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Mazda BT-50 BT50 2.2L 3.2L DURATORQ Diesel TDCi & 2.5L DURATEC Petrol I4 HE Complete Workshop Service Repair Manual 2011 2012 2013

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🏷️ Basic Information Identification Make: Mazda Model: BT-50 Model Code: BT50 Generation: Second Generation (UN/CM) Codes Production Years: 2011, 2012, 2013 👋 Introduction Market Position Segment: Mid-size Pickup Truck (LUV - Light Utility Vehicle) Competitive Analysis Competitors: Toyota Hilux, Mitsubishi Triton, Ford Ranger, Nissan Navara Key Features Vehicle Strengths: Robust chassis, capable powertrains, strong towing and payload capacity, proven off-road ability. 📋 Manual Details Coverage Areas Coverage: Complete Workshop Service Repair Page Count Estimated Page Count: Extensive (typically 1000+ pages for a complete workshop manual) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: 2.2L Duratorq TDCi Diesel, 3.2L Duratorq TDCi Diesel, 2.5L Duratec Petrol I4 HE Transmission: Manual and Automatic Transmissions (Specifics to be detailed within manual) Drivetrain: 4WD System, Differential Systems, Driveshafts Suspension: Front and Rear Suspension Systems, Shock Absorbers, Springs, Bushings Steering: Power Steering System, Steering Column, Tie Rods Brakes: Front and Rear Brake Systems (Disc/Drum), ABS, Parking Brake Electrical: Battery, Charging System, Starting System, Lighting, Fuses, Relays, ECU, Wiring Diagrams Bodywork: Exterior Panels, Doors, Hood, Tailgate, Interior Trim, Seats, Glass HVAC: Heating, Ventilation, and Air Conditioning System Fuel: Fuel System (Diesel and Petrol), Fuel Tank, Injectors, Fuel Pump Exhaust: Exhaust System Components, Emission Control Systems Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks Diagnostics: Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs) Repair: Component Removal and Installation, Engine Overhaul, Transmission Rebuild, Brake System Repair Assembly: Detailed Reassembly Instructions for all Major Components Specifications: Torque Specifications, Clearances, Tolerances Wiring Diagrams: Comprehensive Electrical Schematics Technical Depth Depth: Complete Workshop Level (from basic maintenance to complete engine and transmission rebuilds) 📊 Manual Specifications File Format Format Details: PDF (Portable Document Format) ensuring universal compatibility across devices. Print Quality Printability: High-resolution, printable pages allowing users to create physical copies of specific sections or the entire manual. Binding Type Binding Type Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital Download) Searchability Text Search: Fully searchable text content for quick information retrieval. Software Requirements Required Software: Adobe Reader (or compatible PDF viewer) ⚙️ Engine Specifications Primary Engine Diesel 2 2L: 2.2L Duratorq TDCi (Common Rail Direct Injection) Diesel I4 HE Diesel 3 2L: 3.2L Duratorq TDCi (Common Rail Direct Injection) Diesel I5 HE Petrol 2 5L: 2.5L Duratec HE (High Performance) Petrol I4 Performance Diesel 2 2L Horsepower Ps 2 2L: ~150 PS (approximate, varies by specific market tune) Torque Nm 2 2L: ~375 Nm (approximate, varies by specific market tune) Performance Diesel 3 2L Horsepower Ps 3 2L: ~200 PS (approximate, varies by specific market tune) Torque Nm 3 2L: ~470 Nm (approximate, varies by specific market tune) Performance Petrol 2 5L Horsepower Ps 2 5L: ~165 PS (approximate, varies by specific market tune) Torque Nm 2 5L: ~225 Nm (approximate, varies by specific market tune) Fuel System Diesel System: Common Rail Direct Injection (CRDi) with Turbocharging and Intercooling Fuel System Petrol System: Multi-Point Fuel Injection (MPI) 🔧 Transmission Standard Transmission Types: 6-speed Manual Transmission, 6-speed Automatic Transmission Optional Transfer Case: Electronic Shift-On-The-Fly 4x4 System (2H, 4H, 4L modes) Features Automatic Features: Adaptive Shift Control, Sequential Sport Mode (typically) 📐 Dimensions Exterior Body Styles: Single Cab, Freestyle Cab (Extended Cab), Double Cab Wheelbase Mm: Varies by cab type (e.g., ~3000mm for Double Cab) Length Mm: Varies by body style and cab type Width Mm: Varies by body style and cab type Height Mm: Varies by body style and cab type Cargo Tray Dimensions Mm: Varies significantly by body style (e.g., length, width, depth of cargo bed) Weights Gross Vehicle Weight Rating Kg: Typically in the range of 3000-3200 kg, depending on configuration. Towing Capacity Kg: Up to 3500 kg (braked trailer, depending on market and configuration) Payload Capacity Kg: Varies by configuration, typically around 1000-1300 kg. 🛡️ Safety Features Ratings Ancap Rating: Likely 4 or 5 Stars ANCAP (Australasian New Car Assessment Program) for Double Cab variants based on comparable models. Active Features Brake Assist: Yes (Brake Assist System - BAS) Traction Control: Yes (Traction Control System - TCS), Electronic Stability Control (ESC) Hill Descent Control: Yes (Hill Descent Control - HDC) Hill Start Assist: Yes (Hill Start Assist - HSA) Passive Features Airbags: Front Airbags (Driver and Passenger), Side Airbags, Curtain Airbags (depending on trim level) Seatbelts: Pre-tensioner seatbelts with load limiters Child Seat Anchors: ISOFIX anchorage points 💡 Technology Features Infotainment Infotainment System: Mazda's 'START' system (or similar) with touchscreen display, CD player, MP3 capability, Bluetooth connectivity, USB/AUX input. Higher trims may feature navigation. Driver Assistance Camera Options: Rearview camera available on certain trims. Connectivity Bluetooth: Standard on many trims for hands-free calling and audio streaming. 🔧 Maintenance Service Intervals Oil Change Interval Km: Typically 10,000 - 15,000 km or 12 months, whichever comes first. Check manual for specific engine/oil type....
