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BACK TO MAIN INDEX MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
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GROUP
General Information 1
SECTION TITLE PAGE
Service Information
General Information.......................................................................................................100-00
Identification Codes.......................................................................................................100-01
Jacking and Lifting.........................................................................................................100-02
Noise, Vibration and Harshness....................................................................................100-04
2011.50 BT50
TO MODEL INDEX
(96kW/130PS) - Puma/2.2L Electrical Distribution

Duratorq-TDCi (110kW/150PS) - Module Communications
Puma/3.2L Duratorq-TDCi Network 418-00
(148kW/200PS) - Puma 310-00B Module Configuration 418-01
Fuel Tank and Lines 310-01A Wiring Harnesses 418-02
Fuel Tank and Lines - 2.2L Electronic Feature Group
Duratorq-TDCi (88kW/120PS) -
Anti-Theft - Active 419-01A
Puma/2.2L Duratorq-TDCi
Anti-Theft - Passive 419-01B
(96kW/130PS) - Puma/2.2L
Multifunction Electronic
Modules 419-10
(148kW/200PS) - Puma 310-01B
Acceleration Control 310-02 GROUP 5 Body and Paint
GROUP 4 Electrical Body and Paint

Body System - General
Climate Control System Information 501-00
Front End Body Panels 501-02
Climate Control System - General
Body Closures 501-03
Information 412-00
Interior Trim and
Climate Control 412-01
Ornamentation 501-05
Auxiliary Climate Control 412-02
Rear View Mirrors 501-09
Instrumentation and Warning Systems Seating 501-10
Instrument Cluster 413-01 Glass, Frames and
Horn 413-06 Mechanisms 501-11
Warning Devices 413-09 Instrument Panel and Console 501-12
Parking Aid 413-13 Handles, Locks, Latches and Entry
Battery and Charging System Systems 501-14
Charging System - General Wipers and Washers 501-16
Information 414-00 Bumpers 501-19
Battery, Mounting and Cables 414-01 Safety Belt System 501-20A
Generator and Regulator 414-02 Supplemental Restraint
System 501-20B
Information and Entertainment Systems Body Repairs - General
Information and Entertainment System Information 501-25
- General Information 415-00 Body Repairs - Vehicle Specific
Information and Entertainment Information and Tolerance
System 415-01 Checks 501-26
Lighting Front End Sheet Metal Repairs 501-27
Exterior Lighting 417-01 Roof Sheet Metal Repairs 501-28
Interior Lighting 417-02 Side Panel Sheet Metal
Daytime Running Lamps Repairs 501-29
(DRL) 417-04 Rear End Sheet Metal Repairs 501-30
Paint - General Information 501-36
2011.50 BT50
TO MODEL INDEX
(110kW/150PS) - Puma/3.2L Transmission/Transaxle

