Manual BT-50 en

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
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
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
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
Table of Contents
Notes:
General Information
General Information
Product Concept
The new Mazda BT-50 supersedes the B-Series, Mazdas present pick-up truck. The aim of the BT-50 development team was to create a new pickup model in line with the current model range delivering Mazdas Zoom-Zoom spirit in its individual and distinctive way. The BT-50 has inherited the tough and reliable commercial truck performance of the BSeries. Simultaneously it presents a new fresh body styling and technologies that customers enjoy on passenger cars and also demand more and more for pick-up trucks. The BT-50 is offered with RWD (Rear Wheel Drive) layout as 2WD or as manually activated part-time 4WD.
BT-50_00001
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
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
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
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
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
General Information
Vehicle Identification Number
The VIN is located on the outside of the right chassis member (visible from the right front wheel arch). The model code of the BT-50 has remained UN, while the serial number starts at 600,001.
BT-50_00011
JMZ UN 1
0 W
600001
Serial No. Plant W= Auto Alliance Thailand Dummy 0 Transmission 2 = 5 speed MTX Engine Type 1 = WL-C (2.5 L) B = REG cab (A)* F = DBL cab (E)* Body style 2 = RAP cab (1)* 1 = 2WD Drive axle 8 = 4WD Vehicle type UN = Mazda BT-50
World manufacturer indication JMZ = European (L.H.D., U.K.)
* without cargo box
BT-50_T00001
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
General Information
Other Vehicle Information Labels
Model Plate The model plate is located on the right side of the bulkhead in the engine compartment.
BT-50_00013
Driving direction
Tyre Pressure Label The tyre pressure label is located on the drivers door as shown below.
BT-50_00014
00-9
General Information
Technical Data
Item Overall length (w/o rear step bumper) Overall width (AWD models with Overfenders) Overall height (unladen) Front track Rear track Wheelbase Ground clearance (unladen) Maximum fording depth Angle of approach (unladen) Angle of departure (unladen) Minimum turning circle (wall-to-wall)
*1
Unit
REG 2WD 1,715 1,620 1,445 1,450 2,985 181 300 24 26 12
RAP 4WD 5,075 1,805 *1 1,745 2 1,750 * *1 1,445 *2 1,495 *1 1,440 *2 1,470 3,000 207 450 32 27 12.6
DBL
1,755 2 1,760 *
*1
mm
P235/75R15
*2
245/70R16
BT-50_T00002
Item Curb weight Gross vehicle weight Gross axle weight Max.trailing load Front Rear unbraked braked 1,600 2WD 1,587 2,795 1,170 1,860
REG
Maximum Weight (kg) RAP 4WD 1,798 1,886 3,010 1,430 1,850 750 3,000 3,080 1,430 1,850
DBL 1,895 3,030 1,430 1,850
BT-50_T00004
Item Engine type Displacement Bore x stroke Compression ratio Max. power Max. torque Emission standard Transmission
2.5 MZR-CD (WL-C) Engine Inline 4 Cyl., DOHC 16-valve, Turbocharged w.Intercooler 2,499 cm3 93 x 92 mm 18.0 : 1 105 kW (143 PS) at 3,500 min-1 330 Nm at 1,800 min-1 Euro 4 5-speed manual (S15M(X)-D)
BT-50_T00005
00-10
General Information
Jacking and Lifting
The front of the vehicle can be lifted with a jack near the centre of the front crossmember.
NOTE: The jacking point on the front axle for the 2WD is different to the 4WD model.
BT-50_00023
1 2
only 2WD only 4WD
2WD and 4WD
00-11
General Information
Towing
The towing hooks on the 2WD model are different from the 4WD model.
BT-50_00020
2WD 1 Towing hooks
The 4WD model has two tie-down hooks that may not be used for towing. The towing hook is located on the left side.
BT-50_00021
4WD 1 Towing hook 2 Tie-down hooks
00-12
General Information
Scheduled Maintenance Table
Number of months or kilometers (miles), whichever comes first Months 12 24 36 48 60 72 84 96 108 x1000 km 20 40 60 80 100 120 140 160 180 x1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5
Maintenance Interval
ENGINE
Engine valve clearance Engine timing belt Engine oil
*2 *2 *1 1
I Replace every 120,000 km (75,000 miles) Replace every 120,000 km (75,000 miles)
Engine timing belt auto tensioner* Engine oil filter Drive belts
*3
R R I
R R I
R R I
R R I
R R I
R R I
R R I
R R I
R R I
COOLING SYSTEM
Cooling system (including coolant level adjustment) FL22 type Engine coolant
*4
Replace every 200,000 km (125,000 miles) or 11 years Replace first at 100,000 km (62,500 miles) or 4 years; after that every 2 years
Others
FUEL SYSTEM
Air cleaner element Fuel filter Fuel lines and hoses Air intake system
*5
C I I
C R I I
R I I
C R I I
C I I
R R I I
C I I
C R I I
R I I
EMISSION CONTROL SYSTEM ELECTRICAL SYSTEM

Battery electrolyte level and specific gravity I I I I I I I I I
BT-50_T00006
00-13
General Information
Maintenance Interval Number of months or kilometers (miles), whichever comes first Months 12 24 36 48 60 72 84 96 108 x1000 km 20 40 60 80 100 120 140 160 180 x1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5
CHASSIS and BODY

Brake lines, hoses and connections *6 Brake fluid Parking brake Brake booster and hoses Disc brakes
*7 *7
I R I
I R I
I R I
I R I
Inspect every 200,000 km (125,000 miles) I I I I I I I I R I I I L I I R I T I T I T I R I I I I I I I R I I I L I R I T I T I R R I R I I I L I R I T I T I R I I I I I I I I R I I L I R I T I T I R I I I I I I I I I
Drum brakes Power steering fluid, lines, hoses and connections Steering operation and linkages Manual transmission oil Rear differential oil (2WD) Front and rear differential oil (4WD) Transfer oil (4x4) Drive shaft dust boots (4WD) Propeller shaft joints (4WD) Front and rear suspension and ball joints Front wheel bearing grease (2WD) Wheel bearing axial play Exhaust system and heat shields Bolts and nuts on chassis and body Body condition (for rust, corrosion and perforation) Tyres (including spare tyre ) with inflation pressure adjustment I
*8
Inspect every 80,000 km (50,000 miles) or 5 years
Inspect annually I I I I I I I I
BT-50_T00007
Chart symbols I: Inspect: Inspect and clean, repair, adjust, or replace if necessary. R: Replace T: Tighten L: Lubricate C: Clean
00-14
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
00-15
General Information
Notes:
00-16
Engine
WL-C Engine

WL-C Engine
The BT-50 is offered with the 2.5 L common rail diesel engine, which has the identification code WL-C. The design and operation of the WL-C engine are essentially carried over from that of the B-Series with WLT-3 engine, except for the new features described in the respective sections.
NOTE: Further information can be found in the Training Manual of the B-Series (NMT-005) and in Basic Diesel Engine Management (CT-L2005) and Advanced Diesel Engine Management (CT-L3004).
Engine Performance Curve
BT-50_01001
X Y1 Y2
Engine speed Engine power Engine torque
1 2
Power curve Torque curve
01-1
WL-C Engine
Overview
Engine
BT-50_01002
01-2
WL-C Engine
Mechanical
Features
Mechanical
The mechanical system of the WL-C engine has the following new features:
Pistons with integrated combustion chamber Coated piston skirt Reduced compression ratio Newly constructed aluminium alloy cylinder head Double overhead camshafts (driven by a timing belt) Four valves per cylinder Adjustable roller-type rocker arms Timing belt auto tensioner
Specifications
Item
Specification
WL-C Type Diesel 4-stroke Cylinder arrangement and number Inline, 4-cylinder Combustion chamber Direct injection Valve system DOHC, timing gear and belt driven, 16 valves Displacement ml 2,499 Bore x stroke mm 93.0 x 92.0 Compression ratio 18.0:1 Compression pressure kPa 2,942 (standard) 2,648 (minimum) Open BTDC () 10 IN Close ABDC () 30 Valve timing Open BBDC () 40 EX Close ATDC () 8 Valve clearance IN mm 0.10-0.16 (engine cold) EX mm 0.17-0.23
BT-50_T01001
01-3
Mechanical
Piston
WL-C Engine
In accordance with the adoption of the common rail injection system, the piston head shape now incorporates the combustion chamber. Due to the modified piston shape the compression ratio is reduced from 21.6: 1 on the WLT-3 engine to 18.0: 1. A reduction of the internal friction and hence of the engines mechanical loss has been achieved by coating of the piston skirt area.
NOTE: The piston side marked with F must be installed towards the timing gear-side of the engine.
BT-50_01006
1 2
Combustion chamber Cooling oil channel
Piston skirt coating
NOTE: Oversize bearings for the crankshaft and connecting rods, as well as oversize pistons are available in various dimensions (refer to Engine W/M).
01-4
WL-C Engine
Cylinder Head
Parts Location
Mechanical
BT-50_01007
1 2 3 4
Cylinder head cover Upper camshaft bearing caps Lower camshaft bearing case with injector sealing rings Cylinder head
5 6 7 8
Cylinder head gasket Seal plate Camshaft pulley Camshaft
01-5
Mechanical

