance Interval Number of months or kilometers (miles), whichever comes first Months 12 24 36 48 60 72 84 96 108 x1000 km 20 40 60 80 100 120 140 160 180 x1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.
General Information Remarks • Refer below for a description of items marked with * in the maintenance chart. – *1: Replacement of the engine timing belt and auto tensioner is required at every 120,000 km (75,000 miles). Failure to replace the timing belt and the auto tensioner may result in damage to the engine. – *2: If the vehicle is operated primarily under any of the following conditions, replace the engine oil and oil filter more often than the recommended intervals.
General Information Notes: 00-16 Service Training BT-50
Engine WL-C Engine WL-C Engine • The BT-50 is offered with the 2.5 L common rail diesel engine, which has the identification code WL-C. • The design and operation of the WL-C engine are essentially carried over from that of the B-Series with WLT-3 engine, except for the new features described in the respective sections.
WL-C Engine Engine Overview BT-50_01002 01-2 Service Training BT-50
WL-C Engine Mechanical Mechanical Features • The mechanical system of the WL-C engine has the following new features: – – – – – – – – Pistons with integrated combustion chamber Coated piston skirt Reduced compression ratio Newly constructed aluminium alloy cylinder head Double overhead camshafts (driven by a timing belt) Four valves per cylinder Adjustable roller-type rocker arms Timing belt auto tensioner Specifications Item Specification WL-C Type Diesel 4-stroke Cylinder arrangement and number I
Mechanical WL-C Engine Piston • In accordance with the adoption of the common rail injection system, the piston head shape now incorporates the combustion chamber. Due to the modified piston shape the compression ratio is reduced from 21.6: 1 on the WLT-3 engine to 18.0: 1. • A reduction of the internal friction and hence of the engine’s mechanical loss has been achieved by coating of the piston skirt area.
WL-C Engine Mechanical Cylinder Head Parts Location BT-50_01007 1 2 3 4 Cylinder head cover Upper camshaft bearing caps Lower camshaft bearing case with injector sealing rings Cylinder head Service Training BT-50 5 6 7 Cylinder head gasket Seal plate Camshaft pulley 8 Camshaft 01-5
Mechanical WL-C Engine • The cylinder head and the full floating cylinder head cover are made of aluminium alloy. • The steel laminated cylinder head gasket is available in three different thicknesses depending on the piston protrusion. The gasket is marked respectively (refer to Engine W/M). • The camshafts are supported in a separate bearing case, which is available as a separate spare part.
WL-C Engine Mechanical Valve Gear • The valve gear comprises helical gears and a timing belt • The timing belt drives two camshafts and is adjusted by an auto tensioner. • Adjustable roller type rocker arms have been adopted to lower the friction between camshaft lobe and rocker arm, reducing the engine’s mechanical loss.
Mechanical WL-C Engine Valve-Clearance Adjustment • The valve clearance is measured between roller and cam lobe. CAUTION: For loosening the locknut of the adjusting screw the cam lobe must push down the rocker arm firmly as shown in the figure below. Otherwise the claw of the rocker arm might be damaged. BT-50_01010 1 2 3 Cam lobe Adjusting screw Locknut 4 5 6 Rocker arm Claw Roller Camshaft Pulleys • The camshaft pulleys for intake and exhaust camshaft are identical.
WL-C Engine Mechanical Timing Belt Auto Tensioner • A timing belt auto tensioner has been adopted to maintain timing belt tension constant. The timing belt tension is released by turning the auto tensioner counterclockwise with the aid of an Allen wrench (with max. 39 Nm apply force). The turned back tensioner is secured by inserting a fixing pin with 6 mm diameter into the appropriate bore (No. 3 in figure below). BT-50_01055 1 2 Apply force (max.
Mechanical WL-C Engine Engine Timing • When replacing the timing belt the timing marks must be positioned as shown in the figure below.
WL-C Engine Lubrication System Lubrication System Features • The lubrication system of the WL-C engine has the following new features: – – – Plastic oil strainer with resin filter Spin-on type oil filter with full-flow paper element Double layer oil pan with additional oil baffle Specifications Specification WL-C Item Type Force-fed type Oil pressure (reference values) [after warm up] (at idle) kPa 100-330 (at 2,500 rpm) kPa 410-570 Type Relief valve Oil pump opening pressure (reference value)
Lubrication System WL-C Engine Parts Location BT-50_01044 1 2 3 4 5 6 Oil jet valve Oil pressure switch Oil dipstick Oil cooler Oil filter body Oil filter 01-12 7 8 9 10 11 12 Oil cooler and oil filter body component Oil pan Oil drain plug Oil strainer Oil outlet pipe Oil pump Service Training BT-50
WL-C Engine Lubrication System System Overview BT-50_01015 1 2 3 4 5 6 7 8 9 10 11 Oil pressure switch Vacuum pump Turbocharger Timing gears Oil Strainer Oil filter Oil cooler Oil cooler and oil filter body component Camshaft Orifice Balancer shaft Service Training BT-50 12 13 14 15 16 17 18 19 20 21 Main bearing Crankshaft Connecting rod bearing Oil pump Piston Oil jet valve Oil pan Oil passage Oil relief passage Oil bypass passage 01-13
Lubrication System WL-C Engine Oil Filter • The spin-on type oil filter consists of one full flow element. The bypass element that has been additionally used on the filter WLT-3 engine has been dropped.
