Mazda 2006 Mazda5 Technical Information

TRAINING MANUAL Mazda5

General Information • A towing eyelet and tie down hook are provided at the rear of the vehicle. M5_00006 1 Tie down hook 2 Towing eyelet Veh

Emission System 2.0 MZR-CD Engine Regeneration Process to the effect of the catalytic coating the diesel particles are burnt off above • Due a temp

2.0 MZR-CD Engine Emission System Regeneration Intervals • Depending on the operating conditions of the vehicle the DPF is regenerated ever100…300 k

Charging System 2.0 MZR-CD Engine Charging System Features The charging system of the vehicles with 2.0 MZR-CD engine has the following features– Sm

2.0 MZR-CD Engine Charging System Smart Charging System lled "Smart Charging System” has been introduced to improve battery charging and durabil

Charging System 2.0 MZR-CD Engine • When the battery voltage/battload is low, the PCM controls ery electrolyte temperature is high and/or the genera

2.0 MZR-CD Engine Control System Control System tures Feaeto resistive-type crankshaft and camshaft position sensor have been introduced. – Hall-typ

Control System 2.0 MZR-CD Engine A LHD B RHD t gas temperature sensor 17 Main fuse box position switch 18 Glow plug relay 5 6 re sensor 7 n8

2.0 MZR-CD Engine Control System Rela ship Chart d Glow contVariable boost controlInjection timing contrololrolrolElectA/C controlGenerator controlIm

Control System 2.0 MZR-CD Engine Powertrain Control Module • The PCM (Powertrain Control Module) is located behind a cover in the passenger footwell

2.0 MZR-CD Engine Control System Crankshaft Position Sensor • An magneto resistive-type CKP (Crankshaft Position) sensor has been introduced,which i

General Information • The VIN key is shown as below: JMZ CR 1 9 8 2 5 # 1 2 3 4 5 6Serial No.Plant0 = Hiroshima1 = HofuFor Europe-RHD : Dummy 0F

Control System 2.0 MZR-CD Engine • The magneto resistive elemedepending on the magnetic flux. Whents have the characteristics that their resistance

2.0 MZR-CD Engine Control System Camshaft Position Sensor An magneto resistive-type CMP (Camshaft Position) sensor has been introduced, wis located a

Control System 2.0 MZR-CD Engine • The magneto resistive elemdepending on the magnetic flux. Wheents have the characteristics that their resistance

2.0 MZR-CD Engine Control System Accelerator Pedal Position Sensor A hall-type APP (Accelerator Pedal Position) sensor has been introduced. For safet

Control System 2.0 MZR-CD Engine • When the magnetic rotor rotates, a vovoltage is very low, it is amplified in the sensor altage is generated in th

2.0 MZR-CD Engine Control System • Each hall-type sensor supplies the PCM with an analogue voltage signal between 0…5 V. In order to facilitate fail

Control System 2.0 MZR-CD Engine Power Steering Pressure Switch A PSP (Powe• r Steering Pressure) switch located at the power steering oil pump has

2.0 MZR-CD Engine Control System Maintenance and Repair Replacing the engine oil Every time the engine oil is replaced, the parameter “Calculated oil

Control System 2.0 MZR-CD Engine NOTE: If the exhaust gas temperature during manual regeneration exceeds a certain limit, regeneration process and i

2.0 MZR-CD Engine Control System Replacing the EGR valve or the ISV r replacing the EGR valve or the ISV, its adaptation values in the PCM must b the

General Information Engine Identification Number • The engine identification number is located on the cylinder block as shown below: L8/LF M5_00008

Control System 2.0 MZR-CD Engine Replacing the HO2S • After replacing the HO2S, its adaptation values in the PCM must be reset with the aid of the W

2.0 MZR-CD Engine On-board Diagnostic System On-board Diagnostic System • diagnostic system consists of the following functions: – ction PID monit

On-board Diagnostic System 2.0 MZR-CD Engine PID Monitor • The PIDTherefore, select the opt monitor function allows to monitor the PIDs of the PCM w

2.0 MZR-CD Engine On-board Diagnostic System Item Definition Unit/ConditionFAN_DUTY Fan control duty cycle %FI_LRN_01 Fuel injection learning value

On-board Diagnostic System 2.0 MZR-CD Engine Item Definition Unit/Conditiong/sVMAF_C Mass air flow per cylinder gMAF_C_DSD Mass air flow per cylinde

2.0 MZR-CD Engine On-board Diagnostic System Simulation Test • The simulation test function allows to activate certain PIDs of the PCM with the aid

On-board Diagnostic System 2.0 MZR-CD Engine Notes: 01-104 Service Training Mazda5

02 Suspension

02 Suspension Wheels and Tires...1 Specifications...

Suspension Wheels and Tires Wheels and Tires • Wheel and tire sizes are the same as the current Mazda3 (BK), but tire speed ratings have changed. Sp

General Information Technical Data Displacement Bore x StrokeCompression RatioMaximum PowerMaximum TorqueEmission StandardDisplacement Bore x Stroke

Front Suspension Suspension Front Suspension Features • The front suspension of the Mazda5 is essentially the same as the current Mazda3 (BK). It ha

Suspension Front Suspension Specifications L8,LF MZR-CD(mm {in})Tire[Tolerance ±4 {0.15}]Rim inner InnerOuter3 °14´ 3 °12´-0 °42´ -0 °44´ 13 °59´ 14

Front Suspension Suspension Front Shock Absorber • A shock absorber with an internal rebound spring is used to control wheel-lift* during hard corne

Suspension Rear Suspension Rear Suspension Features • The rear suspension is essentially the same as the current Mazda3 (BK). It has the following fe

Rear Suspension Suspension Specifications (mm {in})Tire[Tolerance ±4{0.15}]Rim innerCamber angle [Tolerance ±1°]SpecificationTypeCoil springMulti-lin

03 Driveline/ Axle

03 Driveline/Axle Front Axle...1 Features...

Driveline/Axle Front Axle Front Axle Features • The front axle on the Mazda5 is essentially the same design as that of the current Mazda3 (BK). It ha

Rear Axle Driveline/Axle Rear Axle Features • The rear axle on the Mazda5 is essentially the same design as that of the current Mazda3 (BK). It has

Driveline/Axle Drive Shaft Drive Shaft Features • The drive shafts on the Mazda5 are essentially the same design as those on the current Mazda3 (BK).