WL-C Engine
The cylinder head and the full floating cylinder head cover are made of aluminium alloy. The steel laminated cylinder head gasket is available in three different thicknesses depending on the piston protrusion. The gasket is marked respectively (refer to Engine W/M). The camshafts are supported in a separate bearing case, which is available as a separate spare part. For lubrication of the cam lobes, bearings / journals and rocker arms, the camshafts are hollow and have oil bores at each lubricating point.
BT-50_01008
A B 1 2
Exhaust camshaft Intake camshaft Thrust force bearing boss Oil bore
3 4 5
Oil passage Location of cylinder no.1 Hexagonal shaped surface
NOTE: The cylinder head surface must not be machined. If necessary, the cylinder head must be replaced (refer to Engine W/M).
01-6
WL-C Engine
Valve Gear The valve gear comprises helical gears and a timing belt
Mechanical
The timing belt drives two camshafts and is adjusted by an auto tensioner. Adjustable roller type rocker arms have been adopted to lower the friction between camshaft lobe and rocker arm, reducing the engines mechanical loss.
BT-50_01009
1 2 3 4
Camshaft pulley Camshaft Rocker arm Balancer shaft
5 6 7
Helical gear Timing belt auto tensioner Timing belt
NOTE: The construction of the helical gears and their adjustment procedure is identical to that of the WLT-3 engine (refer to the engine W/M).
01-7
Mechanical
Valve-Clearance Adjustment The valve clearance is measured between roller and cam lobe.
WL-C Engine
CAUTION: For loosening the locknut of the adjusting screw the cam lobe must push down the rocker arm firmly as shown in the figure below. Otherwise the claw of the rocker arm might be damaged.
BT-50_01010
1 2 3
Cam lobe Adjusting screw Locknut
4 5 6
Rocker arm Claw Roller
Camshaft Pulleys The camshaft pulleys for intake and exhaust camshaft are identical. They are positioned on the camshaft with pins and have to be installed as shown in the figure below.
BT-50_01011
1 2
Intake side camshaft pulley Pin
Exhaust side camshaft pulley
01-8
WL-C Engine
Timing Belt Auto Tensioner
Mechanical
A timing belt auto tensioner has been adopted to maintain timing belt tension constant. The timing belt tension is released by turning the auto tensioner counterclockwise with the aid of an Allen wrench (with max. 39 Nm apply force). The turned back tensioner is secured by inserting a fixing pin with 6 mm diameter into the appropriate bore (No. 3 in figure below).
BT-50_01055
1 2
Apply force (max. 39 Nm) Mounting bolts (C+B)
Hole for fixing pin
BT-50_01014
1 2 3
Rod Seal Plunger
4 5 6
Spring Oil Ball
NOTE: In case air has entered the pressure chamber of the auto tensioner, it must be bled using a certain procedure (refer to W/M).
01-9
Mechanical
Engine Timing
WL-C Engine
When replacing the timing belt the timing marks must be positioned as shown in the figure below.
BT-50_01013
1 2
Intake camshaft pulley Exhaust camshaft pulley
3 4
Timing mark High-pressure pump pulley
01-10
WL-C Engine
Lubrication System
Features
Lubrication System
The lubrication system of the WL-C engine has the following new features:
Plastic oil strainer with resin filter Spin-on type oil filter with full-flow paper element Double layer oil pan with additional oil baffle
Specifications
Specification WL-C Force-fed type (at idle) kPa (at 2,500 rpm) kPa 100-330 410-570 Gear type kPa 580-700 Water-cooled kPa 164-200 Full-flow paper element, spin-on type kPa 80-120 8.0 6.8 7.0 API CF or ACEA B1/B3/B5 5W-30 e.g. Mazda genuine Dexelia oil
BT-50_T01003
Item Type Oil pressure (reference values) [after warm up] Type Relief valve Oil pump opening pressure (reference value) Type Oil cooler Oil cooler bypass valve opening pressure Type Oil filter Bypass pressure Total (dry engine) Oil capacity Oil replacement (approx. Oil and oil filter quantity) replacement Grade Viscosity (SAE) Remarks
01-11
Lubrication System
Parts Location
WL-C Engine
BT-50_01044
1 2 3 4 5 6
Oil jet valve Oil pressure switch Oil dipstick Oil cooler Oil filter body Oil filter
7 8 9 10 11 12
Oil cooler and oil filter body component Oil pan Oil drain plug Oil strainer Oil outlet pipe Oil pump
01-12
WL-C Engine
System Overview
Lubrication System
BT-50_01015
1 2 3 4 5 6 7 8 9 10 11
Oil pressure switch Vacuum pump Turbocharger Timing gears Oil Strainer Oil filter Oil cooler Oil cooler and oil filter body component Camshaft Orifice Balancer shaft
12 13 14 15 16 17 18 19 20 21
Main bearing Crankshaft Connecting rod bearing Oil pump Piston Oil jet valve Oil pan Oil passage Oil relief passage Oil bypass passage
01-13
Lubrication System
Oil Filter
WL-C Engine
The spin-on type oil filter consists of one full flow element. The bypass element that has been additionally used on the filter WLT-3 engine has been dropped.
BT-50_01017
Full-flow paper element
01-14
WL-C Engine
Cooling System
Features
Cooling System
The cooling system of the WL-C engine has the following new features:
Longlife engine coolant FL-22 Asymmetric positioned radiator fan blades for noise reduction (thermo-modulated fan-type)
Specifications
Specification WL-C Water-cooled, forced circulation Without heater: 8.8 With heater: 9.4 Centrifugal, V-belt driven Wax, bottom-bypass C C mm kPa 80-84 95 8.5 or more Corrugated fin 93.2-122.6 Thermo-modulation type mm 9 450
BT-50_T01005
Item Type Coolant capacity (approx. quantity) Water pump Type Type Thermostat Opening temperature Full-open temperature Full-open lift Type Cap valve opening pressure Type Cooling fan Number of blades Outer diameter L
Radiator Cooling system cap
01-15
Cooling System
Parts Location
WL-C Engine
BT-50_01045
1 2 3 4
Radiator cowling Water pump pulley Thermostat Water pump
5 6 7 8
Cooling fan Coolant reserve tank Radiator Cooling system cap
NOTE: To bleed the cooling system follow the instructions of the W/M.
01-16
WL-C Engine
System Overview
Cooling System
BT-50_01018
1 2 3 4 5 6
Coolant reserve tank EGR cooler Cylinder head Turbocharger Cylinder block Oil cooler
7 8 9 10 11
Heater Water pump Thermostat Radiator Coolant flow direction
01-17
Intake-Air System
Intake-Air System
Features
WL-C Engine
The intake-air system of the WL-C engine has the following new features:
Newly designed air cleaner housing with dry filter element MAF (Mass Air Flow) sensor with integrated IAT (Intake Air Temperature) sensor no.2 *1) and MAF learning function VGT (Variable Geometry Turbocharger) with VBC (Variable Boost Control) system *1) Enlarged charge-air cooler made of aluminium alloy Newly designed intake manifold with VSC (Variable Swirl Control) system *1) Vacuum chamber to reduce vacuum fluctuations MAP (Manifold Absolute Pressure) sensor with integrated IAT sensor no. 1
*1) Similar to Mazda6 pre F/L (2.0 MZR-CD)
01-18
WL-C Engine
Parts Location
Intake-Air System
BT-50_01021
1 2 3 4 5 6 7 8
Glow plug VGT Check valve VBC solenoid valve Vacuum chamber VBC vacuum actuator Air cleaner MAF / IAT no.2 sensor
9 10 11 12 13 14 15 16
Fresh-air duct Glow plug cord Charge-air cooler VSC solenoid valve Glow plug relay MAP / IAT no.1 sensor VSC vacuum actuator Intake manifold
01-19
Intake-Air System
System Overview
WL-C Engine
BT-50_01020
1 2 3 4 5 6 7 8 9
Charge-air cooler Check valve Vacuum chamber VBC solenoid valve MAF / IAT no.2 sensor Air cleaner VGT VBC vacuum actuator Guide blades
10 11 12 13 14 15 16 17
Glow plug Vacuum pump VSC vacuum actuator VSC solenoid valve VSC shutter valves MAP / IAT no.1 sensor Intake manifold To PCM
01-20
WL-C Engine
MAF Sensor
Intake-Air System
The MAF sensor with integrated IAT sensor no.2 is installed on the air filter.
MAF Learning Function

The MAF learning function is used to compensate any deterioration of the MAF sensor. It should be carried out at each service interval by means of M-MDS (refer to chapter Maintenance and Repair).
MAF Data Reset

When the MAF sensor is replaced the adaptation values in the PCM must be reset by means of M-MDS (refer to chapter Maintenance and Repair).
MAP Sensor / IAT Sensor No.1

The MAP sensor incorporates IAT sensor no.1 and is installed on the intake manifold.
BT-50_01052
1 2
Boost sensor IAT sensor no.1
PCM
01-21
Intake-Air System
Variable Geometry Turbocharger
WL-C Engine
The BT-50 uses a VGT, which controls the boost pressure by adjusting guide blades. The operation is similar to that of the VGT used on the Mazda6 (2.0 MZR-CD).
BT-50_01046
1 2
VBC vacuum actuator Intake-air flow
Exhaust-gas flow
01-22
WL-C Engine
Intake Manifold
Intake-Air System
The intake manifold features two helical intake ports per cylinder for optimal swirl of intake air. The 2nd and 3rd cylinder share a common secondary intake port to minimise the required space.
BT-50_01024
1 2 3
Secondary intake port Primary intake port VSC shutter valves
4 5
VSC vacuum actuator Intake manifold
BT-50_01023
01-23
Intake-Air System
Variable Swirl Control Shutter Valves
WL-C Engine
The BT-50 uses VSC shutter valves, which reduce the exhaust emissions at low engine speeds. The operation is similar to that of the VSC shutter valves used on the Mazda6 pre F/L with 2.0 MZR-CD engine. The VSC shutter valves are located in the secondary intake ports. The VSC shutter valves are operated from idle speed to 2,300 rpm.
Vacuum Chamber
The vacuum chamber reduces vacuum fluctuations in the vacuum supply line for the VBC and EGR solenoid valve.
BT-50_01025
1 2
To vacuum pump To VBC solenoid valve
3 4
Vacuum chamber To EGR solenoid valve
01-24
WL-C Engine
Fuel System
Features
The fuel system of the WL-C engine has the following new features:
Fuel System

