TRAINING MANUAL MPV Facelift

MME Technical Training 2004

No part of this hardcopy may be reproduced in any form without prior permission of Mazda Motor Europe GmbH. The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of going to print. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

2004
Mazda Motor Europe GmbH Technical Training Department

MPV Facelift
Table of contents
General Information...................................................................................................1 Introduction............................................................................................................1 Overview ...............................................................................................................1 Exterior dimensions ........................................................................................1 Engine number location ..................................................................................2 Scheduled maintenance..................................................................................3 Engine.........................................................................................................................4 Emission System (RF)...........................................................................................4 Features..........................................................................................................4 EGR valve position sensor..............................................................................4 Control System (RF)..............................................................................................5 Features..........................................................................................................5 Parts location ..................................................................................................5 System overview.............................................................................................7 Relationship chart ...........................................................................................9 DLC-2 outline ................................................................................................10 On-board diagnostic system .........................................................................11 Diagnostic test modes...................................................................................11 OBD drive mode ...........................................................................................12 PID monitor ...................................................................................................13 L3 Engine ............................................................................................................16 Features........................................................................................................16 Overview .......................................................................................................16 Lubrication ....................................................................................................16 Specifications................................................................................................16 Suspension ..............................................................................................................17 Front and Rear Suspension.................................................................................17 Features ..............................................................................................................17 Parts Location .....................................................................................................17 Brakes.......................................................................................................................18 Conventional Brake System ................................................................................18 Features........................................................................................................18 Specifications................................................................................................18 Parts location ................................................................................................19 TCS (RF-T)..........................................................................................................20 Features ..............................................................................................................20 Parts location ................................................................................................20 Wiring diagram..............................................................................................21 Control system ..............................................................................................22 On-board diagnostic system .........................................................................22

Table of contents

MPV Facelift
Table of contents (continued)
HVAC ........................................................................................................................23 Rear Climate Control...........................................................................................23 Features........................................................................................................23 Parts location ................................................................................................23 Wiring diagram..............................................................................................24 Fuel Fired Heater ................................................................................................25 On-board diagnostic system .........................................................................25 Combustion test ............................................................................................25 Lockout reset ................................................................................................25 PID monitor ...................................................................................................26 Simulation Test Item Table ...........................................................................26 Body and Accessories ............................................................................................27 Features ..............................................................................................................27 Multiplex communication system.........................................................................28

Table of contents

General Information
Introduction
The new Mazda MPV facelift has now been further enhanced to ensure it continues to meet the demands of European customers looking for a vehicle that is safe, fun to be in and drive, with lots of space and flexibility. At the same time, full compliance with EOBD regulations of the RF-T engine models and the inclusion of a Karakuri seat version all improve on what was already a successful formula.

Overview

BME0910T001

Exterior dimensions
Item Overall length Overall width Overall height Wheel base Front tread Rear tread 2.3L, Euro 4 mm mm mm mm mm mm 4805 1830 1785 (roof rail standard) 2840 1540 1550
Homologation

2.0L-Diesel, Euro 3

Service Training

General Information
Engine number location L3

BME0000W006

Front

RF-T

BME0000W006

Front

Service Training

General Information
Scheduled maintenance
The following items in the maintenance schedule have been changed

Maintenance Interval (Number of months or kilometers (miles), whichever comes first) Maintenance Months 12 24 36 48 60 72 84 96 Item 1000 km 20 40 60 80 100 120 140 160 1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 GASOLINE ENGINE Engine valve clearance Evaporative system (if installed) Front and rear suspension and ball joints Drive shaft dust boots Exhaust system and heat shields Cabin air filter (if installed)(pollen filter) I I

108 180 112.5

Audible inspect every 120,000km (75,000miles), if noisy, adjust I I I I I I I I I

Inspect every 80,000km (50,000miles) or 60 months R R R R

Scheduled maintenance

Service Training

Engine
Emission System (RF)
Features

Emission system (RF)

An EGR (Exhaust Gas Recirculation) valve position sensor has been added to allow compliance with EOBD regulations

EGR valve position sensor

The EGRVP (EGR Valve Position) sensor is located at the EGR valve and detects its position by a sliding contact potentiometer. When the EGR valve opens the resistance of the potentiometer rises. The sensor supplies the PCM with an analogue voltage signal between 05 V.

