Mazda Premacy Training Manual: GI B1 D E F1 G H J1 K

Mazda CONTENTS
PREMACY Title Section
Training
General Information GI
Engine FP B1
Manual Lubrication System D
Cooling System E
Fuel and Emission
Control Systems FP F1
FOREWORD
This manual explains each component or Engine Electrical System G
system operation and function for
the Mazda PREMACY. Clutch H
For proper repair and maintenance, Manual Transaxle F25M-R J1

a thorough familiarization with this manual
is important, and it should always be kept Automatic Transaxle K
in a handy place for quick and easy
reference. Front and Rear Axles M
Steering System N
All the contents of this manual, including
drawings and specifications, are the latest Braking System P
available at the time of printing.
As modifications affecting repair or Suspension R
maintenance occur, relevant information
supplementary to this volume will be made Body S
available at Mazda dealers. This manual
should be kept upĆtoĆdate. Body Electrical System T
Mazda Motor Corporation reserves Heater and Air Conditioner Systems U

the right to alter the specifications and
contents of this manual without obligation
2001 Mazda Motor Corporation
or advance notice.
PRINTED IN AUSTRALIA, JANUARY 2001
All rights reserved. No part of this book
3351-1A-01A
may be reproduced or used in any form or
by any means, electronic or
mechanicalĊincluding photocopying and
recording and the use of any kind of
information storage and retrieval
systemĊwithout permission in writing.
Mazda Motor Corporation

HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials
shown on the following page.
Downloaded from www.Manualslib.com manuals search engine

VEHICLE IDENTIFICATION NUMBERS (VIN)
Australian specs.
JM0 CP10P100 100001 Ċ
RELATED MATERIALS
323 Training Manual
(Australia, General (R.H.D. L.H.D.)) . . . . . . . . . . . . . . 3327-10-98G
323 Workshop Manual Supplement (Europe) . . . . . . 1633-10-98G
626 Training Manual (Europe) . . . . . . . . . . . . . . . . . . . . 3303-10-97D
626 Training Manual
(Australia, General (R.H.D. L.H.D.)) . . . . . . . . . . . . . . 3304-10-97F
626, 626 Station Wagon Workshop Manual
Supplement (Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . 1614-10-98D

GENERAL INFORMATION GI
VIN CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-1 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI-3

UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-2
VIN CODE
Australian specs.
JM0 CP10 P 1 00 100001

Serial No. 100001Ċ
No Significance 00 (Dummy)
Model Change Code 1
Engine Type P= FP
Body Style 10= Closed body
Vehicle Type CP= PREMACY
World Manufacturer Identification

JM0= Mazda (Australian specs.)
GI-1
UNITS D The actual converted values for 2.7 kgf/cm2 are
265 kPa and 38.4 psi. In the top specification, 2.7
is used as an upper limit, so its converted values
Electric current A (ampere) are rounded down to 260 and 38. In the bottom
Electric power W (watt) specification, 2.7 is used as a lower limit, so its
converted values are rounded up to 270 and 39.
Electric resistance Ω (ohm)
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
kgf/cm2 (kilogram force per
Positive pressure
square centimeter)
psi (pounds per square inch)
Number of
rpm (revolutions per minute)
revolutions
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
lmp qt (lmperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)
Conversion to SI Units (Système International
d'Unités)
D All numerical values in this manual are based on
SI units. Numbers shown in conventional units are
converted from these values.
Rounding off
D Converted values are rounded off to the same
number of places as the SI unit value. For
example, if the SI unit value is 17.2 and the value
after conversion is 37.84, the converted value will
be rounded off to 37.8.
Upper and lower limits

D When the data indicates upper and lower limits,
the converted values are rounded down if the SI
unit value is an upper limit and rounded up if the
SI unit value is a lower limit. Therefore, converted
values for the same SI unit value may differ after
conversion. For example, consider 2.7 kgf/cm2 in
the following specifications:
210Ċ260 kPa {2.1Ċ2.7 kgf/cm2, 30Ċ38 psi}

