Mazda B-Series Training Manual Download Page 103

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Transmission

S15M(X)-D Manual Transmission

Counter lever

Reverse gear

Washer

Countershaft rear bearing

3 Retaining

ring

20 Locknut

4 5

/reverse clutch hub and shift fork

component

21 Synchronizer

key

spring

Steel ball

Clutch hub sleeve

6 5

gear bearing inner race

Detent spring

Needle bearing

Detent ball

8 5

gear

/reverse shift rod

9 Synchronizer

ring

26 5

/reverse shift fork

10 Retaining

bolt

27 Synchronizer

key

Reverse idler gear shaft component

/reverse clutch hub

Reverse idler gear shaft

Output rear bearing

Thrust washer

Reverse counter gear

Reverse idler gear

Spacer

15 Friction

damper

32 5

counter gear

Thrust washer (Selective)

Counter lever shaft component

17 Spacer

(Selective)

Service Training BT-50

05-13

Summary of Contents for B-Series

Page 1: ...Training Manual Mazda BT 50 NMT 009 ...

Page 2: ...rmation 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 ...

Page 3: ...n 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 Locat...

Page 4: ...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 Rela...

Page 5: ... 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 Pa...

Page 6: ...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 Overvi...

Page 7: ...elf 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 ...

Page 8: ...Table of Contents Notes Service Training BT 50 ...

Page 9: ...Mazda s Zoom Zoom spirit in its individual and distinctive way The BT 50 has inherited the tough and reliable commercial truck performance of the B Series 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 pa...

Page 10: ...ion Plane body panels without the formerly used swage lines and other new styling elements contribute to a more brawny but clear and modern overall styling impression BT 50_00002 BT 50_00022 00 2 Service Training BT 50 ...

Page 11: ...enger 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 ...

Page 12: ... 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 ...

Page 13: ...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 ...

Page 14: ...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 ...

Page 15: ... while the serial number starts at 600 001 BT 50_00011 JMZ UN 1 A 1 2 0 W 6 0 0 0 0 1 Serial No Plant W Auto Alliance Thailand Dummy 0 Transmission 2 5 speed MTX Engine Type 1 WL C 2 5 L Body style B REG cab A F DBL cab E 2 RAP cab 1 Drive axle 1 2WD 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 ...

Page 16: ...General Information Engine Identification Number The engine identification number of the WL C engine is located on the timing gear side of the cylinder block BT 50_00012 00 8 Service Training BT 50 ...

Page 17: ...el Plate The model plate is located on the right side of the bulkhead in the engine compartment BT 50_00013 1 Driving direction Tyre Pressure Label The tyre pressure label is located on the driver s door as shown below BT 50_00014 Service Training BT 50 00 9 ...

Page 18: ...nit BT 50_T00002 REG 5 075 1 805 12 6 3 000 1 450 Rear track RAP DBL 2WD 1 587 1 798 1 886 1 895 2 795 3 010 3 080 3 030 Front 1 170 1 430 1 430 1 430 Rear 1 860 1 850 1 850 1 850 unbraked braked 1 600 BT 50_T00004 Max trailing load 750 3 000 Maximum Weight kg Item 4WD Gross axle weight Curb weight Gross vehicle weight REG Item 2 5 MZR CD WL C Engine Engine type Inline 4 Cyl DOHC 16 valve Turbocha...

Page 19: ...ront 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 only 2WD 3 2WD and 4WD 2 only 4WD Service Training BT 50 00 11 ...

Page 20: ...odel 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 ...

Page 21: ...pecific gravity Fuel lines and hoses Air intake system FUEL SYSTEM Air cleaner element 5 Fuel filter COOLING SYSTEM Engine oil 2 Engine oil filter 2 Drive belts 3 Replace first at 100 000 km 62 500 miles or 4 years after that every 2 years Replace every 200 000 km 125 000 miles or 11 years Engine coolant Cooling system including coolant level adjustment Maintenance Interval Number of months or kil...

Page 22: ... first Brake booster and hoses Disc brakes 7 Inspect every 200 000 km 125 000 miles Parking brake CHASSIS and BODY Brake lines hoses and connections Brake fluid 6 Drum brakes 7 Front and rear differential oil 4WD Drive shaft dust boots 4WD Propeller shaft joints 4WD Rear differential oil 2WD Power steering fluid lines hoses and connections Steering operation and linkages Manual transmission oil Fr...

Page 23: ...he 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 ...

Page 24: ...General Information Notes 00 16 Service Training BT 50 ...

Page 25: ...f 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 Engine speed 1 Power curve Y1 Engine power 2 Torque curve Y2 Engine torque Service T...

Page 26: ...WL C Engine Engine Overview BT 50_01002 01 2 Service Training BT 50 ...