Duratorq-TDCi (148kW/200PS) - Cooling 307-02
Puma 303-05B Automatic Transmission/Transaxle
Starting System - 2.5L Duratec-HE External Controls 307-05
(122kW/165PS) - MI4 303-06A Manual Transmission/Transaxle, Clutch and
Starting System - 2.2L Duratorq-TDCi Transfer Case
(88kW/120PS) - Puma/2.2L Manual Transmission/Transaxle and
Duratorq-TDCi (96kW/130PS) - Clutch - General Information 308-00
Puma/2.2L Duratorq-TDCi Clutch - Vehicles With: 5-Speed Manual
(110kW/150PS) - Puma/3.2L Transmission - MT75 308-01A
Duratorq-TDCi (148kW/200PS) - Clutch - Vehicles With: 6-Speed Manual
Puma 303-06B Transmission - MT82 308-01B
Engine Ignition - 2.5L Duratec-HE Clutch Controls - Vehicles With:
(122kW/165PS) - MI4 303-07A 5-Speed Manual Transmission -
Glow Plug System - 2.2L Duratorq-TDCi MT75 308-02A
(88kW/120PS) - Puma/2.2L Clutch Controls - Vehicles With:
Duratorq-TDCi (96kW/130PS) - 6-Speed Manual Transmission -
Puma/2.2L Duratorq-TDCi MT82 308-02B
(110kW/150PS) - Puma 303-07B Manual Transmission/Transaxle -
Glow Plug System - 3.2L Duratorq-TDCi Vehicles With: 5-Speed Manual
(148kW/200PS) - Puma 303-07C Transmission - MT75 308-03A
Engine Emission Control - 2.2L Manual Transmission/Transaxle -
Duratorq-TDCi (88kW/120PS) - Vehicles With: 6-Speed Manual
Puma/2.2L Duratorq-TDCi Transmission - MT82 308-03B
(96kW/130PS) - Puma/2.2L Manual Transmission/Transaxle
Duratorq-TDCi (110kW/150PS) - External Controls - Vehicles With:
Puma/3.2L Duratorq-TDCi MT-75 308-06A
(148kW/200PS) - Puma 303-08A Manual Transmission/Transaxle
Engine Emission Control 303-08B External Controls - Vehicles With:
Intake Air Distribution and Filtering - MT82 308-06B
2.5L Duratec-HE (122kW/165PS) - Transfer Case - Vehicles With: 5-Speed
MI4 303-12A Manual Transmission -
Intake Air Distribution and Filtering - MT75/6-Speed Manual Transmission
2.2L Duratorq-TDCi (88kW/120PS) - - MT82 308-07A
Puma/2.2L Duratorq-TDCi Transfer Case - Vehicles With: 6-Speed
(96kW/130PS) - Puma/2.2L Automatic Transaxle -
Duratorq-TDCi (110kW/150PS) - 6R80 308-07B
(148kW/200PS) - Puma 303-12B Exhaust System
Evaporative Emissions 303-13 Exhaust System - 2.5L Duratec-HE
Electronic Engine Controls - 2.5L (122kW/165PS) - MI4 309-00A
Duratec-HE (122kW/165PS) - Exhaust System - 2.2L Duratorq-TDCi
MI4 303-14A (88kW/120PS) - Puma/2.2L
Electronic Engine Controls - 2.2L Duratorq-TDCi (96kW/130PS) -
Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (148kW/200PS) -
Duratorq-TDCi (110kW/150PS) - Puma 309-00B
Puma/3.2L Duratorq-TDCi Fuel System - General Information
(148kW/200PS) - Puma 303-14B Fuel System - General Information -
Automatic Transmission/Transaxle 2.5L Duratec-HE (122kW/165PS) -
Automatic Transmission/Transaxle - MI4 310-00A
Vehicles With: 6-Speed Automatic Fuel System - General Information -
Transaxle - 6R80 307-01 2.2L Duratorq-TDCi (88kW/120PS) -
2011.50 BT50
BACK TO FOREWORD & FRONT PAGE MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
TO MODEL INDEX
Workshop Manual
Table of Contents
GROUP 1 General Information GROUP 3 Powertrain
Service Information Engine
General Information 100-00 Engine System - General
Identification Codes 100-01 Information 303-00
Jacking and Lifting 100-02 Engine - 2.5L Duratec-HE
Noise, Vibration and (122kW/165PS) - MI4 303-01A
Harshness 100-04 Engine - 2.2L Duratorq-TDCi
(88kW/120PS) - Puma/2.2L
GROUP 2 Chassis Duratorq-TDCi (96kW/130PS) -
Suspension (110kW/150PS) - Puma 303-01B
Engine - 3.2L Duratorq-TDCi
Suspension System - General (148kW/200PS) - Puma 303-01C
Information 204-00 Engine Cooling - 2.2L Duratorq-TDCi
Front Suspension 204-01 (88kW/120PS) - Puma/2.2L
Rear Suspension 204-02 Duratorq-TDCi (96kW/130PS) -
Wheels and Tires 204-04 Puma/2.2L Duratorq-TDCi
Driveline (110kW/150PS) - Puma 303-03A
Driveshaft 205-01 Engine Cooling - 3.2L Duratorq-TDCi
Rear Drive Axle/Differential 205-02 (148kW/200PS) - Puma 303-03B
Front Drive Axle/Differential 205-03 Engine Cooling 303-03C
Front Drive Halfshafts 205-04 Fuel Charging and Controls - 2.5L
Rear Drive Halfshafts 205-05 Duratec-HE (122kW/165PS) -
Brake System MI4 303-04A
Brake System - General Fuel Charging and Controls - 2.2L
Information 206-00 Duratorq-TDCi (88kW/120PS) -
Drum Brake 206-02 Puma/2.2L Duratorq-TDCi
Front Disc Brake 206-03 (96kW/130PS) - Puma/2.2L
Parking Brake and Actuation 206-05 Duratorq-TDCi (110kW/150PS) -
Hydraulic Brake Actuation 206-06 Puma 303-04B
Power Brake Actuation 206-07 Fuel Charging and Controls - 3.2L
Anti-Lock Control 206-09A Duratorq-TDCi (148kW/200PS) -
Anti-Lock Control - Traction Puma 303-04C
Control 206-09B Fuel Charging and Controls -
Turbocharger 303-04D
Steering System Accessory Drive - 2.5L Duratec-HE
Steering System - General (122kW/165PS) - MI4 303-05A
Information 211-00 Accessory Drive - 2.2L Duratorq-TDCi
Power Steering 211-02 (88kW/120PS) - Puma/2.2L
Steering Linkage 211-03 Duratorq-TDCi (96kW/130PS) -
Steering Column 211-04 Puma/2.2L Duratorq-TDCi
Steering Column Switches 211-05
2011.50 BT50
BACK TO FRONT PAGE MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
VIEW MAIN INDEX
FOREWORD
To the best of our knowledge, the illustrations,

technical information, data and descriptions in
this issue were correct at the time of going to
print. The right to change prices, specifications,
equipment and maintenance instructions at
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FMCSA policy of continuous development and
improvement for the benefit of our customers.
No part of this publication may be reproduced,

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transmitted in any form, electronic, mechanical,
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been taken to make it as complete and
accurate as possible.
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6
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FRONT WHEEL ALIGNMENT
id021100800200
Front wheel alignment (Unloaded)*1 [4x2]

