Training Manual Powertrain (NTOM) CT-L1001.4

Introduction Powertrain Notes: 00-2 Curriculum Training

Engines Powertrain Lubrication Features • The lubrication system of the WL-C engine has the following features: – Gear type oil pump, directly drive

Powertrain Engines Cooling System Features • The cooling system of the WL-C engine has the following features: – Water pump driven by the accessory

Engines Powertrain Service Procedures MAF Sensor Learning Function • The MAF learning function is used to compensate the deviations of the amount du

Powertrain Engines Y-type Engines • In the Y-type engine line-up the following engines are available: – Y4 type with 1.4 L displacement (also terme

Engines Powertrain Overview L1001.4_01086 NOTE: Some of the components of the Y4 engine are very similar in construction and operation to those of

Powertrain Engines Cylinder Block • The cylinder block is equipped with cylinder liners, the coolant jackets of which are open towards the top. • Th

Engines Powertrain Pistons • The pistons have valve recesses for the intake and exhaust valves. • The piston skirt is coated to reduce friction betw

Powertrain Engines Crankshaft • The crankshaft is equipped with a key for the installation of the crankshaft timing pulley and the crankshaft pulley.

Engines Powertrain L1001.4_01090 1 Diameter classes of the main journals 2 Diameter classes of the main bearings • The correct tolerance class

Powertrain Engines • There is no positioning tab for locating the lower bearings in the main journals. For installing the lower main bearing shells a

Powertrain Engine MESI for Engine Service and Repairs • For engine service and repairs MESI provides two different types of information within the Se

Engines Powertrain Cylinder Head • The cylinder head features a bolted on camshaft housing, which comprises an upper and a lower part. Upper and lowe

Powertrain Engines Valve Actuation • The camshaft actuates the valves via roller cam followers. • The adjustment of the valve clearance is performe

Engines Powertrain Valve Train • The camshaft is driven by a timing belt, which has to be replaced every 240,000 km or 10 years (whichever occurs fir

Powertrain Engines Timing Belt Tensioner • An automatic timing belt tensioner is fitted to ensure optimum belt tension over the service life of the e

Engines Powertrain Valve Timing • For verifying or adjusting the valve timing, the crankshaft timing peg (SST) has to be installed in the cylinder bl

Powertrain Engines Mechanical (Y6 Engine) Features • The mechanical system of the Y6 engine has the following features: – Belt and chain driven 16 v

Engines Powertrain Cylinder Head • The cylinder head is composed of an upper and a lower part. Upper and lower cylinder head are matched to each othe

Powertrain Engines Camshafts • The camshafts are mounted hanging in the upper part of the cylinder head. • The intake camshaft drives the exhaust ca

Engines Powertrain • An automatic timing chain tensioner is fitted to ensure optimum chain tension over the service life of the engine. • The timing

Powertrain Engines Valve Train • The valve train is similar to that of the Y4 engine except for the additional chain drive of the exhaust camshaft. F

Engine Powertrain • Clicking a Hyperlink (e.g. compression inspection) provides the technician with additional information, which is essential for th

Engines Powertrain Lubrication Features • The lubrication system of the Y-type engines has the following features: – Trochoid gear type oil pump, di

Powertrain Engines Cooling System Features • The cooling system of the Y-type engines has the following features: – Timing belt driven water pump –

Engines Powertrain Diesel Particulate Filter System • The Mazda3 with Y6 high-power engine features a DPF with a honeycomb structure, which must be r

Powertrain Engines Service Procedures Bleeding the Fuel System • Since the Mazda3 with Y6 engine features no priming pump for the low-pressure fuel

Engines Powertrain Refilling the Fuel Additive Tank • The fuel additive tank must be refilled every 60,000 km. Due to its installation position at th

Powertrain Engines Installing a New DPF • The DPF must be replaced every 120,000 km Thereafter, the parameters for the regeneration control in the P

Engines Powertrain Notes: 01-116 Curriculum Training

Powertrain Transmissions Drive Train • The following drive train types are used on the current Mazda models: – FWD (Front Wheel Drive) – RWD (Rea

Transmissions Powertrain Transmission Code • The transmissions of the current Mazda models except for Mazda2 (DY) have a 5- or 6-digit alphanumerica

Powertrain Transmissions Manual Transmissions • Depending on the installation position of the engine different types of manual transmissions are use

Powertrain Engine • The Engine Workshop Manual can be found by choosing “Engine WM” of the Service Contents menu and then selecting “Engine). See exa

Transmissions Powertrain F35M-R Transmission • The F35M-R transmission is a two-shaft five-speed MTX, which is operated via cables. It is only fitted

