MAZDA BT-50 User Manual
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
th
5
/ 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, Mazda’s present pick-up truck. The
aim of the BT-50 development team was to create a new pickup model in line with the
current model range delivering Mazda’s Zoom-Zoom spirit in its individual and distinctive
way.
• The BT-50 has inherited the tough and reliable commercial truck performance of the BSeries. 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
– DBL (DouBLe) Cabin, available in 4WD layout
BT-50_00009
BT-50_00010
00-6 Service Training BT-50
General Information
y
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.
JMZ UN 1 A 1 2 0 W 6 0 0 0 0 1
Serial No.
Plant
Dumm
Transmission
Engine Type
Body style
Drive axle
Vehicle type UN = Mazda BT-50
W= Auto Alliance Thailand
0
2 = 5 speed MTX
1 = WL-C (2.5 L)
B = REG cab (A)*
F = DBL cab (E)*
2 = RAP cab (1)*
1 = 2WD
8 = 4WD
BT-50_00011
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.
1 Driving direction
Tyre Pressure Label
• The tyre pressure label is located on the driver’s door as shown below.
BT-50_00013
BT-50_00014
Service Training BT-50 00-9
General Information
(
Technical Data
Item Unit
2WD
Overall length (w/o rear step bumper)
Overall width (AWD models with Overfenders) 1,715
Overall height (unladen) 1,620
Front track
mm
1,445
1,450Rear track
REG
1,745
1,750 *
RAP DBL
4WD
5,075
1,805
*1
2
1,445
1,495
1,440
1,470
Wheelbase 2,985
Ground clearance (unladen) 181
Maximum fording depth 300
Angle of approach (unladen) 24 32
Angle of departure (unladen) 26 27
°
Minimum turning circle (wall-to-wall) m 12
*1
P235/75R15 *2 245/70R16
3,000
207
450
12.6
Maximum Weight (kg)
Curb weight
Gross vehicle weight
Gross axle weight
Max.trailing load
Item
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
REG
RAP DBL
4WD
750
3,000
*1
1,755
1,760 *
*1
*2
*1
*2
BT-50_T00002
2
BT-50_T00004
Item 2.5 MZR-CD (WL-C) Engine
Engine type Inline 4 Cyl., DOHC 16-valve, Turbocharged w.Intercooler
Displacement
2,499 cm
3
Bore x stroke 93 x 92 mm
Compression ratio 18.0 : 1
Max. power
Max. torque
105 kW
143 PS) at 3,500 min
330 Nm at 1,800 min
-1
-1
Emission standard Euro 4
Transmission 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.
1 only 2WD 3 2WD and 4WD
2 only 4WD
BT-50_00023
Service Training BT-50 00-11
General Information
Towing
• The towing hooks on the 2WD model are different from the 4WD model.
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_00020
4WD
1 Towing hook 2
Tie-down hooks
BT-50_00021
00-12 Service Training BT-50
General Information
y
Scheduled Maintenance Table
Number of months or kilometers (miles), whichever comes first
Maintenance Interval
ENGINE
Engine valve clearance
Engine timing belt
Engine timing belt auto tensioner*
Engine oil
Engine oil filter
Drive belts
*2
*1
*2
*3
COOLING SYSTEM
Cooling system (including coolant level
adjustment)
Engine coolant
FUEL SYSTEM
Air cleaner element
Fuel filter
Fuel lines and hoses
*5
EMISSION CONTROL SYSTEM
Air intake system
ELECTRICAL SYSTEM
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
1
FL22 t
pe
Others
II
Replace every 120,000 km (75,000 miles)
Replace every 120,000 km (75,000 miles)
RRRRRRRRR
RRRRRRRRR
IIIIIIIII
IIII
*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
CCRCCRCCR
RRRR
IIIIIIIII
IIIIIIIII
Battery electrolyte level and specific gravity
IIIIIIIII
BT-50_T00006
Service Training BT-50 00-13
General Information
Number of months or kilometers (miles), whichever comes first
Maintenance Interval
CHASSIS and BODY
Brake lines, hoses and connections
Brake fluid
Parking brake
*6
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
IIII
RRRR
IIIIIIIII
Brake booster and hoses
Disc brakes
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) I I R I I
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
*7
*7
*8
IIIIIIIII
IIIIIIIII
RIRIRIRIR
IIIIIIIII
IIIIIIIII
TTTTTTTTT
IIIIIIIII
Inspect every 200,000 km (125,000 miles)
IIII
IIII
IIRI
IRIR
IIII
LLLL
RRRR
Inspect every 80,000 km (50,000 miles) or 5 years
Inspect annually
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 Engine speed 1 Power curve
Y1 Engine power 2 Torque curve
Y2 Engine torque
Service Training BT-50 01-1
WL-C Engine Engine
Overview
BT-50_01002
01-2 Service Training BT-50
WL-C Engine Mechanical
Mechanical
Features
• The mechanical system of the WL-C engine has the following new features:
– Pistons with integrated combustion chamber
– Coated piston skirt
– Reduced compression ratio
– Newly constructed aluminium alloy cylinder head
– Double overhead camshafts (driven by a timing belt)
– Four valves per cylinder
– Adjustable roller-type rocker arms
– Timing belt auto tensioner
Specifications
Item
Type
Cylinder arrangement and number
Combustion chamber
Valve system
Displacement
Bore x stroke
Compression ratio
Compression pressure
IN
Valve timing
EX
Valve clearance
(engine cold)
IN mm 0.10-0.16
EX mm 0.17-0.23
Specification
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
BT-50_T01001
Service Training BT-50 01-3
Mechanical WL-C Engine
Piston
• In accordance with the adoption of the common rail injection system, the piston head
shape now incorporates the combustion chamber. Due to the modified piston shape the
compression ratio is reduced from 21.6: 1 on the WLT-3 engine to 18.0: 1.
• A reduction of the internal friction and hence of the engine’s mechanical loss has been
achieved by coating of the piston skirt area.
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 available in various dimensions (refer to Engine W/M).
01-4 Service Training BT-50
WL-C Engine Mechanical
Cylinder Head
Parts 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
4 Cylinder head 8 Camshaft
7 Camshaft pulley
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 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 must not be machined. If necessary, the cylinder head
must be replaced (refer to Engine W/M).
01-6 Service Training BT-50
Loading...