1)
High-pressure pump incorporating gear-type feed pump with overflow valve, three element-type radial piston pump, fuel metering valve, and fuel temperature sensor *1) Common rail with fuel pressure sensor and pressure limiter valve *2) Solenoid valve-type fuel injectors with injector correction factors, directly controlled by the PCM *1) Multiple fuel injection (up to two pilot injections, but no post injections) Check valve in the fuel return line to prevent fuel from flowing back to the injectors
* Similar to Mazda3 (1.6 MZ-CD) *2) Similar to Mazda6 (2.0 MZR-CD)
Specifications
Item High-pressure pump Rail Pressure Fuel tank capacity MPa L Specification Bosch CP3S3 at idle Max. 32 160 2WD 4WD 63 70
BT-50_T01012
01-25
Fuel System
Parts Location
WL-C Engine
BT-50_01027
1 2
Fuel gauge sender unit Fuel tank (4WD)
3 4
Vehicles with cargo box Vehicles without cargo box
01-26
WL-C Engine
Fuel System
BT-50_01028
1 2 3 4 5
Check valve in fuel return line Fuel injectors Fuel pressure sensor High-pressure pump Fuel metering valve
6 7 8 9
Sedimentor switch Fuel filter (incl. fuel warmer for cold regions) Common rail Pressure limiter valve
01-27
Fuel System
System Overview
WL-C Engine
BT-50_01029
1 2 3 4 5 6 7
Pressure limiter valve Check valve Fuel injector Common rail Fuel pressure sensor Fuel metering valve Fuel temperature sensor
8 9 10 11 12 13
High-pressure pump Fuel filter Sedimentor switch Fuel tank To PCM Fuel flow
01-28
WL-C Engine
High-Pressure Pump
Fuel System
The BT-50 uses the high-pressure pump (CP3S3) with three pumping elements offset by 120. The operation is similar to the high-pressure pump (CP3.2) used on the Mazda3 (1.6 MZ-CD), which is also manufactured by Bosch.
BT-50_01030
1 2 3
Fuel return Fuel high-pressure from fuel filter Fuel temperature sensor
4 5 6
High-pressure pump Fuel metering valve Gear-type feed pump
Common Rail
The common rail is equipped with a fuel pressure sensor and a pressure limiter valve, which are not available as separate spare parts. In case of a malfunction on these components the common rail must be replaced as a unit.
BT-50_01031
1 2 3
Connection (fuel injector side) Fuel pressure sensor Connection (high-pressure pump side)
4 5
Common rail Pressure limiter valve
NOTE: The high-pressure pipes can be re-used up to five times after removing.
01-29
Fuel System
Fuel Injectors