Specifications
Except high clearance model
Item
Freestyle cab, double High clearance model
Regular cab
cab
Maximum steering angle Inner 41°24′ 38°00′
[Tolerance ±3°] Outer 35°30′ 33°00′
Tire
0 {0}
[Tolerance ±4 {0.2}]
(mm {in})
Total toe-in Rim inner
0 {0}
(degree) 0°00′±0°00′
*2
Caster angle (Reference value) RH: 2°34′
2°53′ 3°00′
[Tolerance ±1°] LH: 3°04′
Camber angle*2 (Reference value) 0°00′
[Tolerance ±1°]
Steering axis inclination (Reference value) 12°22′ 11°06′
Front wheel alignment (Unloaded)*1 [4x4]

Item Specifications
Maximum steering angle Inner 38°00′
[Tolerance ±3°] Outer 33°00′
Tire
0 {0}
(mm {in})
Total toe-in Rim inner
0 {0}
(degree) 0°00′±0°00′
Caster angle*2 (Reference value) RH: 2°34′
[Tolerance ±1°] LH: 3°04′
[Tolerance ±1°]
Steering axis inclination (Reference value) 11°06′
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.
Steering Angle Adjustment

1. Loosen the tie-rod end locknuts.
2. Remove the steering gear boot clamp.
3. Turn the tie rods.
Standard length L
11.1—29.1 mm {0.44—1.14 in}
4. Turn the tie rods equally to provide the correct L

maximum steering angle.
5. Tighten the tie-rod end locknuts.
Tightening torque
68—92 N·m {7.0—9.3 kgf·m, 51—67 ft·lbf}
6. Verify that the boot is not twisted, and install the boot abs0zw00000589
clamp.
7. Adjust the toe-in after adjusting the steering angle.
TO MODEL INDEX
Camber Adjustment
1. Loosen the front upper arm nut. FRONT
UPPER
ARM
NUT
abs0zw00000590
2. Loosen the fixing nut of the adjusting cam bolt (front 4x2 (EXCEPT HIGH CLEARANCE
lower arm). MODEL)
4x2 (HIGH CLEARANCE

MODEL), 4x4
FIXING NUT
FIXING NUT
abs0zw00001252
3. Rotate the adjusting cam bolt in either direction to adjust the camber.
4×2 (Except high clearance model)
Left wheel Right wheel LEFT WHEEL FRONT OF RIGHT WHEEL
Camber Front Front VEHICLE
Rear cam Rear cam TOP OF TOP OF
cam cam VEHICLE VEHICLE
Positive Counter- Counter-
Clockwise Clockwise
direction clockwise clockwise
Negative Counter- Counter-
Clockwise Clockwise
POSITIVE POSITIVE
ADJUSTING
CAM BOLT
TOP OF TOP OF
VEHICLE VEHICLE
ADJUSTING
CAM BOLT
POSITIVE POSITIVE
abs0zw00000592
TO MODEL INDEX
4×2 (High clearance model), 4×4

VEHICLE
Camber Front Front
cam cam
VEHICLE VEHICLE
Positive Counter- Counter-
Clockwise Clockwise
direction clockwise clockwise ADJUSTING
Negative Counter- Counter- CAM BOLT
Clockwise Clockwise
POSITIVE POSITIVE
4. Tighten the front upper arm nut.
Tightening torque
141—189 N·m {15—19 kgf·m, 104—139 ft·lbf} ADJUSTING
CAM BOLT
5. Tighten the the fixing nut of the adjusting cam bolt
(front lower arm).
Tightening torque TOP OF

TOP OF
240—281 N·m {25—28 kgf·m, 178—207 ft·lbf} VEHICLE VEHICLE
6. Adjust the total toe-in. (SeeTotal Toe-in

Adjustment.)
POSITIVE POSITIVE
abs0zw00001253
Caster Adjustment
1. Loosen the front upper arm nut. FRONT
UPPER
ARM
NUT
abs0zw00000590
2. Loosen the fixing nut of the adjusting cam bolt (front 4x2 (EXCEPT HIGH CLEARANCE
lower arm). MODEL)
4x2 (HIGH CLEARANCE

MODEL), 4x4
FIXING NUT
FIXING NUT
abs0zw00001252
3. Rotate the adjusting cam bolt in either direction to adjust the caster.
TO MODEL INDEX
4×2 (Except high clearance model)

VEHICLE
Caster Front Front
cam cam VEHICLE VEHICLE
Counter- Counter-
Increase Clockwise Clockwise
clockwise clockwise
Counter- Counter-
Decrease Clockwise Clockwise
clockwise clockwise
INCREASE INCREASE
4×2 (High clearance model), 4×4

Left wheel Right wheel
Caster Front Front ADJUSTING
Rear cam Rear cam CAM BOLT
cam cam
Counter- Counter-
Increase Clockwise Clockwise
clockwise clockwise
Counter- Counter-
Decrease Clockwise Clockwise
clockwise clockwise TOP OF TOP OF
VEHICLE ADJUSTING VEHICLE
4. Tighten the front upper arm nut. CAM BOLT
Tightening torque
141—189 N·m {15—19 kgf·m, 104—139 ft·lbf} INCREASE INCREASE
5. Tighten the the fixing nut of the adjusting cam bolt abs0zw00000593
(front lower arm). LEFT WHEEL FRONT OF RIGHT WHEEL