General Information Maintenance Schedule 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

Driveline/Axle NOTES: 03-4 Service Training Mazda5

04 Brakes

04 Brakes Conventional Brake System...1 Features...

Brakes Conventional Brake System Conventional Brake System Features • The construction and operation of the brake system is essentially the same as

Conventional Brake System Brakes Master Cylinder • The master cylinder remote reservoir is attached to the vehicle body under the cowl panel, and co

Brakes Antilock Brake System Antilock Brake System Features • The construction and operation of the ABS (Antilock Brake System) is essentially the s

Dynamic Stability Control Brakes Dynamic Stability Control • The construction and operation of the DSC (Dynamic Stability Control) is essentially th

Brakes Dynamic Stability Control Combine Sensor • The combine sensor is located on the cross member under the front right seat, and detects the vehi

Dynamic Stability Control Brakes NOTES: 04-6 Service Training Mazda5

05 Transmission/ Transaxle

General Information I : Inspect and clean, repair, adjust, or replace if necessary. R : Replace C : Clean D : Drain • Refer below for a descripti

05 Transmission/ Transaxle Manual Transaxle ...1 Features

Transmission/Transaxle Manual Transaxle Features • The transmission/transaxle has the following features: – Cable operated shift mechanism. – Shif

G35M-R Transmission/Transaxle G35M-R Transmission • The G35M-R manual transaxle is essentially the same as that used on the current Mazda3 (BK) with

Transmission/Transaxle Overview M5_05016 1 First gear 9 Secondary shaft fourth gear 2 Reverse idler gear 10 Secondary shaft third gear 3 Re

G35M-R Transmission/Transaxle Triple Cone Synchronizer • A triple-cone synchronizer mechanism is used for the first and second gears. • The constru

Transmission/Transaxle Shift Mechanism • A cable operated shift mechanism similar to the current Mazda3 (BK) is used. • The main selector cable is

A26M-R Transmission/Transaxle A26M-R Transmission • The A26M-R 6-speed manual transaxle is manufactured by Aisin, and designed for front-wheel-drive

Transmission/Transaxle A26M-R Construction • The A26M-R manual transaxle is a three-shaft design; one primary (input) shaft and two secondary (output

A26M-R Transmission/Transaxle Cross-sectional View M5_05007 1 Primary shaft 8 Final gear No. 1 2 Final gear No. 2 9 First gear 3 Reverse

Transmission/Transaxle A26M-R Power Flow First to Sixth Gear M5_05008 1 First gear 4 Fourth gear 2 Second gear 5 Fifth gear 3 Third g

General Information NOTES: 00-10 Service Training Mazda5

A26M-R Transmission/Transaxle Reverse Gear M5_05009 1 Reverse gear 05-10 Service Training Mazda5

Transmission/Transaxle A26M-R Synchronizer Clutch Hub • A ball-type detent mechanism is used in each clutch hub to reduce the overall dimensions of

A26M-R Transmission/Transaxle Shift Interlock Mechanism • The shift interlock mechanism prevents two gears being engaged at the same time. During sh

Transmission/Transaxle A26M-R 1 Reverse shift fork 9 First gear 2 Inner lever 10 Second gear 3 Fifth/sixth gear shift fork 11 Third gea

A26M-R Transmission/Transaxle Shift Mechanism • A cable operated shift mechanism similar to the current Mazda3 (BK) is used. • The main selector cab

Transmission/Transaxle A26M-R Reverse Lockout Mechanism • The reverse lockout mechanism consists of a guide plate attached to the shift lever assemb

A26M-R Transmission/Transaxle Oil Level Inspection • The A26M-R manual transaxle is filled with 2.55 litres of manual transaxle oil which complies wi

06 Steering

06 Steering Steering...1 Features...

Steering Steering Features • The steering system has the following features: – Steering column with tilt and telescopic adjustment, as well as bend

01 Engines

Power Steering Steering Power Steering Features • Electro-hydraulic power steering for vehicles with L8/LF engine (similar to Mazda3 (BK) with LF en

Steering Power Steering 1 Steering wheel 7 Steering angle sensor 2 Steering column and shaft 8 Instrument cluster 3 Steering gear and linkage 9

Power Steering Steering Electro Hydraulic Power Assist Steering (L8/LF engines) Features • The same EHPAS as that utilized on the current Mazda3 (BK

Steering Power Steering Wiring Diagram M5_06003 1 EHPAS control module 8 CAN driver 2 Battery 9 CAN_L 3 EHPAS 80 A fuse 10 CAN_H 4 Ignition

Steering NOTES: 06-6 Service Training Mazda5

07 Heating, Ventilation& Air Conditioning

07 HVAC Basic System...1 Features...

HVAC Basic System Basic System Features • The construction and operation of the HVAC (Heater/Ventilator/Air Conditioning) is essentially the same as

Control System HVAC Control System Manual Air Conditioning • Control of the manual air conditioning is essentially the same as that for the current