WL-C Engine
The WL-C engine uses solenoid valve-type fuel injectors, which are directly controlled by the PCM. The operation is similar to the Mazda3 (1.6 MZ-CD). The fuel injectors are mounted with brackets to the cylinder head. When a fuel injector has to be replaced the eight-digit injector correction factor must be programmed into the PCM by means of M-MDS (refer to the chapter Maintenance and Repair).
BT-50_01048
1 2 3 4 5 6
Return fuel flow (to fuel tank) Fuel flow (from common rail) Injector head Injector classification code (A0 for the WL-C engine) Injector correction factor Fuel injector
7 8 9 10 11
Valve control plunger Nozzle needle Valve ball Orifice plate Solenoid valve coil
NOTE: The injector sealing rings located in the lower camshaft bearing case have to be replaced at each removal of the injectors.
01-30
WL-C Engine
Exhaust System
Features
The exhaust system has the following new features:
Exhaust System
Modified exhaust manifold Warm up system with exhaust shutter valve (if equipped)
Parts Location
BT-50_01034
1 2 3 4 5
Exhaust manifold Joint pipe Oxidation catalytic converter Main silencer Tail pipe
6 7 8 9
Warm up switch With exhaust shutter valve Front pipe VGT
01-31
Exhaust System
Warm-Up System
Engine
Since the common-rail diesel engines do not provide enough residual heat for the heating system of the vehicle, a warm-up system has been adopted to heat up the passenger compartment quickly at low ambient temperatures. It consists of:
Warm-up switch PCM Exhaust shutter valve solenoid valve Exhaust shutter valve vacuum actuator Exhaust shutter valve
When the driver pushes the warm-up switch the PCM energizes the exhaust shutter valve solenoid valve. Thereby vacuum is applied to the exhaust shutter valve vacuum actuator, which closes the exhaust shutter valve in the front pipe of the exhaust system. Due to the closed shutter valve the exhaust gas backpressure raises, accelerating engine warming-up and thus quickly providing warm engine coolant for the heating system.
Wiring Diagram
BT-50_01054
1 2
PCM Warm up switch
Exhaust shutter valve solenoid valve
01-32
WL-C Engine
Exhaust Shutter Valve Solenoid Valve
Exhaust System
The exhaust shutter valve solenoid valve (ON/OFF-type) is located above the vacuum chamber in the engine compartment.
Exhaust Shutter Valve Unit The exhaust shutter valve unit consists of exhaust shutter valve, exhaust flange, transfer lever, stop screw, actuation rod, and vacuum actuator.
BT-50_01053
1 2 3 4
Transfer lever Actuation rod Exhaust shutter valve vacuum actuator Stop screw
5 6 7
Exhaust flange Pivot Exhaust shutter valve
Operating Conditions The warm-up system operates when all of the following conditions are met:
Warm-up switch pushed ECT below 77 C IAT (no.2) below 13 C Engine speed below 1,370 rpm.
01-33
Emission System
Emission System
Features
The emission system of the WL-C engine has the following features:
WL-C Engine
One EGR solenoid valve to control EGR valve position instead of two solenoid valves as used on the B-series *1) EGR control solenoid valve for quick EGR cut-off EGR valve position sensor Enlarged EGR cooler Three-step ISV (Intake Shutter Valve) with vacuum actuator *2) ISV solenoid valve (half) and ISV solenoid valve (full) *2) Oxidation catalytic converter
*1) Similar to Mazda2 pre F/L (1.4 MZ CD) *2) Similar to Mazda6 pre F/L (2.0 MZR CD)
Parts Location
BT-50_01032
1 2 3
Rollover valves Vehicles with cargo box Vehicles without cargo box
4 5
Evaporative chamber Check valve (two-way)
01-34
WL-C Engine
Emission System
BT-50_01033
1 2 3 4 5
Oxidation catalytic converter EGR cooler EGR solenoid valve MAF sensor ISV
6 7 8 9 10
EGR control solenoid valve ISV solenoid valve (full) ISV solenoid valve (half) EGR valve Air filter
01-35
Emission System
System Overview
WL-C Engine
BT-50_01035
1 2 3 4 5 6 7 8
Air filter ISV EGR valve position sensor EGR valve MAF sensor Oxidation catalytic converter ISV solenoid valve (full) ISV solenoid valve (half)
9 10 11 12 13 14 15
EGR solenoid valve EGR control solenoid valve Fuel tank Rollover valves Check valve (two-way) (without cargo box) Evaporative chamber (without cargo box) To PCM
01-36
WL-C Engine
EGR Solenoid Valve
Emission System
BT-50_01047
A B
To EGR valve To vacuum chamber
EGR solenoid valve
EGR Control
The PCM controls the position of the EGR valve by means of the EGR solenoid valve (via duty signal) and the EGR control solenoid valve (via ON/OFF signal).
When EGR is desired the PCM controls the EGR solenoid valve with a large duty ratio and energizes the EGR control solenoid valve, so that vacuum is applied to the EGR vacuum actuator. Due to this the EGR valve opens and exhaust gas is recirculated. When less or no EGR is desired the PCM controls the EGR solenoid valve with a small duty ratio and energizes the EGR control solenoid valve, so that the vacuum applied to the EGR vacuum actuator is reduced by a ventilation passage. Due to this the spring-loaded EGR valve closes and less or no exhaust gas is recirculated. When the EGR should be cut off (e.g. during acceleration) the PCM de-energizes the EGR control solenoid valve, so that the EGR vacuum actuator is ventilated irrespective of the control by the EGR solenoid valve. Due to this the EGR valve closes quickly and EGR is stopped.
01-37
Emission System
Intake Shutter Valve
WL-C Engine
The WL-C engine uses a three-step ISV, which increases the EGR rate at low engine speeds and prevents bucking movements of the engine during shut-off. The operation is similar to the ISV used on the Mazda6 pre F/L (2.0 MZR-CD).
BT-50_01026
Fully opened at normal driving (for low EGR rate or no EGR) Fully closed when the engine is shut off Slightly opened to create vacuum (for high EGR rate)
2 3
First vacuum actuator operates for high EGR rate and shortly when the engine is shut off Second vacuum actuator operates shortly when the engine is shut off
NOTE: Function and operation of the ISV are as described for the Denso common rail system in the course Basic Diesel Engine Management (CT-L2005).
01-38
WL-C Engine
Charging and Starting System
Charging and Starting System
A modified generator has been adopted for the charging system, while the starting system is identical to that used on the B-Series.
Specification WL-C 12 95D31R (64) 12-70 14.1-14.7 Equipped Coaxial reduction 2.2
BT-50_T01009
Item Battery Voltage Type and capacity (5-hour rate) Output Regulated voltage Self diagnosis function Type Output (V) (Ah) (V-A) (V)
Generator Starter
(kW)
Parts Location
BT-50_01039
1 2
Starter Additional battery (for cold regions)
3 4
Generator Main battery
01-39
Control System
Control System
Features
WL-C Engine
The control system of the WL-C engine has the following new features:
CKP (CranKshaft Position) sensor located at the flywheel CMP (CaMshaft Position) sensor PCM (Powertrain Control Module) with extended control strategies
Specifications
Specification WL-C Thermistor Hot-wire Thermistor Piezoelectric element Thermistor Hall element type Inductive type Potentiometer Potentiometer Piezoelectric element Thermistor Piezoelectric element ON/OFF ON/OFF ON/OFF
BT-50_T01006
Item IAT sensor No.2 (built into MAF sensor) MAF sensor IAT sensor No.1(built into MAP sensor) MAP sensor ECT sensor CMP sensor CKP sensor APP sensor EGR valve position sensor BARO sensor (built into PCM) Fuel temperature sensor Fuel pressure sensor Neutral switch CPP switch Idle switch
01-40
WL-C Engine
Parts Location
Control System
BT-50_01036
1 2 3 4 5 6 7 8 9 10 11 12
MIL (Malfunction Indicator Lamp) Glow indicator light APP sensor Main relay Idle switch Brake switch DLC-2 (Data Link Connector) CPP switch A/C switch DLC-1 Warm up switch MAF sensor / IAT sensor no.2
13 14 15 16 17 18 19 20 21 22 23 24
CMP sensor Fuel pressure sensor High-pressure pump Fuel temperature sensor Fuel metering valve ECT sensor MAP sensor / IAT sensor no.1 Glow plug relay A/C relay EGR valve position sensor PCM (with built-in BARO sensor) CKP sensor
01-41
Control System
System Overview
WL-C Engine
BT-50_01037
01-42
WL-C Engine
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 EGR valve position sensor VBC solenoid valve MAF sensor / IAT sensor no.2 Exhaust shutter valve Exhaust shutter solenoid valve Oxidation catalytic converter CMP sensor ECT sensor Fuel injectors CKP sensor Glow plugs VSC solenoid valve MAP sensor / IAT sensor no.1 Fuel pressure sensor Fuel metering valve Fuel temperature sensor Sedimentor switch ISV solenoid valve (full) ISV solenoid valve (half) EGR solenoid valve EGR control solenoid valve 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Control System
Idle switch APP sensor Main relay Engine switch Neutral switch A/C switch DLC-1 / DLC-2 Vehicle speed signal CAN Bus CPP switch A/C relay BARO sensor PCM Glow plug relay MIL Glow indicator light Tachometer To PCM To glow plug relay To IC (Instrument Cluster)
01-43
Control System
Block Diagram
Input Battery CPP switch Neutral switch APP sensor Idle switch MAF sensor / IAT sensor no.2 ECT sensor Fuel temperature sensor BARO sensor MAP sensor / IAT sensor no.1 Fuel pressure sensor CMP sensor CKP sensor Immobiliser-related information Vehicle speed signal OBD A/C switch EGR valve position sensor Immobiliser module Warm up switch Warm up system control Fuel injection amount control Fuel injection timing control Multiple fuel injection control Fuel pressure control EGR control A/C cut-off control Variable boost control Variable swirl control Idle speed control Glow control PCM Control Strategies
WL-C Engine
Output
Fuel metering valve Fuel injectors VBC solenoid valve VSC solenoid valve EGR solenoid valve EGR control solenoid valve ISV solenoid valves (half, full) Glow indicator light Glow plug relay A/C relay Immobiliser module MIL Exhaust shutter solenoid valve
BT-50_T01007
01-44
WL-C Engine
Relationship Chart
Control System
x: Applicable Control Item Multiple fuel injection control Fuel injection timing control Warm up system control
Variable boost control
Fuel pressure control
Variable swirl control
Item
Input device Battery CPP switch Neutral switch APP sensor Idle switch MAF sensor IAT sensor no.2 IAT sensor no.1 ECT sensor Fuel temperature sensor BARO sensor MAP sensor Fuel pressure sensor CMP sensor CKP sensor Vehicle speed signal A/C switch EGR valve position sensor Warm up switch Immobiliser-related information Output device Fuel metering valve Fuel injectors VBC solenoid valve VSC solenoid valve EGR control solenoid valve ISV solenoid valve (half, full) Exhaust shutter solenoid valve Glow indicator light Glow plug relay A/C relay Immobiliser-related information
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
BT-50_T01008
x x x x x x x x x
x x x x x x x
x x x x x x x
x x x
x x x x x x x x x x x x
x x
x x
x x
01-45
Immobiliser system x x
A/C cut-off control
Idle speed control
Glow control
EGR control
Control System
Crankshaft Position Sensor
WL-C Engine
The inductive type CKP sensor is located at the upper part of clutch housing. The pulse wheel is installed to the primary mass of the flywheel, and has 58 projections with a space of 6crank angle between each projection. A space of 18 defines a determined crankshaft position.
BT-50_01050
1 2
CKP sensor Pulse wheel
Flywheel
NOTE: When the CKP signal fails during engine operation, the engine stalls and will not start again.
01-46
WL-C Engine
Camshaft Position Sensor
Control System
The Hall-type CMP sensor is installed at the right front side of the cylinder head. A projection on the intake camshaft pulley covers 26 camshaft rotation angle.
BT-50_01051
1 2 3
CMP sensor PCM CPU
4 5 6
Pulse wheel Intake camshaft pulley Gap (1,4 mm)
NOTE: When the CMP signal fails during engine operation, the engine continues to run and will start again (with little extended cranking time) after it has been shut off.
01-47
Control System
Powertrain Control Module
Features The PCM has the following new features:
WL-C Engine
Programmable module Built in BARO sensor A/C (Air Conditioning) cut-off control Glow plug relay with feedback to PCM *1) Integrated RFW (Remote Free Wheel) control on versions with 4WD (refer to chapter Driveline / Axle) HS-CAN (High Speed Controller Area Network) connection to DLC-2 for communication with M-MDS (refer to chapter Body & Accessories)
*1) Similar to Mazda6 (2.0 MZR CD) The PCM is mounted on the drivers side in the passenger compartment at the lower Apillar. On vehicles with U.K. specification a cover with shear bolts secures the PCM.
BT-50_01040
1 2
PCM Bracket
Connector
01-48
WL-C Engine
The PCM has two connectors with 154 pins in total.
Control System
BT-50_01041
Similar to other current modules the PCM now allows to carry out the following programming functions by means of M-MDS:
Programmable module installation (to replace PCM) Module reprogramming (to update software calibration) Programmable parameters (to input injector correction factors) As-build data (to update As-build data) Data reset (PCM and MAF sensor) MAF learning (to adapt MAF sensor condition to PCM)
NOTE: For replacement of the PCM certain procedures have to be followed (refer to the chapter Maintenance and Repair). A/C Cut-Off Control Under the following engine operating conditions the PCM turns the A/C relay off to improve driveability:
For a certain time when the accelerator-opening angle is 87.5 % or more. Permanently when ECT is above 113 C until temperature falls below 110 C.
01-49
Control System
Glow Plug Relay
WL-C Engine
The glow plug relay has a feedback line to the PCM to facilitate failure detection. The PCM operates the glow plug relay for max. 120 s at an engine coolant temperature below 32 C.
BT-50_01038
1 2 3 4
From main relay Glow plug relay PCM Glow indicator light (IC)
5 6 7
Glow plugs Glow plug circuit fuse From battery
01-50
WL-C Engine
On-Board Diagnostic System
Features
Control System
The OBD (On-Board Diagnostic) system has the following features:
MIL Self test PID monitor Simulation test
Malfunction Indicator Lamp The MIL is located in the IC. It illuminates when emission related malfunction have been detected by the OBD system. In this case a corresponding DTC is stored in the PCM. The glow plug indicator light has no indication function for any detected malfunction as on the B-series.
Self Test The self-test function allows reading out DTCs of the PCM. Therefore connect the MMDS to the DLC-2 of the vehicle and select the option Toolbox Self Test Modules PCM Retrieve CMDTCs. In addition the KOEO (Key On, Engine Off) self-test and the KOER (Key On, Engine Running) self test can be performed. Therefore connect the M-MDS to the DLC-2 of the vehicle and select the option Toolbox Self Test Modules PCM KOEO/KOER On Demand Self Test.
NOTE: The self-test function cannot be carried out by using DLC-1.
01-51
Control System
PID Monitor
WL-C Engine
The PID monitor function allows monitoring the PIDs of the PCM. Therefore connect the M-MDS to the vehicle and select the option Toolbox Datalogger Modules PCM.
PID AAT AC_REQ ACCS APP APP1 APP2 ARPMDES BARO BOO CPP DTCCNT ECT EGRV2 FIP_FL FIP_SCV FLT FRP GP_LMP GPC IASV IASV2 IAT INGEAR IVS LOAD Definition Ambient air temperature A/C request signal A/C relay Accelerator pedal position Accelerator pedal position sensor no.1 Accelerator pedal position sensor no.2 Target engine speed Barometric pressure Brake switch Clutch pedal position switch DTC count Engine coolant temperature EGR control solenoid valve High-pressure pump flow control Fuel metering valve Fuel temperature Fuel rail pressure Glow indicator light Glow plug relay ISV solenoid valve (half) ISV solenoid valve (full) Intake air temperature (IAT sensor no.1) Load / no load condition Idle switch Engine load Unit/Condition C OFF/ON OFF/ON % % V % V rpm Pa V OFF/ON OFF/ON C V OFF/ON A % A C Pa OFF/ON OFF/ON OFF/ON OFF/ON C V OFF/ON OFF Idle / Idle %
BT-50_T01010a
01-52
WL-C Engine
PID MAF MAP MIL MIL_DIS RPM SEGRP DSD SELTESTDTC VBCV VPWR VSS WARMSW WARMSOL Mass airflow Manifold absolute pressure Malfunction indicator lamp Distance travelled since the MIL was activated Engine speed Desired EGR valve position Diagnostic trouble codes VBC solenoid valve Module supply voltage Vehicle speed Warm-up switch Exhaust solenoid valve shutter valve Definition
Control System
Unit/Condition g/s V Pa V OFF/ON km rpm % % V km/h OFF/ON OFF/ON
BT-50_T01010b
Simulation Test
The simulation test function allows activating certain PIDs of the PCM. Therefore connect the M-MDS to the vehicle and select the option Toolbox Datalogger Modules PCM.
: Applicable : Not applicable Test condition KOEO KOER x x x x x x x x
BT-50_T01011
PID ACCS # EGRV2 # GP_LMP # GPC # IASV # IASV2 # INJ_1 # INJ_2 # INJ_3 # INJ_4 # SEGRP # VBCV #
Applicable component A/C relay EGR control solenoid valve Glow indicator light Glow plug relay ISV solenoid valve (half) ISV solenoid valve (full) Fuel injector no.1 Fuel injector no.2 Fuel injector no.3 Fuel injector no.4 EGR solenoid valve VBC solenoid valve
Unit/Condition OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF OFF OFF OFF % %
01-53
Control System
Maintenance and Repair
MAF Sensor Learning Function
WL-C Engine
The MAF learning procedure by means of M-MDS must be carried out at every service interval. During this procedure the MAF learning is performed at engine speeds of 750 min-1, 1850 min-1, and 2500 min-1. To perform the procedure select Toolbox Powertrain Engine Checks Learning and follow the instructions. The MAF learning procedure can also be initiated manually via DLC-1. Therefore, connect terminal TEN (Test ENgine) five times to ground within five seconds. The glow indicator light is illuminated while MAF learning is performed and flashes five times after the procedure is completed.
Replacing the MAF Sensor After replacing the MAF sensor certain procedures have to be performed in the following order: 1. Perform MAF sensor data reset procedure to reset the adaptation values in the PCM for the MAF sensor. Therefore, select the option Toolbox Powertrain Data Reset MAF sensor and follow the instructions. 2. Perform KOEO self-test procedure. 3. Turn the engine switch to the OFF position. 4. Wait for 5 s. 5. Start the engine. 6. Perform KOER self-test procedure. 7. Turn the engine switch to the off position.
NOTE: It is recommended to perform the MAF sensor learning function when a MAF data reset has been carried out.
01-54
WL-C Engine
PCM Replacement
Control System
When the PCM has been replaced certain procedures have to be performed in the following order: 1. Perform PCM configuration procedure. 2. Perform IMMOBILISER SYSTEM programming. 3. Perform PCM data reset procedure to reset all adaptation values in the PCM with the aid of the M-MDS. Therefore, select the option Toolbox Powertrain Data Reset PCM and follow the instructions. 4. Perform After repair procedure. 5. Start the engine. 6. Turn the engine switch to the off position. 7. Turn the engine switch to the ON position (Engine off). 8. Perform KOEO self-test procedure. 9. Turn the engine switch to the off position. 10. Wait for 5 s. 11. Start the engine. 12. Perform KOER self-test procedure. 13. Turn the engine switch to the off position.
NOTE: For further information refer to the W/M. NOTE: It is recommended to perform the MAF sensor learning function when a PCM data reset has been carried out.
01-55
Control System
Notes:
WL-C Engine
01-56
Suspension
Suspension
Features
The front and rear suspension of the BT-50 have the following new features:
Enlarged diameter and modified damper valve tuning of the double acting low pressurised shock absorbers Enlarged diameter of the front stabiliser Extended leaf springs on the rear axle Modified wheel alignment values
Specifications
Specification 2WD Double wishbone Torsion bar spring Torsion bar 27 28 Cylindrical, double-acting 3300'-3700' 3130'-3530' 3000'-3500' 2700'-3200' 2-8 3-9 RAP cab: 044' 1 035' 1 DBL cab: 045' 1 RAP cab: 207' 1 156' 1 DBL cab: 206' 1 RAP cab: 1037' 825' DBL cab: 1035' Leaf spring Semi elliptic leaf spring Cylindrical, double-acting 4WD
Item Front suspension Suspension type Spring type Type Stabilizer Diameter mm Shock absorber type Maximum steering Inner angle Outer Total toe-in mm Front wheel Camber angle (reference value) alignment (Unloaded Caster angle (reference value) condition*) Steering axis inclination Rear suspension Suspension type Spring type Shock absorber type
* : Fuel tank full; engine coolant and engine oil at specified level, and spare tire, jack and tools in designated position.
BT-50_T02001
02-1
Suspension
Parts Location
Front Suspension 2WD
BT-50_02002
1 2 3
Front shock absorber Torsion bar spring Upper arm
4 5 6
Lower arm Tension rod Front stabiliser
Front Suspension 4WD
BT-50_02003
1 2 3
Shock absorber Torsion bar spring Upper arm
4 5
Lower arm Front stabiliser
02-2
Suspension
Rear Suspension
BT-50_02004
1 2
4WD 2WD
3 4
Shock absorber Leaf spring
02-3
Wheels and Tyres