WL-C Engine Cooling System Cooling System Features • The cooling system of the WL-C engine has the following new features: – – Longlife engine coolant FL-22 Asymmetric positioned radiator fan blades for noise reduction (thermo-modulated fan-type) Specifications Specification WL-C Item Type Type Water-cooled, forced circulation Without heater: 8.8 With heater: 9.4 Centrifugal, V-belt driven Type Wax, bottom-bypass Coolant capacity (approx.
Cooling System WL-C Engine Parts Location BT-50_01045 1 2 3 4 Radiator cowling Water pump pulley Thermostat Water pump 5 6 7 8 Cooling fan Coolant reserve tank Radiator Cooling system cap NOTE: To bleed the cooling system follow the instructions of the W/M.
WL-C Engine Cooling System System Overview BT-50_01018 1 2 3 4 5 6 Coolant reserve tank EGR cooler Cylinder head Turbocharger Cylinder block Oil cooler Service Training BT-50 7 8 9 10 11 Heater Water pump Thermostat Radiator Coolant flow direction 01-17
Intake-Air System WL-C Engine Intake-Air System Features • The intake-air system of the WL-C engine has the following new features: – – Newly designed air cleaner housing with dry filter element – VGT (Variable Geometry Turbocharger) with VBC (Variable Boost Control) system *1) – – – – Enlarged charge-air cooler made of aluminium alloy MAF (Mass Air Flow) sensor with integrated IAT (Intake Air Temperature) sensor no.
WL-C Engine Intake-Air System Parts Location BT-50_01021 1 2 3 4 5 6 7 8 Glow plug VGT Check valve VBC solenoid valve Vacuum chamber VBC vacuum actuator Air cleaner MAF / IAT no.2 sensor Service Training BT-50 9 10 11 12 13 14 15 16 Fresh-air duct Glow plug cord Charge-air cooler VSC solenoid valve Glow plug relay MAP / IAT no.
Intake-Air System WL-C Engine System Overview BT-50_01020 1 2 3 4 5 6 7 8 9 Charge-air cooler Check valve Vacuum chamber VBC solenoid valve MAF / IAT no.2 sensor Air cleaner VGT VBC vacuum actuator Guide blades 01-20 10 11 12 13 14 15 16 17 Glow plug Vacuum pump VSC vacuum actuator VSC solenoid valve VSC shutter valves MAP / IAT no.
WL-C Engine Intake-Air System MAF Sensor • The MAF sensor with integrated IAT sensor no.2 is installed on the air filter. MAF Learning Function • The MAF learning function is used to compensate any deterioration of the MAF sensor. It should be carried out at each service interval by means of M-MDS (refer to chapter ‘Maintenance and Repair’). MAF Data Reset • When the MAF sensor is replaced the adaptation values in the PCM must be reset by means of M-MDS (refer to chapter ‘Maintenance and Repair’).
Intake-Air System WL-C Engine Variable Geometry Turbocharger • The BT-50 uses a VGT, which controls the boost pressure by adjusting guide blades. The operation is similar to that of the VGT used on the Mazda6 (2.0 MZR-CD).
WL-C Engine Intake-Air System Intake Manifold • The intake manifold features two helical intake ports per cylinder for optimal swirl of intake air. The 2nd and 3rd cylinder share a common secondary intake port to minimise the required space.
Intake-Air System WL-C Engine Variable Swirl Control Shutter Valves • The BT-50 uses VSC shutter valves, which reduce the exhaust emissions at low engine speeds. The operation is similar to that of the VSC shutter valves used on the Mazda6 pre F/L with 2.0 MZR-CD engine. The VSC shutter valves are located in the secondary intake ports. • The VSC shutter valves are operated from idle speed to 2,300 rpm.
WL-C Engine Fuel System Fuel System Features • The fuel system of the WL-C engine has the following new features: – High-pressure pump incorporating gear-type feed pump with overflow valve, three element-type radial piston pump, fuel metering valve, and fuel temperature sensor *1) – – Common rail with fuel pressure sensor and pressure limiter valve *2) – – Multiple fuel injection (up to two pilot injections, but no post injections) Solenoid valve-type fuel injectors with injector correction factor
Fuel System WL-C Engine Parts Location BT-50_01027 1 2 Fuel gauge sender unit Fuel tank (4WD) 01-26 3 4 Vehicles with cargo box Vehicles without cargo box Service Training BT-50
WL-C Engine Fuel System BT-50_01028 1 2 3 4 5 Check valve in fuel return line Fuel injectors Fuel pressure sensor High-pressure pump Fuel metering valve Service Training BT-50 6 7 8 9 Sedimentor switch Fuel filter (incl.
Fuel System WL-C Engine System Overview BT-50_01029 1 2 3 4 5 6 7 Pressure limiter valve Check valve Fuel injector Common rail Fuel pressure sensor Fuel metering valve Fuel temperature sensor 01-28 8 9 10 11 12 13 High-pressure pump Fuel filter Sedimentor switch Fuel tank To PCM Fuel flow Service Training BT-50
WL-C Engine Fuel System High-Pressure Pump • The BT-50 uses the high-pressure pump (CP3S3) with three pumping elements offset by 120°. The operation is similar to the high-pressure pump (CP3.2) used on the Mazda3 (1.6 MZ-CD), which is also manufactured by Bosch.