270Ċ310 kPa {2.7Ċ3.2 kgf/cm2, 39Ċ45 psi}
GI-2
NEW STANDARDS
D Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
GI
AbbreviĆ AbbreviĆ Remark
Name Name
ation ation
AP Accelerator Pedal Ċ Accelerator Pedal
ACL Air Cleaner Ċ Air Cleaner
A/C Air Conditioning Ċ Air Conditioning
BARO Barometric Pressure Ċ Atmospheric Pressure
B) Battery Positive Voltage VB Battery Voltage
Ċ Brake Switch Ċ Stoplight Switch
Ċ Calibration Resistor Ċ Corrected Resistance #6
CMP
Camshaft Position Sensor Ċ Crank Angle Sensor
sensor
CAC Charge Air Cooler Ċ Intercooler
CLS Closed Loop System Ċ Feedback System
CTP Closed Throttle Position Ċ Fully Closed
Ċ Closed Throttle Position Switch Ċ Idle Switch
CPP Clutch Pedal Position Ċ Clutch Position
CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System
CSP
CS sensor Control Sleeve Sensor Control Sleeve Position Sensor #6
sensor
CKP
Crankshaft Position Sensor Ċ Crank Angle Sensor 2
sensor
DLC Data Link Connector Ċ Diagnosis Connector
DTM Diagnostic Test Mode Ċ Test Mode #1
DTC Diagnostic Trouble Code(s) Ċ Service Code(s)
DI Distributor Ignition Ċ Spark Ignition
DLI Distributorless Ignition Ċ Direct Ignition
EI Electronic Ignition Ċ Electronic Spark Ignition #2
ECT Engine Coolant Temperature Ċ Water Thermo
EM Engine Modification Ċ Engine Modification
Ċ Engine Speed Input Signal Ċ Engine RPM Signal
EVAP Evaporative Emission Ċ Evaporative Emission
EGR Exhaust Gas Recirculation Ċ Exhaust Gas Recirculation
FC Fan Control Ċ Fan Control
FF Flexible Fuel Ċ Flexible Fuel
4GR Fourth Gear Ċ Overdrive
Ċ Fuel Pump Relay Ċ Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator Ċ Alternator
GND Ground Ċ Ground/Earth
HO2S Heated Oxygen Sensor Ċ Oxygen Sensor With heater
IAC Idle Air Control Ċ Idle Speed Control
Ċ Incorrect Gear Ratio Ċ Ċ
#1: Diagnostic trouble codes depend on the diagnostic test mode
#2: Controlled by the PCM
#3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#6: Part name of diesel engine
GI-3
Name Name
ation ation
Ċ Injection Pump FIP Fuel Injection Pump #6
Ċ Input/Turbine Speed Sensor Ċ Pulse Generator
IAT Intake Air Temperature Ċ Intake Air Thermo
KS Knock Sensor Ċ Knock Sensor
MIL Malfunction Indicator Lamp Ċ Malfunction Indicator Light
MAP Manifold Absolute Pressure Ċ Intake Air Pressure
MAF
Mass Air Flow Sensor Ċ Airflow Sensor
sensor
MFL Multiport Fuel Injection Ċ Multiport Fuel Injection
OBD OnĆBoard Diagnostic Ċ Diagnosis/SelfĆDiagnosis
OL Open Loop Ċ Open Loop
Ċ Output Speed Sensor Ċ Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter Ċ Catalytic Converter
O2S Oxygen Sensor Ċ Oxygen Sensor
PNP Park/Neutral Position Ċ Park/Neutral Range
Ċ PCM Control Relay Ċ Main Relay #6
PSP Power Steering Pressure Ċ Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
Ċ Pressure Control Solenoid Ċ Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection Ċ Secondary Air Injection System
injection
Ċ Pump Speed Sensor Ċ NE Sensor #6
Inject with
AIR Secondary Air Injection Ċ Secondary Air Injection System
compressor
SAPV Secondary Air Pulse Valve Ċ Reed Valve
SFI Sequential Multipoint Fuel Injection Ċ Sequential Fuel Injection
Ċ IDM relay Ċ Spill valve relay #6
Ċ 1-2 Shift Solenoid Valve
Ċ Shift Solenoid A
Ċ Shift A Solenoid Valve
Ċ 2-3 Shift Solenoid Valve
Ċ Shift Solenoid B
Ċ Shift B Solenoid Valve
Ċ Shift Solenoid C Ċ 3-4 Shift Solenoid Valve
3GR Third Gear Ċ 3rd Gear
TWC Three Way Catalytic Converter Ċ Catalytic Converter
TB Throttle Body Ċ Throttle Body
TP sensor Throttle Position Sensor Ċ Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch Ċ LockĆup Position
Transmission (Transaxle) Control
TCM Ċ ECĆAT Control Unit
Module
Transmission (Transaxle) Fluid
Ċ Ċ ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range Ċ Inhibitor Position
