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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.

2006
Mazda Motor Europe GmbH Training Services

Table of Contents
General Information ..........................................................................00-1
Product Concept....................................................................................................00-1 Vehicle Identification Number................................................................................00-7 Engine Identification Number ................................................................................00-8 Other Vehicle Information Labels ..........................................................................00-9 Model Plate.....................................................................................................00-9 Tyre Pressure Label .......................................................................................00-9 Technical Data.....................................................................................................00-10 Jacking and Lifting...............................................................................................00-11 Towing .................................................................................................................00-12 Scheduled Maintenance Table ............................................................................00-13 Remarks .......................................................................................................00-15

WL-C Engine ......................................................................................01-1


Engine Performance Curve ...................................................................................01-1 Overview................................................................................................................01-2 Mechanical ..................................................................................................................01-3 Features ................................................................................................................01-3 Specifications ........................................................................................................01-3 Piston.....................................................................................................................01-4 Cylinder Head........................................................................................................01-5 Parts Location.................................................................................................01-5 Valve Gear......................................................................................................01-7 Valve-Clearance Adjustment ..........................................................................01-8 Camshaft Pulleys............................................................................................01-8 Timing Belt Auto Tensioner ............................................................................01-9 Engine Timing...............................................................................................01-10 Lubrication System ..................................................................................................01-11 Features ..............................................................................................................01-11 Specifications ......................................................................................................01-11 Parts Location......................................................................................................01-12 System Overview.................................................................................................01-13 Oil Filter ...............................................................................................................01-14 Cooling System ........................................................................................................01-15 Features ..............................................................................................................01-15 Specifications ......................................................................................................01-15 Parts Location......................................................................................................01-16 System Overview.................................................................................................01-17 Intake-Air System .....................................................................................................01-18 Features ..............................................................................................................01-18 Parts Location......................................................................................................01-19 System Overview.................................................................................................01-20 MAF Sensor.........................................................................................................01-21 MAF Learning Function .......................................................................................01-21 MAF Data Reset ..................................................................................................01-21 MAP Sensor / IAT Sensor No.1...........................................................................01-21 Variable Geometry Turbocharger ........................................................................01-22 Intake Manifold ....................................................................................................01-23 Variable Swirl Control Shutter Valves...........................................................01-24 Vacuum Chamber................................................................................................01-24

Service Training BT-50

Table of Contents
Fuel System ..............................................................................................................01-25 Features ..............................................................................................................01-25 Specifications ......................................................................................................01-25 Parts Location......................................................................................................01-26 System Overview.................................................................................................01-28 High-Pressure Pump ...........................................................................................01-29 Common Rail.......................................................................................................01-29 Fuel Injectors .......................................................................................................01-30 Exhaust System........................................................................................................01-31 Features ..............................................................................................................01-31 Parts Location......................................................................................................01-31 Warm up system..................................................................................................01-32 Wiring Diagram.............................................................................................01-32 Exhaust Shutter Valve Solenoid Valve .........................................................01-33 Exhaust Shutter Valve Unit...........................................................................01-33 Operating Conditions....................................................................................01-33 Emission System......................................................................................................01-34 Features ..............................................................................................................01-34 Parts Location......................................................................................................01-34 System Overview.................................................................................................01-36 EGR Solenoid Valve............................................................................................01-37 EGR Control ........................................................................................................01-37 Intake Shutter Valve ............................................................................................01-38 Charging and Starting System ................................................................................01-39 Parts Location......................................................................................................01-39 Control System .........................................................................................................01-40 Features ..............................................................................................................01-40 Specifications ......................................................................................................01-40 Parts Location......................................................................................................01-41 System Overview.................................................................................................01-42 Block Diagram .....................................................................................................01-44 Relationship Chart ...............................................................................................01-45 Crankshaft Position Sensor .................................................................................01-46 Camshaft Position Sensor ...................................................................................01-47 Powertrain Control Module ..................................................................................01-48 Features .......................................................................................................01-48 A/C Cut-Off Control ......................................................................................01-49 Glow Plug Relay ...........................................................................................01-50 On-Board Diagnostic System ..............................................................................01-51 Features .......................................................................................................01-51 Malfunction Indicator Lamp ..........................................................................01-51 Self Test .......................................................................................................01-51 PID Monitor..........................................................................................................01-52 Simulation Test....................................................................................................01-53 Maintenance and Repair .....................................................................................01-54 MAF Sensor Learning Function....................................................................01-54 Replacing the MAF Sensor...........................................................................01-54 PCM Replacement .......................................................................................01-55

Service Training BT-50

Table of Contents
Suspension ........................................................................................02-1
Features ................................................................................................................02-1 Specifications ........................................................................................................02-1 Parts Location........................................................................................................02-2 Front Suspension 2WD ..................................................................................02-2 Front Suspension 4WD ..................................................................................02-2 Rear Suspension ............................................................................................02-3 Wheels and Tyres .......................................................................................................02-4 Specifications ........................................................................................................02-5

Driveline / Axle...................................................................................03-1
Features ................................................................................................................03-1 Specifications ........................................................................................................03-1 RFW System .........................................................................................................03-2 Parts Location.................................................................................................03-2 System Overview............................................................................................03-3 On-Board Diagnostic System .........................................................................03-4

Transmission .....................................................................................05-1
Clutch ..........................................................................................................................05-1 Features ................................................................................................................05-1 Specifications ........................................................................................................05-1 Parts Location........................................................................................................05-2 Clutch Master Cylinder ..........................................................................................05-3 Dual Mass Flywheel ..............................................................................................05-4 S15M(X)-D Manual Transmission..............................................................................05-5 Features ................................................................................................................05-5 Specifications ........................................................................................................05-6 Overview................................................................................................................05-7 Power Flow............................................................................................................05-8 Shift Mechanism ..................................................................................................05-10 Shift Mechanism Unit....................................................................................05-11 5th / Reverse Gear Mechanism .....................................................................05-12 Reverse Gear Lockout Mechanism ..............................................................05-14

HVAC ..................................................................................................07-1
Basic System ..............................................................................................................07-1 Features ................................................................................................................07-1 Specifications ........................................................................................................07-1 Parts Location........................................................................................................07-2 Refrigerant System................................................................................................07-3 Control System ...........................................................................................................07-4 Features ................................................................................................................07-4 Parts Location........................................................................................................07-4 Wiring Diagram......................................................................................................07-5 Climate Control Unit ..............................................................................................07-6

Service Training BT-50

Table of Contents
Restraints...........................................................................................08-1
Airbag System ............................................................................................................08-1 Features ................................................................................................................08-1 Parts Location........................................................................................................08-2 Wiring Diagram......................................................................................................08-3 SAS Control Module ..............................................................................................08-4 Side Airbag Sensors..............................................................................................08-5 Side Airbags ..........................................................................................................08-5 Seat Belt Pretensioners.........................................................................................08-6 On-Board Diagnostic System ................................................................................08-7 Features .........................................................................................................08-7 Self Test .........................................................................................................08-7 PID Monitor.....................................................................................................08-8

Body & Accessories..........................................................................09-1


Body Panels ................................................................................................................09-1 Cabin .....................................................................................................................09-1 Ladder Frame ........................................................................................................09-2 Cargo Box..............................................................................................................09-3 Anti-Corrosion Measures.......................................................................................09-3 Glass/Windows/Mirrors..............................................................................................09-4 Security and Locks.....................................................................................................09-5 Features ................................................................................................................09-5 Theft Deterrent System .........................................................................................09-5 Wiring Diagram...............................................................................................09-6 Exterior Trim ...............................................................................................................09-7 Features ................................................................................................................09-7 Parts Location........................................................................................................09-7 Front and Rear Bumper.........................................................................................09-8 Interior Trim ................................................................................................................09-9 Features ................................................................................................................09-9 Parts Location........................................................................................................09-9 Lighting System........................................................................................................09-10 Features ..............................................................................................................09-10 Parts Location......................................................................................................09-10 Front Combination Light ...............................................................................09-10 Rear Combination Light................................................................................09-11 Overview..............................................................................................................09-12 Daytime Running Light ........................................................................................09-12 Wiring Diagram....................................................................................................09-13 Wiper / Washer System............................................................................................09-14 Features ..............................................................................................................09-14 Parts Location......................................................................................................09-14 Wiring Diagram....................................................................................................09-15

Service Training BT-50

Table of Contents
Audio System............................................................................................................09-16 Features ..............................................................................................................09-16 Specifications ......................................................................................................09-16 Audio Unit .....................................................................................................09-16 Speakers ......................................................................................................09-16 Parts Location......................................................................................................09-17 System Overview.................................................................................................09-18 On-Board Diagnostic System ..............................................................................09-20 Self-Test Function ........................................................................................09-20 Diagnostic Assist Function ...........................................................................09-20 Power Systems .........................................................................................................09-21 Parts Location......................................................................................................09-21 Instrumentation / Driver Information System ........................................................09-22 Features ..............................................................................................................09-22 Specifications ......................................................................................................09-22 Instrument Cluster Overview ...............................................................................09-23 Key Reminder Warning Alarm .............................................................................09-24 Input / Output Check Mode..................................................................................09-24 Control System .........................................................................................................09-25 Features ..............................................................................................................09-25 Data Link Connector............................................................................................09-25 Wiring Diagram....................................................................................................09-26

Service Training BT-50

Table of Contents
Notes:

Service Training BT-50

General Information
General Information
Product Concept
The new Mazda BT-50 supersedes the B-Series, Mazdas 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 Mazdas Zoom-Zoom spirit in its individual and distinctive way. The BT-50 has inherited the tough and reliable commercial truck performance of the BSeries. Simultaneously it presents a new fresh body styling and technologies that customers enjoy on passenger cars and also demand more and more for pick-up trucks. The BT-50 is offered with RWD (Rear Wheel Drive) layout as 2WD or as manually activated part-time 4WD.

