TRAINING MANUAL MPV Facelift MME Technical Training 2004 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 © 2004 Mazda Motor Europe GmbH Technical Training Department MPV Facelift Table of contents General Information Introduction Overview .1 Exterior dimensions Engine number location Scheduled maintenance Engine .4 Emission System (RF) Features EGR valve position sensor Control System (RF) Features Parts location System overview Relationship chart DLC-2 outline 10 On-board diagnostic system 11 Diagnostic test modes 11 OBD drive mode 12 PID monitor 13 L3 Engine 16 Features 16 Overview .16 Lubrication 16 Specifications 16 Suspension 17 Front and Rear Suspension .17 Features 17 Parts Location .17 Brakes .18 Conventional Brake System 18 Features 18 Specifications 18 Parts location 19 TCS (RF-T) 20 Features 20 Parts location 20 Wiring diagram 21 Control system 22 On-board diagnostic system 22 Table of contents MPV Facelift Table of contents (continued) HVAC 23 Rear Climate Control 23 Features 23 Parts location 23 Wiring diagram 24 Fuel Fired Heater 25 On-board diagnostic system 25 Combustion test 25 Lockout reset 25 PID monitor 26 Simulation Test Item Table 26 Body and Accessories 27 Features 27 Multiplex communication system .28 Table of contents General Information Introduction • The new Mazda MPV facelift has now been further enhanced to ensure it continues to meet the demands of European customers looking for a vehicle that is safe, fun to be in and drive, with lots of space and flexibility At the same time, full compliance with EOBD regulations of the RF-T engine models and the inclusion of a Karakuri seat version all improve on what was already a successful formula Overview BME0910T001 Exterior dimensions Item Overall length Overall width Overall height Wheel base Front tread Rear tread 2.3L, Euro mm mm mm mm mm mm 2.0L-Diesel, Euro 4805 1830 1785 (roof rail standard) 2840 1540 1550 Homologation Service Training General Information Engine number location L3 BME0000W006 Front RF-T BME0000W006 Front Service Training General Information Scheduled maintenance • The following items in the maintenance schedule have been changed Maintenance Interval (Number of months or kilometers (miles), whichever comes first) Maintenance Months 12 24 36 48 60 72 84 96 Item ×1000 km 20 40 60 80 100 120 140 160 ×1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 GASOLINE ENGINE Engine valve clearance 108 180 112.5 Audible inspect every 120,000km (75,000miles), if noisy, adjust Evaporative system (if installed) I I I Front and rear suspension and ball joints I I I I Drive shaft dust boots I I I I Exhaust system and heat shields Inspect every 80,000km (50,000miles) or 60 months Cabin air filter (if installed)(pollen filter) R R R R Scheduled maintenance Service Training Engine Emission system (RF) Emission System (RF) Features • An EGR (Exhaust Gas Recirculation) valve position sensor has been added to allow compliance with EOBD regulations EGR valve position sensor • The EGRVP (EGR Valve Position) sensor is located at the EGR valve and detects its position by a sliding contact potentiometer When the EGR valve opens the resistance of the potentiometer rises The sensor supplies the PCM with an analogue voltage signal between 0…5 V Diesel_B_series_4 • EGRVP sensor PCM The signal of the EGRVP sensor serves to detect a malfunction of the EGR valve, i.e the PCM (Powertrain Control Module) permanently compares the sensor information with the actual EGR amount The amount of recirculated exhaust gas is determined from the difference between target intake air amount (calculated from the engine speed and the fuel injection amount) and the actual intake air amount detected by the MAF (Mass Air Flow) sensor Service Training Engine Control System (RF) Control System (RF) Features • To comply with EOBD regulations, diagnostic test modes and corresponding DTCs have been added Parts location BME0140W501 Service Training Control System (RF) Engine Parts location (continued) PCM (with built-in BARO sensor) Clutch pedal position switch Neutral switch Idle switch Accelerator pedal position sensor MAF/IAT sensor IAT sensor No.2 ECT sensor Fuel temperature sensor 10 11 12 13 14 15 16 17 18 Boost sensor Fuel pressure sensor CMP sensor CKP sensor Calibration resistor IDM EGR valve position sensor L.H.D R.H.D Service Training Engine Control System (RF) On-board diagnostic system (continued) PID monitor (continued) Monitor item Definition Unit/Condition g/s MAF Mass air flow amount V MAF_C MAF per cylinder G MAF_C_DSD MAF per cylinder desired g MAF_LRN_DIS Distance from the last MAF learning MAINRLY PCM control relay MAP Manifold absolute pressure MIL Malfunction indicator