HVAC Control System Climate Control Unit • A wire operated climate control unit is used with the manual air conditioning. • The airflow mode dial fe

01 Engines Table of Contents L8/LF Engines Mechanical System ...

Control System HVAC Operation • When the A/C is switched on, the climate control unit sends an “A/C on request” signal via cable to the BCM (Body Co

HVAC Control System Wiring Diagram M5_07005 1 Blower relay 8 Refrigerant pressure switch 2 Blower motor 9 Fan switch 3 Resistor 10 Climate co

Control System HVAC Full-auto Air Conditioning • Control of the full-auto air conditioning is essentially the same as that for the current Mazda3 (B

HVAC Control System Wiring Diagram M5_07012 Service Training Mazda5 07-7

Control System HVAC 1 Ambient temperature sensor 11 Blower relay 2 Cabin temperature sensor 12 Power MOS-FET 3 Evaporator temperature sensor

HVAC Control System Climate Control Unit • A logic-type climate control unit is used. It is connected via the MS-CAN to the BCM. • The current statu

Control System HVAC M5_07008 07-10 Service Training Mazda5

HVAC Control System 1 Ambient temperature sensor 15 Airflow mode actuator 2 ECT sensor 16 Air intake actuator 3 Cabin temperature sensor 17

Control System HVAC On-board Diagnostic System • The on-board diagnostic system is essentially the same as the current Mazda3 (BK) except for the fo

HVAC Water Heater System Water Heater System (MZR-CD engine) • To improve heating capability directly after cold start, an additional water heater s

01 Engines Table of Contents (continued) Emission System...

Water Heater System HVAC Operation • The water heater control module outputs a signal to the blower fan and the fuel pump, which then deliver air an

HVAC Water Heater System Starting Conditions • The water heater system will start to operate when all of the following conditions are met: – Ambien

Water Heater System HVAC On-board Diagnostics • The on-board diagnostic system consists of the following functions: – Self-test – PID monitor – S

HVAC Water Heater System Start Heater Utility • The operation of the water heater can be tested by using the FFH Start Heater Utility. To do this fi

HVAC NOTES: 07-18 Service Training Mazda5

08 Restraint System

08 Restraint System Airbag System ...1 Features...

Restraints Airbag System Airbag System Features • The airbag system has the following features: – Single-stage front airbags are used. – Side airba

Airbag System Restraints Parts Location M5_08001 1 Airbag system warning light 8 Side airbag 2 Driver-side airbag 9 Curtain airbag 3 Clock

Restraints Airbag System Wiring Diagram M5_08002 Service Training Mazda5 08-3

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

01 Engines Table of Contents (continued) Cooling System ...

Airbag System Restraints 1 SAS control module 14 Passenger-side side airbag sensor No. 2 2 Instrument cluster 15 Poor connection detector bar

Restraints Airbag System SAS Control Module • The SAS (Sophisticated Airbag Sensor) control module is located on the centre tunnel, near to the gear

Airbag System Restraints Side Airbag Sensors • Two side airbag sensors are installed to each side of the vehicle, one at the base of the B-pillar an

Restraints Airbag System Curtain Airbags • Instead of using propellants to inflate the curtain airbags, the curtain airbags of the Mazda5 utilize gas

Airbag System Restraints Seatbelt Pretensioners • Rack-type seatbelt pretensioners similar to those used in the Mazda2 have been adopted for the fro

Restraints Airbag System Operation • Under normal conditions, the clutch rollers that are installed around the circumference of the spindle roll free

Airbag System Restraints • When a deployment signal is received from the SAS module, gas is produced by the gas generator (gas is generated in the s

Restraints Airbag System On-board Diagnostic System • The main functions of the on-board diagnostic system are: – Self-test – PID monitor Self Tes

Airbag System Restraints PID Monitor • The PID monitor function allows airbag system PIDs to be monitored. To do this, connect the WDS to the vehicl

Restraints Seat Belts Seat Belts Features • The seatbelts of the Mazda5 have the following features: – Seatbelts with pretensioners, load limiter, a

01 Engines Table of Contents (continued) Charging System...

Seat Belts Restraints Child Restraint Anchors M5_08011 1 Top tether belt 3 Second-row seat 2 ISOFIX anchor 08-14 Service Training Mazda5

09 Body & Accessories

09 Body & Accessories Table of Contents Body Panels...

09 Body & Accessories Table of Contents (continued) Keyless Start Function ...

09 Body & Accessories Table of Contents (continued) Front Combination Light...

09 Body & Accessories Table of Contents (continued) LCD Unit ...

09 Body & Accessories Table of Contents (continued) Instrument Cluster ...

Body & Accessories Body Panels Body Panels Features • The body shell of the Mazda5 has the following features: – Triple H-construction is used.

Body Panels Body & Accessories • In the event of a side collision, the triple-H frame structure effectively distributes force in an H-pattern al

Body & Accessories Doors and Liftgate Doors and Liftgate Features • The doors on the Mazda5 have the following features: – Door units integrati

NOTES: Table of Contents 01 Service Training Mazda5

Doors and Liftgate Body & Accessories Sliding Doors • To allow easier entry and exiting of the vehicle, sliding doors are provided on both sides

Body & Accessories Doors and Liftgate Sliding Door Open Lock Actuator • The sliding door open lock actuator holds the sliding door in the fully

Doors and Liftgate Body & Accessories Liftgate • The liftgate consists of an outer skin made of polycarbonate ABS (Acrylonitrile-Butadiene-Styre

Body & Accessories Seats Seats Features • The seats on the Mazda5 have the following features: – The Mazda5 is available in two seating layouts

Security and Locks Body & Accessories Security and Locks Features • The security and lock system on the Mazda5 (CR) has the following features:

Body & Accessories Security and Locks Standard Keyless Entry system • The standard Keyless Entry system is similar to that on the Mazda3, with t

Security and Locks Body & Accessories Wiring Diagram M5_09026 09-10 Service Training Mazda5

Body & Accessories Security and Locks 1 Cargo compartment light 12 Sliding door lock actuator (LH) 2 Liftgate latch switch 13 Sliding door l

Security and Locks Body & Accessories M5_09028 1 Release tab 09-12 Service Training Mazda5

Body & Accessories Security and Locks Advanced Keyless Entry and Start System • The Advanced Keyless Entry and Start System allows the vehicle t

L8/LF Engines Mechanical System Mechanical System Features • The mechanical system of the L8/LF engines is essentially the same as the Mazda6 (GG/GY

Security and Locks Body & Accessories 1 Start knob (ignition switch) 14 Rear door lock actuator 2 Security light 15 Rear door latch 3 Coi

Body & Accessories Security and Locks Wiring Diagram M5_09012 Service Training Mazda5 09-15

Security and Locks Body & Accessories 1 Keyless control module 18 Keyless antenna (interior, front) 2 Keyless receiver 19 Keyless antenna

Body & Accessories Security and Locks Card Key • A thin, card type transmitter has been adopted. • The card key incorporates buttons to lock an

Security and Locks Body & Accessories Request Switch • Request switches are installed to driver’s door, passenger’s door, and liftgate respectiv

Body & Accessories Security and Locks Keyless Antennas • A total of six antennas send request signals to card keys, and relay card key ID’s to t

Security and Locks Body & Accessories Keyless Control Module • The Keyless Control Module is located behind the driver’s side kick panel. It con

Body & Accessories Security and Locks Steering Lock Unit • The steering lock unit consists of the steering lock and the start knob. When the sta

Security and Locks Body & Accessories Keyless Entry Function • Unlocking and locking of doors can be achieved either by using the auxiliary key,

Body & Accessories Security and Locks Locking/Unlocking Using Transmitter • When either of the buttons on the transmitter is pushed, the transmi

Mechanical System L8/LF Engines Engine Performance Curve M501T066 1 L8 engine 4 Output 2 LF engine 5 Torque 3 Engine speed 01-2 Service Tra

Security and Locks Body & Accessories Locking/Unlocking Using Request Switches • Whenever one of the request switches is pressed, the Keyless Co

Body & Accessories Security and Locks • The doors will only lock when a request switch is pushed if the following conditions are all met: – The

Security and Locks Body & Accessories Auto Re-lock Function • The doors will automatically re-lock 30 seconds after being unlocked unless any of

Body & Accessories Security and Locks Keyless Start Function • If the driver has a card key with them when they enter the car, it is not necessa

Security and Locks Body & Accessories M5_09016 1 ID verification NG 6 Keyless control module 2 Red keyless indicator light (flashing) 7

Body & Accessories Security and Locks Guidance Function • The driver is informed of faults or misuse of the system via the warning light and the

Security and Locks Body & Accessories M5_09T001a ustomization • The following functions can be switched ON or OFF using WDS: ). Buzzer(Interio

Body & Accessories Security and Locks Service and Repair Programming Additional Card Keys With Two or More Card Keys • If two or more registered

Security and Locks Body & Accessories Erasing Registered Card Keys 1. Establish communication between WDS and the vehicle. 2. Select the option

Body & Accessories Security and Locks On-board Diagnostic System • The on-board diagnostic system consists of the following functions: – Self-t

L8/LF Engines Lubrication System Lubrication System Features • The lubrication system is essentially the same as that on the Mazda6 (GG/GY). It has

Security and Locks Body & Accessories Simulation Test • The simulation test function allows certain PIDs for the Advanced Keyless Entry system t

Body & Accessories Security and Locks Immobilizer System (vehicles with standard Keyless Entry system) • The immobilizer system is basically the

Security and Locks Body & Accessories UNSATISFACTORYRESULT SATISFACTORY RESULTUNSATISFACTORYRESULT SATISFACTORY RESULT5. The instrument cluster

Body & Accessories Security and Locks Service Training Mazda5 09-37 Immobilizer System (vehicles with Advanced Keyless Entry system) • A D-PATS

Security and Locks Body & Accessories 09-38 Service Training Mazda5 Operation • Control of the immobilizer system on the Mazda5 with Advanced Ke

Body & Accessories Security and Locks Service Training Mazda5 09-39 UNSATISFACTORYRESULT SATISFACTORY RESULTUNSATISFACTORYRESULT SATISFACTORY

Security and Locks Body & Accessories 09-40 Service Training Mazda5 Immobilizer System Component Replacement Operation Necessary Preparation Req

Body & Accessories Security and Locks Service Training Mazda5 09-41 This page is intentionally left blank!

Security and Locks Body & Accessories 09-42 Service Training Mazda5 On-board Diagnostic System • The on-board diagnostic system consists of the

Body & Accessories Security and Locks Theft Deterrent System • The construction and operation of the theft deterrent system on the Mazda5 is ess

Lubrication System L8/LF Engines Parts Location M5_01001 1 Oil pump chain tensioner 9 Washer 2 Oil pump chain guide 10 Oil pan 3 Oil pump ch

Security and Locks Body & Accessories 1 Front intruder sensor (vehicles with sunroof) 8 Rear door switch 2 Front intruder sensor (vehicles wi

Body & Accessories Security and Locks Wiring Diagram M5_09032 1 Cargo compartment light switch 8 Intruder sensor (front) 2 Liftgate latch s

Glass/Windows/Mirrors Body & Accessories Glass/Windows/Mirrors Features • The glass/windows/mirrors have the following features: – Rear defroste

