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TRAINING MANUAL

Mazda5

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.

© 2005
Mazda Motor Europe GmbH Training Services

Contents

Title General Information Engine Suspension Driveline / Axle Brakes Transmission / Transaxle Steering Heater, Ventilation & Air Conditioning (HVAC) Restraints Body & Accessories

Section 00 01 02 03 04 05 06 07 08 09

Service Training Mazda5

Service Training Mazda5

00
General Information

00 General Information
General Information ............................................................................................1 Product Concept .............................................................................................1 Jacking and Lifting ..........................................................................................2 Towing ............................................................................................................3 Vehicle Identification Number .........................................................................4 For European (L.H.D.) Specifications .......................................................5 For UK Specifications ...............................................................................5 Engine Identification Number ..........................................................................6 L8/LF ........................................................................................................6 MZR-CD ...................................................................................................6 Technical Data ................................................................................................7 Maintenance Schedule ...................................................................................8

Table of Contents 00

Service Training Mazda5

it set its sights on creating a new global standard.0 liter gasoline engine coupled to a 5-speed manual transmission. Given our focus on creating a MAV that enhances communication. rather than the kind of performance that’s reflected in overwhelming power. At the same time. we characterized our MAV as a ‘lifestyle partner’ that enables people to enjoy activities together with relatives and friends.8 liter or 2. providing a total Zoom-Zoom driving experience for the driver and passengers. creating more space for the rest of the occupants. or 2. From this basic premise. • • M5_00001 Service Training Mazda5 00-1 . enjoyable driving and riding. whereby space is evenly divided among the five seating positions rear of the front seats.0 liter turbo-diesel engine (in high-power and standard-power versions) with particulate filter coupled to a six-speed manual transmission allow the customer to choose between performance and economy. our ‘6+One’ packaging concept provides for the occasional use of one seat. In contrast to the ‘5+2’ concept. The choice of either a 1. Sporty chassis performance completes the package. we decided to use an entirely new seven seater packaging concept. It goes without saying that a MAV is intended to carry a lot of people and a lot of luggage. we provided the Mazda5 with performance that’s focused on easy.General Information General Information Product Concept • When Mazda began developing its next-generation MAV (Multi Activity Vehicle).

General Information Jacking and Lifting • The front of the vehicle can be lifted with a jack near the center of the front crossmember.78 in} thick) between the rear crossmember and the jack to prevent damage to the crossmember. M5_00002 1 2 Front crossmember Jack up position 3 Front NOTE: To prevent obstruction between the jack body and front bumper when the jack body is inserted. M5_00003 1 Rear crossmember NOTE: Place a board (approximately 20 mm {0. use a low floor type jack (frame height is 170 mm or less). • The rear of the vehicle can be lifted with a jack at the center of the rear crossmember. 00-2 Service Training Mazda5 .

open the cap located on the front bumper and install the towing eyelet. M5_00004 Towing • When towing the vehicle. M5_00005 1 Towing eyelet Service Training Mazda5 00-3 . remove the towing eylet from the storage box in the rear cargo area.General Information • The vehicle can be lifted with a lift at the indicated positions on the side sill.

M5_00006 1 Tie down hook 2 Towing eyelet Vehicle Identification Number • The VIN (Vehicle Identification Number) is located on the cowl plate in the engine compartment.General Information • A towing eyelet and tie down hook are provided at the rear of the vehicle. M5_00007 00-4 Service Training Mazda5 .

U.K.D.0 L) Engine Type R = RF-Turbo-High power (2.H.8 L) F = LF (2.0 L) T = RF-Turbo-Standard power (2.0 L) Body style 9 = 4-door station wagen Drive axle 1 = FF Vehicle type CR = Mazda5 World manufacturer indication JMZ = European (L.General Information • The VIN key is shown as below: JMZ CR 1 9 8 2 5 # 1 2 3 4 5 6 Serial No.) Specifications JMZCR1982##100001 ⎯ JMZCR19F2##100001 ⎯ JMZCR19R6##100001 ⎯ JMZCR19T6##100001 ⎯ For UK Specifications JMZCR19820#100001 ⎯ JMZCR19F20#100001 ⎯ JMZCR19R60#100001 ⎯ JMZCR19T60#100001 ⎯ Service Training Mazda5 00-5 . 0 = Hiroshima Plant 1 = Hofu For Europe-RHD : For Europe-LHD For Others : : Dummy Dummy Model year 0 5 to 9 (Same as model year-Israel etc..) M5_00T001 For European (L.H.D.) 5 = 2005 2 = 5MTX 5 = 4ATX Transmission 6 = 6MTX 8 = L8 (1.

General Information Engine Identification Number • The engine identification number is located on the cylinder block as shown below: L8/LF M5_00008 MZR-CD M5_00009 1 Front 00-6 Service Training Mazda5 .

8:1 107kW {145 PS} at 6.8:1 85 kW {115 PS} at 5.5 x 83.500 rpm Euro 4 3 87.300 rpm 165 Nm at 4.000 rpm 185 Nm at 4.8 L MZR Engine Displacement Bore x Stroke Compression Ratio Maximum Power Maximum Torque Emission Standard 1798 cm 10.1 mm 2.000 rpm Euro 4 M5_00T002 Service Training Mazda5 00-7 .7:1 81 kW {110PS} at 3.000 rpm Euro 4 3 83 x 83.1 mm 2.500 rpm 360 Nm at 2.0 L MZR-CD Engine Displacement Bore x Stroke Compression Ratio Maximum Power Maximum Torque Emission Standard Standard Power 1998 cm 16.0 L MZR Engine Displacement Bore x Stroke Compression Ratio Maximum Power Maximum Torque Emission Standard 1999 cm 10.General Information Technical Data 1.000 rpm 3 High Power 86 x 86 mm 105 kW {143 PS} at 3.500 rpm 310 Nm at 2.

after that.000 miles) R I I R I R I I Replace every 120. hoses and connections Brake fluid *3 Parking brake Disc brakes Power steering fluid.000 km (75.5 GASOLINE ENGINE Engine valve clearance Spark plugs Air cleaner element Evaporative system (if installed) DIESEL ENGINE Engine valve clearance Engine timing belt Fuel filter Fuel injection system Fuel system (Drain water) Air cleaner element GASOLINE and DIESEL ENGINE Engine oil *1 Engine oil filter *1 Drive belts Cooling system/coolant top-up FL22 type *2 Engine coolant Others Fuel lines and hoses Battery electrolyte level and specific gravity Brake lines.000 km (75.000 miles) R I D R R R I R I D R R R I I R I D R R R I I D C R R D C R R I D C R R I D C R R D C R R D C R R I Replace every 200.000 km (62. every 2 years I I I I I I I I R I I I I I I I I I I I I R I I I I I I I I I I I I R I I I I I I I I I I I I R I I I I I I I I I R I I I I I I I I Inspect every 80. whichever comes first) Maintenance Item Months x1000 km x1000 miles 12 20 12. if noisy.5 24 40 25 36 60 37. hoses. corrosion and perforation) Cabin air filter (if installed) Tires (including spare tire) (with inflation pressure adjustment) I Audible inspection every 120. and connections Steering operation and linkages Manual transaxle oil Front and rear suspension and ball joints Drive shaft dust boots Exhaust system and heat shields Body condition (for rust.000 miles) or 11 years Replace at first 100.5 96 108 160 180 100 112.000 km (75.000 miles) or 5 years Inspect annually R I I R I I R I I R I I M5_00T003 00-8 Service Training Mazda5 .5 48 80 50 60 100 62.000 km (125.General Information Maintenance Schedule Maintenance Interval (Number of months or km (miles). lines. adjust.500 miles) or 4 years.5 72 120 75 84 140 87. Replace every 120.000 miles).000 km (50.

– – – *1: If the vehicle is operated under hard conditions (dusty road. Use FL22 when replacing the coolant.000 km (6. change the engine oil and oil filter every 10. Service Training Mazda5 00-9 . *2: Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding area. : Replace : Clean : Drain Refer below for a description of items marked * in the maintenance chart. repair. cold temperature or short driving distances).250 miles) or less. extended periods of idling or low speed operation.General Information I R C D • : Inspect and clean. continuous hard driving or mountain driving) or if the vehicle is operated in extremely humid climates. adjust. or replace if necessary. *3: If the brakes are used extensively (for example. change the brake fluid annually.

General Information NOTES: 00-10 Service Training Mazda5 .

01 Engines .

....................................................................................1 Features......................18 Excessive Speed Fuel Cut.....................................................................................................................7 Cooling Fan........................................................................................................6 System Overview ...........................................................................................12 System Overview ..................18 Fuel Injection Control ...........10 Intake-air System..............................................................................................................................................3 Specifications........3 Engine Oil .................................1 Engine Performance Curve.8 Control ........................................................13 Fuel System ......................8 Wiring Diagram ..................................................................................................................3 Features......................................................................................................................................................................14 Parts Location ...........................................................................................................................................................5 Parts Location .........7 Long Life Coolant........................................................1 Specifications.............................................................................................................................................................................................................10 Overheat Failsafe .........................................................................................................................................................................................................................................................................14 Features.........................................................................................................................................................................................15 Fuel Line Removal ...................................11 Features........................................................1 Overview .............................14 Specifications.......................................................5 Features.......................................2 Lubrication System ....................................................................................................................................................................................................................19 Features........................................4 Cooling System .......................................................................................................5 Specifications................................................................................................................................................................................19 Table of Contents 01 Service Training Mazda5 ...............................................................10 Fan Control Module Input Signal Failsafe..........................3 Parts Location ................................9 Fail-safe Function ..........................................................11 Parts Location .................................................18 Exhaust System...17 Fuel Pump Control .........................................................................................10 Over-current Failsafe .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................01 Engines Table of Contents L8/LF Engines Mechanical System ...................................

.....................23 Parts Location .......................................................25 Specifications...................................35 Engine Oil....................................................................................................................................................................................................................34 Parts Location ................................38 Oil Cooler and Oil Filter .......................................................................................................................................................................................................................30 Overview ......................................................................................................................................................20 Features....................................29 Specifications............................................................................................................................................................................................................................................................................................................29 Features..............................................................................................23 Ignition Coil .......................29 Engine Performance Curve.....................................................................................................................................28 2.............................................34 Engine Oil .............34 Features..............................................................................................25 Features...............27 Relationship Chart .............................................................................................................31 Pistons ................................................................................................................25 Parts Location ..............................................................................37 Oil Dilution Calculation .......................22 Features..............................................24 Control System....................................................................................................................................................................................20 Parts Location ..........................................................................................20 Charging System................................................................... Service Training Mazda5 Table of Contents 01 .............................................................22 Ignition System....................................................................................................................23 Features................................................................................................................................................................01 Engines Table of Contents (continued) Emission System..............................33 Lubrication System .................................................................34 Specifications.........................22 Parts Location ................................................................26 System Overview .........................................................................0 MZR-CD Engine Mechanical System ...................................................................................................................................................36 Oil Dipstick .......................................................................................................................................................................................................................22 Specifications............32 Cylinder Head .............................................

.............................................................................................................................................................................................................................................................................................................................................................................................................76 Regeneration Process .........................................................................................................................................................................................................................................................................................................................................................61 Diesel Particulate Filter ................................46 Common Rail ...............57 Intake Shutter Valve..........................................................................................43 Features.......................................................................70 Heated Oxygen Sensor.........................................................................................50 Injection Amount Learning Function...........................................................................................58 Diesel Particulate Filter System ......................................................................76 Soot Amount Calculation ...................................65 Diagnostics ...............................................................................40 Features............................................................52 Parts Location ........54 Features............................79 Table of Contents 01 Service Training Mazda5 .............................................................................................................................................................51 Emission System............................52 Exhaust System.............44 Manifold Absolute Pressure Sensor........................................................41 Specifications.....................46 Parts Location ..........................53 Features.........48 Injector Correction Factors..........................................................................................................................47 Injectors ..............43 Turbocharger ...................01 Engines Table of Contents (continued) Cooling System ....................................................................................................................................................................61 Features.........................................................................................45 Fuel System ...............................................................................................................................................................................................................................................53 Exhaust Gas Recirculation System ........................................61 Diesel Particulates ................................46 Features....................................78 Regeneration Intervals.........................................................................................................................................................41 Parts Location ....................................................................................................43 Parts Location ......................................................................................................................72 DPF Indicator Light .........................................................................................................75 Regeneration Control ..........54 EGR Valve .......62 DPF Differential Pressure Sensor ........................................................................................................................................................................................................................42 Intake-air System.....................................................................................................53 Parts Location ...................................................................................54 EGR Cooler.......................68 Exhaust Gas Temperature Sensors...........................................................................................

.........................................................................................99 Features...........................................99 PID Monitor ................................................................99 Self Test......................................................89 Accelerator Pedal Position Sensor..............................95 Replacing the engine oil .......................83 Features................................................................................80 Smart Charging System........................95 Replacing the MAF sensor .............................................................................................................................................................................................................................................................................................................81 Control System............................................................................................87 Camshaft Position Sensor............................98 Replacing the PCM.............................................................95 Manual regeneration.....................................................97 Replacing the HO2S .................................................................................................................................................................................................................................................................................................................................85 Powertrain Control Module......................................................................83 Parts Location ................................................96 Replacing injectors ...........................................................................................................................................................103 Service Training Mazda5 Table of Contents 01 .............97 Replacing the DPF differential pressure sensor ....................................80 Specifications.............................................................80 Features............................................................80 Parts Location ..83 Relationship Chart ................................................................................98 On-board Diagnostic System .............................................................01 Engines Table of Contents (continued) Charging System............................................................................................................................................................................97 Replacing the DPF.............................................96 Replacing the EGR valve or the ISV...........................................................................................................................................................................................100 Simulation Test ...............................................91 Power Steering Pressure Switch...................86 Crankshaft Position Sensor............................................................................................................96 Replacing the high-pressure pump ...........94 Maintenance and Repair ........................

NOTES: Table of Contents 01 Service Training Mazda5 .

8 1. 249.L8/LF Engines Mechanical System Features • Mechanical System The mechanical system of the L8/LF engines is essentially the same as the Mazda6 (GG/GY) with L8/LF engines except for the following: – A new engine support hanger SST (49C0175AO) has been introduced.8 1. 4-cylinder Pentroof DOHC.54.1 10.0107-0.798 {1.999.0087-0.1 10.22-0.720 {17. 253. cu in}) Bore x stroke (mm {in}) Compression ratio Compression pressure (kPa {kgf/cm 2 .27-0. 16 valves 1.0129} M5_01T018 L8 Item Type Cylinder arrangement and number Combustion chamber Valve system Displacement (ml {cc.750 {17.85.5} [300] 4 52 37 4 0. 122} 87. 109.0110} 0. Timing chain driven.33 {0.999 {1. Specifications Specification LF Gasoline 4-stroke Inline.5 x 83.82} [300] [rpm]) Open BTDC (°) Close ABDC (°) Open BBDC (°) Close ATDC (°) (mm {in}) (mm {in}) 4 33 37 4 IN Valve timing EX Valve clearance (engine cold) IN EX Overview M5_01017 Service Training Mazda5 01-1 .7} 83 x 83.28 {0. psi} 1.798.

Mechanical System Engine Performance Curve L8/LF Engines M501T066 1 2 3 L8 engine LF engine Engine speed 4 5 Output Torque 01-2 Service Training Mazda5 .

1. 4. 3.L8/LF Engines Lubrication System Features • Lubrication System The lubrication system is essentially the same as that on the Mazda6 (GG/GY).61.4} 4.22. 33. Imp qt}) (L {US qt.9 {4.6—17.39—5.4} 4. Specifications Item Type Oil pressure [oil temperature: 100°C {212°F}] Type Oil pump Relief valve opening pressure Type Type Bypass pressure Total (dry engine) Oil replacement (kPa {kgf/cm2. It has the following features: – – Spin-on type oil filter. 11.8} Water-cooled Full-flow.6 {4. paper element 80— 120 {0. 3.5} [3. psi} [rpm]) Specification Force-fed type 234—521 {2.3 {4. psi} (kPa {kgf/cm2.9—75. Water-cooled type oil cooler.5.3—79. quantity) Oil and oil filter replacement Engine Oil Item Grade Viscosity (SAE) Remarks 5W – 30 Specification API SL.59—5.31.82— 1. Service Training Mazda5 01-3 .0} 3.g.8} M5_01T001 Oil Cooler Oil filter Oil capacity (approx. Imp qt}) (L {US qt.8. ACEA A3 10W – 40 5W – 20 – M5_01T002 Mazda genuine Dexelia oil e. psi}) (L {US qt. Imp qt}) (kPa {kgf/cm2.000] Trochoid gear type 450—550 {4.65.

Lubrication System Parts Location L8/LF Engines M5_01001 1 2 3 4 5 6 7 8 Oil pump chain tensioner Oil pump chain guide Oil pump chain Oil pump sprocket Oil pump O-ring Oil strainer Oil drain plug 9 10 11 12 13 14 15 16 Washer Oil pan Oil jet valve Oil filter adapter Oil pressure switch Oil filter Gasket Oil cooler 01-4 Service Training Mazda5 .

psi}) Radiator Cooling system cap Cooling fan (mm {in}) (W) M5_01T003 Service Training Mazda5 01-5 .31} or more Corrugated fin 93.2} Without heater: 6.2—122. bottom-bypass 80—84 {176—183} 97 {207} 8.25.5—17. 6.L8/LF Engines Cooling System Features • The cooling system has the following features: Cooling System – – – – Cooling system pressure cap has been moved from the coolant reserve tank to the cooling system filler neck.7} Centrifugal. Separate cooling system filler neck has been introduced. Specifications Item Type Coolant capacity (approx. 13.8} Electric 7 360 {14.2} 240 Thermostat (°C {°F}) (° C {° F}) (mm {in}) (kPa {kgf/cm 2 .0 {0.0 {7.4. 5.95—1. V-ribbed belt-driven Wax. quantity) Water pump Type Type Opening temperature Full-open temperature Full-open lift Type Cap valve opening pressure Type Number of blades Outer diameter Fan motor output (L {US qt. Stepless cooling fan controlled by a fan control module has been introduced.9.5 {6. A long-life engine coolant has been introduced.6 {0. Electromotive With heater: 7. lmp qt}) Specification Water-cooled.

Cooling System Parts Location L8/LF Engines M5_01002 1 2 3 4 5 6 Cooling system cap Coolant reserve tank Cooling system filler neck Radiator Thermostat Water pump 7 8 9 10 11 Cooling fan assembly Cooling fan Radiator cowling Cooling fan motor Fan control module 01-6 Service Training Mazda5 .

L8/LF Engines System Overview Cooling System M5_01003 1 2 3 4 5 6 Coolant reserve tank Cooling system filler neck Radiator Thermostat Water pump Cylinder block 7 8 9 10 11 12 Cylinder head EGR valve Heater Oil cooler (AT) Oil cooler Coolant flow Long Life Coolant • • • The use of long life coolant means that coolant life is extended to 200. M5_01004 Service Training Mazda5 01-7 . Because the long life coolant is green. as the life of the long life coolant will be reduced. the designation ‘FL22’ is written on or near the cooling system pressure cap to indicate the correct coolant type.000 km (125. It is not recommended that normal coolant is mixed with long life coolant.000 miles) or 11 years. and therefore indistinguishable from normal coolant.

and the fan control module. and supplied through two 30 A fuses by the cooling fan relay (similar to current MPV).Cooling System Cooling Fan • • L8/LF Engines The cooling fan assembly consists of the radiator cowling. Power to the fan control module is controlled by the main relay. cooling fan motor. and improving engine warm up time. reducing fan operation noise and electrical load. This allows variable control of the fan motor speed. cooling fan. • Wiring Diagram M5_01005 01-8 Service Training Mazda5 . The fan control module drives the fan motor based on a duty signal received from the PCM.

— Vehicle speed is 45 km/h {27 mph} or less. — Vehicle speed is 85 km/h {53 mph} or more. Duty ratio 0% 75% 100% M5_01T004 • The cooling fan is controlled according to the refrigerant pressure switch condition as follows: Conditions • When all of the following conditions are met: — A/C is on. • A/C is off. — Refrigerant pressure switch (medium pressure) is off. • When all of the following conditions are met: — A/C is on. • When all of the following conditions are met: — A/C is on. • Engine coolant temperature is 106—108 ° C {223—226 ° F}. Duty ratio 0% 60% 65% 75% M5_01T005 Service Training Mazda5 01-9 .L8/LF Engines Control • Cooling System The cooling fan is controlled according to the engine coolant temperature as follows : Conditions • Engine coolant temperature is less than 100 ° C {212 ° F}. — Refrigerant pressure switch (medium pressure) is off. — Refrigerant pressure switch (medium pressure) is off. — Vehicle speed is 45—85 km/h {28—52 mph}. • Engine coolant temperature is 108 ° C {226 ° F} or more. • When all of the following conditions are met: — A/C is on. — Refrigerant pressure switch (medium pressure) is on.

the fan control module operates the cooling fan at high speed. the cooling fan is switched off (normal cooling fan control will be resumed by switching the ignition switch OFF and then ON again).Cooling System Fail-safe Function Over-current Failsafe • L8/LF Engines If current to the fan motor exceeds a specified value. 01-10 Service Training Mazda5 . Fan Control Module Input Signal Failsafe • If the voltage at input signal terminal from the fan control module remains low or high. If the temperature continues to rise. Overheat Failsafe • If the internal temperature of the fan module exceeds a specified value. the fan control module stops the fan motor for a specified amount of time. the module determines that the fan control circuit has a malfunction and will operate the fan at high speed.

Plastic intake manifold is used.L8/LF Engines Intake-air System Features • Intake-air System The intake-air system is essentially the same as that on the current Mazda3 (BK) with LF engine. one near the fresh-air duct and one near the air cleaner are used. Variable tumble control system is used. It has the following features: – – – – Variable intake air system is used (LF engines only). Service Training Mazda5 01-11 . Two resonance chambers.

Intake-air System Parts Location L8/LF Engines M5_01070 1 2 3 4 5 6 7 Fresh-air duct Resonance chamber (fresh-air duct side) Air cleaner Resonance chamber (air cleaner side) Throttle body IAC valve Variable intake air solenoid valve (LF engine) 8 9 10 11 12 13 Variable tumble solenoid valve Variable intake air shutter valve actuator (LF engine) Variable tumble shutter valve actuator Intake manifold Accelerator cable Accelerator pedal 01-12 Service Training Mazda5 .

L8/LF Engines System Overview Intake-air System M5_01071 1 2 3 4 5 6 7 8 Air cleaner Resonance chamber (fresh-air duct side) Resonance chamber (air cleaner side) IAC valve Throttle body Vacuum chamber Check valve Variable intake air solenoid valve (LF engine) 9 10 11 12 13 14 15 Variable intake air shutter valve actuator (LF engine) Variable intake air shutter valve (LF engine) Variable tumble solenoid valve Variable tumble shutter valve actuator Variable tumble shutter valve Intake manifold To Powertrain Control Module Service Training Mazda5 01-13 .

Quick connectors attaching the fuel hoses to the fuel tank have been changed. Fuel pump unit can be disassembled and individual components replaced (fuel pump motor. low pressure filter. 13} Electric Premium unleaded fuel (Research octane number is 95 or more (conforming to EN228) M5_01T006 01-14 Service Training Mazda5 . 56. New SST for quick connector removal has been established. psi}) (L {US gal.Fuel System Fuel System Features • L8/LF Engines The fuel system is essentially the same as that used on the current Mazda3 (BK) except for the following: – – – – – Steel fuel tank is used.98. Specifications Item Type Injector Type of fuel delivery Type of drive Pressure regulator Fuel tank Fuel pump Fuel Regulating pressure (approximately) Capacity Type Quality (kPa {kgf/cm 2 . Fuel pump unit can be removed through access hole under second row seats.6} 60 {16. lmp gal}) Specifications Hi-ohmic Top-feed Voltage 390 {3. pressure regulator). fuel gauge sender.

L8/LF Engines Parts Location Fuel System M5_01007 1 2 Fuel injector Quick release connectors 3 4 Main fuse block Fuel pump relay Service Training Mazda5 01-15 .

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

M5_01010 1 2 Checker tab Fuel pipe 3 Fuel pipe correctly connected Service Training Mazda5 01-17 .L8/LF Engines Fuel Line Removal • • Fuel System A new SST has been introduced to enable the disconnection of the fuel line quick connector used at the fuel pump unit. M5_01009 1 SST 49 E042 001 • The quick release connectors are fitted with a checker tab that prevents improper fit. the lock is released and the checker tab comes off.. The quick release connector can be disconnected by pinching the retainer tab with the SST and pulling the connector. This checker tab cannot normally be removed. When the quick release connector is properly connected to the fuel pipe.

When a crankshaft position sensor signal is detected during cranking. the fuel pump relay is turned ON.800 rpm or more on the L8 engine. Fuel Injection Control Excessive Speed Fuel Cut • Fuel injection is cut when any of the following conditions are met: – – – When the engine speed is 6. When engine speed is 5. If the vehicle is stopped.500 rpm or more and the engine coolant temperature is approximately -15 °C {5 °F} or less.000 rpm or more on the LF engine. to improve engine starting. the PCM turns the fuel pump relay on for one second.000 rpm or more and the engine coolant temperature is approximately 117 °C {243 °F}. 01-18 Service Training Mazda5 . and for 2 min or more the engine speed is 5.Fuel System Fuel Pump Control • • • L8/LF Engines When the ignition is switched ON. The fuel pump relay remains ON for approximately two seconds after the ignition has been switched OFF. or 7.

M5_01011 1 2 3 4 Exhaust manifold Front oxygen sensor Warm-up three-way-catalyst Rear oxygen sensor 5 6 7 Three-way-catalyst Pre-silencer Main silencer Service Training Mazda5 01-19 .L8/LF Engines Exhaust System Features • The exhaust system has the following features: Exhaust System – An exhaust system that can be replaced in sections has been utilized.

Emission System Emission System Features • L8/LF Engines The emission system on the Mazda5 is the same as that of the current Mazda3 (BK) with LF engine. Three-way catalytic converter with warm-up converter is used. It has the following features: – – Exhaust gas recirculation system is used. Parts Location M5_01067 1 2 3 Positive crankcase ventilation valve Exhaust gas recirculation valve Purge solenoid valve 4 5 Warm-up three-way catalyst Three-way catalyst 01-20 Service Training Mazda5 .

L8/LF Engines Fuel Tank Emission System M5_01068 1 2 3 Fuel filler cap Charcoal canister Evaporative chamber 4 5 Check valve (two-way) Rollover valve Service Training Mazda5 01-21 .

Cooling duct is provided for the battery.Ignition System Charging System Features • L8/LF Engines The charging system on the Mazda5 is the same as that of the current Mazda3 (BK) with LF engine. 12-90 Controlled by PCM M5_01T020 Output Generator Regulated voltage Self diagnosis function Parts Location M5_01069 1 Battery 2 Generator 01-22 Service Training Mazda5 . 75D26L (52). It has the following features: – – A non-regulator type generator with built-in power transistor is used. Specifications Item Voltage Battery Type and capacity (5-hour rate) (V) (A·h) (V-A) Specifications 12 50D20L (40).

Iridium type spark plugs are used.L8/LF Engines Ignition System Features • The ignition system has the following features: Charging System – – An ignition system with direct ignition coils and independent ignition control has been adopted. Parts Location M5_01013 1 Ignition coil 2 Spark plug Service Training Mazda5 01-23 .

3 No.Ignition System Ignition Coils • • • L8/LF Engines Ignition coils installed directly to each spark plug have been adopted. The direct ignition coil consists of an ignition coil with integrated power transistor. ignition coil connector. 2 No. and rubber boot. M5_01014 1 2 3 4 5 6 Ignition coil external view Ignition coil Ignition coil electrical circuit PCM Cylinder number No. 4 Capacitor Ignition switch Battery 01-24 Service Training Mazda5 . 1 7 8 9 10 11 12 No. Construction of the ignition coils is essentially the same as those on the current Mazda3 (BK) with ZJ/Z6 engine.

L8/LF Engines Control System Features • Control System The engine control system is essentially the same as that of the Mazda3 (BK) with LF engine. Specifications Item Neutral switch CPP switch ECT sensor IAT sensor (inside MAF) TP sensor MAF sensor Front HO2S Rear HO2S BARO sensor (built into PCM) KS MAP sensor CKP sensor CMP sensor Brake switch Specification ON/OFF ON/OFF Thermistor Thermistor Potentiometer Hot-wire Zirconia element (Stoichiometric air/fuel ratio sensor) Zirconia element (Stoichiometric air/fuel ratio sensor) Piezoelectric element Piezoelectric element Piezoelectric element Magnetic pickup Magnetic pickup ON/OFF M5_01T019 Service Training Mazda5 01-25 .