Page 27: ...ype rocker arms Timing belt auto tensioner Specifications WL C Diesel 4 stroke Inline 4 cylinder Direct injection DOHC timing gear and belt driven 16 valves ml 2 499 mm 93 0 x 92 0 18 0 1 kPa 2 942 standard 2 648 minimum Open BTDC 10 Close ABDC 30 Open BBDC 40 Close ATDC 8 IN mm 0 10 0 16 EX mm 0 17 0 23 BT 50_T01001 Valve clearance engine cold Displacement Compression pressure Bore x stroke Item ...

Page 28: ...uction of the internal friction and hence of the engine s 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 Combustion chamber 3 Piston skirt coating 2 Cooling oil channel NOTE Oversize bearings for the crankshaft and connecting rods as well as oversize pistons are avai...

Page 29: ...ts Location BT 50_01007 1 Cylinder head cover 5 Cylinder head gasket 2 Upper camshaft bearing caps 6 Seal plate 3 Lower camshaft bearing case with injector sealing rings 7 Camshaft pulley 4 Cylinder head 8 Camshaft Service Training BT 50 01 5 ...

Page 30: ... 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 Exhaust camshaft 3 Oil passage B Intake camshaft 4 Location of cylinder no 1 1 Thrust force bearing boss 5 Hexagonal shaped surface 2 Oil bore NOTE The cylinder head surface mus...

Page 31: ... been adopted to lower the friction between camshaft lobe and rocker arm reducing the engine s mechanical loss BT 50_01009 1 Camshaft pulley 5 Helical gear 2 Camshaft 6 Timing belt auto tensioner 3 Rocker arm 7 Timing belt 4 Balancer shaft 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 5...

Page 32: ...igure below Otherwise the claw of the rocker arm might be damaged BT 50_01010 1 Cam lobe 4 Rocker arm 2 Adjusting screw 5 Claw 3 Locknut 6 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 Intake side camshaft pulley 3 Exhaust side camshaft pull...

Page 33: ...nch 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 Apply force max 39 Nm 3 Hole for fixing pin 2 Mounting bolts C B BT 50_01014 1 Rod 4 Spring 2 Seal 5 Oil 3 Plunger 6 Ball NOTE In case air has entered the pressure chamber of the auto tensioner it must be bled using a certain ...

Page 34: ...ming When replacing the timing belt the timing marks must be positioned as shown in the figure below BT 50_01013 1 Intake camshaft pulley 3 Timing mark 2 Exhaust camshaft pulley 4 High pressure pump pulley 01 10 Service Training BT 50 ...

Page 35: ... rpm kPa 410 570 Gear type Relief valve opening pressure reference value kPa 580 700 Oil cooler Water cooled kPa 164 200 Full flow paper element spin on type Bypass pressure kPa 80 120 Total dry engine 8 0 Oil replacement 6 8 Oil and oil filter replacement 7 0 API CF or ACEA B1 B3 B5 5W 30 e g Mazda genuine Dexelia oil BT 50_T01003 Oil cooler bypass valve opening pressure Grade Item Oil pressure r...

Page 36: ...50_01044 1 Oil jet valve 7 Oil cooler and oil filter body component 2 Oil pressure switch 8 Oil pan 3 Oil dipstick 9 Oil drain plug 4 Oil cooler 10 Oil strainer 5 Oil filter body 11 Oil outlet pipe 6 Oil filter 12 Oil pump 01 12 Service Training BT 50 ...

Page 37: ...haft 3 Turbocharger 14 Connecting rod bearing 4 Timing gears 15 Oil pump 5 Oil Strainer 16 Piston 6 Oil filter 17 Oil jet valve 7 Oil cooler 18 Oil pan 8 Oil cooler and oil filter body component 19 Oil passage 9 Camshaft 20 Oil relief passage 10 Orifice 21 Oil bypass passage 11 Balancer shaft Service Training BT 50 01 13 ...

Page 38: ...il Filter The spin on type oil filter consists of one full flow element The bypass element that has been additionally used on the filter WLT 3 engine has been dropped BT 50_01017 1 Full flow paper element 01 14 Service Training BT 50 ...

Page 39: ...ater cooled forced circulation L Without heater 8 8 With heater 9 4 Water pump Type Centrifugal V belt driven Type Wax bottom bypass Opening temperature C 80 84 Full open temperature C 95 Full open lift mm 8 5 or more Radiator Type Corrugated fin Cooling system cap Cap valve opening pressure kPa 93 2 122 6 Type Thermo modulation type Number of blades 9 Outer diameter mm 450 BT 50_T01005 Thermostat...

Page 40: ... BT 50_01045 1 Radiator cowling 5 Cooling fan 2 Water pump pulley 6 Coolant reserve tank 3 Thermostat 7 Radiator 4 Water pump 8 Cooling system cap NOTE To bleed the cooling system follow the instructions of the W M 01 16 Service Training BT 50 ...

Page 41: ... System Overview BT 50_01018 1 Coolant reserve tank 7 Heater 2 EGR cooler 8 Water pump 3 Cylinder head 9 Thermostat 4 Turbocharger 10 Radiator 5 Cylinder block 11 Coolant flow direction 6 Oil cooler Service Training BT 50 01 17 ...