Powertrain Transmissions Service Procedures Transmission Oil Inspection • For transmission oil inspection on the F35M-R transmission the distance be

Transmissions Powertrain A26M(X)-R Transmission • The A26M(X)-R transmission is a three-shaft (non-coaxial arranged) six-speed MTX, which is operated

Powertrain Transmissions • The three shaft design with one input shaft and two output shafts allows for a more compact construction, since each outp

Transmissions Powertrain S15M(X)-D Transmission • The S15M(X)-D is a three-shaft (coaxial arranged) five-speed MT, which is directly operated by the

Powertrain Transmissions Automated Shift Manual Transmission • The automated shift manual transmission is based on the two-shaft five-speed MTX iB5.

Transmissions Powertrain Service Procedures Bleeding the Clutch System • The hydraulic fluid of the clutch system should be replaced every two years

Powertrain Transmissions Automatic Transmissions • Depending on the installation position of the engine different types of automatic transmissions a

Transmissions Powertrain FS5A-EL Transmission • The FS5A-EL transmission is a five-speed ATX, which is controlled electronically by a TCM. It is only

Powertrain Transmissions Limited Slip Differential • For the current Mazda models a taper ring type LSD (Limited Slip Differential) is used (also te

Engine Powertrain Notes: 01-4 Curriculum Training

Transmissions Powertrain Service Procedures Rear Differential Oil Inspection and Oil Replacement • There are two different rear differentials (type A

Powertrain List of Abbreviations A/C Air Conditioning ACEA Association des Constructeurs Européens d'Automobiles API American Petroleum Institut

List of Abbreviations Powertrain SAE Society of Automotive Engineers SOHC Single Overhead Camshaft SST Special Service Tool TCM Transmission Control

Powertrain Engines Petrol Engines • The following petrol engine types are fitted in the current Mazda models: Model / Engine 1.25 MZI 1.4 MZI 1.6 MZ

Engines Powertrain Mechanical (L8, LF, L3 Engine) Features • The mechanical system of the L8, LF and L3 engine has the following features: – Chain

Powertrain Engines Cylinder Block • The cylinder block features a bearing support frame, in which the main bearing caps are integrated. Cylinder bloc

Engines Powertrain Pistons • The piston skirt is coated to reduce friction between the piston and the cylinder. • Piston, piston pin and connecting

Powertrain Engines Crankshaft • The crankshaft for the L8 and LF engine has four counterweights, while the crankshaft for the L3 engine has eight cou

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Engines Powertrain • There is no positioning tab for locating the upper and lower bearing in the main journal. For installing the main bearing shells

Powertrain Engines Balancer Shaft Unit • The balancer shafts minimize the engine vibrations by rotating at twice the speed of the crankshaft. • The

Engines Powertrain Cylinder Head • The cylinder head is a conventional construction with separate camshaft bearing caps. • The cylinder head bolts a

Powertrain Engines Camshafts • The camshafts feature no key for the installation of the camshaft sprockets, i.e. solely the clamping force of the loc

Engines Powertrain Valve Actuation • The camshafts actuate the valves via mechanical bucket tappets without adjustment shims. • The valve clearance

Powertrain Engines Valve Train • The camshafts are driven by a maintenance-free pinned link timing chain. L1001.4_01010 1 Exhaust camshaft sprocke

Engines Powertrain Timing Chain Tensioner • An automatic timing chain tensioner is fitted to ensure optimum chain tension over the service life of th

Powertrain Engines • The timing chain tension can be released as following (refer to the workshop manual for details): 1. Using a suitable screwdriv

Engines Powertrain Variable Valve Timing System • The variable valve timing system continuously varies the valve timing of the intake valves, control

Powertrain Engines Valve Timing • For verifying or adjusting the valve timing a timing peg (SST) has to be installed in the blind plug hole, which is

Powertrain Table of Contents Introduction ...00-1 Engines ...

Engines Powertrain • For verifying or adjusting the valve timing a timing plate (SST) has to be installed in the camshafts. NOTE: Never use the tim

Powertrain Engines Accessory Drive Belt • A V-ribbed drive belt is fitted to drive the engine accessories. • An automatic tensioner provides constan

Engines Powertrain Mechanical (L3-T Engine) Features • The mechanical system of the L3-T engine has the following features: – Chain driven 16 valve

Powertrain Engines Pistons • The shape of the pistons has been adapted to the requirements of the direct injection system, i.e. the piston top is re

Engines Powertrain Camshafts • The intake camshaft features a trochoid shaped cam, which drives the high-pressure pump of the direct injection syste

Powertrain Engines Valve Train • The valve train is equipped with a roller chain and respective sprockets to improve durability. L1001.4_01021 1

Engines Powertrain Valve Timing • Due to the modified intake camshaft a different timing plate (SST) is required to verify or adjust the valve timing

Powertrain Engines Lubrication Features • The lubrication system of the L-type engines has the following features: – Chain driven trochoid gear typ

Engines Powertrain Cooling System Features • The cooling system of the L-type engines has the following features: – Water pump driven by the access

Powertrain Engines Engine Coolant • For all current Mazda vehicles except for Mazda2 (DY) Mazda has developed a special engine coolant called ‘FL22’.

