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

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🏷️ Basic Information Identification Make: Mazda Model: BT-50 Generation: Second Generation (UN/UR) Model Years Covered: 2011-2013 Codes Chassis Code: UR 👋 Introduction Market Position Vehicle Segment: Mid-size pickup truck (ute), known for ruggedness and utility Target Audience: Work vehicle, fleet use, adventure/lifestyle vehicle, farmers, tradespeople Competitive Analysis Key Competitors: Toyota Hilux, Ford Ranger, Mitsubishi Triton, Isuzu D-Max, Nissan Navara Key Features Engine Options: Durable diesel engines (Duratorq) and a reliable petrol option (Duratec), offering a range of power and efficiency Capability: Strong towing capacity, good off-road performance, robust chassis construction Manual Value Proposition: Provides comprehensive factory-level repair and maintenance information, enabling DIY repairs or informed discussions with mechanics 📋 Manual Details Coverage Areas Engine Variants Covered: 2.2L Duratorq Diesel TDCi, 3.2L Duratorq Diesel TDCi, 2.5L Duratec Petrol I4 HE Transmission Types Covered: Manual and Automatic Transmissions Body Styles Covered: Single Cab, Freestyle Cab, Double Cab (specific to UR generation) Page Count Estimated Page Count: Hundreds of pages (exact number not specified, but described as comprehensive) Manual Type Type: Service Repair Workshop Manual Professional Standard: Factory-level, used by professional mechanics and technicians Language Language: English Format Delivery Format: PDF Download Platform Compatibility: Windows and MAC computers, tablets, smartphones Licensing Usage License: Lifetime use, unlimited installations Updates: No expiry dates, no renewal fees 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (diesel and petrol) Engine Electrical: Ignition system (petrol), glow plug system (diesel), fuel injection system (common rail for diesel, port injection for petrol), engine control module (ECM), sensors, wiring diagrams Transmission Drivetrain: Manual transmission overhaul, automatic transmission operation and repair, transfer case, driveshafts, differentials, axles Braking System: Front and rear brake systems (disc/drum configurations), ABS, EBD, brake lines, master cylinder, calipers, pads, rotors Suspension Steering: Front independent suspension (e.g., double wishbone), rear leaf spring suspension, power steering system, steering column, tie rods, ball joints Electrical Systems: Battery, charging system, starting system, lighting systems (headlights, taillights, interior), instrument cluster, power windows, central locking, HVAC controls Body And Chassis: Body panel removal and installation, chassis lubrication, frame components, doors, hoods, tailgates, bumpers, interior trim HVAC: Air conditioning system diagnosis and repair, heater core, blower motor, climate controls Safety Systems: Airbag system (SRS) diagnosis and component replacement, seatbelt mechanisms Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks and top-offs, belt inspections, brake checks, tire rotation Troubleshooting: Diagnostic procedures for various systems, symptom-based troubleshooting guides, fault code interpretation (OBD-II) Repair Overhaul: Detailed step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems Diagnostics: Electrical system diagnostics, engine performance diagnostics, ABS and SRS system diagnostics Wiring Diagrams: Comprehensive electrical wiring diagrams for all circuits, including component location charts Technical Specifications: Torque specifications for all fasteners, fluid capacities, engine specifications, dimensions, clearances Special Tools: Identification and usage instructions for any specialized tools required for specific repair procedures Technical Depth Depth Of Information: Comprehensive, from basic maintenance to full engine and transmission rebuilds Visual Aids: Hundreds of detailed photos and exploded diagrams illustrating procedures 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely searchable text (standard for professional PDF manuals) Print Quality Print Capability: Printable pages (single or entire manual) Resolution: High resolution for clear viewing of text and diagrams Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine 2.2L Duratorq Diesel Tdci: Four-cylinder turbocharged diesel common rail. Power output typically around 150 PS (110 kW) and torque around 375 Nm (277 lb-ft). Known for fuel efficiency and good low-end torque. 3.2L Duratorq Diesel Tdci: Five-cylinder turbocharged diesel common rail. Power output typically around 200 PS (147 kW) and torque around 470 Nm (347 lb-ft). Offers higher performance and towing capability. 2.5L Duratec Petrol I4 He: Four-cylinder naturally aspirated petrol engine. Power output typically around 166 PS (122 kW) and torque around 227 Nm (167 lb-ft). Less common in this generation but offered for petrol preference. Performance Diesel Performance Characteristics: Strong pulling power at lower RPMs, suitable for towing and hauling. Modern common rail injection for efficiency and emissions. Fuel System Diesel Fuel System Type: High-pressure common rail direct injection with Denso or Bosch fuel injection system components. Petrol Fuel System Type: Multi-point fuel injection (MPI). 🔧 Transmission Standard Manual Transmission Type: 6-speed manual transmission (MT82 or similar Getrag-derived unit for diesel engines). Optional Automatic Transmission Type: 6-speed automatic transmission (e.g., 6R80 derived from Ford's SelectShift family). Features Transfer Case: Part-time 4WD system with electronic or manual engagement, featuring high and low range gearing. 📐 Dimensions Exterior Wheelbase Range: Approximately 3000-3220 mm (varies by body style and configuration). Weights Gross Vehicle Weight Rating: Typically in the 2800-3100 kg range, depending on configuration and engine. Towing Capacity: Up to 3500 kg (braked), depending on market...