lamp MULTI_INJ Multiple fuel injection control status RPM Engine speed START_SW Starter switch value TC_CMP Fuel correction for traction control VBCV VBC solenoid valve control VFDES Volume fuel desired VPWR Battery positive voltage VSS Vehicle speed Service Training m mile On/Off V Pa inHg On/Off 1_INJ/2_INJ/3_INJ/4_INJ/5_INJ/Disable d RPM On/Off mm /Stroke % mm /Stroke V KPH MPH 15 L3 Engine Engine L3 Engine Features • The L3 engine is basically carried over from the present MPV (LW) except for the following: – – Catylitic convertor performance has been improved – Engine oil capacity has been increased Engine management maps in PCM altered to suit improved catalytic convertor performance Overview AME2202N102 Lubrication Specifications Item Oil pressure (reference value) Specification (kPa {kgf/cm , psi} [rpm]) Total (Dry engine) (L {US qt, lmp qt}) Oil capacity (Approx quantity) Oil replacement (L {US qt, lmp qt}) Oil and oil filter replacement (L {US qt, lmp qt}) 16 300-549 {3.1-5.6, 44-80} [3,000] 5.1 {5.4, 4.5} 4.0 {4.2, 3.5} 4.4 {4.6, 3.9} Service Training Suspension Front and Rear Suspension Front and Rear Suspension Features • New front and rear dampers with multi-layer valves have been adopted (Karakuri seat version only) Parts Location ZMU0214W120 Front shock absorber and spring Front shock absorber Front lower arm Front stabilizer Stabilizer control link Service Training 10 Transverse member Front crossmember Rear shock absorber and spring Rear shock absorber Torsion beam axle 17 Conventional Brake System Brakes Conventional Brake System Features • The brake system on the F/L MPV has undergone the following changes: – – – – Ventilated rear disc brakes have been adopted Larger bore master cylinder has been adopted A tandem diaphragm power brake unit has been adopted Replacement procedure for master cylinder has been changed Specifications L3 Master cylinder Power brake unit Front disc brake Rear disc brake 18 Type Cylinder diameter (mm {in}) Diameter (mm {in}) Type Disc plate dimensions (outer diameter x thickness) (mm {in}) Type Disc plate dimensions (outer diameter x thickness) (mm {in}) RF-T Tandem 25.4 {1.0} 213.4 + 240.2 {8.40 + 9.43} Ventilated 274 x 28 {10.8 x 1.1} 296 x 28 {11.7 x 1.1} Ventilated 286 x 18 {11.3 x 0.7} Service Training Brakes Conventional Brake System Parts location BME0411W506 Vacuum hose check valve Brake pedal Brake switch Master cylinder Fluid level sensor Power brake unit Brake pipe joint Service Training 10 11 12 13 14 Front brake (disc) Disc pad (front) Caliper (front) Rear brake (disc) Disc pad (rear) Caliper (rear) Vacuum pump (MZR-CD (RF Turbo)) 19 TCS (RF-T) Brakes Traction Control System (RF-T) Features • TCS (Traction Control System) has been adopted for RF-T engine models Parts location BME0414W501 20 TCS off switch ABS/TCS HU/CM TCS OFF TCS Service Training Brakes TCS (RF-T) Wiring diagram BME0402W504 10 Ignition switch Battery TCS OFF light TCS indicator light ABS warning light BRAKE system warning light Instrument cluster Motor relay ABS motor Brake switch Service Training 11 12 13 14 15 16 17 18 19 ABS wheel-speed sensor Fail-safe relay Solenoid valve ABS/TCS HU/CM TCS OFF switch Data link connector (DLC) Parking brake switch Brake fluid level sensor Data link connector-2 (DLC-2) 21 TCS (RF-T) Brakes Control system • Communication between the ABS/TCS module and the PCM is carried out through a high-speed CAN-BUS (Controller Area Network-BUS) Data sent – Torque reduction request – Wheel speeds of all four wheels Data received – Engine speed – – – Engine torque Throttle valve opening angle Vehicle speed On-board diagnostic system • The on-board diagnostic system for the RF-T TCS is basically the same as that for the L3 engine system except for the following: – 22 Diagnostic procedures for DTCs C1117,C1119, U0100, U0073 are different than those for the L3 engine Service Training HVAC Rear Climate Control Rear Climate Control Features • A two-dial type rear climate control unit has been adopted • The air-mix door and airflow mode door are actuated by a single actuator, eliminating the air mix actuator (vehicles fitted with rear A/C and heater only) • A ½ hot position (actuator in center position) is available on some models (vehicles fitted with rear heater only) Parts location BME0740W001 Magnetic clutch Refrigerant pressure switch Front blower motor Rear blower motor Front resistor Rear resistor Thermosensor A/C relay Service Training 10 11 12 13 14 15 16 Front blower relay Rear blower relay Front climate control unit Rear main fan switch Rear climate control unit Intake actuator Rear airflow mode actuator (heater only) Rear airflow mode/mix actuator (A/C and heater) 23 Rear Climate