Page 42: ...e 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 ...

Page 43: ... VGT 10 Glow plug cord 3 Check valve 11 Charge air cooler 4 VBC solenoid valve 12 VSC solenoid valve 5 Vacuum chamber 13 Glow plug relay 6 VBC vacuum actuator 14 MAP IAT no 1 sensor 7 Air cleaner 15 VSC vacuum actuator 8 MAF IAT no 2 sensor 16 Intake manifold Service Training BT 50 01 19 ...

Page 44: ...2 Check valve 11 Vacuum pump 3 Vacuum chamber 12 VSC vacuum actuator 4 VBC solenoid valve 13 VSC solenoid valve 5 MAF IAT no 2 sensor 14 VSC shutter valves 6 Air cleaner 15 MAP IAT no 1 sensor 7 VGT 16 Intake manifold 8 VBC vacuum actuator 17 To PCM 9 Guide blades 01 20 Service Training BT 50 ...

Page 45: ... 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 Boost sensor 3 PCM 2 IAT se...

Page 46: ...ger 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 VBC vacuum actuator 3 Exhaust gas flow 2 Intake air flow 01 22 Service Training BT 50 ...

Page 47: ...s 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 Secondary intake port 4 VSC vacuum actuator 2 Primary intake port 5 Intake manifold 3 VSC shutter valves BT 50_01023 Service Training BT 50 01 23 ...

Page 48: ...d 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 To vacuum pump 3 Vacuum chamber 2 To VBC solenoid valve 4 To EGR solenoid valve 01 24 ...

Page 49: ...ure 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 1 Similar to Mazda3 1 6 MZ CD 2 Similar to Mazda6 2 0 MZR CD Specifications High pressure pump at idle Max 32 160 2WD ...

Page 50: ...Fuel System WL C Engine Parts Location BT 50_01027 1 Fuel gauge sender unit 3 Vehicles with cargo box 2 Fuel tank 4WD 4 Vehicles without cargo box 01 26 Service Training BT 50 ...

Page 51: ... valve in fuel return line 6 Sedimentor switch 2 Fuel injectors 7 Fuel filter incl fuel warmer for cold regions 3 Fuel pressure sensor 8 Common rail 4 High pressure pump 9 Pressure limiter valve 5 Fuel metering valve Service Training BT 50 01 27 ...

Page 52: ...ressure limiter valve 8 High pressure pump 2 Check valve 9 Fuel filter 3 Fuel injector 10 Sedimentor switch 4 Common rail 11 Fuel tank 5 Fuel pressure sensor 12 To PCM 6 Fuel metering valve 13 Fuel flow 7 Fuel temperature sensor 01 28 Service Training BT 50 ...

Page 53: ... metering valve 3 Fuel temperature sensor 6 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 Connection fuel injector side 4 Common rail 2 Fuel pressure sensor 5 Pressure limiter val...

Page 54: ...r must be programmed into the PCM by means of M MDS refer to the chapter Maintenance and Repair BT 50_01048 1 Return fuel flow to fuel tank 7 Valve control plunger 2 Fuel flow from common rail 8 Nozzle needle 3 Injector head 9 Valve ball 4 Injector classification code A0 for the WL C engine 10 Orifice plate 5 Injector correction factor 11 Solenoid valve coil 6 Fuel injector NOTE The injector seali...

Page 55: ...ures Modified exhaust manifold Warm up system with exhaust shutter valve if equipped Parts Location BT 50_01034 1 Exhaust manifold 6 Warm up switch 2 Joint pipe 7 With exhaust shutter valve 3 Oxidation catalytic converter 8 Front pipe 4 Main silencer 9 VGT 5 Tail pipe Service Training BT 50 01 31 ...

Page 56: ...or 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 providin...

Page 57: ...xhaust shutter valve exhaust flange transfer lever stop screw actuation rod and vacuum actuator BT 50_01053 1 Transfer lever 5 Exhaust flange 2 Actuation rod 6 Pivot 3 Exhaust shutter valve vacuum actuator 7 Exhaust shutter valve 4 Stop screw 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...

Page 58: ...or 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 Rollover valves 4 Evaporative chamber 2 Vehicles with cargo box 5 Check valve two wa...

Page 59: ...T 50_01033 1 Oxidation catalytic converter 6 EGR control solenoid valve 2 EGR cooler 7 ISV solenoid valve full 3 EGR solenoid valve 8 ISV solenoid valve half 4 MAF sensor 9 EGR valve 5 ISV 10 Air filter Service Training BT 50 01 35 ...

Page 60: ...rol solenoid valve 3 EGR valve position sensor 11 Fuel tank 4 EGR valve 12 Rollover valves 5 MAF sensor 13 Check valve two way without cargo box 6 Oxidation catalytic converter 14 Evaporative chamber without cargo box 7 ISV solenoid valve full 15 To PCM 8 ISV solenoid valve half 01 36 Service Training BT 50 ...

