Mazda 2009 5 Informations techniques

Training Manual Mazda BT-50 NMT-009

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

S15M(X)-D Manual Transmission Transmission Shift Mechanism • Most of the shift mechanism components are accommodated in the shift mechanism unit. Du

Transmission S15M(X)-D Manual Transmission Shift Mechanism Unit BT-50_05010 1 Transmission breather 11 Interlock pin 2 Spring 12 1st/2nd shif

S15M(X)-D Manual Transmission Transmission 5th / Reverse Gear Mechanism • The shift fork for the 5th / reverse gear is mounted on an additional shif

Transmission S15M(X)-D Manual Transmission 1 Counter lever 18 Reverse gear 2 Washer 19 Countershaft rear bearing 3 Retaining ring 20 Locknut

S15M(X)-D Manual Transmission Transmission Reverse Gear Lockout Mechanism • To prevent accidental shifting into reverse gear while downshifting from

HVAC Basic System Basic System Features • The HVAC (Heating, Ventilation, Air Conditioning) basic system of the BT-50 has the following new features:

Basic System HVAC Parts Location BT-50_07001 1 Heater / air distribution unit 6 High pressure charging valve 2 Cooling unit 7 Condenser 3 Blow

HVAC Basic System Refrigerant System BT-50_07006 1 Low-pressure charging valve 5 Condenser 2 Expansion valve 6 Evaporator 3 High-pressure char

Control System HVAC Control System Features • The HVAC control of the BT-50 has the following new features: – Newly designed control panel with lar

HVAC Control System Wiring Diagram BT-50_07004 1 PCM 7 A/C switch 2 A/C relay 8 Fan switch 3 Refrigerant pressure switch 9 Blower resistor 4

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 tru

Control System HVAC Climate Control Unit • A new designed cable operated climate control unit has been adopted. BT-50_07005 1 A/C switch 5 Fan

Restraints Airbag System Airbag System Features • The airbag system of the BT-50 has the following new features: – Side airbags integrated in the ba

Airbag System Restraints Parts Location BT-50_08001 1 Airbag system warning light 5 Side airbag sensor 2 Clock spring 6 Side airbag module 3

Restraints Airbag System Wiring Diagram BT-50_08002 1 Clock spring 9 SAS control module 2 Driver-side airbag module 10 Twisted pair wire 3 P

Airbag System Restraints SAS Control Module • The SAS control module is located on the centre tunnel, in front of the shift lever. • The SAS contro

Restraints Airbag System Side Airbag Sensors • The side airbag sensors are installed under the vehicle on the door sills, close to the B-pillar. A ri

Airbag System Restraints Seat Belt Pretensioners • The BT-50 is equipped with rack-type seat belt pretensioners, which remove the excess slack from

Restraints Airbag System On-Board Diagnostic System Features • The OBD system of the airbag system allows bi-directional communication with M-MDS, en

Airbag System Restraints PID Monitor • The PID monitor function allows monitoring the PIDs of the SAS control module. Therefore, connect the M-MDS t

Body & Accessories Body Panels Body Panels Cabin • The cabin structure of the BT-50 (DBL cab version) with its triple-H structure, the side-doo

General Information • New features of the powertrain, such as the 16-valve DOHC-diesel engine with common rail direct injection and Euro 4 emission

Body Panels Body & Accessories Ladder Frame • The cross-braced ladder frame of the BT-50 is essentially carried over from the B-Series, just as

Body & Accessories Body Panels Cargo Box • The cargo box of the BT-50 has the following new features allowing a more versatile usage of the car

Glass/Windows/Mirrors Body & Accessories Glass/Windows/Mirrors • The glass/windows/mirrors of the BT-50 have following new features: – Rear wind

Body & Accessories Security and Locks Security and Locks Features • The security and locks system of the BT-50 has the following features: – Po

Security and Locks Body & Accessories Wiring Diagram BT-50_09009 1 Instrument cluster 9 Theft-deterrent horn 2 Door ajar warning light 10

