Training Manual Powertrain (NTOM) CT-L1001.4 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 © 2007 Mazda Motor Europe GmbH Training Services Powertrain Table of Contents Introduction .00-1 Engines 01-1 MESI for Engine Service and Repairs .01-1 Petrol Engines 01-5 L-type Engines 01-5 Mechanical (L8, LF, L3 Engine) 01-6 Features 01-6 Overview .01-6 Cylinder Block .01-7 Pistons 01-8 Crankshaft 01-9 Balancer Shaft Unit .01-11 Cylinder Head .01-12 Camshafts 01-13 Valve Actuation 01-14 Valve Train 01-15 Timing Chain Tensioner .01-16 Variable Valve Timing System 01-18 Valve Timing .01-19 Accessory Drive Belt 01-21 Mechanical (L3-T Engine) 01-22 Features .01-22 Overview .01-22 Pistons 01-23 Cylinder Head .01-23 Camshafts 01-24 Valve Train 01-25 Timing Chain Tensioner .01-25 Valve Timing .01-26 Lubrication 01-27 Features .01-27 Parts Location .01-27 Cooling System 01-28 Features .01-28 Parts Location .01-28 Engine Coolant .01-29 Z-type Engines 01-30 Mechanical 01-30 Features .01-30 Curriculum Training Table of Contents Powertrain Overview .01-31 Cylinder Block .01-32 Pistons 01-33 Crankshaft 01-34 Camshafts 01-35 Valve Train 01-35 Valve Timing .01-36 Lubrication 01-37 Features .01-37 Pats Location 01-37 Cooling System 01-38 Features .01-38 Parts Location .01-38 Service Procedures .01-39 Adjusting the Idle Speed .01-39 MZI-type Engines 01-40 Mechanical 01-40 Features .01-40 Overview .01-41 Cylinder Block .01-42 Valve Train 01-43 Timing Belt Tensioner 01-44 Accessory Drive Belts 01-46 Lubrication 01-48 Features .01-48 Cooling System 01-48 Features .01-48 13B-MSP Rotary Engine 01-49 Mechanical 01-49 Features .01-49 Overview .01-49 Construction 01-50 Operating Principle .01-52 Intake Stroke 01-53 Compression Stroke .01-53 Combustion Stroke .01-53 Exhaust Stroke .01-53 Lubrication 01-55 Features .01-55 Parts Location .01-55 Engine Oil .01-56 Cooling System 01-57 Features .01-57 Parts Location .01-57 Service Procedures .01-58 Compression Test 01-58 Curriculum Training Powertrain Table of Contents Diesel Engines 01-61 RF-T Engine 01-61 Mechanical 01-61 Features .01-61 Overview .01-62 Cylinder Block .01-63 Pistons 01-63 Crankshaft 01-64 Cylinder Head .01-65 Camshaft 01-66 Valve Actuation 01-66 Valve Train 01-67 Timing Belt Tensioner 01-68 Valve Timing .01-70 Accessory Drive Belt 01-71 Lubrication 01-72 Features .01-72 Parts Location .01-72 Engine Oil .01-73 Oil Dipstick 01-73 Cooling System 01-74 Features .01-74 Parts Location .01-74 Diesel Particulate Filter System 01-75 Service Procedures .01-76 Replacing the Engine Oil 01-76 Injection Amount Learning Function .01-76 DPF Manual Regeneration 01-77 WL-C Engine .01-78 Mechanical 01-78 Features .01-78 Overview .01-79 Balancer Shafts 01-80 Cylinder Head .01-81 Camshaft 01-82 Valve Actuation 01-83 Valve Train 01-84 Timing Belt Tensioner 01-86 Valve Timing .01-87 Accessory Drive Belt 01-89 Lubrication 01-90 Features .01-90 Parts Location .01-90 Cooling System 01-91 Features .01-91 Parts Location .01-91 Service Procedures .01-92 MAF Sensor Learning Function 01-92 Curriculum Training Table of Contents Powertrain Y-type Engines 01-93 Mechanical (Y4 Engine) 01-93 Features .01-93 Overview .01-94 Cylinder Block .01-95 Pistons 01-96 Crankshaft 01-97 Cylinder Head 01-100 Valve Actuation 01-101 Valve Train 01-102 Timing Belt Tensioner .01-103 Valve Timing .01-104 Mechanical (Y6 Engine) 01-105 Features .01-105 Overview 01-105 Cylinder Head 01-106 Camshafts 01-107 Valve Train 01-109 Lubrication 01-110 Features .01-110 Parts Location 01-110 Cooling System 01-111 Features .01-111 Parts Location 01-111 Diesel Particulate Filter System .01-112 Service Procedures 01-113 Bleeding the Fuel System 01-113 Refilling the Fuel Additive Tank 01-114 Installing a New DPF 01-115 DPF Manual Regeneration 01-115 Curriculum Training Powertrain Table of Contents Transmissions 02-1 Drive Train 02-1 Transmission Code 02-2 Manual Transmissions .02-3 F35M-R Transmission 02-4 Overview .02-4 Service Procedures .02-5 Transmission Oil Inspection 02-5 A26M(X)-R Transmission 02-6 Overview .02-6 S15M(X)-D Transmission 02-8 Overview .02-8 Automated Shift Manual Transmission 02-09 Overview 