VEHICLE
Tightening torque TOP OF TOP OF
240—281 N·m {25—28 kgf·m, 178—207 ft·lbf} VEHICLE VEHICLE
ADJUSTING
6. Adjust the total toe-in. (SeeTotal Toe-in CAM BOLT
Adjustment.)
INCREASE INCREASE
ADJUSTING
CAM BOLT
TOP OF TOP OF
VEHICLE VEHICLE
INCREASE INCREASE
abs0zw00001254
Total Toe-in Adjustment

1. Loosen the locknut of the tie-rod end.
2. Remove the rack boot clamp.
3. Adjust the total toe-in by rotating each tie rod (left and right) in the opposite directions by the same amount
respectively.
Note
• Toe angle changes by approx. 6 mm {0.2 in} per one rotation of the tie rod for one wheel.
• Each tie rod has a right-hand thread. When increasing the toe-in angle, rotate the right tie rod toward the
front of the vehicle and rotate the left tie rod toward the rear of the vehicle by the same amount.
4. Tighten the locknut of the tie-rod end.

TO MODEL INDEX
Tightening torque
68—92 N·m {7.0—9.3 kgf·m, 51—67 ft·lbf}
5. Verify that the rack boot does not have any twisting and install the rack boot clamp.
TO MODEL INDEX
REAR WHEEL ALIGNMENT

id021100800300
Rear wheel alignment (Unloaded)*1

Item Specifications
Tire
0 {0}
Total toe-in [Tolerance ±4 {±0.2}]
(mm {in})
(Reference value) Rim inner
0 {0}
[Tolerance ±3 {±0.1}]
[Tolerance ±1°]
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.
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LOAD SENSING PROPORTIONING VALVE (LSPV)

id041100200600
Purpose/Function
• This valve is used to allocate the braking force to the front and rear wheels as ideally as possible for higher safety
when the brakes are applied, it controls the brake fluid pressure to the rear brakes according to the load on the
rear axle so that the rear end of the vehicle does not spin due to the locking of the rear wheels in advance of the
front wheels.
• This valve also incorporates a bypass passage that prevents pressure reduction so that rear wheels will still have
enough braking force to stop the vehicle in the event of a front master cylinder malfunction.
Construction
REAR REAR FRONT

IN OUT IN
CUP
RETAINER BODY
BREATHER
RING VALVE VALVE
X-RING
PLUNGER
4x2 (EXCEPT HIGH

4x2 (HIGH CLEARANCE MODEL), 4x4
CLEARANCE MODEL)
BRACKET MAIN SPRING

LEVER
MAIN SPRING
AXLE L
L CASING
ADJUSTING LINK
ADJUSTING LINK
abs0zn00000103
Operation
Braking When Vehicle Empty
• The hydraulic pressure generated at the front section of the master cylinder is applied, via input port 1, to the
hydraulic-pressure control section of the LSPV.
• The hydraulic pressure generated at the rear section of the master cylinder is applied to the front brakes, and to
the bypass section of the LSPV via input port 2. The rear wheel and front wheel hydraulic pressure are separated
by the X-ring of the plunger. Since port 1 hydraulic pressure is normally equal to port 2 hydraulic pressure, the
plunger is pressed against the cylinder base by L.
• When port 1 hydraulic pressure is applied to the plunger, the plunger tries to move to the left. But, because there
is also at the same time force applied in the right direction by the lever link (force L), the plunger is held against
the cylinder base. The result is that the hydraulic pressure at the output side is the same as at the input side
when force L is higher than the input pressure.
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PORT-2
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RETAINER
PLUNGER
AXLE CASING
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• When the input hydraulic pressure increases further and overcomes force L, the plunger is moved slightly
leftward, sealing it against the ring valve. This temporarily separates the input side from the output side. The
output pressure at this time is called the break point. If force L from the lever link changes (i.e. lowering of the
vehicle body), this break point changes accordingly.
PORT-1 PORT-2
OUTPUT PRESSURE
kP
INPUT PRESSURE
PLUNGER RING VALVE
AXLE CASING
abs0zn00000105
• When the input pressure passes the break point, the plunger is moved back against the cylinder base. The output
port is opened, and hydraulic pressure generated at the rear section of the master cylinder is applied to the rear
wheel cylinders.
• As the output pressure continues to increase, the plunger is again moved toward the left against the ring valve,
thus separating the input and output side again.
• This action is repeated to control the output pressure.
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OUTPUT PRESSURE
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INPUT PRESSURE
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Braking When Vehicle Loaded

• The vehicle height (from the ground) decreases when cargo is loaded into the vehicle. This causes the force of
the spring connected to the axle casing to decrease and the force of the spring on the LSPV to increase force
L, increasing the pressure holding the plunger to the right.
• The master cylinder hydraulic pressure (input) needed to cause the plunger to move back to the left also becomes
equally higher as a result.
• This causes the break point to be increased and extra braking power is provided in accordance with the weight
of cargo loaded.
OUTPUT PRESSURE
LOADED
L kP'
EMPTY
kP
kP
INPUT PRESSURE
AXLE CASING
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If Malfunction Of Front Hydraulic System