Fuel System WL-C Engine Fuel Injectors • The WL-C engine uses solenoid valve-type fuel injectors, which are directly controlled by the PCM. The operation is similar to the Mazda3 (1.6 MZ-CD). • The fuel injectors are mounted with brackets to the cylinder head. • When a fuel injector has to be replaced the eight-digit injector correction factor must be programmed into the PCM by means of M-MDS (refer to the chapter ‘Maintenance and Repair’).
WL-C Engine Exhaust System Exhaust System Features • The exhaust system has the following new features: – – Modified exhaust manifold Warm up system with exhaust shutter valve (if equipped) Parts Location BT-50_01034 1 2 3 4 5 Exhaust manifold Joint pipe Oxidation catalytic converter Main silencer Tail pipe Service Training BT-50 6 7 8 9 Warm up switch With exhaust shutter valve Front pipe VGT 01-31
Exhaust System Engine Warm-Up System • Since the common-rail diesel engines do not provide enough residual heat for the heating system of the vehicle, a warm-up system has been adopted to heat up the passenger compartment quickly at low ambient temperatures. It consists of: – – – – – • Warm-up switch PCM Exhaust shutter valve solenoid valve Exhaust shutter valve vacuum actuator Exhaust shutter valve When the driver pushes the warm-up switch the PCM energizes the exhaust shutter valve solenoid valve.
WL-C Engine Exhaust System Exhaust Shutter Valve Solenoid Valve • The exhaust shutter valve solenoid valve (ON/OFF-type) is located above the vacuum chamber in the engine compartment. Exhaust Shutter Valve Unit • The exhaust shutter valve unit consists of exhaust shutter valve, exhaust flange, transfer lever, stop screw, actuation rod, and vacuum actuator.
Emission System WL-C Engine Emission System Features • The emission system of the WL-C engine has the following features: – One EGR solenoid valve to control EGR valve position instead of two solenoid valves as used on the B-series *1) – – – – – – EGR control solenoid valve for quick EGR cut-off EGR valve position sensor Enlarged EGR cooler Three-step ISV (Intake Shutter Valve) with vacuum actuator *2) ISV solenoid valve (half) and ISV solenoid valve (full) *2) Oxidation catalytic converter *1) Simi
WL-C Engine Emission System BT-50_01033 1 2 3 4 5 Oxidation catalytic converter EGR cooler EGR solenoid valve MAF sensor ISV Service Training BT-50 6 7 8 9 10 EGR control solenoid valve ISV solenoid valve (full) ISV solenoid valve (half) EGR valve Air filter 01-35
Emission System WL-C Engine System Overview BT-50_01035 1 2 3 4 5 6 7 8 Air filter ISV EGR valve position sensor EGR valve MAF sensor Oxidation catalytic converter ISV solenoid valve (full) ISV solenoid valve (half) 01-36 9 10 11 12 13 14 15 EGR solenoid valve EGR control solenoid valve Fuel tank Rollover valves Check valve (two-way) (without cargo box) Evaporative chamber (without cargo box) To PCM Service Training BT-50
WL-C Engine Emission System EGR Solenoid Valve BT-50_01047 A B To EGR valve To vacuum chamber 1 EGR solenoid valve EGR Control • The PCM controls the position of the EGR valve by means of the EGR solenoid valve (via duty signal) and the EGR control solenoid valve (via ON/OFF signal). – When EGR is desired the PCM controls the EGR solenoid valve with a large duty ratio and energizes the EGR control solenoid valve, so that vacuum is applied to the EGR vacuum actuator.
Emission System WL-C Engine Intake Shutter Valve • The WL-C engine uses a three-step ISV, which increases the EGR rate at low engine speeds and prevents bucking movements of the engine during shut-off. The operation is similar to the ISV used on the Mazda6 pre F/L (2.0 MZR-CD).
WL-C Engine Charging and Starting System Charging and Starting System • A modified generator has been adopted for the charging system, while the starting system is identical to that used on the B-Series. (V) Specification WL-C 12 (Ah) 95D31R (64) (V-A) 12-70 Item Battery Generator Starter Voltage Type and capacity (5-hour rate) Output Regulated voltage Self diagnosis function Type Output (V) (kW) 14.1-14.7 Equipped Coaxial reduction 2.
Control System WL-C Engine Control System Features • The control system of the WL-C engine has the following new features: – – – CKP (CranKshaft Position) sensor located at the flywheel CMP (CaMshaft Position) sensor PCM (Powertrain Control Module) with extended control strategies Specifications Item IAT sensor No.2 (built into MAF sensor) MAF sensor IAT sensor No.
WL-C Engine Control System Parts Location BT-50_01036 1 2 3 4 5 6 7 8 9 10 11 12 MIL (Malfunction Indicator Lamp) Glow indicator light APP sensor Main relay Idle switch Brake switch DLC-2 (Data Link Connector) CPP switch A/C switch DLC-1 Warm up switch MAF sensor / IAT sensor no.2 Service Training BT-50 13 14 15 16 17 18 19 20 21 22 23 24 CMP sensor Fuel pressure sensor High-pressure pump Fuel temperature sensor Fuel metering valve ECT sensor MAP sensor / IAT sensor no.
Control System WL-C Engine System Overview BT-50_01037 01-42 Service Training BT-50
WL-C Engine 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 EGR valve position sensor VBC solenoid valve MAF sensor / IAT sensor no.2 Exhaust shutter valve Exhaust shutter solenoid valve Oxidation catalytic converter CMP sensor ECT sensor Fuel injectors CKP sensor Glow plugs VSC solenoid valve MAP sensor / IAT sensor no.