Control HVAC Wiring diagram P_07-402 24 Service Training HVAC Fuel Fired Heater Fuel Fired Heater On-board diagnostic system • A self test/combustion test procedure, and lockout reset procedure have been added • PID and simulation item tables have been added to the workshop manual • A symptom troubleshooting index for the fuel fired heater has been added to the workshop manual Combustion test Connect the SST (WDS or equivalent) to the vehicle DLC-2 16-pin connector Select the "Supplemental Heater Test" in the "Supplemental Heater Menu" of the "Guided Diagnosis" function Perform the KOEO Self Test/Combustion Test NOTE: If the water heater unit is operating, the water heater unit will reject the test command Perform the DTC reading procedure after the water heater unit stops operating Lockout reset (using WDS) Connect the SST (WDS or equivalent) to the vehicle DLC-2 16-pin connector Select "CLR_LOCKOUT" and "LOCKOUT Turn "CLR_LOCKOUT" to ON using the simulation function Verify that the "LOCKOUT" reading changes to "Unlocked" Lockout reset (not using WDS) For factory equipped water heater unit Turn the ignition switch to the OFF position Remove the W.HEAT 40 A fuse from the main fuse block for more than seconds Re-install the W.HEAT 40 fuse For vehicles with a transmitter or timer Turn the ignition switch to the OFF position Remove the power supply 40 A fuse from the heater wiring harness for approx seconds Re-install the power supply 40 A fuse Press and hold down the ON switch of the transmitter or timer for approx seconds Remove the power supply 40 A fuse from the heater wiring harness for approx seconds Re-install the power supply 40 A fuse Service Training 25 Fuel Fired Heater HVAC On-board diagnostic system (continued) PID monitor PID Name CCNTFFH ECT VPWR_FFH VPWR_LMT FAN GPD BLOWRMTR FP WATER_PMP GLOW PLUG COMB_FAN LOCKOUT FS HEATER HEATER_SW Definition Number of continuous codes) Engine coolant temperature Module supply voltage Low voltage threshold Fan control Glow plug duty cycle Blower motor Fuel pump Water pump Glow plugs Combustion air fan Heater lockout Flame sensor Heater status Heater activation switch Unit/Condition °C °F V V % % On/Off On/Off On/Off On/Off On/Off Lock/Unlock On/Off Inactive/Active Inactive/Active Simulation Test Item Table Item CLR_LOCKOUT FUEL_PRIME 26 Definition Heater lockout mode clearing command Fuel pump priming command (The fuel pump is activated for seconds.) Operation On/On/- Service Training Body and Accessories Body and Accessories Features • The headlamp design has been changed • Seven new body colours have been introduced: Blue Pacific Mica, Gloaming Silver, Razor Blue, Nordic Green Mica, Titanium Grey II Mica, Arctic White, Snowflake White Pearl • A three spoke steering wheel has been adopted • Karakuri seats are available on some versions • Driver information system now available for diesel vehicles Service Training 27 Body and Accessories Multiplex communication system • A high-speed CAN multiplex communication system, as well as the existing ISO 9141 communication system have been adopted on diesel engine vehicles CAN • The following modules are connected to the CAN bus: – – – – PCM ABS/TCS module Fuel fired heater DLC-2 CAN diagram MPV PCM ABS/TCS module Fuel fired heater DLC-2 Twisted wires ISO 9141 • The following items are connected to the ISO 9141 network: – – – 28 ABS/TCS module DLC-2 DLC-1 Service Training List of abbreviations ABS Anti-Lock Brake System L.H.D Left Hand Drive A/C Air Conditioning R.H.D Right Hand Drive BARO Barometric Pressure MAF Mass Air Flow CAN* Controller Area Network MAP Manifold Absolute Pressure CKP Crankshaft Position OBD On Board Diagnostics CMP Camshaft Position PCM Powertrain Control Module CPP Clutch Pedal Position PID Parameter Identification DLC Data Link Connector SST Special Service Tool DSC Dynamic Stability Control TCS Traction Control System DTC Diagnostic Trouble Code VBC Variable Boost Control ECT Engine Coolant Temperature VSC Variable Swirl Control EGR Exhaust Gas Recirculation VSS Vehicle Speed Sensor HU/CM Hydraulic Unit/Control Module WDS Worldwide Diagnostic System IDM Injector Driver Module KOEO Key On Engine Off Service Training ... make it as complete and accurate as possible © 2004 Mazda Motor Europe GmbH Technical Training Department MPV Facelift Table of contents General Information Introduction ... 21 Control system 22 On-board diagnostic system 22 Table of contents MPV Facelift Table of contents (continued) HVAC 23 Rear Climate Control ... communication system .28 Table of contents General Information Introduction • The new Mazda MPV facelift has now been further enhanced to ensure it continues to meet the demands of European