Control System Parts Location L8/LF Engines M5_01015 1 2 3 4 5 6 7 8 9 10 MAF/IAT sensor TP sensor IAC valve MAP sensor CKP sensor KS Fuel injector CMP sensor VIS solenoid valve (LF engine) VTCS solenoid valve 11 12 13 14 15 16 17 18 19 PCM Purge solenoid valve EGR valve Neutral switch (MT) TR switch (AT) HO2S (front. rear) ECT sensor Brake switch CPP switch (MT) 01-26 Service Training Mazda5 .

L8/LF Engines System Overview Control System M5_01016 1 2 3 4 5 6 7 8 9 10 Air cleaner MAF/IAT sensor TP sensor MAP sensor CMP sensor ECT sensor CKP sensor Front H O2S Rear HO2S Purge solenoid valve 11 12 13 14 15 16 17 18 19 20 EGR valve VIS solenoid valve (LF engine) VTCS solenoid valve IAC valve Fuel pump unit KS Fuel injector BARO sensor PCM To PCM Service Training Mazda5 01-27 .

low pressure) Refrigerant pressure switch (medium pressure) Battery voltage Generator (terminal P: stator coil) Vehicle speed signal Instrument cluster Output IAC valve VIS solenoid valve VTCS solenoid valve Fuel injectors Fuel pump relay Ignition coil EGR valve Purge solenoid valve Front HO2S heater Rear HO2S heater A/C relay Fan control module Starter relay Generator (terminal D: field coil) x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x M5_01T007 01-28 Service Training Mazda5 Generator control x x x x Purge control EGR control .Control System Relationship Chart Electronic spark advance (ESA) control L8/LF Engines Variable tumble control system Front HO2S heater control Fuel injection control Electrical fan control Idle air control (IAC) Component Rear HO2S heater control Variable intake-air system Immobiliser system x x A/C cut-off control Fuel pump control Input IAT sensor MAF sensor TP sensor MAP sensor ECT sensor CMP sensor CKP sensor KS Front HO2S Rear HO2S BARO sensor Neutral switch CPP switch Brake switch A/C on request signal. refrigerant pressure switch (high.

Specifications Item Type Cylinder arrangement and number Combustion chamber Valve system Displacement Bore x stroke Compression ratio Compression pressure IN Valve timing EX Valve clearance (engine cold) IN EX Specification Diesel 4-stroke Inline.0 x 86.32-0.12-0.0070} 0.7 2.0 MZR-CD engine has the following features: – – Pistons with a modified combustion chamber have been introduced.0 {3. 122. Cylinder head with integrated injector leak-off lines has been introduced. 16-valve 1.900 {29.39 x 3.988.0 MZR-CD Engine Mechanical System Features • Mechanical System The mechanical system of the vehicles with 2.0048-0.2.9} 86.39} 16.0149} M5_01T008 (ml {cc. psi} [rpm]) Open BTDC (°) Close ABDC (°) Open BBDC (°) Close ATDC (°) (mm {in}) (mm {in}) Service Training Mazda5 01-29 . belt driven.7} [250] 6 30 41 8 0.6. 4-cylinder Direct injection SOHC. 420.18 {0. cu in}) (mm {in}) (kPa {kgf/cm2.38 {0.0126-0.998 {1.

0 MZR-CD Engine M5_01018 1 2 3 Engine speed Power Torque 4 5 Standard power engine High power engine 01-30 Service Training Mazda5 .Mechanical System Engine Performance Curve 2.

0 MZR-CD Engine Overview Mechanical System M5_01019 Service Training Mazda5 01-31 .2.

7 . M5_01020 1 Coating 2 Combustion chamber 01-32 Service Training Mazda5 . This leads to lower pumping losses and optimized thermal efficiency at middle and high engine load. reducing the fuel consumption.Mechanical System Pistons • 2.0 MZR-CD Engine Pistons with a modified combustion chamber have been introduced to achieve a lower compression ratio of ε = 16.

2. M5_01021 Service Training Mazda5 01-33 .0 MZR-CD Engine Cylinder Head • Mechanical System A cylinder head with integrated leak-off lines for the injectors has been introduced.

5.5} M5_01T009 (kPa {kgf/cm2. 4. Specifications Item Type Oil pressure (reference value) [oil temperature: 100 °C {212 °F}] Type Oil pump Relief valve opening pressure (reference value) Type Oil cooler Type Oil filter Bypass pressure Oil capacity Total (dry engine) (approx.1-101.5 {5.4. An oil dipstick with an additional “X” mark has been introduced. 21} min. Oil replacement quantity) Oil and oil filter replacement Specification Force-fed type 147 {1. Mazda genuine Dexelia DPF M5_01T010 01-34 Service Training Mazda5 .2. paper element 78-118 {0. psi}) (L {US qt. psi} [rpm]) (kPa {kgf/cm2.3-17.1.8} 4.0 MZR-CD engine has the following features: – – – An engine oil with reduced ash content has been introduced.5} [3. [3. 4. psi} [rpm]) (kPa {kgf/cm2.000] Trochoid gear type 580-700 {5.1} 5.5. 84.000] 343 {3. lmp qt}) (L {US qt. 50} min.8. 11.0 MZR-CD Engine The lubrication system of the vehicles with 2.8-1.3} 5.9-7. 4. lmp qt}) (L {US qt. [1.000] Water-cooled Full-flow. lmp qt}) Engine Oil Item Grade Viscosity Recommended oil Specification ACEA C1 or JASO DL-1 SAE 5W-30 e.9 {5.2. Oil cooler and oil filter located at the rear of the engine have been introduced.1 {5.Lubrication System Lubrication System Features • 2.g.

0 MZR-CD Engine Parts Location Lubrication System M5_01022 1 2 3 4 5 6 Oil filter Oil cooler O-ring Oil jet valve Oil drain plug Washer 7 8 9 10 11 Oil pan Oil strainer Gasket Oil pressure switch Oil pump Service Training Mazda5 01-35 .2.

Phosphor. As a result. Sulphur) oil. the usable filter volume is reduced significantly due to the ash amount deposited in the DPF. M5_01058 X 1 2 Service life of DPF Normal engine oil (ACEA A3/B3/B4) Conventional low SAPS oil (ACEA C2/C3) Y 3 4 Ash amount in the DPF Mazda low SAPS oil (ACEA C1) DPF blocked with ash 01-36 Service Training Mazda5 . so that the fuel consumption and hence the oil dilution are increased. In addition. the regeneration intervals are shortened.Lubrication System Engine Oil • 2. an engine oil with reduced ash content is required.0 MZR-CD Engine In order to limit the ash amount accumulated in the diesel particulate filter. since it has a reduced proportion of these components. NOTE: The use of engine oil with a higher ash content is strictly forbidden as this can lead to blockage of the DPF. This oil must meet the specification ACEA C1 (equivalent to the Japanese specification JASO DL-1) and is also termed as low SAPS (Sulphate Ash.

Maintenance and Repair”). the parameter “Calculated oil dilution” in the PCM must be reset (refer to the section “Control System.2.0 MZR-CD Engine Oil Dipstick • Lubrication System Since the fuel post-injections required to regenerate the DPF can lead to an excessively high engine oil dilution. the engine oil must be replaced. M5_01023 1 2 L mark (Low) F mark (Full) 3 X mark (Excessive) Service Training Mazda5 01-37 . an “X” mark has been added to the oil dipstick to make the customer aware of this condition. If the oil level is close to or exceeds the “X” mark. NOTE: Every time the engine oil is replaced.

In this case. This DTC comes up when the regeneration of the DPF has been started multiple times but could never be completed due to the driving method (such as frequent short distance driving with low engine speed etc. If the oil level is lower than the “X” mark on the dipstick. In addition. delete the DTC. However.). the engine could be damaged if the vehicle continues to be driven.0 MZR-CD Engine The PCM calculates the oil dilution amount based on the duration of the regeneration process and the regeneration intervals. the PCM reduces the fuel injection amount to protect the engine. In addition. In this case. the customer must be informed to change the driving method (such as driving the vehicle at middle or high engine speeds for a longer distance). so that regeneration of the DPF is enabled. In addition.Lubrication System Oil Dilution Calculation • • 2. the DPF indicator light flashes and DTC P253F is stored in the PCM. so that regeneration of the DPF is enabled. • 01-38 Service Training Mazda5 . check the engine oil level. replace the engine oil even if the engine oil level is lower than the “X” mark on the dipstick. If the engine oil level reaches a certain limit due to oil dilution. DTC P252F is stored in the PCM but no warning light is illuminated. If the engine oil performance and engine oil level is approaching the limit due to oil dilution. the customer must be informed to change the driving method (such as driving the vehicle at middle or high engine speeds for a longer distance).

2. mark on the oil dipstick.0 MZR-CD Engine • Lubrication System The different conditions of the oil dilution are described in the following table. M5_01T011 Dealer action — — 1 2 3 F mark X mark Oil dipstick 4 5 Oil level okay Oil level excessive Service Training Mazda5 01-39 . replace the engine oil even if After inspecting the engine oil level is engine oil level lower than the "X" replace the engine oil.4 s — Max. Item Engine oil dilution Engine oil level DPF indicator light MIL Output restriction DTC stored in PCM Customer action DPF automatic regeneration — — — P252F — Enabled — — — — Flashes every 0. 150 km/h (93 mph) P253F Bring the vehicle to a dealer Disabled If DTC 253F is stored in the PCM.

0 MZR-CD Engine An oil cooler and oil filter located at the rear of the engine have been introduced. M5_01024 1 2 External view Cut-view A-A 3 Engine coolant flow direction 01-40 Service Training Mazda5 .Lubrication System Oil Cooler and Oil Filter • 2.

7.2-122.8} Electric 7 360 {14.2} 240 M5_01T012 (°C {°F}) (°C {°F}) (mm {in}) (kPa {kgf/cm2. quantity) W ater pump Thermostat Radiator Cooling system cap Type Type Opening temperature Full-open temperature Full-open lift Type Cap valve opening pressure Type Number of blades Outer diameter Fan motor output (L {US qt.5 {9.6 {0.5 {0. Stepless cooling fan controlled by a fan control module has been introduced (similar to that of the L8/LF engines).5} Without heater: 8. Specifications Item Type Coolant capacity (approx.5.95-1.5-17. bottom-bypass 80-84 {176-183} 95 {203} 8. Timing belt-driven Wax.2.0 {8.0. psi}) Cooling fan (mm {in}) (W) Service Training Mazda5 01-41 . 13. Electromotive With heater: 8. 7. lmp qt}) Specification Water-cooled.0 MZR-CD Engine Cooling System Features • Cooling System The cooling system of the vehicles with 2.25. Separate cooling system filler neck has been introduced (similar to that of the L8/LF engines).33} or more Corrugated fin 93.0} Centrifugal.0 MZR-CD engine has the following features: – – – A long-life engine coolant has been introduced (similar to that of the L8/LF engines).

0 MZR-CD Engine M5_01025 1 2 3 4 5 6 Cooling fan assembly Fan control module Radiator cowling Cooling fan motor Cooling fan Coolant reserve tank 7 8 9 10 11 Cooling system cap Cooling system filler neck Radiator Thermostat Water pump 01-42 Service Training Mazda5 .Cooling System Parts Location 2.

Manifold absolute pressure sensor located above the intake manifold has been introduced. Turbocharger with variable geometry turbine and reduced turbine diameter has been introduced.2.0 MZR-CD engine has the following features: – – – – MAF learning function has been cancelled. Parts Location M5_01026 1 2 3 4 Glow plug lead VBC vacuum actuator Turbocharger Air cleaner 5 6 7 8 Charge-air cooler Charge-air cooler duct Intake manifold Glow plug Service Training Mazda5 01-43 . Variable swirl control valves have been cancelled.0 MZR-CD Engine Intake-air System Features • Intake-air System The intake-air system of the vehicles with 2.

M5_01027 1 2 VBC vacuum actuator Intake air flow 3 Exhaust gas flow 01-44 Service Training Mazda5 . This leads to a lower inertia moment of the turbine.Intake-air System Turbocharger • 2. improving the response of the engine during acceleration.0 MZR-CD Engine A turbocharger with variable geometry turbine and reduced turbine diameter has been introduced.

2.0 MZR-CD Engine Manifold Absolute Pressure Sensor • Intake-air System A MAP (Manifold Absolute Pressure) sensor located above the intake manifold has been introduced. M5_01059 1 Intake manifold 2 MAP sensor Service Training Mazda5 01-45 .

Fuel System Fuel System Features • 2. Injector driver module has been cancelled.0 MZR-CD Engine The fuel system of the vehicles with 2.0 MZR-CD engine has the following features: – – – – Common rail located above the intake manifold has been introduced. Parts Location M5_01028 A 1 2 3 4 LHD Fuel warmer Priming pump Fuel filter Fuel injector B 5 6 7 8 RHD Pressure limiter valve Common rail Fuel metering valve High-pressure pump 01-46 Service Training Mazda5 . Injection amount learning function has been modified. Solenoid valve-type injectors with injector correction factors have been introduced.

0 MZR-CD Engine Common Rail • Fuel System A common rail located above the intake manifold has been introduced.2. M5_01060 1 2 3 Common rail Pressure limiter valve Connection (high-pressure pump-side) 4 5 Fuel pressure sensor Connection (fuel injector-side) Service Training Mazda5 01-47 .

there might be an interference between the connector and the injector seal during removal and installation of the cylinder head cover. M5_01072 1 2 From common rail Connector 3 To fuel tank NOTE: Since the size of the injector connector is relatively big compared to the diameter of the injector head. the total leak-off amount of the injectors must be measured and compared to the values of a known good vehicle in order to detect a leaking solenoid valve. wrap vinyl tape around the injector connector covering its edges. This results in engine oil dilution and hence in engine damage. the leak-off lines of the injectors are located under the cylinder head cover. NOTE: Always replace the gaskets of the injector leak-off lines when removing them.0 MZR-CD Engine Solenoid valve-type injectors with lower power consumption and better response have been introduced. As a result. fuel leaking from the lines can contaminate the engine oil. • In addition. As the leak-off lines are located under the cylinder head cover. In order to prevent any damage to the seal.Fuel System Injectors • 2. 01-48 Service Training Mazda5 .

A control circuit outputs the high voltage to the injectors as a drive signal.2. The module has a high-voltage generator inside. 90 V and stores it in a capacitor. M5_01073 1 2 3 4 From PCM control relay High voltage generator PCM Injector no. In case of an open circuit on one injector the PCM cuts off the power supply for this injector. so that the engine still runs on three cylinders. which amplifies the battery voltage into a high voltage of approx. i.1 5 6 7 8 Injector no 2 Injector no 3 Injector no. Service Training Mazda5 01-49 .e.0 MZR-CD Engine • Fuel System The injectors are directly driven by the PCM.4 Control circuit • All injectors are connected in parallel. they feature the same PCM terminal for the positive voltage supply.

the PCM outputs a short drive signal to the injectors. combustion noise and exhaust emissions. • Injector Correction Factors • The manufacturing tolerances of the injectors are taken into account by injector correction factors. As a result. several steps must be performed to ensure their proper function (refer to the section “Control System. As a result. At the end of the vehicle production line the injector correction factors of the installed injectors are programmed into the PCM.Fuel System • 2. 01-50 Service Training Mazda5 . When the required injection amount is large. the PCM outputs a long drive signal to the injectors. The correction factors are determined during injector production and are labeled as hexadecimal numbers (seven four-digit blocks and one two-digit block) on top of the injector connector. Maintenance and Repair”). resulting in a large injection amount. the opening time of the injectors is short. resulting in a small injection amount.0 MZR-CD Engine When the required injection amount is small. Hereby the PCM equalizes the injection amount of the individual injectors in order to improve engine running. • M5_01029 1 Injector correction factor 2 View from A NOTE: After replacing one or more injectors. the opening time of the injectors is long.

the PCM carries out the injection amount learning function every 150 km within the first 1. they must be matched to the cylinders they were removed from. NOTE: The injection amount learning function is performed several times at a fuel pressure of 35 MPa. the process will be suspended until the conditions are once again met.000 km. although the communication between WDS and PCM is okay Service Training Mazda5 01-51 . Failure to follow this instruction may cause irregular idling.g. the injection amount learning function has to be carried out at specified service intervals (refer to the workshop manual). when all of the following conditions are met: – – – – – – – • Engine is idling Shift lever is in Neutral position Vehicle speed is 0 km/h Engine coolant temperature is between 65…95 °C A/C is not operating Accelerator pedal is not depressed DPF regeneration is not performed If any of these conditions change while carrying out the injection amount learning function. As a result.500 km and after that every 3.2. 100 MPa and 140 MPa. In this case the WDS indicates a communication fault. Injection Amount Learning Function • The injection amount learning function has been modified. NOTE: The injection amount learning function will be aborted. slight changes in engine sound are normal.0 MZR-CD Engine Fuel System NOTE: When re-installing the injectors after a repair. Therefore make a note of the injector correction factors and the allocated cylinders before removing the injectors. As a result. increased combustion noise and/or increased black smoke emissions. if the idle fluctuation of the engine is too high (e. In addition. 65 MPa. due to a faulty injector).

0 MZR-CD Engine M5_01030 1 2 Oxidation catalytic converter and diesel particulate filter EGR cooler 3 4 Intake shutter valve EGR valve 01-52 Service Training Mazda5 .Emission System Emission System Parts Location 2.

0 MZR-CD Engine Exhaust System Features • Emission System The exhaust system of the vehicles with 2. Parts Location M5_01031 1 2 3 Exhaust manifold Flexible pipe Oxidation catalytic converter and diesel particulate filter 4 5 Middle pipe Main silencer Service Training Mazda5 01-53 . Diesel particulate filter integrated in the housing of the oxidation catalytic converter has been introduced.0 MZR-CD engine has the following features: – – Warm-up oxidation catalytic converter has been cancelled.2.

EGR Valve • An EGR valve with DC (Direct Current) motor and position sensor has been introduced.0 MZR-CD Engine The exhaust gas recirculation system of the vehicles with 2. A threaded spindle transforms the rotational movement of the motor into an axial movement of the EGR valve.0 MZR-CD engine has the following features: – – – EGR valve with direct current motor and position sensor has been introduced. M5_01032 1 2 3 EGR valve position sensor Valve Push rod 4 5 6 Return spring DC motor Exhaust gas flow 01-54 Service Training Mazda5 . EGR cooler located at the transmission-side of the engine has been introduced. Intake shutter valve with direct current motor and position sensor has been introduced.Emission System Exhaust Gas Recirculation System Features • 2.

2. 10 s. At high engine speeds the PCM controls the DC motor with a small duty cycle. Therefore. This process takes approx. Service Training Mazda5 01-55 . M5_01033 1 2 DC motor PCM 3 Current detection circuit • • • At low engine speeds the PCM controls the DC motor with a large duty cycle.0 MZR-CD Engine • Emission System The position of the EGR valve is controlled by the PCM. so that the EGR valve closes and no exhaust gas is recirculated. The PCM controls the DC motor by a duty signal 0 V/12 V. • NOTE: If the EGR system fails. the PCM actuates the EGR valve so that it is moved from the fully open to the fully closed position several times. the EGR valve adopts in the closed position in which no exhaust gas is recirculated. which activates the DC motor via a duty signal. In order to remove any carbon deposits from the EGR valve seat a cleaning mode is activated each time the engine is shut off. so that the EGR valve opens and exhaust gas is recirculated.

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 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.

NOTE: After the EGR valve is replaced, its adaptation values in the PCM must be reset and the EGRVP sensor initialized (refer to the section “Control System, Maintenance and Repair”).

M5_01034

1

EGRVP sensor

2

PCM

01-56

Service Training Mazda5

2.0 MZR-CD Engine
EGR Cooler

Emission System

An EGR cooler located at the transmission-side of the engine has been introduced.

M5_01061

1 2 3

EGR valve To intake manifold EGR cooler

4 5

From exhaust manifold Engine coolant flow

Service Training Mazda5

01-57

Emission System
Intake Shutter Valve

2.0 MZR-CD Engine

An ISV (Intake Shutter Valve) with DC motor and position sensor has been introduced. A reduction gear ensures, that a large rotation angle of the motor results in a small rotation angle of the valve. The valve body is connected to the engine coolant circuit to prevent icing of the ISV at low ambient temperatures.

M5_01035

1 2 3 4 5

ISV Valve body Return spring Stator with hall element Driven gear with magnetic rotor

6 7 8 9

Drive circuit Intermediate gear Drive gear DC motor

01-58

Service Training Mazda5

2.0 MZR-CD Engine

Emission System

The position of the ISV is controlled by the PCM, which activates the DC motor via a duty signal.

M5_01033

1 2

DC motor PCM

3

Current detection circuit

When the required EGR rate is high the PCM controls the DC motor with a large duty cycle. As a result, the ISV closes halfway, reducing the cross-section of the intake pipe. Thus a vacuum is generated in the intake manifold and a large amount of exhaust gas can be recirculated. When the required EGR rate is low the PCM controls the DC motor with a small duty cycle. As a result, the ISV opens, making the complete cross-section of the intake pipe available. Thus atmosphere or boost pressure is generated in the intake manifold (depending on the operating conditions) and only a small amount of exhaust gas can be recirculated. When the engine is switched off the PCM controls the DC motor with maximum duty cycle. As a result, the ISV closes fully and no air is induced into the engine, preventing bucking movements during shut-off.

Service Training Mazda5

01-59

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. Therefore, the PCM actuates the ISV so that it is moved from the fully open position to the fully closed position several times. This process takes approx. 10 s. The PCM controls the DC motor by a duty signal 0 V/12 V.

NOTE: If the ISV system fails, the ISV adopts in the open position in which no vacuum is produced. • The ISV position sensor is integrated in the cover of the valve body and detects the ISV position by a hall-type sensor. The sensor consists of a stator with hall element and a magnetic rotor joint to the driven gear.

M5_01036

1

ISV position sensor

2

PCM

When the magnetic rotor rotates, a voltage is generated in the hall element. As the hall voltage is very low, it is amplified in the sensor and input to the PCM.

NOTE: After the ISV is replaced, its adaptation values in the PCM must be reset and the ISV position sensor initialized (refer to the section “Control System, Maintenance and Repair”).

01-60

Service Training Mazda5

2.0 MZR-CD Engine
Diesel Particulate Filter System
Features

Emission System

The diesel particulate filter system of the vehicles with 2.0 MZR-CD engine has the following features:

– –

Diesel particulate filter with differential pressure sensor and three exhaust gas temperature sensors (upper/middle/lower) has been introduced. Heated oxygen sensor located behind the diesel particulate filter has been introduced.

Diesel Particulates
• Under engine operating conditions such as cold start, acceleration and high load the combustion process of the diesel engine is incomplete, resulting in an increased formation of soot particles. These microscopically small particles have a diameter of only about 0.05 µm. Soot itself has no harmful effect on the human organism. Hydrocarbons originating from the fuel and lubricants, as well as water and sulphates, attach themselves to these granulates, increasing their size to 0.09 µm. In this way the harmful soot particles are formed. The human nose and bronchial tubes are not able to filter out particles smaller than 2.5 µm (for comparison: a hair is about 70 µm thick). As a result, the particles can then penetrate through the airways deep into the lungs and pose a health threat especially to children and adults with certain medical conditions. Soot particles are suspected of triggering allergies and even cancer. This is especially true of the smallest particles measuring between 0.1…1.0 µm. The European Union is introducing progressively stricter emissions legislation to achieve a long-lasting reduction in air pollution from vehicle emissions. As part of this legislation, all new Diesel passenger vehicles requiring type approval from January 1st 2005 must comply with the Euro 4 emission standard. In addition, all Diesel passenger vehicles first registered from January 1st 2006 must meet the Euro 4 standard.

Service Training Mazda5

01-61

05 g/km). the Mazda5 CR with 2. the limit for Euro 4 vehicles (0. In order to comply with the strict Euro 4 emission legislation. The following sample calculation shows the benefit of a diesel particulate filter: A modern Common Rail diesel engine without diesel particulate filter has emitted on average about 3 kg of soot after 80. coldstart accelerator) is strictly forbidden since this leads to an increased ash formation.025 g/km) has been lowered by 50 %.0 MZR-CD engine is equipped with a diesel particulate filter system. • Diesel Particulate Filter • The oxidation catalytic converter and the DPF (Diesel Particulate Filter) are located one behind another in a combined housing. 01-62 Service Training Mazda5 .0 MZR-CD Engine In comparison to the particulate matter limit for Euro 3 vehicles (0. M5_01037 1 2 3 4 Oxidation catalytic converter and DPF Heated oxygen sensor Exhaust gas temperature sensor (lower) Exhaust gas temperature sensor (middle) 5 6 7 Exhaust gas temperature sensor (upper) Connection for reference pressure Connection for high pressure NOTE: To ensure proper function of the DPF system only mineral diesel fuel with a maximum sulphur proportion of 350 ppm according to DIN EN 590 must be used. valve cleaner.000 km.Emission System • 2. which is a reduction of 95 %. The use of fuel with a higher sulphur proportion is strictly forbidden as this can lead to blockage of the DPF.g. NOTE: Mixing of any additives with metallic compounds to the diesel fuel (e. resulting in a blocked DPF. With a filter it would have emitted less than 100 g over the same mileage.

NOTE: Under certain conditions it is possible for white smoke to be emitted from the exhaust tailpipe during regeneration. which features a high resistance against temperature fluctuations. the exhaust gas is forced to flow through the dividing walls. Service Training Mazda5 01-63 . As a result. i. preventing an increase in fuel consumption.2. The individual channels of the filter have porous dividing walls and are closed at alternative ends. This is also a by-product of the regeneration process and should not be considered a concern. In addition.e. This is an inherent by-product of the regeneration process and should not be considered a concern. The accumulation of particles in the filter increases the filtration effect still further.0 MZR-CD Engine • Emission System The DPF is a monolith made of silicon carbide ceramics. the regeneration process reduces the exhaust gas back-pressure caused by the soot amount accumulated. which retain the soot particles and allow gaseous components to pass. the soot particles accumulated in the filter are burnt off. M5_01038 1 2 • Cleaned exhaust gas DPF 3 4 Exhaust gas from engine Oxidation catalytic converter To avoid the DPF from becoming blocked with soot particles it must be regenerated at regular intervals. NOTE: On vehicles with a higher mileage soot residues can often form on the exhaust tailpipe.

These residues reduce the usable filter volume. several steps must be performed to ensure its proper function (refer to the section “Control System. the DPF must be replaced. After regeneration ash residues that have formed from the engine oil and diesel fuel remain in the DPF and cannot be further converted. these effects can be reduced to a minimum. Since the filter pores are clogged by the ash residues. M5_01039 X 1 2 Exhaust-gas volume flow Used filter New filter Y 3 Differential pressure Differential pressure limit 01-64 Service Training Mazda5 . depending on the operating conditions the usable filter volume reaches the limit within the lifetime of the vehicle.0 MZR-CD Engine The channels of the DPF are coated with platinum. For this reason. • • NOTE: After replacing the DPF. Due to the effect of the platinum coating the light-off temperature of the soot is lowered to 500 °C. This catalytic coating facilitates the regeneration of the filter by significantly lowering the light-off temperature of the soot and by accelerating the combustion of the particles. Without coating the burn-off of the particles takes place above a temperature of approx.Emission System • 2. In this case. there is no replacement interval given for the filter. 600 °C. Due to the use of an engine oil with low ash content. However. the exhaust gas back-pressure and hence the fuel consumption are increased. Maintenance and Repair”). shortening the regeneration intervals.

when its shape changes due to exposure to pressure.2.0 MZR-CD Engine DPF Differential Pressure Sensor • Emission System The DPF differential pressure sensor detects the pressure difference in the exhaust gas flow upstream and downstream of the DPF. The pressure difference is a measure for the soot amount accumulated in the filter (i. The sensor is located in the engine compartment at the bulkhead and is connected to the upstream and downstream measuring point of the DPF by means of pressure lines. The electrical resistance of the element varies. The differential pressure sensor consists of a pressure chamber with integrated semiconductor element. • M5_01040 1 2 3 DPF differential pressure sensor Pressure lines Oxidation catalytic converter and DPF 4 5 6 Temperature correction sensor Connection for reference pressure Connection for high pressure Service Training Mazda5 01-65 . the higher the pressure difference.e. the higher the soot amount).

• M5_01042 1 DPF differential pressure sensor 2 PCM 01-66 Service Training Mazda5 . the signal serves to monitor the regeneration process. The DPF differential pressure sensor supplies the PCM with an analogue voltage signal between 0…5 V.Emission System 2.0 MZR-CD Engine M5_01041 1 2 DPF Measuring points for DPF differential pressure sensor 3 Oxidation catalytic converter • The signal of the DPF differential pressure sensor is used to determine. whether the soot amount requires regeneration of the filter. In addition.