Table of Contents Powertrain Overview...01-31 Cyl

Engines Powertrain Z-type Engines • In the Z-type engine line-up the following engines are available: – ZJ engine with 1.3 L displacement (also ter

Powertrain Engines Overview L1001.4_01026 NOTE: Some of the components of the Z-type engine are very similar in construction and operation to those

Engines Powertrain Cylinder Block • The cylinder block is equipped with cylinder liners, the coolant jackets of which are open towards the top. • Th

Powertrain Engines Pistons • The pistons of the ZJ engine only have valve recesses on the intake side, whereas the pistons of the Z6 engine have valv

Engines Powertrain Crankshaft • The crankshaft is equipped with a key for the installation of the crankshaft sprocket and the crankshaft pulley. • T

Powertrain Engines Camshafts • The camshafts are equipped with a pin for the installation of the camshaft pulleys. • The intake camshaft is equipped

Engines Powertrain Valve Timing • For verifying or adjusting the valve timing, the crankshaft sprocket key has to be aligned with the timing mark on

Powertrain Engines Lubrication Features • The lubrication system of the Z-type engines has the following features: – Trochoid gear type oil pump, di

Engines Powertrain Cooling System Features • The cooling system of the Z-type engines has the following features: – Water pump driven by the accesso

Powertrain Engines Service Procedures Adjusting the Idle Speed • On the Mazda3 with ZJ and Z6 engine the idle speed must be adjusted at specified ser

Powertrain Table of Contents Diesel Engines...

Engines Powertrain MZI-type Engines • In the MZI engine line-up the following engines are available: – 1.25 MZI engine with 1.25 L displacement – 1

Powertrain Engines Overview L1001.4_01040 NOTE: Some of the components of the MZI-type engine are very similar in construction and operation to tho

Engines Powertrain Cylinder Block • The cylinder block features a bearing support frame, in which the main bearing caps are integrated. The bearing s

Powertrain Engines Valve Train • The camshafts are driven by a timing belt, which has to be replaced every 160,000 km or 10 years (whichever occurs f

Engines Powertrain Timing Belt Tensioner • Depending on the build date of the vehicle different manual or automatic timing belt tensioners are fitted

Powertrain Engines L1001.4_01046 Automatic timing belt tensioner (vehicles built from 09/2003 onwards) 1 Locking pin (SST) L1001.4_01047 Au

Engines Powertrain Accessory Drive Belts • A V-ribbed drive belt is fitted to drive the engine accessories. There are two variants of the accessory b

Powertrain Engines • In order to remove the drive belt cut it through with a knife. New drive belts are supplied in a service kit, which also contain

Engines Powertrain Lubrication Features • The lubrication system of the MZI-type engines has the following features: – G-rotor type oil pump, direct

Powertrain Engines 13B-MSP Rotary Engine • The 13B-MSP (Multi Side Port) rotary engine is fitted in the Mazda RX-8 models, and is available as a stan

Table of Contents Powertrain Y-type Engines...

Engines Powertrain Construction • The main components of the rotary engine are the rotors, the eccentric shaft, the rotor housings, the front, rear a

Powertrain Engines • Due to the large bathub shaped combustion chambers the rotary engine is equipped with two spark plugs per rotor housing, improvi

Engines Powertrain Operating Principle • In the rotary engine, each of the three faces of the rotor forms a chamber. These three chambers are not int

Powertrain Engines Intake Stroke • The volume of the operating chamber in position 1 is at its minimum, thus corresponding with intake TDC (Top Dead

Engines Powertrain • The above is a description for only one chamber; the other two operate in exactly the same way. As a result of these actions by

Powertrain Engines Lubrication Features • The lubrication system of the 13B-MSP engine has the following features: – Chain driven trochoid gear type

Engines Powertrain Engine Oil • For the rotary engine, Mazda specifies the use of mineral engine oil. If synthetic or semi-synthetic engine oil is us

Powertrain Engines Cooling System Features • The cooling system of the 13B-MSP engine has the following features: – Water pump driven by the accesso

Engines Powertrain Service Procedures Compression Test • Since the operation of the rotary engine is different to that of a reciprocating engine, a c

Powertrain Engines L1001.4_01118 1 Vehicle battery 3 Adapter (SST) 2 Rotary engine compression tester (SST) NOTE: If the cranking speed d

Powertrain Table of Contents Transmissions...02-1 Drive Train...