Wheels and Tyres
The wheels and tyres have the following new features:
Suspension
Modified wheel and tyre sizes Modified wheel offset New designs for 15- and 16-inch aluminium alloy wheels and 15-inch steel wheels.
BT-50_02001
1 2
15-inch standard steel rim (2WD) 15-inch design steel rim (4WD)
3 4
15-inch aluminium alloy rim (2WD) 16-inch aluminium alloy rim (4WD)
02-4
Suspension
Specifications
Item Size Offset Wheel Pitch circle diameter Material Size Up to four persons Full load Up to four persons Full load Remaining tread Wheel nut tightening torque mm Nm mm mm
Wheels and Tyres
Specification 15 x 61/2J 15 x 61/2JJ 20 25 139.7 Steel Aluminium alloy Steel 235/75R15 109S 210
16 x 7J 10 Aluminium alloy 245/70R16 111S 210
215/70R15C 106/104S
Tyre
Air pressure kPa
Front
220
Rear
210 375 1.6
210 290
210 270
88.2-117.6 1.5 max. 2.0 max.

BT-50_T02002
Wheel Radial and direction Wheel and tyre tyre runout mm Axial direction
02-5
Wheels and Tyres

Notes:
Suspension
02-6
Driveline / Axle
Driveline / Axle
Features
The driveline / axle of the BT-50 has the following new features:
Modified transfer case due to increased engine torque and new transmission RFW control with OBD function integrated in PCM (separate RFW module has been dropped)
NOTE: Further information can be found in the Training Manuals B-Series (NMT-005) and in Manual transmission and 4WD (CT-L1002).
Specifications
Item Drive type Transmission type Front axle Bearing type Rear axle Bearing type Support type Casing Length Diameter Rear differential Reduction gear Differential gear Ring gear size Final gear ratio Differential oil Front differential Reduction gear Differential gear Ring gear size Final gear ratio Grade Differential oil Type Viscosity Capacity L Type Grade Viscosity Capacity Specification 2WD 4WD S15M-D S15MX-D Taper roller bearing Taper roller bearing Semi-floating Banjo type 739 35.0 Hypoid gear Straight bevel gear 8.9 3.416 3.727 API service GL-5 SAE 90 2.45 2.35 Hypoid gear Straight bevel gear 8.00 3.727 API service GL-5 Above -18C: SAE 90 Below -18C: SAE 80 1.9
BT-50_T03001
mm mm
(Inch)
(Inch) _
03-1
RFW System
RFW System
Driveline / Axle
The RFW system is controlled by the PCM. The input and output components are the same as used for the B-Series with separate RFW control module.
Parts Location
BT-50_03001
1 2 3 4 5 6
RFW main switch Transfer neutral switch 4WD switch One-way check valve RFW switch RFW unit
7 8 9 10 11
RFW vacuum actuator Joint shaft component Lock solenoid valve Free solenoid valve PCM
03-2
Driveline / Axle
System Overview
RFW System
BT-50_03002
1 2 3 4 5 6 7 8 9 10
4WD indicator light RFW indicator light To battery Front differential
Lock
Free RFW vacuum actuator RFW unit RFW switch To vacuum pump
11 12 13 14 15 16 17 18 19 20
One-way check valve Lock solenoid valve Free solenoid valve RFW main switch PCM Vehicle battery Engine switch Selector lever 4WD switch Transfer neutral switch
03-3
RFW System
Driveline / Axle
Detected malfunctions are stored as 4-digit DTCs in the PCM memory and can be retrieved by means of M-MDS.
DTC Table
DTC P1812 P1813 P1814 P1815 P1878 P1879 P1880 P1885 Malfunction RFW lock solenoid valve circuit failure RFW lock solenoid valve open circuit RFW lock solenoid valve circuit/short to battery RFW lock solenoid valve circuit/short to ground RFW free solenoid valve circuit failure RFW free solenoid valve open circuit RFW free solenoid valve circuit/short to battery RFW free solenoid valve circuit/short to ground
BT-50_T03002
Simulation Test A simulation test has been adopted to check the function of certain output components by means of M-MDS.
PID 4WDMODE_L # HUBLOCK # HUBLOCK_L # NTFLAMP # Applicable component 4WD indicator light RFW lock solenoid valve RFW free solenoid valve RFW indicator light Condition OFF/ON OFF/ON OFF/ON OFF/ON Test condition Engine switch at ON
BT-50_T03003
NOTE: Further diagnosis is supported by the symptom troubleshooting section in the W/M.
03-4
Transmission
Clutch
Features
The clutch system of the BT-50 has the following new features:
Clutch
Clutch master cylinder with one-way valve and pulsation damper Dual mass flywheel
Specifications
Item Manual transmission type Clutch control Spring type Clutch cover Set load Outer diameter Clutch disc Inner diameter Type Clutch pedal Pedal ratio Full stroke Clutch master cylinder inner diameter Clutch release cylinder inner diameter Clutch fluid type Specification S15M-D, S15MX-D Hydraulic Diaphragm 10,100 250 155 Suspended 5.2 152 15.87 22.23 SAE J1703, FMVSS 116 DOT-3
BT-50_T05001
N mm mm
mm mm mm
05-1
Clutch
Parts Location
Transmission
BT-50_05013
1 2 3 4
Dual-mass flywheel Clutch disc Clutch cover Clutch release fork
5 6 7 8
Clutch release cylinder Clutch release collar Clutch pedal Clutch master cylinder
05-2
Transmission
Clutch Master Cylinder
Clutch
The one-way valve prevents harsh clutch engagement by a throttle, which prevents too quick back flowing of the fluid when the clutch is engaged thus ensuring smooth driving off. The pulsation damper reduces pressure fluctuations in the hydraulic line during clutch operation, minimizing operation noise and vibration transmission to the clutch pedal.
BT-50_05001
One-way valve
Pulsation damper
05-3
Clutch
Dual Mass Flywheel
Transmission
The dual mass flywheel compensates torque fluctuations thus reducing rattle noises of the transmission gears.
BT-50_05014
1 2
Torsional-vibration damping spring Secondary flywheel
Primary flywheel
05-4
Transmission
S15M(X)-D Manual Transmission

Due to the increased engine torque the newly developed three-shaft 5-speed manual transmission S15M-D has been adopted for the 2WD version, while the S15MX-D transmission with an additional transfer case has been adopted for the 4WD version. Except for the transfer case the construction and operation of both transmissions are basically the same. They have superseded the R15M(X)-D transmission used on the BSeries.
Features
Construction and operation of the S15M(X)-D transmission are quite similar to the P66MD transmission introduced on the MX-5 (NC). It has the following features:
Triple-cone synchroniser mechanism for the 1st and 2nd gear Double-cone synchroniser mechanism for the 3rd gear Single-cone synchroniser mechanism for 4th, 5th and reverse gear Integrated shift mechanism unit comprising shift rods and forks, detent balls, and pintype interlock mechanism Cam-type reverse lockout mechanism
05-5