• NOTE: Since the output characteristics of the DPF differential pressure sensor is adjusted while it is installed to the bracket. i. The temperature correction sensor supplies the PCM with an analogue voltage signal between 0…5 V.0 MZR-CD Engine • Emission System In addition.e. M5_01042A 1 Temperature correction sensor 2 PCM Service Training Mazda5 01-67 . Maintenance and Repair”). several steps must be performed to ensure its proper function (refer to the section “Control System. always replace the sensor and the bracket as a unit.2. its resistance becomes smaller when the temperature rises. which is located on the bracket of the differential pressure sensor and detects the temperature in the engine compartment. NOTE: After replacing the DPF differential pressure sensor. The signal of the temperature correction sensor is used to compensate the temperature characteristics of the DPF differential pressure sensor. the DPF differential pressure sensor features a temperature correction sensor. The sensor is a temperature-resistive resistor with NTC (Negative Temperature Coefficient).

M5_01043 X 1 2 3 4 Exhaust-gas volume flow Blocked condition of filter Overloaded condition of filter Loaded condition of filter Intermediate condition of filter Y 5 6 7 Differential pressure Regenerated condition of filter Damaged condition of filter Differential pressure limit • If the value measured by the DPF differential pressure sensor is above a certain limit. due to EGR valve stuck open. Maintenance and Repair”). • 01-68 Service Training Mazda5 . the DPF is recognized as being blocked. The blocking of the DPF is often as a result of excessive soot emission by the engine (e. Then the PCM stores a corresponding DTC. To rectify this concern. leak in the intake-air system etc.g.0 MZR-CD Engine Since the filter itself creates a certain resistance in the exhaust gas flow.) or can be attributed to multiple failed regeneration processes.Emission System Diagnostics • 2. the signal of the DPF differential pressure sensor is also used to determine the filter condition. a manual regeneration should be carried out using WDS (refer to the section “Control System. illuminates the MIL and activates the limp home mode.

Otherwise check the upstream pressure line and the DPF differential pressure sensor. Then connect a hand-operated pressure/vacuum pump to the upstream pressure line at the DPF. If the PID indicates 30 kPa. apply a pressure of 30 kPa and monitor the PID. replace the DPF. illuminates the MIL and activates the limp home mode. the DPF is recognized as being damaged.2. In this case. the DPF differential pressure sensor should be checked first. Then the PCM stores a corresponding DTC.0 MZR-CD Engine • Emission System If the value measured by the DPF differential pressure sensor is below a certain limit. • Service Training Mazda5 01-69 . Call up the Datalogger of the PCM and select the PID EXHPRESS_DIF (Press).

its resistance becomes smaller when the temperature rises. Each exhaust gas temperature sensor supplies the PCM with an analogue voltage signal between 0…5 V.0 MZR-CD Engine The three exhaust gas temperature sensors (upper/middle/lower) are located in the combined housing of the oxidation catalytic converter/DPF and detect the temperature of the exhaust gas upstream of the oxidation catalytic converter.e. Each sensor is a temperature-resistive resistor with NTC.Emission System Exhaust Gas Temperature Sensors • 2. M5_01044 1 2 3 4 Exhaust gas temperature sensor (upper) Oxidation catalytic converter and DPF Exhaust gas temperature sensor (lower) Exhaust gas temperature sensor (middle) 5 6 7 8 Exhaust gas temperature sensor NTC element Cover Sheath pin 01-70 Service Training Mazda5 . as well as upstream and downstream of the DPF. i.

the information from the exhaust gas temperature sensors is used for the calculation of the soot amount burnt off in the DPF.2. whether the exhaust gas temperature required for regeneration of the filter is reached. The signal of the middle exhaust gas temperature sensor is used to determine. The signal of the lower exhaust gas temperature sensor serves to monitor the exhaust gas temperature during the regeneration process. In addition. • • • M5_01042A 1 Exhaust gas temperature sensor 2 PCM Service Training Mazda5 01-71 . whether the exhaust gas temperature required for operation of the oxidation catalytic converter is reached.0 MZR-CD Engine • Emission System The signal of the upper exhaust gas temperature sensor allows to check.

i. which generally works with an excess-air factor of λ ∼ 1. and outputs a voltage to the PCM.e. it generates a clear electrical signal in a wide range from λ = 0. As a result.7…∞ (∞ = air with 21 % oxygen). By applying a voltage to the pump cell. • 01-72 Service Training Mazda5 . The pump cell serves to maintain the composition of gas in the diffusion gap at λ = 1. • M5_01045 1 HO2S • The broad-band type HO2S consists of an oxygen pump cell and a narrow-band O2 sensor (= Nernst cell). into which exhaust gas enters through the gas access passage. the sensor is also capable of detecting the oxygen concentration in the exhaust gas of a diesel engine.4 (at full load) to λ ∼ 3. oxygen can be pumped from the exhaust gas into the diffusion gap or vice versa.0 MZR-CD Engine The HO2S (Heated O2 Sensor) is located behind the DPF and detects the oxygen concentration in the exhaust gas. The HO2S is a broad-band type sensor.Emission System Heated Oxygen Sensor • 2. The Nernst cell compares the oxygen concentration of the exhaust gas in the diffusion gap to the oxygen concentration of the ambient air in the reference air chamber. Between the pump cell and Nernst cell is a diffusion gap. the PCM compares the output voltage of the Nernst cell with a reference voltage of 450 mV (equivalent to λ = 1) and controls the voltage applied to the pump cell accordingly. The information of the HO2S is used for the calculation of the soot amount burnt off in the DPF. To achieve this.4 (at idle).

Conversely. if the exhaust gas is rich.0 MZR-CD Engine • Emission System If the exhaust gas is lean. leading to a negative pump current. M5_01046 1 2 3 4 5 6 7 Exhaust gas flow Exhaust pipe Heater element PCM Reference air chamber Diffusion gap Nernst cell 8 9 10 11 12 13 Pump cell Porous protective layer Gas access passage Porous diffusion barrier Sensor voltage Pump voltage Service Training Mazda5 01-73 .2. the pump cell pumps oxygen out of the diffusion gap back into the exhaust gas. resulting in a positive pump current. no pumping takes place and the pump current is zero. oxygen is pumped from the exhaust gas into the diffusion gap. If the composition of gas in the diffusion gap is λ = 1.

The temperature of the HO2S is controlled by the PCM. M5_01048 1 2 From PCM control relay Heater element 3 PCM 01-74 Service Training Mazda5 .Emission System • 2. M5_01047 X Excess-air factor λ Y Current • Since the HO2S only generates a usable signal above a certain temperature.0 MZR-CD Engine The HO2S supplies the PCM with a current between -1.8 mA. which activates the heater element via a duty signal. it features an integral heater element.8…+1.

The PCM controls the heater element by a duty signal 0 V/12 V. Maintenance and Repair”). If the DPF indicator light illuminates or flashes during driving. M5_01049 Service Training Mazda5 01-75 . its adaptation values in the PCM must be reset (refer to the section “Control System. During normal operation the DPF indicator light illuminates when the ignition is on and is extinguished after a few seconds. so that no heating takes place. At high exhaust gas temperatures the PCM controls the heater element by a small duty cycle.0 MZR-CD Engine • • • Emission System At low exhaust gas temperatures the PCM controls the heater element by a large duty cycle. then a fault has been detected. NOTE: After replacing the HO2S. so that the required operating temperature is reached quickly. DPF Indicator Light • The DPF indicator light is located in the instrument cluster and serves to alert the driver to a malfunction in the DPF system.2.

0 MZR-CD Engine The regeneration control determines the soot amount accumulated in the DPF and starts the regeneration process accordingly. In this case an automatic regeneration of the DPF must be penabled by driving the vehicle at an engine speed of 2000 min-1 or more and a vehicle speed of 40 km/h or more for approx. the calculated soot emission. As a result. the PCM decides whether and when a regeneration should be carried out. • If the soot accumulation rate in the DPF reaches 100 % or more. the PCM calculates the soot amount burnt off in the DPF using the signals from the HO2S and the exhaust gas temperature sensors. the regeneration process is continued until the soot accumulation rate decreases to 60 % or less. Depending on the signal from the DPF differential pressure sensor. he must be informed to change the driving method (such as driving the vehicle at middle or high engine speeds for a longer distance). In this way. the DPF indicator light turns off. the PCM reduces the fuel injection amount to lower the exhaust gas temperature. In addition. 10…15 min. the DPF indicator light flashes and DTC P2458 is stored in the PCM. so that regeneration of the DPF is enabled. In addition. Due to the reduced injection amount the soot emission of the engine and hence the soot amount accumulated in the filter is also reduced. it is possible to maintain the long-term integrity of the DPF while achieving minimum fuel consumption. Soot Amount Calculation • The PCM receives information about the soot amount accumulated in the filter from the DPF differential pressure sensor. 01-76 Service Training Mazda5 .Emission System Regeneration Control • 2. In this case a manual regeneration of the DPF must be performed. minimum oil dilution and optimum engine performance. As soon as the automatic regeneration process starts. If the soot accumulation rate in the DPF is 80 % or more. the PCM evaluates the customers driving method by monitoring the engine load. engine speed and vehicle speed. the burnt-off soot amount and the distance travelled. the DPF indicator light illuminates. the filter does neither become blocked nor damaged by a violent regeneration following an overaccumulation of soot. preventing the filter from overheating. The regeneration control is integrated in the PCM. • • NOTE: Although the DPF indicator light turns off when the automatic regeneration is started. NOTE: If the customer complains that the DPF indicator light illuminates frequently. In order to establish the soot emission of the engine.

the MIL also illuminates and DTC P242F is stored in the PCM. 150 km/h (93 mph) Customer action — — Bring the vehicle to a dealer DPF automatic regeneration — Enabled Disabled Dealer action — — Perform manual regeneration (normal mode) Perform manual regeneration (long mode) Replace the DPF M5_01T013 Service Training Mazda5 01-77 ..15 min — P2458 Soot accumulation in the DPF 100% 125% 140% 200% • • Flashes every 0. If the soot accumulation rate in the DPF reaches 200 %. Here.4 s — Illuminates Max. since this may cause damage to the filter or the engine.2.. • If the soot accumulation rate in the DPF reaches 140 % or more. resulting in a lower soot amount accumulated in the filter. a manual regeneration of the DPF must also be performed.000 rpm or more and a vehicle speed of 40 km/h (22 mph) or more for 10. the filter cannot be regenerated anymore and must therefore be replaced. the PCM further reduces the fuel injection amount and hence the soot emission of the engine. In addition. The different conditions of the soot accumulation in the DPF are described in the following table: Item Soot accumulation rate DPF indicator light MIL Output restriction DTC stored in PCM — — — — 60% — — — — 80% Illuminates — — — Enable automatic regeneration by driving the vehicle at an engine speed of 2. 70 km/h (43 mph) P242F Max.0 MZR-CD Engine Emission System NOTE: Do NOT perform automatic regeneration when the soot accumulation rate in the DPF is 100 % or more.

the PCM performs the following measures to artificially increase the exhaust gas temperature: • – – – – • Closing the EGR valve to increase the combustion temperature by highering the oxygen proportion of the cylinder charge Closing the ISV partially to increase the combustion temperature by reducing the excess air Performing an early post-injection to increase the combustion temperature by burning an additional fuel amount Performing two late post-injections to increase the exhaust gas temperature by burning fuel in the oxidation catalytic converter By these measures the minimum exhaust gas temperature of 150 °C (at low engine load and engine speed) is increased to 500 °C and regenerations starts. In this case. the regeneration process is started again once the required operating conditions are met. If regeneration of the DPF is required. it must be increased artificially by external intervention from the engine management system to start the regeneration process.Emission System Regeneration Process • 2. • 01-78 Service Training Mazda5 . It is only stopped when the engine is shut off.0 MZR-CD Engine Due to the effect of the catalytic coating the diesel particles are burnt off above a temperature of 500 °C. Since the exhaust gas temperature during normal driving is between 150…400 °C (depending on the engine operating conditions). Then the PCM monitors the regeneration process using the signals from the DPF differential pressure sensor and from the exhaust gas temperature sensors. the PCM checks whether the engine operating conditions are suitable to start the regeneration process. If the requirements for regeneration are met. When regeneration has started it will be completed regardless of the engine operating conditions. Control over the regeneration process is critically important since the DPF is damaged when its temperature exceeds 1000 °C. The regeneration process takes up to 15 min.

Due to the ash residues that have formed from the engine oil and diesel fuel the usable filter volume is reduced. high engine oil consumption and low oil quality (high ash content) accelerate the accumulation of ash in the DPF. Service Training Mazda5 01-79 . the regeneration intervals become shorter with rising mileage. low fuel quality (high sulphur content). shortening the regeneration intervals more quickly. Since the ash amount accumulated in the DPF increases with every regeneration process.0 MZR-CD Engine Regeneration Intervals • Emission System Depending on the operating conditions of the vehicle the DPF is regenerated every 100…300 km. NOTE: High fuel consumption.2.

0 MZR-CD Engine The charging system of the vehicles with 2. 115D31L (70) 12-90 Controlled by PCM M5_01T014 Battery Generator Parts Location M5_01050 1 Generator 2 Battery 01-80 Service Training Mazda5 .0 MZR-CD engine has the following features: – Smart charging system has been introduced.Charging System Charging System Features • 2. Specifications Item Voltage Type and capacity (5-hour rate) Output Regulated voltage Self diagnosis function (V) (Ah) (V-A) Specification 12 95D31L (64).

0 MZR-CD Engine Smart Charging System • Charging System A so-called "Smart Charging System” has been introduced to improve battery charging and durability. the PCM transmits information about the generator warning light status via the high-speed CAN bus to the instrument cluster. which hereby monitors the generator load. which actuates the generator by a duty signal. In addition. battery electrolyte temperature (derived from the intake air temperature. In addition. The PCM determines the duty ratio outputted to the generator according to the battery voltage.2. the generator sends a feedback signal to the PCM. • M5_01051 1 2 3 4 Stator coil Power transistor PCM High-speed CAN bus 5 6 7 Instrument cluster Battery Field coil Service Training Mazda5 01-81 . which activates the generator warning light accordingly. The exciting current of the field coil and hence the charging voltage is controlled by the PCM. engine coolant temperature and vehicle speed signal) and generator load.

As a result. the PCM controls the generator with a large duty cycle. When the battery voltage/battery electrolyte temperature is low and/or the generator load is high.0 MZR-CD Engine When the battery voltage/battery electrolyte temperature is high and/or the generator load is low. • 01-82 Service Training Mazda5 . the PCM controls the generator with a small duty cycle. a low exciting current flows through the field coil and the generator outputs a low charging voltage. a high exciting current flows through the field coil and the generator outputs a high charging voltage. As a result.Charging System • 2.

2. Magneto resistive-type crankshaft and camshaft position sensor have been introduced. Idle switch has been cancelled. Hall-type accelerator pedal position sensor has been introduced. Power steering pressure switch has been introduced.0 MZR-CD Engine Control System Features • Control System The control system of the vehicles with 2. Parts Location M5_01052 Service Training Mazda5 01-83 .0 MZR-CD engine has the following features: – – – – – Powertrain control module with FEEPROM has been introduced.

0 MZR-CD Engine RHD Main fuse box Glow plug relay Starter relay PCM control relay A/C relay DPF differential pressure sensor Temperature correction sensor Power steering pressure switch Camshaft position sensor VBC solenoid valve Accelerator pedal position sensor Brake switch Clutch pedal position switch PCM (with built-in BARO sensor) Cruise control switches HO2S 01-84 Service Training Mazda5 .Control System A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LHD Exhaust gas temperature sensor Park neutral position switch Intake air temperature sensor no.2 Crankshaft position sensor MAF/IAT sensor ISV with DC motor and position sensor EGR valve with DC motor and position sensor Engine coolant temperature sensor Fuel temperature sensor Fuel metering valve Generator (stator coil and field coil) Fuel pressure sensor Glow plug MAP sensor Fuel injector Refrigerant pressure switch B 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 2.

2 Engine coolant temperature sensor Fuel temperature sensor BARO sensor (integrated in PCM) MAP sensor Fuel pressure sensor Camshaft position sensor Crankshaft position sensor Vehicle speed signal Generator (stator coil) DPF differential pressure sensor Temperature correction sensor Exhaust gas temperature sensor (upper/middle/lower) ISV position sensor EGRVP sensor HO2S (sensor) Immobilizer-related information Starter relay Fuel metering valve Fuel injectors VBC solenoid valve EGR valve DC motor ISV DC motor Glow indicator light Cruise main indicator light Cruise set indicator light Glow plug relay Generator (field coil) HO2S (heater element) A/C relay Fan control module Immobilizer-related information X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Input X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Output M5_01T015 Service Training Mazda5 01-85 Immobilizer system X Idle speed control Generator control Glow control EGR control A/C control ISV control .0 MZR-CD Engine Relationship Chart Control System Control Item DPF regeneration control Injection timing control Variable boost control Multiple injection control Injection amount control Cruise control system Fuel pressure control HO2S heater control Electrical fan control Device Battery Starter signal Clutch pedal position switch Park/Neutral position switch Brake switch Power steering pressure switch Refrigerant pressure switch Cruise control switches Accelerator pedal position sensor MAF/IAT sensor IAT sensor no.2.

Maintenance and Repair”). Therefore.Control System Powertrain Control Module • 2.0 MZR-CD Engine The PCM (Powertrain Control Module) is located behind a cover in the passenger footwell and features a 121-pin (two-block) connector. the module has to be reprogrammed with the aid of the WDS. module reprogramming should only be carried out when recommended e. by a Service Information or by the Technical Hotline/Technical Service Department. which can be erased electronically by a flash voltage and reprogrammed with updated calibration data. the strategy program and the calibration data logged in the FEEPROM can be updated without replacing the PCM. • NOTE: As later software calibrations are usually released to resolve specific customer concerns. NOTE: When replacing the PCM. As a result. M5_01062 1 Wiring harness side-connector of the PCM • The PCM features an FEEPROM (Flash Electronically Erasable Programmable ROM). 01-86 Service Training Mazda5 . several steps must be performed to ensure its proper function (refer to the section “Control System. If the PCM should be updated with a later software calibration.g. select the option Toolbox Module ProgrammingModule ReprogrammingPCM and follow the instructions of the WDS.

The rotor is integrated in the flywheel.2. which is located at the rear side of the clutch housing.5 V Ground Crank angle Toothed rotor Service Training Mazda5 01-87 . M5_01053 1 2 3 4 Clutch housing CKP sensor Output signal 5V 5 6 7 8 0. The sensor consists of two magneto resistive elements and a magnet. which scan a rotor with 56 teeth. missing five teeth in one location.0 MZR-CD Engine Crankshaft Position Sensor • Control System An magneto resistive-type CKP (Crankshaft Position) sensor has been introduced.

An integrated circuit converts the output voltage of the magneto resistive elements into a rectangular wave signal. These could cause fluctuation of the magnetic flux. verify that no swarfs adhere to the sensor. an alternating magnetic field is generated that changes the resistance of the magneto resistive elements. • The CKP sensor supplies the PCM with a digital voltage signal 0 V/5 V. NOTE: When the CKP sensor fails. When the rotor passes the sensor. the engine stalls and does not start anymore.0 MZR-CD Engine The magneto resistive elements have the characteristics that their resistance changes depending on the magnetic flux.Control System • 2. which is then input to the PCM. M5_01054 1 CKP sensor 2 PCM 01-88 Service Training Mazda5 . NOTE: When installing the CKP sensor. affecting the sensor signal and hence the engine control.

0 MZR-CD Engine Camshaft Position Sensor • Control System An magneto resistive-type CMP (Camshaft Position) sensor has been introduced. The rotor is attached to the drive gear of the power steering oil pump.2. The sensor consists of two magneto resistive elements and a magnet. which is located at the vacuum pump. M5_01055 1 2 3 4 Cylinder head CMP sensor Output signal 5V 5 6 7 8 0.5 V Ground Cam angle Toothed rotor Service Training Mazda5 01-89 . which scan a rotor with five teeth.

These could cause fluctuation of the magnetic flux. verify that no swarfs adhere to the sensor.1 during engine start the PCM injects metered quantities of fuel into the individual cylinders and monitors the engine speed via the CKP sensor. As a result. the starting process takes longer than normal. In order to identify cylinder no. an alternating magnetic field is generated that changes the resistance of the magneto resistive elements. An integrated circuit converts the output voltage of the magneto resistive elements into a rectangular wave signal. NOTE: When the CMP sensor is faulty. this can be recognized by the increased engine noise (Diesel knocking). • The CMP sensor supplies the PCM with a digital voltage signal 0 V/5 V. M5_01063 1 CMP sensor 2 PCM 01-90 Service Training Mazda5 . NOTE: When installing the CMP sensor. affecting the sensor signal and hence the engine control. which is then input to the PCM.Control System • 2.0 MZR-CD Engine The magneto resistive elements have the characteristics that their resistance changes depending on the magnetic flux. When the rotor passes the sensor. The cylinder in question is the one where the engine speed increases after fuel has been injected.

NOTE: If one hall-type sensor fails.0 MZR-CD Engine Accelerator Pedal Position Sensor • Control System A hall-type APP (Accelerator Pedal Position) sensor has been introduced. If the APP sensor fails completely. As a result. the PCM uses the signal from the other sensor to detect the driver’s acceleration demand. M5_01056 1 Accelerator pedal 2 APP sensor Service Training Mazda5 01-91 . the engine speed is limited to approx. 2500 min-1. the engine speed is limited to 1500 min-1. For safety reasons the APP sensor consists of two hall elements integrated in the stator and a magnetic rotor joint to the accelerator pedal.2.

0 MZR-CD Engine When the magnetic rotor rotates. it is amplified in the sensor and input to the PCM.Control System • 2. a voltage is generated in the hall elements. As the hall voltage is very low. M5_01057 1 2 Sensor body Stator with hall elements 3 4 Magnetic rotor Shaft 01-92 Service Training Mazda5 .

2. M5_01064 1 APP sensor 2 PCM Service Training Mazda5 01-93 . In order to facilitate failure detection there is a voltage offset of 0.0 MZR-CD Engine • Control System Each hall-type sensor supplies the PCM with an analogue voltage signal between 0…5 V.5 V between both signals.

the switch closes and supplies the PCM with a voltage signal of 0 V.0 MZR-CD Engine A PSP (Power Steering Pressure) switch located at the power steering oil pump has been introduced to detect the load condition of the power steering.Control System Power Steering Pressure Switch • 2. M5_01065 1 PSP switch 2 Power steering oil pump M5_01066 1 PSP switch 2 PCM 01-94 Service Training Mazda5 . If the power steering oil pressure exceeds a given value.

Depress the clutch pedal. In addition. Long regeneration mode is performed when the soot accumulation rate exceeds 125 %.0 MZR-CD Engine Maintenance and Repair Replacing the engine oil • Control System Every time the engine oil is replaced. damage of the DPF by a violent regeneration following an overaccumulation of soot is prevented. 2. select the option Toolbox PowertrainData ResetEngine Oil. shift to 1st gear and verify that the engine speed decreases to idle speed (manual regeneration is cancelled). since high temperature exhaust gas is emitted during this process. The vehicle should also not be parked in front of any flammable or low heat resistant material.2. NOTE: Always perform the manual regeneration in a well-ventilated place and use an appropriate exhaust-gas extraction system. since the post injection amount is changed and regeneration may not be performed correctly. Therefore. • • Service Training Mazda5 01-95 . Shift to neutral and increase the engine speed to 3000 min-1 for 1 min (DPF is cooled). Depending on the amount of soot accumulated in the DPF the PCM automatically selects normal regeneration mode (34 min) or long regeneration mode (60 min). select the option Toolbox PowertrainDPFDPF Regeneration. As a result. In order to cancel the manual regeneration process perform the following procedure: 1. the parameter “Calculated oil dilution” in the PCM must be reset with the aid of WDS. the hood should be opened to prevent the engine from overheating. 5 min before re-starting the regeneration process. wait for approx. If the manual regeneration must be performed again. Due to the longer duration the manual regeneration can be performed at a lower exhaust gas temperature. Therefore. Do NOT apply electrical load (such as turning on the headlights or rear window defroster) during manual regeneration. it must be regenerated manually with the aid of WDS. Manual regeneration • If the DPF is blocked due to an excessive soot amount accumulated. 3.

The injection amount learning function must be performed using the option ToolboxPowertrainEngine ChecksLearningCorrection after Parts Installation.0 MZR-CD Engine NOTE: If the exhaust gas temperature during manual regeneration exceeds a certain limit. If the DPF indicator light does not extinguish after the manual regeneration is completed. Replacing the MAF sensor • After replacing the MAF sensor. Therefore. select the option ToolboxPowertrainData Reset MAF Sensor.Control System 2. The injector correction factors must be programmed into the PCM via the option ToolboxModule ProgrammingProgrammable ParametersInjector Correction Factors. the PCM stops the regeneration process and increases the engine speed to 2500 min-1 to cool the DPF. Replacing the high-pressure pump • After replacing the high-pressure pump. select the option ToolboxPowertrain Data ResetFuel Pump. 3. perform the regeneration process again. NOTE: Depending on the amount of soot accumulated the PCM performs normal and long regeneration mode one after another. its adaptation values in the PCM must be reset with the aid of the WDS. Therefore. The injector adaptation values in the PCM must be reset using the option Toolbox PowertrainData ResetInjector. the regeneration process may take up to 94 min. 01-96 Service Training Mazda5 . the following steps must be performed: 1. i. Replacing injectors • After replacing one or more injectors. its adaptation values in the PCM must be reset with the aid of the WDS.e. 2.

4. The adaptation values of the DPF differential pressure sensor in the PCM must be reset using the option ToolboxPowertrainData ResetDPF Pressure Sensor. Then the EGRVP sensor or the ISV position sensor must be initialized using the option ToolboxPowertrainETB/EGR Initialization. The DPF must be regenerated manually via the option ToolboxPowertrain DPFDPF Regeneration. The regeneration control in the PCM must be reset via the option Toolbox PowertrainDPFDPF Reset. 3. The pressure difference of the DPF must be assessed using the option Toolbox PowertrainDPFDPF Assessment. the following steps must be performed: 1. select the option ToolboxPowertrain Data ResetETB/EGR. Replacing the DPF differential pressure sensor • After replacing the DPF differential pressure sensor. The regeneration control in the PCM must be reset via the option Toolbox PowertrainDPFDPF Reset. Replacing the DPF • After replacing the DPF. Service Training Mazda5 01-97 . its adaptation values in the PCM must be reset with the aid of the WDS. 2. The injection amount learning function must be performed using the option ToolboxPowertrainEngine ChecksLearningInjection Amount Correction. the following steps must be performed: 1. 2. The pressure difference of the DPF must be assessed using the option Toolbox PowertrainDPFDPF Assessment. Therefore. 5.2. 3. The DPF adaptation values in the PCM must be reset using the option Toolbox PowertrainData ResetDPF.0 MZR-CD Engine Replacing the EGR valve or the ISV • Control System After replacing the EGR valve or the ISV.

All the adaptation values in the PCM must be reset using the option Toolbox PowertrainData ResetPCM. 7. Therefore. The injection amount learning function must be performed via the options Toolbox PowertrainEngine ChecksLearningCorrection after Parts Installation/Injection Amount Correction. 6. Since the parameter “Calculated oil dilution” has also been reset. The PCM must be configured using the option ToolboxModule Programming Programmable Module InstallationPCM. The pressure difference of the DPF must be assessed using the option Toolbox PowertrainDPFDPF Assessment. 01-98 Service Training Mazda5 . 8. select the option ToolboxPowertrainData Reset O2 Sensor. its adaptation values in the PCM must be reset with the aid of the WDS. The EGRVP sensor and the ISV position sensor must be initialized via the option ToolboxPowertrainETB/EGR Initialization. The DPF must be regenerated manually via the option ToolboxPowertrain DPFDPF Regeneration. 2. If the oil level is close to or exceeds the “X” mark on the dipstick. the engine oil level must be checked. 5. The keys must be programmed via the option ToolboxBodySecurityPATS Functions. replace the engine oil. the following steps must be performed: 1. 4. 3. 9. The regeneration control in the PCM must be reset using the option Toolbox PowertrainDPFDPF Reset.0 MZR-CD Engine After replacing the HO2S.Control System Replacing the HO2S • 2. Replacing the PCM • After replacing the PCM.