TC Turbocharger Ċ Turbocharger
VSS Vehicle Speed Sensor Ċ Vehicle Speed Sensor
VR Voltage Regulator Ċ IC Regulator
#4: Device that controls engine and powertrain
#6: Part name of diesel engine
GI-4
Name Name
ation ation GI
VAF
Volume Air Flow Sensor Ċ Air flow Sensor
sensor
Warm Up Three Way Catalytic
WUĆTWC Ċ Catalytic Converter #5
Converter
WOT Wide Open Throttle Ċ Fully Open
#5: Directly connected to exhaust manifold
GI-5
ENGINE (FP)
B1
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . B1-1
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1 ENGINE MECHANISM . . . . . . . . . . . . . . . . . . . . . B1-2
OUTLINE OF CONSTRUCTION . . . . . . . . . . . B1-1 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . B1-2
ABBREVIATIONS
ABDC After bottom dead center DOHC Double over head camshaft
ATDC After top dead center EX Exhaust
BBDC Before bottom dead center IN Intake
BTDC Before top dead center Ċ Ċ
OUTLINE
OUTLINE OF CONSTRUCTION
D The construction and operation of the FP engine models for Australian specs are the same as those of the
current 323 (BJ) FP engine model for each respective specification. (Refer to 323 Training Manual
3327-10-98G.)
Exceptions are as follows:
Ċ As the ignition coil is installed on the cylinder head, the shape of the cylinder head cover has been
changed.
SPECIFICATIONS
Specification
Item
FP
Type Gasoline, 4Ćcycle
Cylinder arrangement and number InĆline, 4Ćcylinders
Combustion chamber Pentroof
Valve system DOHC, Timing belt driven, 16 valves
Displacement (ml {cc, cu in}) 1,840 {1,840, 112.2}
Bore X stroke (mm {in}) 83.0 85.0 {3.27 3.35}
Compression ratio 9.1:1
Compression pressure (kPa {kgf/cm2, psi} [rpm]) 1, 180 {12.0, 171} [300]
Open BTDC (°) 0
IN
Close ABDC (°) 45
Valve timing
Open BBDC (°) 44
EX
Close ATDC (°) 6
0.225Ċ0.295 {0.009Ċ0.011}
IN (mm {in})
(0.26"0.035 {0.010"0.001})
Valve clearance [Engine cold]
0.225Ċ0.295 {0.009Ċ0.011}
EX (mm {in})
(0.26"0.035 {0.010"0.001})
B1-1
ENGINE MECHANISM
CYLINDER HEAD COVER
D Bosses for ignition coil installation are installed at the spark plug holes for the No.2 and No.4 cylinders on the
cylinder head cover.
1 Ignition coil installation position 2 Boss for ignition coil
B1-2
LUBRICATION SYSTEM
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . D-1
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 LUBRICATION MECHANISM . . . . . . . . . . . . . . . . D-2 D
OUTLINE OF CONSTRUCTION . . . . . . . . . . . . D-1
ABBREVIATIONS
R.H.D. Right hand drive
OUTLINE
D The construction and operation of the FP engine lubrication system for Australian specs. models are the same
as those of the current 323 (BJ) models. (Refer to 323 Training Manual 3327-10-98G.)
SPECIFICATIONS
Specification
Item
FP
Lubrication system ForceĆfed type
Oil cooler Ċ
Type Trochoid gear
Oil pump
Relief pressure kPa {kgf/cm2, psi} 450Ċ530 {4.5Ċ5.5, 64Ċ78}
Type FullĆflow, paper element
Oil filter Bypass pressure
79Ċ110 {0.8Ċ1.2, 12Ċ17}
kPa {kgf/cm2, psi}
Oil pressure kPa {kgf/cm2, psi} [rpm] 400Ċ490 {4.0Ċ5.0, 57Ċ71} [3,000]
Oil replacement (Approximate quantity)
3.3 {3.5, 2.9}
L {US qt, lmp qt}
Oil and oil filter replacement
(Approximate quantity) 3.5 {3.7, 3.1}
Oil capacity
L {US qt, lmp qt}
Total (dry engine)
(Approximate quantity) 3.7 {3.9, 3.3}
L {US qt, lmp qt}
Engine oil API service SG, SH, or SJ
Above 30 °C {86 °F} SAE 40
0 °CĊ40 °C {32 °FĊ104 °F} SAE 30
-10 °CĊ20 °C {14 °FĊ68 °F} SAE 20W-20
-15 °CĊ40 °C {5 °FĊ104 °F} Ċ
Above -10 °C {14 °F} SAE 20W-40, 20W-50
Viscosity
SAE 10W-30,
Above -25 °C {-13 °F}
10W-40, 10W-50
Below 10 °C {50 °F} Ċ
-30 °CĊ37 °C {-22 °FĊ98 °F} SAE 5W-30
Below -20 °C {-4 °F} SAE 5W-20
D-1
LUBRICATION MECHANISM
STRUCTURAL VIEW AND LUBRICATION FLOW DIAGRAM
1 Oil pan 8 Main bearing

