Mazda-BT-50-NMT-009

Training Manual
Mazda BT-50
NMT-009

No part of this hardcopy may be reproduced in any form without prior permission of
Mazda Motor Europe GmbH.
The illustrations, technical information, data and descriptive text in this issue, to the best of our
knowledge, were correct at the time of going to print.
No liability can be accepted for any inaccuracies or omissions in this publication, although every
possible care has been taken to make it as complete and accurate as possible.
© 2006
Mazda Motor Europe GmbH
Training Services

Table of Contents
General Information ..........................................................................00-1
Product Concept....................................................................................................00-1
Vehicle Identification Number................................................................................00-7
Engine Identification Number ................................................................................00-8
Other Vehicle Information Labels..........................................................................00-9
Model Plate.....................................................................................................00-9
Tyre Pressure Label.......................................................................................00-9
Technical Data.....................................................................................................00-10
Jacking and Lifting...............................................................................................00-11
Towing.................................................................................................................00-12
Scheduled Maintenance Table............................................................................00-13
Remarks.......................................................................................................00-15
WL-C Engine......................................................................................01-1
Engine Performance Curve...................................................................................01-1
Overview................................................................................................................01-2
Mechanical..................................................................................................................01-3
Features ................................................................................................................01-3
Specifications ........................................................................................................01-3
Piston.....................................................................................................................01-4
Cylinder Head........................................................................................................01-5
Parts Location.................................................................................................01-5
Valve Gear......................................................................................................01-7
Valve-Clearance Adjustment..........................................................................01-8
Camshaft Pulleys............................................................................................01-8
Timing Belt Auto Tensioner............................................................................01-9
Engine Timing...............................................................................................01-10
Lubrication System..................................................................................................01-11
Features ..............................................................................................................01-11
Specifications ......................................................................................................01-11
Parts Location......................................................................................................01-12
System Overview.................................................................................................01-13
Oil Filter...............................................................................................................01-14
Cooling System ........................................................................................................01-15
Features ..............................................................................................................01-15
Specifications ......................................................................................................01-15
Parts Location......................................................................................................01-16
System Overview.................................................................................................01-17
Intake-Air System.....................................................................................................01-18
Features ..............................................................................................................01-18
Parts Location......................................................................................................01-19
System Overview.................................................................................................01-20
MAF Sensor.........................................................................................................01-21
MAF Learning Function.......................................................................................01-21
MAF Data Reset..................................................................................................01-21
MAP Sensor / IAT Sensor No.1...........................................................................01-21
Variable Geometry Turbocharger........................................................................01-22
Intake Manifold....................................................................................................01-23
Variable Swirl Control Shutter Valves...........................................................01-24
Vacuum Chamber................................................................................................01-24
Service Training BT-50

Table of Contents
Fuel System ..............................................................................................................01-25
Features ..............................................................................................................01-25
Specifications ......................................................................................................01-25
Parts Location......................................................................................................01-26
System Overview.................................................................................................01-28
High-Pressure Pump...........................................................................................01-29
Common Rail.......................................................................................................01-29
Fuel Injectors.......................................................................................................01-30
Exhaust System........................................................................................................01-31
Features ..............................................................................................................01-31
Parts Location......................................................................................................01-31
Warm up system..................................................................................................01-32
Wiring Diagram.............................................................................................01-32
Exhaust Shutter Valve Solenoid Valve.........................................................01-33
Exhaust Shutter Valve Unit...........................................................................01-33
Operating Conditions....................................................................................01-33
Emission System......................................................................................................01-34
Features ..............................................................................................................01-34
Parts Location......................................................................................................01-34
System Overview.................................................................................................01-36
EGR Solenoid Valve............................................................................................01-37
EGR Control........................................................................................................01-37
Intake Shutter Valve............................................................................................01-38
Charging and Starting System................................................................................01-39
Parts Location......................................................................................................01-39
Control System.........................................................................................................01-40
Features ..............................................................................................................01-40
Specifications ......................................................................................................01-40
Parts Location......................................................................................................01-41
System Overview.................................................................................................01-42
Block Diagram.....................................................................................................01-44
Relationship Chart...............................................................................................01-45
Crankshaft Position Sensor.................................................................................01-46
Camshaft Position Sensor...................................................................................01-47
Powertrain Control Module..................................................................................01-48
Features .......................................................................................................01-48
A/C Cut-Off Control ......................................................................................01-49
Glow Plug Relay...........................................................................................01-50
On-Board Diagnostic System..............................................................................01-51
Features .......................................................................................................01-51
Malfunction Indicator Lamp ..........................................................................01-51
Self Test .......................................................................................................01-51
PID Monitor..........................................................................................................01-52
Simulation Test....................................................................................................01-53
Maintenance and Repair .....................................................................................01-54
MAF Sensor Learning Function....................................................................01-54
Replacing the MAF Sensor...........................................................................01-54
PCM Replacement .......................................................................................01-55
Service Training BT-50

Table of Contents
Suspension........................................................................................02-1
Features ................................................................................................................02-1
Specifications ........................................................................................................02-1
Parts Location........................................................................................................02-2
Front Suspension 2WD ..................................................................................02-2
Front Suspension 4WD ..................................................................................02-2
Rear Suspension............................................................................................02-3
Wheels and Tyres.......................................................................................................02-4
Specifications ........................................................................................................02-5
Driveline / Axle...................................................................................03-1
Features ................................................................................................................03-1
Specifications ........................................................................................................03-1
RFW System .........................................................................................................03-2
Parts Location.................................................................................................03-2
System Overview............................................................................................03-3
On-Board Diagnostic System.........................................................................03-4
Transmission.....................................................................................05-1
Clutch ..........................................................................................................................05-1
Features ................................................................................................................05-1
Specifications ........................................................................................................05-1
Parts Location........................................................................................................05-2
Clutch Master Cylinder..........................................................................................05-3
Dual Mass Flywheel ..............................................................................................05-4
S15M(X)-D Manual Transmission..............................................................................05-5
Features ................................................................................................................05-5
Specifications ........................................................................................................05-6
Overview................................................................................................................05-7
Power Flow............................................................................................................05-8
Shift Mechanism..................................................................................................05-10
Shift Mechanism Unit....................................................................................05-11
5th / Reverse Gear Mechanism.....................................................................05-12
Reverse Gear Lockout Mechanism..............................................................05-14
HVAC ..................................................................................................07-1
Basic System..............................................................................................................07-1
Features ................................................................................................................07-1
Specifications ........................................................................................................07-1
Parts Location........................................................................................................07-2
Refrigerant System................................................................................................07-3
Control System...........................................................................................................07-4
Features ................................................................................................................07-4
Parts Location........................................................................................................07-4
Wiring Diagram......................................................................................................07-5
Climate Control Unit ..............................................................................................07-6
Service Training BT-50