Body & Accessories Exterior Trim Exterior Trim Features • The exterior trim of the BT-50 has the following new features (depending on grade): –

Exterior Trim Body & Accessories Front and Rear Bumper • The front bumper is completely new designed, while the rear bumper is the same as used

Body & Accessories Interior Trim Interior Trim Features • The interior trim of the BT-50 has the following new features: – Newly designed dashb

Lighting System Body & Accessories Lighting System Features • The lighting system of the BT-50 has the following new features: – Front combinat

Body & Accessories Lighting System Rear Combination Light BT-50_09013 1 Brake/taillight bulb 4 Section A-A 2 Turn light bulb 5 Rear com

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,

Lighting System Body & Accessories Overview BT-50_09014 1 Combination switch 5 Centre console illumination 2 Light switch 6 Glove compar

Body & Accessories Lighting System Wiring Diagram BT-50_09028 Service Training BT-50 09-13

Wiper / Washer System Body & Accessories Wiper / Washer System Features • The wiper / washer system of the BT-50 has the following new feature

Body & Accessories Wiper / Washer System Wiring Diagram BT-50_09024 1 Wiper switch 5 Auto-stop switch 2 Washer switch 6 Interval relay 3

Entertainment Body & Accessories Audio System Features • The modular audio system of the BT-50 is available in two different variants: Radio wi

Body & Accessories Entertainment Parts Location BT-50_09017 1 Roof antenna 6 Audio unit 2 Tweeter LH 7 Antenna cable 3 Rear speaker RH

Entertainment Body & Accessories System Overview BT-50_09019 1 Roof antenna 8 Rear speaker (LH) 2 Audio unit 9 Base unit 3 Tweeter (RH

Body & Accessories Entertainment • The modular audio system consists of the base unit, the lower module (if equipped) and the centre panel. The

Entertainment Body & Accessories On-Board Diagnostic System • The OBD system of the modular audio system comprises a self-test and a diagnosti

Body & Accessories Power Systems Power Systems Parts Location BT-50_09020 1 Main fuse block 2 Fuse block Service Training BT-50 09-21

General Information • The BT-50 is basically offered in three different body versions: – REG (REGular) Cabin, available in 2WD or 4WD layout BT

Instrumentation / Driver Info Body & Accessories Instrumentation / Driver Information System Features • The instrumentation / driver information

Body & Accessories Instrumentation / Driver Info Instrument Cluster Overview BT-50_09023 No. Item Input signal source1 RFW indicator light PCM

Instrumentation / Driver Info Body & Accessories Key Reminder Warning Alarm • This function warns with an intermittent sound from the buzzer in

Body & Accessories Control System Control System Features • The control system of the BT-50 has the following new features: – DLC-2 – HS-CAN

Control System Body & Accessories Wiring Diagram BT-50_09027 09-26 Service Training BT-50

List of Abbreviations ABS Anti-lock Brake System A/C Air Conditioning APP Accelerator Pedal Position CAN Controller Area Network CKP

List of Abbreviations OBD On-Board Diagnostics PCM Powertrain Control Module PID Parameter IDentification RAP Random Access Panel RE

General Information Vehicle Identification Number • The VIN is located on the outside of the right chassis member (visible from the right front wheel

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

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

General Information Technical Data RAP DBL2WDOverall length (w/o rear step bumper)Overall width (AWD models with Overfenders) 1,7151,755 *11,760 *2

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

No part of this hardcopy may be reproduced in any form without prior permission of Mazda Motor Europe GmbH.