2 Oil strainer 9 Crankshaft
3 Oil pump 10 Connecting rod bearing
4 Oil filter 11 Oil jet
5 Oil pressure switch 12 Piston
6 Orifice 13 Cylinder head
7 Camshaft 14 Cylinder block
D-2
COOLING SYSTEM
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 COOLING MECHANISM . . . . . . . . . . . . . . . . . . . . . E-2
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 STRUCTURAL VIEW AND COOLANT FLOW
OUTLINE OF CONSTRUCTION . . . . . . . . . . . . E-1 DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . E-1 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3 E
ABBREVIATIONS
ATF Automatic transaxle fluid
OUTLINE
FP, FP (HiĆpower)
D The construction and operation of the cooling system for Australian specs. are the same as those of the
current 323 (BJ) FP engine model for each respective specification. (Refer to 323 Training Manual
3327-10-98G.)
Due to the change in vehicle body shape, the radiator shape has also been changed from the current 323
(BJ).
SPECIFICATIONS
Specification
Item
FP
Cooling system WaterĆcooled, forced circulation
Coolant capacity (Approximate quantity) (L {US qt, lmp qt.}) 7.5 {7.9, 6.6}
Water pump Type Centrifugal, VĆribbed belt driven
Type Wax, bottomĆbypass
InitialĆopening temperature (°C {°F}) 80Ċ84 {176Ċ183}
Thermostat
FullĆopening temperature (°C {°F}) 95 {203}
FullĆopening lift (mm {in}) 8.5 {0.33} min.
Radiator Type Corrugated fin
Radiator cap opening pressure (kPa {kgf/cm2, psi}) 94Ċ122 {0.95Ċ1.25, 13.6Ċ17.7}
Type Electrical
Cooling fan Number 4
Blade
Outer diameter mm {in} 300 {11.8}
E-1
COOLING MECHANISM
STRUCTURAL VIEW AND COOLANT FLOW DIAGRAM
1 Coolant reservoir 5 Cylinder block