Control System WL-C Engine Block Diagram Input PCM Control Strategies Output Battery CPP switch Neutral switch APP sensor Idle speed control Fuel metering valve Glow control Idle switch MAF sensor / IAT sensor no.2 Fuel injectors Variable boost control VBC solenoid valve Variable swirl control ECT sensor Fuel temperature sensor VSC solenoid valve Fuel injection amount control EGR solenoid valve BARO sensor Fuel injection timing control EGR control solenoid valve MAP sensor / IAT sensor no.
WL-C Engine Control System Relationship Chart x: Applicable x x x x x x x x x x x x x x Immobiliser system x A/C cut-off control x x x EGR control Multiple fuel injection control x x x x Fuel pressure control Fuel injection timing control Variable boost control x x x Glow control x x x Variable swirl control Input device Battery CPP switch Neutral switch APP sensor Idle switch MAF sensor IAT sensor no.2 IAT sensor no.
Control System WL-C Engine Crankshaft Position Sensor • The inductive type CKP sensor is located at the upper part of clutch housing. The pulse wheel is installed to the primary mass of the flywheel, and has 58 projections with a space of 6°crank angle between each projection. A space of 18° defines a determined crankshaft position. BT-50_01050 1 2 CKP sensor Pulse wheel 3 Flywheel NOTE: When the CKP signal fails during engine operation, the engine stalls and will not start again.
WL-C Engine Control System Camshaft Position Sensor • The Hall-type CMP sensor is installed at the right front side of the cylinder head. A projection on the intake camshaft pulley covers 26° camshaft rotation angle. BT-50_01051 1 2 3 CMP sensor PCM CPU 4 5 6 Pulse wheel Intake camshaft pulley Gap (1,4 mm) NOTE: When the CMP signal fails during engine operation, the engine continues to run and will start again (with little extended cranking time) after it has been shut off.
Control System WL-C Engine Powertrain Control Module Features • The PCM has the following new features: – – – – – Programmable module Built in BARO sensor A/C (Air Conditioning) cut-off control Glow plug relay with feedback to PCM *1) Integrated RFW (Remote Free Wheel) control on versions with 4WD (refer to chapter ‘Driveline / Axle’) – HS-CAN (High Speed Controller Area Network) connection to DLC-2 for communication with M-MDS (refer to chapter ‘Body & Accessories’) *1) Similar to Mazda6 (2.
WL-C Engine • Control System The PCM has two connectors with 154 pins in total.
Control System WL-C Engine Glow Plug Relay • The glow plug relay has a feedback line to the PCM to facilitate failure detection. The PCM operates the glow plug relay for max. 120 s at an engine coolant temperature below 32 °C.
WL-C Engine Control System On-Board Diagnostic System Features • The OBD (On-Board Diagnostic) system has the following features: – – – – MIL Self test PID monitor Simulation test Malfunction Indicator Lamp • The MIL is located in the IC. It illuminates when emission related malfunction have been detected by the OBD system. In this case a corresponding DTC is stored in the PCM. The glow plug indicator light has no indication function for any detected malfunction as on the B-series.
Control System WL-C Engine PID Monitor • The PID monitor function allows monitoring the PIDs of the PCM. Therefore connect the M-MDS to the vehicle and select the option ToolboxÆDataloggerÆModulesÆPCM. PID AAT AC_REQ ACCS APP Definition Ambient air temperature A/C request signal A/C relay Accelerator pedal position APP1 Accelerator pedal position sensor no.1 APP2 Accelerator pedal position sensor no.
WL-C Engine Control System PID Definition MAF Mass airflow MAP Manifold absolute pressure MIL MIL_DIS RPM SEGRP DSD SELTESTDTC VBCV VPWR VSS WARMSW WARMSOL Malfunction indicator lamp Distance travelled since the MIL was activated Engine speed Desired EGR valve position Diagnostic trouble codes VBC solenoid valve Module supply voltage Vehicle speed Warm-up switch Exhaust solenoid valve shutter valve Unit/Condition g/s V Pa V OFF/ON km rpm % — % V km/h OFF/ON OFF/ON BT-50_T01010b Simulation Test •
Control System WL-C Engine Maintenance and Repair MAF Sensor Learning Function • The MAF learning procedure by means of M-MDS must be carried out at every service interval. During this procedure the MAF learning is performed at engine speeds of 750 min-1, 1850 min-1, and 2500 min-1. To perform the procedure select ToolboxÆ PowertrainÆEngine ChecksÆLearning and follow the instructions. • The MAF learning procedure can also be initiated manually via DLC-1.
WL-C Engine Control System PCM Replacement • When the PCM has been replaced certain procedures have to be performed in the following order: 1. Perform PCM configuration procedure. 2. Perform IMMOBILISER SYSTEM programming. 3. Perform PCM data reset procedure to reset all adaptation values in the PCM with the aid of the M-MDS. Therefore, select the option ToolboxÆPowertrainÆData ResetÆPCM and follow the instructions. 4. Perform After repair procedure. 5. Start the engine. 6.