BT-50_00001

Service Training BT-50

00-1

General Information
Plane body panels without the formerly used swage lines and other new styling elements contribute to a more brawny, but clear and modern overall styling impression.

BT-50_00002

BT-50_00022

00-2

Service Training BT-50

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.

BT-50_00004

Service Training BT-50

00-3

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.

BT-50_00005

00-4

Service Training BT-50

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).

BT-50_00007

Service Training BT-50

00-5

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

0 W

600001
Serial No. Plant W= Auto Alliance Thailand Dummy 0 Transmission 2 = 5 speed MTX Engine Type 1 = WL-C (2.5 L) B = REG cab (A)* F = DBL cab (E)* Body style 2 = RAP cab (1)* 1 = 2WD Drive axle 8 = 4WD Vehicle type UN = Mazda BT-50

World manufacturer indication JMZ = European (L.H.D., U.K.)

* without cargo box

BT-50_T00001

Service Training BT-50

00-7

General Information
Engine Identification Number
The engine identification number of the WL-C engine is located on the timing gear-side of the cylinder block.

BT-50_00012

00-8

Service Training BT-50

General Information
Other Vehicle Information Labels
Model Plate The model plate is located on the right side of the bulkhead in the engine compartment.

BT-50_00013

Driving direction

Tyre Pressure Label The tyre pressure label is located on the drivers door as shown below.

BT-50_00014

Service Training BT-50

00-9

General Information
Technical Data
Item Overall length (w/o rear step bumper) Overall width (AWD models with Overfenders) Overall height (unladen) Front track Rear track Wheelbase Ground clearance (unladen) Maximum fording depth Angle of approach (unladen) Angle of departure (unladen) Minimum turning circle (wall-to-wall)
*1

Unit

REG 2WD 1,715 1,620 1,445 1,450 2,985 181 300 24 26 12

RAP 4WD 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 12.6

DBL

1,755 2 1,760 *

*1

mm

P235/75R15

*2

245/70R16

BT-50_T00002

Item Curb weight Gross vehicle weight Gross axle weight Max.trailing load Front Rear unbraked braked 1,600 2WD 1,587 2,795 1,170 1,860

REG

Maximum Weight (kg) RAP 4WD 1,798 1,886 3,010 1,430 1,850 750 3,000 3,080 1,430 1,850

DBL 1,895 3,030 1,430 1,850

BT-50_T00004

Item Engine type Displacement Bore x stroke Compression ratio Max. power Max. torque Emission standard Transmission

2.5 MZR-CD (WL-C) Engine Inline 4 Cyl., DOHC 16-valve, Turbocharged w.Intercooler 2,499 cm3 93 x 92 mm 18.0 : 1 105 kW (143 PS) at 3,500 min-1 330 Nm at 1,800 min-1 Euro 4 5-speed manual (S15M(X)-D)
BT-50_T00005

00-10

Service Training BT-50

General Information
Jacking and Lifting
The front of the vehicle can be lifted with a jack near the centre of the front crossmember.

NOTE: The jacking point on the front axle for the 2WD is different to the 4WD model.

BT-50_00023

1 2

only 2WD only 4WD

2WD and 4WD

Service Training BT-50

00-11

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.

BT-50_00021

4WD 1 Towing hook 2 Tie-down hooks

00-12

Service Training BT-50

General Information
Scheduled Maintenance Table
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 87.5 100 112.5

Maintenance Interval

ENGINE
Engine valve clearance Engine timing belt Engine oil
*2 *2 *1 1

I Replace every 120,000 km (75,000 miles) Replace every 120,000 km (75,000 miles)

Engine timing belt auto tensioner* Engine oil filter Drive belts
*3

R R I

R R I

R R I

R R I

R R I

R R I

R R I

R R I

R R I

COOLING SYSTEM
Cooling system (including coolant level adjustment) FL22 type Engine coolant
*4

Replace every 200,000 km (125,000 miles) or 11 years Replace first at 100,000 km (62,500 miles) or 4 years; after that every 2 years

Others

FUEL SYSTEM
Air cleaner element Fuel filter Fuel lines and hoses Air intake system
*5

C I I

C R I I

R I I

C R I I

C I I

R R I I

C I I

C R I I

R I I

EMISSION CONTROL SYSTEM ELECTRICAL SYSTEM


Battery electrolyte level and specific gravity I I I I I I I I I

BT-50_T00006

Service Training BT-50

00-13

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 87.5 100 112.5

CHASSIS and BODY


Brake lines, hoses and connections *6 Brake fluid Parking brake Brake booster and hoses Disc brakes
*7 *7

I R I

I R I

I R I

I R I

Inspect every 200,000 km (125,000 miles) I I I I I I I I R I I I L I I R I T I T I T I R I I I I I I I R I I I L I R I T I T I R R I R I I I L I R I T I T I R I I I I I I I I R I I L I R I T I T I R I I I I I I I I I

Drum brakes Power steering fluid, lines, hoses and connections Steering operation and linkages Manual transmission oil Rear differential oil (2WD) Front and rear differential oil (4WD) Transfer oil (4x4) Drive shaft dust boots (4WD) Propeller shaft joints (4WD) Front and rear suspension and ball joints Front wheel bearing grease (2WD) Wheel bearing axial play Exhaust system and heat shields Bolts and nuts on chassis and body Body condition (for rust, corrosion and perforation) Tyres (including spare tyre ) with inflation pressure adjustment I
*8

Inspect every 80,000 km (50,000 miles) or 5 years

Inspect annually I I I I I I I I

BT-50_T00007
Chart symbols I: Inspect: Inspect and clean, repair, adjust, or replace if necessary. R: Replace T: Tighten L: Lubricate C: Clean

00-14

Service Training BT-50

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. a) Driving in dusty conditions b) Extended periods of idling or low speed driving c) Driving for long periods in cold temperatures or driving regularly at short distance (less than 8 km/ 5 miles) only

3: Also inspect and adjust the power steering and air conditioner drive belts, if installed. 4: Use FL22 type coolant in vehicles with the inscription FL22 on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant. 5: If the vehicle is operated in very dusty or sandy areas, clean the air cleaner element at every 10,000 km (6,250 miles) or 6 months. Replace the air cleaner element at every 30,000 km (18,750 miles) or 18 months. 6: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is operated in extremely humid climates, replace the brake fluid annually. 7: If the vehicle is operated primarily under any of the following conditions, inspect the disc brakes and drum brakes more often than the recommended intervals. a) Driving on bumpy roads, gravel roads, snowy roads or unpaved roads b) Driving uphill and downhill frequently c) Repeated short-distance driving
* * * *

8: If the vehicle is operated primarily under any of the following conditions, replace the front wheel bearing grease at every 20,000 km (12,500 miles) or 12 months. a) Driving in dusty conditions b) Driving in rough, muddy or snow-melted conditions c) Towing a trailer

Service Training BT-50

00-15

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.

NOTE: Further information can be found in the Training Manual of the B-Series (NMT-005) and in Basic Diesel Engine Management (CT-L2005) and Advanced Diesel Engine Management (CT-L3004).

Engine Performance Curve

BT-50_01001

X Y1 Y2

Engine speed Engine power Engine torque

1 2

Power curve Torque curve

Service Training BT-50

01-1

WL-C Engine
Overview

Engine

BT-50_01002

01-2

Service Training BT-50

WL-C Engine
Mechanical
Features

Mechanical

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 Inline, 4-cylinder Combustion chamber Direct injection Valve system DOHC, timing gear and belt driven, 16 valves Displacement ml 2,499 Bore x stroke mm 93.0 x 92.0 Compression ratio 18.0:1 Compression pressure kPa 2,942 (standard) 2,648 (minimum) Open BTDC () 10 IN Close ABDC () 30 Valve timing Open BBDC () 40 EX Close ATDC () 8 Valve clearance IN mm 0.10-0.16 (engine cold) EX mm 0.17-0.23
BT-50_T01001

Service Training BT-50

01-3

Mechanical
Piston

WL-C Engine

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 engines mechanical loss has been achieved by coating of the piston skirt area.