2 Radiator 6 Cylinder head
3 Thermostat 7 Heater unit
4 Water pump
E-2
RADIATOR
D To increase the coolant capacity, the height of the radiator core has been increased approx. 25 mm {0.98 in}.
1 Radiator cap 4 Lower tank

2 Upper tank 5 Radiator drain plug
3 Core 6 Integrated with ATF cooler
E-3
FUEL AND EMISSION CONTROL SYSTEMS
(FP)
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . F1-ă2 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-13
FUEL AND EMISSION CONTROL STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . F1-13
SYSTEMS OUTLINE . . . . . . . . . . . . . . . . . . . . . F1-ă2 SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . F1-14
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-ă2 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . F1-15 F1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-ă2 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-15
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . F1-ă3 STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . F1-17
CONTROL SYSTEM DIAGRAM . . . . . . . . . . F1-ă4 BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . F1-18
CONTROL SYSTEM WIRING DIAGRAM . . F1-ă5 CONTROL DEVICES AND CONTROL
INTAKEĆAIR SYSTEM . . . . . . . . . . . . . . . . . . . . . F1-ă8 RELATIONSHIP CHART . . . . . . . . . . . . . . . . F1-20
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-ă8 IDLE AIR CONTROL (IAC) . . . . . . . . . . . . . . . . . F1-21
STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . F1-ă8 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-21
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . F1-ă9 EGR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . F1-21
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-10 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-21
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-10 OPERATION CONDITIONS . . . . . . . . . . . . . . F1-21
STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . F1-10 ONĆBOARD DIAGNOSTIC SYSTEM . . . . . . . . F1-22
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . F1-11 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-22
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F1-12 DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-22
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-12 PID/DATA MONITOR AND RECORD . . . . . . F1-24
STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . F1-12 SIMULATION TEST . . . . . . . . . . . . . . . . . . . . . F1-25
EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . F1-13
F1-1
ABBREVIATIONS
A/C Air conditioner IAT Intake air temperature
ABS Antilock brake system IC Integrated circuit
ACC Accessories IG Ignition
ATF Automatic transaxle fluid M Motor
ATX Automatic transaxle MAF Mass air flow sensor
B Battery MTX Manual transaxle
B+ Battery positive voltage NOx Nitrogen oxide
CKP Crankshaft position O2S Oxygen sensor
CM Control module PCM Powertrain control module
CMP Camshaft position PCV Positive crankcase ventilation
CO Carbon monoxide PRC Pressure regulator control
CO2 Carbon dioxide PSP Power steering pressure
DLC Data link connector STA Start
DTC Diagnostic trouble code TCS Traction control system
ECT Engine coolant temperature TP Throttle position
EGR Exhaust gas recirculation TR Transaxle range
ESA Electronic spark advance TWC Three way catalytic converter
HC Hydrocarbon VICS Variable inertia charging system
HO2S Heated oxygen sensor VSS Vehicle speed sensor
IAC Idle air control
FUEL AND EMISSION CONTROL SYSTEMS OUTLINE

OUTLINE
D The fuel and emission control systems are essentially carried over from those 323 (BJ) FP engine models,
except for the following features. (Refer to 323 Training Manual 3327-10-98G.)
FEATURES
Improved serviceability
D The OBD tester has been changed from the NGS tester to WDS.
Modification to match vehicle characteristics

D Idle speed has been changed to match the vehicle characteristics.
D The operation condition of EGR control has been modified to match the vehicle characteristic.
F1-2
SPECIFICATIONS
Item FP, FP (HiĆpower)
Air cleaner element Type Paper element (oil permeated)
IAC valve Type Duty control
Type HiĆohmic
Fuel injector Type of fuel delivery TopĆfeed
Type of drive Voltage
Regulating pressure
Pressure regulator 280 {2.9, 41}
(kPa {kgf/cm2, psi})
Fuel pump Type Impeller (inĆtank) F1
Capacity
Fuel tank 58 {61, 51}
(L {US qt, Imp qt})
Fuel Specification Unleaded (RON 90 or higher)
Catalyst Type TWC (monolythic)
EGR control Type Stepping motor type
Evaporative emission control system Type Canister type
PCV system Type Closed type
F1-3
CONTROL SYSTEM DIAGRAM
1 IAT sensor 17 Pulsation dumper

