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
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, 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 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 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 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)

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

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

General Information

Technical Data

Item	Unit	REG			RAP	DBL
		2WD			4WD
Overall length (w/o rear step bumper)				5,075
Overall width (AWD models with Overfenders)		1,715		1,805
Overall height (unladen)		1,620		1,745 *1		1,755 *1
				1,750 *2		1,760 *2
Front track		1,445		1,445 *1
	mm			1,495 *2
Rear track		1,450		1,440 *1
				1,470 *2
Wheelbase		2,985		3,000
Ground clearance (unladen)		181		207
Maximum fording depth		300		450
Angle of approach (unladen)	°	24		32
Angle of departure (unladen)		26		27
Minimum turning circle (wall-to-wall)	m	12		12.6
*1 P235/75R15 *2 245/70R16					BT-50_T00002

Item				Maximum Weight (kg)
			REG			RAP	DBL
		2WD				4WD
Curb weight		1,587		1,798		1,886	1,895
Gross vehicle weight		2,795		3,010		3,080	3,030
Gross axle weight	Front	1,170		1,430		1,430	1,430
	Rear	1,860		1,850		1,850	1,850
Max.trailing load	unbraked				750
	braked	1,600			3,000
							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 cm3
Bore x stroke	93 x 92 mm
Compression ratio	18.0 : 1
Max. power	105 kW (143 PS) at 3,500 min-1
Max. torque	330 Nm at 1,800 min-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.

BT-50_00023

1	only 2WD	3 2WD and 4WD
2	only 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

1Towing 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

Maintenance Interval

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

ENGINE

Engine valve clearance

I

I

Engine timing belt*1

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

Engine timing belt auto tensioner*1

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

Engine oil*2

R

R

R

R

R

R

R

R

R

Engine oil filter*2

R

R

R

R

R

R

R

R

R

Drive belts*3

I

I

I

I

I

I

I

I

I

COOLING SYSTEM

Cooling system (including coolant level

I

I

I

I

adjustment)

FL22 type *4

Replace

every

200,000

km (125,000 miles) or 11 years

Engine coolant

Others

Replace first at 100,000 km (62,500 miles) or 4 years;

after that every 2 years

FUEL SYSTEM

Air cleaner element *5

C

C

R

C

C

R

C

C

R

Fuel filter

R

R

R

R

Fuel lines and hoses

I

I

I

I

I

I

I

I

I

EMISSION CONTROL SYSTEM

Air intake system

I

I

I

I

I

I

I

I

I

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

Number of months or kilometers (miles), whichever comes first

Maintenance Interval

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

I

I

I

I

Brake fluid *6

R

R

R

R

Parking brake

I

I

I

I

I

I

I

I

I

Brake booster and hoses

Inspect every 200,000 km (125,000 miles)

Disc brakes*7

I

I

I

I

I

I

I

I

I

Drum brakes*7

I

I

I

I

Power steering fluid, lines, hoses and

I

I

I

I

connections

Steering operation and linkages

I

I

I

I

I

I

I

I

I

Manual transmission oil

I

I

R

I

I

Rear differential oil (2WD)

I

R

I

R

Front and rear differential oil (4WD)

R

I

R

I

R

I

R

I

R

Transfer oil (4x4)

I

I

R

I

I

Drive shaft dust boots (4WD)

I

I

I

I

Propeller shaft joints (4WD)

L

L

L

L

Front and rear suspension and ball joints

I

I

I

I

I

I

I

I

I

Front wheel bearing grease (2WD) *8

R

R

R

R

Wheel bearing axial play

I

I

I

I

I

I

I

I

I

Exhaust system and heat shields

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

Bolts and nuts on chassis and body

T

T

T

T

T

T

T

T

T

Body condition (for rust, corrosion and

Inspect annually

perforation)

Tyres (including spare tyre ) with inflation

I

I

I

I

I

I

I

I

I

pressure adjustment

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			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)
	IN		Open BTDC (°)		10
Valve timing			Close ABDC (°)		30
	EX		Open BBDC (°)		40
			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

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	7	Camshaft pulley
	injector sealing rings
4	Cylinder head	8	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	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