NOTE: The piston side marked with F must be installed towards the timing gear-side of the engine.

BT-50_01006

1 2

Combustion chamber Cooling oil channel

Piston skirt coating

NOTE: Oversize bearings for the crankshaft and connecting rods, as well as oversize pistons are available in various dimensions (refer to Engine W/M).

01-4

Service Training BT-50

WL-C Engine
Cylinder Head
Parts Location

Mechanical

BT-50_01007

1 2 3 4

Cylinder head cover Upper camshaft bearing caps Lower camshaft bearing case with injector sealing rings Cylinder head

5 6 7 8

Cylinder head gasket Seal plate Camshaft pulley Camshaft

Service Training BT-50

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. For lubrication of the cam lobes, bearings / journals and rocker arms, the camshafts are hollow and have oil bores at each lubricating point.

BT-50_01008

A B 1 2

Exhaust camshaft Intake camshaft Thrust force bearing boss Oil bore

3 4 5

Oil passage Location of cylinder no.1 Hexagonal shaped surface

NOTE: The cylinder head surface must not be machined. If necessary, the cylinder head must be replaced (refer to Engine W/M).

01-6

Service Training BT-50

WL-C Engine
Valve Gear The valve gear comprises helical gears and a timing belt

Mechanical

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 engines mechanical loss.

BT-50_01009

1 2 3 4

Camshaft pulley Camshaft Rocker arm Balancer shaft

5 6 7

Helical gear Timing belt auto tensioner Timing belt

NOTE: The construction of the helical gears and their adjustment procedure is identical to that of the WLT-3 engine (refer to the engine W/M).

Service Training BT-50

01-7

Mechanical
Valve-Clearance Adjustment The valve clearance is measured between roller and cam lobe.

WL-C Engine

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. They are positioned on the camshaft with pins and have to be installed as shown in the figure below.

BT-50_01011

1 2

Intake side camshaft pulley Pin

Exhaust side camshaft pulley

01-8

Service Training BT-50

WL-C Engine
Timing Belt Auto Tensioner

Mechanical

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. 39 Nm) Mounting bolts (C+B)

Hole for fixing pin

BT-50_01014

1 2 3

Rod Seal Plunger

4 5 6

Spring Oil Ball

NOTE: In case air has entered the pressure chamber of the auto tensioner, it must be bled using a certain procedure (refer to W/M).

Service Training BT-50

01-9

Mechanical
Engine Timing

WL-C Engine

When replacing the timing belt the timing marks must be positioned as shown in the figure below.

BT-50_01013

1 2

Intake camshaft pulley Exhaust camshaft pulley

3 4

Timing mark High-pressure pump pulley

01-10

Service Training BT-50

WL-C Engine
Lubrication System
Features

Lubrication System

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 Force-fed type (at idle) kPa (at 2,500 rpm) kPa 100-330 410-570 Gear type kPa 580-700 Water-cooled kPa 164-200 Full-flow paper element, spin-on type kPa 80-120 8.0 6.8 7.0 API CF or ACEA B1/B3/B5 5W-30 e.g. Mazda genuine Dexelia oil
BT-50_T01003

Item Type Oil pressure (reference values) [after warm up] Type Relief valve Oil pump opening pressure (reference value) Type Oil cooler Oil cooler bypass valve opening pressure Type Oil filter Bypass pressure Total (dry engine) Oil capacity Oil replacement (approx. Oil and oil filter quantity) replacement Grade Viscosity (SAE) Remarks

Service Training BT-50

01-11

Lubrication System
Parts Location

WL-C Engine

BT-50_01044

1 2 3 4 5 6

Oil jet valve Oil pressure switch Oil dipstick Oil cooler Oil filter body Oil filter

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

01-12

Service Training BT-50

WL-C Engine
System Overview

Lubrication System

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

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

Service Training BT-50

01-13

Lubrication System
Oil Filter

WL-C Engine

The spin-on type oil filter consists of one full flow element. The bypass element that has been additionally used on the filter WLT-3 engine has been dropped.

BT-50_01017

Full-flow paper element

01-14

Service Training BT-50

WL-C Engine
Cooling System
Features

Cooling System

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 Water-cooled, forced circulation Without heater: 8.8 With heater: 9.4 Centrifugal, V-belt driven Wax, bottom-bypass C C mm kPa 80-84 95 8.5 or more Corrugated fin 93.2-122.6 Thermo-modulation type mm 9 450
BT-50_T01005

Item Type Coolant capacity (approx. quantity) Water pump Type Type Thermostat Opening temperature Full-open temperature Full-open lift Type Cap valve opening pressure Type Cooling fan Number of blades Outer diameter L

Radiator Cooling system cap

Service Training BT-50

01-15

Cooling System
Parts Location

WL-C Engine

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.

01-16

Service Training BT-50

WL-C Engine
System Overview

Cooling System

BT-50_01018

1 2 3 4 5 6

Coolant reserve tank EGR cooler Cylinder head Turbocharger Cylinder block Oil cooler

7 8 9 10 11

Heater Water pump Thermostat Radiator Coolant flow direction

Service Training BT-50

01-17

Intake-Air System
Intake-Air System
Features

WL-C Engine

The intake-air system of the WL-C engine has the following new features:

Newly designed air cleaner housing with dry filter element MAF (Mass Air Flow) sensor with integrated IAT (Intake Air Temperature) sensor no.2 *1) and MAF learning function VGT (Variable Geometry Turbocharger) with VBC (Variable Boost Control) system *1) Enlarged charge-air cooler made of aluminium alloy Newly designed intake manifold with VSC (Variable Swirl Control) system *1) Vacuum chamber to reduce vacuum fluctuations MAP (Manifold Absolute Pressure) sensor with integrated IAT sensor no. 1

*1) Similar to Mazda6 pre F/L (2.0 MZR-CD)

01-18

Service Training BT-50

WL-C Engine
Parts Location

Intake-Air System

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

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.1 sensor VSC vacuum actuator Intake manifold

Service Training BT-50

01-19

Intake-Air System
System Overview

WL-C Engine

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

10 11 12 13 14 15 16 17

Glow plug Vacuum pump VSC vacuum actuator VSC solenoid valve VSC shutter valves MAP / IAT no.1 sensor Intake manifold To PCM

01-20

Service Training BT-50

WL-C Engine
MAF Sensor

Intake-Air System

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).

MAP Sensor / IAT Sensor No.1


The MAP sensor incorporates IAT sensor no.1 and is installed on the intake manifold.

BT-50_01052

1 2

Boost sensor IAT sensor no.1

PCM

Service Training BT-50

01-21

Intake-Air System
Variable Geometry Turbocharger

WL-C Engine

The BT-50 uses a VGT, which controls the boost pressure by adjusting guide blades. The operation is similar to that of the VGT used on the Mazda6 (2.0 MZR-CD).

BT-50_01046

1 2

VBC vacuum actuator Intake-air flow

Exhaust-gas flow

01-22

Service Training BT-50

WL-C Engine
Intake Manifold

Intake-Air System

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.

BT-50_01024

1 2 3

Secondary intake port Primary intake port VSC shutter valves

4 5

VSC vacuum actuator Intake manifold

BT-50_01023

Service Training BT-50

01-23

Intake-Air System
Variable Swirl Control Shutter Valves

WL-C Engine

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.

Vacuum Chamber
The vacuum chamber reduces vacuum fluctuations in the vacuum supply line for the VBC and EGR solenoid valve.

BT-50_01025

1 2

To vacuum pump To VBC solenoid valve

3 4

Vacuum chamber To EGR solenoid valve

01-24

Service Training BT-50

WL-C Engine
Fuel System
Features
The fuel system of the WL-C engine has the following new features:

Fuel System


1)

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) Solenoid valve-type fuel injectors with injector correction factors, directly controlled by the PCM *1) Multiple fuel injection (up to two pilot injections, but no post injections) Check valve in the fuel return line to prevent fuel from flowing back to the injectors

* Similar to Mazda3 (1.6 MZ-CD) *2) Similar to Mazda6 (2.0 MZR-CD)

Specifications
Item High-pressure pump Rail Pressure Fuel tank capacity MPa L Specification Bosch CP3S3 at idle Max. 32 160 2WD 4WD 63 70
BT-50_T01012

Service Training BT-50

01-25

Fuel System
Parts Location

WL-C Engine

BT-50_01027

1 2

Fuel gauge sender unit Fuel tank (4WD)

3 4

Vehicles with cargo box Vehicles without cargo box

01-26

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

6 7 8 9

Sedimentor switch Fuel filter (incl. fuel warmer for cold regions) Common rail Pressure limiter valve

Service Training BT-50

01-27

Fuel System
System Overview

WL-C Engine

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

8 9 10 11 12 13

High-pressure pump Fuel filter Sedimentor switch Fuel tank To PCM Fuel flow

01-28

Service Training BT-50

WL-C Engine
High-Pressure Pump

Fuel System

The BT-50 uses the high-pressure pump (CP3S3) with three pumping elements offset by 120. The operation is similar to the high-pressure pump (CP3.2) used on the Mazda3 (1.6 MZ-CD), which is also manufactured by Bosch.