Diesel_B_series_4

EGRVP sensor

PCM

The signal of the EGRVP sensor serves to detect a malfunction of the EGR valve, i.e. the PCM (Powertrain Control Module) permanently compares the sensor information with the actual EGR amount. The amount of recirculated exhaust gas is determined from the difference between target intake air amount (calculated from the engine speed and the fuel injection amount) and the actual intake air amount detected by the MAF (Mass Air Flow) sensor.

Service Training

Engine
Control System (RF)
Features

Control System (RF)

To comply with EOBD regulations, diagnostic test modes and corresponding DTCs have been added

Parts location

BME0140W501

Service Training

Control System (RF)

Parts location (continued)
1 2 3 4 5 6 7 8 9 PCM (with built-in BARO sensor) Clutch pedal position switch Neutral switch Idle switch Accelerator pedal position sensor MAF/IAT sensor IAT sensor No.2 ECT sensor Fuel temperature sensor 10 11 12 13 14 15 16 17 18 Boost sensor Fuel pressure sensor CMP sensor CKP sensor Calibration resistor IDM EGR valve position sensor L.H.D. R.H.D.

Engine

Service Training

Engine
System overview

Control System (RF)

B6E4002W002

Service Training

Control System (RF)

System overview (continued)
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 28 29 Air cleaner Vacuum chamber VBC check valve MAF/IAT sensor VBC solenoid valve Vacuum damper Guide blade actuator Turbocharger Charge air cooler IAT sensor No.2 Boost sensor Intake shutter valve actuator Intake shutter solenoid valve (half) Intake shutter solenoid valve (full) EGR solenoid valve (vacuum) EGR solenoid valve (vent) EGR control solenoid valve EGR valve EGR water cooler VSC valve actuator VSC solenoid valve Fuel tank Fuel filter Fuel warmer Supply pump Suction control valve Fuel temperature sensor Common rail Fuel pressure sensor 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Fuel pressure limiter Glow plug Fuel injector ECT sensor Calibration resistor CMP sensor Warm up oxidation catalytic converter Oxidation catalytic converter Silencer Vacuum pump CKP sensor Idle switch APP sensor Glow plug relay IDM PCM BARO sensor PCM control relay Engine switch Starter (starter signal) Neutral switch Clutch pedal position switch A/C switch CAN bus To PCM EGR valve position sensor DLC-2 Fuel flow

Engine

Service Training

Engine
Relationship chart
: Applicable

Control System (RF)

A/C cut-off control

Idle speed control

Multiple fuel injection control

Boost pressure control

Fuel injection amount control

Fuel injection timing control

Glow control

EGR control

Input device Battery Starter (starter signal) Starter relay Clutch pedal position switch Neutral switch Idle switch A/C switch Refrigerant pressure switch Accelerator position sensor MAF/IAT sensor IAT sensor No.2 ECT sensor Fuel temperature sensor BARO sensor (integrated in PCM) Boost sensor Fuel pressure sensor CMP sensor CKP sensor ABS HU/CM (CAN signal) Calibration resistor Immobilizer unit EGR valve position sensor Suction control valve IDM VSC solenoid valve VBC solenoid valve EGR control solenoid valve EGR solenoid valve (vacuum) EGR solenoid valve (vent) Intake shutter solenoid valve (half) Intake shutter solenoid valve (full) Glow indicator light Glow plug relay Main fan relay A/C relay Fan control module

Electrical fan control

Item

Relationship Chart

Service Training

Immobilizer system

VSC

Control System (RF)

DLC-2 outline

Engine

The DLC-2 (Data Link Connector-2) located in the driver compartment is a service connector defined by EOBD regulations.