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Mazda BT-50 BT50 2.2L 3.2L DURATORQ Diesel TDCi & 2.5L DURATEC Petrol I4 HE Complete Workshop Service Repair Manual 2011 2012 2013
🏷️ Basic Information
Identification
Make:
Mazda
Model:
BT-50
Model Code:
BT50
Generation:
Second Generation (UN/CM)
Codes
Production Years:
2011, 2012, 2013
👋 Introduction
Market Position
Segment:
Mid-size Pickup Truck (LUV - Light Utility Vehicle)
Competitive Analysis
Competitors:
Toyota Hilux, Mitsubishi Triton, Ford Ranger, Nissan Navara
Key Features
Vehicle Strengths:
Robust chassis, capable powertrains, strong towing and payload capacity, proven off-road ability.
📋 Manual Details
Coverage Areas
Coverage:
Complete Workshop Service Repair
Page Count
Estimated Page Count:
Extensive (typically 1000+ pages for a complete workshop manual)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
2.2L Duratorq TDCi Diesel, 3.2L Duratorq TDCi Diesel, 2.5L Duratec Petrol I4 HE
Transmission:
Manual and Automatic Transmissions (Specifics to be detailed within manual)
Drivetrain:
4WD System, Differential Systems, Driveshafts
Suspension:
Front and Rear Suspension Systems, Shock Absorbers, Springs, Bushings
Steering:
Power Steering System, Steering Column, Tie Rods
Brakes:
Front and Rear Brake Systems (Disc/Drum), ABS, Parking Brake
Electrical:
Battery, Charging System, Starting System, Lighting, Fuses, Relays, ECU, Wiring Diagrams
Bodywork:
Exterior Panels, Doors, Hood, Tailgate, Interior Trim, Seats, Glass
HVAC:
Heating, Ventilation, and Air Conditioning System
Fuel:
Fuel System (Diesel and Petrol), Fuel Tank, Injectors, Fuel Pump
Exhaust:
Exhaust System Components, Emission Control Systems
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs)
Repair:
Component Removal and Installation, Engine Overhaul, Transmission Rebuild, Brake System Repair
Assembly:
Detailed Reassembly Instructions for all Major Components
Specifications:
Torque Specifications, Clearances, Tolerances
Wiring Diagrams:
Comprehensive Electrical Schematics
Technical Depth
Depth:
Complete Workshop Level (from basic maintenance to complete engine and transmission rebuilds)
📊 Manual Specifications
File Format
Format Details:
PDF (Portable Document Format) ensuring universal compatibility across devices.
Print Quality
Printability:
High-resolution, printable pages allowing users to create physical copies of specific sections or the entire manual.
Binding Type
Binding Type Digital:
N/A (Digital Download)
Paper Type
Paper Type Digital:
N/A (Digital Download)
Searchability
Text Search:
Fully searchable text content for quick information retrieval.