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Sku: 207575
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Mazda BT-50 BT50 2.2L 3.2L DURATORQ Diesel TDCi & 2.5L DURATEC Petrol I4 HE 2011-2013 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
BT-50
Generation:
Second Generation (UN/UR)
Model Years Covered:
2011-2013
Codes
Chassis Code:
UR
👋 Introduction
Market Position
Vehicle Segment:
Mid-size pickup truck (ute), known for ruggedness and utility
Target Audience:
Work vehicle, fleet use, adventure/lifestyle vehicle, farmers, tradespeople
Competitive Analysis
Key Competitors:
Toyota Hilux, Ford Ranger, Mitsubishi Triton, Isuzu D-Max, Nissan Navara
Key Features
Engine Options:
Durable diesel engines (Duratorq) and a reliable petrol option (Duratec), offering a range of power and efficiency
Capability:
Strong towing capacity, good off-road performance, robust chassis construction
Manual Value Proposition:
Provides comprehensive factory-level repair and maintenance information, enabling DIY repairs or informed discussions with mechanics
📋 Manual Details
Coverage Areas
Engine Variants Covered:
2.2L Duratorq Diesel TDCi, 3.2L Duratorq Diesel TDCi, 2.5L Duratec Petrol I4 HE
Transmission Types Covered:
Manual and Automatic Transmissions
Body Styles Covered:
Single Cab, Freestyle Cab, Double Cab (specific to UR generation)
Page Count
Estimated Page Count:
Hundreds of pages (exact number not specified, but described as comprehensive)
Manual Type
Type:
Service Repair Workshop Manual
Professional Standard:
Factory-level, used by professional mechanics and technicians
Language
Language:
English
Format
Delivery Format:
PDF Download
Platform Compatibility:
Windows and MAC computers, tablets, smartphones
Licensing
Usage License:
Lifetime use, unlimited installations
Updates:
No expiry dates, no renewal fees
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (diesel and petrol)
Engine Electrical:
Ignition system (petrol), glow plug system (diesel), fuel injection system (common rail for diesel, port injection for petrol), engine control module (ECM), sensors, wiring diagrams
Transmission Drivetrain:
Manual transmission overhaul, automatic transmission operation and repair, transfer case, driveshafts, differentials, axles
Braking System:
Front and rear brake systems (disc/drum configurations), ABS, EBD, brake lines, master cylinder, calipers, pads, rotors
Suspension Steering:
Front independent suspension (e.g., double wishbone), rear leaf spring suspension, power steering system, steering column, tie rods, ball joints
Electrical Systems:
Battery, charging system, starting system, lighting systems (headlights, taillights, interior), instrument cluster, power windows, central locking, HVAC controls
Body And Chassis:
Body panel removal and installation, chassis lubrication, frame components, doors, hoods, tailgates, bumpers, interior trim
HVAC:
Air conditioning system diagnosis and repair, heater core, blower motor, climate controls
Safety Systems:
Airbag system (SRS) diagnosis and component replacement, seatbelt mechanisms
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, belt inspections, brake checks, tire rotation
Troubleshooting:
Diagnostic procedures for various systems, symptom-based troubleshooting guides, fault code interpretation (OBD-II)
Repair Overhaul:
Detailed step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems
Diagnostics:
Electrical system diagnostics, engine performance diagnostics, ABS and SRS system diagnostics
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all circuits, including component location charts
Technical Specifications:
Torque specifications for all fasteners, fluid capacities, engine specifications, dimensions, clearances
Special Tools:
Identification and usage instructions for any specialized tools required for specific repair procedures
Technical Depth
Depth Of Information:
Comprehensive, from basic maintenance to full engine and transmission rebuilds
Visual Aids:
Hundreds of detailed photos and exploded diagrams illustrating procedures
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely searchable text (standard for professional PDF manuals)
Print Quality
Print Capability:
Printable pages (single or entire manual)
Resolution:
High resolution for clear viewing of text and diagrams
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
2.2L Duratorq Diesel Tdci:
Four-cylinder turbocharged diesel common rail. Power output typically around 150 PS (110 kW) and torque around 375 Nm (277 lb-ft). Known for fuel efficiency and good low-end torque.
3.2L Duratorq Diesel Tdci:
Five-cylinder turbocharged diesel common rail. Power output typically around 200 PS (147 kW) and torque around 470 Nm (347 lb-ft). Offers higher performance and towing capability.
2.5L Duratec Petrol I4 He:
Four-cylinder naturally aspirated petrol engine. Power output typically around 166 PS (122 kW) and torque around 227 Nm (167 lb-ft). Less common in this generation but offered for petrol preference.