Therefore. Service Training Mazda5 01-99 . select the option ToolboxSelf TestModulesPCMRetrieve CMDTCs. the KOEO self-test can be performed using the option ToolboxSelf Test ModulesPCMKOEO On-demand Self Test.2. In order to conduct the KOER self-test select the option ToolboxSelf Test ModulesPCMKOER On-demand Self Test.0 MZR-CD Engine On-board Diagnostic System Features • On-board Diagnostic System The On-board diagnostic system consists of the following functions: – – – Self-test function PID monitor function Simulation test function Self Test • • • The self-test function allows to read out the CMDTCs of the PCM with the aid of WDS. In addition.

closed APP sensor no.On-board Diagnostic System PID Monitor • 2. select the option ToolboxDataloggerModulesPCM. Therefore. Item AC_REQ ACCS ALTF ALTT V APP APP_LRN APP1 APP2 ARPMDES BARO BOO BOOST_DSD CATT11_DSD CATT12_DSD CATT21_DSD CHRGLP CPP DEC_CMP DSC_ACT DTCCNT ECT EGR_LRN EGRP EQ_RAT11 ETC_ACT ETC_DSD EXHPRESS_DIF EXHPRESS_LRN EXHPRESS2 EXHTEMP1 EXHTEMP2 EXHTEMP3 Definition A/C ON request A/C compressor cycling switch Generator field current control duty cycle Generator output voltage Accelerator pedal position APP learning value .2 Target idle speed Barometric pressure sensor Brake switch Boost pressure desired Catalyst temperature desired (upper) Catalyst temperature desired (middle) Catalyst temperature desired (lower) Generator warning light CPP switch Fuel correction for deceleration DSC control DTC count ECT sensor EGR valve learning value .closed EGRVP sensor Equivalence ratio (lambda) ISV position actual ISV position desired DPF differential pressure sensor DPF differential pressure sensor learning value DPF differential pressure sensor (middle) Exhaust gas temperature sensor (upper) Exhaust gas temperature sensor (middle) Exhaust gas temperature sensor (lower) Unit/Condition On/Off On/Off % V % V % V % V RPM Pa V On/Off Pa °C °C °C On/Off On/Off No unit Enabled/ Disabled No unit °C V mm V mm % No unit ° % °C Pa Pa Pa °C °C °C M5_01016 01-100 Service Training Mazda5 .1 APP sensor no.0 MZR-CD Engine The PID monitor function allows to monitor the PIDs of the PCM with the aid of WDS.

2.0 MZR-CD Engine Item FAN_DUTY FI_LRN_01 FI_LRN_02 FI_LRN_03 FI_LRN_04 FI_LRN_11 FI_LRN_12 FI_LRN_13 FI_LRN_14 FI_LRN_21 FI_LRN_22 FI_LRN_23 FI_LRN_24 FI_LRN_31 FI_LRN_32 FI_LRN_33 FI_LRN_34 FIA_DSD FIP_FL FIP_FL_DSD FIP_SCV FLT FP FRP FRP_A GENVDSD GLWPG V GP_LMP GPC HTR11 HTR_OFF HTR_ON IAT IAT2 ICP ICP_DSD INGEAR ISV_LRN_C ISV_LRN_O IVS LOAD On-board Diagnostic System Unit/Condition % ms ms ms ms ms ms ms ms ms ms ms ms ms ms ms ms No unit A No unit A °C % V Pa Pa V V On/Off On/Off % Ohms V V V °C V °C Pa Pa On/Off % % Idle/Off Idle % M5_01T016A Definition Fan control duty cycle Fuel injection learning value (injector 1 at 35 MPa) Fuel injection learning value (injector 2 at 35 MPa) Fuel injection learning value (injector 3 at 35 MPa) Fuel injection learning value (injector 4 at 35 MPa) Fuel injection learning value (injector 1 at 65 MPa) Fuel injection learning value (injector 2 at 65 MPa) Fuel injection learning value (injector 3 at 65 MPa) Fuel injection learning value (injector 4 at 65 MPa) Fuel injection learning value (injector 1 at 100 MPa) Fuel injection learning value (injector 2 at 100 MPa) Fuel injection learning value (injector 3 at 100 MPa) Fuel injection learning value (injector 4 at 100 MPa) Fuel injection learning value (injector 1 at 140 MPa) Fuel injection learning value (injector 2 at 140 MPa) Fuel injection learning value (injector 3 at 140 MPa) Fuel injection learning value (injector 4 at 140 MPa) Fuel injection amount desired [mm3/stroke] High-pressure pump flow High-pressure pump flow desired Fuel metering valve Fuel temperature sensor Fuel metering valve duty cycle Fuel pressure sensor Fuel pressure after fuel injection Generator voltage desired Glow plug voltage Glow plug indicator light Glow plug relay HO2S (heater element) HO2S voltage .off HO2S voltage .open Idle validation switch Engine load Service Training Mazda5 01-101 .closed ISV learning value .on IAT sensor IAT sensor no.2 Injector control pressure Injector control pressure desired Load/No load condition ISV learning value .

On-board Diagnostic System
Item MAF MAF_C MAF_C_DSD MAP MIL MIL_DIS O2 O2S11 O2S11_CAL PM_ACC PM_ACC_DSD PM_GEN PSP REG_AUTO REG_MAN RPM SC_CANCEL SC_COAST SC_MAIN MAF sensor Mass air flow per cylinder Mass air flow per cylinder desired MAP sensor Malfunction indicator light Travelled distance since MIL illuminated Oxygen concentration in exhaust gas HO2S (sensor) HO2S calibration value Soot accumulation amount Soot accumulation amount desired Soot generation amount PSP switch Automatic regeneration Manual regeneration Engine speed Cruise control cancel switch Cruise control coast switch Cruise control main switch Definition

2.0 MZR-CD Engine
Unit/Condition g/s V g g Pa V On/Off km % Current No unit g/L g/L g/L Low/High On/Off On/Off RPM Active/Inactive Active/Inactive Active/Inactive Off/Standby/ Active/Tap-up/ Set/Tap-down/ Coast On/Off Active/Inactive On/Off Active/Inactive V No unit rev/mile % V % V km/h M5_01T016B

SC_MODE

Cruise control operation mode

SC_ON SC_RES SC_SET SC_SET/ACC SCCS TC_CMP TIRESIZE TP1 VBCV VPWR VSS

Cruise control actuator switch on Cruise control resume switch Cruise control set indicator light Cruise control set/acceleration switch Cruise control command switch Fuel correction for torque-down control [mm3/stroke] Tire revolution per mile ISV position sensor VBC solenoid valve duty cycle Battery positive voltage Vehicle speed

01-102

Service Training Mazda5

2.0 MZR-CD Engine
Simulation Test

On-board Diagnostic System

The simulation test function allows to activate certain PIDs of the PCM with the aid of WDS. Therefore, select the option ToolboxDataloggerModulesPCM.
x: Applicable —: Not applicable Test condition Unit/Condition KOEO KOER On/Off X X % X X ___ V X On/Off X X On/Off X X ___ On/Off X ___ On/Off X ___ On/Off X ___ On/Off X % X X M5_01T0017

Item ACCS EGRP GENVDSD GP_LMP GPC INJ_1 INJ_2 INJ_3 INJ_4 VBCV

Definition A/C compressor cycling switch EGR valve position sensor Generator voltage desired Glow plug indicator light Glow plug relay Fuel injector no.1 Fuel injector no.2 Fuel injector no.3 Fuel injector no.4 VBC solenoid valve duty cycle

Service Training Mazda5

01-103

On-board Diagnostic System
Notes:

2.0 MZR-CD Engine

01-104

Service Training Mazda5

02
Suspension

02 Suspension
Wheels and Tires.................................................................................................1 Specifications..................................................................................................1 Standard Tire ............................................................................................1 Temporary Spare Tire...............................................................................1 Front Suspension................................................................................................2 Features..........................................................................................................2 Overview .........................................................................................................2 Specifications..................................................................................................3 Front Shock Absorber .....................................................................................4 Rear Suspension .................................................................................................5 Features..........................................................................................................5 Overview .........................................................................................................5 Specifications..................................................................................................6 Rear Shock Absorber......................................................................................6

Table of Contents 02

Service Training Mazda5

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.

Specifications
Standard Tire
Item Tire Size Size Material Wheel Offset Pitch circle diameter (mm {in}) (mm {in}) Steel 195/65R15 91V 15 X 6J Aluminium alloy 52.5 (2.07) 114.3 (4.50)
M5_02T002

Specifications 205/55R 16 91V 16 X 6 1/2J 205/50R 17 93V 17 X 6 1/2J

Aluminium alloy

Temporary Spare Tire
Item Tire Size Size Material Wheel Offset Pitch circle diameter mm/(in) mm/(in) Specifications T115/70D 15 15 X 4T Steel 4.5 (1.8) 114.3 (4.50)
M5_02T003

T125/70D 16 16 X 4T

Service Training Mazda5

02-1

Front crossmember rubber mounted to the body at four points. Overview M5_02003 1 2 3 Front shock absorber and coil spring Front stabilizer control link Front stabilizer 4 5 Front lower arm Front crossmember 02-2 Service Training Mazda5 .Front Suspension Front Suspension Features • Suspension The front suspension of the Mazda5 is essentially the same as the current Mazda3 (BK). Oil filled bushes used for the front lower arms. It has the following features: – – – Strut-type design.

LF Front Suspension Specification MZR-CD Strut type Coil spring Low-pressure gas charged. cylindrical.90} 2 {0.08} 1 ± 3 {0. Service Training Mazda5 02-3 .12} 0 ° 11´ ± 22 40 ° 05´ 33 ° 07´ 3 ° 12´ -0 ° 44´ 14 ° 04´ M5_02T001 Front suspension Wheel alignment (unloaded) NOTE: The camber and caster angle are not adjustable.Suspension Specifications Item Engine type Type Spring type Shock absorber type Stabilizer Type Diameter (mm {in}) Tire [Tolerance ±4 (mm {in}) Total {0.15}] toe-in Rim inner Degree Maximum steering Inner angle Outer [Tolerance ±3 °] Caster angle (Reference) [Tolerance ±1 °] Camber angle (Reference) [Tolerance ±1 °] Steering axis inclination (Reference) 3 ° 14´ -0 ° 42´ 13 ° 59´ L8. double-acting Torsion bar 23 {0.04 ± 0.

M5_02001 1 2 Rebound spring Oil chamber 3 Gas chamber 02-4 Service Training Mazda5 .Front Suspension Front Shock Absorber • Suspension A shock absorber with an internal rebound spring is used to control wheel-lift* during hard cornering. *Wheel-lift: Tendency for wheels on the inside of a curve to lift off the ground during cornering. Without the spring the shock absorber would top-out. making the suspension ineffective and causing wheel hop or wheel lift. The rebound spring allows a limited amount of movement of the shock absorber when it is fully extended.

Overview M5_02004 1 2 3 4 5 Rear shock absorber Rear crossmember Rear trailing link View from rear of vehicle Rear lower arm 6 7 8 9 10 Rear coil spring Rear stabilizer control link Rear stabilizer Rear lateral link Rear upper arm Service Training Mazda5 02-5 . It has the following features: – – E-type design layout. Separate shock absorber and springs.Suspension Rear Suspension Features • Rear Suspension The rear suspension is essentially the same as the current Mazda3 (BK).

double-acting Torsion bar 20 {0.04 ± 0. M5_02002 1 2 Oil Free piston 3 High-pressure gas 02-6 Service Training Mazda5 .Rear Suspension Specifications Item Type Spring type Shock absorber type Stabilizer Rear suspension Wheel alignment (unloaded) Type Diameter Tire [Tolerance ±4 Total {0.12} 0 ° 11´ ± 22´ -1°29´ 0° M5_02T004 Degree Camber angle [Tolerance ± 1° ] Thrust angle [Tolerance ± 48´] NOTE: The camber angle is not adjustable.15}] toe-in Rim inner (mm {in}) (mm {in}) Suspension Specification Multi-link Coil spring High-pressure gas charged. The advantages of monotube construction are that oil foaming is eliminated. Rear Shock Absorber • A monotube-type rear shock absorber is used. and that shock absorber performance does not deteriorate at high temperatures. cylindrical.79} 2 {0.08} 1 ± 3 {0.

03 Driveline/ Axle .

..........................................................................................................................................................................................................2 Drive Shaft ......................1 Overview .2 Features...........3 Specifications......................................................................3 Overview .......................................................................................................................................................1 Rear Axle.........................................................................................................................................1 Features..........................................................................................................................................................................................................................2 Overview ............................................................3 Features........................................03 Driveline/Axle Front Axle..........................................................................................................3 Table of Contents 03 Service Training Mazda5 ........................................

It has the following features: – Unit-design angular ball bearings are used.Driveline/Axle Front Axle Features • Front Axle The front axle on the Mazda5 is essentially the same design as that of the current Mazda3 (BK). Overview M5_03002 1 Wheel hub 2 Wheel bearing Service Training Mazda5 03-1 .

Rear Axle Rear Axle Features • Driveline/Axle The rear axle on the Mazda5 is essentially the same design as that of the current Mazda3 (BK). Overview M5_03001 1 Wheel hub (integrated with wheel bearing) 03-2 Service Training Mazda5 . It has the following features: – Unit-design angular ball bearings are used.

02} 40. A tripod joint is used for the transaxle-side constant velocity joint.Driveline/Axle Drive Shaft Features • Drive Shaft The drive shafts on the Mazda5 are essentially the same design as those on the current Mazda3 (BK).0 {1.0 {1. LF MZR-CD Service Training Mazda5 03-3 .57} M5_03T001 L8 MZR-CD Tripod joint Shaft diameter Joint shaft Shaft diameter Overview M5_03003 1 2 Front drive shaft Joint shaft 3 4 L8. They have the following features: – – A bell joint is used for the wheel-side constant velocity joints. Specifications Item Wheel side Joint type Differential side RH LH (mm{in}) (mm{in}) Tripod joint Specifications LF Bell joint Double offset joint Tripod joint 26.

Driveline/Axle NOTES: 03-4 Service Training Mazda5 .

04 Brakes .

...5 Table of Contents 04 Service Training Mazda5 ....................................................................................................................................1 Features......................................................04 Brakes Conventional Brake System .........................................................................................4 Combine Sensor ........................................................................................................................................................................................................................................3 Features...1 Specifications............................................1 Master Cylinder......................................................................................4 Parts Location ........................................................................................3 Dynamic Stability Control........................................................................3 Parts Location ..................................2 Antilock Brake System .........................................................................................................

FMVSS 116 DOT-3 or DOT-4 M5_04T001 Type Cylinder bore (mm {in}) Pad dimensions (area x thickness) 2 2 (mm x mm {in x in}) Disc plate dimensions (mm {in}) (mm {in}) Power brake unit Rear wheel braking force control device Brake piping Parking brake Brake fluid Type Outer diameter Type Piping layout Type Operating method (application/release) Play adjustment method Type Service Training Mazda5 04-1 . It has the following features: – – – An intrusion minimizing brake pedal is used.9 × 0.140 × 12.61} Tandem 22.2 {0.2} 5.0 {7.967 × 0. A remote master cylinder reservoir tank has been added. single diaphragm 272.8 117 {4.0 × 0.98} With 16 inch brake: 300 × 25 {11.8 {4.5} 2.9 × 0. Mechanical brake assist is included in the power brake unit.1 {10.185 × 0.8 × 0. Stroke (mm {in}) Type Master cylinder Cylinder bore (mm {in}) Type Cylinder bore (mm {in}) Pad dimensions (area x thickness) 2 2 Front brake (mm x mm {in x in}) Disc plate dimensions Rear brake Rear brake (mm {in}) Specification Suspended design 2. Specifications Item Type Brake pedal Pedal lever ratio Max.43} With 16 inch brake: 302 × 11 {11.700 × 10.98} Solid disc 38 {1.43} Vacuum multiplier.43} With 15 inch brake: 280 × 11 {11. rear two-wheel braking Manually operated lever design Auto-adjusting SAE J1703.Brakes Conventional Brake System Features • Conventional Brake System The construction and operation of the brake system is essentially the same as the current Mazda3 (BK).874} Ventilated disc 57 {2.47} With 15 inch brake: 278 × 25 {10.71} Electronic Brakeforce Distribution (EBD) X pattern Mechanical design.

and connected to the master cylinder via a rubber hose. M5_04001 1 Brake master cylinder and reservoir 04-2 Service Training Mazda5 . but the master cylinder and main reservoir cannot. If a fault exists in the master cylinder or main reservoir. they must be replaced as an assembly.Conventional Brake System Master Cylinder • Brakes The master cylinder remote reservoir is attached to the vehicle body under the cowl panel. NOTE: The remote reservoir and connecting hoses can be replaced separately.

Parts Location M5_04002 1 2 3 4 5 Front ABS wheel-speed sensor Front ABS sensor rotor Rear ABS wheel-speed sensor Rear ABS sensor rotor Instrument cluster 6 7 8 9 10 Brake system warning light ABS warning light ABS HU/CM PCM (L8. select the option ToolboxModule programmingProgrammable module installationABS. Magnetic encoder type ABS sensor rotor that is integrated with the hub is used. Service Training Mazda5 04-3 . To do this connect the WDS to the vehicle. Giant Magneto Resistance element type ABS wheel speed sensors are used.LF) PCM (MZR-CD) NOTE: When replacing the ABS control module. the new module has to be configured. It has the following features: – – – A TEVES MK7 hydraulic unit/control module is used to control ABS and Electronic Brake force Distribution operation (vehicles without DSC).Brakes Antilock Brake System Features • Antilock Brake System The construction and operation of the ABS (Antilock Brake System) is essentially the same as the current Mazda3 (BK).

Parts Location M5_04003 1 2 3 4 5 6 7 8 9 Front ABS wheel-speed sensor Front ABS sensor rotor Rear ABS wheel-speed sensor Rear ABS sensor rotor Combine sensor Brake fluid pressure sensor (built into DSC HU/CM) Steering angle sensor DSC OFF switch Instrument cluster 10 11 12 13 14 15 16 17 DSC OFF light DSC indicator light Brake system warning light ABS warning light PCM (MZR-CD) PCM ( L8.Dynamic Stability Control Dynamic Stability Control • Brakes The construction and operation of the DSC (Dynamic Stability Control) is essentially the same as the current Mazda3 (BK). controlling DSC/TCS/ABS/EBD is used. integrating both the yaw rate sensor and lateral-G sensor is used.LF) Diesel engine Gasoline engine 04-4 Service Training Mazda5 . A private controller area network system is used for communication between the combine sensor and DSC control module. A combine sensor. It has the following features: – – – A TEVES MK6 DSC hydraulic unit/control module.

To do this. After initialization has been completed.Brakes Combine Sensor • Dynamic Stability Control The combine sensor is located on the cross member under the front right seat. Then set the PIDs LATACCEL # and YAWRATE # to TRUE. and detects the vehicle yaw rate and lateral-G force. select the option Toolbox→Datalogger→Modules→ABS. the new sensor has to be initialized. M5_04004 1 2 3 External view Combine sensor Vehicle front 4 5 6 System wiring diagram CAN driver DSC HU/CM Service Training Mazda5 04-5 . connect WDS (Worldwide Diagnostic System) to the vehicle and select the option Toolbox→Chassis→ABS/DSC→Sensor Initialization. the vehicle should be driven for five minutes or more. NOTE: When replacing the combine sensor. Alternatively. The combine sensor transmits yaw and lateral acceleration information to the DSC HU/CM via a dedicated CAN bus (independent of the MS-CAN/HS-CAN).

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

05 Transmission/ Transaxle .

.....................................................................9 Reverse Gear .....................16 Drain Plug Location ........................1 G35M-R Transmission ...........................11 Shift Interlock Mechanism ........................................................................................2 Overview ............6 Overview .......................................................10 Synchronizer Clutch Hub .............................................................................................................................................................................................14 Reverse Lockout Mechanism................................................2 Specifications.............................................................................6 Specifications.....................................................................................................................................................................8 Power Flow ....................................................................................................................................................................................................................................................................................................................................15 Oil Level Inspection...................4 Shift Mechanism .........3 Triple Cone Synchronizer..................................................1 Features.........................................................................................................................................................................7 Cross-sectional View ..........................05 Transmission/ Transaxle Manual Transaxle ...............................................................................................................................................................................4 Operation...............................................................................9 First to Sixth Gear..........................................12 Shift Mechanism ............................................................................16 Table of Contents 05 Service Training Mazda5 ........................................................................6 Construction.................................................................................................................................5 A26M-R Transmission..........................................................

Transmission/Transaxle Manual Transaxle Features • The transmission/transaxle has the following features: – – – – – – – – Cable operated shift mechanism. 5-speed G35M-R manual transmission for gasoline engine models (similar to Mazda3 (BK)). Self-adjusting clutch cover for diesel engine models (same as Mazda2 (DY)). Quick connector clutch pipes (same as Mazda3 (BK)). Shift lever located at centre of dashboard. Dual-mass flywheel for diesel engine models (same as Mazda6 (GG/GY)). Hydraulically operated clutch (same as Mazda3 (BK)). Service Training Mazda5 05-1 . 6-speed A26M-R manual transmission for diesel engine models.

03.666 3.87 {3.454 4. lmp qt}) Specifications LF G35M-R Cable Floor-shift Synchromesh Selective sliding and synchromesh 3.392 1.795 3.307 2. Double-cone synchronizer is used for third and fourth gears. 2.059 1. except for the following: – – Triple-cone synchronizer is used for first and second gears.G35M-R G35M-R Transmission • Transmission/Transaxle The G35M-R manual transaxle is essentially the same as that used on the current Mazda3 (BK) with LF engine.53} M5_05T001 L8 05-2 Service Training Mazda5 .310 1.030 0.388 4. Specifications Item Engine type Manual transaxle type Operation system Transaxle control Forward Shift assist Reverse 1GR 2GR 3GR Gear ratio 4GR 5GR Reverse Final gear ratio Grade Viscosity Oil Capacity (approximately) All season Above 10°C{50°F} (L{US qt.842 1.588 API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 2.

Transmission/Transaxle Overview M5_05016 1 2 3 4 5 6 7 8 First gear Reverse idler gear Reverse gear Second gear Third gear Fourth gear Fifth gear Secondary shaft fifth gear 9 10 11 12 13 14 15 16 Secondary shaft fourth gear Secondary shaft third gear Secondary shaft second gear Secondary shaft first gear Secondary shaft Clutch hub sleeve (reverse gear) Primary shaft Differential gear Service Training Mazda5 05-3 .

G35M-R Triple Cone Synchronizer • • Transmission/Transaxle A triple-cone synchronizer mechanism is used for the first and second gears. The construction of the triple-cone synchronizer is essentially the same as a double-cone synchronizer. M5_05002 1 2 3 Gear Inner synchronizer ring Synchronizer cone 4 5 Outer synchronizer ring Synchronizer hub assembly Operation M5_05003 1 2 3 Synchronizer ring Synchronizer key Key groove 4 5 Synchronizer hub sleeve Friction surface 05-4 Service Training Mazda5 . except that the inner surface of the inner ring is used as a friction surface on the triple-cone synchronizer.

Transmission/Transaxle Shift Mechanism • • A cable operated shift mechanism similar to the current Mazda3 (BK) is used. M5_05004 1 Main shift cable 2 Main selector cable Service Training Mazda5 05-5 . The main selector cable is adjusted by unclipping it from the selector mechanism and then reattaching it to achieve the correct cable length. the same as on the Mazda3.

673 3.809 0. 6GR.913 1. 4GR: 3. 2GR. lmp qt}) Specifications MZR-CD A26M-R Cable Synchromesh Synchromesh (lever type) 3. 3GR. 2.095 API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 2.538 1.24} M5_05T002 Overview M5_05005 05-6 Service Training Mazda5 . Specifications Item Engine type Manual transaxle type Operation system Forward Shift assist Reverse 1GR 2GR 3GR Gear ratio 4GR 5GR 6GR Reverse Final gear ratio Grade Oil Viscosity Capacity (approximately) All season Above 10°C{50°F} (L{US qt.69. and designed for frontwheel-drive vehicles with a transversely mounted powertrain.166 1GR.A26M-R A26M-R Transmission • Transmission/Transaxle The A26M-R 6-speed manual transaxle is manufactured by Aisin.611 5GR.218 0. Reverse: 3.880 0.55 {2.

Transmission/Transaxle Construction • • • • A26M-R The A26M-R manual transaxle is a three-shaft design. one for the first to fourth gears and a different one for the fifth. 1 3 4 Primary shaft Secondary shaft No. The three-shaft design allows for a more compact construction due to the fact that each output shaft needs only to carry three or four gears. sixth and reverse gears. M5_05006 1 2 Differential Secondary shaft No. A triple-cone synchronizer mechanism is used for first. one primary (input) shaft and two secondary (output) shafts. As a result of the three shaft construction there are two final gear ratios. 2 Service Training Mazda5 05-7 . and third gears. second. so can thus be made shorter. Fourth gear has a double-cone synchronizer mechanism.

1 Differential ring gear 8 9 10 11 12 13 14 Final gear No. 2 Secondary shaft No. 1 First gear Second gear Third gear Fourth gear Fifth gear Sixth gear 05-8 Service Training Mazda5 .A26M-R Cross-sectional View Transmission/Transaxle M5_05007 1 2 3 4 5 6 7 Primary shaft Final gear No. 2 Reverse gear Reverse idler gear Secondary shaft No.

Transmission/Transaxle Power Flow First to Sixth Gear A26M-R M5_05008 1 2 3 First gear Second gear Third gear 4 5 6 Fourth gear Fifth gear Sixth gear Service Training Mazda5 05-9 .

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

synchronizer key.Transmission/Transaxle Synchronizer Clutch Hub • • A26M-R A ball-type detent mechanism is used in each clutch hub to reduce the overall dimensions of the hub. The ball-type detent mechanism consists of a coil-type synchronizer key spring. M5_05010 1 2 3 4 Outer synchronizer ring Synchronizer cone Inner synchronizer ring Hub sleeve 5 6 7 8 Ball Synchronizer key Synchroniser key spring Synchronizer hub Service Training Mazda5 05-11 . Its function is essentially the same as the radial-type spring found in other transaxles. and ball.

M5_05011 05-12 Service Training Mazda5 . are locked in the neutral position by the interlock plate. except for the one in operation.A26M-R Shift Interlock Mechanism • Transmission/Transaxle The shift interlock mechanism prevents two gears being engaged at the same time. During shifting. the shift forks and control rod.

Transmission/Transaxle 1 2 3 4 5 6 7 8 Reverse shift fork Inner lever Fifth/sixth gear shift fork Interlock plate First/second gear shift fork Third/fourth gear control rod A-A sectional view Neutral 9 10 11 12 13 14 15 First gear Second gear Third gear Fourth gear Fifth gear Sixth gear Reverse gear A26M-R Service Training Mazda5 05-13 .

The main selector cable is adjusted the same way as on the Mazda3.A26M-R Shift Mechanism • • Transmission/Transaxle A cable operated shift mechanism similar to the current Mazda3 (BK) is used. M5_05012 1 Main shift cable 2 Main selector cable 05-14 Service Training Mazda5 .

which restricts the movement of the shift lever to prevent accidentally selecting reverse when shifting into first gear. • M5_05013 1 2 3 Normal conditions Pushing shift lever Reverse position 4 5 Guide plate Movement restricted Service Training Mazda5 05-15 . movement of the shift lever is restricted by the guide plate. thus allowing reverse gear to be selected.Transmission/Transaxle Reverse Lockout Mechanism • A26M-R The reverse lockout mechanism consists of a guide plate attached to the shift lever assembly. When the shift lever is pressed down and moved towards the reverse position. Under normal conditions. the projection is pushed below the guide plate.

• M5_05014 1 2 Oil level Back-up light switch 3 Neutral switch Drain Plug Location M5_05015 1 Drain plug 05-16 Service Training Mazda5 . If the oil level is low. verify that the oil level is near the brim of the filler plug hole.55 litres of manual transaxle oil which complies with the specification API Service GL-4 or GL-5 (grade) and SAE 75W-90 (viscosity). add the specified amount and type of oil through the plug hole. To check the transaxle oil level.A26M-R Oil Level Inspection • Transmission/Transaxle The A26M-R manual transaxle is filled with 2.

06 Steering .

....................................................................................................................................................1 Power Steering ......4 Features................4 Wiring Diagram ............................2 Electro Hydraulic Power Assist Steering (L8/LF engines)..........................................................................................................................1 Specifications..............................................5 Steering Angle Sensor ......................06 Steering Steering ......................................................................1 Features.........................2 Features...............................................................................................5 Table of Contents 06 Service Training Mazda5 ............................................2 Parts Location ..........................................................................................................................................................................................................................................................................................................................

LF) Type Fluid specification Capacity * (approximate quantity) (L {USqt.03.0 {3.0} Rack and pinion design (mm {in}) 81.85} (MZR-CD) 0.Steering Steering Features • The steering system has the following features: – Steering column with tilt and telescopic adjustment.80 {0. 0. M5_06T001 Service Training Mazda5 06-1 . Dexron®II) 1 .70} (L8. 0. Specifications Item Outer diameter Lock to lock Shaft type Coupling type Tilt amount Telescope amount (mm {in}) (turns) Specifications 372 {14.84.6} 2.6} 50 {2.19} x 2 Engine speed sensing (MZR-CD) Vehicle speed sensing (L8.97 {1.g. lmp qt) ATF M-III or equivalent (e.9 Collapsible design Cross-shaped joint design 40 {1. as well as bending sheet and telescopic energy absorption mechanism (same as current Mazda3 (BK)). LF) Steering wheel Steering shaft (mm {in}) (mm {in}) Type Steering gear and linkage Rack stroke Power assist system Power steering * When fluid reservoir tank is at maximum volume.