Page 61: ...is 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 cu...

Page 62: ... Fully opened at normal driving for low EGR rate or no EGR 4 First vacuum actuator operates for high EGR rate and shortly when the engine is shut off 2 Fully closed when the engine is shut off 5 Second vacuum actuator operates shortly when the engine is shut off 3 Slightly opened to create vacuum for high EGR rate NOTE Function and operation of the ISV are as described for the Denso common rail sy...

Page 63: ...d on the B Series Specification WL C Voltage V 12 Type and capacity 5 hour rate Ah 95D31R 64 Output V A 12 70 Regulated voltage V 14 1 14 7 Self diagnosis function Equipped Type Coaxial reduction Output kW 2 2 BT 50_T01009 Battery Generator Item Starter Parts Location BT 50_01039 1 Starter 3 Generator 2 Additional battery for cold regions 4 Main battery Service Training BT 50 01 39 ...

Page 64: ...No 2 built into MAF sensor Thermistor MAF sensor Hot wire IAT sensor No 1 built into MAP sensor Thermistor MAP sensor Piezoelectric element ECT sensor Thermistor CMP sensor Hall element type CKP sensor Inductive type APP sensor Potentiometer EGR valve position sensor Potentiometer BARO sensor built into PCM Piezoelectric element Fuel temperature sensor Thermistor Fuel pressure sensor Piezoelectric...

Page 65: ... 4 Main relay 16 Fuel temperature sensor 5 Idle switch 17 Fuel metering valve 6 Brake switch 18 ECT sensor 7 DLC 2 Data Link Connector 19 MAP sensor IAT sensor no 1 8 CPP switch 20 Glow plug relay 9 A C switch 21 A C relay 10 DLC 1 22 EGR valve position sensor 11 Warm up switch 23 PCM with built in BARO sensor 12 MAF sensor IAT sensor no 2 24 CKP sensor Service Training BT 50 01 41 ...

Page 66: ...Control System WL C Engine System Overview BT 50_01037 01 42 Service Training BT 50 ...

Page 67: ...Vehicle speed signal 9 Fuel injectors 30 CAN Bus 10 CKP sensor 31 CPP switch 11 Glow plugs 32 A C relay 12 VSC solenoid valve 33 BARO sensor 13 MAP sensor IAT sensor no 1 34 PCM 14 Fuel pressure sensor 35 Glow plug relay 15 Fuel metering valve 36 MIL 16 Fuel temperature sensor 37 Glow indicator light 17 Sedimentor switch 38 Tachometer 18 ISV solenoid valve full 39 To PCM 19 ISV solenoid valve half...

Page 68: ...es half full Fuel pressure sensor Glow indicator light CMP sensor Glow plug relay CKP sensor A C relay Vehicle speed signal Immobiliser module A C switch MIL EGR valve position sensor Exhaust shutter solenoid valve Immobiliser module Warm up switch BT 50_T01007 Idle speed control Glow control Variable boost control Variable swirl control Fuel injection amount control Fuel injection timing control ...

Page 69: ...or no 1 x ECT sensor x x x x x x x x x x Fuel temperature sensor x x BARO sensor x x x x x x MAP sensor x Fuel pressure sensor x x CMP sensor x x x CKP sensor x x x x x x x x x Vehicle speed signal x x x A C switch x EGR valve position sensor x Warm up switch x x Immobiliser related information x Output device Fuel metering valve x x Fuel injectors x x x x VBC solenoid valve x VSC solenoid valve x...

Page 70: ...nstalled to the primary mass of the flywheel and has 58 projections with a space of 6 crank angle between each projection A space of 18 defines a determined crankshaft position BT 50_01050 1 CKP sensor 3 Flywheel 2 Pulse wheel NOTE When the CKP signal fails during engine operation the engine stalls and will not start again 01 46 Service Training BT 50 ...

Page 71: ... on the intake camshaft pulley covers 26 camshaft rotation angle BT 50_01051 1 CMP sensor 4 Pulse wheel 2 PCM 5 Intake camshaft pulley 3 CPU 6 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 ...

Page 72: ...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 driver s side in the passenger compartment at the lower A pillar On vehicles with U K specification a cover with shear bolts secures the PCM BT 50_01040 1 PC...

Page 73: ...or 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 wh...

Page 74: ...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 From main relay 5 Glow plugs 2 Glow plug relay 6 Glow plug circuit fuse 3 PCM 7 From battery 4 Glow indicator light IC 01 50 Service Training BT 50 ...

Page 75: ...ndication 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 M MDS to the DLC 2 of the vehicle and select the option ToolboxÆSelf TestÆModulesÆ PCM ÆRetrieve 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 ...