DLC-2

1 2 3 4 5 6 7 8

Not used Not used Not used Chassis ground Signal ground CAN high (+) ISO 9141 (K line) Not used

9 10 11 12 13 14 15 16

Not used Not used Not used Not used Not used CAN low (-) Not used Battery power supply (B+)

10

Service Training

Engine
On-board diagnostic system Diagnostic test modes

Control System (RF)

To meet EOBD regulations, the following diagnostic test modes have been adopted:
Item Sending diagnostic data (PID data monitor/On-board system readiness test) Sending freeze frame data Sending emission-related malfunction code (DTC) Clearing/resetting emission-related malfunction information Sending continuous monitoring system test results (pending code) Request vehicle information

Diagnostic test mode Mode 01 Mode 02 Mode 03 Mode 04 Mode 07 Mode 09

Recording of continuous monitoring system test results

These appear when a problem is detected in a monitored system

1-drive cycle type

If any problems are detected in the first drive cycle, pending codes will be stored in the PCM memory, as well as DTCs. After pending codes are stored, if the PCM determines that the system is normal in any future drive cycle, the PCM deletes the pending codes.

2-drive cycle type

The code for a failed system is stored in the PCM memory in the first drive cycle. If the problem is not found in the second drive cycle, the PCM determines that the system returned to normal or the problem was mistakenly detected, and deletes the pending code. If the problem is found in the second drive cycle too, the PCM determines that the system has failed, and stores the pending codes, and the DTCs. After pending codes are stored, if the PCM determines that the system is normal in any future drive cycle, the PCM deletes the pending codes.

Service Training

11

Control System (RF)

On-board diagnostic system (continued) OBD drive mode

Engine

With the addition of system monitors for EOBD, it is now necessary to carry out the OBD Drive Mode to confirm the absence of the below DTCs:

P0101: MAF sensor circuit range/performance problem P0106: Boost sensor circuit range/performance problem P0401: EGR flow insufficient detected P0402: EGR flow excessive detected P0404: EGR valve stuck P2227: BARO sensor circuit range/performance problem

To conduct the OBD Drive Mode: 1. Warm up the engine to normal operating temperature. 2. Verify all accessory loads (A/C, headlights, blower fan, rear window defroster) are off. 3. Drive the vehicle five times in the driving mode indicated in the figure on a road with a 0% gradient. 4. Stop the vehicle. 5. Verify no DTCs are present.

B6E4070W078

1 2 3

Time Vehicle Speed Start Engine

4 5 6

Idle nd Above 35 km/h {21.7 mph} (2 gear) nd Above 50 km/h {31 mph} (3 gear)

12

Service Training

Engine
On-board diagnostic system (continued) PID monitor

Control System (RF)

The PID (Parameter Identification) monitor function allows the PIDs of the PCM to be monitored. To do this connect the WDS (Worldwide Diagnostic System) to the vehicle and select the option Toolbox Datalogger Modules PCM.
Definition A/C relay A/C switch A/C relay Accelerator pedal position sensor No.1 - voltage Accelerator pedal position sensor No.2 - voltage Target engine speed Barometric pressure Desired boost pressure Refrigerant pressure switch (middle) Clutch pedal position switch neutral switch Calibration resistor voltage 1 Calibration resistor voltage 2 Calibration resistor voltage 3 Calibration resistor voltage 4 Fuel correction for deceleration DSC control enable/disable DTC count Engine coolant temperature Exhaust gas recirculation solenoid valve (vent) C V % Unit/Condition On/Off On/Off On/Off V V RPM Pa inHg V Pa psi Bar On/Off On/Off Neutral/Drive V

Monitor item ACCS AC_REQ ACR APS1 APS2 ARPMDES BARO BOOST_DSD COLP CPP CPP/PNP CR_1 CR_2 CR_3 CR_4 DEC_CMP DSC_ACT DTCCNT ECT EGRA

mm /Stroke Enabled/Disabled F

EGRV

Exhaust gas recirculation solenoid valve (vacuum)