Specifications
Item Transmission type Transmission/Transfer control Shift assist 1GR 2GR 3GR Gear ratio 4GR 5GR Reverse Type Transmission case oil Capacity (approx.quantity) Type Shift control case oil Capacity [S15M-D] (approx.quantity) Transfer ratio Transfer case oil [S15MX-D] High Low Type Capacity (approx.quantity) L
Transmission
Specification S15M-D, S15MX-D Floor-shift Synchromesh 3.905 2.248 1.491 1.000 0.800 3.391 Manual Transmission fluid type A L 3.55 Manual Transmission fluid type A ml 220-260 1.000 2.020 Manual Transmission fluid type A 1.85
BT-50_T05002
05-6
Transmission
Overview
BT-50_05002
A B 1 2 3 4
Extension housing (S15M-D) Transfer case (S15MX-D) Output shaft 3rd gear 2nd gear 1st gear
5 6 7 8 9
Reverse idler gear Reverse gear 5th gear Counter shaft Input shaft
05-7

Power Flow
Transmission
1st Gear
BT-50_05003
2nd Gear
BT-50_05004
3rd Gear
BT-50_05005
05-8
Transmission
4th Gear
BT-50_05006
5th Gear
BT-50_05007
BT-50_05008
Reverse Gear
05-9

Shift Mechanism
Transmission
Most of the shift mechanism components are accommodated in the shift mechanism unit. Due to its five speed layout the S15M(X)-D transmission requires four shift rods in total (three in the shift mechanism unit and one in the transmission housing).
BT-50_05009
1 2
Section A-A Shift mechanism unit
3 4
Control rod Shift rod
05-10
Transmission
Shift Mechanism Unit
BT-50_05010
1 2 3 4 5 6 7 8 9 10
Transmission breather Spring Plastic spring seat Detent ball Oil baffle plate Retaining bolt 3rd/4th shift fork Stopper block 1st/2nd shift fork 5th/reverse shift rod
11 12 13 14 15 16 17 18 19 20
Interlock pin 1st/2nd shift rod 3rd/4th shift rod Retaining ring Plain washer Push pin 5th/reverse shift rod end Rubber plug 3rd/4th shift rod end 1st/2nd shift rod end
05-11

5th / Reverse Gear Mechanism
Transmission
The shift fork for the 5th / reverse gear is mounted on an additional shift rod inside the gearbox. It is operated by the 5th / reverse shift rod in the shift mechanism unit via the counter lever.
BT-50_05011
05-12
Transmission
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Counter lever Washer Retaining ring 5th/reverse clutch hub and shift fork component Steel ball 5th gear bearing inner race Needle bearing 5th gear Synchronizer ring Retaining bolt Reverse idler gear shaft component Reverse idler gear shaft Thrust washer Reverse idler gear Friction damper Thrust washer (Selective) Spacer (Selective)

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Reverse gear Countershaft rear bearing Locknut Synchronizer key spring Clutch hub sleeve Detent spring Detent ball 5th/reverse shift rod 5th/reverse shift fork Synchronizer key 5th/reverse clutch hub Output rear bearing Reverse counter gear Spacer 5th counter gear Counter lever shaft component
05-13

Reverse Gear Lockout Mechanism
Transmission
To prevent accidental shifting into reverse gear while downshifting from the 5th to the 4th gear a cam-type lockout mechanism is installed in the extension housing (2WD) or in the transfer case (4WD). The figure below shows the variant of the 4WD version.
BT-50_05012
A B 1
Shifting directly from 5th to reverse gear (locked) Shifting from 5th to reverse gear via neutral (released) Selector locked
2 3 4
Selector in 5th gear position Lockout mechanism released Selector in Neutral position
05-14
HVAC
Basic System
Features
Basic System
The HVAC (Heating, Ventilation, Air Conditioning) basic system of the BT-50 has the following new features:
Modified blower unit to reduce fan noise Condenser with sub-cooling function and integrated receiver / drier
Specifications
Item Heating capacity Cooling capacity Refrigerant Type Regular amount approx. Type Discharge capacity Max. allowable speed A/C compressor PAG oil type Lubrication Sealed volume Magnetic clutch clearance Fusible plug Melting point Type Radiated heat Condenser Receiver/drier capacity Desiccant Expansion valve Type Evaporator Type Temperature control Electrical consumption (during Blower motor A/C operation) Magnetic clutch Blower motor Type Refrigerant pressure switch Evaporator temperature sensor Condition Operating High pressure kPa Low Condition Evaporator C temperature kW kW g ml rpm ml mm C kW ml Specification 4.86 4.012 R-134a 475 Swash plate 154 7,000 FD46XG 180 0.35-0.75 102-107 Multiflow (sub-cooling type) 10.46 220 Synthetic zeolite Internal regulating type Single tank drawn cup Reheat full air mix type 220 48 Sirocco ON 390 - 790 176 - 216 ON 3.0 +/- 0.6 OFF 2940 - 3340 20 or less OFF 1.0 +/- 0.6
BT-50_T07001
W W
Magnetic clutch control
07-1
Basic System
Parts Location
HVAC
BT-50_07001
1 2 3 4 5
Heater / air distribution unit Cooling unit Blower unit Low pressure charging valve Refrigerant pressure switch
6 7 8 9
High pressure charging valve Condenser Receiver / drier Compressor
07-2
HVAC
Refrigerant System
Basic System
BT-50_07006
1 2 3 4
Low-pressure charging valve Expansion valve High-pressure charging valve Receiver / drier
5 6 7
Condenser Evaporator A/C Compressor
07-3
Control System
Control System
Features
The HVAC control of the BT-50 has the following new features:
HVAC
Newly designed control panel with larger dials
Parts Location
BT-50_07003
1 2 3 4
A/C relay Climate control unit Evaporator temperature sensor Blower resistor
5 6 7
Blower motor Refrigerant pressure switch Magnetic clutch
07-4
HVAC
Wiring Diagram
Control System
BT-50_07004
1 2 3 4 5 6
PCM A/C relay Refrigerant pressure switch Magnetic clutch Climate control unit A/C Amplifier / Thermoswitch (incl. evaporator temperature sensor)
7 8 9 10 11
A/C switch Fan switch Blower resistor Blower motor Blower relay
07-5
Control System
Climate Control Unit
A new designed cable operated climate control unit has been adopted.
HVAC
BT-50_07005
1 2 3 4
A/C switch Rear window defroster switch Airflow mode selector dial Climate control unit
5 6 7
Fan switch Rec/Fresh lever Temperature control dial
07-6
Restraints
Airbag System
Features
The airbag system of the BT-50 has the following new features:
Airbag System
Side airbags integrated in the backrests of the front seats (depending on grade) *1) Side airbag sensors installed on the door sills SAS (Sophisticated Airbag Sensor) control module with enhanced OBD system Rack-type seatbelt pretensioners, height-adjustable on front seats of DBL cab version *1)
*1) Similar to MX-5 (NC) NOTE: Further information can be found in the Training Manual of the B-Series (NMT-005) and MX-5 (NMT-008), and Supplemental Restraint System (CT-L1003).
08-1
Airbag System
Parts Location
Restraints
BT-50_08001
1 2 3 4
Airbag system warning light Clock spring Seat belt pretensioner Driver-side airbag module
5 6 7 8
Side airbag sensor Side airbag module SAS control module Passenger-side airbag module
08-2
Restraints
Wiring Diagram
Airbag System
BT-50_08002
1 2 3 4 5 6 7 8
Clock spring Driver-side airbag module Passenger-side airbag module Driver-side seat belt pretensioner Driver-side side airbag module Passenger-side seat belt pretensioner Passenger-side side airbag module Poor connection detection bar (connector no.2)
9 10 11 12 13 14 15 16
SAS control module Twisted pair wire Passenger-side side airbag sensor Driver-side side airbag sensor IC Airbag system warning light DLC-2 Poor connection detection bar (connector no.1)
08-3
Airbag System
SAS Control Module

Restraints
The SAS control module is located on the centre tunnel, in front of the shift lever. The SAS control module processes the signals it receives from the internal micromechanical sensor and the side airbag sensors. If the acceleration/deceleration caused by a frontal or side impact exceeds a predetermined threshold, the SAS control module triggers the airbags / pre-tensioners or only the side airbags with a DC signal.
BT-50_08003
1 2
SAS control module Driving direction
Connector
08-4
Restraints
Side Airbag Sensors
Airbag System
The side airbag sensors are installed under the vehicle on the door sills, close to the Bpillar. A rigid metal cover protects the sensors against any damage during off-road driving. The side airbag sensor measures the acceleration / deceleration of the vehicle during a side impact and transmits this information to the SAS control module.
BT-50_08004
Protection cover
Side airbag sensor
Side Airbags
The BT-50 is equipped with side airbags, which protect the head and chest area of the occupants during a side impact. The operation is similar to that of the MX-5 (NC).
BT-50_08005
1 2
Inflator Module cover
3 4
Airbag Side airbag module
08-5
Airbag System
Seat Belt Pretensioners
Restraints
The BT-50 is equipped with rack-type seat belt pretensioners, which remove the excess slack from the seat belt in case of an accident. The operation is similar to that of the MX5 (NC) seat belt pretensioners.
BT-50_08006
1 2 3 4 5 6 7
Spindle Spring seat Spring shaft Spring Spring case Cover Gear
8 9 10 11 12 13
Clutch roller Cylinder Gas generator Cap nut Rack Base
08-6
Restraints
Features
Airbag System
The OBD system of the airbag system allows bi-directional communication with M-MDS, enabling a quicker and more precise diagnosis. It has the following new features:
Selftest (retrieving four digit DTCs stored for present and past malfunctions) PID monitor
Self Test
The self-test function comprises displaying present and past four-digit DTCs by means of M-MDS. To read out the DTCs of the SAS control module connect the M-MDS to the vehicle and select the option Toolbox Self Test Modules RCM. The excerpt of the DTC table below shows that a malfunction, which is indicated by the airbag system warning light with only one flashing pattern e.g. DTC 22, can actually have several different root causes. A more detailed description of the root cause is only displayed when performing the self test with M-MDS. When a malfunction of the airbag system is present the warning light flashes a two-digit DTC for ten times. Then the light stays illuminated. The flashing starts again when the ignition is switched off and on.
DTC Air bag system warning light M-MDS display B1933 B1934 B1935 B1992 B1993 22 B1994 B1995 12 21 19 21 Flashing pattern Priority ranking 7 8 7 Malfunction
Passenger-side air bag module circuit resistance high Driver-side air bag module circuit resistance low Passenger-side air bag module circuit resistance low Driver-side side air bag module circuit short to power supply Driver-side side air bag module circuit short to ground Driver-side side air bag module circuit resistance high Driver-side side air bag module circuit resistance low
BT-50_T08001
08-7
Airbag System
PID Monitor
Restraints
The PID monitor function allows monitoring the PIDs of the SAS control module. Therefore, connect the M-MDS to the vehicle and select the option Toolbox Datalogger Modules RCM.
PID Definition Number of continuous DTCs Driver-side airbag sensor communication state Driver-side airbag sensor circuit state Passenger-side airbag sensor communication state Passenger-side airbag sensor circuit state Driver-side seat belt pretensioner circuit state Driver-side airbag module resistance Driver-side seat belt pretensioner resistance Driver-side, side airbag module resistance Driver-side, side airbag module circuit state Driver-side airbag module circuit state Driver-side seat belt pretensioner circuit state System IG1 voltage value On-demand driver-side, side airbag sensor communication state On-demand driver-side, side airbag sensor circuit state On-demand passenger-side, side airbag sensor communication state On-demand passenger-side, side airbag sensor circuit state On-demand driver-side airbag module circuit state On-demand driver-side, side airbag circuit state On-demand passenger-side airbag module circuit state On-demand passenger-side, side airbag sensor circuit state Passenger-side seat belt pretensioner circuit state Passenger-side airbag module resistance Passenger-side, side airbag module resistance Passenger-side, side airbag sensor circuit state Passenger-side seat belt pretensioner resistance Passenger-side airbag module circuit state Passenger-side seat belt pretensioner circuit state Unit/Condition Num OK/FAULT OK/FAULT OK/FAULT OK/FAULT *1) ohm ohm ohm *1) *1) *1) V OK/FAULT OK/FAULT OK/FAULT OK/FAULT *1) *1) *1) *1) *1) ohm ohm *1) ohm *1) *1)
BT-50_T08002
CONT_RCM CRSH_ST_D1 CRSH_ST_D2 CRSH_ST_P1 CRSH_ST_P2 D_PTENSFLT DABAGR DR_PTENS DS_AB DS_AB_ST DS1_STAT DSB_P_ST IG_V_2 OD_CRST_D1 OD_CRST_D2 OD_CRST_P1 OD_CRST_P2 OD_DAB1_ST OD_DSAB_ST OD_PAB1_ST OD_PSAB_ST P_PTENSFLT PABAGR PS_AB PS_AB_ST PS_PTENS PS1_STAT PSB_P_ST
*1) SQ_LOWRES / OPEN / SHRT_B+ / SHRT_GND / Normal
08-8
Body & Accessories