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 m

General Information Scheduled Maintenance Table Months 12 24 36 48 60 72 84 96 108x1000 km 20 40 60 80 100 120 140 160 180x1000 miles 12.5 25 37.5 50

General Information Months 12 24 36 48 60 72 84 96 108x1000 km 20 40 60 80 100 120 140 160 180x1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5IIIIR

General Information Remarks • Refer below for a description of items marked with * in the maintenance chart. – *1: Replacement of the engine timing

General Information Notes: 00-16 Service Training BT-50

Engine WL-C Engine WL-C Engine • The BT-50 is offered with the 2.5 L common rail diesel engine, which has the identification code WL-C. • The des

WL-C Engine Engine Overview BT-50_01002 01-2 Service Training BT-50

WL-C Engine Mechanical Mechanical Features • The mechanical system of the WL-C engine has the following new features: – Pistons with integrated co

Mechanical WL-C Engine Piston • In accordance with the adoption of the common rail injection system, the piston head shape now incorporates the combu

WL-C Engine Mechanical Cylinder Head Parts Location BT-50_01007 1 Cylinder head cover 5 Cylinder head gasket 2 Upper camshaft bearing caps 6

Table of Contents General Information ...00-1 Product Concept...

Mechanical WL-C Engine • The cylinder head and the full floating cylinder head cover are made of aluminium alloy. • The steel laminated cylinder hea

WL-C Engine Mechanical Valve Gear • The valve gear comprises helical gears and a timing belt • The timing belt drives two camshafts and is adjusted

Mechanical WL-C Engine Valve-Clearance Adjustment • The valve clearance is measured between roller and cam lobe. CAUTION: For loosening the locknu

WL-C Engine Mechanical Timing Belt Auto Tensioner • A timing belt auto tensioner has been adopted to maintain timing belt tension constant. The timi

Mechanical WL-C Engine Engine Timing • When replacing the timing belt the timing marks must be positioned as shown in the figure below. BT-50_01013

WL-C Engine Lubrication System Lubrication System Features • The lubrication system of the WL-C engine has the following new features: – Plastic

Lubrication System WL-C Engine Parts Location BT-50_01044 1 Oil jet valve 7 Oil cooler and oil filter body component 2 Oil pressure switch 8

WL-C Engine Lubrication System System Overview BT-50_01015 1 Oil pressure switch 12 Main bearing 2 Vacuum pump 13 Crankshaft 3 Turbocharger

Lubrication System WL-C Engine Oil Filter • The spin-on type oil filter consists of one full flow element. The bypass element that has been addition

WL-C Engine Cooling System Cooling System Features • The cooling system of the WL-C engine has the following new features: – Longlife engine cool

Table of Contents Fuel System ...01-25 Fe

Cooling System WL-C Engine Parts Location BT-50_01045 1 Radiator cowling 5 Cooling fan 2 Water pump pulley 6 Coolant reserve tank 3 Thermost

WL-C Engine Cooling System System Overview BT-50_01018 1 Coolant reserve tank 7 Heater 2 EGR cooler 8 Water pump 3 Cylinder head 9 Therm

Intake-Air System WL-C Engine Intake-Air System Features • The intake-air system of the WL-C engine has the following new features: – Newly design

WL-C Engine Intake-Air System Parts Location BT-50_01021 1 Glow plug 9 Fresh-air duct 2 VGT 10 Glow plug cord 3 Check valve 11 Charge-

Intake-Air System WL-C Engine System Overview BT-50_01020 1 Charge-air cooler 10 Glow plug 2 Check valve 11 Vacuum pump 3 Vacuum chamber 1

WL-C Engine Intake-Air System MAF Sensor • The MAF sensor with integrated IAT sensor no.2 is installed on the air filter. MAF Learning Function

Intake-Air System WL-C Engine Variable Geometry Turbocharger • The BT-50 uses a VGT, which controls the boost pressure by adjusting guide blades. Th

WL-C Engine Intake-Air System Intake Manifold • The intake manifold features two helical intake ports per cylinder for optimal swirl of intake air

Intake-Air System WL-C Engine Variable Swirl Control Shutter Valves • The BT-50 uses VSC shutter valves, which reduce the exhaust emissions at low

WL-C Engine Fuel System Fuel System Features • The fuel system of the WL-C engine has the following new features: – High-pressure pump incorpora

Table of Contents Suspension...02-1 Features ...