Control System WL-C Engine Notes: 01-56 Service Training BT-50
Suspension Suspension Features • The front and rear suspension of the BT-50 have the following new features: – Enlarged diameter and modified damper valve tuning of the double acting low pressurised shock absorbers – – – Enlarged diameter of the front stabiliser Extended leaf springs on the rear axle Modified wheel alignment values Specifications Item Front suspension Suspension type Spring type Type Stabilizer Diameter mm Shock absorber type Maximum steering Inner angle Outer Total toe-in mm Front w
Suspension Parts Location Front Suspension 2WD BT-50_02002 1 2 3 Front shock absorber Torsion bar spring Upper arm 4 5 6 Lower arm Tension rod Front stabiliser Front Suspension 4WD BT-50_02003 1 2 3 02-2 Shock absorber Torsion bar spring Upper arm 4 5 Lower arm Front stabiliser Service Training BT-50
Suspension Rear Suspension BT-50_02004 1 2 4WD 2WD Service Training BT-50 3 4 Shock absorber Leaf spring 02-3
Wheels and Tyres Suspension Wheels and Tyres • The wheels and tyres have the following new features: – – – Modified wheel and tyre sizes Modified wheel offset New designs for 15- and 16-inch aluminium alloy wheels and 15-inch steel wheels.
Suspension Wheels and Tyres Specifications Item Size Offset Wheel Pitch circle diameter mm mm Material Tyre Front Rear Up to four persons Full load Up to four persons Full load Aluminium alloy 215/70R15C 106/104S 235/75R15 109S 245/70R16 111S 220 210 210 210 210 210 375 290 270 Aluminium alloy Remaining tread mm 1.6 Wheel nut tightening torque Nm 88.2-117.
Wheels and Tyres Suspension Notes: 02-6 Service Training BT-50
Driveline / Axle Driveline / Axle Features • The driveline / axle of the BT-50 has the following new features: – – Modified transfer case due to increased engine torque and new transmission RFW control with OBD function integrated in PCM (separate RFW module has been dropped) NOTE: Further information can be found in the Training Manuals ‘B-Series’ (NMT-005) and in ‘Manual transmission and 4WD’ (CT-L1002).
RFW System Driveline / Axle RFW System • The RFW system is controlled by the PCM. The input and output components are the same as used for the B-Series with separate RFW control module.
Driveline / Axle RFW System System Overview BT-50_03002 1 2 3 4 5 6 7 8 9 10 4WD indicator light RFW indicator light To battery Front differential Lock Free RFW vacuum actuator RFW unit RFW switch To vacuum pump Service Training BT-50 11 12 13 14 15 16 17 18 19 20 One-way check valve Lock solenoid valve Free solenoid valve RFW main switch PCM Vehicle battery Engine switch Selector lever 4WD switch Transfer neutral switch 03-3
RFW System Driveline / Axle On-Board Diagnostic System • Detected malfunctions are stored as 4-digit DTCs in the PCM memory and can be retrieved by means of M-MDS.
Transmission Clutch Clutch Features • The clutch system of the BT-50 has the following new features: – – Clutch master cylinder with one-way valve and pulsation damper Dual mass flywheel Specifications Item Manual transmission type Clutch control Spring type Clutch cover Set load Outer diameter Clutch disc Inner diameter Type Clutch pedal Pedal ratio Full stroke Clutch master cylinder inner diameter Clutch release cylinder inner diameter Clutch fluid type N mm mm mm mm mm Specification S15M-D, S15M
Clutch Transmission Parts Location BT-50_05013 1 2 3 4 05-2 Dual-mass flywheel Clutch disc Clutch cover Clutch release fork 5 6 7 8 Clutch release cylinder Clutch release collar Clutch pedal Clutch master cylinder Service Training BT-50
Transmission Clutch Clutch Master Cylinder • The one-way valve prevents harsh clutch engagement by a throttle, which prevents too quick back flowing of the fluid when the clutch is engaged thus ensuring smooth driving off. • The pulsation damper reduces pressure fluctuations in the hydraulic line during clutch operation, minimizing operation noise and vibration transmission to the clutch pedal.
Clutch Transmission Dual Mass Flywheel • The dual mass flywheel compensates torque fluctuations thus reducing rattle noises of the transmission gears.
Transmission S15M(X)-D Manual Transmission S15M(X)-D Manual Transmission • Due to the increased engine torque the newly developed three-shaft 5-speed manual transmission S15M-D has been adopted for the 2WD version, while the S15MX-D transmission with an additional transfer case has been adopted for the 4WD version. • Except for the transfer case the construction and operation of both transmissions are basically the same. They have superseded the R15M(X)-D transmission used on the BSeries.
S15M(X)-D Manual Transmission Transmission Specifications Item Transmission type Transmission/Transfer control Shift assist 1GR 2GR 3GR Gear ratio 4GR 5GR Reverse Type Transmission case oil Capacity (approx.quantity) Type Shift control case oil Capacity [S15M-D] (approx.quantity) Transfer ratio Transfer case oil [S15MX-D] Specification S15M-D, S15MX-D Floor-shift Synchromesh 3.905 2.248 1.491 1.000 0.800 3.391 Manual Transmission fluid type A L 3.