Parts Location M5_06001 06-2 Service Training Mazda5 .Power Steering Power Steering Features • • Steering Electro-hydraulic power steering for vehicles with L8/LF engine (similar to Mazda3 (BK) with LF engine). Hydraulic power steering for vehicles with MZR-CD engine (similar to Mazda6 (GG/GY) with MZR-CD engine.

LF MZR-CD Service Training Mazda5 06-3 .Steering 1 2 3 4 5 6 Steering wheel Steering column and shaft Steering gear and linkage Power steering oil pump Electric power steering oil pump EHPAS control module ( built into electric power steering oil pump 7 8 9 10 11 12 Power Steering Steering angle sensor Instrument cluster EHPAS warning light PCM L8.

M5_06002 1 2 3 4 5 6 EHPAS control module Reserve tank Pump Motor Steering wheel Steering shaft 7 8 9 10 11 Steering angle sensor Steering gear and linkage Hydraulic pressure Electric signal PCM 06-4 Service Training Mazda5 . with the following changes: – Steering angle sensor built into steering gear has been discontinued.Power Steering Electro Hydraulic Power Assist Steering (L8/LF engines) Features • Steering The same EHPAS as that utilized on the current Mazda3 (BK) with LF engine is used on the Mazda5 with L8/LF engines.

• Service Training Mazda5 06-5 . Vehicles that do not have DSC fitted will still have a steering angle sensor fitted to the steering column. the Mazda5 EHPAS uses the DSC steering angle sensor (fitted to the steering column) to detect steering rotation speed.Steering Wiring Diagram Power Steering M5_06003 1 2 3 4 5 6 7 EHPAS control module Battery EHPAS 80 A fuse Ignition switch EHPAS 5 A fuse Instrument cluster EHPAS warning light 8 9 10 11 12 13 14 CAN driver CAN_L CAN_H Steering angle sensor DLC-2 DSC HU/CM PCM Steering Angle Sensor • Instead of using a steering angle sensor located on the steering gear as on the Mazda3.

Steering NOTES: 06-6 Service Training Mazda5 .

07 Heating. Ventilation& Air Conditioning .

07 HVAC
Basic System .......................................................................................................1 Features..........................................................................................................1 Specifications..................................................................................................1 Control System....................................................................................................2 Manual Air Conditioning ..................................................................................2 Parts Location...........................................................................................2 Climate Control Unit..................................................................................3 Operation..................................................................................................4 Wiring Diagram .........................................................................................5 Full-auto Air Conditioning................................................................................6 Parts Location...........................................................................................6 Wiring Diagram .........................................................................................7 Climate Control Unit..................................................................................9 Operation..................................................................................................9 On-board Diagnostic System ..................................................................12 Simulation Test .......................................................................................12 Water Heater System (MZR-CD engine) ..........................................................13 Parts Location ...............................................................................................13 Operation ......................................................................................................14 Starting Conditions........................................................................................15 Full/half Switching .........................................................................................15 On-board Diagnostics ...................................................................................16 Self Test .................................................................................................16 PID Monitor.............................................................................................16 Simulation Test .......................................................................................16 Start Heater Utility.........................................................................................17 Prefill Utility ...................................................................................................17 Water Heater System Unlock Utility ..............................................................17

Table of Contents 07

Service Training Mazda5

HVAC
Basic System
Features

Basic System

The construction and operation of the HVAC (Heater/Ventilator/Air Conditioning) is essentially the same as the current Mazda3 (BK).

– – – –

Sirocco blower motor is used. Pollen filter is used. Triple-type refrigerant pressure switch is used. Sub-cooling type condenser is used.

Specifications
Item Heating capacity Cooling capacity Type Refrigerant Amount (approximately) Type Discharge capacity A/C compressor Max. allowable speed Type Lube oil Type Radiated heat Condenser Receiver/drier capacity Desiccant Expansion valve Evaporator Temperature control Type Type (kW {kcal/h}) (ml {cc, fl,oz}) Sealed volume (approximately) (ml {cc, fl,oz}) (ml {cc, fl,oz}) (rpm) (g {oz}) (kW {kcal/h}) (kW {kcal/h}) Specification 4.550 {3,913}: LF, L8 5.200 {4.472}: MZR-CD 3.960 {3,406} R-134a 500 {17.7} Vane-rotary 120 {120, 4.06} 7,200: LF, L8 6,400: MZR-CD ATMOS GU10 150 {150, 5.07} Multiflow (sub-cooling type) 6.600 {5,680} 180 {180, 6.08} Synthetic zeolite Block type Double-tank drawn cup Reheat full air mix type
M5_07T001

Service Training Mazda5

07-1

Control System
Control System
Manual Air Conditioning

HVAC

Control of the manual air conditioning is essentially the same as that for the current Mazda3 (BK).

Parts Location

M5_07002

1 2 3 4 5 6

Blower motor Air intake actuator Resistor Magnetic clutch (LF, L8) Magnetic clutch (MZR-CD) Evaporator temperature sensor

7 8 9 10 11 12

Refrigerant pressure switch Climate control unit A/C relay Blower relay BCM Water heater unit (MZR-CD)

07-2

Service Training Mazda5

HVAC
Climate Control Unit • •

Control System

A wire operated climate control unit is used with the manual air conditioning. The airflow mode dial features an additional microswitch to turn the air intake mode to fresh when the airflow mode is set to the defrost position.

NOTE: The illumination bulbs can be replaced separately.

M5_07003

1 2 3 4

Climate control unit Temperature control dial Fan control dial Airflow mode selector dial

5 6 7

A/C switch REC switch Rear window defroster switch

Service Training Mazda5

07-3

Control System
Operation •

HVAC

When the A/C is switched on, the climate control unit sends an “A/C on request” signal via cable to the BCM (Body Control Module). The BCM forwards this information via the MS-CAN (Middle-Speed CAN) bus to the instrument cluster. From there the signal is transmitted via the HS-CAN (High-Speed CAN) bus to the PCM, which operates the A/C relay and the fan control module accordingly.

M5_07004

1 2 3 4 5 6 7 8 9 10

Airflow mode selector switch Evaporator temperature sensor A/C switch Fan switch Climate control unit Defroster control A/C compressor control Air intake actuator BCM Instrument cluster

11 12 13 14 15 16 17 18 19 20

PCM Refrigerant pressure switch High/low pressure signal A/C cut-off control Electric fan control A/C relay Stator and thermal protector Magnetic clutch Fan control module Medium pressure signal

07-4

Service Training Mazda5

HVAC
Wiring Diagram

Control System

M5_07005

1 2 3 4 5 6 7

Blower relay Blower motor Resistor Air intake actuator Evaporator temperature sensor A/C relay Magnetic clutch

8 9 10 11 12 13 14

Refrigerant pressure switch Fan switch Climate control unit TNS relay PCM BCM To CPU

Service Training Mazda5

07-5

L8) Magnetic clutch (MZR-CD) Solar radiation sensor Ambient temperature sensor Cabin temperature sensor 11 12 13 14 15 16 17 18 19 Evaporator temperature sensor Refrigerant pressure switch Climate control unit A/C relay Blower relay PCM ( LF.Control System Full-auto Air Conditioning • HVAC Control of the full-auto air conditioning is essentially the same as that for the current Mazda3 (BK). L8) PCM (MZR-CD) BCM Water heater (MZR-CD) 07-6 Service Training Mazda5 . Parts Location M5_07006 1 2 3 4 5 6 7 8 9 10 Air intake actuator Air mix actuator Air flow mode actuator Blower motor Power MOS-FET Magnetic clutch (LF.

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

Control System 1 2 3 4 5 6 7 8 9 10 Ambient temperature sensor Cabin temperature sensor Evaporator temperature sensor Solar radiation sensor Magnetic clutch Refrigerant pressure switch Air mix actuator Airflow mode actuator Air intake actuator Blower motor 11 12 13 14 15 16 17 18 19 Blower relay Power MOS-FET Climate control unit A/C relay TNS relay Climate control unit switches CPU BCM PCM HVAC 07-8 Service Training Mazda5 .

The BCM forwards this information via the MS-CAN to the instrument cluster. The current status of the full-auto A/C system is displayed on the information display (refer to section 09. It is connected via the MS-CAN to the BCM.HVAC Climate Control Unit • • Control System A logic-type climate control unit is used. From there the signal is transmitted via the HS-CAN to the PCM which operates the A/C relay and the fan control module accordingly. the climate control unit sends an “A/C on request” signal via the MS-CAN to the BCM. NOTE: The illumination bulbs can be replaced separately. “Instrumentation/Driver Info”). Service Training Mazda5 07-9 . M5_07007 1 2 3 4 5 6 Climate control unit Fan control dial OFF switch MODE switch DEFROSTER switch Temperature control dial 7 8 9 10 11 AUTO switch A/C switch Recirculate switch Rear window defroster switch Ambient temperature display switch Operation • When the A/C is switched on.

Control System HVAC M5_07008 07-10 Service Training Mazda5 .

HVAC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Ambient temperature sensor ECT sensor Cabin temperature sensor Evaporator temperature sensor Solar radiation sensor Climate control unit Airflow temperature control Airflow volume control Airflow mode control Air intake control A/C compressor control Air mix actuator Power MOS-FET Blower motor 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Control System Airflow mode actuator Air intake actuator Refrigerant pressure switch High/Low pressure signal Medium pressure signal A/C cut-off control A/C relay Thermal protector Magnetic clutch Electric fan control Fan control module BCM Instrument cluster PCM Service Training Mazda5 07-11 .

Control System
On-board Diagnostic System •

HVAC

The on-board diagnostic system is essentially the same as the current Mazda3 (BK) except for the following:

Simulation test function for climate control unit has been added to WDS.

Simulation Test • The simulation test function allows the respective components controlled by the climate control unit to be operated manually. To do this, connect the WDS to the vehicle and select the option Toolbox→Datalogger→Modules→EATC.
Item DISPLAY # Target Part Information display Operation condition All A/C related segments in information display illuminated Off – 1st – 2nd – 3rd – 4th – 5th – 6th – 7th BLOWER # Blower motor 1 Display* ALL

0% – 50% – 100% – 50% MIX_ACT # Air mix door

20.0 (0%) 20.5 (50%) 21.0 (100%) 20.5 (50%) 3

VENT – BL-LEVEL – HEAT – HEAT/DEF – DFROSTER MODE_ACT # Airflow mode door REC/FRESH switch FRESH ON REC OFF

REC/FRESH #

4

* Status displayed in Information Display
M5_07T002

07-12

Service Training Mazda5

HVAC
Water Heater System (MZR-CD engine)
• •

Water Heater System

To improve heating capability directly after cold start, an additional water heater system has been adopted. The heater mainly consists of a combustion chamber, heat exchanger, fresh air blower and electronic control module. The unit used on the Mazda5 (CR) is supplied by Eberspächer. Fuel is combusted within the water heater unit and used to heat the engine coolant. The heated coolant is then passed through the heater core, which uses it to provide heated air to the vehicle cabin. The water heater is connected to the MS-CAN to allow it to access ambient temperature, engine speed and ignition switch position information, and to send water heater fuel consumption information to the instrument cluster. The MS-CAN is also used for diagnostics of the water heater.

• • •

Parts Location

M5_07009

1 2 3 4

Air intake Coolant inlet Fuel inlet Coolant outlet (to HVAC)

5 6 7

Water heater unit Exhaust Fuel metering pump

Service Training Mazda5

07-13

Water Heater System
Operation
• • • •

HVAC

The water heater control module outputs a signal to the blower fan and the fuel pump, which then deliver air and fuel to the unit. Within the unit, fuel is vaporized and mixed with air, and then sent to the combustion chamber. The mixture is ignited by the glow plug in the combustion chamber. Engine coolant temperature is raised as it circulates along the outside of the combustion chamber.

M5_07010

1 2 3 4 5 6 7

Blower fan Temperature sensor Combustion chamber Overheating sensor Heat exchanger Burner Glow plug

8 9 A B C D E

Flame sensor Electronic control module From fuel metering pump Coolant outlet Coolant inlet Exhaust Fresh air supply

07-14

Service Training Mazda5

HVAC
Starting Conditions

Water Heater System

The water heater system will start to operate when all of the following conditions are met:

– –

Ambient temperature less than 5 °C {41 °F}. Water temperature less than 70 °C {158 °F}.

Full/half Switching
• Depending on the engine coolant temperature, the water heater control module sets the heater output to either full or half strength settings.

M5_07011

1 2

Full mode Half mode

3

Idle mode

Service Training Mazda5

07-15

Water Heater System
On-board Diagnostics
• The on-board diagnostic system consists of the following functions:

HVAC

– – –

Self-test PID monitor Simulation test function

Self Test • The self-test function allows water heater DTCs to be displayed. To view these connect the WDS to the vehicle and select the option Toolbox→Self Test→ Electrical→ Supplemental Heater.

PID Monitor • The PID monitor function allows the PIDs of the water heater to be monitored. To view these connect the WDS to the vehicle and select the option Toolbox→Datalogger→ Modules→FFH.
Item CCNTFFH VOLT_MDL Unit/ Condition – V Definition Continuous Codes Control Module Voltage

Simulation Test • The simulation function allows certain water heater PIDs to be activated. To do this connect the WDS to the vehicle and select the option Toolbox→Datalogger→ Modules→FFH.
Item HEATER FAN GLOW FUEL_PMP Unit/ Condition Inactive/Active On/Off On/Off On/Off Definition Heater Status Blower fan Glow plug Fuel pump

07-16

Service Training Mazda5

HVAC
Start Heater Utility

Water Heater System

The operation of the water heater can be tested by using the FFH Start Heater Utility. To do this first verify that the coolant temperature is low, then connect the WDS to the vehicle and select the option Toolbox→Electrical→Supplemental Heater→FFH→FFH Start Heater Utility.

NOTE: The Start Heater Utility will operate the water heater for a predetermined length of time, after which the heater will automatically switch off. After switching off the blower fan will operated for approximately two minutes.

Prefill Utility
• If the water heater metering pump is replaced, the fuel supply line must first be primed before the water heater is operated. To do this connect the WDS to the vehicle and select the option Toolbox→Electrical→ Supplemental Heater→FFH→FFH Self Test and Prefill Utility.

Water Heater System Unlock Utility
• If the water heater has been disabled due to a malfunction, or a new water heater has been installed the system must be ‘unlocked’ before it can be operated again. To do this connect the WDS to the vehicle and select the option Toolbox→Electrical→ Supplemental Heater→FFH→FFH Unlock Utility.

Service Training Mazda5

07-17

HVAC NOTES: 07-18 Service Training Mazda5 .

08 Restraint System .

........................................................................................................................................................11 Self Test..................................................................14 Table of Contents 08 Service Training Mazda5 .............................................................................................................................13 Features........5 Side Airbag Sensors ...................2 Wiring Diagram .......11 PID Monitor ...........6 Curtain Airbags ...........3 SAS Control Module ....................9 On-board Diagnostic System ...................................................................................................................................................................................................................................................1 Features....12 Seat Belts .......................................................................................................................................................................................................................................................................1 Parts Location...................................................13 Parts Location .................................................................................................................................8 Operation ..13 Child Restraint Anchors ......................................................................................................08 Restraint System Airbag System ...................7 Seatbelt Pretensioners.............................................................................................................................................................................................................................................................................................

Rack-operated belt pretensioners are used.Restraints Airbag System Features • The airbag system has the following features: Airbag System – – – – – Single-stage front airbags are used. Stored gas-type curtain airbags are used. Side airbags are fitted. Service Training Mazda5 08-1 . Dual side airbag sensors are fitted.

Airbag System Parts Location Restraints M5_08001 1 2 3 4 5 6 7 Airbag system warning light Driver-side airbag Clock spring PAD switch Passenger-side airbag SAS control module PAD indicator light 8 9 10 11 12 13 Side airbag Curtain airbag Crash zone sensor Side airbag sensor No. 1 Side airbag sensor No. 2 Belt pretensioner 08-2 Service Training Mazda5 .

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

Airbag System 1 2 3 4 5 6 7 8 9 10 11 12 13 SAS control module Instrument cluster Airbag system warning light DLC-2 PAD indicator light PAD switch PASS AIRBAG ON PASS AIRBAG OFF Crash zone sensor Twisted pair Driver-side side airbag sensor No. 1 Passenger-side side airbag sensor No. 1 Driver-side side airbag sensor No. 2 14 15 16 17 18 19 20 21 22 23 24 25 Restraints Passenger-side side airbag sensor No. 2 Poor connection detector bar Clock spring Driver-side airbag Passenger-side airbag Driver-side pre-tensioner seat belt Driver-side curtain airbag Driver-side side airbag Passenger-side belt pre-tensioner Passenger-side curtain airbag Passenger-side side airbag KLN 08-4 Service Training Mazda5 .

To do this. If the acceleration/deceleration caused by a frontal or side impact exceeds a predetermined threshold. which measures the acceleration/deceleration of the vehicle in a crash. the SAS control module triggers the airbags and pretensioners with a DC signal. A micromechanical crash sensor is incorporated into the SAS control module. the side airbag sensors and the internal micromechanical sensor. M5_08003 1 SAS control module Service Training Mazda5 08-5 . connect the WDS to the vehicle and select the option Toolbox→Module Programming→Programmable Module Installation→RCM. NOTE: When replacing the SAS control module. near to the gear lever.Restraints SAS Control Module • • • Airbag System The SAS (Sophisticated Airbag Sensor) control module is located on the centre tunnel. The SAS control module processes the signals it receives from the crash zone sensor. the new module has to be configured.

1 and No. Side airbag sensor No.Airbag System Side Airbag Sensors • • • Restraints Two side airbag sensors are installed to each side of the vehicle. During this time the SAS control module learns the ID of the new sensor). M5_08004 1 Side airbag sensor No. so are not interchangeable. 2 08-6 Service Training Mazda5 . 1 2 Side airbag sensor No. 2 are different part numbers. one at the base of the B-pillar and one near the rear wheelhouse. The sensor initialisation procedure is the same as that for the Mazda3 (BK) (turn ignition switch to ON and confirm that the airbag warning light illuminates for approximately six seconds. then goes out. NOTE: If the initialisation procedure is not carried out correctly the side airbag sensor will have to be replaced with a new one.

M5_08005 1 2 Curtain airbag Inflator 3 Airbag Service Training Mazda5 08-7 .Restraints Curtain Airbags • Airbag System Instead of using propellants to inflate the curtain airbags. the curtain airbags of the Mazda5 utilize gas stored inside the inflator.

the pretensioners operate. tightening the seat belt webbing thus restraining the driver and front seat passenger.Airbag System Seatbelt Pretensioners • • Restraints Rack-type seatbelt pretensioners similar to those used in the Mazda2 have been adopted for the front seats. M5_08007 1 2 3 4 5 6 7 Cap nut Gas generator Cylinder Spindle Base Rack Clutch roller 8 9 10 11 12 13 Gear Cover Spring seat Spring shaft Spring Spring case 08-8 Service Training Mazda5 . When a deployment signal is received from the SAS module during a frontal or offset collision.

only the spindle rotates when the seatbelt webbing is extended/retracted. while the gear remains stationary.Restraints Operation • Airbag System Under normal conditions. Because the spindle and gear are free to move separately. without resistance being applied to the spindle. • M5_08008 1 2 Gear Spindle 3 Clutch roller Service Training Mazda5 08-9 . the clutch rollers that are installed around the circumference of the spindle roll freely in the space between the gear and spindle.

The rotation of the gear pushes the clutch rollers against the spindle.Airbag System • Restraints When a deployment signal is received from the SAS module. • • • M5_08009 1 2 3 Gear Gas generator Rack 4 5 Clutch roller Spindle 08-10 Service Training Mazda5 . As the rack moves upwards. it causes the gear to rotate. The pressure of this gas pushes the rack up in the cylinder. As the gear is rotated. so is the spindle. gas is produced by the gas generator (gas is generated in the same way as in airbag inflators). locking the gear and spindle together. and the seat belt webbing is retracted.

Restraints On-board Diagnostic System • The main functions of the on-board diagnostic system are: Airbag System – – Self-test PID monitor Self Test • The self-test function allows airbag system DTCs to be displayed. Service Training Mazda5 08-11 . To do this. connect the WDS to the vehicle and select the option Toolbox→Self Test→Modules→RCM.

2 system communication data error Passenger-side side airbag sensor No. 1 side airbag sensors DTCs stored by the onboard diagnostic system may be used. 2 system communication data error Driver-side side airbag sensor No. 2 system internal circuit disabled Driver-side side airbag sensor No. 2 assembly incorrect Driver-side side airbag sensor No. 2 presently. 2 system internal circuit disabled Passenger-side side airbag sensor No. Item CCNT_RCM CR2D_Comm CR2D_Inter CR2D_Mount CR2D_Short CR2P_Comm CR2P_Inter CR2P_Mount CR2P_Short IGN_V_2 I_PAD_SW RES_AB_D RES_AB_P RES_CAB_D RES_CAB_P RES_PT_D RES_PT_P RES_SAB_D RES_SAB_P Definition Number of continuous DTCs Driver-side side airbag sensor No. 2 assembly incorrect Passenger-side side airbag sensor No. For diagnostics of the No.Airbag System PID Monitor • Restraints The PID monitor function allows airbag system PIDs to be monitored. 08-12 Service Training Mazda5 . connect the WDS to the vehicle and select the option Toolbox→Datalogger→Modules→RCM. To do this. 2 system communication error Passenger-side side airbag sensor No. 1 sensor. 2 system communication error IG1 voltage PAD switch status Driver-side airbag resistance Passenger-side airbag resistance Driver-side curtain airbag resistance Passenger-side curtain airbag resistance Driver-side belt pretensioner resistance Passenger-side belt pretensioner resistance Driver-side side airbag resistance Passenger-side side airbag resistance Unit/Condition — OK/FAULT OK/FAULT OK/FAULT OK/FAULT OK/FAULT OK/FAULT OK/FAULT OK/FAULT V On/Off ohm ohm ohm ohm ohm ohm ohm ohm M5_08T001 NOTE: PIDs are only available for side airbag sensor No. but not for No.

Parts Location M5_08010 1 2 3 4 Front seat belt Front buckle Second-row seat belt Second-row centre seat belt 5 6 7 8 Second-row centre buckle Second-row buckle Third-row seat belt Third-row buckle Service Training Mazda5 08-13 . Seatbelts with ELR are used for the two outer second row seats and the third row seats.Restraints Seat Belts Features • The seatbelts of the Mazda5 have the following features: Seat Belts – – – Seatbelts with pretensioners. load limiter. and ELR are used for the front seats. Isofix and tether strap child restraint seat anchors are provided for the two outer second row seats.

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

09 Body & Accessories .

.......................................................................22 Locking/Unlocking Using Transmitter ...........................................................................................................3 Sliding Doors ......................................................................................13 Parts Location ...............09 Body & Accessories Table of Contents Body Panels.................................................................................................................................9 Wiring Diagram .....................................................13 Wiring Diagram ...............................26 Table of Contents 09 Service Training Mazda5 ...23 Locking/Unlocking Using Request Switches..................................11 Advanced Keyless Entry and Start System .............................3 Features................................................................................................18 Keyless Antennas ............................................................15 Card Key ..........................................................8 Standard Keyless Entry system.........................................................7 Security and Locks ....................................................26 Out of Range Auto Lock Function..............................................................8 Features...........................................................................................................................................1 Cabin ............................................................................................................................................................................9 Parts Location ....................................................................10 Transmitter.........................................................................................................................................................................................................................................20 Steering Lock Unit......................................................................................................21 Keyless Buzzer ...............................................6 Seats..............1 Features..................................4 Sliding Door Open Lock Actuator........................5 Liftgate .........................................................................................................................................................................................................3 Parts Location ..........................8 Power Door Lock System ............7 Features.........................................1 Doors and Liftgate.........................................................................19 Keyless Control Module ....................................................................................................17 Request Switch .............21 Keyless Entry Function ........................................................................................................................................................................................................................................................................................................................................................................................................................................24 Auto Re-lock Function ..................................................................................................................................................................................7 Second Row Seats ....................................................................................................................

........................................................................................................................46 Features............................................31 Programming Additional Card Keys With WDS .............37 Operation.....................................................................................................................................................................................................................33 Simulation Test .......................................................48 Exterior Opening/Closing Function .........................................................................51 Operation Prohibition .............................................................53 Lighting System ..........................33 PID Monitor .................................................................55 Service Training Mazda5 Table of Contents 09 ....................................................................................32 On-board Diagnostic System ........................................31 Erasing Registered Card Keys ...............................................................................................................................................................................43 Parts Location ............................................................................................................................................................35 Operation ......................................................................................................35 Immobilizer System (vehicles with Advanced Keyless Entry system) .....................................................................................50 Using Request Switch.....................................................................................................................................46 Features.....................................49 Operation ..............................................................................09 Body & Accessories Table of Contents (continued) Keyless Start Function .......................................................33 Self Test.........................................................................29 Customization ...........................45 Glass/Windows/Mirrors ................................................................................42 Self Test ..........................................30 Service and Repair .............................................................................27 Guidance Function ..........32 Steering Lock Unit Programming ....................................................................................52 Sunroof ..............................................................................................................................46 Power Window Main Switch..................53 Specifications....................................................................................................................................................42 Theft Deterrent System ..................................................................................55 Specifications...........55 Features...............31 Programming Additional Card Keys With Two or More Card Keys .43 Wiring Diagram ..............................40 On-board Diagnostic System ...............................................................................34 Immobilizer System (vehicles with standard Keyless Entry system) ...46 Power Window System ..................................................................................................50 Using Transmitter .........................................................................................................................................................................................................................................................................................................................47 Power Window Subswitch..................................................................38 Immobilizer System Component Replacement ............................

.........................................................................................................................................................................................................64 Parts Location .................................................................................................................................................................................................09 Body & Accessories Table of Contents (continued) Front Combination Light...........................................................................................................................................71 Self Diagnostic Function ...............................................................68 Music Hard Disc Drive...........................................................................57 Parts Location ................72 LCD Unit ...............................................................................................................75 Table of Contents 09 Service Training Mazda5 .......................................................56 Headlight Auto Leveling System.................................................................................................61 Parts Location ..............63 Features..........................................................................................65 System Overview ..............................................................62 Entertainment Systems Audio System ...................................................................................................................................66 Centre Panel Module ...............................70 On-board Diagnostic System ....................................................................................................................................................72 Parts Location ............................................69 Secret Menu ........63 Type C .....................72 Specifications................................63 Type B ...............................................................................64 Speakers ...63 Type A ....................................................................................................................................................................................................................................................................................................................62 Initialization Using WDS ..........72 Speaker ............................59 Rear Combination Light....................................................................................................61 Rain Sensor Initialization...........................................................................74 Car Navigation Unit ................................60 Wiper/Washer System.......................64 Audio Unit .........................................................69 Specifications ....................................................................................................................................71 Car Navigation System ...............................................................................................................................................................71 Diagnostic Assist Function..................................................................................................................................73 System Overview ........72 Features...................................................................................................58 Operation ....59 Auto Leveling Control Module Initialization ....................................................................................................72 Navigation Unit ................................62 Initialization Without Using WDS .........................................................................................................................................................................................................................63 Specifications..................................................................................................57 Wiring Diagram .......................................................................................................................

..............98 Rear View Monitor .............................................................................................................................................76 Night Mode ...94 Error Code ....................................................................................................09 Body & Accessories Table of Contents (continued) LCD Unit .................103 Specifications..............................86 Activation of TMC and DRGS ...........................................................................................................................................................................................................................................................................................................................................................................................91 Vehicle Sensors...........................................................................................98 Overheat Protection Function ....................................................................................................92 History .....................................................................................96 Features....................................................................101 Rear View Monitor Control Module Initialization..................................................................................................96 Parts Location .................100 System Overview ..........76 Split Screen ..............................100 Reference Lines............................................76 Day Mode .........................................................................................................................................................................................................................................89 GPS Information ...83 TMC Availability ...........................................................................................................................................90 Microphone Check............................................................................................................................................................97 DVD/CD Playback.........................................102 Instrumentation/Driver Information System.........................77 Microphone .........................................87 On-board Diagnostic System ......................98 Low Voltage Detection Function ............89 Navigation Check..............................................................................................82 Traffic Message Channel ..........................................................................................................................................................................................................................................................................................103 Features........................................80 Control Panel .99 Parts Location ..............................................................................................................................................95 Rear Entertainment System.....................98 Cooling Function ...........................................................................................88 Vehicle Signal Check........................................................76 Automatic Mode..........................................................................94 Product Version ...............................................................................................................................................................................................................................................93 Remote Control Test .....96 Specifications.........................................................................................................104 Service Training Mazda5 Table of Contents 09 ....79 Voice Recognition Button ..................................................................97 Customisation ..........................................................................................................................................................