• If there is a malfunction of the front-brake hydraulic system, the hydraulic pressure from input port 2 becomes
zero. The result is that the input pressure presses the plunger to the right, opening the bypass passage.
• The output pressure thus equals the input pressure, and there is no pressure reduction.
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SECTION TITLE PAGE
PAGE 1 OF 2
Engine
Engine System - General Information............................................................................303-00
Engine2.5L Duratec-HE (122kW/165PS) - MI4.............................................................303-01A
Engine2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-01B
Engine3.2L Duratorq-TDCi (148kW/200PS) - Puma.....................................................303-01C
Engine Cooling2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-03A
Engine Cooling3.2L Duratorq-TDCi (148kW/200PS) - Puma........................................303-03B
Engine Cooling..............................................................................................................303-03C
Fuel Charging and Controls2.5L Duratec-HE (122kW/165PS) - MI4............................303-04A
Fuel Charging and Controls2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) -
Puma..........................................................................................................................303-04B
Fuel Charging and Controls3.2L Duratorq-TDCi (148kW/200PS) - Puma....................303-04C
Fuel Charging and Controls - Turbocharger..................................................................303-04D
Accessory Drive2.5L Duratec-HE (122kW/165PS) - MI4..............................................303-05A
Accessory Drive2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L
Duratorq-TDCi (148kW/200PS) - Puma.....................................................................303-05B
Starting System2.5L Duratec-HE (122kW/165PS) - MI4...............................................303-06A
Starting System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
Engine Ignition2.5L Duratec-HE (122kW/165PS) - MI4.................................................303-07A
Glow Plug System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-07B
Glow Plug System3.2L Duratorq-TDCi (148kW/200PS) - Puma...................................303-07C
Engine Emission Control2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................303-08A
Engine Emission Control................................................................................................303-08B
Intake Air Distribution and Filtering2.5L Duratec-HE (122kW/165PS) - MI4.................303-12A
Intake Air Distribution and Filtering2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................303-12B
Evaporative Emissions...................................................................................................303-13
Electronic Engine Controls2.5L Duratec-HE (122kW/165PS) - MI4..............................303-14A
Electronic Engine Controls2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
2011.50 BT-50
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PAGE 2 OF 2
Automatic Transmission/Transaxle
Automatic Transmission/TransaxleVehicles With: 6-Speed Automatic Transaxle -
6R80...........................................................................................................................307-01
Transmission/Transaxle Cooling....................................................................................307-02
Automatic Transmission/Transaxle External Controls...................................................307-05
Manual Transmission/Transaxle, Clutch and Transfer Case
Manual Transmission/Transaxle and Clutch - General Information...............................308-00
ClutchVehicles With: 5-Speed Manual Transmission - MT75........................................308-01A
ClutchVehicles With: 6-Speed Manual Transmission - MT82........................................308-01B
Clutch ControlsVehicles With: 5-Speed Manual Transmission - MT75.........................308-02A
Clutch ControlsVehicles With: 6-Speed Manual Transmission - MT82.........................308-02B
Manual Transmission/TransaxleVehicles With: 5-Speed Manual Transmission -
MT75..........................................................................................................................308-03A
Manual Transmission/TransaxleVehicles With: 6-Speed Manual Transmission -
MT82..........................................................................................................................308-03B
Manual Transmission/Transaxle External ControlsVehicles With: MT-75.....................308-06A
Manual Transmission/Transaxle External ControlsVehicles With: MT82.......................308-06B
Transfer CaseVehicles With: 5-Speed Manual Transmission - MT75/6-Speed Manual
Transmission - MT82..................................................................................................308-07A
Transfer CaseVehicles With: 6-Speed Automatic Transaxle - 6R80.............................308-07B
Exhaust System
Exhaust System2.5L Duratec-HE (122kW/165PS) - MI4..............................................309-00A
Exhaust System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
Fuel System - General Information
Fuel System - General Information2.5L Duratec-HE (122kW/165PS) - MI4.................310-00A
Fuel System - General Information2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Fuel Tank and Lines.......................................................................................................310-01A
Fuel Tank and Lines2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
Acceleration Control.......................................................................................................310-02
2011.50 BT-50
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Suspension System - General Information....................................................................204-00
Front Suspension...........................................................................................................204-01
Rear Suspension...........................................................................................................204-02
Wheels and Tires...........................................................................................................204-04
Driveline
Driveshaft.......................................................................................................................205-01
Rear Drive Axle/Differential............................................................................................205-02
Front Drive Axle/Differential...........................................................................................205-03
Front Drive Halfshafts....................................................................................................205-04
Rear Drive Halfshafts.....................................................................................................205-05
Brake System
Brake System - General Information..............................................................................206-00
Drum Brake....................................................................................................................206-02
Front Disc Brake............................................................................................................206-03
Parking Brake and Actuation.........................................................................................206-05
Hydraulic Brake Actuation..............................................................................................206-06
Power Brake Actuation..................................................................................................206-07
Anti-Lock Control...........................................................................................................206-09A
Anti-Lock Control - Traction Control...............................................................................206-09B
Steering System
Steering System - General Information..........................................................................211-00
Power Steering...............................................................................................................211-02
Steering Linkage............................................................................................................211-03
Steering Column............................................................................................................211-04
Steering Column Switches.............................................................................................211-05
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CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (FREESTYLE CAB) [DIMENSIONS]
id098010628700
JUHDWHVW GLVWDQFH WR WKH PHDVXULQJ SRLQW 0HDVXULQJ SRLQWV DQG GLPHQVLRQV