Body & Accessories Glass/Windows/Mirrors Power Window Main Switch M5_09006 1 Power window main switch 9 Open relay 2 Power window motor (dr

Glass/Windows/Mirrors Body & Accessories Power Window Subswitch M5_09007 1 Power window subswitch 7 Open relay 2 Power window motor 8 Hall

Body & Accessories Glass/Windows/Mirrors Exterior Opening/Closing Function • The exterior opening/closing function allows all of the windows to

Glass/Windows/Mirrors Body & Accessories Operation Using Request Switch M5_09086 1 Transmitter 10 Control signal 2 Request switch (driver side

Body & Accessories Glass/Windows/Mirrors Using Transmitter M5_09008 1 Transmitter 10 Power window subswitch (RF) 2 Keyless receiver 11 Po

Glass/Windows/Mirrors Body & Accessories Operation Prohibition • When the following conditions are met before, or during window operation, the ex

Body & Accessories Sunroof Sunroof • The construction and operation of the sunroof on the Mazda5 is essentially the same as that on the current

L8/LF Engines Cooling System Cooling System Features • The cooling system has the following features: – Cooling system pressure cap has been moved

Sunroof Body & Accessories M5_09033 1 Drip rail 6 Sunroof motor 2 Drip guide 7 Guide and decoration trim 3 Rear stopper 8 Drive unit 4 Sun

Body & Accessories Lighting System Lighting System Features • The headlight system on the Mazda5 is essentially the same as the current Mazda3 (

Lighting System Body & Accessories Front Combination Light • Projector type headlights with built-in front turn signal light and parking light a

Body & Accessories Lighting System Headlight Auto Leveling System • The construction and operation of the headlight auto leveling system is esse

Lighting System Body & Accessories Wiring Diagram M5_09036 09-58 Service Training Mazda5

Body & Accessories Lighting System Operation • If the auto leveling control module detects the vehicle is moving at a constant vehicle speed of

Lighting System Body & Accessories Rear Combination Light • A stepped reflector that diffuses and reflects the light of the rear combination lig

Body & Accessories Wiper/Washer System Wiper/Washer System • The wiper/washer system is essentially the same as the current Mazda3 (BK). It has

Wiper/Washer System Body & Accessories 1 Wiper and washer switch 10 Rear washer hose 2 Rain sensor 11 Rear washer nozzle 3 Windshield wip

Body & Accessories Entertainment Systems Entertainment Systems Audio System Features • The audio unit is of a modular construction, similar to t

Cooling System L8/LF Engines Parts Location M5_01002 1 Cooling system cap 7 Cooling fan assembly 2 Coolant reserve tank 8 Cooling fan 3 Cool

Entertainment Systems Body & Accessories Specifications Audio Unit M5_09T011 peakers Type A Type B Type CWithout RDS(V)LW (kHz) –MW (kHz) 530 –

Body & Accessories Entertainment Systems Parts Location M5_09040 1 Rear speaker 6 Audio control switches 2 Front door speaker 7 Centre roof

Entertainment Systems Body & Accessories System Overview M5_09041 09-66 Service Training Mazda5

Body & Accessories Entertainment Systems 1 Centre panel module 11 Front door speaker (right) 2 Information display 12 Front tweeter (left)

Entertainment Systems Body & Accessories Centre Panel Module • The centre panel module consists of the audio unit and switches, and the heater c

Body & Accessories Entertainment Systems Music Hard Disc Drive • The HDD (Hard Disc Drive) unit allows albums to be recorded from the CD player,

Entertainment Systems Body & Accessories Secret Menu • The secret menu allows the following operations to be carried out: – Format the hard dis

Body & Accessories Entertainment Systems On-board Diagnostic System • The on-board diagnostic system is similar to the Mazda3 (BK), and consists

Entertainment Systems Body & Accessories Car Navigation System Features • The Mazda5 is equipped with a new navigation system manufactured by De

Body & Accessories Entertainment Systems Parts Location M5_09054 1 Microphone 7 Front door speaker 2 Car-navigation unit 8 Front tweeter 3

L8/LF Engines Cooling System System Overview M5_01003 1 Coolant reserve tank 7 Cylinder head 2 Cooling system filler neck 8 EGR valve 3 Radiat

Entertainment Systems Body & Accessories System Overview M5_09055 1 RDS-TMC tuner 13 LCD 2 Gyro sensor 14 GPS antenna 3 DVD driver 15 Mi

Body & Accessories Entertainment Systems Car Navigation Unit • The car navigation unit is located in the glove compartment and incorporates the

Entertainment Systems Body & Accessories LCD Unit • The LCD unit is a pop-up type incorporated in the dashboard. It serves as a display for the

Body & Accessories Entertainment Systems Split Screen • Different display modes can be selected with the split screen function. Some of the poss

Entertainment Systems Body & Accessories Map and Turn Arrows M5_09061 Automatically Enlarged Illustration of a Nearby Intersection M5_09062

Body & Accessories Entertainment Systems Microphone • The microphone is located beside the LCD unit and recognizes verbal commands in order to c

Entertainment Systems Body & Accessories Voice Recognition Button • The voice recognition button is incorporated in the steering wheel. Its sign

Body & Accessories Entertainment Systems • The list of verbal commands that the navigation system will follow is shown below: M5_09083 Servic

Entertainment Systems Body & Accessories Control Panel • The navigation control panel is located on the centre console. RHD vehicles are equippe

Body & Accessories Entertainment Systems Traffic Message Channel • The TMC (Traffic Message Channel) function is a specific application of the R

Contents General Information00Engine01Suspension02Driveline / Axle03Brakes04Transmission / Transaxle05Steering06Heater, Ventilation & Air Conditi

