TRAINING MANUAL Mazda2 Facelift

Service Training Mazda2 Facelift

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.

Key Dates

• Production start for Mazda2 Facelift is 1st September 2005
• Press Launch for Mazda2 Facelift is in September 2005
• Sales start for Mazda2 Facelift is in November 2005

Product Changes For New Mazda2 Facelift

Safety, Security, Others
DSC For All Engines

• DSC (Dynamic Stability Control) is now available for 1.25l MZI and 1.4l MZI (was only available for 1.6l MZI and 1.4l MZ-CD); DSC can not be combined with ASM (Automated Shift Manual Transmission)

Single Stage Airbag

• Cross-carline action to replace current dual stage airbag systems by single stage systems

Double Locking Deleted

• Double locking is not available anymore for left-hand drive vehicles

Retractable Key

• Cross-carline action to replace the current remote control and key

Euro 4 Compliant Diesel Engine

• 1.4l MZ-CD now meets Euro 4 emission legislation requirements
• ASM is not available anymore for 1.4l MZ-CD

CD Player Available As Factory Option

• CD player is now available as factory option (new generation audio unit)

Revised Audio Steering Switches

• Cross-carline action to harmonize functionality of the audio switch and improve usability of the system

Exterior

New Front And Rear Lamps

• Projector-type front lamps
• Clear-type rear lamps

All New 16 Inch Alloy Wheel

• Completely new design
• Available as factory option (not on 1.25l MZI engine)

New Design 15 Inch Alloy Wheel

• Replacement for current 15 inch alloy wheel (carry over design from special model)

C-Pillar Black Out

• Standard on all Mazda2 to visually lower the rear of the car, giving a more sporty appearance

New Design Fog Lamps

• Round-type design to replace current square shape fog lamp
• Gives a better integration with the new front lights

Three New Exterior Colours

• Sea Grey 33T (launch colour for Sport configuration) to replace Magnum Grey
• Breeze 33V (launch colour for basic configuration) to replace Vitro Green
• Kelp 33W to rep

Interior

Changed Interior Colour And Trim For Sport Configuration

• Seat main and bolster fabric replaced by a new material (Black)
• Black/Blue fabric not available anymore for Sport configuration

Changed Interior Colour And Trim For Basic Configuration

• Current Dark Grey environment colour replaced by Lunar Grey
• Seat main fabric replaced by a new material (Lunar Grey)
• Seat bolster fabric is carried over, but the colour is changed to Lunar Grey

Addition Of 2nd Colour And Trim For Basic Configuration

• Second Black trim level introduced to basic configuration (similar to Black trim from Sport configuration, but without leather steering wheel, silver colored steering switches and shift patterns)
• Black trim on basic configuration (for left-hand drive vehicles in conjunction with side airbags, only)

Audio System
The new generation audio system is also introduced on Mazda2 Facelift. Since the CD player is part of the base module, this feature is now available as factory option(rather than dealer-fit option).

Revised audio steering switches

1. To harmonize the functionality of the audio switches of all Mazda vehicles, the former P•SET switch has been replaced by a seek down switch (∇). The functionality has been changed slightly.
2. When listening to the radio:
   • Press the seek switch (Δ,∇), the radio switches to the next/previous stored station in the order that it was stored (1 - 6).
   • Press the seek switch (Δ,∇) for about 2 seconds until a beep sound is heard to seek all usable stations at a higher or lower frequency whether programmed or not.
3. When playing a cassette tape:
   • Press the seek switch (Δ), release, and it will advance to the next selection.
   • Press the seek switch (∇), release, and it will repeat the selection being played.
4. When playing a CD or MD:
   • Press the seek switch (Δ) to skip to the next track.
   • Press the seek switch (∇) to repeat the current track.

Exterior Lighting

Headlamps
The new designed headlamps use separate lamps for main beam and dipped beam:

• projector optics and H7 55W bulbs for dipped beam
• free form reflectors and HB3 60W bulbs for main beam

Fog lamps

1. The fog lamps have been re-designed. The bulb type HB4 51W has been carried over from the previous design.
2. The HB4 bulbs use bayonet-type sockets. After releasing a wire clip, the HB4 bulbs can be removed like the HB3 bulbs.