02-09 Service Procedures .02-10 Bleeding the Clutch System 02-10 Automatic Transmissions 02-11 FS5A-EL Transmission 02-12 Overview .02-12 Limited Slip Differential 02-13 Overview 02-13 Service Procedures .02-14 Rear Differential Oil Inspection and Oil Replacement 02-14 List of Abbreviations .03-1 Curriculum Training Table of Contents Powertrain Notes: Curriculum Training Powertrain Introduction Introduction • The training course “Powertrain” introduces the various engines and transmissions of the current Mazda models with the main focus on the mechanical system • It is one part of the NTOM (New-To-Mazda) course, which is addressed to entry-level Mazda technicians Successful attendance of the NTOM course is a prerequisite for participation in any technical courses of the Mazda Masters program • Anyone associated with the diagnosis and repair of Mazda vehicles must have the knowledge to deliver a “Fix it right first time” repair Therefore, the Mazda Masters development and qualification path provides the following training courses required for servicing Mazda vehicles: – – – – Introduction To Mazda (NTOM) CT-L1001.1 Mazda Modular Diagnostic System (NTOM) CT-L1001.2 Chassis and Body (NTOM) CT-L1001.3 Powertrain (NTOM) CT-L1001.4 • The ranking of this course within the Mazda Masters educational system is Level – ‘Mazda Technician’ It is intended for technicians without Mazda experience, who already have started their new job at a Mazda dealer • The training manual “Powertrain” is divided into the following main chapters: – – Engines Transmissions Curriculum Training 00-1 Introduction Powertrain Notes: 00-2 Curriculum Training Transmissions Powertrain Transmission Code • The transmissions of the current Mazda models except for Mazda2 (DY) have a 5- or 6-digit alphanumerical code, which contains the information shown below A2 M X - R * Additional information Operation system Drive train type Transmission type Number of forward gears Transmission type L = Torque converter clutch (AT or ATX) D = Direct control E = Electronic control H = Hydraulic control R = Remote control (Cable/Rod) X = 4WD A = Automatic transmission (AT or ATX) M = Manual transmission (MT or MTX) = Four speed = Five speed = Six speed Transmission series L1001.4_T02001 02-2 Curriculum Training Powertrain Transmissions Manual Transmissions • Depending on the installation position of the engine different types of manual transmissions are used Vehicles with transversally installed engine feature a MTX (Manual Transaxle) and vehicles with longitudinally installed engine a MT (Manual Transmission) The basic difference between MTX and MT is that the MTX has a differential integrated in the transmission housing, while the MT has an external differential at the rear axle • The MTX and MT fitted in the current Mazda models have the following features: – – – – – – • Five or six speeds Two shafts or three shafts (the latter ones in coaxial or non-coaxial arrangement) Single-cone, double-cone or triple-cone synchronizer mechanism Operated via cable or directly by shift lever Hydraulic clutch actuation Conventional or dual-mass flywheel The following MTX are fitted in the current Mazda models: Model / MTX Mazda2 (DY) Mazda3 Mazda3 MPS Mazda5 Mazda6 Mazda6 MPS Mazda CX-7 iB5 X F35M-R G35M-R J65M-R G66M-R A26M-R X X X X X X X X X X A26MX-R X X L1001.4_T02002 • The following MT are fitted in the current Mazda models: Model / MT Mazda MX-5 Mazda RX-8 Mazda BT-50 M15M-D X R15M-D S15M-D S15MX-D X X X P66M-D X Y16M-D X L1001.4_T02003 NOTE: All the manual transmissions are very similar in operation and servicing Therefore, this section only shows some samples of current manual transmissions Curriculum Training 02-3 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 in the Mazda3 models with Z-type engine Overview L1001.4_02020 02-4 Input shaft Output shaft Differential Curriculum Training Powertrain Transmissions Service Procedures Transmission Oil Inspection • For transmission oil inspection on the F35M-R transmission the distance between upper edge of the hole in the transmission housing and oil level must be measured as shown below (refer