RSSRVLWH ;; PP ;; PP
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1
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1799 {70.83}
1543 {70.83}
1516 {59.69}
6
4
5
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abs0zb00000013
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FRAME DIMENSIONS (UNDERBODY FREESTYLE CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010618100
FLAT-PLANE DIMENSIONS
mm {in}
1248 {49.13}
1270 {50.00}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
866 {34.1}
839 {33.0}
785 {30.9}
969 {38.1}
669 {26.3}
424 668 1713 492 564 452

{16.7} {26.3} {67.44} {19.4} {22.2} {17.8}
155 134
{6.10} {5.28}
STRAIGHT-LINE DIMENSIONS 241 {9.49}
770 C' D'

E' H'
461 B' {30.3} 1717 {67.60} 1191 {46.89} 604 I'
A' {23.8}
{18.2}
2019 G'
1505
{79.49} {59.25}
2129 {83.82}
LH
1326 1722 {67.80} 1258 {49.53}

{52.20} 1280 {50.39}
1045 {41.14} 2634 {103.7}
RH
1008 {39.69}
1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000006
Hole diameter Hole diameter

Point Point
Designation or bolt or nut Designation or bolt or nut
symbol symbol
size mm {in} size mm {in}
Cabin mounting bracket No.1 Cabin mounting bracket No.3
A ø15.25 {0.6004} D ø38.65 {1.522}
datum hole datum hole
B Upper arm bracket datum hole ø28.9 {1.14} Box mounting bracket No.1
E ø10 {0.39}
Cabin mounting bracket No.2 datum hole
C ø38.65 {1.522} F Damper bracket -
datum hole
G’ Damper bracket -
5DQJHU
TO MODEL INDEX
f- - - -I----+--
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Point Point
symbol symbol
I IH
Box mounting bracket No.3
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
I Side member datum hole
size mm {in}
ø6.5 {0.26}
5DQJHU
TO MODEL INDEX
FRAME DIMENSIONS (UNDERBODY REGULAR CAB 4WD) [DIMENSIONS]

id098010618300
mm {in}
1248 {49.13}
1314 {51.73}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
969 {38.2}
869 {34.2}
839 {33.0}
670 {26.4}
669 {26.3}
424 668 1228 938 564 452

{16.7} {26.3} {48.35} {36.9} {22.2} {17.8}
194 134
{7.64} {5.28}
STRAIGHT-LINE DIMENSIONS
770 C' D'

1229 {48.39} 985 {38.8} E' 893 {35.2} H'
{30.3} 603 I'
A' 461 B' {23.7}
{18.2}
G'
1505
{59.25}
1775 {69.88} 1531 {60.28}
LH
1326 1258 {49.53}

{52.20} 1614 {63.54}
1045 {41.14} 2232 {87.87} 1785
RH
1008 {39.69}
{70.28} 1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000002

Point Point
symbol symbol
A ø15.25 {0.6004} D ø38.65 {1.522}
E ø10 {0.39}
datum hole
5DQJHU
TO MODEL INDEX
f- - - -I----+--
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symbol symbol
I IH
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
size mm {in}
ø6.5 {0.26}
5DQJHU
TO MODEL INDEX
FRAME DIMENSIONS (UNDERBODY REGULAR CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010618400
mm {in}
1248 {49.13}
1314 {51.73}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
969 {38.2}
869 {34.2}
839 {33.0}
670 {26.4}
669 {26.3}
424 668 1228 938 564 452

{16.7} {26.3} {48.35} {36.9} {22.2} {17.8}
194 134
{7.64} {5.28}
770 C' D'

1229 {48.39} 985 {38.8} E' 893 {35.2} H'
{30.3} 603 I'
A' 461 B' {23.7}
{18.2}
G'
1505
{59.25}
1775 {69.88} 1531 {60.28}
LH
1326 1258 {49.53}

{52.20} 1614 {63.54}
1045 {41.14} 2232 {87.87} 1785
RH
1008 {39.69}
{70.28} 1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000003

Point Point
symbol symbol
A ø15.25 {0.6004} D ø38.65 {1.522}
E ø10 {0.39}
datum hole
5DQJHU
TO MODEL INDEX
f- - - -I----+--
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Point Point
symbol symbol
I IH
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
size mm {in}
ø6.5 {0.26}
5DQJHU
TO MODEL INDEX
FRAME DIMENSIONS (UNDERBODY DOUBLE CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010619000
mm {in}
LH
1248 {49.13}
1036 {40.79}
1270 {50.00}
1244 {48.98}
1096 {43.15}
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
869 {34.2}
871 {34.3}
839 {33.0}
588 {23.1}
669 {26.3}
424 668 1376 635 349 564 451

{16.7} {26.3} {54.17} {25.0} {13.7} {22.2} {17.8}
135
{5.31}
770 C' E'

H'
461 B' {30.3} D' 1052 {41.42} 603 I'
A' 1382 {54.41} 705 {27.8} {23.7}
{18.2}
1910 G'
1505
{75.20} {59.25}
1790 {70.47}
LH
1326 1639 {64.53} 1258 {49.53}