BT-50_01030

1 2 3

Fuel return Fuel high-pressure from fuel filter Fuel temperature sensor

4 5 6

High-pressure pump Fuel metering valve Gear-type feed pump

Common Rail
The common rail is equipped with a fuel pressure sensor and a pressure limiter valve, which are not available as separate spare parts. In case of a malfunction on these components the common rail must be replaced as a unit.

BT-50_01031

1 2 3

Connection (fuel injector side) Fuel pressure sensor Connection (high-pressure pump side)

4 5

Common rail Pressure limiter valve

NOTE: The high-pressure pipes can be re-used up to five times after removing.

Service Training BT-50

01-29

Fuel System
Fuel Injectors

WL-C Engine

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).

BT-50_01048

1 2 3 4 5 6

Return fuel flow (to fuel tank) Fuel flow (from common rail) Injector head Injector classification code (A0 for the WL-C engine) Injector correction factor Fuel injector

7 8 9 10 11

Valve control plunger Nozzle needle Valve ball Orifice plate Solenoid valve coil

NOTE: The injector sealing rings located in the lower camshaft bearing case have to be replaced at each removal of the injectors.

01-30

Service Training BT-50

WL-C Engine
Exhaust System
Features
The exhaust system has the following new features:

Exhaust System

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

6 7 8 9

Warm up switch With exhaust shutter valve Front pipe VGT

Service Training BT-50

01-31

Exhaust System
Warm-Up System

Engine

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. Thereby vacuum is applied to the exhaust shutter valve vacuum actuator, which closes the exhaust shutter valve in the front pipe of the exhaust system. Due to the closed shutter valve the exhaust gas backpressure raises, accelerating engine warming-up and thus quickly providing warm engine coolant for the heating system.

Wiring Diagram

BT-50_01054

1 2

PCM Warm up switch

Exhaust shutter valve solenoid valve

01-32

Service Training BT-50

WL-C Engine
Exhaust Shutter Valve Solenoid Valve

Exhaust System

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.

BT-50_01053

1 2 3 4

Transfer lever Actuation rod Exhaust shutter valve vacuum actuator Stop screw

5 6 7

Exhaust flange Pivot Exhaust shutter valve

Operating Conditions The warm-up system operates when all of the following conditions are met:

Warm-up switch pushed ECT below 77 C IAT (no.2) below 13 C Engine speed below 1,370 rpm.

Service Training BT-50

01-33

Emission System
Emission System
Features
The emission system of the WL-C engine has the following features:

WL-C Engine

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) Similar to Mazda2 pre F/L (1.4 MZ CD) *2) Similar to Mazda6 pre F/L (2.0 MZR CD)

Parts Location

BT-50_01032

1 2 3

Rollover valves Vehicles with cargo box Vehicles without cargo box

4 5

Evaporative chamber Check valve (two-way)

01-34

Service Training BT-50

WL-C Engine

Emission System

BT-50_01033

1 2 3 4 5

Oxidation catalytic converter EGR cooler EGR solenoid valve MAF sensor ISV

6 7 8 9 10

EGR control solenoid valve ISV solenoid valve (full) ISV solenoid valve (half) EGR valve Air filter

Service Training BT-50

01-35

Emission System
System Overview

WL-C Engine

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)

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

01-36

Service Training BT-50

WL-C Engine
EGR Solenoid Valve

Emission System

BT-50_01047

A B

To EGR valve To vacuum chamber

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. Due to this the EGR valve opens and exhaust gas is recirculated. When less or no EGR is desired the PCM controls the EGR solenoid valve with a small duty ratio and energizes the EGR control solenoid valve, so that the vacuum applied to the EGR vacuum actuator is reduced by a ventilation passage. Due to this the spring-loaded EGR valve closes and less or no exhaust gas is recirculated. When the EGR should be cut off (e.g. during acceleration) the PCM de-energizes the EGR control solenoid valve, so that the EGR vacuum actuator is ventilated irrespective of the control by the EGR solenoid valve. Due to this the EGR valve closes quickly and EGR is stopped.

Service Training BT-50

01-37

Emission System
Intake Shutter Valve

WL-C Engine

The WL-C engine uses a three-step ISV, which increases the EGR rate at low engine speeds and prevents bucking movements of the engine during shut-off. The operation is similar to the ISV used on the Mazda6 pre F/L (2.0 MZR-CD).

BT-50_01026

Fully opened at normal driving (for low EGR rate or no EGR) Fully closed when the engine is shut off Slightly opened to create vacuum (for high EGR rate)

2 3

First vacuum actuator operates for high EGR rate and shortly when the engine is shut off Second vacuum actuator operates shortly when the engine is shut off

NOTE: Function and operation of the ISV are as described for the Denso common rail system in the course Basic Diesel Engine Management (CT-L2005).

01-38

Service Training BT-50

WL-C Engine
Charging and Starting System

Charging and Starting System

A modified generator has been adopted for the charging system, while the starting system is identical to that used on the B-Series.
Specification WL-C 12 95D31R (64) 12-70 14.1-14.7 Equipped Coaxial reduction 2.2
BT-50_T01009

Item Battery Voltage Type and capacity (5-hour rate) Output Regulated voltage Self diagnosis function Type Output (V) (Ah) (V-A) (V)

Generator Starter

(kW)

Parts Location

BT-50_01039

1 2

Starter Additional battery (for cold regions)

3 4

Generator Main battery

Service Training BT-50

01-39

Control System
Control System
Features

WL-C Engine

The control system of the WL-C engine has the following new features:

CKP (CranKshaft Position) sensor located at the flywheel CMP (CaMshaft Position) sensor PCM (Powertrain Control Module) with extended control strategies

Specifications
Specification WL-C Thermistor Hot-wire Thermistor Piezoelectric element Thermistor Hall element type Inductive type Potentiometer Potentiometer Piezoelectric element Thermistor Piezoelectric element ON/OFF ON/OFF ON/OFF
BT-50_T01006

Item IAT sensor No.2 (built into MAF sensor) MAF sensor IAT sensor No.1(built into MAP sensor) MAP sensor ECT sensor CMP sensor CKP sensor APP sensor EGR valve position sensor BARO sensor (built into PCM) Fuel temperature sensor Fuel pressure sensor Neutral switch CPP switch Idle switch

01-40

Service Training BT-50

WL-C Engine
Parts Location

Control System

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

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.1 Glow plug relay A/C relay EGR valve position sensor PCM (with built-in BARO sensor) CKP sensor

Service Training BT-50

01-41

Control System
System Overview

WL-C Engine

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.1 Fuel pressure sensor Fuel metering valve Fuel temperature sensor Sedimentor switch ISV solenoid valve (full) ISV solenoid valve (half) EGR solenoid valve EGR control solenoid valve 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

Control System
Idle switch APP sensor Main relay Engine switch Neutral switch A/C switch DLC-1 / DLC-2 Vehicle speed signal CAN Bus CPP switch A/C relay BARO sensor PCM Glow plug relay MIL Glow indicator light Tachometer To PCM To glow plug relay To IC (Instrument Cluster)

Service Training BT-50

01-43

Control System
Block Diagram
Input Battery CPP switch Neutral switch APP sensor Idle switch MAF sensor / IAT sensor no.2 ECT sensor Fuel temperature sensor BARO sensor MAP sensor / IAT sensor no.1 Fuel pressure sensor CMP sensor CKP sensor Immobiliser-related information Vehicle speed signal OBD A/C switch EGR valve position sensor Immobiliser module Warm up switch Warm up system control Fuel injection amount control Fuel injection timing control Multiple fuel injection control Fuel pressure control EGR control A/C cut-off control Variable boost control Variable swirl control Idle speed control Glow control PCM Control Strategies

WL-C Engine

Output

Fuel metering valve Fuel injectors VBC solenoid valve VSC solenoid valve EGR solenoid valve EGR control solenoid valve ISV solenoid valves (half, full) Glow indicator light Glow plug relay A/C relay Immobiliser module MIL Exhaust shutter solenoid valve

BT-50_T01007

01-44

Service Training BT-50

WL-C Engine
Relationship Chart

Control System

x: Applicable Control Item Multiple fuel injection control Fuel injection timing control Warm up system control

Variable boost control

Fuel pressure control

Variable swirl control

Item

Input device Battery CPP switch Neutral switch APP sensor Idle switch MAF sensor IAT sensor no.2 IAT sensor no.1 ECT sensor Fuel temperature sensor BARO sensor MAP sensor Fuel pressure sensor CMP sensor CKP sensor Vehicle speed signal A/C switch EGR valve position sensor Warm up switch Immobiliser-related information Output device Fuel metering valve Fuel injectors VBC solenoid valve VSC solenoid valve EGR control solenoid valve ISV solenoid valve (half, full) Exhaust shutter solenoid valve Glow indicator light Glow plug relay A/C relay Immobiliser-related information

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 x x x x x x x x
BT-50_T01008

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 x

x x x x x x x x x x x x

x x

x x

x x

Service Training BT-50

01-45

Immobiliser system x x

A/C cut-off control

Idle speed control

Glow control

EGR control

Control System
Crankshaft Position Sensor

WL-C Engine

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 6crank angle between each projection. A space of 18 defines a determined crankshaft position.