Page 76: ...h OFF ON DTCCNT DTC count C V EGRV2 EGR control solenoid valve OFF ON A FIP_SCV Fuel metering valve A FLT Fuel temperature C FRP Fuel rail pressure Pa GP_LMP Glow indicator light OFF ON GPC Glow plug relay OFF ON IASV ISV solenoid valve half OFF ON IASV2 ISV solenoid valve full OFF ON C V INGEAR Load no load condition OFF ON IVS Idle switch OFF Idle Idle LOAD Engine load BT 50_T01010a High pressur...

Page 77: ...on Test The simulation test function allows activating certain PIDs of the PCM Therefore connect the M MDS to the vehicle and select the option ToolboxÆDataloggerÆ ModulesÆPCM KOEO KOER ACCS A C relay OFF ON x EGRV2 EGR control solenoid valve OFF ON x GP_LMP Glow indicator light OFF ON x GPC Glow plug relay OFF ON x IASV ISV solenoid valve half OFF ON x IASV2 ISV solenoid valve full OFF ON x INJ_1...

Page 78: ...ht 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 ToolboxÆPowertrainÆData ResetÆMAF sensor and...

Page 79: ...ResetÆPCM 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 fur...

Page 80: ...Control System WL C Engine Notes 01 56 Service Training BT 50 ...

Page 81: ...cab 2 06 1 Caster angle reference value Suspension type Fuel tank full engine coolant and engine oil at specified level and spare tire jack and tools in designated position Stabilizer Spring type Shock absorber type Cylindrical double acting 0 35 1 Leaf spring Semi elliptic leaf spring Spring type Rear suspension RAP cab 0 44 1 DBL cab 0 45 1 Suspension type Front wheel alignment Unloaded conditio...

Page 82: ...50_02002 1 Front shock absorber 4 Lower arm 2 Torsion bar spring 5 Tension rod 3 Upper arm 6 Front stabiliser Front Suspension 4WD BT 50_02003 1 Shock absorber 4 Lower arm 2 Torsion bar spring 5 Front stabiliser 3 Upper arm 02 2 Service Training BT 50 ...

Page 83: ...Suspension Rear Suspension BT 50_02004 1 4WD 3 Shock absorber 2 2WD 4 Leaf spring Service Training BT 50 02 3 ...

Page 84: ...odified 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 15 inch standard steel rim 2WD 3 15 inch aluminium alloy rim 2WD 2 15 inch design steel rim 4WD 4 16 inch aluminium alloy rim 4WD 02 4 Service Training BT 50 ...

Page 85: ...rsons 210 210 Full load 290 270 mm Nm Radial direction Axial direction BT 50_T02002 375 1 6 210 1 5 max 2 0 max 215 70R15C 106 104S Front Rear 220 Remaining tread 88 2 117 6 210 210 Wheel and tyre runout mm Size Air pressure kPa Tyre Wheel nut tightening torque Wheel and tyre Specification Wheel Offset Pitch circle diameter 15 x 61 2J 20 139 7 Item Size Material Service Training BT 50 02 5 ...

Page 86: ...Wheels and Tyres Suspension Notes 02 6 Service Training BT 50 ...

Page 87: ...2 35 Hypoid gear Straight bevel gear 8 00 3 727 Grade API service GL 5 Viscosity Above 18 C SAE 90 Below 18 C SAE 80 Capacity L 1 9 BT 50_T03001 Final gear ratio Final gear ratio _ Differential gear Ring gear size Type Differential oil Inch Inch Ring gear size Front differential Reduction gear SAE 90 Type Differential oil Support type Casing Hypoid gear mm mm Length Diameter Straight bevel gear 8 ...

Page 88: ...same as used for the B Series with separate RFW control module Parts Location BT 50_03001 1 RFW main switch 7 RFW vacuum actuator 2 Transfer neutral switch 8 Joint shaft component 3 4WD switch 9 Lock solenoid valve 4 One way check valve 10 Free solenoid valve 5 RFW switch 11 PCM 6 RFW unit 03 2 Service Training BT 50 ...

Page 89: ...r light 12 Lock solenoid valve 3 To battery 13 Free solenoid valve 4 Front differential 14 RFW main switch 5 Lock 15 PCM 6 Free 16 Vehicle battery 7 RFW vacuum actuator 17 Engine switch 8 RFW unit 18 Selector lever 9 RFW switch 19 4WD switch 10 To vacuum pump 20 Transfer neutral switch Service Training BT 50 03 3 ...

Page 90: ...1879 RFW free solenoid valve open circuit P1880 RFW free solenoid valve circuit short to battery P1885 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 Applicable component Condition Test condition 4WDMODE_L 4WD indicator light OFF ON HUBLOCK RFW lock solenoid val...

Page 91: ...D S15MX D Hydraulic Diaphragm Set load N 10 100 Outer diameter mm 250 Inner diameter mm 155 Suspended 5 2 Full stroke mm 152 mm 15 87 mm 22 23 SAE J1703 FMVSS 116 DOT 3 BT 50_T05001 Clutch fluid type Pedal ratio Clutch disc Clutch pedal Type Clutch master cylinder inner diameter Clutch release cylinder inner diameter Spring type Clutch control Clutch cover Item Manual transmission type Service Tra...