Transmission S15M(X)-D Manual Transmission Overview BT-50_05002 A B 1 2 3 4 Extension housing (S15M-D) Transfer case (S15MX-D) Output shaft 3rd gear 2nd gear 1st gear Service Training BT-50 5 6 7 8 9 Reverse idler gear Reverse gear 5th gear Counter shaft Input shaft 05-7
S15M(X)-D Manual Transmission Transmission Power Flow 1st Gear 2nd Gear 3rd Gear 05-8 BT-50_05003 BT-50_05004 BT-50_05005 Service Training BT-50
Transmission 4th Gear 5th Gear S15M(X)-D Manual Transmission BT-50_05006 BT-50_05007 BT-50_05008 Reverse Gear Service Training BT-50 05-9
S15M(X)-D Manual Transmission Transmission Shift Mechanism • Most of the shift mechanism components are accommodated in the shift mechanism unit. Due to its five speed layout the S15M(X)-D transmission requires four shift rods in total (three in the shift mechanism unit and one in the transmission housing).
Transmission S15M(X)-D Manual Transmission Shift Mechanism Unit BT-50_05010 1 2 3 4 5 6 7 8 9 10 Transmission breather Spring Plastic spring seat Detent ball Oil baffle plate Retaining bolt 3rd/4th shift fork Stopper block 1st/2nd shift fork 5th/reverse shift rod Service Training BT-50 11 12 13 14 15 16 17 18 19 20 Interlock pin 1st/2nd shift rod 3rd/4th shift rod Retaining ring Plain washer Push pin 5th/reverse shift rod end Rubber plug 3rd/4th shift rod end 1st/2nd shift rod end 05-11
S15M(X)-D Manual Transmission Transmission 5th / Reverse Gear Mechanism • The shift fork for the 5th / reverse gear is mounted on an additional shift rod inside the gearbox. It is operated by the 5th / reverse shift rod in the shift mechanism unit via the counter lever.
Transmission 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Counter lever Washer Retaining ring 5th/reverse clutch hub and shift fork component Steel ball 5th gear bearing inner race Needle bearing 5th gear Synchronizer ring Retaining bolt Reverse idler gear shaft component Reverse idler gear shaft Thrust washer Reverse idler gear Friction damper Thrust washer (Selective) Spacer (Selective) Service Training BT-50 S15M(X)-D Manual Transmission 18 19 20 21 Reverse gear Countershaft rear bearing Locknut Synchro
S15M(X)-D Manual Transmission Transmission Reverse Gear Lockout Mechanism • To prevent accidental shifting into reverse gear while downshifting from the 5th to the 4th gear a cam-type lockout mechanism is installed in the extension housing (2WD) or in the transfer case (4WD). The figure below shows the variant of the 4WD version.
HVAC Basic System Basic System Features • The HVAC (Heating, Ventilation, Air Conditioning) basic system of the BT-50 has the following new features: – – Modified blower unit to reduce fan noise Condenser with sub-cooling function and integrated receiver / drier Specifications Item Heating capacity Cooling capacity kW kW Type Regular amount approx. Type Discharge capacity Max.
Basic System HVAC Parts Location BT-50_07001 1 2 3 4 5 07-2 Heater / air distribution unit Cooling unit Blower unit Low pressure charging valve Refrigerant pressure switch 6 7 8 9 High pressure charging valve Condenser Receiver / drier Compressor Service Training BT-50
HVAC Basic System Refrigerant System BT-50_07006 1 2 3 4 Low-pressure charging valve Expansion valve High-pressure charging valve Receiver / drier Service Training BT-50 5 6 7 Condenser Evaporator A/C Compressor 07-3
Control System HVAC Control System Features • The HVAC control of the BT-50 has the following new features: – Newly designed control panel with larger dials Parts Location BT-50_07003 1 2 3 4 07-4 A/C relay Climate control unit Evaporator temperature sensor Blower resistor 5 6 7 Blower motor Refrigerant pressure switch Magnetic clutch Service Training BT-50
HVAC Control System Wiring Diagram BT-50_07004 1 2 3 4 5 6 PCM A/C relay Refrigerant pressure switch Magnetic clutch Climate control unit A/C Amplifier / Thermoswitch (incl.
Control System HVAC Climate Control Unit • A new designed cable operated climate control unit has been adopted.
Restraints Airbag System Airbag System Features • The airbag system of the BT-50 has the following new features: – – – – Side airbags integrated in the backrests of the front seats (depending on grade) *1) Side airbag sensors installed on the door sills SAS (Sophisticated Airbag Sensor) control module with enhanced OBD system Rack-type seatbelt pretensioners, height-adjustable on front seats of DBL cab version *1) *1) Similar to MX-5 (NC) NOTE: Further information can be found in the Training Manual o
Airbag System Restraints Parts Location BT-50_08001 1 2 3 4 08-2 Airbag system warning light Clock spring Seat belt pretensioner Driver-side airbag module 5 6 7 8 Side airbag sensor Side airbag module SAS control module Passenger-side airbag module Service Training BT-50
Restraints Airbag System Wiring Diagram BT-50_08002 1 2 3 4 5 6 7 8 Clock spring Driver-side airbag module Passenger-side airbag module Driver-side seat belt pretensioner Driver-side side airbag module Passenger-side seat belt pretensioner Passenger-side side airbag module Poor connection detection bar (connector no.
Airbag System Restraints SAS Control Module • The SAS control module is located on the centre tunnel, in front of the shift lever. • The SAS control module processes the signals it receives from the internal micromechanical sensor and the side airbag sensors. If the acceleration/deceleration caused by a frontal or side impact exceeds a predetermined threshold, the SAS control module triggers the airbags / pre-tensioners or only the side airbags with a DC signal.