BT-50_01050

1 2

CKP sensor Pulse wheel

Flywheel

NOTE: When the CKP signal fails during engine operation, the engine stalls and will not start again.

01-46

Service Training BT-50

WL-C Engine
Camshaft Position Sensor

Control System

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.

Service Training BT-50

01-47

Control System
Powertrain Control Module
Features The PCM has the following new features:

WL-C Engine

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 (2.0 MZR CD) The PCM is mounted on the drivers side in the passenger compartment at the lower Apillar. On vehicles with U.K. specification a cover with shear bolts secures the PCM.

BT-50_01040

1 2

PCM Bracket

Connector

01-48

Service Training BT-50

WL-C Engine
The PCM has two connectors with 154 pins in total.

Control System

BT-50_01041

Similar to other current modules the PCM now allows to carry out the following programming functions by means of M-MDS:

Programmable module installation (to replace PCM) Module reprogramming (to update software calibration) Programmable parameters (to input injector correction factors) As-build data (to update As-build data) Data reset (PCM and MAF sensor) MAF learning (to adapt MAF sensor condition to PCM)

NOTE: For replacement of the PCM certain procedures have to be followed (refer to the chapter Maintenance and Repair). A/C Cut-Off Control Under the following engine operating conditions the PCM turns the A/C relay off to improve driveability:

For a certain time when the accelerator-opening angle is 87.5 % or more. Permanently when ECT is above 113 C until temperature falls below 110 C.

Service Training BT-50

01-49

Control System
Glow Plug Relay

WL-C Engine

The glow plug relay has a feedback line to the PCM to facilitate failure detection. The PCM operates the glow plug relay for max. 120 s at an engine coolant temperature below 32 C.

BT-50_01038

1 2 3 4

From main relay Glow plug relay PCM Glow indicator light (IC)

5 6 7

Glow plugs Glow plug circuit fuse From battery

01-50

Service Training BT-50

WL-C Engine
On-Board Diagnostic System
Features

Control System

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.

Self Test The self-test function allows reading out DTCs of the PCM. Therefore connect the MMDS to the DLC-2 of the vehicle and select the option Toolbox Self Test Modules PCM Retrieve CMDTCs. In addition the KOEO (Key On, Engine Off) self-test and the KOER (Key On, Engine Running) self test can be performed. Therefore connect the M-MDS to the DLC-2 of the vehicle and select the option Toolbox Self Test Modules PCM KOEO/KOER On Demand Self Test.

NOTE: The self-test function cannot be carried out by using DLC-1.

Service Training BT-50

01-51

Control System
PID Monitor

WL-C Engine

The PID monitor function allows monitoring the PIDs of the PCM. Therefore connect the M-MDS to the vehicle and select the option Toolbox Datalogger Modules PCM.
PID AAT AC_REQ ACCS APP APP1 APP2 ARPMDES BARO BOO CPP DTCCNT ECT EGRV2 FIP_FL FIP_SCV FLT FRP GP_LMP GPC IASV IASV2 IAT INGEAR IVS LOAD Definition Ambient air temperature A/C request signal A/C relay Accelerator pedal position Accelerator pedal position sensor no.1 Accelerator pedal position sensor no.2 Target engine speed Barometric pressure Brake switch Clutch pedal position switch DTC count Engine coolant temperature EGR control solenoid valve High-pressure pump flow control Fuel metering valve Fuel temperature Fuel rail pressure Glow indicator light Glow plug relay ISV solenoid valve (half) ISV solenoid valve (full) Intake air temperature (IAT sensor no.1) Load / no load condition Idle switch Engine load Unit/Condition C OFF/ON OFF/ON % % V % V rpm Pa V OFF/ON OFF/ON C V OFF/ON A % A C Pa OFF/ON OFF/ON OFF/ON OFF/ON C V OFF/ON OFF Idle / Idle %
BT-50_T01010a

01-52

Service Training BT-50

WL-C Engine
PID MAF MAP MIL MIL_DIS RPM SEGRP DSD SELTESTDTC VBCV VPWR VSS WARMSW WARMSOL Mass airflow Manifold absolute pressure 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 Definition

Control System
Unit/Condition g/s V Pa V OFF/ON km rpm % % V km/h OFF/ON OFF/ON
BT-50_T01010b

Simulation Test
The simulation test function allows activating certain PIDs of the PCM. Therefore connect the M-MDS to the vehicle and select the option Toolbox Datalogger Modules PCM.
: Applicable : Not applicable Test condition KOEO KOER x x x x x x x x
BT-50_T01011

PID ACCS # EGRV2 # GP_LMP # GPC # IASV # IASV2 # INJ_1 # INJ_2 # INJ_3 # INJ_4 # SEGRP # VBCV #

Applicable component A/C relay EGR control solenoid valve Glow indicator light Glow plug relay ISV solenoid valve (half) ISV solenoid valve (full) Fuel injector no.1 Fuel injector no.2 Fuel injector no.3 Fuel injector no.4 EGR solenoid valve VBC solenoid valve

Unit/Condition OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF OFF OFF OFF % %

Service Training BT-50

01-53

Control System
Maintenance and Repair
MAF Sensor Learning Function

WL-C Engine

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 Toolbox Powertrain Engine Checks Learning and follow the instructions. The MAF learning procedure can also be initiated manually via DLC-1. Therefore, connect terminal TEN (Test ENgine) five times to ground within five seconds. The glow indicator light is illuminated while MAF learning is performed and flashes five times after the procedure is completed.

Replacing the MAF Sensor After replacing the MAF sensor certain procedures have to be performed in the following order: 1. Perform MAF sensor data reset procedure to reset the adaptation values in the PCM for the MAF sensor. Therefore, select the option Toolbox Powertrain Data Reset MAF sensor and follow the instructions. 2. Perform KOEO self-test procedure. 3. Turn the engine switch to the OFF position. 4. Wait for 5 s. 5. Start the engine. 6. Perform KOER self-test procedure. 7. Turn the engine switch to the off position.

NOTE: It is recommended to perform the MAF sensor learning function when a MAF data reset has been carried out.

01-54

Service Training BT-50

WL-C Engine
PCM Replacement

Control System

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 Toolbox Powertrain Data Reset PCM and follow the instructions. 4. Perform After repair procedure. 5. Start the engine. 6. Turn the engine switch to the off position. 7. Turn the engine switch to the ON position (Engine off). 8. Perform KOEO self-test procedure. 9. Turn the engine switch to the off position. 10. Wait for 5 s. 11. Start the engine. 12. Perform KOER self-test procedure. 13. Turn the engine switch to the off position.

NOTE: For further information refer to the W/M. NOTE: It is recommended to perform the MAF sensor learning function when a PCM data reset has been carried out.

Service Training BT-50

01-55

Control System
Notes:

WL-C Engine

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
Specification 2WD Double wishbone Torsion bar spring Torsion bar 27 28 Cylindrical, double-acting 3300'-3700' 3130'-3530' 3000'-3500' 2700'-3200' 2-8 3-9 RAP cab: 044' 1 035' 1 DBL cab: 045' 1 RAP cab: 207' 1 156' 1 DBL cab: 206' 1 RAP cab: 1037' 825' DBL cab: 1035' Leaf spring Semi elliptic leaf spring Cylindrical, double-acting 4WD

Item Front suspension Suspension type Spring type Type Stabilizer Diameter mm Shock absorber type Maximum steering Inner angle Outer Total toe-in mm Front wheel Camber angle (reference value) alignment (Unloaded Caster angle (reference value) condition*) Steering axis inclination Rear suspension Suspension type Spring type Shock absorber type

* : Fuel tank full; engine coolant and engine oil at specified level, and spare tire, jack and tools in designated position.

BT-50_T02001

Service Training BT-50

02-1

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

Shock absorber Torsion bar spring Upper arm

4 5

Lower arm Front stabiliser

02-2

Service Training BT-50

Suspension
Rear Suspension

BT-50_02004

1 2

4WD 2WD

3 4

Shock absorber Leaf spring

Service Training BT-50

02-3

Wheels and Tyres


Wheels and Tyres
The wheels and tyres have the following new features:

Suspension

Modified wheel and tyre sizes Modified wheel offset New designs for 15- and 16-inch aluminium alloy wheels and 15-inch steel wheels.