Page 92: ...on Parts Location BT 50_05013 1 Dual mass flywheel 5 Clutch release cylinder 2 Clutch disc 6 Clutch release collar 3 Clutch cover 7 Clutch pedal 4 Clutch release fork 8 Clutch master cylinder 05 2 Service Training BT 50 ...

Page 93: ...k 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 1 One way valve 2 Pulsation damper Service Training BT 50 05 3 ...

Page 94: ...lywheel The dual mass flywheel compensates torque fluctuations thus reducing rattle noises of the transmission gears BT 50_05014 1 Torsional vibration damping spring 3 Primary flywheel 2 Secondary flywheel 05 4 Service Training BT 50 ...

Page 95: ...asically the same They have superseded the R15M X D transmission used on the B Series Features Construction and operation of the S15M X D transmission are quite similar to the P66M D 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 f...

Page 96: ...5 Type Manual Transmission fluid type A Capacity approx quantity ml 220 260 1 000 2 020 Manual Transmission fluid type A Capacity approx quantity L 1 85 BT 50_T05002 5GR Transmission case oil Type High Transfer ratio Gear ratio 1GR 2GR 3GR 4GR Item Transmission type Transmission Transfer control Shift assist Type Transfer case oil S15MX D Shift control case oil S15M D Reverse Low 05 6 Service Trai...

Page 97: ...nsmission Overview BT 50_05002 A Extension housing S15M D 5 Reverse idler gear B Transfer case S15MX D 6 Reverse gear 1 Output shaft 7 5th gear 2 3rd gear 8 Counter shaft 3 2nd gear 9 Input shaft 4 1st gear Service Training BT 50 05 7 ...

Page 98: ...S15M X D Manual Transmission Transmission Power Flow BT 50_05003 1st Gear BT 50_05004 2nd Gear BT 50_05005 3rd Gear 05 8 Service Training BT 50 ...

Page 99: ...Transmission S15M X D Manual Transmission BT 50_05006 4th Gear BT 50_05007 5th Gear BT 50_05008 Reverse Gear Service Training BT 50 05 9 ...

Page 100: ...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 Section A A 3 Control rod 2 Shift mechanism unit 4 Shift rod 05 10 Service Training BT 50 ...

Page 101: ...d 3 Plastic spring seat 13 3rd 4th shift rod 4 Detent ball 14 Retaining ring 5 Oil baffle plate 15 Plain washer 6 Retaining bolt 16 Push pin 7 3rd 4th shift fork 17 5th reverse shift rod end 8 Stopper block 18 Rubber plug 9 1st 2nd shift fork 19 3rd 4th shift rod end 10 5th reverse shift rod 20 1st 2nd shift rod end Service Training BT 50 05 11 ...

Page 102: ...erse Gear Mechanism The shift fork for the 5th reverse gear is mounted on an additional shift rod inside the gearbox It is operated by the 5th reverse shift rod in the shift mechanism unit via the counter lever BT 50_05011 05 12 Service Training BT 50 ...

Page 103: ...pring 7 Needle bearing 24 Detent ball 8 5th gear 25 5th reverse shift rod 9 Synchronizer ring 26 5th reverse shift fork 10 Retaining bolt 27 Synchronizer key 11 Reverse idler gear shaft component 28 5th reverse clutch hub 12 Reverse idler gear shaft 29 Output rear bearing 13 Thrust washer 30 Reverse counter gear 14 Reverse idler gear 31 Spacer 15 Friction damper 32 5th counter gear 16 Thrust washe...

Page 104: ...echanism 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 Shifting directly from 5th to reverse gear locked 2 Selector in 5th gear position B Shifting from 5th to reverse gear via neutral released 3 Lockout mechanism released 1 Selector locked 4 Selector in Neutral position 05 14 Service Training BT 50 ...

Page 105: ...ition Evaporator temperature Magnetic clutch control ON 3 0 0 6 Item Regular amount approx Refrigerant Type Heating capacity Cooling capacity Specification R 134a 7 000 475 Swash plate 154 4 86 4 012 Sirocco FD46XG 180 Multiflow sub cooling type Single tank drawn cup 220 48 Reheat full air mix type Expansion valve 10 46 220 Synthetic zeolite Internal regulating type Type Electrical consumption dur...

Page 106: ... BT 50_07001 1 Heater air distribution unit 6 High pressure charging valve 2 Cooling unit 7 Condenser 3 Blower unit 8 Receiver drier 4 Low pressure charging valve 9 Compressor 5 Refrigerant pressure switch 07 2 Service Training BT 50 ...

Page 107: ...asic System Refrigerant System BT 50_07006 1 Low pressure charging valve 5 Condenser 2 Expansion valve 6 Evaporator 3 High pressure charging valve 7 A C Compressor 4 Receiver drier Service Training BT 50 07 3 ...