EGRV2 EGRVP FAN_DUTY FFH_STAT FIP_FL FIP_FL_DSD

Exhaust gas recirculation control solenoid valve EGR valve position Variable fan duty cycle FFH status FIP flow control FIP flow desired

On/Off V % Active/Inactive A % mm /Stroke

3

Service Training

13

Control System (RF)

On-board diagnostic system (continued) PID monitor (continued)
Monitor item FIP_LRN FIP_MODE FIP learning amount FIP duty control status Definition Unit/Condition A

Engine

Normal/Fixed_1/Fixed_2/Disabled A

FIP_SCV

Suction control valve V

FLT FLTV FRP

Fuel temperature FLT signal voltage Fuel pressure sensor

C V V Pa

FRP_A GLWPG V GPC IASV IASV2 IAT IAT2 ICP IMRC INGEAR INJ_LRN_DIS INJ_MODE INJ_TIM INJ1_CMP INJ2_CMP INJ3_CMP INJ4_CMP ISC_CMP IVS

FRP after fuel injection Glow plugs Glow plug control Intake shutter solenoid valve (half) control Intake shutter solenoid valve (full) control Intake air temperature Intake air temperature No.2 Injector control pressure VSC solenoid valve In gear Distance from the last injector learning Fuel injection timing control status Fuel injection timing Injector 1 correction value Injector 2 correction value Injector 3 correction value Injector 4 correction value Fuel correction for idle speed control Idle switch C

Pa V On/Off On/Off On/Off F V C V Pa psi Bar On/Off On/Off m mile Normal/Disabled/Splitted/Fixed F

mm /Stroke mm /Stroke Idle/Off Idle

3

14

Service Training

Engine
On-board diagnostic system (continued) PID monitor (continued)
Monitor item Definition

Control System (RF)

Unit/Condition g/s

MAF

Mass air flow amount V

MAF_C MAF_C_DSD MAF_LRN_DIS MAINRLY MAP MIL MULTI_INJ RPM START_SW TC_CMP VBCV VFDES VPWR VSS

MAF per cylinder MAF per cylinder desired Distance from the last MAF learning PCM control relay Manifold absolute pressure Malfunction indicator lamp Multiple fuel injection control status Engine speed Starter switch value Fuel correction for traction control VBC solenoid valve control Volume fuel desired Battery positive voltage Vehicle speed KPH
3

G g m mile On/Off V Pa On/Off 1_INJ/2_INJ/3_INJ/4_INJ/5_INJ/Disable d RPM On/Off mm /Stroke % mm /Stroke V MPH

3

inHg

Service Training

15

L3 Engine
L3 Engine
Features

Engine

The L3 engine is basically carried over from the present MPV (LW) except for the following:

Catylitic convertor performance has been improved. Engine management maps in PCM altered to suit improved catalytic convertor performance Engine oil capacity has been increased

Overview

AME2202N102

Lubrication Specifications
Item Oil pressure (reference value) (kPa {kgf/cm , psi} [rpm]) Total (Dry engine) (L {US qt, lmp qt}) Oil capacity (Approx. quantity) Oil replacement (L {US qt, lmp qt}) Oil and oil filter replacement (L {US qt, lmp qt})
2

Specification 300-549 {3.1-5.6, 44-80} [3,000] 5.1 {5.4, 4.5} 4.0 {4.2, 3.5} 4.4 {4.6, 3.9}

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Service Training

Suspension
Front and Rear Suspension
Features

Front and Rear Suspension

New front and rear dampers with multi-layer valves have been adopted (Karakuri seat version only)

Parts Location

ZMU0214W120

1 2 3 4 5

Front shock absorber and spring Front shock absorber Front lower arm Front stabilizer Stabilizer control link

6 7 8 9 10

Transverse member Front crossmember Rear shock absorber and spring Rear shock absorber Torsion beam axle

Service Training

17

Conventional Brake System

Conventional Brake System
Features
The brake system on the F/L MPV has undergone the following changes:

Brakes

Ventilated rear disc brakes have been adopted Larger bore master cylinder has been adopted A tandem diaphragm power brake unit has been adopted Replacement procedure for master cylinder has been changed