Restraints Airbag System Side Airbag Sensors • The side airbag sensors are installed under the vehicle on the door sills, close to the Bpillar. A rigid metal cover protects the sensors against any damage during off-road driving. • The side airbag sensor measures the acceleration / deceleration of the vehicle during a side impact and transmits this information to the SAS control module.
Airbag System Restraints Seat Belt Pretensioners • The BT-50 is equipped with rack-type seat belt pretensioners, which remove the excess slack from the seat belt in case of an accident. The operation is similar to that of the MX5 (NC) seat belt pretensioners.
Restraints Airbag System On-Board Diagnostic System Features • The OBD system of the airbag system allows bi-directional communication with M-MDS, enabling a quicker and more precise diagnosis. It has the following new features: – – Selftest (retrieving four digit DTCs stored for present and past malfunctions) PID monitor Self Test • The self-test function comprises displaying present and past four-digit DTCs by means of M-MDS.
Airbag System Restraints PID Monitor • The PID monitor function allows monitoring the PIDs of the SAS control module. Therefore, connect the M-MDS to the vehicle and select the option ToolboxÆ DataloggerÆModulesÆ RCM.
Body & Accessories Body Panels Body Panels Cabin • The cabin structure of the BT-50 (DBL cab version) with its triple-H structure, the sidedoor beams, and the use of high-tensile steel, provide a class top level of passive safety in conjunction with the rigid ladder frame satisfying stringent European collision-safety standards. BT-50_09001 • Despite having no B-pillars the RAP cab version satisfies the European collision-safety standards by reinforcements in the rear access panel.
Body Panels Body & Accessories Ladder Frame • The cross-braced ladder frame of the BT-50 is essentially carried over from the B-Series, just as four cabin mounts, which minimise lateral movement, but allow for compliance in vertical movement providing comfortable driving.
Body & Accessories Body Panels Cargo Box • The cargo box of the BT-50 has the following new features allowing a more versatile usage of the cargo box: – – Taller cargo box walls to increase the load capacity. – Inner rope hooks that are placed closer to the floor to ease firm securing of load. New structure of the inner cargo box walls with one horizontal and several vertical guiding grooves that allow splitting up the cargo space with boards.
Glass/Windows/Mirrors Body & Accessories Glass/Windows/Mirrors • The glass/windows/mirrors of the BT-50 have following new features: – – – Rear window defroster switch installed in centre panel Power outer mirror switch installed in driver door trim Enlarged power outer mirrors BT-50_09006 1 Rear window defroster switch BT-50_09007 1 09-4 Power outer mirror switch Service Training BT-50
Body & Accessories Security and Locks Security and Locks Features • The security and locks system of the BT-50 has the following features: – – – – Power door lock system (without double lock) Keyless entry system (keyless transmitter with retractable key) Mazda immobiliser system with separate immobiliser module Theft-deterrent system (for vehicles with U.K. specification) NOTE: Further information can be found in the Training Manuals of the ‘B-Series’ (NMT-005) and ‘Immobiliser System’ (CT-L 1007).
Security and Locks Body & Accessories Wiring Diagram BT-50_09009 1 2 3 4 5 6 7 8 09-6 Instrument cluster Door ajar warning light Security light Door switches Driver’s door lock-link switch Rear door lock-link switches Bonnet switch Theft-deterrent horn relay 9 10 11 12 13 14 15 16 Theft-deterrent horn Theft-deterrent control module Door key cylinder switches Door lock control module Keyless control module Hazard warning switch Flasher control module Key reminder switch Service Training BT-50
Body & Accessories Exterior Trim Exterior Trim Features • The exterior trim of the BT-50 has the following new features (depending on grade): – – – – Painted front bumper with integrated front grille New designed chrome door handles Larger wheel arch extensions Modified side steps Parts Location BT-50_09026 1 2 3 4 Side step Wheel arch extension Rear bumper Rope hook Service Training BT-50 5 6 7 Side protector Front flap Front bumper 09-7
Exterior Trim Body & Accessories Front and Rear Bumper • The front bumper is completely new designed, while the rear bumper is the same as used on the B-Series. • The plastic front bumper is installed on a steel reinforcement. The bumper also accommodates the front grille, newly designed front fog lights and the lower wheel arch extensions (if equipped).
Body & Accessories Interior Trim Interior Trim Features • The interior trim of the BT-50 has the following new features: – – – – Newly designed dashboard installed on a steel crossmember Front door pockets with bottle holder Sliding upper glove compartment Newly designed centre console Parts Location BT-50_09010 1 2 3 4 Sliding upper glove compartment Glove compartment Storage compartment Door pocket Service Training BT-50 5 6 7 Cup holder Cup holder (except REG cab) Centre console 09-9
Lighting System Body & Accessories Lighting System Features • The lighting system of the BT-50 has the following new features: – – – – Front combination light with multi-reflector headlight type, turn and parking light – – – Centre console illumination light Rear combination light with stepped reflector Front and rear fog light switch incorporated in light switch Rear fog light integrated in rear combination light or in rear bumper (depending on market) Room light incorporating spot lights DRL (Day
Body & Accessories Lighting System Rear Combination Light BT-50_09013 1 2 3 Brake/taillight bulb Turn light bulb Back-up light bulb (LH) Rear fog light bulb (RH) Service Training BT-50 4 5 Section A-A Rear combination light 09-11
Lighting System Body & Accessories Overview BT-50_09014 1 2 3 4 Combination switch Light switch Panel light control switch Headlight levelling switch 5 6 7 8 Centre console illumination Glove compartment light Hazard warning switch Interior light Daytime Running Light • Since some countries outlaw driving vehicles without switched on headlights during daytime, a DRL system is available for these markets.