Page 108: ...s the following new features Newly designed control panel with larger dials Parts Location BT 50_07003 1 A C relay 5 Blower motor 2 Climate control unit 6 Refrigerant pressure switch 3 Evaporator temperature sensor 7 Magnetic clutch 4 Blower resistor 07 4 Service Training BT 50 ...

Page 109: ...M 7 A C switch 2 A C relay 8 Fan switch 3 Refrigerant pressure switch 9 Blower resistor 4 Magnetic clutch 10 Blower motor 5 Climate control unit 11 Blower relay 6 A C Amplifier Thermoswitch incl evaporator temperature sensor Service Training BT 50 07 5 ...

Page 110: ...igned cable operated climate control unit has been adopted BT 50_07005 1 A C switch 5 Fan switch 2 Rear window defroster switch 6 Rec Fresh lever 3 Airflow mode selector dial 7 Temperature control dial 4 Climate control unit 07 6 Service Training BT 50 ...

Page 111: ... 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 ...

Page 112: ...tion BT 50_08001 1 Airbag system warning light 5 Side airbag sensor 2 Clock spring 6 Side airbag module 3 Seat belt pretensioner 7 SAS control module 4 Driver side airbag module 8 Passenger side airbag module 08 2 Service Training BT 50 ...

Page 113: ...nger side side airbag sensor 4 Driver side seat belt pretensioner 12 Driver side side airbag sensor 5 Driver side side airbag module 13 IC 6 Passenger side seat belt pretensioner 14 Airbag system warning light 7 Passenger side side airbag module 15 DLC 2 8 Poor connection detection bar connector no 2 16 Poor connection detection bar connector no 1 Service Training BT 50 08 3 ...

Page 114: ... receives from the internal micro mechanical sensor and the side airbag sensors If the acceleration deceleration caused by a frontal or side impact exceeds a predetermined threshold the SAS control module triggers the airbags pre tensioners or only the side airbags with a DC signal BT 50_08003 1 SAS control module 3 Connector 2 Driving direction 08 4 Service Training BT 50 ...

Page 115: ...sures the acceleration deceleration of the vehicle during a side impact and transmits this information to the SAS control module BT 50_08004 1 Protection cover 2 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 Inflator 3 Airbag 2 Module c...

Page 116: ...ve the excess slack from the seat belt in case of an accident The operation is similar to that of the MX 5 NC seat belt pretensioners BT 50_08006 1 Spindle 8 Clutch roller 2 Spring seat 9 Cylinder 3 Spring shaft 10 Gas generator 4 Spring 11 Cap nut 5 Spring case 12 Rack 6 Cover 13 Base 7 Gear 08 6 Service Training BT 50 ...

Page 117: ... 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 Priority ranking B1933 21 7 Passenger side air bag module...

Page 118: ...rcuit state 1 IG_V_2 System IG1 voltage value V OD_CRST_D1 On demand driver side side airbag sensor communication state OK FAULT OD_CRST_D2 On demand driver side side airbag sensor circuit state OK FAULT OD_CRST_P1 On demand passenger side side airbag sensor communication state OK FAULT OD_CRST_P2 On demand passenger side side airbag sensor circuit state OK FAULT OD_DAB1_ST On demand driver side a...

Page 119: ...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 ...

Page 120: ... 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 ...

Page 121: ...e firm securing of load BT 50_09004 1 Vertical guiding grooves 3 Inner rope hook 2 Horizontal guiding groove 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...

Page 122: ...f the BT 50 have following new features Rear window defroster switch installed in centre panel Power outer mirror switch installed in driver door trim Enlarged power outer mirrors BT 50_09006 1 Rear window defroster switch BT 50_09007 1 Power outer mirror switch 09 4 Service Training BT 50 ...

Page 123: ... 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 Engine switch 6 Theft deter...

Page 124: ...rrent control module 3 Security light 11 Door key cylinder switches 4 Door switches 12 Door lock control module 5 Driver s door lock link switch 13 Keyless control module 6 Rear door lock link switches 14 Hazard warning switch 7 Bonnet switch 15 Flasher control module 8 Theft deterrent horn relay 16 Key reminder switch 09 6 Service Training BT 50 ...

Page 125: ...es 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 Side step 5 Side protector 2 Wheel arch extension 6 Front flap 3 Rear bumper 7 Front bumper 4 Rope hook Service Training BT 50 09 7 ...

Page 126: ...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 Bumper reinforcement 4 Front bumper 2 Lower wheel arch extension 5 Front hole cover without front fog lights 3 Front hole cover with front fog lights 09 8 Service Training BT 50 ...

Page 127: ...ard 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 Sliding upper glove compartment 5 Cup holder 2 Glove compartment 6 Cup holder except REG cab 3 Storage compartment 7 Centre console 4 Door pocket Service Training BT 50 09 9 ...