to the workshop manual for details) NOTE: Since the oil inspection and oil replacement procedures may differ depending on the transmission type or may be revised concerning the oil capacity and/or oil specification, always refer to the respective workshop manual L1001.4_02022 Distance Hole in the transmission housing Curriculum Training Vehicle front 02-5 Transmissions Powertrain A26M(X)-R Transmission • The A26M(X)-R transmission is a three-shaft (non-coaxial arranged) six-speed MTX, which is operated via cables • The A26M-R transmission is fitted in the Mazda3, Mazda5 and Mazda6 models with RF-T engine, and in the Mazda3 MPS models The A26MX-R transmission with boltedon transfer case is fitted in the Mazda6 MPS and Mazda CX-7 models NOTE: When replacing or refilling the transmission oil and/or the separate transfer oil only use the specified type of oil (refer to the workshop manual for details) Overview L1001.4_02021 02-6 Output shaft no Input shaft Transfer case (A26MX-R) Differential Output shaft no Curriculum Training Powertrain Transmissions • The three shaft design with one input shaft and two output shafts allows for a more compact construction, since each output shaft only carries three or four gears • As a result of this construction there are two different final gear ratios available, i.e one for the first to fourth gear and another one for the fifth, sixth and reverse gear L1001.4_02003 Differential Output shaft no Curriculum Training Output shaft no Input shaft 02-7 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 shift lever • The S15M-D transmission is fitted in the RWD version of the Mazda BT-50, while the S15MX-D transmission with bolted-on transfer case is fitted in the 4WD version NOTE: When replacing or refilling the transmission oil and/or the separate transfer oil only use the specified MTF (Manual Transmission Fluid) “Type A” (refer to the workshop manual for details) Overview L1001.4_02006 02-8 Output shaft Extension housing (S15M-D) Transfer case (S15MX-D) Counter shaft Input shaft Curriculum Training Powertrain Transmissions Automated Shift Manual Transmission • The automated shift manual transmission is based on the two-shaft five-speed MTX iB5 Compared to the cable operated version of the iB5 transmission the automated shift manual transmission features a bolted-on shift actuator, and a separate clutch actuator with integrated TCM (Transmission Control Module) Depending on the signals from the TCM the clutch actuator operates the clutch via the clutch slave cylinder, and the shift actuator performs the gearshifts accordingly • The automated shift manual transmission is only fitted in the Mazda2 (DY) models with 1.4 MZI engine Overview L1001.4_02011 Clutch actuator with integrated TCM Shift actuator Curriculum Training Clutch slave cylinder 02-9 Transmissions Powertrain Service Procedures Bleeding the Clutch System • The hydraulic fluid of the clutch system should be replaced every two years, together with the hydraulic fluid of the brake system Since the clutch system can only be bled in a certain position of the clutch master cylinder, the clutch actuator first needs to be driven to this position with the aid of M-MDS To perform the procedure select the option ToolboxÆ PowertrainÆASM Service FunctionsÆShift Actuator Bleed and follow the instructions of M-MDS 02-10 Curriculum Training Powertrain Transmissions Automatic Transmissions • Depending on the installation position of the engine different types of automatic transmissions are used Vehicles with transversally installed engine feature an ATX (Automatic Transaxle) and vehicles with longitudinally installed engine an AT (Automatic Transmission) The basic difference between ATX and AT is that the ATX has a differential integrated in the transmission housing, while the AT has an external differential at the rear axle For the current European Mazda models only ATX are available • The ATX fitted in the current Mazda models have the following features: • – – Four, five or six speeds – – – Hydraulically controlled clutches, brakes and brake bands Two or three single type planetary gear sets, or a single