{52.20} 1346 {52.99}
1045 {41.14} 2310 {90.94}
RH
1008 {39.69}
1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B D
{43.94} I
H
C E
abs0zb00000007
Hole diameter
Point
Designation or bolt or nut
symbol
size mm {in}
Cabin mounting bracket No.1
A ø15.25 {0.6004}
datum hole
B Upper arm bracket datum hole ø28.9 {1.14}
C ø38.65 {1.522}
datum hole
D Side member datum hole ø6 {0.2}
5DQJHU
TO MODEL INDEX
Hole diameter
Point
symbol
size mm {in}
E ø38.65 {1.522}
datum hole
F Damper bracket -
Box mounting bracket No.3 20 × 26
H
datum hole {0.79 × 1.0}
I Side member datum hole ø6.5 {0.26}
5DQJHU
TO MODEL INDEX
FRAME DIMENSIONS (UNDERBODY FREESTYLE CAB 4WD) [DIMENSIONS]

id098010608000
mm {in}
1248 {49.13}
1270 {50.00}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
969 {38.1}
973 {38.3}
933 {36.7}
866 {34.1}
839 {33.0}
785 {30.9}
969 {38.1}
669 {26.3}
424 668 1713 492 564 452

{16.7} {26.3} {67.44} {19.4} {22.2} {17.8}
155 134
{6.10} {5.28}
770 C' D'

E' H'
{30.3} 1717 {67.60} 604 I'
A' 461 B' 1191 {46.89}
{23.8}
{18.2}
2019 G'
1505
{79.49} {59.25}
2129 {83.82}
LH
1326 1722 {67.80} 1258 {49.53}

{52.20} 1280 {50.39}
1045 {41.14} 2634 {103.7}
RH
1008 {39.69}
1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000005

Point Point
symbol symbol
A ø15.25 {0.6004} D ø38.65 {1.522}
E ø10 {0.39}
datum hole
5DQJHU
TO MODEL INDEX
f- - - -I----+--
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symbol symbol
I IH
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
size mm {in}
ø6.5 {0.26}
5DQJHU
TO MODEL INDEX

id098010604900
mm {in}
1248 {49.13}
1314 {51.73}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
969 {38.2}
869 {34.2}
839 {33.0}
666 {26.2}
669 {26.3}
424 668 1228 938 564 452

{16.7} {26.3} {48.35} {36.9} {22.2} {17.8}
194 134
{7.64} {5.28}
770 C' D'

1229 {48.39} 986 {38.8} E' 893 {35.2} H'
461 B' {30.3} 603 I'
A' {23.7}
{18.2}
G'
1505
{59.25}
1775 {69.88} 1531 {60.28}
LH
1326 1258 {49.53}

{52.20} 1615 {63.58}
1045 {41.14} 2232 {87.87} 1785
RH
1008 {39.69}
{70.28} 1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000001

Point Point
symbol symbol
A ø15.25 {0.6004} D ø38.65 {1.522}
E ø10 {0.39}
datum hole
5DQJHU
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symbol symbol
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datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
size mm {in}
ø6.5 {0.26}
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TO MODEL INDEX
FRAME DIMENSIONS (UNDERBODY DOUBLE CAB 4WD) [DIMENSIONS]

id098010607900
mm {in}
1248 {49.13}
1036 {40.79}
1270 {50.00}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
869 {34.2}
875 {34.4}
839 {33.0}
588 {23.1}
669 {26.3}
424 668 1376 635 349 564 452

{16.7} {26.3} {54.17} {25.0} {13.7} {22.2} {17.8}
134
{5.28}
770 C' E'

H'
461 B' {30.3} D' 1052 {41.42} 603 I'
A' 1382 {54.41} 707 {27.8} {23.7}
{18.2}
1910 G'
1505
{75.20} {59.25}
1790 {70.47}
LH
1326 1639 {64.53} 1258 {49.53}

{52.20} 1347 {53.03}
1045 {41.14} 2310 {90.94}
RH
1008 {39.69}
1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B D
{43.94} I
H
C E
abs0zb00000004
Hole diameter
Point
symbol
size mm {in}
A ø15.25 {0.6004}
datum hole
C ø38.65 {1.522}
datum hole
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TO MODEL INDEX
Hole diameter
Point
symbol
size mm {in}
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datum hole
F Damper bracket -
H
datum hole {0.79 × 1.0}
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FRONT FENDER PANEL REMOVAL/INSTALLATION

id091000801000
Removal
2. Refer to: Front Bumper Cover.
3. Refer to: Headlamp Assembly.
4.
abs0zw00001190
5.
abs0zw00001191
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abs0zw00001192
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abs0zw00001193
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BODY REPAIR MANUAL
Body and Paint 5