Page 128: ...flector 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 Headlight bulb 4 Section B B 2 Front turn light bulb 5 Section A A 3 Pa...

Page 129: ...ories Lighting System Rear Combination Light BT 50_09013 1 Brake taillight bulb 4 Section A A 2 Turn light bulb 5 Rear combination light 3 Back up light bulb LH Rear fog light bulb RH Service Training BT 50 09 11 ...

Page 130: ...itch 7 Hazard warning switch 4 Headlight levelling switch 8 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 ...

Page 131: ...Body Accessories Lighting System Wiring Diagram BT 50_09028 Service Training BT 50 09 13 ...

Page 132: ...r system of the BT 50 has the following new features Intermittent wiper function with adjustable interval Parts Location BT 50_09016 1 Wiper and washer switch 5 Wiper arm and blade 2 Washer nozzle 6 Washer motor 3 Washer hose 7 Washer tank 4 Wiper motor 09 14 Service Training BT 50 ...

Page 133: ... Wiper Washer System Wiring Diagram BT 50_09024 1 Wiper switch 5 Auto stop switch 2 Washer switch 6 Interval relay 3 Washer motor 7 Interval control switch 4 Wiper motor 8 One touch switch Service Training BT 50 09 15 ...

Page 134: ...tibility 16 pin connector 6 Loudspeaker system comprising four door speakers and two tweeters OBD system Specifications Audio Unit With RDS Without RDS V LW kHz 153 279 MW kHz 531 1602 522 1629 531 1629 FM MHz W ohm BT 50_T09004 Output impedance 35 4 4 87 5 108 Frequency band AM Audio amplifier maximum output power Item Rated voltage Specification 12 Type A Type B Speakers DBL cab RAP cab Maximum ...

Page 135: ...es Entertainment Parts Location BT 50_09017 1 Roof antenna 6 Audio unit 2 Tweeter LH 7 Antenna cable 3 Rear speaker RH 8 Front speaker RH 4 Rear speaker LH 9 Tweeter RH 5 Front speaker LH Service Training BT 50 09 17 ...

Page 136: ...r RH 10 Lower module 4 Front speaker RH 11 Vehicle speed signal 5 Front speaker LH 12 TNS signal 6 Tweeter LH 13 Centre panel unit 7 Rear speaker RH NOTE A telephone mute function is only available by using an appropriate connector adapter which is provided as accessory part by Mazda Motor Europe 09 18 Service Training BT 50 ...

Page 137: ... panel The base unit with CD player is different from the one with 6 CD changer BT 50_09018 1 Base unit 4 Cover 2 Audio unit 5 Centre panel 3 Lower module 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 ...

Page 138: ...he 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...

Page 139: ...Body Accessories Power Systems Power Systems Parts Location BT 50_09020 1 Main fuse block 2 Fuse block Service Training BT 50 09 21 ...

Page 140: ... Stepper motor type Reset to zero type Fuel gauge sender unit Rated voltage V DC 12 Stepper motor type Medium range stabilised type ECT sensor Rated voltage V DC 12 LCD Odometer 6 digits Tripmeter 4 digits Rated voltage V DC 12 Sound frequency Hz 2 000 2 200 Output sound pressure level dB 67 5 s day 1 5 1 5 BT 50_T09009 Clock accuracy reference value If the clock accuracy varies largely from the r...

Page 141: ...ht Rear fog light relay 10 Fuel level gauge Fuel gauge sender unit 11 Fuel level warning light Fuel gauge sender unit 12 ABS warning light ABS HU CM 13 Brake system warning light Parking brake switch Brake fluid level sensor 14 Airbag system warning light SAS control module 15 Generator warning light Generator 16 Security light Immobilizer module Theft deterrent control module 17 Oil pressure warn...

Page 142: ...ect a check code 5 Inspect the check codes according to the W M Check code Check item Related items 04 Door switch Key reminder warning alarm Lights on reminder warning alarm 08 TNS relay Lights on reminder warning alarm Each illumination light 09 Headlight switch Headlight Rear fog light control system 10 Speedometer sensor Speedometer 11 PCM Tachometer 12 Speedometer Speedometer 13 Tachometer Ta...

Page 143: ... 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 T...

Page 144: ...Control System Body Accessories Wiring Diagram BT 50_09027 09 26 Service Training BT 50 ...

Page 145: ...rature EGR Exhaust Gas Recirculation FEN Fault ENgine HVAC Heating Ventilation Air Conditioning HU CM Hydraulic Unit Control Module IAT Intake Air Temperature IC Instrument Cluster ISO International Standard Organisation ISV Intake Shutter Valve KLN K LiNe LCD Liquid Crystal Display LED Light Emitting Diode LSD Limited Slip Differential MAF Mass Air Flow MAP Manifold Absolute Pressure MIL Malfunct...

Page 146: ... 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 VSC Variable Swirl Control VSS Vehicle Speed Sensor VIN Vehicle Identification Number Service Training Mazda BT 50 ...

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