BT-50_02001

1 2

15-inch standard steel rim (2WD) 15-inch design steel rim (4WD)

3 4

15-inch aluminium alloy rim (2WD) 16-inch aluminium alloy rim (4WD)

02-4

Service Training BT-50

Suspension
Specifications
Item Size Offset Wheel Pitch circle diameter Material Size Up to four persons Full load Up to four persons Full load Remaining tread Wheel nut tightening torque mm Nm mm mm

Wheels and Tyres

Specification 15 x 61/2J 15 x 61/2JJ 20 25 139.7 Steel Aluminium alloy Steel 235/75R15 109S 210

16 x 7J 10 Aluminium alloy 245/70R16 111S 210

215/70R15C 106/104S

Tyre

Air pressure kPa

Front

220

Rear

210 375 1.6

210 290

210 270

88.2-117.6 1.5 max. 2.0 max.


BT-50_T02002

Wheel Radial and direction Wheel and tyre tyre runout mm Axial direction

Service Training BT-50

02-5

Wheels and Tyres


Notes:

Suspension

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).

Specifications
Item Drive type Transmission type Front axle Bearing type Rear axle Bearing type Support type Casing Length Diameter Rear differential Reduction gear Differential gear Ring gear size Final gear ratio Differential oil Front differential Reduction gear Differential gear Ring gear size Final gear ratio Grade Differential oil Type Viscosity Capacity L Type Grade Viscosity Capacity Specification 2WD 4WD S15M-D S15MX-D Taper roller bearing Taper roller bearing Semi-floating Banjo type 739 35.0 Hypoid gear Straight bevel gear 8.9 3.416 3.727 API service GL-5 SAE 90 2.45 2.35 Hypoid gear Straight bevel gear 8.00 3.727 API service GL-5 Above -18C: SAE 90 Below -18C: SAE 80 1.9
BT-50_T03001

mm mm

(Inch)

(Inch) _

Service Training BT-50

03-1

RFW System
RFW System

Driveline / Axle

The RFW system is controlled by the PCM. The input and output components are the same as used for the B-Series with separate RFW control module.

Parts Location

BT-50_03001

1 2 3 4 5 6

RFW main switch Transfer neutral switch 4WD switch One-way check valve RFW switch RFW unit

7 8 9 10 11

RFW vacuum actuator Joint shaft component Lock solenoid valve Free solenoid valve PCM

03-2

Service Training BT-50

Driveline / Axle
System Overview

RFW System

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

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

Service Training BT-50

03-3

RFW System
On-Board Diagnostic System

Driveline / Axle

Detected malfunctions are stored as 4-digit DTCs in the PCM memory and can be retrieved by means of M-MDS.

DTC Table
DTC P1812 P1813 P1814 P1815 P1878 P1879 P1880 P1885 Malfunction RFW lock solenoid valve circuit failure RFW lock solenoid valve open circuit RFW lock solenoid valve circuit/short to battery RFW lock solenoid valve circuit/short to ground RFW free solenoid valve circuit failure RFW free solenoid valve open circuit RFW free solenoid valve circuit/short to battery RFW free solenoid valve circuit/short to ground
BT-50_T03002

Simulation Test A simulation test has been adopted to check the function of certain output components by means of M-MDS.
PID 4WDMODE_L # HUBLOCK # HUBLOCK_L # NTFLAMP # Applicable component 4WD indicator light RFW lock solenoid valve RFW free solenoid valve RFW indicator light Condition OFF/ON OFF/ON OFF/ON OFF/ON Test condition Engine switch at ON
BT-50_T03003

NOTE: Further diagnosis is supported by the symptom troubleshooting section in the W/M.

03-4

Service Training BT-50

Transmission
Clutch
Features
The clutch system of the BT-50 has the following new features:

Clutch

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 Specification S15M-D, S15MX-D Hydraulic Diaphragm 10,100 250 155 Suspended 5.2 152 15.87 22.23 SAE J1703, FMVSS 116 DOT-3
BT-50_T05001

N mm mm

mm mm mm

Service Training BT-50

05-1

Clutch
Parts Location

Transmission

BT-50_05013

1 2 3 4

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

05-2

Service Training BT-50

Transmission
Clutch Master Cylinder

Clutch

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.

BT-50_05001

One-way valve

Pulsation damper

Service Training BT-50

05-3

Clutch
Dual Mass Flywheel

Transmission

The dual mass flywheel compensates torque fluctuations thus reducing rattle noises of the transmission gears.

BT-50_05014

1 2

Torsional-vibration damping spring Secondary flywheel

Primary flywheel

05-4

Service Training BT-50

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.

Features
Construction and operation of the S15M(X)-D transmission are quite similar to the P66MD transmission introduced on the MX-5 (NC). It has the following features:

Triple-cone synchroniser mechanism for the 1st and 2nd gear Double-cone synchroniser mechanism for the 3rd gear Single-cone synchroniser mechanism for 4th, 5th and reverse gear Integrated shift mechanism unit comprising shift rods and forks, detent balls, and pintype interlock mechanism Cam-type reverse lockout mechanism

Service Training BT-50

05-5

S15M(X)-D Manual 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] High Low Type Capacity (approx.quantity) L

Transmission

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 3.55 Manual Transmission fluid type A ml 220-260 1.000 2.020 Manual Transmission fluid type A 1.85
BT-50_T05002

05-6

Service Training BT-50

Transmission
Overview

S15M(X)-D Manual Transmission

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

5 6 7 8 9

Reverse idler gear Reverse gear 5th gear Counter shaft Input shaft

Service Training BT-50

05-7

S15M(X)-D Manual Transmission


Power Flow

Transmission

1st Gear

BT-50_05003

2nd Gear

BT-50_05004

3rd Gear

BT-50_05005

05-8

Service Training BT-50

Transmission

S15M(X)-D Manual Transmission

4th Gear

BT-50_05006

5th Gear

BT-50_05007

BT-50_05008

Reverse Gear

Service Training BT-50

05-9

S15M(X)-D Manual Transmission


Shift Mechanism

Transmission

Most of the shift mechanism components are accommodated in the shift mechanism unit. Due to its five speed layout the S15M(X)-D transmission requires four shift rods in total (three in the shift mechanism unit and one in the transmission housing).

BT-50_05009

1 2

Section A-A Shift mechanism unit

3 4

Control rod Shift rod

05-10

Service Training BT-50

Transmission
Shift Mechanism Unit

S15M(X)-D Manual Transmission

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

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

Service Training BT-50

05-11

S15M(X)-D Manual Transmission


5th / Reverse Gear Mechanism

Transmission

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.

BT-50_05011

05-12

Service Training BT-50

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)

S15M(X)-D Manual Transmission


18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Reverse gear Countershaft rear bearing Locknut Synchronizer key spring Clutch hub sleeve Detent spring Detent ball 5th/reverse shift rod 5th/reverse shift fork Synchronizer key 5th/reverse clutch hub Output rear bearing Reverse counter gear Spacer 5th counter gear Counter lever shaft component

Service Training BT-50

05-13

S15M(X)-D Manual Transmission


Reverse Gear Lockout Mechanism

Transmission

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.

BT-50_05012

A B 1

Shifting directly from 5th to reverse gear (locked) Shifting from 5th to reverse gear via neutral (released) Selector locked

2 3 4

Selector in 5th gear position Lockout mechanism released Selector in Neutral position

05-14

Service Training BT-50

HVAC
Basic System
Features

Basic System

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 Refrigerant Type Regular amount approx. Type Discharge capacity Max. allowable speed A/C compressor PAG oil type Lubrication Sealed volume Magnetic clutch clearance Fusible plug Melting point Type Radiated heat Condenser Receiver/drier capacity Desiccant Expansion valve Type Evaporator Type Temperature control Electrical consumption (during Blower motor A/C operation) Magnetic clutch Blower motor Type Refrigerant pressure switch Evaporator temperature sensor Condition Operating High pressure kPa Low Condition Evaporator C temperature kW kW g ml rpm ml mm C kW ml Specification 4.86 4.012 R-134a 475 Swash plate 154 7,000 FD46XG 180 0.35-0.75 102-107 Multiflow (sub-cooling type) 10.46 220 Synthetic zeolite Internal regulating type Single tank drawn cup Reheat full air mix type 220 48 Sirocco ON 390 - 790 176 - 216 ON 3.0 +/- 0.6 OFF 2940 - 3340 20 or less OFF 1.0 +/- 0.6
BT-50_T07001

W W

Magnetic clutch control

Service Training BT-50

07-1

Basic System
Parts Location

HVAC

BT-50_07001

1 2 3 4 5

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

07-2

Service Training BT-50

HVAC
Refrigerant System

Basic System

BT-50_07006

1 2 3 4

Low-pressure charging valve Expansion valve High-pressure charging valve Receiver / drier

5 6 7

Condenser Evaporator A/C Compressor

Service Training BT-50

07-3

Control System
Control System
Features
The HVAC control of the BT-50 has the following new features:

HVAC

Newly designed control panel with larger dials

Parts Location

BT-50_07003

1 2 3 4

A/C relay Climate control unit Evaporator temperature sensor Blower resistor

5 6 7

Blower motor Refrigerant pressure switch Magnetic clutch

07-4

Service Training BT-50

HVAC
Wiring Diagram

Control System

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. evaporator temperature sensor)

7 8 9 10 11

A/C switch Fan switch Blower resistor Blower motor Blower relay

Service Training BT-50

07-5

Control System
Climate Control Unit
A new designed cable operated climate control unit has been adopted.