Fuel System WL-C Engine Parts Location BT-50_01027 1 Fuel gauge sender unit 3 Vehicles with cargo box 2 Fuel tank (4WD) 4 Vehicles without

WL-C Engine Fuel System BT-50_01028 1 Check valve in fuel return line 6 Sedimentor switch 2 Fuel injectors 7 Fuel filter (incl. fuel warme

Fuel System WL-C Engine System Overview BT-50_01029 1 Pressure limiter valve 8 High-pressure pump 2 Check valve 9 Fuel filter 3 Fuel inject

WL-C Engine Fuel System High-Pressure Pump • The BT-50 uses the high-pressure pump (CP3S3) with three pumping elements offset by 120°. The operati

Fuel System WL-C Engine Fuel Injectors • The WL-C engine uses solenoid valve-type fuel injectors, which are directly controlled by the PCM. The oper

WL-C Engine Exhaust System Exhaust System Features • The exhaust system has the following new features: – Modified exhaust manifold – Warm up s

Exhaust System Engine Warm-Up System • Since the common-rail diesel engines do not provide enough residual heat for the heating system of the vehicl

WL-C Engine Exhaust System Exhaust Shutter Valve Solenoid Valve • The exhaust shutter valve solenoid valve (ON/OFF-type) is located above the vac

Emission System WL-C Engine Emission System Features • The emission system of the WL-C engine has the following features: – One EGR solenoid valve

WL-C Engine Emission System BT-50_01033 1 Oxidation catalytic converter 6 EGR control solenoid valve 2 EGR cooler 7 ISV solenoid valve (ful

Table of Contents Restraints...08-1 Airbag System ...

Emission System WL-C Engine System Overview BT-50_01035 1 Air filter 9 EGR solenoid valve 2 ISV 10 EGR control solenoid valve 3 EGR valve p

WL-C Engine Emission System EGR Solenoid Valve BT-50_01047 A To EGR valve 1 EGR solenoid valve B To vacuum chamber EGR Control • The

Emission System WL-C Engine Intake Shutter Valve • The WL-C engine uses a three-step ISV, which increases the EGR rate at low engine speeds and prev

WL-C Engine Charging and Starting System Charging and Starting System • A modified generator has been adopted for the charging system, while the s

Control System WL-C Engine Control System Features • The control system of the WL-C engine has the following new features: – CKP (CranKshaft Posit

WL-C Engine Control System Parts Location BT-50_01036 1 MIL (Malfunction Indicator Lamp) 13 CMP sensor 2 Glow indicator light 14 Fuel pressure

Control System WL-C Engine System Overview BT-50_01037 01-42 Service Training BT-50

WL-C Engine Control System 1 EGR valve position sensor 22 Idle switch 2 VBC solenoid valve 23 APP sensor 3 MAF sensor / IAT sensor no.2 24

Control System WL-C Engine Block Diagram InputPCM Control StrategiesOutputBatteryCPP switchNeutral switchAPP sensor Fuel metering valveIdle switch Fu

WL-C Engine Control System Relationship Chart Idle speed controlWarm up system controlGlow controlVariable boost controlVariable swirl controlFuel i

Table of Contents Audio System...09-16 Feat

Control System WL-C Engine Crankshaft Position Sensor • The inductive type CKP sensor is located at the upper part of clutch housing. The pulse whee

WL-C Engine Control System Camshaft Position Sensor • The Hall-type CMP sensor is installed at the right front side of the cylinder head. A projecti

Control System WL-C Engine Powertrain Control Module Features • The PCM has the following new features: – Programmable module – Built in BARO sen

WL-C Engine Control System • The PCM has two connectors with 154 pins in total. BT-50_01041 • Similar to other current modules the PCM now allows

Control System WL-C Engine Glow Plug Relay • The glow plug relay has a feedback line to the PCM to facilitate failure detection. The PCM operates th