Software Requirements
Required Software:
Adobe Reader (or compatible PDF viewer)
⚙️ Engine Specifications
Primary Engine
Diesel 2 2L:
2.2L Duratorq TDCi (Common Rail Direct Injection) Diesel I4 HE
Diesel 3 2L:
3.2L Duratorq TDCi (Common Rail Direct Injection) Diesel I5 HE
Petrol 2 5L:
2.5L Duratec HE (High Performance) Petrol I4
Performance Diesel 2 2L
Horsepower Ps 2 2L:
~150 PS (approximate, varies by specific market tune)
Torque Nm 2 2L:
~375 Nm (approximate, varies by specific market tune)
Performance Diesel 3 2L
Horsepower Ps 3 2L:
~200 PS (approximate, varies by specific market tune)
Torque Nm 3 2L:
~470 Nm (approximate, varies by specific market tune)
Performance Petrol 2 5L
Horsepower Ps 2 5L:
~165 PS (approximate, varies by specific market tune)
Torque Nm 2 5L:
~225 Nm (approximate, varies by specific market tune)
Fuel System Diesel
System:
Common Rail Direct Injection (CRDi) with Turbocharging and Intercooling
Fuel System Petrol
System:
Multi-Point Fuel Injection (MPI)
🔧 Transmission
Standard
Transmission Types:
6-speed Manual Transmission, 6-speed Automatic Transmission
Optional
Transfer Case:
Electronic Shift-On-The-Fly 4x4 System (2H, 4H, 4L modes)
Features
Automatic Features:
Adaptive Shift Control, Sequential Sport Mode (typically)
📐 Dimensions
Exterior
Body Styles:
Single Cab, Freestyle Cab (Extended Cab), Double Cab
Wheelbase Mm:
Varies by cab type (e.g., ~3000mm for Double Cab)
Length Mm:
Varies by body style and cab type
Width Mm:
Varies by body style and cab type
Height Mm:
Varies by body style and cab type
Cargo
Tray Dimensions Mm:
Varies significantly by body style (e.g., length, width, depth of cargo bed)
Weights
Gross Vehicle Weight Rating Kg:
Typically in the range of 3000-3200 kg, depending on configuration.
Towing Capacity Kg:
Up to 3500 kg (braked trailer, depending on market and configuration)
Payload Capacity Kg:
Varies by configuration, typically around 1000-1300 kg.
🛡️ Safety Features
Ratings
Ancap Rating:
Likely 4 or 5 Stars ANCAP (Australasian New Car Assessment Program) for Double Cab variants based on comparable models.
Active Features
Brake Assist:
Yes (Brake Assist System - BAS)
Traction Control:
Yes (Traction Control System - TCS), Electronic Stability Control (ESC)
Hill Descent Control:
Yes (Hill Descent Control - HDC)
Hill Start Assist:
Yes (Hill Start Assist - HSA)
Passive Features
Airbags:
Front Airbags (Driver and Passenger), Side Airbags, Curtain Airbags (depending on trim level)
Seatbelts:
Pre-tensioner seatbelts with load limiters
Child Seat Anchors:
ISOFIX anchorage points
💡 Technology Features
Infotainment
Infotainment System:
Mazda's 'START' system (or similar) with touchscreen display, CD player, MP3 capability, Bluetooth connectivity, USB/AUX input. Higher trims may feature navigation.
Driver Assistance
Camera Options:
Rearview camera available on certain trims.
Connectivity
Bluetooth:
Standard on many trims for hands-free calling and audio streaming.
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
Typically 10,000 - 15,000 km or 12 months, whichever comes first. Check manual for specific engine/oil type.
Air Filter Replacement Km:
Recommended every 30,000 - 40,000 km or annually.
Fuel Filter Replacement Km Diesel:
Crucial for diesel engines. Typically every 40,000 - 60,000 km. Refer to manual for exact interval.
Fluid Specifications
Engine Oil Type Diesel:
API CJ-4 or CK-4 synthetic diesel engine oil, viscosity typically 5W-30 or 10W-30 (confirm with manual based on climate).
Engine Oil Type Petrol:
API SN or SP, ACEA A3/B4 or C3 synthetic gasoline engine oil, viscosity typically 5W-30 (confirm with manual).
Transmission Oil Manual:
GL-4 gear oil, viscosity typically 75W-90 (for both RWD and 4WD variants).
Transmission Oil Automatic:
Mercon LV or equivalent Automatic Transmission Fluid (ATF). Refer to manual for exact specification.
Coolant Type:
Mazda Super Long Life Coolant (SLLC) or equivalent, typically a pink ethylene glycol based coolant with organic acid technology (OAT).
Known Issues
Diesel Particulate Filter:
Potential DPF regeneration issues if driven primarily on short city trips without adequate highway driving.
E Grille Control Issues:
Some owners report issues with the electronic grille shutter control system in certain weather conditions.
Rear Main Seal Leaks:
Occasional reports of rear main seal leaks on higher mileage examples, particularly on diesel engines.
📚 Vehicle History
Brand Heritage
Mazda Truck History:
Mazda has a long history of producing capable light commercial vehicles, often in partnership with other manufacturers. The BT-50 is the successor to the Mazda Bravo/B-Series pickups.
Model Evolution
Generation Un:
This second generation (UN) BT-50, also known as the Mazda BT-50 Pro in some markets, marked a significant styling and engineering update, sharing its platform with the Ford Ranger (T6 generation).
Production
Manufacturing Location:
Primarily produced in Thailand, which is a major global hub for pickup truck manufacturing.
🏆 Awards & Recognition
Recognitions
Segment Awards:
The Mazda BT-50 has often been recognized for its strong value proposition, towing capability, and refinement within the pickup truck segment, particularly in markets like Australia and New Zealand.
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