type planetary gear set in combination with a Ravigneaux planetary gear set Torque converter with torque converter clutch Electronic control system integrated in the PCM or in a separate TCM The following ATX are fitted in the current Mazda models: Model / ATX Mazda3 Mazda6 Mazda CX-7 FN4A-EL FS5A-EL AW6AX-EL X X X L1001.4_T02005 NOTE: All the automatic transmissions are very similar in operation and servicing Therefore, this section only shows one sample of the current automatic transmissions Curriculum Training 02-11 Transmissions Powertrain FS5A-EL Transmission • The FS5A-EL transmission is a five-speed ATX, which is controlled electronically by a TCM It is only fitted in the Mazda6 models with LF and L3 engine NOTE: When replacing or refilling the ATF (Automatic Transmission Fluid) and/or the separate transfer oil only use the specified type of oil (refer to the workshop manual for details) Overview L1001.4_02013 Torque converter Torque converter clutch 02-12 Differential Curriculum Training Powertrain Transmissions Limited Slip Differential • For the current Mazda models a taper ring type LSD (Limited Slip Differential) is used (also termed as “Super LSD”) It is fitted to the rear axle of the Mazda6 MPS, Mazda MX-5, Mazda RX-8, Mazda BT-50, and to the MTX of the Mazda3 MPS Overview L1001.4_02017 Mazda MX-5 Pinion gear Side gear Cone Curriculum Training Taper ring Retainer Spring 02-13 Transmissions Powertrain Service Procedures Rear Differential Oil Inspection and Oil Replacement • There are two different rear differentials (type A and type B) for the Mazda BT-50 The difference is the position of the oil filler hole due to a revised oil capacity On the type A rear differential the oil level is higher than the oil filler hole, i.e special measures are required for rear differential oil inspection and oil replacement A caution label on the rear differential informs about this condition (refer to the respective service information for details) • On the type B rear differential the oil level is flush with the oil filler hole, i.e rear differential oil inspection and oil replacement can be performed as usual (refer to the workshop manual for details) L1001.4_02019 Type A rear differential Type B rear differential Oil filler plug 02-14 Oil drain plug Caution label Curriculum Training Powertrain List of Abbreviations A/C Air Conditioning F/L Facelift ACEA Association des Constructeurs Européens d'Automobiles FWD Front Wheel Drive HC Hydro Carbon API American Petroleum Institute LCD Liquid Crystal Display AT Automatic Transmission LF Left Front ATF Automatic Transmission Fluid LSD Limited Slip Differential ATX Automatic Transaxle MAF Mass Air Flow AWD All Wheel Drive MESI BDC Bottom Dead Center Mazda Electronic Service Information CKP Crankshaft Position M-MDS Mazda - Modular Diagnostic System CM Control Module MPS Mazda Performance Series MSP Multi Side Port MT Manual Transmission MTF Manual Transmission Fluid MTX Manual Transaxle Electronically Controlled Coupling PCM Powertrain Control Module FACM Fuel Additive Control Module RF Right Front FGT Fixed Geometry Turbine RWD Rear Wheel Drive FIP Fuel Injection Pump CMP DISI DOHC DPF ECC Camshaft Position Direct Injection Spark Ignition Double Overhead Camshaft Diesel Particulate Filter Curriculum Training 03-1 List of Abbreviations SAE Society of Automotive Engineers SOHC Single Overhead Camshaft SST Special Service Tool TCM Transmission Control Module TEN Test ENgine TCM Transmission Control Module TDC Top Dead Center VGT Variable Geometry Turbocharger WDS Worldwide Diagnostic System W/M Workshop Manual 2WD Wheel Drive 4WD Wheel Drive 03-2 Powertrain Curriculum Training ... vehicles: – – – – Introduction To Mazda (NTOM) CT- L1001. 1 Mazda Modular Diagnostic System (NTOM) CT- L1001. 2 Chassis and Body (NTOM) CT- L1001. 3 Powertrain (NTOM) CT- L1001. 4 • The ranking of this... 01 -40 Mechanical 01 -40 Features .01 -40 Overview .01 -41 Cylinder Block .01 -42 Valve Train 01 -43 Timing Belt Tensioner 01 -44 ... 01 -46 Lubrication 01 -48 Features .01 -48 Cooling System 01 -48 Features .01 -48 13B-MSP Rotary Engine 01 -49 Mechanical 01 -49