Retractable key

• The retractable "Jack Knife" key has been adopted for Mazda2 Facelift.

Diesel Engine

General
The 1.4 MZ-CD Diesel engine of the Mazda2 Facelift basically has been carried over from the previous Mazda2. In order to complywith Euro 4 emission legislation the engine has been upgraded as follows:

1. new injectors
2. revised intake air system
3. revisedEGR(ExhaustGasRecirculation) system
4. revisedPCM(PowertrainControlModule)

Injectors

• The injectors have been basically carried overfrom the previous 1.4 MZ-CD Diesel engine. They are piezo-type injectors, which consist of nozzle body with nozzle needle,hydraulic servo system and piezo actuator.
• Since the Diesel engine of the Mazda2 Facelift meets Euro 4 emission regulations, it uses injectors with a different spray hole diameter. In order to distinguish between injectors for Euro 3 vehicles and injectors for Euro 4 vehicles, an injector classification code (“E3” for Euro 3 vehicles and “E4” for Euro 4 vehicles) is stamped onto the injector shaft. NOTE: Never disconnect any connectors of the piezo-type injectors (such as injectorconnectors, PCM connectors etc.) while the engine is running. If there is an open circuit at an injector, the corresponding piezo actuator may remain extended for a certain time so that the nozzle needle stays open. This would result in continuous injection and hence in engine damage.
• The injectors are numbered according to the firing order (e.g. injector No.2 is located at cylinder No.3). On the 1.4 MZ-CD engine the cylinder No.1 is located next to the transmission (French-style cylinder numbering).

Intake-air System

• In order to comply with Euro 4 emission legislation, the intake-air system of the
• 1.4 MZ-CD Diesel engine of the Mazda2 Facelift has been revised as follows:
  • MAP(ManifoldAbsolutePressure) sensor has been added
  • new hot film-typeMAF(MassAirFlow) sensor (instead of hot wire-type) with integratedIAT(IntakeAirTemperature) sensor
  • additional IAT sensor
  • ISV(IntakeShutterValve) has been introduced for upgrading the EGR system
• The operation of MAP sensor, MAF sensor, IAT sensor and the actuation of the ISV can be monitored using the Datalogger function of theWDS(WorldwideDiagnosticSystem).

Parts Location

1. MAP sensor
2. Hot film-type MAF sensor
3. Fixed geometry turbo charger
4. IAT sensor
5. Intake shutter valve

Exhaust Gas Recirculation System
For meeting the Euro 4 emission regulations the exhaust gas recirculation system of the Mazda2 Facelift with 1.4 MZ-CD Diesel engine has the following new features:

• EGR valve withDC(DirectCurrent) motor and position sensor
• EGR cooler
• ISV with DC motor

EGR Valve

• For more precise exhaust gas admeasurementthe previous pneumatic EGR valve has been replaced by an electrically operated EGR valve.
• The EGR valve is located at the rear side of the engine and is connected to the exhaust manifold via an EGR duct integrated in the cylinder head.
• It uses a DC motor for actuation. A cam plate transforms the rotational movement of the motor into an axial movement of the EGR valve. AnEGRVP(EGRValvePosition) sensor is installed for monitoring the valve position.
  1. DC motor with EGRVP sensor
  2. EGR valve housing
• The position of the EGR valve is controlled by the PCM, which activates the DC motor via a duty signal. 
• At low engine speed the PCM controls the DC motor with a large duty cycle, so that the EGR valve opens and exhaust gas is recirculated.
• At high engine speed the PCM controls the DC motor with a small duty cycle, so that the EGR valve closes and no exhaust gas is recirculated.
• In order to remove any carbon deposits from the EGR valve seat a cleaning mode is activated each time the ignition is switched off. Therefore, the PCM actuates the EGR valve so that it is moved from the fully open position to the fully closed position several times. This process takes approx. 30 s.

NOTE: If the engine coolant temperature is below -5°C, the EGR cleaning mode is cancelledas the EGR valve could be frozen and would not move.