Body & Accessories Lighting System Wiring Diagram BT-50_09028 Service Training BT-50 09-13
Wiper / Washer System Body & Accessories Wiper / Washer System Features • The wiper / washer system of the BT-50 has the following new features: – Intermittent wiper function with adjustable interval Parts Location BT-50_09016 1 2 3 4 Wiper and washer switch Washer nozzle Washer hose Wiper motor 09-14 5 6 7 Wiper arm and blade Washer motor Washer tank Service Training BT-50
Body & Accessories Wiper / Washer System Wiring Diagram BT-50_09024 1 2 3 4 Wiper switch Washer switch Washer motor Wiper motor Service Training BT-50 5 6 7 8 Auto-stop switch Interval relay Interval control switch One-touch switch 09-15
Entertainment Body & Accessories Audio System Features • The modular audio system of the BT-50 is available in two different variants: Radio with CD player or with 6-CD changer.
Body & Accessories Entertainment Parts Location BT-50_09017 1 2 3 4 5 Roof antenna Tweeter LH Rear speaker RH Rear speaker LH Front speaker LH Service Training BT-50 6 7 8 9 Audio unit Antenna cable Front speaker RH Tweeter RH 09-17
Entertainment Body & Accessories System Overview BT-50_09019 1 2 3 4 5 6 7 Roof antenna Audio unit Tweeter (RH) Front speaker (RH) Front speaker (LH) Tweeter (LH) Rear speaker (RH) 8 9 10 11 12 13 Rear speaker (LH) Base unit Lower module Vehicle speed signal TNS signal Centre panel unit NOTE: A telephone mute function is only available by using an appropriate connector adapter, which is provided as accessory part by Mazda Motor Europe.
Body & Accessories • Entertainment The modular audio system consists of the base unit, the lower module (if equipped) and the centre panel. The base unit with CD player is different from the one with 6-CD changer. BT-50_09018 1 2 3 Base unit Audio unit Lower module 4 5 Cover Centre panel NOTE: MC (Music Cassette) drive or MD (Mini Disc) player are currently not available for Europe.
Entertainment Body & Accessories On-Board Diagnostic System • The OBD system of the modular audio system comprises a self-test and a diagnostic assist function. Self-Test Function • The fault memory of the audio module can store up to three DTCs. If a fourth fault is detected when three DTCs are already stored, the oldest DTC is deleted and the new one stored.
Body & Accessories Power Systems Power Systems Parts Location BT-50_09020 1 Main fuse block Service Training BT-50 2 Fuse block 09-21
Instrumentation / Driver Info Body & Accessories Instrumentation / Driver Information System Features • The instrumentation / driver information system of the BT-50 has the following new features: – – – – LED-type warning and indicator lights Front and rear fog light indicator lights incorporated in the IC Key reminder warning alarm Extended input / output check code functions Specifications Item Meter type Indication range Speedometer Input signal source Tachometer Fuel level gauge Water temperatur
Body & Accessories Instrumentation / Driver Info Instrument Cluster Overview BT-50_09023 No.
Instrumentation / Driver Info Body & Accessories Key Reminder Warning Alarm • This function warns with an intermittent sound from the buzzer in the IC that the key is in the steering lock in position ACC or LOCK when any door is opened. Additionally a permanent sound warns when a door is opened and the lights are switched on. Input / Output Check Mode • This function allows checking the input and output circuits of the instrument cluster. It can be activated in the following way: 1.
Body & Accessories Control System Control System Features • The control system of the BT-50 has the following new features: – – DLC-2 HS-CAN connection between PCM and DLC-2 for communication with M-MDS Data Link Connector • The DLC-2 is located under the dashboard next to the centre panel. • The 17-pin DLC-1, known from the previous B-Series, is installed on the left rear side in the engine compartment. It cannot be used for communication with M-MDS.
Control System Body & Accessories Wiring Diagram BT-50_09027 09-26 Service Training BT-50
List of Abbreviations ABS Anti-lock Brake System HU/CM Hydraulic Unit/Control Module A/C Air Conditioning IAT Intake Air Temperature APP Accelerator Pedal Position IC Instrument Cluster CAN Controller Area Network ISO International Standard Organisation CKP CranKshaft Position ISV Intake Shutter Valve CMP CaMshaft Position KLN K-LiNe CPP Clutch Pedal Position LCD Liquid Crystal Display DBL DouBLe LED Light Emitting Diode DLC Data Link Connector LSD Limited Slip Differentia
List of Abbreviations OBD On-Board Diagnostics VSC Variable Swirl Control PCM Powertrain Control Module VSS Vehicle Speed Sensor PID Parameter IDentification VIN Vehicle Identification Number RAP Random Access Panel REG REGular RFW Remote FreeWheel RWD Rear Wheel Drive SAS Sophisticated Airbag Sensor SRS Supplemental Restraint System SST Special Service Tool TEN Test ENgine W/D Wiring Diagram W/M Workshop Manual VBC Variable Boost Control VGT Variable Geometry Turbocharger