Specifications
L3 Master cylinder Power brake unit Front disc brake Type Cylinder diameter (mm {in}) Diameter (mm {in}) Type Disc plate dimensions (outer diameter x thickness) (mm {in}) Type Disc plate dimensions (outer diameter x thickness) (mm {in}) RF-T Tandem 25.4 {1.0} 213.4 + 240.2 {8.40 + 9.43} Ventilated 296 x 28 {11.7 x 1.1}

274 x 28 {10.8 x 1.1}

Ventilated 286 x 18 {11.3 x 0.7}

Rear disc brake

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Service Training

Brakes
Parts location

Conventional Brake System

BME0411W506

1 2 3 4 5 6 7

Vacuum hose check valve Brake pedal Brake switch Master cylinder Fluid level sensor Power brake unit Brake pipe joint

8 9 10 11 12 13 14

Front brake (disc) Disc pad (front) Caliper (front) Rear brake (disc) Disc pad (rear) Caliper (rear) Vacuum pump (MZR-CD (RF Turbo))

Service Training

19

TCS (RF-T)
Traction Control System (RF-T)
Features
TCS (Traction Control System) has been adopted for RF-T engine models.

Brakes

Parts location

BME0414W501

1 2

TCS off switch ABS/TCS HU/CM

3 4

TCS OFF TCS

20

Service Training

Brakes
Wiring diagram

TCS (RF-T)

BME0402W504

1 2 3 4 5 6 7 8 9 10

Ignition switch Battery TCS OFF light TCS indicator light ABS warning light BRAKE system warning light Instrument cluster Motor relay ABS motor Brake switch

11 12 13 14 15 16 17 18 19

ABS wheel-speed sensor Fail-safe relay Solenoid valve ABS/TCS HU/CM TCS OFF switch Data link connector (DLC) Parking brake switch Brake fluid level sensor Data link connector-2 (DLC-2)

Service Training

21

TCS (RF-T)
Control system

Brakes

Communication between the ABS/TCS module and the PCM is carried out through a high-speed CAN-BUS (Controller Area Network-BUS).

Data sent Torque reduction request

Wheel speeds of all four wheels

Data received Engine speed

Engine torque Throttle valve opening angle Vehicle speed

On-board diagnostic system

The on-board diagnostic system for the RF-T TCS is basically the same as that for the L3 engine system except for the following:

Diagnostic procedures for DTCs C1117,C1119, U0100, U0073 are different than those for the L3 engine

22

Service Training

HVAC
Rear Climate Control
Features

Rear Climate Control

A two-dial type rear climate control unit has been adopted The air-mix door and airflow mode door are actuated by a single actuator, eliminating the air mix actuator (vehicles fitted with rear A/C and heater only) A hot position (actuator in center position) is available on some models (vehicles fitted with rear heater only)

Parts location

BME0740W001

1 2 3 4 5 6 7 8

Magnetic clutch Refrigerant pressure switch Front blower motor Rear blower motor Front resistor Rear resistor Thermosensor A/C relay

9 10 11 12 13 14 15 16

Front blower relay Rear blower relay Front climate control unit Rear main fan switch Rear climate control unit Intake actuator Rear airflow mode actuator (heater only) Rear airflow mode/mix actuator (A/C and heater)

Service Training

23

Rear Climate Control

Wiring diagram

HVAC

P_07-402

24

Service Training

HVAC
Fuel Fired Heater
On-board diagnostic system

Fuel Fired Heater

A self test/combustion test procedure, and lockout reset procedure have been added PID and simulation item tables have been added to the workshop manual A symptom troubleshooting index for the fuel fired heater has been added to the workshop manual.