Cooling System L8/LF Engines Cooling Fan • The cooling fan assembly consists of the radiator cowling, cooling fan, cooling fan motor, and the fan co

Entertainment Systems Body & Accessories • Traffic events received by the TMC receiver are shown as a symbol on the Navigation display in a scal

Body & Accessories Entertainment Systems • Each traffic event is indicated by one sign. M5_09072 1 Icon for traffic event Service Traini

Entertainment Systems Body & Accessories TMC Availability • The map below shows the availability of TMC in Europe. NOTE: Even when the TMC dis

Body & Accessories Entertainment Systems Activation of TMC and DRGS • To switch on the TMC and DRGS first select “RDS-TMC” from the main menu. A

Entertainment Systems Body & Accessories On-board Diagnostic System • The on-board diagnostic system has the following functions: – Vehicle Sig

Body & Accessories Entertainment Systems Vehicle Signal Check • The “Vehicle Signal Check” allows several input signals of the navigation system

Entertainment Systems Body & Accessories GPS Information • The option “GPS Information” allows the data received from GPS satellites to be check

Body & Accessories Entertainment Systems Microphone Check • The “Microphone Check” allows to check the input signals of the microphone. M5_090

Entertainment Systems Body & Accessories Vehicle Sensors • The option “Vehicle Sensors” allows the sensor signals of the navigation system to be

Body & Accessories Entertainment Systems History • The option “History” allows the usage of the navigation system in the past to be checked. M

L8/LF Engines Cooling System Control • The cooling fan is controlled according to the engine coolant temperature as follows : M5_01T004 The cool

Entertainment Systems Body & Accessories Remote Control Test • The “Remote Control Test” allows the buttons of the control panel/remote control

Body & Accessories Entertainment Systems Error Code • The option “Error Code” allows DTCs stored in the navigation system to be inspected. M5

Entertainment Systems Body & Accessories Rear Entertainment System Features • The RES (Rear Entertainment System) unit consists of a DVD/CD play

Body & Accessories Entertainment Systems Parts Location M5_09043 1 Remote control 5 Tweeter 2 Rear speaker 6 Auxiliary terminal unit 3 RES

Entertainment Systems Body & Accessories Customisation • The following DVD preset and playback settings can be changed using the remote control:

Body & Accessories Entertainment Systems Rear View Monitor • The rear view monitor consists of the rear view monitor control module, the rear ca

Entertainment Systems Body & Accessories Parts Location M5_09044 1 Steering angle sensor 4 Car-navigation unit 2 LCD unit 5 Rear camera 3

Body & Accessories Entertainment Systems Reference Lines • The following reference lines are superimposed on the image provided by the back came

Entertainment Systems Body & Accessories Rear View Monitor Control Module Initialization • When replacing the rear view monitor control module,

Body & Accessories Control System Instrumentation/Driver Information System Features • The construction and operation of the instrumentation/dri

Cooling System L8/LF Engines Fail-safe Function Over-current Failsafe • If current to the fan motor exceeds a specified value, the fan control modul

Instrumentation/Driver Information Body & Accessories Specifications M5_09T017 SpecificationStepper motor typeIndication range (mph {km/h}) 0—1

Body & Accessories Control System Instrument Cluster • The instrument cluster features LEDs for the warning and indicator lights. It is connecte

Instrumentation/Driver Information Body & Accessories M5_09T018 Item Input signal source CAN system1 EHPAS warning light EHPAS control module

Body & Accessories Control System Input/Output Check Mode 1. To enter the input/output check mode, turn the ignition switch to ON while pushing

Instrumentation/Driver Information Body & Accessories Configuring Instrument Cluster • When replacing the instrument cluster, the new cluster ha

Body & Accessories Control System Seat Belt Warning • Seat belt warnings are provided for both the driver’s seat and the passenger’s seat. The o

Instrumentation/Driver Information Body & Accessories Passenger’s Seat Belt Warning • For the control of the passenger’s seat belt warning, the

Body & Accessories Control System Information Display • The information display indicates information for the audio system, climate control syst

Instrumentation/Driver Information Body & Accessories Wiring Diagram M5_09049 09-112 Service Training Mazda5

Body & Accessories Control System Control System Features • With the introduction of the Mazda5 (CR) a new control system for body electrics has

L8/LF Engines Intake-air System Intake-air System Features • The intake-air system is essentially the same as that on the current Mazda3 (BK) with L

Control System Body & Accessories BCM Location M5_09050 1 BCM NOTE: The BCM does not require configuring when it is replaced. NOTE: Di

Body & Accessories Control System On-board Diagnostic System • The on-board diagnostic system consists of the following functions: – Self test

Control System Body & Accessories PID Monitor • The PID monitor function allows BCM PIDs to be displayed. To do this, connect WDS to the vehicle

Body & Accessories Control System Controller Area Network • The Mazda5 uses an MS-CAN (Middle Speed-Controller Area Network) and an HS-CAN (High

Control System Body & Accessories M5_09051 1 PCM (MZR-CD) 10 Climate control unit (with full-auto A/C) 2 PCM (L8, LF) 11 Information dis

Body & Accessories Control System HS-CAN Signal Chart • The following signals are transmitted via the HS-CAN bus. M5_09T022-1 DSC HU/CMABS HU/

Control System Body & Accessories DSC HU/CMABS HU/CMDSC indicator lighton request––OUT – – INDSC OFF lighton request––OUT – – INKeyless warning/i

Body & Accessories Control System MS-CAN Signal Chart • The following signals are transmitted via the MS-CAN bus. M5_09T023 Body controlmoduleCl

Control System Body & Accessories On-board Diagnostic System • The on-board diagnostic system is essentially the same as the Mazda3, except for