Engines Powertrain Notes: 01-60 Curriculum Training

Powertrain Engines Diesel Engines • The following diesel engine types are fitted in the current Mazda models: Model / Engine Y4 Y6 RF-T WL-CMazda2 (

Engines Powertrain Overview L1001.4_01060 01-62 Curriculum Training

Powertrain Engines Cylinder Block • The cylinder block is a conventional construction with separate main bearing caps. L1001.4_01061 Pistons • The

Engines Powertrain Crankshaft • The crankshaft is equipped with a key for the installation of the crankshaft timing pulley and the crankshaft pulley.

Powertrain Engines Cylinder Head • The cylinder head is a conventional construction with separate camshaft bearing caps. • The cylinder head bolts a

Engines Powertrain Camshaft • The camshaft is equipped with a key for the installation of the camshaft pulley. • The camshaft drives the vacuum pump

Powertrain Engines Valve Train • The camshaft is driven by a timing belt, which has to be replaced every 120,000 km. L1001.4_01066 1 Camshaft pull

Engines Powertrain Timing Belt Tensioner • An automatic timing belt tensioner is fitted to ensure optimum belt tension over the service life of the e

Powertrain Engines • When replacing the timing belt, the timing belt tensioner has to be checked as following (refer to the workshop manual for detai

Table of Contents Powertrain Notes: Curriculum Training

Engines Powertrain Valve Timing • For verifying or adjusting the valve timing the timing marks have to be aligned as shown below (refer to the worksh

Powertrain Engines Accessory Drive Belt • A V-ribbed drive belt is fitted to drive the engine accessories. • An automatic tensioner provides constan

Engines Powertrain Lubrication Features • The lubrication system of the RF-T engine has the following features: – Trochoid gear type oil pump, direc

Powertrain Engines Engine Oil • For vehicles with RF-T engine and DPF (Diesel Particulate Filter), Mazda has developed special engine oil called ‘Maz

Engines Powertrain Cooling System Features • The cooling system of the RF-T engine has the following features: – Timing belt driven water pump – U

Powertrain Engines Diesel Particulate Filter System • The DPF is a honeycomb structure with many channels closed off at alternate ends. The soot part

Engines Powertrain Service Procedures Replacing the Engine Oil • Every time the engine oil is replaced, the parameter “Calculated oil dilution” in

Powertrain Engines DPF Manual Regeneration • If the DPF indicator light is illuminated and the DPF is blocked due to an excessive soot amount accumu

Engines Powertrain WL-C Engine • The WL-C engine with 2.5 L displacement (also termed as 2.5 MZR-CD engine) is fitted in the BT-50 models. It is equi

Powertrain Engines Overview L1001.4_01073 NOTE: Some of the components of the WL-C engine are very similar in construction and operation to those o

Powertrain Introduction Introduction • The training course “Powertrain” introduces the various engines and transmissions of the current Mazda model

Engines Powertrain Balancer Shafts • The balancer shafts are directly fitted into the cylinder block. The crankshaft drives the balancer shafts via h

Powertrain Engines Cylinder Head • The cylinder head features a bolted on camshaft bearing frame, which can be replaced separately. • The cylinder h

Engines Powertrain Camshaft • The camshafts are equipped with a pin for the installation of the camshaft pulleys. • The camshaft pulleys for the int

Powertrain Engines Valve Actuation • The camshafts actuate the valves via roller cam followers. • The valve clearance has to be measured between the

Engines Powertrain Valve Train • The camshafts are driven via a timing belt by the fuel high-pressure pump pulley/gear, which in turn is driven via h

Powertrain Engines • The crankshaft gear and the fuel high-pressure pump gear are equipped with friction gears. The spring-loaded friction gears elim

Engines Powertrain Timing Belt Tensioner • The WL-C engine features a modified automatic timing belt tensioner with integrated tensioner pulley. Howe

Powertrain Engines Valve Timing • For verifying or adjusting the valve timing of the gear drive the timing marks have to be aligned as shown below (r

Engines Powertrain • For verifying or adjusting the valve timing of the belt drive, the timing marks have to be aligned as shown below (refer to the

Powertrain Engines Accessory Drive Belt • Three V-drive belts are fitted to drive the engine accessories, i.e. two belts drive the generator and one