Combustion test
1. Connect the SST (WDS or equivalent) to the vehicle DLC-2 16-pin connector 2. Select the "Supplemental Heater Test" in the "Supplemental Heater Menu" of the "Guided Diagnosis" function 3. Perform the KOEO Self Test/Combustion Test NOTE: If the water heater unit is operating, the water heater unit will reject the test command. Perform the DTC reading procedure after the water heater unit stops operating

Lockout reset (using WDS)

1. 2. 3. 4. Connect the SST (WDS or equivalent) to the vehicle DLC-2 16-pin connector Select "CLR_LOCKOUT" and "LOCKOUT Turn "CLR_LOCKOUT" to ON using the simulation function Verify that the "LOCKOUT" reading changes to "Unlocked"

Lockout reset (not using WDS) For factory equipped water heater unit
1. Turn the ignition switch to the OFF position 2. Remove the W.HEAT 40 A fuse from the main fuse block for more than 5 seconds 3. Re-install the W.HEAT 40 fuse

For vehicles with a transmitter or timer

1. Turn the ignition switch to the OFF position 2. Remove the power supply 40 A fuse from the heater wiring harness for approx. 3 seconds 3. Re-install the power supply 40 A fuse 4. Press and hold down the ON switch of the transmitter or timer for approx. 3 seconds 5. Remove the power supply 40 A fuse from the heater wiring harness for approx. 3 seconds 6. Re-install the power supply 40 A fuse

Service Training

25

Fuel Fired Heater

On-board diagnostic system (continued) PID monitor
PID Name CCNTFFH ECT VPWR_FFH VPWR_LMT FAN GPD BLOWRMTR FP WATER_PMP GLOW PLUG COMB_FAN LOCKOUT FS HEATER HEATER_SW Definition Number of continuous codes) Engine coolant temperature Module supply voltage Low voltage threshold Fan control Glow plug duty cycle Blower motor Fuel pump Water pump Glow plugs Combustion air fan Heater lockout Flame sensor Heater status Heater activation switch Unit/Condition C F V V % % On/Off On/Off On/Off On/Off On/Off Lock/Unlock On/Off Inactive/Active Inactive/Active

HVAC

Simulation Test Item Table

Item CLR_LOCKOUT FUEL_PRIME Definition Heater lockout mode clearing command Fuel pump priming command (The fuel pump is activated for 5 seconds.) Operation On/On/-

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Service Training

Body and Accessories

Body and Accessories
Features
The headlamp design has been changed Seven new body colours have been introduced: Blue Pacific Mica, Gloaming Silver, Razor Blue, Nordic Green Mica, Titanium Grey II Mica, Arctic White, Snowflake White Pearl A three spoke steering wheel has been adopted Karakuri seats are available on some versions Driver information system now available for diesel vehicles

Service Training

27

Body and Accessories

Multiplex communication system
A high-speed CAN multiplex communication system, as well as the existing ISO 9141 communication system have been adopted on diesel engine vehicles.

CAN
The following modules are connected to the CAN bus:

PCM ABS/TCS module Fuel fired heater DLC-2

CAN diagram MPV

1 2 3

PCM ABS/TCS module Fuel fired heater

4 5

DLC-2 Twisted wires

ISO 9141
The following items are connected to the ISO 9141 network:

ABS/TCS module DLC-2 DLC-1

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Service Training

List of abbreviations
ABS Anti-Lock Brake System L.H.D. Left Hand Drive

A/C

Air Conditioning

R.H.D.

Right Hand Drive

BARO

Barometric Pressure

MAF

Mass Air Flow

CAN*

Controller Area Network

MAP

Manifold Absolute Pressure

CKP

Crankshaft Position

OBD

On Board Diagnostics

CMP

Camshaft Position

PCM

Powertrain Control Module

CPP

Clutch Pedal Position

PID

Parameter Identification

DLC

Data Link Connector

SST

Special Service Tool

DSC

Dynamic Stability Control

TCS

Traction Control System

DTC

Diagnostic Trouble Code

VBC

Variable Boost Control

ECT

Engine Coolant Temperature

VSC

Variable Swirl Control

EGR

Exhaust Gas Recirculation

VSS

Vehicle Speed Sensor

HU/CM

Hydraulic Unit/Control Module

WDS

Worldwide Diagnostic System

IDM

Injector Driver Module

KOEO

Key On Engine Off

Service Training