List of Abbreviations ABS A crylonitrile-Butadiene-Styrene ABS Anti-lock Brake System ABDC After Bottom Dead Center A/C Air Conditi

Intake-air System L8/LF Engines Parts Location M5_01070 1 Fresh-air duct 8 Variable tumble solenoid valve 2 Resonance chamber (fresh-air duct si

List of Abbreviations DVD Digital Versatile Disc EBD Electronic Brake Force Distribution ECT E ngine Coolant Temperature EGR Exhaus

List of Abbreviations KS Knock Sensor LCD Liquid Crystal Display LED Light Emitting Diode LF Left Front LH Left Hand LO Lo

List of Abbreviations PID Parameter Identification PJB Passenger Junction Box P/S Power Steering PSP Power Steering Pressure P/W

List of Abbreviations VSS Vehicle Speed Sensor VTCS Variable Tumble Control System WDS Worldwide Diagnostic System WU-TWC Warm Up Th

List of Abbreviations Service Training Mazda5

L8/LF Engines Intake-air System System Overview M5_01071 1 Air cleaner 9 Variable intake air shutter valve actuator (LF engine) 2 Resonance cha

Fuel System L8/LF Engines Fuel System Features • The fuel system is essentially the same as that used on the current Mazda3 (BK) except for the foll

L8/LF Engines Fuel System Parts Location M5_01007 1 Fuel injector 3 Main fuse block 2 Quick release connectors 4 Fuel pump relay Service Tr

Fuel System L8/LF Engines M5_01008 1 Fuel tank 3 Quick release connector 2 Fuel pump unit 01-16 Service Training Mazda5

L8/LF Engines Fuel System Fuel Line Removal • A new SST has been introduced to enable the disconnection of the fuel line quick connector used at the

Service Training Mazda5

Fuel System L8/LF Engines Fuel Pump Control • When the ignition is switched ON, the PCM turns the fuel pump relay on for one second. • When a cran

L8/LF Engines Exhaust System Exhaust System Features • The exhaust system has the following features: – An exhaust system that can be replaced in s

Emission System L8/LF Engines Emission System Features • The emission system on the Mazda5 is the same as that of the current Mazda3 (BK) with LF en

L8/LF Engines Emission System Fuel Tank M5_01068 1 Fuel filler cap 4 Check valve (two-way) 2 Charcoal canister 5 Rollover valve 3 Evaporative c

Ignition System L8/LF Engines Charging System Features • The charging system on the Mazda5 is the same as that of the current Mazda3 (BK) with LF en

L8/LF Engines Charging System Ignition System Features • The ignition system has the following features: – An ignition system with direct ignition

Ignition System L8/LF Engines Ignition Coils • Ignition coils installed directly to each spark plug have been adopted. l with integrated power tran

L8/LF Engines Control System Control System Specifications M5_01T019 Features • The engine control system is essentially the same as that of the Ma

Control System L8/LF Engines Parts Location M5_01015 1 MAF/IAT sensor 11 PCM 2 TP sensor 12 Purge solenoid valve 3 IAC valve 13 EGR valve 4

L8/LF Engines Control System System Overview M5_01016 1 Air cleaner 11 EGR valve 2 MAF/IAT sensor 12 VIS solenoid valve (LF engine) 3 TP sen

00 General Information

Control System L8/LF Engines Relationship Chart atte x x x xenerator (terminal P: stator coil) x xx x xnstr x xxIS s xC eueluelnitiR xPurge solenoid

2.0 MZR-CD Engine Mechanical System Mechanical System Features • The mechanical system of the vehicles with 2.0 MZR-CD engine has the following feat

Mechanical System 2.0 MZR-CD Engine Engine Performance Curve M5_01018 1 Engine speed 4 Standard power engine 2 Power 5 High power engine 3 Torq

2.0 MZR-CD Engine Mechanical System Overview M5_010 19 Service Training Mazda5 01-31

Mechanical System 2.0 MZR-CD Engine Pistons • Pistons with a modified combustion chamber have been introduced to achieve a lower compression ratio o

2.0 MZR-CD Engine Mechanical System Cylinder Head • A cylinder head with integrated leak-off lines for the injectors has been introduced. M5_01021

Lubrication System 2.0 MZR-CD Engine Lubrication System Features • The lubrication system of the vehicles with 2.0 MZR-CD engine has the following f

2.0 MZR-CD Engine Lubrication System Parts Location M5_01022 1 Oil filter 7 Oil pan 2 Oil cooler 8 Oil strainer 3 O-ring 9 Gasket 4 Oil je

Lubrication System 2.0 MZR-CD Engine Engine Oil • In order to limit the ash amount accumulated in the diesel particulate filter, an engine oil with

2.0 MZR-CD Engine Lubrication System Oil Dipstick • Since the fuel post-injections required to regenerate the DPF can lead to an excessively high en

00 General Information General Information ...1 Product Conce

Lubrication System 2.0 MZR-CD Engine Oil Dilution Calculation • s illuminated. This DTC comes up when the regeneration of the DPF has been started m

2.0 MZR-CD Engine Lubrication System • The different conditions of the oil dilution are described in the following table. DPMILOuTCuDPDelower than

Lubrication System 2.0 MZR-CD Engine Oil Cooler and Oil Filter • An oil cooler and oil filter located at the rear of the engine have been introduced

2.0 MZR-CD Engine Cooling System Cooling System Features • The cooling system of the vehicles with 2.0 MZR-CD engine has the following features: –

Cooling System 2.0 MZR-CD Engine Parts Location M5_01025 1 Cooling fan assembly 7 Cooling system cap 2 Fan control module 8 Cooling system f