...........................................................................................................................................................................................................................122 Table of Contents 09 Service Training Mazda5 ...............119 MS-CAN Signal Chart ............................................................................................................................112 Control System.........................................................................................117 HS-CAN Signal Chart .............105 Input/Output Check Mode .107 Configuring Instrument Cluster ...............................................................................................................................................09 Body & Accessories Table of Contents (continued) Instrument Cluster ......................111 Input/Output Check Mode .....................................113 Features.........................................109 Driver’s Seat Belt Warning........................................................................................115 PID Monitor ...................................................113 BCM Location .......................................108 Seat Belt Warning ..........110 Information Display..............................121 On-board Diagnostic System ...........................................................116 Controller Area Network ......................................................111 Wiring Diagram ..........................114 On-board Diagnostic System ....................................................................................................................................................................................................109 Passenger’s Seat Belt Warning ........................................................................................113 Body Control Module .................................................................................................................................................................................................................................................................................116 Self Test............................................

1 Crossbeam Service Training Mazda5 09-1 . therefore minimizing deformation in the area around the front seat occupants feet.Body & Accessories Body Panels Features • The body shell of the Mazda5 has the following features: Body Panels – – Cabin • Triple H-construction is used. Front bumper and rear bumper reinforcements used. The cabin utilizes the same MAIDAS (Mazda Advanced Impact Distribution and Absorption System) concept as the Mazda3. 1. and the side sill. M5_09001 1 2 3 4 Front bumper reinforcement Collision energy Front side frame To side sill 5 6 7 8 To A-pillar Impact dispersing three-fork structure To crossmember No. crossmember No. A crossbeam is also utilized to prevent hinge pillars from moving outward during collisions. The three fork structure at the back of each front side frame directs frontal impact energy toward the A-pillar.

the triple-H frame structure effectively distributes force in an H-pattern along the floor.Body Panels • Body & Accessories In the event of a side collision.2 Crossmember No. This structure not only improves the safety of the cabin.3 Collision energy 4 5 6 Side sill B-pillar Roof reinforcement 09-2 Service Training Mazda5 . M5_09002 1 2 3 Crossmember No. but also helps it resist body twisting and improves steering performance. the side and the roof of the vehicle.

inner door handle and speaker (front doors only) are used.Body & Accessories Doors and Liftgate Features • The doors on the Mazda5 have the following features: Doors and Liftgate – – – – Door units integrating power window motor and regulator. Parts Location M5_09003 1 2 3 4 5 Front door Sliding door Front door unit Sliding door unit Wiring harness 6 7 8 9 10 Liftgate Sliding door catcher pin Sliding door open lock actuator Side impact bar Sliding door guide rail Service Training Mazda5 09-3 . Side impact bars are utilized. Plastic liftgate has been utilized. Sliding doors are used on both sides of vehicle.

M5_09004 1 2 3 4 Sliding door catcher pin Sliding door Inside of vehicle Outside of vehicle 5 6 7 8 Collision energy Side impact bar Section A-A Section B-B 09-4 Service Training Mazda5 . The sliding doors incorporate a side impact bar. and catcher pins to increase safety in the event of a side collision. sliding doors are provided on both sides.Doors and Liftgate Sliding Doors • • Body & Accessories To allow easier entry and exiting of the vehicle.

When the inner or outer sliding door handle is operated. a cable releases the open lock actuator. allowing the door to be closed.Body & Accessories Sliding Door Open Lock Actuator • • Doors and Liftgate The sliding door open lock actuator holds the sliding door in the fully open position to prevent the door closing unexpectedly. M5_09052 1 2 3 Lower roller bracket Open lock actuator Closing direction 4 5 Cable Latch Service Training Mazda5 09-5 .

Doors and Liftgate Liftgate • Body & Accessories The liftgate consists of an outer skin made of polycarbonate ABS (AcrylonitrileButadiene-Styrene) plastic. Liftgate dampers that allow the liftgate to be opened to two heights are used. and an inner made of glass fibre reinforced polypropylene bonded together. The liftgate harness is incorporated into the liftgate assembly and cannot be replaced separately. • M5_09005 1 Liftgate 2 Access panels 09-6 Service Training Mazda5 .

a five seater and a seven seater. The seat cushion and seat back of the second row seats fold separately. The third row seats are a ‘Karakuri’ design. the seat back of which can also be used as an armrest. Second Row Seats M5_0909010 1 2 Storage box Armrest 3 4 ‘Karakuri’ 7th seat Double fold-down Service Training Mazda5 09-7 . The second row of both layouts features a fold-away centre seat.as well as a stowable tray that can be unfolded and positioned between the second row seats. allowing a nearly flat floor surface for storage. The right-hand second row seat features a storage box under the seat cushion. When this seat is not needed it can be stowed in a storage compartment under the left-hand second row seat seat-cushion. and fold into the floor for more rear storage space when not being used.Body & Accessories Seats Features • The seats on the Mazda5 have the following features: Seats – – – – – The Mazda5 is available in two seating layouts.

Power Door Lock System • When the driver’s door is unlocked or locked with the key. or by pushing the lock knob. which operates the locks on all doors. Theft deterrent system controlled by BCM is used. Power door lock system controlled by the BCM is used. M5_09013 1 2 3 Driver's door lock knob Driver's door key cylinder Door lock-link switch 4 5 BCM Lock Actuator 09-8 Service Training Mazda5 . the lock link switch in the door lock actuator sends a lock or unlock signal to the BCM (Body Control Module).Security and Locks Security and Locks Features • Body & Accessories The security and lock system on the Mazda5 (CR) has the following features: – – – – – Advanced Keyless Entry and Starting System has been adopted (depends on grade). Double-locking function is used. Auto re-lock function is used.

Parts Location M5_09025 1 2 3 4 5 Liftgate key cylinder Driver’s door key cylinder Liftgate latch and lock actuator Front door latch and lock actuators Rear door lock actuators 6 7 8 9 Rear door latches Transmitter Keyless receiver BCM Service Training Mazda5 09-9 .Body & Accessories Standard Keyless Entry system • Security and Locks The standard Keyless Entry system is similar to that on the Mazda3. with the following exceptions: – Switchblade type retractable key has been adopted.

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

a button type battery (CR2025). • • M5_09027 1 2 3 Retractable key Keyless transmitter Lock button 4 5 Unlock button Intruder sensor cut-off button (with theftdeterrent system) Service Training Mazda5 09-11 . When the key is no longer needed. The key can be separated from the transmitter. it can be folded back into the transmitter case. and a retractable ignition key with integrated transponder. and the transmitter case opened to allow battery replacement.Body & Accessories 1 2 3 4 5 6 7 8 9 10 11 Cargo compartment light Liftgate latch switch Door lock-link switch Front door latch switch (LH) Front door latch switch (RH) Sliding door switch (LH) Sliding door switch (RH) To CAN bus Keyless receiver Front door lock actuator (driver side) Front door lock actuator (passenger side) 12 13 14 15 16 17 18 19 20 21 Security and Locks Sliding door lock actuator (LH) Sliding door lock actuator (RH) Liftgate lock actuator Front turn signal (LH) Side turn signal (LH) Front turn signal (RH) Side turn signal (RH) Rear turn signal (LH) Rear turn signal (RH) BCM Transmitter • The keyless transmitter on vehicles with standard keyless entry incorporates buttons to lock and unlock the doors and to disable the intrusion sensor (when theft-deterrent system fitted). By pushing the release button on the transmitter the ignition key will automatically pop out.

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

Body & Accessories Advanced Keyless Entry and Start System • Security and Locks The Advanced Keyless Entry and Start System allows the vehicle to be unlocked and started without using a key. Parts Location M5_09011 Service Training Mazda5 09-13 . As long as the driver has an advanced keyless entry card key in their possession. operation of the doorlocks and start knob (to start the engine) can be achieved without actually removing the card key from their pocket or bag.

front) 09-14 Service Training Mazda5 . rear-left) Keyless antenna (interior. rear-right) Keyless control module Keyless receiver BCM Keyless antenna (interior.Security and Locks 1 2 3 4 5 6 7 8 9 10 11 12 13 Start knob (ignition switch) Security light Coil antenna Steering lock unit Keyless warning light (red) Keyless indicator light (green) Keyless buzzer Keyless antenna (driver side) Request switch (driver side) Front door key cylinder Keyless antenna (passenger side) Request switch (liftgate) Front door latch and lock actuator 14 15 16 17 18 19 20 21 22 23 24 25 26 Body & Accessories Rear door lock actuator Rear door latch Liftgate latch and lock actuator Keyless antenna (liftgate) Card key Transmitter Auxiliary key Keyless antenna (interior.

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

front) Keyless antenna (interior. RR) Keyless antenna (interior. RL) Security light Keyless indicator light (green) Keyless warning light (red) Instrument cluster Keyless buzzer DLC-2 LOCK UNLOCK Door lock actuator BCM Door lock-link switch With AT CAN-L CAN-H 09-16 Service Training Mazda5 .Security and Locks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Keyless control module Keyless receiver Coil antenna PCM Steering lock unit Start knob push switch Key reminder switch Request switch (liftgate) Request switch (driver side) Request switch (passenger side) Brake light switch Brake light Selector lever Key interlock solenoid Keyless antenna (driver side) Keyless antenna (passenger side) Keyless antenna (liftgate) 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Body & Accessories Keyless antenna (interior.

Body & Accessories Card Key • • A thin. • • • M5_09017 1 2 3 Indicator light Lock button Unlock button 4 5 6 Intruder sensor cut-off button (with theftdeterrent system) Auxiliary key Transmitter Service Training Mazda5 09-17 . an auxiliary key. the driver’s door can be opened and the engine started using the auxiliary key. card type transmitter has been adopted. the indicator light illuminates. and an indicator light. When the LOCK or UNLOCK buttons are operated or a request signal is received from the vehicle. A transponder is built into the auxiliary key. If the Advanced Keyless Entry system is malfunctioning. Security and Locks The card key incorporates buttons to lock and unlock the doors and to disable the intrusion sensor (when theft-deterrent system fitted). a button type battery (CR2025).

the Keyless Control Module sends a request signal to the card key. and liftgate respectively.Security and Locks Request Switch • Body & Accessories Request switches are installed to driver’s door. The request switch on the driver’s door can also be used to open and close the windows (see “Power Window System”) M5_09019 1 Request switch 2 Internal circuit diagram 09-18 Service Training Mazda5 . When the request switch is pressed. passenger’s door.

liftgate) Keyless antenna (interior. and relay card key ID’s to the Keyless Control Module. front) Service Training Mazda5 09-19 . RL) Keyless antenna (interior. passenger side) Keyless antenna (interior. If more than one card keys are within the reception range of the keyless antennas. RR) 4 5 6 Keyless antenna (exterior.Body & Accessories Keyless Antennas • • Security and Locks A total of six antennas send request signals to card keys. driver side) Keyless antenna (exterior. • M5_09018 1 2 3 Keyless antenna (exterior. and those in the rear interior panels and behind the glovebox detect card keys inside the vehicle. The antennas in the front doors and the liftgate are used to detect card keys outside the vehicle. the card key ID received by the antenna with the strongest signal is used by the Keyless Control Module.

M5_09022 1 Keyless control module 09-20 Service Training Mazda5 . The Keyless Control Module is connected to the HS-CAN bus. the new module has to be configured. NOTE: When replacing the Keyless Control Module.Security and Locks Keyless Control Module • • Body & Accessories The Keyless Control Module is located behind the driver’s side kick panel. To do this connect WDS to the vehicle and select the option Toolbox→Module Programming→Programmable Module Installation→RKE. It confirms the identification of the card keys and transmits this information to the PCM and BCM.

M5_09021 1 Steering lock unit 2 Start knob Keyless Buzzer • • The keyless buzzer provides audible confirmation that the doors have been locked or unlocked (answer-back function). allowing the steering to be unlocked and the start knob to be turned to the ON position. M5_09020 1 Keyless buzzer Service Training Mazda5 09-21 . or that the system is not being used correctly. or is not functioning. When the start knob is pushed in a request signal is sent by the Keyless Control Module via the keyless antennas. it sends a signal to the steering lock unit. To access it. The keyless buzzer is attached to the body inside the left side mudguard. the start knob can be removed and the auxiliary key inserted to start the engine.Body & Accessories Steering Lock Unit • Security and Locks The steering lock unit consists of the steering lock and the start knob. If for some reason the card key cannot be identified. the front inner mudguard must be removed. If the Keyless Control Module successfully identifies a valid card key.

or simply by pressing the request switches on each of the front doors or liftgate. • • • 09-22 Service Training Mazda5 . by pushing the buttons on the transmitter (card key). A rolling code type transmitter is used in the card key to reduce the possibility of theft. and interior and exterior buzzers informs the driver if the system is not being used correctly.Security and Locks Keyless Entry Function • Body & Accessories Unlocking and locking of doors can be achieved either by using the auxiliary key. or if there is a fault. An answer-back function is provided for visual and audible confirmation of door lock operation. A guidance function consisting of two indicator lights in the instrument cluster.

the doors will not be locked: • – – – – • • The auxiliary key is in the ignition. Any of the doors or the liftgate are open. The Keyless Control Module then sends a signal to the keyless buzzer.Body & Accessories Locking/Unlocking Using Transmitter • Security and Locks When either of the buttons on the transmitter is pushed. and sends a signal to the BCM to operate the door lock actuators. The start knob is being pressed. and to the BCM to operate the hazard lights (answer back function). The Keyless Control Module verifies that the ID of the key is valid. The start knob is being pressed. the transmitter ID (Identification) and a rolling code are transmitted as radio waves. If any of the below conditions are met while the unlock button is being pressed. The start knob is in any position other than LOCK. the doors will not be unlocked: – – – The auxiliary key is in the ignition. If any of the below conditions are met while the lock button is being pressed. M5_09014 1 2 3 Transmitter (card key) Keyless receiver Keyless control module 4 5 BCM Lock actuator Service Training Mazda5 09-23 . The start knob is in any position other than LOCK. The signal is detected by the keyless receiver and communicated to the Keyless Control Module.

the ID request signal will only be transmitted to the area outside the driver’s door. and to the BCM to operate the hazard lights (answer-back function).6 ft} Effective range 09-24 Service Training Mazda5 . which passes the information on to the Keyless Control Module (b).Security and Locks Locking/Unlocking Using Request Switches • Body & Accessories Whenever one of the request switches is pressed. The same occurs respectively for the other request switches. The Keyless Control Module then sends a signal to the keyless buzzer. for example. If the driver’s door request switch is operated. and it transmits its ID to the keyless receiver. the Keyless Control Module transmits an ID request signal via the keyless antennas to the card key (a). the indicator light on it flashes once. When the card key receives the ID request signal. and sends a signal to the BCM to operate the door lock actuators (c). The Keyless Control Module verifies that the ID of the card key is valid. • • • M5_09015 1 2 3 4 5 Keyless receiver Keyless control module Transmitter (card key) Request switch Keyless antenna 6 7 8 9 Lock Actuator BCM Approximately 80 cm {2.

Start knob is in the LOCK position.Body & Accessories • Security and Locks The doors will only lock when a request switch is pushed if the following conditions are all met: – – – – – • There is no card key inside the vehicle. All doors and liftgate are closed. The doors will only unlock when a request switch is pushed if the following conditions are all met: – – – Auxiliary key is not in the ignition. A card key is within the reception range of the keyless antennas in the front doors/liftgate. A card key is within the reception range of the keyless antennas in the front doors/liftgate. Auxiliary key is not in the ignition. Start knob is in the LOCK position. Service Training Mazda5 09-25 .

Any of the request switches are pushed. Any of the buttons of the transmitter are operated (the auto re-lock timer will be reset to ‘0’ if the UNLOCK button is pressed). The start knob is in the LOCK position. The keyless buzzer sounds one time and the system enters ‘standby mode’ (but locks are not operated) when the following conditions are met: • – – – – – • • All doors and liftgate are closed (door switch OFF) after one or more having been opened (door switch ON). The auxiliary key is not in the ignition. A card key is within the reception range of the keyless antennas in the front doors/liftgate. The auxiliary key is inserted in the ignition.Security and Locks Auto Re-lock Function • Body & Accessories The doors will automatically re-lock 30 seconds after being unlocked unless any of the following conditions are met: – – – – – Any of the doors or liftgate are opened. Out of Range Auto Lock Function • If the card key moves out of the reception range of the front door/liftgate antennas while all the doors are closed. the doors will automatically be locked (this function is set to OFF for new vehicles). The hazard lights flash once to indicate the doors are locked. 09-26 Service Training Mazda5 . The card key is not inside the vehicle. Approximately two seconds after the keyless antenna detects that no card keys are within the reception range the doors are locked. The start knob is pressed.

The ignition can be switched ON and the engine started simply by turning the start knob. When the card key receives the ID request signal. Service Training Mazda5 09-27 . it is not necessary to insert a key in the ignition switch to start the engine. When the start knob is pressed the Keyless Control Module transmits an ID request signal inside the vehicle. and a permission signal is sent to the PCM to allow the engine to be started. At the same time. The Keyless Control Module verifies that the ID of the card key is valid. and it transmits its ID to the keyless receiver. • The card key ID is verified a second time when the ignition is turned to the ON position. the indicator light on the card key will flash once. and unlocks the steering lock. it illuminates the green keyless indicator light in the instrument cluster (c). which passes the information on to the Keyless Control Module (b).Body & Accessories Keyless Start Function • Security and Locks If the driver has a card key with them when they enter the car. • • • NOTE: If the ID of the card key is not recognised (unregistered or a faulty card key) the start steering lock will not be unlocked and the red keyless indicator light will flash on and off. the indicator light on it flashes once. via the interior keyless antennas (a).

Security and Locks Body & Accessories M5_09016 1 2 3 4 5 ID verification NG Red keyless indicator light (flashing) ID verification OK Green keyless indicator light (illuminated) Keyless receiver 6 7 8 9 10 Keyless control module Steering lock unit Transmitter (card key) Keyless antenna Reception range (interior) 09-28 Service Training Mazda5 .

or the external keyless buzzer. Instrument cluster Interior buzzer Keyless Keyless warning indicator light light (green) (red) - Item Operation condition Exterior keyless buzzer Start knob not in LOCK position Driver’s door is open with start knob in ACC position Card key cannot be detected inside vehicle with driver’s door open and start knob in any position except lock - Sounds (approx. 6 s) Sounds 3 times *2 - Flashes *4 - Card key cannot be detected Card key out inside vehicle with all doors of vehicle *1 closed and start knob in any position except lock Card key cannot be detected inside vehicle with start knob in any position except lock and under any condition other than above Request switch is pressed from outside vehicle with proper card Door lock inoperable *3 key inside vehicle and another card key carried Attempt is made to lock doors with request switch while carrying card key. when a door is already open or the start knob in any position other than lock Battery voltage low Card key battery voltage depleted Sounds 3 times - Flashes *4 - - - Warning Flashes *4 - Sounds 3 times - - - Sounds 3 times - - - - - - Flashes (Approx.Body & Accessories Guidance Function • Security and Locks The driver is informed of faults or misuse of the system via the warning light and the internal buzzer in the instrument cluster. 30 s after IG ON) M5_09T001 Service Training Mazda5 09-29 .

“Start knob not in LOCK warning” (continuous buzzer sound) overrides. the engine cannot be restarted by turning the start knob from the ACC position to the START position even though the start knob has not been turned to the LOCK position. Low card key battery warning (set to ON from factory). *3 : Set to OFF from factory. Lock/unlock answer back function (set to OFF from factory). the steering will be locked (the engine cannot be restarted). M5_09T001a Customization • The following functions can be switched ON or OFF using WDS: – – – Out of range auto-lock function (set to OFF from factory). 09-30 Service Training Mazda5 . *4 : Stops flashing and goes out if the card key is detected inside the vehicle. *2 : When the ignition switch is off (except for LOCK position). For vehicles with the immobilizer system. 3 s) - - - - *1 : If the start knob is turned to the LOCK position with the card key out of the vehicle.Security and Locks Body & Accessories Keyless buzzer (outside the vehicle) Instrument cluster Keyless Keyless Buzzer warning indicator (Interior) light light (red) (green) Item Operation condition Start knob operable Start knob Guidance inoperable Lock/unlock answer back *3 Start knob is operable (lock released) when it is pressed Start knob is inoperable (locked) when it is pressed Doors are locked/unlocked with normal/advanced keyless entry function Locked: Once Unlocked: Twice - Flashes On (Max.

6. Turn ignition switch to ACC then back to ON three times. 2. then unlock to confirm that programming was successful. NOTE: Steps 3 to 6 below must be completed within 30 seconds of inserting the auxiliary key in the ignition. Push the UNLOCK button on card key 1 once. Select the option Toolbox→Body→Security→PATS Functions. 5. Bring the two registered card keys (key 1 and key 2). Push the UNLOCK button on the card key card to be programmed twice. 4.Body & Accessories Service and Repair Security and Locks Programming Additional Card Keys With Two or More Card Keys • If two or more registered card keys are available. The door lock actuators will lock once. NOTE: Do not program card keys while WDS or any other computer devices are in the vehicle. 3. additional keys can be programmed without the use of WDS. Select the option “Card Key Programming”. and input corresponding incode). Open and close the driver’s door three times. Carry out the security access procedure (read out the WDS outcode. 8. Make sure all card keys are operational and have good batteries. and the card keys to be programmed into the vehicle and close all doors. Service Training Mazda5 09-31 . The door lock actuators will lock once. The door lock actuators will lock once. Programming Additional Card Keys With WDS 1. then unlock to confirm that key programming mode is active. Push the UNLOCK button on the card key to be programmed twice. 2. 1. Insert auxiliary key in ignition. Turn the ignition ON. then unlock to confirm that programming was successful. A maximum of six card keys can be programmed. The door lock actuators will lock once. then unlock to confirm that key programming mode is active. Establish communication between WDS and the vehicle. 5. 3. 4. 7. Push the UNLOCK button on card key 2 once.

Establish communication between WDS and the vehicle. If there is no programmed card key. 4. Body & Accessories Select the option Toolbox→Body→Security→PATS Functions. 4. and input corresponding incode). and input corresponding incode). it is recommended that two card keys be programmed so that the “Programming additional card keys with two or more card keys” procedure can be carried out by the customer if they wish to do so in the future.Security and Locks Erasing Registered Card Keys 1. NOTE: To program the steering lock unit a registered card key is necessary. 5. Complete procedure by programming at least one new card keys. Carry out the security access procedure (read out the WDS outcode. 2. Select the option “Card Key Clearing”. NOTE: Do not program the steering lock unit while WDS or any other computer devices are in the vehicle. 3. Steering Lock Unit Programming • If the steering lock unit is replaced. Bring a registered card key into the vehicle and close all the doors. Make sure all card keys are operational and have good batteries. 5. Select the option “Steering Lock Unit Programming”. Carry out the security access procedure (read out the WDS outcode. 3. NOTE: Only one registered card key is necessary for the system to function correctly. 1. perform the steering lock unit programming after the card key programming. the new unit must be programmed using WDS. 2. 09-32 Service Training Mazda5 . Select the option Toolbox→Body→Security→PATS Functions. Establish communication between WDS and the vehicle. However.

PID Monitor • The PID monitor function allows the PIDs for the Advanced Keyless Entry system to be monitored. connect WDS to the vehicle and select the option Toolbox→Self Test→Modules→RKE. Item DTC_CNT RPM VSS VPWR NUMCARD NUMKEY DRSW_D DRSW_ALL BOO REQ_SW_D REQ_SW_P REQ_SW_BK LOCK_SW_D IMMOBI TR/LG_SW IG_KEY_IN IG_SW_ST BUZZER PWR_IG1 PWR_ACC Definition Number of continuous DTCs Engine speed Vehicle speed Supply voltage Number of programmed card keys Number of programmed key ID numbers Door switch (Driver’s door) Door switch (All doors and liftgate) Brake pedal position (Brake switch) Request switch (Driver’s door) Request switch (Passenger door) Request switch (Liftgate) Door lock-link switch Immobilizer system equipped or not Liftgate latch switch Key reminder switch Ignition switch (Push switch) Keyless buzzer Power supply (IG1) Power supply (ACC) Unit/ Condition RPM KPH V OPEN/ CLOSE OPEN/ CLOSE On/Off On/Off On/Off On/Off On/Off On/Off OPEN/ CLOSE Key-In/ Key-Out Pushed/ Not Pushed On/Off On/Off On/Off M5_09T002 Service Training Mazda5 09-33 . To view these. To view these connect WDS to the vehicle and select the option Toolbox→Datalogger→Modules→RKE.Body & Accessories On-board Diagnostic System • Security and Locks The on-board diagnostic system consists of the following functions: – – – Self-test PID monitor Simulation test function Self Test • The self-test function allows the Advanced Keyless Entry system DTCs to be displayed.

Unit/ Condition On/Off On/Off On/Off On/Off Lock/ Off Unlock/ Off Lock/ Off M5_09T003 Item BZR_OUT BZR_IN LNP_RED LNP_GREEN DR_LOCK DR_UNLOCK SUPERLOCK Keyless buzzer Applicable Component Interior buzzer (Instrument cluster) Keyless warning light (red) Keyless indicator light (green) All doors Lock/Off All doors unlock/Off All doors Lock/Off 09-34 Service Training Mazda5 . connect WDS to the vehicle and select the option Toolbox→Datalogger→Modules→RKE. To do this.Security and Locks Simulation Test • Body & Accessories The simulation test function allows certain PIDs for the Advanced Keyless Entry system to be activated.

M5_09029 1 2 3 4 5 Coil antenna Tx line Rx line Instrument cluster Fuel injector 6 7 8 9 Fuel pump relay (gasoline engine) or fuel metering valve (diesel engine) Ignition coil (only gasoline engine) Starter relay PCM Operation M5_T09030 1 2 Key (transponder) Coil antenna 3 4 Instrument cluster PCM Service Training Mazda5 09-35 .Body & Accessories Security and Locks Immobilizer System (vehicles with standard Keyless Entry system) • The immobilizer system is basically the same as that in the Mazda3 (BK). Control of the immobilizer is carried out by the instrument cluster.

SATISFACTORY RESULT Engine starting is permitted. SATISFACTORY RESULT 5.) Body & Accessories 1. The instrument cluster makes a calculation using received data B and compares it with sent data A. M5_09T008 09-36 Service Training Mazda5 . The key (transponder) calculates data B from received data A and sends its specific key ID number and data B to the instrument cluster via the coil. SATISFACTORY RESULT 4. The instrument cluster calculates data D from received data C and sends it to the PCM. The PCM sends data C* to the instrument cluster. the security light illuminates or flashes continuously for approx. 3 s. The instrument cluster sends data A* to the key (transponder) via the coil. UNSATISFACTORY RESULT UNSATISFACTORY RESULT 6. (Security light illuminates. 8. The instrument cluster verifies consistency between the received key ID number and the previously registered key ID numbers. 3. The instrument cluster requests data for verification from the PCM. 7. UNSATISFACTORY RESULT Engine starting is not permitted. The PCM makes a calculation using received data D and compares it with sent data C. 2.) *: Data A and C are different random values each time. 1 min. and then a DTC is repeatedly displayed 10 times. (The security light goes out after approx.Security and Locks The ignition switch is turned from the LOCK (ACC) to the ON (START) position. After detecting the error (such as non-verification or malfunction).

The coil antenna is connected to the Keyless Control Module. A maximum of eight keys can be programmed. Keyless Control Module. • • M5_09087 1 2 3 4 5 6 Coil antenna PCM Keyless control module Instrument cluster Security light Tx signal 7 8 9 10 11 Rx signal CAN-High CAN-Low Tx line Rx line Service Training Mazda5 09-37 . which communicates via two separate communication lines to the instrument cluster. Communication between instrument cluster and PCM is conducted via the HS-CAN bus. instrument cluster and PCM. The system consists of the auxiliary key (with integrated transponder). coil antenna.Body & Accessories Security and Locks Immobilizer System (vehicles with Advanced Keyless Entry system) • A D-PATS (Distributed Passive Anti-Theft System) type immobilizer system is used.

PCM and Keyless Control Module. M5_09088 1 2 3 Key transponder Coil antenna Keyless control module 4 5 6 Security light Instrument cluster PCM 09-38 Service Training Mazda5 .Security and Locks Operation • Body & Accessories Control of the immobilizer system on the Mazda5 with Advanced Keyless Entry system is carried out by the instrument cluster. The keys contain a unique ID number that is programmed into the instrument cluster.