HVAC

BT-50_07005

1 2 3 4

A/C switch Rear window defroster switch Airflow mode selector dial Climate control unit

5 6 7

Fan switch Rec/Fresh lever Temperature control dial

07-6

Service Training BT-50

Restraints
Airbag System
Features
The airbag system of the BT-50 has the following new features:

Airbag System

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 of the B-Series (NMT-005) and MX-5 (NMT-008), and Supplemental Restraint System (CT-L1003).

Service Training BT-50

08-1

Airbag System
Parts Location

Restraints

BT-50_08001

1 2 3 4

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

08-2

Service Training BT-50

Restraints
Wiring Diagram

Airbag System

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.2)

9 10 11 12 13 14 15 16

SAS control module Twisted pair wire Passenger-side side airbag sensor Driver-side side airbag sensor IC Airbag system warning light DLC-2 Poor connection detection bar (connector no.1)

Service Training BT-50

08-3

Airbag System
SAS Control Module

Restraints

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.

BT-50_08003

1 2

SAS control module Driving direction

Connector

08-4

Service Training BT-50

Restraints
Side Airbag Sensors

Airbag System

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.

BT-50_08004

Protection cover

Side airbag sensor

Side Airbags
The BT-50 is equipped with side airbags, which protect the head and chest area of the occupants during a side impact. The operation is similar to that of the MX-5 (NC).

BT-50_08005

1 2

Inflator Module cover

3 4

Airbag Side airbag module

Service Training BT-50

08-5

Airbag System
Seat Belt Pretensioners

Restraints

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.

BT-50_08006

1 2 3 4 5 6 7

Spindle Spring seat Spring shaft Spring Spring case Cover Gear

8 9 10 11 12 13

Clutch roller Cylinder Gas generator Cap nut Rack Base

08-6

Service Training BT-50

Restraints
On-Board Diagnostic System
Features

Airbag System

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. To read out the DTCs of the SAS control module connect the M-MDS to the vehicle and select the option Toolbox Self Test Modules RCM. The excerpt of the DTC table below shows that a malfunction, which is indicated by the airbag system warning light with only one flashing pattern e.g. DTC 22, can actually have several different root causes. A more detailed description of the root cause is only displayed when performing the self test with M-MDS. When a malfunction of the airbag system is present the warning light flashes a two-digit DTC for ten times. Then the light stays illuminated. The flashing starts again when the ignition is switched off and on.
DTC Air bag system warning light M-MDS display B1933 B1934 B1935 B1992 B1993 22 B1994 B1995 12 21 19 21 Flashing pattern Priority ranking 7 8 7 Malfunction

Passenger-side air bag module circuit resistance high Driver-side air bag module circuit resistance low Passenger-side air bag module circuit resistance low Driver-side side air bag module circuit short to power supply Driver-side side air bag module circuit short to ground Driver-side side air bag module circuit resistance high Driver-side side air bag module circuit resistance low
BT-50_T08001

Service Training BT-50

08-7

Airbag System
PID Monitor

Restraints

The PID monitor function allows monitoring the PIDs of the SAS control module. Therefore, connect the M-MDS to the vehicle and select the option Toolbox Datalogger Modules RCM.
PID Definition Number of continuous DTCs Driver-side airbag sensor communication state Driver-side airbag sensor circuit state Passenger-side airbag sensor communication state Passenger-side airbag sensor circuit state Driver-side seat belt pretensioner circuit state Driver-side airbag module resistance Driver-side seat belt pretensioner resistance Driver-side, side airbag module resistance Driver-side, side airbag module circuit state Driver-side airbag module circuit state Driver-side seat belt pretensioner circuit state System IG1 voltage value On-demand driver-side, side airbag sensor communication state On-demand driver-side, side airbag sensor circuit state On-demand passenger-side, side airbag sensor communication state On-demand passenger-side, side airbag sensor circuit state On-demand driver-side airbag module circuit state On-demand driver-side, side airbag circuit state On-demand passenger-side airbag module circuit state On-demand passenger-side, side airbag sensor circuit state Passenger-side seat belt pretensioner circuit state Passenger-side airbag module resistance Passenger-side, side airbag module resistance Passenger-side, side airbag sensor circuit state Passenger-side seat belt pretensioner resistance Passenger-side airbag module circuit state Passenger-side seat belt pretensioner circuit state Unit/Condition Num OK/FAULT OK/FAULT OK/FAULT OK/FAULT *1) ohm ohm ohm *1) *1) *1) V OK/FAULT OK/FAULT OK/FAULT OK/FAULT *1) *1) *1) *1) *1) ohm ohm *1) ohm *1) *1)
BT-50_T08002

CONT_RCM CRSH_ST_D1 CRSH_ST_D2 CRSH_ST_P1 CRSH_ST_P2 D_PTENSFLT DABAGR DR_PTENS DS_AB DS_AB_ST DS1_STAT DSB_P_ST IG_V_2 OD_CRST_D1 OD_CRST_D2 OD_CRST_P1 OD_CRST_P2 OD_DAB1_ST OD_DSAB_ST OD_PAB1_ST OD_PSAB_ST P_PTENSFLT PABAGR PS_AB PS_AB_ST PS_PTENS PS1_STAT PSB_P_ST

*1) SQ_LOWRES / OPEN / SHRT_B+ / SHRT_GND / Normal

08-8

Service Training BT-50

Body & Accessories


Body Panels
Cabin

Body Panels

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.

BT-50_09002

Service Training BT-50

09-1

Body Panels
Ladder Frame

Body & Accessories

The cross-braced ladder frame of the BT-50 is essentially carried over from the B-Series, just as four cabin mounts, which minimise lateral movement, but allow for compliance in vertical movement providing comfortable driving.

BT-50_09003

DBL Cab Frame

09-2

Service Training BT-50

Body & Accessories


Cargo Box

Body Panels

The cargo box of the BT-50 has the following new features allowing a more versatile usage of the cargo box:

Taller cargo box walls to increase the load capacity. New structure of the inner cargo box walls with one horizontal and several vertical guiding grooves that allow splitting up the cargo space with boards. Inner rope hooks that are placed closer to the floor to ease firm securing of load.

BT-50_09004

1 2

Vertical guiding grooves Horizontal guiding groove

Inner rope hook

Anti-Corrosion Measures
The body of the BT-50 features improved anti-corrosion measures:

Organic-resin coated steel is used on body panels that are regularly exposed to weather, such as the cowl, bonnet and outer door panels. Undercoating, PVC and wax coatings are used extensively to protect the underbody, frame and other exposed areas, against corrosion. Galvanized steel is used for fenders, rocker panels, outer cargo box panels, the cargo box floor panel, wheel wells and load gate.

Service Training BT-50

09-3

Glass/Windows/Mirrors
Glass/Windows/Mirrors

Body & Accessories

The glass/windows/mirrors of the BT-50 have following new features:

Rear window defroster switch installed in centre panel Power outer mirror switch installed in driver door trim Enlarged power outer mirrors

BT-50_09006

Rear window defroster switch

BT-50_09007

Power outer mirror switch

09-4

Service Training BT-50

Body & Accessories


Security and Locks
Features

Security and Locks

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).

Theft-Deterrent System
The theft-deterrent system activates the turn lights and the theft-deterrent horn when the bonnet or a door is opened by means of other than the key or the keyless transmitter. The system is deactivated when a door is opened with the key or the unlock button of the keyless transmitter.

BT-50_09008

1 2 3 4 5

Engine switch Front door latch and lock actuator Rear door latch and lock actuator Door switch Keyless control module

6 7 8 9

Theft-deterrent horn Bonnet switch Door lock control module Theft-deterrent control module

Service Training BT-50

09-5

Security and Locks


Wiring Diagram

Body & Accessories

BT-50_09009

1 2 3 4 5 6 7 8

Instrument cluster Door ajar warning light Security light Door switches Drivers 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

09-6

Service Training BT-50

Body & Accessories


Exterior Trim
Features

Exterior Trim

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

5 6 7

Side protector Front flap Front bumper

Service Training BT-50

09-7

Exterior Trim
Front and Rear Bumper

Body & Accessories

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).