2.0 MZR-CD Engine Intake-air System Intake-air System eatures • The intake-air system of the vehicles with 2.0 MZR-CD engine has the following featu

Intake-air System 2.0 MZR-CD Engine Turbocharger • A turbocharger with variable geometry turbine and reduced turbine diameter has been se introduce

2.0 MZR-CD Engine Intake-air System Manifold Absolute Pressure Sensor n • A MAP (Manifold Absolute Pressure) sensor located above the intake manifo

Fuel System 2.0 MZR-CD Engine Fuel System Features • The fuel system of the vehicles with 2.0 MZR-CD engine has the following features: – Common ra

2.0 MZR-CD Engine Fuel System Common Rail on rail located above the intake manifold has been introduced. • A comm M5_01060 1 Common rail 4 Fuel

General Information General Information Product Concept • When Mazda began developing its next-generation MAV (Multi Activity Vehicle), it set its

Fuel System 2.0 MZR-CD Engine Injectors • Solenoid valve-type injectors with lower power consumption and better response have been introduced. M5

2.0 MZR-CD Engine Fuel System • The injecinside, wtors are directly driven by the PCM. The module has a high-voltage generator hich amplifies the ba

Fuel System 2.0 MZR-CD Engine • When the required injection amount is small, the PCM outputs a short drive signal to theinjectors. As a result, the

2.0 MZR-CD Engine Fuel System E: When re-installing the injectors after a repair, they must be matched to the cylinthey were remNOT ders oved from.

Emission System 2.0 MZR-CD Engine Emission System ocation Parts L M5_0103dation catalytic conve0 1 Oxi rter and diesel particulate filter 3 Intak

2.0 MZR-CD Engine Emission System Exhaust System Features • The exhaust system of the vehicles with 2.0 MZR-CD engine has the following features: –

Emission System 2.0 MZR-CD Engine Exhaust Gas Recirculation System o– the transmission-side of the engine has been introduced. – Intake shutter val

2.0 MZR-CD Engine Emission System • The position of the EGR valve is controlled bvia a duty signal. y the PCM, which activates the DC motor M5_0103

Emission System 2.0 MZR-CD Engine • The EGRVP (EGR Valve Position) sensor is integrated in the DC motor and detects its position by a sliding contac

2.0 MZR-CD Engine Emission System EGR Cooler An EGR cooler located at the transmission-side of the engine has been introduced. • M5_01061 1 EGR v

General Information Jacking and Lifting • The front of the vehicle can be lifted with a jack near the center of the front crossmember. M5_00002 1

Emission System 2.0 MZR-CD Engine Intake Shutter Valve d. A reduction gear ensures, that a large rotation angle of the motor results in a small rotat

2.0 MZR-CD Engine Emission System • The position of the ISduty signal. V is controlled by the PCM, which activates the DC motor via a M5_01033 1 D

Emission System 2.0 MZR-CD Engine • In order to remove any deposits from the ISV a cleaning mode is activated each time the engine is shut off. Ther

2.0 MZR-CD Engine Emission System Diesel Particulate Filter System tures Fea The diesel particulate filter system of the vehicles with 2.0 MZR-CD en

Emission System 2.0 MZR-CD Engine • In comparison to the particulate matter lEuro 4 vehicles (0.025 g/km) has been limit for Euro 3 vehicles (0.05 g

2.0 MZR-CD Engine Emission System • The DPF is a monolith made of silicon carbide ceramics, which features a high resistance against temperature flu

Emission System 2.0 MZR-CD Engine • The channels of the DPF are coated with platinum. This catalytic coating facilitaregeneration of the filter by s

2.0 MZR-CD Engine Emission System DPF Differential Pressure Sensor The DPF differential pressure sensor detects the pressure difference in the exhaus

Emission System 2.0 MZR-CD Engine M5_01041 1 DPF 3 Oxidation catalytic converter 2 Measuring points for DPF differential pressure sensor •

2.0 MZR-CD Engine Emission System • In addition, the DPF differential pressure sensor features a temperature correction sensor, which is located on

General Information • The vehicle can be lifted with a lift at the indicated positions on the side sill. M5_00004 Towing • When towing the veh

Emission System 2.0 MZR-CD Engine Diagnostics Since the filter itself creates a certain resistance in the exhaust gas flow, the signal DPF differenti

2.0 MZR-CD Engine Emission System • If the valuDPF is recognized as be measured by the DPF differential pressure sensor is below a certain limit, th

Emission System 2.0 MZR-CD Engine Exhaust Gas Temperature Sensors The three exhaust gas temperature sensors (upper/midd• le/lower) are located in th

2.0 MZR-CD Engine Emission System • The signal of the upper exhaust gas teexhaust gas temperature required for operationmperature sensor allows to c

Emission System 2.0 MZR-CD Engine Heated Oxygen Sensor The HO2S• (Heated O2 Sensor) is located behind the DPF and detects the oxygen 21 % concent

2.0 MZR-CD Engine Emission System • If the exhaust gas is leathe exhaust gas, resultinn, the pump cell pumps oxygen out of the diffusion gap back in

Emission System 2.0 MZR-CD Engine • The HO2S supplies the PCM with a current between -1.8…+1.8 mA. M5_01047 X Excess-air factor λ Y Current •

2.0 MZR-CD Engine Emission System • At low exhaust gas temperatures the PCM controls the heater element by a large duty cycle, so that the required

Emission System 2.0 MZR-CD Engine Regeneration Control • The regeneration control determines the soot amount accumulated in the DPF and startsthe re

2.0 MZR-CD Engine Emission System NOTE: Do NOT perform automatic regeneration when the soot accumulation rate in the DPF and DTC P242F is stored in