Body Panels
Cabin
Body Panels
The cabin structure of the BT-50 (DBL cab version) with its triple-H structure, the sidedoor beams, and the use of high-tensile steel, provide a class top level of passive safety in conjunction with the rigid ladder frame satisfying stringent European collision-safety standards.
BT-50_09001
Despite having no B-pillars the RAP cab version satisfies the European collision-safety standards by reinforcements in the rear access panel.
BT-50_09002
09-1
Body Panels
Ladder Frame
Body & Accessories
The cross-braced ladder frame of the BT-50 is essentially carried over from the B-Series, just as four cabin mounts, which minimise lateral movement, but allow for compliance in vertical movement providing comfortable driving.
BT-50_09003
DBL Cab Frame
09-2
Body & Accessories

Cargo Box
Body Panels
The cargo box of the BT-50 has the following new features allowing a more versatile usage of the cargo box:
Taller cargo box walls to increase the load capacity. New structure of the inner cargo box walls with one horizontal and several vertical guiding grooves that allow splitting up the cargo space with boards. Inner rope hooks that are placed closer to the floor to ease firm securing of load.
BT-50_09004
1 2
Vertical guiding grooves Horizontal guiding groove
Inner rope hook
Anti-Corrosion Measures
The body of the BT-50 features improved anti-corrosion measures:
Organic-resin coated steel is used on body panels that are regularly exposed to weather, such as the cowl, bonnet and outer door panels. Undercoating, PVC and wax coatings are used extensively to protect the underbody, frame and other exposed areas, against corrosion. Galvanized steel is used for fenders, rocker panels, outer cargo box panels, the cargo box floor panel, wheel wells and load gate.
09-3
Glass/Windows/Mirrors
Glass/Windows/Mirrors
Body & Accessories
The glass/windows/mirrors of the BT-50 have following new features:
Rear window defroster switch installed in centre panel Power outer mirror switch installed in driver door trim Enlarged power outer mirrors
BT-50_09006
Rear window defroster switch
BT-50_09007
Power outer mirror switch
09-4
Body & Accessories

Security and Locks
Features
Security and Locks
The security and locks system of the BT-50 has the following features:
Power door lock system (without double lock) Keyless entry system (keyless transmitter with retractable key) Mazda immobiliser system with separate immobiliser module Theft-deterrent system (for vehicles with U.K. specification)
NOTE: Further information can be found in the Training Manuals of the B-Series (NMT-005) and Immobiliser System (CT-L 1007).
Theft-Deterrent System
The theft-deterrent system activates the turn lights and the theft-deterrent horn when the bonnet or a door is opened by means of other than the key or the keyless transmitter. The system is deactivated when a door is opened with the key or the unlock button of the keyless transmitter.
BT-50_09008
1 2 3 4 5
Engine switch Front door latch and lock actuator Rear door latch and lock actuator Door switch Keyless control module
6 7 8 9
Theft-deterrent horn Bonnet switch Door lock control module Theft-deterrent control module
09-5
Security and Locks

Wiring Diagram
Body & Accessories
BT-50_09009
1 2 3 4 5 6 7 8
Instrument cluster Door ajar warning light Security light Door switches Drivers door lock-link switch Rear door lock-link switches Bonnet switch Theft-deterrent horn relay
9 10 11 12 13 14 15 16
Theft-deterrent horn Theft-deterrent control module Door key cylinder switches Door lock control module Keyless control module Hazard warning switch Flasher control module Key reminder switch
09-6
Body & Accessories

Exterior Trim
Features
Exterior Trim
The exterior trim of the BT-50 has the following new features (depending on grade):
Painted front bumper with integrated front grille New designed chrome door handles Larger wheel arch extensions Modified side steps
Parts Location
BT-50_09026
1 2 3 4
Side step Wheel arch extension Rear bumper Rope hook
5 6 7
Side protector Front flap Front bumper
09-7
Exterior Trim
Front and Rear Bumper

Body & Accessories
The front bumper is completely new designed, while the rear bumper is the same as used on the B-Series. The plastic front bumper is installed on a steel reinforcement. The bumper also accommodates the front grille, newly designed front fog lights and the lower wheel arch extensions (if equipped).
BT-50_09005
1 2 3
Bumper reinforcement Lower wheel arch extension Front hole cover (with front fog lights)
4 5
Front bumper Front hole cover (without front fog lights)
09-8
Body & Accessories

Interior Trim
Features
The interior trim of the BT-50 has the following new features:
Interior Trim
Newly designed dashboard installed on a steel crossmember Front door pockets with bottle holder Sliding upper glove compartment Newly designed centre console
Parts Location
BT-50_09010
1 2 3 4
Sliding upper glove compartment Glove compartment Storage compartment Door pocket
5 6 7
Cup holder Cup holder (except REG cab) Centre console
09-9
Lighting System
Lighting System
Features
Body & Accessories
The lighting system of the BT-50 has the following new features:
Front combination light with multi-reflector headlight type, turn and parking light Rear combination light with stepped reflector Front and rear fog light switch incorporated in light switch Rear fog light integrated in rear combination light or in rear bumper (depending on market) Centre console illumination light Room light incorporating spot lights DRL (Daytime Running Light) (depending on market)
Parts Location
Front Combination Light
BT-50_09012
1 2 3
Headlight bulb Front turn light bulb Parking light bulb
4 5
Section B-B Section A-A
09-10
Body & Accessories

Rear Combination Light
Lighting System
BT-50_09013
1 2 3
Brake/taillight bulb Turn light bulb Back-up light bulb (LH) Rear fog light bulb (RH)
4 5
Section A-A Rear combination light
09-11
Lighting System
Overview
Body & Accessories
BT-50_09014
1 2 3 4
Combination switch Light switch Panel light control switch Headlight levelling switch
5 6 7 8
Centre console illumination Glove compartment light Hazard warning switch Interior light
Daytime Running Light

Since some countries outlaw driving vehicles without switched on headlights during daytime, a DRL system is available for these markets. On the BT-50, a DRL control module automatically switches on the headlights when the ignition is in IG1 position.
09-12
Body & Accessories

Wiring Diagram
Lighting System
BT-50_09028
09-13
Wiper / Washer System

Features
Body & Accessories
The wiper / washer system of the BT-50 has the following new features:
Intermittent wiper function with adjustable interval
Parts Location
BT-50_09016
1 2 3 4
Wiper and washer switch Washer nozzle Washer hose Wiper motor
5 6 7
Wiper arm and blade Washer motor Washer tank
09-14
Body & Accessories

Wiring Diagram
BT-50_09024
1 2 3 4
Wiper switch Washer switch Washer motor Wiper motor
5 6 7 8
Auto-stop switch Interval relay Interval control switch One-touch switch
09-15
Entertainment
Audio System
Features
Body & Accessories
The modular audio system of the BT-50 is available in two different variants: Radio with CD player or with 6-CD changer. It has the following features:
AM/FM tuner with RDS (Radio Data System) and ALC (Audio Level Control) Single CD player or 6-CD changer with MP3 compatibility I-Pod adapter compatibility (16-pin connector) 6-Loudspeaker system comprising four door speakers and two tweeters OBD system
Specifications
Audio Unit
Specification Type A With RDS Without RDS 12 153-279 531-1602 522-1629 87.5-108 354 4
BT-50_T09004
Item Rated voltage Frequency band AM LW MW V kHz kHz MHz W ohm
Type B
531-1629
FM Audio amplifier maximum output power Output impedance
Speakers
Specification Rear speaker DBL cab RAP cab 25 4 100 160
Item Maximum input Impedance Size W ohm mm
Front speaker
Tweeter
160
30
BT-50_T09005
09-16
Body & Accessories