Performance
Diesel Performance Characteristics:
Strong pulling power at lower RPMs, suitable for towing and hauling. Modern common rail injection for efficiency and emissions.
Fuel System
Diesel Fuel System Type:
High-pressure common rail direct injection with Denso or Bosch fuel injection system components.
Petrol Fuel System Type:
Multi-point fuel injection (MPI).
🔧 Transmission
Standard
Manual Transmission Type:
6-speed manual transmission (MT82 or similar Getrag-derived unit for diesel engines).
Optional
Automatic Transmission Type:
6-speed automatic transmission (e.g., 6R80 derived from Ford's SelectShift family).
Features
Transfer Case:
Part-time 4WD system with electronic or manual engagement, featuring high and low range gearing.
📐 Dimensions
Exterior
Wheelbase Range:
Approximately 3000-3220 mm (varies by body style and configuration).
Weights
Gross Vehicle Weight Rating:
Typically in the 2800-3100 kg range, depending on configuration and engine.
Towing Capacity:
Up to 3500 kg (braked), depending on market regulations and specific vehicle configuration.
🛡️ Safety Features
Ratings
Ancap Rating:
Achieved 5-star ANCAP safety rating for the UR generation in many configurations, highlighting good occupant protection.
Active Features
Braking Assistance:
ABS (Anti-lock Braking System), EBA (Emergency Brake Assist), EBD (Electronic Brakeforce Distribution).
Passive Features
Airbags:
Front airbags for driver and passenger, side airbags, and curtain airbags (depending on trim level).
Seatbelts:
Pretensioner and load limiter seatbelts, particularly for front occupants.
💡 Technology Features
Infotainment
Infotainment System:
Base models may have basic radio systems, while higher trims could feature touch-screen infotainment with CD player, USB, AUX input, and Bluetooth connectivity. Some might offer satellite navigation.
Driver Assistance
Traction Control:
Traction Control System (TCS) and Electronic Stability Control (ESC) are typically standard or available on higher trims.
Hill Descent Control:
Hill Descent Control (HDC) is often featured on 4WD models to assist with off-road descents.
Connectivity
Bluetooth:
Bluetooth hands-free calling and audio streaming available on models equipped with compatible infotainment systems.
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Typically every 10,000-15,000 km or 12 months, whichever comes first, depending on driving conditions. Check manual for specific recommendations.
Fuel Filter Diesel:
Often recommended replacement every 40,000-60,000 km for diesel engines to ensure fuel system integrity.
Air Filter:
Inspect every 15,000 km, replace as needed (typically every 30,000-45,000 km) or when dirty.
Fluid Specifications
Engine Oil Diesel:
API CI-4 or higher, SAE 5W-30 or 10W-30 (check specific engine variant for exact recommendation, e.g., Ford WSS-M2C171-D compliant).
Engine Oil Petrol:
API SN or SP, SAE 5W-30 (e.g., Ford WSS-M2C913-D or similar).
Transmission Fluid Manual:
GL-4 or GL-5 rated gear oil, viscosity typically SAE 75W-90. Specific recommendations should be followed from the manual.
Transmission Fluid Automatic:
Mercon LV or equivalent Dexron-VI compatible fluid. Specific Mazda or Ford specifications are critical.
Coolant:
OAT (Organic Acid Technology) or HOAT (Hybrid Organic Acid Technology) coolant, typically a pink or red color. Mazda FL22 or equivalent.
Known Issues
Diesel Egr System:
EGR (Exhaust Gas Recirculation) valve can become clogged with carbon deposits, leading to reduced performance or engine warning lights.
Diesel Dpf System:
Diesel Particulate Filter (DPF) regeneration issues can occur, especially with vehicles used for short trips, potentially leading to DPF clogging and performance problems.
Turbocharger Hoses:
Intercooler hoses and vacuum lines can degrade or split over time, leading to boost leaks and loss of power.
Automatic Transmission Shifting:
Some units might experience hesitant shifting or rough gear changes, potentially related to transmission fluid degradation or valve body issues.
📚 Vehicle History
Brand Heritage
Mazda'S Pickup Truck Lineage:
Mazda has a long history of producing light commercial vehicles and pickup trucks, often in partnership with other manufacturers. The BT-50 nameplate signifies Mazda's dedicated pickup offering.
Model Evolution
Bt-50 Generations:
The UR generation (2011-2013) marked a significant styling and engineering update, sharing its platform with the Ford Ranger of the same era, resulting in robust construction and shared powertrain components.
Production
Manufacturing Location:
Primarily produced in Thailand (AutoAlliance Thailand plant) for global markets.
🏆 Awards & Recognition
Recognitions
Safety Awards:
Multiple 5-star ANCAP safety ratings for the relevant period indicate strong safety performance against independent testing standards.
Ratings
Utility Vehicle Awards:
The BT-50 (UR) often received positive reviews for its robust chassis, powerful engines, and towing capabilities, making it a popular choice in the utility segment.
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