UNSATISFACTORY RESULT Engine starting is not permitted. 3. The instrument cluster requests data for verification from the PCM. M5_09T004a Service Training Mazda5 09-39 . 1 min. The instrument cluster transmits data A* to the key (transponder) via the keyless control module and coil antenna. The instrument cluster verifies consistency between the received key ID number and the previously registered key ID numbers. 1. SATISFACTORY RESULT 4. the security light illuminates or flashes continuously for approx. The instrument cluster makes a calculation using received data B and compares it with sent data A. The PCM sends data C* to the instrument cluster. 3 s.Body & Accessories Security and Locks The start knob is pressed and the ignition switch is turned to the ON position. 8. and then repeatedly displays a DTC 10 times. 2. and transmits unique key ID number and data B to the instrument cluster via the coil antenna and keyless control module.) *: Data A and C are different random values each time. SATISFACTORY RESULT Engine starting is permitted. The PCM makes a calculation using received data D and compares it with sent data C. 7. The instrument cluster calculates data D from received data C and sends it to the PCM. The key (transponder) calculates data B from received data A. After detecting a fault (such as non-verification or malfunction). UNSATISFACTORY RESULT UNSATISFACTORY RESULT 6. (The security light goes out after approx. SATISFACTORY RESULT 5.

• Keys to be programmed (two or more. Required Action • Can be performed without WDS. • Perform the following procedure with WDS: Parameter Reset • Perform the following procedures with WDS in the indicated order: 1. Parameter Reset • No immobilizer system programming or resetting necessary. Card Key Code Erase 3.) • New steering lock unit.) Replacing coil antenna • New coil antenna. Ignition Key Code Erase 2. providing "Customer spare key programming" function is enabled. • Perform the following procedures with WDS in the indicated order: 1. Adding keys/card keys (one • One or more keys/card or no programmed key/card keys to be programmed.) • New keyless control module. M5_09T005b Clearing card key IDs • One or more card keys to be programmed. Ignition Key Code Erase 2. • Keys to be programmed (two or more. • One ore more keys/card keys to be programmed. • Keys to be programmed (two or more. Steering Lock Unit Programming • All keys for the vehicle must be collected and programmed. Steering Lock Unit Programming • All keys and card keys for the vehicle must be collected and programmed. Replacing PCM • New PCM.Security and Locks Immobilizer System Component Replacement Operation Necessary Preparation Body & Accessories Adding keys/card keys (two or more programmed keys/card keys available) • Two or more programmed keys/card keys. • Perform the following procedures with WDS in the indicated order: 1. • Perform the following procedure with WDS: Ignition Key Code Erase • All card keys for the vehicle must be collected and programmed. 09-40 Service Training Mazda5 . • Card keys to be programmed (one or more).) Replacing steering lock unit Replacing keyless control module Replacing instrument cluster • New instrument cluster. Ignition Key Code Erase 2. perform the following procedure with WDS: Program Additional Ignition Key/ Program Additional Card Key • Perform the following procedure with WDS: Program Additional Ignition Key/ Program Additional Card Key • All keys for the vehicle must be collected and programmed. • If "Customer spare key programming" function is disabled. • Perform the following procedure with WDS: Card Key Code Erase • All keys for the vehicle must be collected and programmed. • Keys to be programmed (two or more. • One programmed card key. key available) Clearing key IDs • Two or more keys to be programmed.

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

DTCs are stored in the instrument cluster.Security and Locks On-board Diagnostic System • The on-board diagnostic system consists of the following: Body & Accessories – Self-test Self Test • The self-test function allows immobilizer system DTCs to be displayed. 09-42 Service Training Mazda5 . The security light displays stored DTCs by flashing on and off. connect the WDS to the vehicle and select the option Toolbox→Self Test→ Modules→IC. To do this. The module that each DTC applies to can be verified by referring to the workshop manual. • • NOTE: If the on-board diagnostic system detects more than one malfunction in the immobilizer system. PCM and/or RKE. it is recommended that WDS be used to verify DTCs whenever a fault is present in the immobilizer system. depending on the malfunction. The on/off pattern will differ depending on which DTC is stored. the security light will display only the DTC with the lowest number. PCM and Keyless Control Module. For this reason.

Body & Accessories Theft Deterrent System • Security and Locks The construction and operation of the theft deterrent system on the Mazda5 is essentially the same as that on the current Mazda3 (BK). Parts Location M5_09031 Service Training Mazda5 09-43 . except for the following: – An additional intruder sensor is installed near the rear of the passenger compartment.

Security and Locks 1 2 3 4 5 6 7 Front intruder sensor (vehicles with sunroof) Front intruder sensor (vehicles without sunroof) Key reminder switch Keyless control module BCM Front door latch and lock actuator (driver side) Front door latch and lock actuator (passenger side) 8 9 10 11 12 13 Body & Accessories Rear door switch Bonnet latch switch Theft-deterrent siren Liftgate latch and lock actuator Rear intruder sensor Transmitter 09-44 Service Training Mazda5 .

Body & Accessories Wiring Diagram Security and Locks M5_09032 1 2 3 4 5 6 7 Cargo compartment light switch Liftgate latch switch Front door latch switch (LH) Front door latch switch (RH) Sliding door switch (LH) Sliding door switch (RH) Theft-deterrent siren 8 9 10 11 12 13 Intruder sensor (front) Intruder sensor (rear) Door lock-link switch Door key cylinder switch (driver side) Bonnet switch BCM Service Training Mazda5 09-45 .

Illumination Light Emitting Diodes are used in the power window main switch and subswitches.Glass/Windows/Mirrors Glass/Windows/Mirrors Features • The glass/windows/mirrors have the following features: Body & Accessories – – Rear defroster controlled by the Body Control Module is used (same as Mazda3). Power window system with auto-open/close function available on all windows. Power Window System Features • The power window system is essentially the same as that on the current Mazda3 (BK). Exterior opening/closing function available. Auto reverse pinch protection function on all windows. Auto open/close function on all windows. Ignition off timer function (40 seconds) is used. 09-46 Service Training Mazda5 . Two step down function on all windows. Power window motors with hall sensors are used. and has the following features: – – – – – – – – Manual open/close function on all windows.

Body & Accessories Power Window Main Switch Glass/Windows/Mirrors M5_09006 1 2 3 4 5 6 7 8 Power window main switch Power window motor (driver side) Close Open Auto Power-cut switch Conjunction circuit Close relay 9 10 11 12 13 14 15 Open relay Hall effect switch 1 Hall effect switch 2 To power mirror switch To power window subswitches BCM Power window control module Service Training Mazda5 09-47 .

Glass/Windows/Mirrors Power Window Subswitch Body & Accessories M5_09007 1 2 3 4 5 6 Power window subswitch Power window motor Close Open Auto Close relay 7 8 9 10 11 Open relay Hall effect switch 1 Hall effect switch 2 Power window control module From power window main switch 09-48 Service Training Mazda5 .

However. i. the windows will open fully. i. or closed from outside the vehicle.5 seconds. or the LOCK button on a card key or a retractable type key transmitter for approximately 1.5 seconds. By pressing the driver’s door request switch. when the UNLOCK button is being pressed the windows will open in automatic mode. the windows will stop closing immediately. Conversely. all of the windows can be opened. by pressing the UNLOCK button on a card key or a retractable type key transmitter for approximately 1. During IG OFF timer operation the power window switch operation has priority over the exterior open/close function.e. even if UNLOCK switch is released while they are still moving. The windows will be closed using manual mode.Body & Accessories Exterior Opening/Closing Function • • Glass/Windows/Mirrors The exterior opening/closing function allows all of the windows to either be opened. all of the windows can be closed. • • • Service Training Mazda5 09-49 . when the LOCK button or request switch is released.e.

Glass/Windows/Mirrors Operation Using Request Switch Body & Accessories M5_09086 1 2 3 4 5 6 7 8 9 Transmitter Request switch (driver side) Keyless receiver Keyless control module Door latch switch Start knob/key reminder switch Cargo compartment light switch Power window main switch Input signal 10 11 12 13 14 15 16 17 18 Control signal Power window subswitch (RF) Power window subswitch (LR) Power window subswitch (RR) Power window motor (LF) Power window motor (RF) Power window motor (LR) Power window motor (RR) BCM 09-50 Service Training Mazda5 .

Body & Accessories Using Transmitter Glass/Windows/Mirrors M5_09008 1 2 3 4 5 6 7 8 9 Transmitter Keyless receiver Keyless control module Door latch switch Start knob/key reminder switch Cargo compartment light switch Power window main switch Input signal Control signal 10 11 12 13 14 15 16 17 Power window subswitch (RF) Power window subswitch (LR) Power window subswitch (RR) Power window motor (LF) Power window motor (RF) Power window motor (LR) Power window motor (RR) BCM Service Training Mazda5 09-51 .

the exterior open/close function does not operate. or during window operation.Glass/Windows/Mirrors Operation Prohibition • Body & Accessories When the following conditions are met before. – – – – – – Either door is opened (when the door switch is ON) The key is inserted in the steering lock (when the keyless switch is ON) The start knob is pressed in (vehicles with Advanced Keyless Entry system) or the ignition switch is in any position other than LOCK The transmitter is not in the reception area A recognised card key is not in the reception area when the driver-side request switch is operated (vehicles with Advanced Keyless Entry system) Any button on the transmitter is operated while window is opening 09-52 Service Training Mazda5 .

95 x 28.Body & Accessories Sunroof • Sunroof The construction and operation of the sunroof on the Mazda5 is essentially the same as that on the current Mazda3 (BK).9 or less M5_09T009 Specification Outer slide Service Training Mazda5 09-53 .4} (mm {in}) (s) 22 – 28 {0. except for the following: – Drive unit for sunroof is now available as a separate part. Tilt: 0.5.9 – 1. Specifications Item Slide system Opening measurement Tilt-up amount Opening/ closing time (mm {in}) 202 x 722 {7.1} Slide: 2.5 – 5.

Sunroof Body & Accessories M5_09033 1 2 3 4 5 Drip rail Drip guide Rear stopper Sunshade Deflector 6 7 8 9 Sunroof motor Guide and decoration trim Drive unit Frame 09-54 Service Training Mazda5 .

Discharge headlights with auto leveling system (depending on grade). Auto headlight system (depending on grade). turn signals and rear fog light controlled by the BCM. Daytime running lights (depending on market).7 x 1 1. Light Emitting Diode type high-mount brake light.Body & Accessories Lighting System Features • Lighting System The headlight system on the Mazda5 is essentially the same as the current Mazda3 (BK). It has the following features: – – – – – – – Projector type headlights (low-beam). Stepped reflectors in the rear combination lights. Headlights.4 5x2 10 x 1 8x1 1. interior illumination.4 x 1 M5_09T010 Service Training Mazda5 09-55 . Specifications Item Headlight bulb (high-beam) Discharge headlight bulb (low-beam) Halogen headlight bulb (low-beam) Front turn signal bulb Parking light bulb Front fog light bulb Exterior light bulb capacity Side turn signal bulb Brake light/taillight bulb Rear turn signal bulb Back-up light bulb Rear fog light License plate light bulb High-mount brake light bulb Map light bulb Interior light bulb Interior light bulb capacity Cargo compartment light bulb Glove compartment light bulb Ignition key illumination bulb Specifications (W) x number 60 x 2 35 x 2 55 x 2 21 x 2 5x2 55 x 2 5x2 21/5 x 2 21 x 2 18 x 2 21 x 2 5x2 21. tail/number plate/side lights.

Lighting System Front Combination Light • Body & Accessories Projector type headlights with built-in front turn signal light and parking light are used. M5_09034 1 2 3 4 5 Halogen headlight type Front turn signal bulb Halogen headlight bulb (LO) Headlight bulb (HI) Front combination light 6 7 8 9 Parking light bulb Discharge headlight type Discharge headlight bulb (LO) Section A-A 09-56 Service Training Mazda5 .

Body & Accessories Headlight Auto Leveling System • Lighting System The construction and operation of the headlight auto leveling system is essentially the same as that on the current Mazda3 (BK). Parts Location M5_09035 1 2 3 Auto leveling control module Headlight leveling actuator Auto leveling sensor 4 5 Instrument cluster Auto leveling warning light Service Training Mazda5 09-57 . The headlight auto leveling module requires initialization after related components are replaced. except for the following: – – Conditions necessary before auto leveling control commences are different.

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

Body & Accessories Operation • Lighting System If the auto leveling control module detects the vehicle is moving at a constant vehicle speed of 8 km/h or more for four seconds while the headlights are on. M5_09037 1 DLC – 2 Service Training Mazda5 09-59 . the average value of the vehicle attitude during this period is calculated and the optical axis is adjusted. Auto Leveling Control Module Initialization • The auto levelling control module should be initialized after performing any of the following procedures: – – – – – – Front combination light replacement Auto leveling control module replacement Auto leveling sensor removal/installation Instrument cluster replacement BCM replacement Suspension parts replacement or work that effects vehicle height NOTE: The auto leveling control module can be initialized by shorting the B terminal of the DLC-2 to earth. or by connecting WDS to the vehicle and selecting Toolbox→Electrical→Exterior Lighting→Headlamp→Auto Leveling Sensor Rezero Procedure.

A round reflector is incorporated in the lower part of the rear combination light.Lighting System Rear Combination Light • • Body & Accessories A stepped reflector that diffuses and reflects the light of the rear combination lights is used. M5_09038 1 2 3 Back-up light bulb Rear turn light bulb Brake light/taillight bulb 4 5 Rear combination light Section A-A 09-60 Service Training Mazda5 .

Rear wiper/washer controlled by the BCM.Body & Accessories Wiper/Washer System • Wiper/Washer System The wiper/washer system is essentially the same as the current Mazda3 (BK). It has the following features: – – – – Front wiper/washer and headlight cleaner system controlled by the BCM. Washer fluid level sensor installed in the windshield washer tank (depending on grade). Parts Location M5_09039 Service Training Mazda5 09-61 . Auto wiper system (depending on grade).

Turn the ignition to OFF. the sensor must be initialized. Switch the ignition ON. 2. On average one cycle of AUTO→ OFF→AUTO per second is recommended. NOTE: Do not operate the wiper switch too quickly. To do this connect the WDS to the vehicle and select the option Toolbox→Electrical→Rain Sensor Reset. Turn the front wiper switch to the AUTO position. 3. Initialization Using WDS • The rain sensor can also be initialized by using WDS. 4. Initialization Without Using WDS 1. 09-62 Service Training Mazda5 . The front wipers will sweep across the windshield once to indicate the initialization procedure was successful. and within 10 seconds turn the wiper switch from AUTO to OFF five times.Wiper/Washer System 1 2 3 4 5 6 7 8 9 Wiper and washer switch Rain sensor Windshield wiper arm and blade Windshield wiper motor Windshield washer hose Headlight cleaner actuator Headlight cleaner nozzle Headlight cleaner hose Windshield washer nozzle 10 11 12 13 14 15 16 17 18 Body & Accessories Rear washer hose Rear washer nozzle Rear wiper arm and blade Rear wiper motor Washer tank Rear washer motor Washer fluid-level sensor Windshield washer motor Headlight cleaner motor Rain Sensor Initialization • When replacing the rain sensor. Clean the front windshield glass. or reinstalling a rain sensor after replacing the windshield.

• • ALC (Auto Level Control) is incorporated into the radio. cassette deck. The optional CD changer is MP3 (Moving Picture Experts Group Layer-3 Audio) compatible. NOTE: To replace the single CD player with a 6-CD changer the base unit must be replaced However. Either a four speaker system or a six speaker system with two additional tweeters is available. or 6-disc CD (Compact Disc) changer are available as options. depending on grade. a socket is provided in the rear panel of the audio unit to allow connection of an external CD-changer. the single CD player fitted to the above base units is not.Body & Accessories Entertainment Systems Audio System Features • Entertainment Systems The audio unit is of a modular construction. Service Training Mazda5 09-63 . Three base audio unit combinations are available: Type A – – Type B AM/FM tuner CD player – – – Type C AM/FM tuner CD player RDS (Radio Data System) – – – – • AM/FM tuner CD player Hard Disc Drive RDS MD (Mini Disc) player. similar to the Mazda3.

5 – 108.Entertainment Systems Specifications Audio Unit Body & Accessories Specification Item Rated Voltage Frequency band AM FM Audio amplifier maximum output power Output impedance HDD LW MW Type A Without RDS (V) (kHz) (kHz) (MHz) (W) (ohm) (GB) – – 530 – 1620 12 153 – 279 531 – 1629 87.0 25 x 4 4 20 M5_09T011 Type B With RDS Type C Speakers Item Maximum input Impedance Size (W) (ohm) (cm) 14 x 9 Specification Front door speaker/rear speaker 35 4 5 M5_09T012 Front tweeter 09-64 Service Training Mazda5 .

Body & Accessories Parts Location Entertainment Systems M5_09040 1 2 3 4 5 Rear speaker Front door speaker Front tweeter Information display Centre panel module 6 7 8 9 Audio control switches Centre roof antenna Capacitor Remote control (with HDD) Service Training Mazda5 09-65 .

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

Body & Accessories 1 2 3 4 5 6 7 8 9 10 Centre panel module Information display Audio control switch TNS signal Audio control circuit Antenna Audio unit Base unit Lower module Front tweeter (right) 11 12 13 14 15 16 17 18 19 Entertainment Systems Front door speaker (right) Front tweeter (left) Front door speaker (left) Rear speaker (right) Rear speaker (left) Remote controller (with HDD) Infrared sensor Type A/Type B (without HDD) Type C (with HDD) Service Training Mazda5 09-67 .

The centre panel module is connected to the MS-CAN bus. A lower module (cassette deck or MD player) may be added to type A or type B audio systems. M5_09042 1 2 3 4 Centre panel Base unit Audio unit Lower module 5 6 7 Cover (without HDD) Cover (with HDD) Climate control unit 09-68 Service Training Mazda5 . and the heater control unit. but not to type C (with HDD).Entertainment Systems Centre Panel Module • Body & Accessories The centre panel module consists of the audio unit and switches. • NOTE: There is no mute connector provided on the audio unit.

or compiled into favourites lists to allow more convenient searching and playback. Recording of music can be carried out while driving. and played back. thus preventing damage to the HDD. even if the ignition was switched OFF then ON again.Body & Accessories Music Hard Disc Drive • • • • • • Entertainment Systems The HDD (Hard Disc Drive) unit allows albums to be recorded from the CD player. or the HDD internal temperature rises above 85°C or below -20°C. The HDD protection function stops HDD operation if supply voltage drops below 10. Specifications Item HDD capacity Playback signal compression method Maximum recordable tracks Maximum recordable albums (artist) Favorite track registration capacity Category registration capacity Specification 20 GB Encrypted MP3 3000 999 Number of favorite lists: 4 Number of registerable tracks per list: 100 Number of categories:5 Number of registerable albums per category: 999 M5_09T014 Service Training Mazda5 09-69 . Recording of a CD can be resumed from the song being played back when recording was stopped. The operation restriction function prevents the HDD main menu or the REC (recording) menu from being entered while the vehicle is moving. Music recorded on the HDD can be categorized by album name. stored on the hard disc in MP3 format.5 V. or while the ignition is OFF (provided the ACC OFF recording function is set to ON). A ‘Secret Menu’ function is provided to allow maintenance of the HDD database. music style. artist.

The HDD secret menu can be activated by using the following procedure: While the HDD is playing back. 3. as this could cause the HDD head to ‘crash’ (contact the HDD disc). 2. it is possible that rebuilding the HDD database will restore the functionality of the unit. 09-70 Service Training Mazda5 . press and hold the MENU button. or press it longer (more than 1. and then immediately press the ENTER and ARTIST buttons simultaneously for approximately 1 second. Display or update the Firmware installed.Entertainment Systems Secret Menu • Body & Accessories The secret menu allows the following operations to be carried out: – – – – Format the hard disc.) Scan the HDD disc for errors. (If “DB ERROR” is displayed on the information display. Press the MENU switch to exit the secret menu.5 seconds) to go back one step.) Rebuild the HDD database. Alternatively. NOTE: Care should be taken not to interrupt the power supply. press the CANCEL button quickly (less than 1. damaging the HDD. (Firmware is the software that manages the HDD database. or to jolt or knock the HDD while any of the secret menu functions are being carried out.5 seconds) to return to the main menu. Rotate and then press the AUDIO CONT switch to select the desired function. • 1. It is usually not necessary for the workshop to update this software.

With the audio power on. Confirm that the audio unit is switched off. 3. While pressing the POWER button. The self-diagnostic function allows DTCs in the audio unit to be displayed. The procedures for entering it are shown below: Component Tested Buttons Procedure With the audio power on.Body & Accessories On-board Diagnostic System • Entertainment Systems The on-board diagnostic system is similar to the Mazda3 (BK). 2. simultaneously press the FM1/2 button and the MEDIA button for 2 seconds or more. and consists of the following functions: – – Self-diagnostic function Diagnostic assist function Self Diagnostic Function • 1. press the POWER button and simultaneously press the AUTO-M button for approximately 1 second. M5_09T028 Speakers Radio reception Service Training Mazda5 09-71 . press the POWER button and simultaneously press the AUTO-M button for approximately 1 second. Diagnostic Assist Function • The diagnostic assist function allows the different components of the audio system to be checked. press the POWER button and simultaneously press the MEDIA button for approximately 1 second. turn the audio POWER button off. With the audio power on. It can be entered as follows: Turn the ignition switch to the ACC or ON position. If it is not.

Spanish and Dutch. Norwegian and Finnish. German. The construction and operation of the navigation system is essentially carried over from that of the Mazda3 (BK). German. The voice guidance and screen display can be set to the following languages: English (British). English (American). Portugese. Swedish. English (American). A voice control system has been adopted to enable the customer to verbally control most functions of the navigation system. French. Spanish. 09-72 Service Training Mazda5 . A split screen function has been adopted for more convenient route guidance. except for the following features: – – – – – – The speed of operation has been improved. The following languages can be selected: English (British). Italian. An OBD function has been adopted to simplify the diagnostic procedure. Specifications Navigation Unit Item Unit type Rated voltage ROM type Voice guidance output power Stand-alone 12 V DVD-ROM 5W Specification LCD Unit Item Unit type Rated voltage Size Display Type LCD TFT (full-colour) Pop-up 12 V 7 inch (wide screen) Specification Speaker • The system uses the audio speakers in the driver’s door. Italian. A Traffic Message Channel function and a Dynamic Route Guidance System have been adopted to automatically select a detour in case of traffic jams.Entertainment Systems Car Navigation System Features • Body & Accessories The Mazda5 is equipped with a new navigation system manufactured by Denso. Danish. French. refer to the audio unit. Dutch.

Body & Accessories Parts Location Entertainment Systems M5_09054 1 2 3 4 5 6 Microphone Car-navigation unit Remote control (RHD) Car-navigation control panel (LHD) Back-up light switch (MTX) TR switch (ATX) 7 8 9 10 11 Front door speaker Front tweeter Voice recognition switch GPS antenna LCD unit Service Training Mazda5 09-73 .

Entertainment Systems System Overview Body & Accessories M5_09055 1 2 3 4 5 6 7 8 9 10 11 12 RDS-TMC tuner Gyro sensor DVD driver GPS receiver CPU RDS-TMC antenna Front tweeter (driver side) Front door speaker (driver side) Rear camera Rear view monitor control module Audio unit CPU 13 14 15 16 17 18 19 20 21 22 23 24 LCD GPS antenna Microphone with amplifier Car-navigation control panel or remote control Parking brake switch Parking brake signal LCD unit TR switch (ATX) or back-up light switch (MTX) R-range signal Instrument cluster Vehicle speed signal Car navigation unit 09-74 Service Training Mazda5 .

M5_09056 1 2 DVD-ROM loading slot Eject button 3 DVD-ROM Service Training Mazda5 09-75 .Body & Accessories Car Navigation Unit • Entertainment Systems The car navigation unit is located in the glove compartment and incorporates the DVDROM drive and the gyro sensor.

It features different illumination brightness levels for the navigation display. On LHD vehicles. day and night mode. Night Mode • When night mode is selected. and it automatically switches back to day mode when the lights are switched off. the display is fixed at a lower brightness level. Day Mode • When day mode is selected. The LCD unit features a dedicated bidirectional serial bus to the navigation unit and the audio unit. • • Automatic Mode • When automatic mode is selected. On LHD vehicles. the display is fixed at a higher brightness level. the driver can select between day mode and night mode by pressing the DIM button when automatic mode is selected. the driver can select between two different brightness levels by pressing the DIM button when night mode is selected. On LHD vehicles. the driver can select between two different brightness levels by pressing the DIM button when day mode is selected.Entertainment Systems LCD Unit • Body & Accessories The LCD unit is a pop-up type incorporated in the dashboard. It serves as a display for the navigation system during normal operation and as a display for the rear view camera when reverse gear is selected. M5_09057 1 LCD unit 09-76 Service Training Mazda5 . All necessary video signals are separately sent as a RGB signal. The driver can select between automatic. the display switches automatically to night mode when at least the parking lights or head lights are switched on.

Some of the possible display options are shown below: One-screen Map Display M5_09058 Dual-screen Map Display with Different Scales M5_09059 Map and Turn List M5_09060 Service Training Mazda5 09-77 .Body & Accessories Split Screen • Entertainment Systems Different display modes can be selected with the split screen function.

Entertainment Systems Map and Turn Arrows Body & Accessories M5_09061 Automatically Enlarged Illustration of a Nearby Intersection M5_09062 M5_09063 09-78 Service Training Mazda5 .

M5_09064 1 Microphone Service Training Mazda5 09-79 . The microphone incorporates an amplifier and is connected to the navigation unit. To enable the recognition function. the voice recognition button on the steering wheel has to be pressed first.Body & Accessories Microphone • • • Entertainment Systems The microphone is located beside the LCD unit and recognizes verbal commands in order to control several functions of the navigation system.

The system then confirms the command. This activates the microphone and mutes the audio unit for a specified time. during which the driver can input verbal commands. To activate the voice recognition.Entertainment Systems Voice Recognition Button • • Body & Accessories The voice recognition button is incorporated in the steering wheel. Its signal is forwarded on the serial bus from the audio unit via the LCD display unit to the navigation unit. carries out the appropriate action and then deactivates the mute function. • M5_09065 1 Voice recognition button 09-80 Service Training Mazda5 . the driver has to press the button.

Body & Accessories • Entertainment Systems The list of verbal commands that the navigation system will follow is shown below: M5_09083 Service Training Mazda5 09-81 .

except for the fact that the remote control does not feature a DIM button. M5_09068 1 2 3 4 5 6 7 Position button Joystick/ Enter button Menu button Dim button Zoom button Return button Voice button Displays the current position Selects items by tilting it up. but the functions are the same. down.Entertainment Systems Control Panel • Body & Accessories The navigation control panel is located on the centre console. M5_09067 • The layout of the control types is different. RHD vehicles are equipped with a remote control instead of the control panel. right and left and executes a selected item Selects menus Switches between display illumination modes Changes the map scale Returns to the previous screen Initiates verbal guidance for route maneuvers and adjusts the display 09-82 Service Training Mazda5 .

Body & Accessories Traffic Message Channel • Entertainment Systems The TMC (Traffic Message Channel) function is a specific application of the RDS (Radio Data System). The quality of the traffic information depends on the source of information. It receives traffic messages and forwards the received information to the CPU. M5_09070 1 TMC icon Service Training Mazda5 09-83 . Either the radio stations receive the information from the police and listeners. Sometimes the verbal information broadcasted by a radio station is different to the TMC information they transmit. The messages can be displayed and the route can be automatically recalculated when there are traffic jams along the first selected route. • M5_09069 1 2 Traffic messages Traffic information center 3 Radio station • The TMC icon is shown on the display when the system receives a signal from at least one radio station that broadcasts TMC information. using a FM receiver that is incorporated in the navigation unit. or in addition from companies providing more detailed information. TMC is a service which is provided free of charge by some radio stations.

The colours which are assigned to each type of traffic event are described in the following table: Traffic event Colour Traffic Red Orange Pink Road Black Pink Yellow Grey • Stationary Traffic Jam Accidents Road closed Road Works/Danger Road Conditions/Weather/Delays Parking/Out of order • Inside the vehicle the TMC signals are processed as shown below.Entertainment Systems • Body & Accessories Traffic events received by the TMC receiver are shown as a symbol on the Navigation display in a scale of 50m…4km. The colour and type of the TMC symbol depends on the traffic information. M5_09071 1 2 3 4 Navigation unit RDS-TMC receiver Vehicle antenna FM tuner 5 6 7 8 Decoder CPU communication control Navigation ECU Display 09-84 Service Training Mazda5 . Events within a 25km radius of the vehicle are monitored by the system in order to automatically select a detour if necessary.

Body & Accessories • Each traffic event is indicated by one sign. Entertainment Systems M5_09072 1 Icon for traffic event Service Training Mazda5 09-85 .