BT-50_09005

1 2 3

Bumper reinforcement Lower wheel arch extension Front hole cover (with front fog lights)

4 5

Front bumper Front hole cover (without front fog lights)

09-8

Service Training BT-50

Body & Accessories


Interior Trim
Features
The interior trim of the BT-50 has the following new features:

Interior Trim

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

5 6 7

Cup holder Cup holder (except REG cab) Centre console

Service Training BT-50

09-9

Lighting System
Lighting System
Features

Body & Accessories

The lighting system of the BT-50 has the following new features:

Front combination light with multi-reflector headlight type, turn and parking light Rear combination light with stepped reflector Front and rear fog light switch incorporated in light switch Rear fog light integrated in rear combination light or in rear bumper (depending on market) Centre console illumination light Room light incorporating spot lights DRL (Daytime Running Light) (depending on market)

Parts Location
Front Combination Light

BT-50_09012

1 2 3

Headlight bulb Front turn light bulb Parking light bulb

4 5

Section B-B Section A-A

09-10

Service Training BT-50

Body & Accessories


Rear Combination Light

Lighting System

BT-50_09013

1 2 3

Brake/taillight bulb Turn light bulb Back-up light bulb (LH) Rear fog light bulb (RH)

4 5

Section A-A Rear combination light

Service Training BT-50

09-11

Lighting System
Overview

Body & Accessories

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. On the BT-50, a DRL control module automatically switches on the headlights when the ignition is in IG1 position.

09-12

Service Training BT-50

Body & Accessories


Wiring Diagram

Lighting System

BT-50_09028

Service Training BT-50

09-13

Wiper / Washer System


Wiper / Washer System
Features

Body & Accessories

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

5 6 7

Wiper arm and blade Washer motor Washer tank

09-14

Service Training BT-50

Body & Accessories


Wiring Diagram

Wiper / Washer System

BT-50_09024

1 2 3 4

Wiper switch Washer switch Washer motor Wiper motor

5 6 7 8

Auto-stop switch Interval relay Interval control switch One-touch switch

Service Training BT-50

09-15

Entertainment
Audio System
Features

Body & Accessories

The modular audio system of the BT-50 is available in two different variants: Radio with CD player or with 6-CD changer. It has the following features:

AM/FM tuner with RDS (Radio Data System) and ALC (Audio Level Control) Single CD player or 6-CD changer with MP3 compatibility I-Pod adapter compatibility (16-pin connector) 6-Loudspeaker system comprising four door speakers and two tweeters OBD system

Specifications
Audio Unit
Specification Type A With RDS Without RDS 12 153-279 531-1602 522-1629 87.5-108 354 4
BT-50_T09004

Item Rated voltage Frequency band AM LW MW V kHz kHz MHz W ohm

Type B

531-1629

FM Audio amplifier maximum output power Output impedance

Speakers
Specification Rear speaker DBL cab RAP cab 25 4 100 160

Item Maximum input Impedance Size W ohm mm

Front speaker

Tweeter

160

30
BT-50_T09005

09-16

Service Training BT-50

Body & Accessories


Parts Location

Entertainment

BT-50_09017

1 2 3 4 5

Roof antenna Tweeter LH Rear speaker RH Rear speaker LH Front speaker LH

6 7 8 9

Audio unit Antenna cable Front speaker RH Tweeter RH

Service Training BT-50

09-17

Entertainment
System Overview

Body & Accessories

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.

09-18

Service Training BT-50

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.

BT-50_09025

Operating key layout of the 6-CD changer

Service Training BT-50

09-19

Entertainment
On-Board Diagnostic System

Body & Accessories

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. Once a DTC is stored in the non-volatile memory of the audio unit it can be displayed on the information display when the test mode has been activated. In addition, the self-test function allows deleting the stored DTCs.

Diagnostic Assist Function The diagnostic assist function allows checking of the following components:

Information display Speakers Radio reception condition Antenna condition

NOTE: For further information about the self-test and diagnostic assist function refer to the W/M.

09-20

Service Training BT-50

Body & Accessories


Power Systems
Parts Location

Power Systems

BT-50_09020

Main fuse block

Fuse block

Service Training BT-50

09-21

Instrumentation / Driver Info


Instrumentation / Driver Information System
Features

Body & Accessories

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 Rated voltage Meter type Indication range Red zone Input signal source Rated voltage Meter type Input signal source Rated voltage Meter type Input signal source Rated voltage Display Indication digits V Specification Stepper motor type 0180 Speedometer sensor DC 12 Stepper motor type 05,500 4,5005,000 PCM DC 12 Stepper motor type (Reset-to-zero type) Fuel gauge sender unit DC 12 Stepper motor type (Medium range stabilised type) ECT sensor DC 12 LCD Odometer: 6 digits, Tripmeter: 4 digits DC 12 2,0002,200 67.5 -1.51.5
BT-50_T09009

km/h V rpm rpm V

Tachometer

Fuel level gauge Water temperature gauge Odometer/ Tripmeter

Rated voltage Sound frequency Warning Output sound alarms pressure level Clock accuracy (reference value)*

V Hz dB s/day

* : If the clock accuracy varies largely from the reference value, battery deterioration or an audio unit (base unit) malfunction may have occurred.

09-22

Service Training BT-50

Body & Accessories


Instrument Cluster Overview

Instrumentation / Driver Info

BT-50_09023

No. 1 2 3 4 5 6 7 8 9 10 11 12

Item RFW indicator light 4x4 indicator light Red Zone Turn indicator light Speedometer gauge Water temperature gauge High-beam indicator light Front fog light indicator light Rear fog light indicator light Fuel level gauge Fuel-level warning light ABS warning light

Input signal source PCM RFW main switch Flasher control module VSS ECT sensor Headlight switch Front fog light relay Rear fog light relay Fuel gauge sender unit Fuel gauge sender unit ABS HU/CM Parking brake switch Brake fluid level sensor SAS control module Generator Immobilizer module Theft deterrent control module Oil pressure switch Door switches Sedimentor switch PCM PCM CKP sensor
BT-50_T09010

13 Brake system warning light 14 Airbag system warning light 15 Generator warning light 16 Security light 17 18 19 20 21 22 Oil pressure warning light Door ajar warning light Sedimentor warning light MIL Glow indicator light Tachometer gauge

Service Training BT-50

09-23

Instrumentation / Driver Info


Key Reminder Warning Alarm

Body & Accessories

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. Press and hold the odometer/tripmeter switch, and turn the ignition switch to the ON position. 2. Continue holding the odometer/tripmeter switch for approx. 5 s. until tESt is displayed on the LCD. 3. Release the odometer/tripmeter switch within 3 s after tESt is displayed.
4. 5.

When the odometer/tripmeter indicates check code 00, push the odometer/tripmeter switch to select a check code. Inspect the check codes according to the W/M.
Check item Door switch TNS relay Headlight switch Speedometer sensor PCM Speedometer Tachometer Buzzer Rear fog light relay Fuel-level warning light Engine key illumination Fuel gauge sender unit Fuel gauge ECT sensor Water temperature gauge Odometer/tripmeter (LCD) Warning and indicator lights Rear fog light switch Key reminder switch Front fog light relay Related items Key reminder warning alarm Lights-on reminder warning alarm Lights-on reminder warning alarm Each illumination light Headlight Rear fog light control system Speedometer Tachometer Speedometer Tachometer Buzzer Rear fog light indicator light Fuel-level warning light Engine key illumination Fuel gauge Fuel gauge Water temperature gauge Water temperature gauge Odometer/tripmeter (LCD) Warning and indicator lights Rear fog light control system Key reminder warning alarm Front fog light relay
BT-50_T09011

Check code 04 08 09 10 11 12 13 14 15 16 18 22 23 24 25 26 29 31 40

09-24

Service Training BT-50

Body & Accessories


Control System
Features
The control system of the BT-50 has the following new features:

Control System

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.

NOTE: For communication with M-MDS the control modules of the ABS (Antilock-Brake System) and the SAS are connected to DLC-2 via ISO (International Standard Organisation) bus.

Service Training BT-50

09-25

Control System
Wiring Diagram

Body & Accessories

BT-50_09027

09-26

Service Training BT-50

List of Abbreviations
ABS Anti-lock Brake System HU/CM Hydraulic Unit/Control Module Intake Air Temperature

A/C

Air Conditioning

IAT

APP

Accelerator Pedal Position

IC

Instrument Cluster

CAN

Controller Area Network

ISO

International Standard Organisation Intake Shutter Valve

CKP

CranKshaft Position

ISV

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 Differential

DLR

Daytime Running Light

MAF

Mass Air Flow

DTC

Diagnostic Trouble Code

MAP

Manifold Absolute Pressure

ECT

Engine Coolant Temperature

MIL

Malfunction Indicator Lamp

EGR

Exhaust Gas Recirculation

MC

Music Cassette

FEN

Fault ENgine

MD

Mini Disc

HVAC

Heating, Ventilation, Air Conditioning

M-MDS

Mazda-Modular Diagnostic System

Service Training Mazda BT-50

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

Service Training Mazda BT-50