WL-C Engine Control System On-Board Diagnostic System Features • The OBD (On-Board Diagnostic) system has the following features: – MIL – Self t

Control System WL-C Engine PID Monitor • The PID monitor function allows monitoring the PIDs of the PCM. Therefore connect the M-MDS to the vehicle

WL-C Engine Control System PID Definition Unit/Condition g/sVPaVMIL Malfunction indicator lamp OFF/ONMIL_DIS Distance travelled since the MIL was ac

Control System WL-C Engine Maintenance and Repair MAF Sensor Learning Function • The MAF learning procedure by means of M-MDS must be carried out a

WL-C Engine Control System PCM Replacement • When the PCM has been replaced certain procedures have to be performed in the following order: 1. Pe

Table of Contents Notes: Service Training BT-50

Control System WL-C Engine Notes: 01-56 Service Training BT-50

Suspension Suspension Features • The front and rear suspension of the BT-50 have the following new features: – Enlarged diameter and modified dam

Suspension Parts Location Front Suspension 2WD BT-50_02002 1 Front shock absorber 4 Lower arm 2 Torsion bar spring 5 Tension rod 3 Upper arm

Suspension Rear Suspension BT-50_02004 1 4WD 3 Shock absorber 2 2WD 4 Leaf spring Service Training BT-50 02-3

Wheels and Tyres Suspension Wheels and Tyres • The wheels and tyres have the following new features: – Modified wheel and tyre sizes – Modified wh

Suspension Wheels and Tyres Specifications 15 x 61/2JJ 16 x 7Jmm 25 10mmSteelAluminium alloySteelAluminium alloy235/75R15 109S245/70R16 111SUp to fou

Wheels and Tyres Suspension Notes: 02-6 Service Training BT-50

Driveline / Axle Driveline / Axle Features • The driveline / axle of the BT-50 has the following new features: – Modified transfer case due to inc

RFW System Driveline / Axle RFW System • The RFW system is controlled by the PCM. The input and output components are the same as used for the B-Se

Driveline / Axle RFW System System Overview BT-50_03002 1 4WD indicator light 11 One-way check valve 2 RFW indicator light 12 Lock solenoid v

General Information General Information Product Concept • The new Mazda BT-50 supersedes the B-Series, Mazda’s present pick-up truck. The aim of the

RFW System Driveline / Axle On-Board Diagnostic System • Detected malfunctions are stored as 4-digit DTCs in the PCM memory and can be retrieved by

Transmission Clutch Clutch Features • The clutch system of the BT-50 has the following new features: – Clutch master cylinder with one-way valve and

Clutch Transmission Parts Location BT-50_05013 1 Dual-mass flywheel 5 Clutch release cylinder 2 Clutch disc 6 Clutch release collar 3 Clutch

Transmission Clutch Clutch Master Cylinder • The one-way valve prevents harsh clutch engagement by a throttle, which prevents too quick back flowing

Clutch Transmission Dual Mass Flywheel • The dual mass flywheel compensates torque fluctuations thus reducing rattle noises of the transmission gears

Transmission S15M(X)-D Manual Transmission S15M(X)-D Manual Transmission • Due to the increased engine torque the newly developed three-shaft 5-spe

S15M(X)-D Manual Transmission Transmission Specifications SpecificationS15M-D, S15MX-DFloor-shiftSynchromesh3.9052.2481.4911.0000.8003.391Manual Tran

Transmission S15M(X)-D Manual Transmission Overview BT-50_05002 A Extension housing (S15M-D) 5 Reverse idler gear B Transfer case (S15MX-D) 6

S15M(X)-D Manual Transmission Transmission Power Flow BT-50_05003 1st Gear BT-50_05004 2nd Gear BT-50_05005 3rd Gear 05-8 Service Training BT-

Transmission S15M(X)-D Manual Transmission BT-50_05006 4th Gear BT-50_05007 5th Gear BT-50_05008 Reverse Gear Service Training BT-50 05-9