Entertainment Systems TMC Availability • The map below shows the availability of TMC in Europe.g. Rerouting always depends on local conditions (such as length of possible detour etc. M5_09073 1 TMC operational 2 TMC planned 09-86 Service Training Mazda5 . major roads). the DRGS (Dynamic Route Guidance System) recalculates the route only for traffic events on motorways. Body & Accessories NOTE: Even when the TMC displays traffic events on other road types (e. NOTE: TMC information about a large traffic jam does not necessarily mean that the navigation system will reroute the vehicle.).

A new menu will be displayed where several options can be selected.Body & Accessories Activation of TMC and DRGS • Entertainment Systems To switch on the TMC and DRGS first select “RDS-TMC” from the main menu. M5_09074 1 2 3 4 5 Displays all traffic events Switches between automatic and manual country selection Selects a TMC radio station Activates TMC Activates verbal information regarding traffic events 6 7 8 9 Displays traffic events on the guided route Selected country Selected TMC radio station Activates DRGS Service Training Mazda5 09-87 .

the ignition must be switched off. To cancel the diagnostic mode. press the “Menu” button and select Navigation Set Up Calibration Distance. 09-88 Service Training Mazda5 . press the “Menu” button and select Navigation Set Up Calibration Map Version. To do this. The “Return” button has to be pressed to leave a menu point. the “Diagnosis Check” screen is displayed. the vehicle speed signal needs to be recalibrated. Then push the joystick up two times and down two times.Entertainment Systems On-board Diagnostic System • Body & Accessories The on-board diagnostic system has the following functions: – – – – • Vehicle Signal Check Navigation Check Product Version Error Code To access the OBD function. Now. After selecting “Menu” the OBD main menu is displayed on the screen. The vehicle speed signal will then be automatically recalibrated during the next few kilometers driven (the required distance depends on the route used for calibration). • NOTE: After the tires have been replaced.

The following options can be entered via this sub menu: – – – – GPS Information Microphone Check Vehicle Sensors History Service Training Mazda5 09-89 .Body & Accessories Vehicle Signal Check • Entertainment Systems The “Vehicle Signal Check” allows several input signals of the navigation system to be checked. M5_09075 1 2 3 4 5 6 7 PKB REV Microphone Speed TNS GPS antenna Traffic system ON = Parking brake signal is ON OFF = Parking brake signal is OFF ON = Reverse gear selected OFF = Reverse gear not selected OK = Connected NCON = Disconnected Current vehicle speed in kph/mph ON: TNS signal ON OFF: TNS signal OFF OK = Connected NCON = Disconnected TMC = TMC tuner incorporated Navigation Check • A sub-menu is displayed when “Navigation Check” has been selected.

Entertainment Systems GPS Information • Body & Accessories The option “GPS Information” allows the data received from GPS satellites to be checked. signals are being received from two or less satellites 7 Status 09-90 Service Training Mazda5 . Elv/Azm LVL STS Latitude/Longitude Measurement Date (GMT) Individual number of the satellite Elevation azimuth (position of the satellite) Signal level Reception status P = Data are received and used for positioning T = Data are received but not used for positioning .= No data are received Current position in degrees. minutes and seconds Date and time obtained from GPS satellites.= Two dimensional positioning is not possible. Time is GMT (Greenwich Mean Time) 2D = Two-dimensional positioning 3D = Three-dimensional positioning NG = Unusable positioning data error = Error in communication between GPS receiver and navigation unit . M5_09076 1 2 3 4 5 6 No.

Body & Accessories Microphone Check • Entertainment Systems The “Microphone Check” allows to check the input signals of the microphone. M5_09077 1 PTT switch status 2 3 Microphone input level judging Microphone level Please Push Switch = Voice recognition button is not pressed OK = Voice recognition button is pressed Blue indicator = spoken word is above the threshold Indicates input level of the microphone by a bar graph Service Training Mazda5 09-91 .

Entertainment Systems Vehicle Sensors • Body & Accessories The option “Vehicle Sensors” allows the sensor signals of the navigation system to be checked. M5_09078 1 REV Shows whether the reverse gear signal is ON or OFF (reverse gear signal is also ON when display switches to rear view camera) Displays the number of vehicle speed pulses for a specified distance and the calculated speed Displays the gyro voltage and the relative angle calculated according to the voltage 2 SPD 3 GYRO 09-92 Service Training Mazda5 .

a time of 65536 hours is set) Displays the elapsed usage distance (in km) of the navigation (if the maximum distance value is exceeded. a distance of 1048576 km is set) 2 Use accumulation time 3 Accumulation Mileage Service Training Mazda5 09-93 .Body & Accessories History • Entertainment Systems The option “History” allows the usage of the navigation system in the past to be checked. M5_09079 1 Use Start date Displays the date on which the navigation was used for the first time Displays the elapsed usage time of the navigation (if the maximum time value is exceeded.

M5_09080 Product Version • The option “Products Version” allows the hardware and software version of the navigation system to be checked. M5_09081 09-94 Service Training Mazda5 .Entertainment Systems Remote Control Test • Body & Accessories The “Remote Control Test” allows the buttons of the control panel/remote control to be checked. The display informs the technician how to proceed after the test has been selected.

M5_09081 Service Training Mazda5 09-95 .Body & Accessories Error Code • Entertainment Systems The option “Error Code” allows DTCs stored in the navigation system to be inspected.

Auto power off. When the source is changed (for example from an external device like a video game.Entertainment Systems Rear Entertainment System Features • • • • • Body & Accessories The RES (Rear Entertainment System) unit consists of a DVD/CD player and built in display. to DVD (Digital Versatile Disc )). An infrared remote control is provided to operate the RES. The RES unit also has the following features: – – – Automatic muting. The remote control can be used in the front or rear of the car. an input for external devices (such as video games) is provided behind the second row seats. or listened to using infrared type wireless headphones (purchased separately). In addition. Automatic dimming. When the RES display is closed during operation the power is automatically switched off. sound and picture are stopped for 0. Audio from the RES can be played back through the vehicle audio system.5 seconds to prevent noise. Specifications Item Rated voltage Output impedance Display Size Type (V) (ohm) (inch) Specification 12 Less than 1000 7 TFT (full-colour) M5_09T015 09-96 Service Training Mazda5 . The RES display will be dimmed when the headlight switch is ON.

MP3) Service Training Mazda5 09-97 .Body & Accessories Parts Location Entertainment Systems M5_09043 1 2 3 4 Remote control Rear speaker RES unit Front door speaker 5 6 7 Tweeter Auxiliary terminal unit Audio unit DVD/CD Playback • The below DVD/CD formats can be played back: – – – – 12 cm or 8 cm DVD-VIDEO (PAL format. Region Code ‘2’ or ‘ALL’) 12 cm or 8 cm Video-CD (PAL format) CD-R (CD-AUDIO. MP3) CD-RW (CD-AUDIO.

5 V. right. operation of the DVD/CD player or display will be automatically stopped to prevent possible malfunctions. subtitle/spoken language) Parent lock setting (when available on DVD) DVD movie camera angle (when available on DVD) DVD movie screen size Picture quality Sound output balance (left.Entertainment Systems Customisation • Body & Accessories The following DVD preset and playback settings can be changed using the remote control: – – – – – – Language (menu language. The cooling fan switches on when the internal temperature of the RES unit reaches approximately 50°C. operation of the RES will be automatically stopped and “Battery Error” displayed on the display if supply voltage drops below 9. Operation will be recommenced when the temperature has dropped to a second threshold. Item DVD/CD player Display Operation Stopped Approximately 88° C Approximately 95° C Operation Resumed Approximately 70° C Approximately 85° C Cooling Function • • The RES unit incorporates an internal cooling fan to control the internal temperature. 09-98 Service Training Mazda5 . or both) Overheat Protection Function • If the internal temperature of the DVD/CD player or display exceeds the threshold. Low Voltage Detection Function • To prevent malfunctions. and switches off when the temperature drops to approximately 40°C .

Reference lines showing the estimated course of the vehicle. When the driver selects reverse gear while the ignition is in the ON position. processed by the module and reflected as different coloured lines on the display. • • • • Service Training Mazda5 09-99 . Information from the steering angle sensor is received by the rear view monitor control module via the HS-CAN. as well as vehicle width reference lines are overlaid onto the image. the LCD (Liquid Crystal Display) unit (integrated with the car navigation system) and the reverse light switch. As the steering wheel is turned. the estimated course of the vehicle is changed on the display.Body & Accessories Rear View Monitor • Entertainment Systems The rear view monitor consists of the rear view monitor control module. the steering angle sensor. the rear camera switches on and displays the area behind the vehicle on the car navigation display. the rear camera.

Entertainment Systems Parts Location Body & Accessories M5_09044 1 2 3 Steering angle sensor LCD unit Rear view monitor control module 4 5 Car-navigation unit Rear camera System Overview M5_09045 1 2 3 Car-navigation unit LCD unit Rear view monitor control module 4 5 6 Steering angle sensor Rear camera Back-up light switch (MTX) 09-100 Service Training Mazda5 .

• These lines indicate the anticipated vehicle course. Line Color Red 1 Distance indication lines Yellow Description • This line indicates about 0. • This line indicates about 1 m {3.5 m {1.64 ft} from the end of rear bumper.64 ft} from the end of rear bumper. • These lines indicate the vehicle width. • It moves according to steering operation. to assist the driver when reversing into a parking space: M5_09046 No. • They move according to steering operation. M5_09T016 2 Distance indication line Vehicle with indication lines Green 3 Green Yellow 4 Anticipated course line Service Training Mazda5 09-101 . • It moves according to steering operation.Body & Accessories Reference Lines • Entertainment Systems The following reference lines are superimposed on the image provided by the back camera.28 ft} from the end of rear bumper. • This line indicates about 0. • It does not move according to steering operation. • They do not move according to the steering operation.5 m {1.

rear camera or liftgate. The initialization mode can be entered by conducting the following procedure: Turn the audio unit off and turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position while pressing the “MODE” switch on the steering wheel audio control. release the “MODE” switch and press the volume switches on the steering wheel in the following order: VOL+→VOL-→VOL+→VOL-→VOL+→VOL 1. and hold for approximately 2 seconds. the rear view monitor control module must be initialized. When “Input Check” is displayed on the car navigation display. 2. 09-102 Service Training Mazda5 . 3.Entertainment Systems Rear View Monitor Control Module Initialization • Body & Accessories When replacing the rear view monitor control module.

Service Training Mazda5 09-103 .Body & Accessories Instrumentation/Driver Information System Features • Control System The construction and operation of the instrumentation/driver information system is essentially the same as that on the Mazda3 (BK) except for the following: – – – – Mileage data is uploaded into new instrument cluster during configuration procedure. Code numbers for instrument cluster input/output check mode have been changed. Information display is now connected to the MS-CAN bus. Seat belt warning with occupancy sensor has been adopted for passenger’s seat.

500—8.Instrumentation/Driver Information Specifications Item Meter type Indication range Input signal source Rated voltage Meter type Indication range Tachometer Red zone Input signal communication system Input signal source Rated voltage Meter type Fuel gauge Input signal communication system Input signal source Rated voltage Meter type Water temperature gauge Input signal communication system Input signal source Rated voltage Display Indication digits Odometer/ Tripmeter Input signal communication system Input signal source Rated voltage (V) (V) (V) (V) (rpm) (rpm) (V) (mph {km/h}) Speedometer Input signal communication system Body & Accessories Specification Stepper motor type 0—143 {0—230} CAN system PCM DC 12 Stepper motor type 0—8.000—6.000 (L8. LF) 5.000 (MZR-CD) 6. LF).000 (MZR-CD) CAN system PCM DC 12 Stepper motor type (Reset-to-zero type) Conventional communication system Fuel gauge sender unit DC 12 Stepper motor type (Medium range stabilized type) CAN system PCM DC 12 LCD Odometer: 6 digits. Tripmeter: 4 digits CAN system PCM DC 12 M5_09T017 09-104 Service Training Mazda5 .000 (L8. 0—6.

Body & Accessories Instrument Cluster • Control System The instrument cluster features LEDs for the warning and indicator lights.and the MS-CAN bus. M5_09085 Service Training Mazda5 09-105 . It is connected to the HS.

Instrumentation/Driver Information No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 1: 2: 1 2 1 2 Body & Accessories CAN system x x x x x x x x x – x – x x – – – – – – x x x x x x – Item EHPAS warning light DSC OFF light Brake system warning light DSC indicator light High-beam indicator light Turn signal light Cruise set indicator light Seat belt warning light Door ajar warning light Front fog indicator light Cruise main indicator light Generator warning light Oil pressure warning light Washer fluid level warning light Headlight auto leveling warning light Fuel-level warning light Rear fog indicator light Security light Keyless indicator light Keyless warning light MIL ABS warning light Glow indicator light DPF indicator light Airbag system warning light MZR-CD L8. LF Input signal source EHPAS control module DSC HU/CM • DSC HU/CM • ABS HU/CM DSC HU/CM BCM BCM PCM Buckle switch BCM Front fog light relay PCM PCM Oil pressure switch Washer fluid level sensor Auto leveling control module Fuel gauge sender unit Rear fog light relay – Keyless control module Keyless control module PCM • DSC HU/CM • ABS HU/CM PCM PCM SAS unit M5_09T018 09-106 Service Training Mazda5 .

Body & Accessories Input/Output Check Mode 1. Control System To enter the input/output check mode. Keep pressing the odometer/tripmeter switch until “test” is displayed on the odomoter/tripmeter display. turn the ignition switch to ON while pushing the odometer/ tripmeter switch. M5_09T029 Service Training Mazda5 09-107 . Check Code 1 8 12 13 14 16 22 23 25 26 31 32 57 58 59 Driver’s buckle switch TNS relay Speedometer Tachometer Buzzer Fuel level warning light Fuel gauge sender unit Fuel gauge Water temperature gauge Odometer display and warning lights controlled by CAN Key reminder switch Indicator buzzer Panel light control • • • • Passenger-side buckle switch Occupancy sensor CAN system Fuel gauge sender unit Item 2. Press the odometer/tripmeter switch to move from one check mode to the next.

The new module must display less than 100 km for the mileage data to be uploaded. 09-108 Service Training Mazda5 . all data other than the mileage will have been uploaded into the new instrument cluster. During this procedure the mileage is uploaded into the new instrument cluster. If a module with more than 100 km is configured. In this situation. To do this. the new cluster has to be configured. NOTE: Configuring of the instrument cluster can only be conducted once. connect the WDS to the vehicle and select the option Toolbox→Module Programming→Programmable Module Installation→IC. WDS will display an error message after configuring and indicate that the procedure failed.Instrumentation/Driver Information Configuring Instrument Cluster • Body & Accessories When replacing the instrument cluster. so the configuration is actually successful.

M5_09048 1 2 3 4 Instrument cluster Microcomputer Timer Buzzer 5 6 7 8 Buckle switch (driver side) Seat occupancy sensor (passenger side) Buckle switch (passenger side) AND logic circuit Driver’s Seat Belt Warning • For the control of the driver’s seat belt warning. the signal from the driver’s seat belt buckle is used. the switch closes and a ground signal is sent to the instrument cluster. Service Training Mazda5 09-109 . When the driver’s seat belt is unbuckled.Body & Accessories Seat Belt Warning • Control System Seat belt warnings are provided for both the driver’s seat and the passenger’s seat. The operation of the seat belt warning light and warning chime is controlled by the instrument cluster.

The below table shows the operation of the warning light and chime (with both driver’s and passenger’s seats occupied). Depending on the vehicle speed and driver’s/passenger’s seat belt buckle switch status.Instrumentation/Driver Information Passenger’s Seat Belt Warning • Body & Accessories For the control of the passenger’s seat belt warning. even if the vehicle speed drops below 20 km/h before 90 seconds has elapsed. 09-110 Service Training Mazda5 . the seat belt warning light will be illuminated and the warning chime operated. both switches close and a ground signal is sent to the instrument cluster. The occupancy sensor is located on the seat cushion. Vehicle speed Condition Between 0 – 20 km/h (0 – 12 mph) 20 km/h (12mph) or more • • Driver seat belt Passenger seat belt Seat belt warning light Warning chime : Fastened : Unfastened : Illuminated : Flashing : Beep M5_09T019 • The chime will continue sounding for 90 seconds. and informs the instrument cluster whether the seat is occupied or not. the signal from the passenger’s seat belt buckle switch and an additional seat occupancy sensor is used. If the occupancy sensor detects a load of approximately 15 kg or more. and the passenger’s seat belt is unbuckled.

Check code 01 Signal output part Information display • Audio unit • Climate control module • Instrument cluster LCD TNS relay Malfunction location CAN system communication error 02 03 04 Communication error to signal output part – • TNS relay • BCM • TNS signal wiring harness • Ambient temperature sensor • Ambient temperature signal wiring harness M5_09T020 05 Ambient temperature sensor • 1. and driver information such as fuel economy data. By using the input/output check mode.Body & Accessories Information Display • • Control System The information display indicates information for the audio system. use the following procedure: Switch the ignition ON while pressing the CLOCK and INFO buttons. To enter the input/output check mode. 2. different check codes can be selected to confirm the operating condition of the input and output devices for the information display. Press the INFO button to move from one check code to the next. Keep pressing the CLOCK and INFO buttons until “test” is displayed on the information display. Information between the information display and other modules is exchanged via the MS-CAN bus. “end” will be displayed on the information display. climate control system. 3. To repeat the test the ignition must be switched OFF once and the above procedure repeated. Input/Output Check Mode • An input/output check mode is provided to allow diagnostics of the information display. Service Training Mazda5 09-111 . When all the check codes have been displayed.

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

Body Control Module • • The BCM is installed on the passenger’s side underneath the dashboard. Controller Area Network with HS-CAN and MS-CAN bus communication.Body & Accessories Control System Features • Control System With the introduction of the Mazda5 (CR) a new control system for body electrics has been adopted. It exchanges information with other modules via the MS-CAN bus. The BCM incorporates the following relays: – – – – • Front wiper relay Front wiper high relay Door lock relay Door unlock relay The BCM controls the following systems: – – – – – Lighting system Wiper and washer Power door lock system Keyless Entry system (except for vehicles equipped with Advanced Keyless Entry system) Rear defroster Service Training Mazda5 09-113 . It has the following features: – – – A Body Control Module has been adopted. An interior fuse box separate to the Body Control Module (at end of instrument panel on passenger’s side).

after which it drops to approximately 20 mA.Control System BCM Location Body & Accessories M5_09050 1 BCM NOTE: The BCM does not require configuring when it is replaced. NOTE: Directly after switching off the ignition a current draw of approximately 180 mA for 30 minutes is normal. 09-114 Service Training Mazda5 .

Body & Accessories On-board Diagnostic System • Control System The on-board diagnostic system consists of the following functions: – – Self test PID monitor Self Test • • • The self test function allows BCM DTCs to be displayed on WDS. the following conditions must first be met: – – – – Ignition switch ON All switches other than ignition switch OFF All doors. To conduct the self test. connect WDS to the vehicle and select the option Toolbox→Self Test→Modules→GEM. When the ignition is switched off. trunk lid and liftgate are closed and unlocked Park brake is engaged Service Training Mazda5 09-115 . bonnet. To do this. DTCs stored by the self test will be deleted.

Item Description Climate control unit (A/C switch) Light switch (AUTO) Parking brake switch.Control System PID Monitor • Body & Accessories The PID monitor function allows BCM PIDs to be displayed. brake fluid level sensor Number of DTCs Driver's door lock-link switch Front fog light switch Hazard warning switch Light switch (high beam) Light switch (low beam) Front door latch switch (LH) Light switch (TNS) Rear fog light switch Climate control unit (rear window defroster switch) Sliding door switch Front door latch switch (RH) Liftgate latch switch Turn signal switch Windshield wiper and washer switch (washer) Windshield wiper and washer switch (high) Windshield wiper and washer switch (INT or AUTO) Rear wiper and washer switch (INT) Windshield wiper motor (auto stop switch) Windshield wiper and washer switch (low) Unit/Condition On/Off On/Off On/Off – LOCK/UNLOCK On/Off On/Off On/Off On/Off Open/Close On/Off On/Off On/Off Open/Close Open/Close Open/Close On/Off On/Off On/Off On/Off On/Off On/Off On/Off ACSW AUTOLMP BRK_WRN CCNT_GE DD_LOCK F_FOG_LMP HAZARD HBEAMSW HEADLAMP LF_AJAR PARK_SW R_FOG_LMP RDEF_SW REAR_AJAR RF_AJAR T_AJAR TURN_SW WASH_FRT WPFAST_FRT WPINT_FRT WPINT_REAR WPRPRKSTS WP_SW_FRT M5_09T021 09-116 Service Training Mazda5 . To do this. connect WDS to the vehicle and select the option Toolbox→Datalogger→Modules→GEM.

Service Training Mazda5 09-117 . The instrument cluster is connected to both networks and operates as portal.Body & Accessories Controller Area Network • Control System The Mazda5 uses an MS-CAN (Middle Speed-Controller Area Network) and an HS-CAN (High Speed-Controller Area Network) for transmission of multiplex input/output signals between electrical modules. similar to the Mazda3. allowing information exchange between the MS-CAN and the HS-CAN.

Control System Body & Accessories M5_09051 1 2 3 4 5 6 7 8 9 PCM (MZR-CD) PCM (L8. LF) DSC HU/CM (with DSC) ABS HU/CM (with ABS) Rear view monitor control module Keyless control module (with Advanced Keyless Entry system) EHPAS control module (with L8/LF engine) Instrument cluster Twisted pair 10 11 12 13 14 15 16 17 Climate control unit (with full-auto A/C) Information display Water heater unit (with MZR-CD engine) Audio unit (base module) DLC-2 BCM CAN-H CAN-L 09-118 Service Training Mazda5 .

RF. Multiplex module EHPAS control module (L8. LF) Brake system status (EBD/ABS/DSC) Wheel speed (LF.Body & Accessories HS-CAN Signal Chart • The following signals are transmitted via the HS-CAN bus. LF) IN IN IN IN – – – – – – – – – – – – – – OUT – – – – DSC HU/CM Rear view monitor control module – – – – – – – – – – – – – – – – IN – – – – – Control System Signal PCM ABS HU/CM IN – – IN – IN – IN – IN – IN OUT IN – – – – – – – – OUT – OUT OUT OUT OUT Keyless control module IN IN – – – – – – – – – – – – – – – – – – – – Instrument cluster Engine speed Vehicle speed Neutral switch position Engine torque Accelerator pedal position Brake pedal position Transaxle specifications Tire circumference Engine specifications Immobilizer-related information Engine coolant temperature Travelled distance Fuel injection amount MIL on request Generator warning light on request Cruise main/set indicator light on request Steering angle EHPAS control module malfunction (L8. LR. RR) Brake system warning light on request ABS warning light on request OUT OUT OUT OUT OUT OUT IN OUT OUT IN OUT OUT IN OUT OUT OUT OUT OUT OUT – – IN IN – – IN IN – – – – OUT – – – IN OUT IN IN IN IN IN IN – IN – – IN IN M5_09T022-1 Service Training Mazda5 09-119 .

LF) – – – – – – – IN – – DSC HU/CM Rear view monitor control module – – – – – – – – – – Keyless control module Signal PCM Instrument cluster ABS HU/CM OUT OUT – – – – – – – – DSC indicator light on request DSC OFF light on request Keyless warning/indicator light on request Keyless warning buzzer on request Fuel tank level A/C on request Transaxle in reverse position Parking brake position Glow indicator light (MZR-CD) DPF indicator light (MZR-CD) – – – – IN IN IN – OUT OUT – – OUT OUT – – – – – – IN IN IN IN OUT OUT OUT OUT IN IN M5_09T022-2 09-120 Service Training Mazda5 .Control System Body & Accessories Multiplex module EHPAS control module (L8.

Multiplex module Signal Body control module OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN OUT IN OUT IN – – IN – – IN IN – – – Climate control unit IN IN – – – – – – – – OUT IN OUT – OUT OUT OUT – – – Information display – – – – – – – – – – – – – – – – – – – IN IN IN IN Audio unit (base module) – – – – – – – – – – – – – – – – – – – IN – IN – Control System Water heater unit – – – – – – – – – – – – IN – – – – – – – – IN – Instrument cluster – IN IN IN IN IN IN IN IN – – IN – – – OUT – IN OUT OUT OUT OUT OUT M5_09T023 Front wiper status TNS status Door lock status Turn signal light on request Security light on request Alarm on request Each door status Brake fluid level High-beam indicator light on request Parking brake position Rear window defroster on request A/C on request Ambient temperature A/C Status display request Temparature measuring unit Audio status display request Water heater fuel consumption Engine speed Vehicle speed Engine coolant temperature Ignition key position Driver information system data IN IN IN – Service Training Mazda5 09-121 .Body & Accessories MS-CAN Signal Chart • The following signals are transmitted via the MS-CAN bus.

09-122 Service Training Mazda5 .Control System On-board Diagnostic System • Body & Accessories The on-board diagnostic system is essentially the same as the Mazda3. except for the following: – CAN related DTCs can now be stored in the information display and Keyless Control Module as these modules are now connected to the area network.

List of Abbreviations ABS Acrylonitrile-ButadieneStyrene CAN-L CAN-Low CD ABS Anti-lock Brake System CKP ABDC After Bottom Dead Center CMDTC A/C Air Conditioning CMP ALC Auto Level Control CPP APP Accelerator Pedal Position CPU AT Automatic Transmission CRS ATDC After Top Dead Center DC ATX Automatic Transaxle DLC BARO Barometric Pressure DSC BBDC Before Bottom Dead Center D-PATS BCM Body Control Module DPF BTDC Before Top Dead Center DRGS CAN Controller Area Network Compact Disc Crankshaft Position Continuous Memory DTC Camshaft Position Clutch Pedal Position Central Processing Unit Child Restraint Seat Direct Current Data Link Connector Dynamic Stability Control Distributed-PATS Diesel Particulate Filter Dynamic Route Guidance System CAN-H CAN-High DTC Diagnostic Trouble Code Service Training Mazda5 .

List of Abbreviations DVD Digital Versatile Disc HDD Hard Disc Drive EBD Electronic Brake Force Distribution HI High HO2S ECT Engine Coolant Temperature HS-CAN EGR Exhaust Gas Recirculation HU/CM EGRVP EGR Valve Position HVAC EHPAS Electro Hydraulic Power Assist Steering IAC ELR Emergency Locking Retractor IAT EVAP Evaporative Emission IC FEEPROM Flash Electronically Erasable Programmable ROM Heated O2 Sensor High-Speed CAN Hydraulic Unit/Control Module Heater. Ventilation & Air Conditioning Idle Air Control Intake Air Temperature Instrument Cluster ID Identification GMR Giant Magneto Resistance IG Ignition GND Ground ISV Intake Shutter Valve GPS Global Positioning System KOEO Key On Engine Off GR Gear Ratio KOER Key On Engine Running Service Training Mazda5 .

List of Abbreviations KS Knock Sensor MOS-FET Metal Oxide Semiconductor Field Effect Transistor LCD Liquid Crystal Display MP3 Moving Picture Experts Group Layer-3 LED Light Emitting Diode MS-CAN Middle-Speed CAN LF Left Front MTX Manual Transaxle LH Left Hand NOx Nitrous Oxide LO Low NTC Negative Temperature Coefficient LR Left Rear MAF Mass Air Flow NVH Noise. Vibration & Harshness MAP Manifold Absolute Pressure OBD On Board Diagnostics MAV Multi Activity Vehicle OCV Oil Control Valve MAIDAS Mazda Advanced Impact Distribution and Absorption System PAD Passenger Airbag Deactivation MD Mini Disc PATS Passive Anti-Theft System MD-LP Mini Disc Long Play PCM Powertrain Control Module MIL Malfunction Indicator Light PCV Positive Crankcase Ventilation Service Training Mazda5 .

Number & Side lights RGB Red. Green. Blue TP Throttle Position RH Right Hand TR Transmission Range ROM Read-Only Memory Tx Transmitter (line) RR Right Rear VBC Variable Boost Control Rx Receiver (line) VIN Vehicle Identification Number SAPS Sulphate Ash. Sulphur VIS Variable Intake-air System Service Training Mazda5 .List of Abbreviations PID Parameter Identification SAS Sophisticated Airbag Sensor PJB Passenger Junction Box SST Special Service Tool P/S Power Steering TCC Torque Converter Clutch PSP Power Steering Pressure TCS Traction Control System P/W CM Power Window Control Module TDC Top Dead Center RDS Radio Data System TFT Transmission Fluid Temperature RES Rear Entertainment System TMC Traffic Message Channel RF Right Front TNS Tail. Phosphor.

List of Abbreviations VSS Vehicle Speed Sensor VTCS Variable Tumble Control System WDS Worldwide Diagnostic System WU-TWC Warm Up Three-Way Catalyst Service Training Mazda5 .

List of Abbreviations Service Training Mazda5 .