SECTION TITLE PAGE
Body and Paint

Body System - General Information...............................................................................501-00
Front End Body Panels..................................................................................................501-02
Body Closures................................................................................................................501-03
Interior Trim and Ornamentation....................................................................................501-05
Exterior Trim and Ornamentation................................................................................... 501-08
Rear View Mirrors..........................................................................................................501-09
Seating...........................................................................................................................501-10
Glass, Frames and Mechanisms....................................................................................501-11
Instrument Panel and Console.......................................................................................501-12
Handles, Locks, Latches and Entry Systems................................................................501-14
Wipers and Washers......................................................................................................501-16
Bumpers.........................................................................................................................501-19
Safety Belt System.........................................................................................................501-20A
Supplemental Restraint System.....................................................................................501-20B
Body Repairs - General Information..............................................................................501-25
Body Repairs - Vehicle Specific Information and Tolerance Checks.............................501-26
Front End Sheet Metal Repairs......................................................................................501-27
Roof Sheet Metal Repairs..............................................................................................501-28
Side Panel Sheet Metal Repairs....................................................................................501-29
Rear End Sheet Metal Repairs......................................................................................501-30
Paint - General Information............................................................................................501-36
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MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
FRAME DIMENSIONS (UNDERBODY FREESTYLE CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010618100
mm {in}
1248 {49.13}
1270 {50.00}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
866 {34.1}
839 {33.0}
785 {30.9}
969 {38.1}
669 {26.3}
424 668 1713 492 564 452

{16.7} {26.3} {67.44} {19.4} {22.2} {17.8}
155 134
{6.10} {5.28}
770 C' D'

E' H'
461 B' {30.3} 1717 {67.60} 1191 {46.89} 604 I'
A' {23.8}
{18.2}
2019 G'
1505
{79.49} {59.25}
2129 {83.82}
LH
1326 1722 {67.80} 1258 {49.53}

{52.20} 1280 {50.39}
1045 {41.14} 2634 {103.7}
RH
1008 {39.69}
1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000006

Point Point
symbol symbol
A ø15.25 {0.6004} D ø38.65 {1.522}
E ø10 {0.39}
datum hole
f- - - -I----+--
+- I
Point Point
symbol symbol
I I
H
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
size mm {in}
ø6.5 {0.26}

id098010618300
mm {in}
1248 {49.13}
1314 {51.73}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
969 {38.2}
869 {34.2}
839 {33.0}
670 {26.4}
669 {26.3}
424 668 1228 938 564 452

{16.7} {26.3} {48.35} {36.9} {22.2} {17.8}
194 134
{7.64} {5.28}
770 C' D'

1229 {48.39} 985 {38.8} E' 893 {35.2} H'
{30.3} 603 I'
A' 461 B' {23.7}
{18.2}
G'
1505
{59.25}
1775 {69.88} 1531 {60.28}
LH
1326 1258 {49.53}

{52.20} 1614 {63.54}
1045 {41.14} 2232 {87.87} 1785
RH
1008 {39.69}
{70.28} 1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000002

Point Point
symbol symbol
A ø15.25 {0.6004} D ø38.65 {1.522}
E ø10 {0.39}
datum hole
f- - - -I----+--
+- I
Point Point
symbol symbol
I I
H
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
size mm {in}
ø6.5 {0.26}
FRAME DIMENSIONS (UNDERBODY REGULAR CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010618400
mm {in}
1248 {49.13}
1314 {51.73}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
969 {38.2}
869 {34.2}
839 {33.0}
670 {26.4}
669 {26.3}
424 668 1228 938 564 452

{16.7} {26.3} {48.35} {36.9} {22.2} {17.8}
194 134
{7.64} {5.28}
770 C' D'

1229 {48.39} 985 {38.8} E' 893 {35.2} H'
{30.3} 603 I'
A' 461 B' {23.7}
{18.2}
G'
1505
{59.25}
1775 {69.88} 1531 {60.28}
LH
1326 1258 {49.53}

{52.20} 1614 {63.54}
1045 {41.14} 2232 {87.87} 1785
RH
1008 {39.69}
{70.28} 1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000003

Point Point
symbol symbol
A ø15.25 {0.6004} D ø38.65 {1.522}
E ø10 {0.39}
datum hole
f- - - -I----+--
+- I
Point Point
symbol symbol
I I
H
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
size mm {in}
ø6.5 {0.26}
FRAME DIMENSIONS (UNDERBODY DOUBLE CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010619000
mm {in}
LH
1248 {49.13}
1036 {40.79}
1270 {50.00}
1244 {48.98}
1096 {43.15}
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
869 {34.2}
871 {34.3}
839 {33.0}
588 {23.1}
669 {26.3}
424 668 1376 635 349 564 451

{16.7} {26.3} {54.17} {25.0} {13.7} {22.2} {17.8}
135
{5.31}
770 C' E'

H'
461 B' {30.3} D' 1052 {41.42} 603 I'
A' 1382 {54.41} 705 {27.8} {23.7}
{18.2}
1910 G'
1505
{75.20} {59.25}
1790 {70.47}
LH
1326 1639 {64.53} 1258 {49.53}

{52.20} 1346 {52.99}
1045 {41.14} 2310 {90.94}
RH
1008 {39.69}
1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B D
{43.94} I
H
C E
abs0zb00000007
Hole diameter
Point
symbol
size mm {in}
A ø15.25 {0.6004}
datum hole
C ø38.65 {1.522}
datum hole
Hole diameter
Point
symbol
size mm {in}
E ø38.65 {1.522}
datum hole
F Damper bracket -
H
datum hole {0.79 × 1.0}
CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (FREESTYLE CAB) [DIMENSIONS]

id098010628700
1
3
1799 {70.83}
1543 {70.83}
1516 {59.69}
6
4
5
mm {in}
abs0zb00000013

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BACK TO CHAPTER INDEX MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.

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