Parts Location
Entertainment
BT-50_09017
1 2 3 4 5
Roof antenna Tweeter LH Rear speaker RH Rear speaker LH Front speaker LH
6 7 8 9
Audio unit Antenna cable Front speaker RH Tweeter RH
09-17
Entertainment
System Overview
Body & Accessories
BT-50_09019
1 2 3 4 5 6 7
Roof antenna Audio unit Tweeter (RH) Front speaker (RH) Front speaker (LH) Tweeter (LH) Rear speaker (RH)
8 9 10 11 12 13
Rear speaker (LH) Base unit Lower module Vehicle speed signal TNS signal Centre panel unit
NOTE: A telephone mute function is only available by using an appropriate connector adapter, which is provided as accessory part by Mazda Motor Europe.
09-18
Body & Accessories
Entertainment
The modular audio system consists of the base unit, the lower module (if equipped) and the centre panel. The base unit with CD player is different from the one with 6-CD changer.
BT-50_09018
1 2 3
Base unit Audio unit Lower module
4 5
Cover Centre panel
NOTE: MC (Music Cassette) drive or MD (Mini Disc) player are currently not available for Europe.
BT-50_09025
Operating key layout of the 6-CD changer
09-19
Entertainment
Body & Accessories
The OBD system of the modular audio system comprises a self-test and a diagnostic assist function.
Self-Test Function The fault memory of the audio module can store up to three DTCs. If a fourth fault is detected when three DTCs are already stored, the oldest DTC is deleted and the new one stored. Once a DTC is stored in the non-volatile memory of the audio unit it can be displayed on the information display when the test mode has been activated. In addition, the self-test function allows deleting the stored DTCs.
Diagnostic Assist Function The diagnostic assist function allows checking of the following components:
Information display Speakers Radio reception condition Antenna condition
NOTE: For further information about the self-test and diagnostic assist function refer to the W/M.
09-20
Body & Accessories

Power Systems
Parts Location
Power Systems
BT-50_09020
Main fuse block
Fuse block
09-21
Instrumentation / Driver Info

Instrumentation / Driver Information System
Features
Body & Accessories
The instrumentation / driver information system of the BT-50 has the following new features:
LED-type warning and indicator lights Front and rear fog light indicator lights incorporated in the IC Key reminder warning alarm Extended input / output check code functions
Specifications
Item Meter type Indication range Speedometer Input signal source Rated voltage Meter type Indication range Red zone Input signal source Rated voltage Meter type Input signal source Rated voltage Meter type Input signal source Rated voltage Display Indication digits V Specification Stepper motor type 0180 Speedometer sensor DC 12 Stepper motor type 05,500 4,5005,000 PCM DC 12 Stepper motor type (Reset-to-zero type) Fuel gauge sender unit DC 12 Stepper motor type (Medium range stabilised type) ECT sensor DC 12 LCD Odometer: 6 digits, Tripmeter: 4 digits DC 12 2,0002,200 67.5 -1.51.5
BT-50_T09009
km/h V rpm rpm V
Tachometer
Fuel level gauge Water temperature gauge Odometer/ Tripmeter
Rated voltage Sound frequency Warning Output sound alarms pressure level Clock accuracy (reference value)*
V Hz dB s/day
* : If the clock accuracy varies largely from the reference value, battery deterioration or an audio unit (base unit) malfunction may have occurred.
09-22
Body & Accessories

Instrument Cluster Overview
BT-50_09023
No. 1 2 3 4 5 6 7 8 9 10 11 12
Item RFW indicator light 4x4 indicator light Red Zone Turn indicator light Speedometer gauge Water temperature gauge High-beam indicator light Front fog light indicator light Rear fog light indicator light Fuel level gauge Fuel-level warning light ABS warning light
Input signal source PCM RFW main switch Flasher control module VSS ECT sensor Headlight switch Front fog light relay Rear fog light relay Fuel gauge sender unit Fuel gauge sender unit ABS HU/CM Parking brake switch Brake fluid level sensor SAS control module Generator Immobilizer module Theft deterrent control module Oil pressure switch Door switches Sedimentor switch PCM PCM CKP sensor
BT-50_T09010
13 Brake system warning light 14 Airbag system warning light 15 Generator warning light 16 Security light 17 18 19 20 21 22 Oil pressure warning light Door ajar warning light Sedimentor warning light MIL Glow indicator light Tachometer gauge
09-23

Key Reminder Warning Alarm
Body & Accessories
This function warns with an intermittent sound from the buzzer in the IC that the key is in the steering lock in position ACC or LOCK when any door is opened. Additionally a permanent sound warns when a door is opened and the lights are switched on.
Input / Output Check Mode

This function allows checking the input and output circuits of the instrument cluster. It can be activated in the following way: 1. Press and hold the odometer/tripmeter switch, and turn the ignition switch to the ON position. 2. Continue holding the odometer/tripmeter switch for approx. 5 s. until tESt is displayed on the LCD. 3. Release the odometer/tripmeter switch within 3 s after tESt is displayed.
4. 5.
When the odometer/tripmeter indicates check code 00, push the odometer/tripmeter switch to select a check code. Inspect the check codes according to the W/M.
Check item Door switch TNS relay Headlight switch Speedometer sensor PCM Speedometer Tachometer Buzzer Rear fog light relay Fuel-level warning light Engine key illumination Fuel gauge sender unit Fuel gauge ECT sensor Water temperature gauge Odometer/tripmeter (LCD) Warning and indicator lights Rear fog light switch Key reminder switch Front fog light relay Related items Key reminder warning alarm Lights-on reminder warning alarm Lights-on reminder warning alarm Each illumination light Headlight Rear fog light control system Speedometer Tachometer Speedometer Tachometer Buzzer Rear fog light indicator light Fuel-level warning light Engine key illumination Fuel gauge Fuel gauge Water temperature gauge Water temperature gauge Odometer/tripmeter (LCD) Warning and indicator lights Rear fog light control system Key reminder warning alarm Front fog light relay
BT-50_T09011
Check code 04 08 09 10 11 12 13 14 15 16 18 22 23 24 25 26 29 31 40
09-24
Body & Accessories

Control System
Features
The control system of the BT-50 has the following new features:
Control System
DLC-2 HS-CAN connection between PCM and DLC-2 for communication with M-MDS
Data Link Connector

The DLC-2 is located under the dashboard next to the centre panel. The 17-pin DLC-1, known from the previous B-Series, is installed on the left rear side in the engine compartment. It cannot be used for communication with M-MDS.
NOTE: For communication with M-MDS the control modules of the ABS (Antilock-Brake System) and the SAS are connected to DLC-2 via ISO (International Standard Organisation) bus.
09-25
Control System
Wiring Diagram
Body & Accessories
BT-50_09027
09-26
List of Abbreviations
ABS Anti-lock Brake System HU/CM Hydraulic Unit/Control Module Intake Air Temperature
A/C
Air Conditioning
IAT
APP
Accelerator Pedal Position
IC
Instrument Cluster
CAN
Controller Area Network
ISO
International Standard Organisation Intake Shutter Valve
CKP
CranKshaft Position
ISV
CMP
CaMshaft Position
KLN
K-LiNe
CPP
Clutch Pedal Position
LCD
Liquid Crystal Display
DBL
DouBLe
LED
Light Emitting Diode
DLC
Data Link Connector
LSD
Limited Slip Differential
DLR
Daytime Running Light
MAF
Mass Air Flow
DTC
Diagnostic Trouble Code
MAP
Manifold Absolute Pressure
ECT
Engine Coolant Temperature
MIL
Malfunction Indicator Lamp
EGR
Exhaust Gas Recirculation
MC
Music Cassette
FEN
Fault ENgine
MD
Mini Disc
HVAC
Heating, Ventilation, Air Conditioning
M-MDS
Mazda-Modular Diagnostic System
Service Training Mazda BT-50
List of Abbreviations
OBD On-Board Diagnostics VSC Variable Swirl Control
PCM
Powertrain Control Module
VSS
Vehicle Speed Sensor
PID
Parameter IDentification
VIN
Vehicle Identification Number
RAP
Random Access Panel
REG
REGular
RFW
Remote FreeWheel
RWD
Rear Wheel Drive
SAS
Sophisticated Airbag Sensor
SRS
Supplemental Restraint System
SST
Special Service Tool
TEN
Test ENgine
W/D
Wiring Diagram
W/M
Workshop Manual
VBC
Variable Boost Control
VGT
Variable Geometry Turbocharger
Service Training Mazda BT-50

Manual BT-50 en

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Manual BT-50 en

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Training Manual

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

Service Training BT-50

Service Training BT-50

Service Training BT-50

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

Service Training BT-50

Service Training BT-50

Service Training BT-50

Service Training BT-50

Service Training BT-50

Service Training BT-50

Service Training BT-50

Service Training BT-50

REG (REGular) Cabin, available in 2WD or 4WD layout

DBL (DouBLe) Cabin, available in 4WD layout

Service Training BT-50

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

* without cargo box

Service Training BT-50

Service Training BT-50

Service Training BT-50

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

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

Service Training BT-50

only 2WD only 4WD

2WD and 4WD

Service Training BT-50

2WD 1 Towing hooks

4WD 1 Towing hook 2 Tie-down hooks

Service Training BT-50

EMISSION CONTROL SYSTEM ELECTRICAL SYSTEM

Service Training BT-50

CHASSIS and BODY

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

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

Service Training BT-50

Service Training BT-50

Service Training BT-50

Engine Performance Curve

Engine speed Engine power Engine torque

Power curve Torque curve

Service Training BT-50

Service Training BT-50

Service Training BT-50

Combustion chamber Cooling oil channel

Piston skirt coating

Service Training BT-50

Cylinder head gasket Seal plate Camshaft pulley Camshaft

Service Training BT-50

Oil passage Location of cylinder no.1 Hexagonal shaped surface

Service Training BT-50

Camshaft pulley Camshaft Rocker arm Balancer shaft

Helical gear Timing belt auto tensioner Timing belt

Service Training BT-50

Cam lobe Adjusting screw Locknut

Rocker arm Claw Roller

Intake side camshaft pulley Pin

Exhaust side camshaft pulley

Service Training BT-50

Apply force (max. 39 Nm) Mounting bolts (C+B)

Hole for fixing pin