2 MAF sensor 18 Purge solenoid valve
3 TP sensor 19 EGR valve
4 ECT sensor 20 VICS solenoid valve
5 CMP sensor 21 VICS vacuum chamber
6 CKP sensor 22 VICS check valve (oneĆway)
7 Knock sensor 23 VICS actuator
8 HO2S (integrated with O2S heater) 24 Charcoal canister
9 IAC valve 25 Rollover valve (evaporative gas check valve
10 Fuel injector (twoĆway) integrated)
11 PRC solenoid valve 26 TWC
12 Pressure regulator 27 Ignition coil No.1
13 Fuel filter (lowĆpressure) 28 Ignition coil No.2
14 Fuel pump 29 Generator
15 Fuel tank 30 PCM
16 Fuel filter (highĆpressure) 31 To PCM
F1-4
CONTROL SYSTEM WIRING DIAGRAM
B A C
TEN
KLN
FEN
AT10
AT5
A B
F1
B H 1V 1F 1L 1E 1D 4M 4O 3H 3J
C 1V 1F 1L 1E 1D 4M 4O 3H 3J
2E
G 2H
F 2G
E 2F
I 2A
D 2C
A 1Q 1T 1O 3I 4E 4F 4P
4Q 4R 4S 4U 4V 4K 4I 1M 2L 2K 1Q 1T 1O 3I 4E 4F 4P 4D
AT1
B F A C G I D E H
A B
A B C
b
F/P
c
d
AT1 e
f
A B
B ACC IG1 IG2 STA
C E
AT5
LOCK
ACC
ON
STA
AT10
A B
C D
M P B
B P D D
A
C
F1-5
IG-
A B
C B A
E A C B F D
A B A B A B A B A B A B A B
3F 3D 3K 3A 1I 3M 3N 3O 3P 4N 4T 4L 4W 4X 4Y 4Z
3F 3D 3K 1M 3M 3N 3O 3P 4N 4T 4L 4W 4X 4Y 4Z
3E 3B 3L 1B 1A 3C 1P 1S 1J 1R 1G 3G 4B 4A 4C 4G 4H
3E 3B 3L 1B 1A 3C 1P 1S 1J 4J 1R 1G 3G 4B 4A 4C 4G 4H
A B A
B A
A
B
B A A B C D
B C A B C A
C
b
c
d
e
f
C A C A
M
D B D B
F1-6
1 PCM 36 CKP sensor
2 Battery 37 CMP sensor
3 MAIN fuse 38 VICS solenoid valve
4 EGI fuse 39 PRC solenoid valve
5 Ignition switch 40 Purge solenoid valve
6 Starter 41 Fuel injector No.1
7 Generator 42 Fuel injector No.2
8 Generator warning light 43 Fuel injector No.3
9 Fuel pump relay 44 Fuel injector No.4 F1
10 Main relay 45 Condenser
11 Fuel pump 46 Ignition coil No.1
12 DLC 47 To spark plug No.1, No.4
13 HOLD switch 48 Ignition coil No.2
14 HOLD indicator light 49 To spark plug No.2, No.3
15 BackĆup light 50 Knock sensor
16 TR switch 51 PSP switch
17 Shift solenoid A 52 Immobilizer unit
18 Shift solenoid B 53 HO2S
19 Shift solenoid C 54 EGR valve
20 Shift solenoid D 55 Cooling fan relay
21 Shift solenoid E 56 Cooling fan motor
22 Pressure control solenoid 57 Condenser fan relay
23 ATF temperature sensor 58 Condenser fan motor
24 Input/turbine speed sensor 59 A/C relay
25 TP sensor 60 A/C compressor
26 ECT sensor 61 Refrigerant pressure switch (high, low pressue)
27 Speedometer sensor 62 A/C switch
28 VSS 63 A/C amplifier
29 Speedometer 64 Fan switch
30 Brake switch 65 Blower motor
31 Neutral switch 66 A/C equipped
32 Clutch switch 67 For MTX
33 IAC valve 68 For ATX
34 IAT sensor 69 To instrument cluster
35 MAF sensor
F1-7
INTAKEĆAIR SYSTEM
OUTLINE
D The intakeĆair system is the same as that of the current 323 (BJ) FP engine model (Refer to 323 Training
Manual 3327-10-98G.) A comparison of major parts for the PREMACY FP engine model and the 323 (BJ) FP
engine models is as follows:
: Applicable
Ċ: Not applicable
Item PREMACY FP 323 (BJ) FP Remark
FreshĆair duct Same as 323 (BJ) FP engine model
Resonance chamber Same as 323 (BJ) FP engine model
Air cleaner Same as 323 (BJ) FP engine model
Throttle body Same as 323 (BJ) FP engine model
Air valve Ċ Same as 323 (BJ) FP engine model
IAC valve Same as 323 (BJ) FP engine model
Intake manifold Same as 323 (BJ) FP engine model
Dynamic chamber Same as 323 (BJ) FP engine model
VICS solenoid valve Same as 323 (BJ) FP engine model
STRUCTURAL VIEW
1 Intake manifold 4 Air cleaner

2 VICS solenoid valve 5 Resonance chamber
3 Throttle body 6 FreshĆair duct
F1-8
SYSTEM DIAGRAM
F1
1 Intake manifold 9 FreshĆair duct

2 To PRC solenoid valve 10 Resonance chamber
3 To purge solenoid valve 11 EGR valve
4 Throttle body 12 VICS shutter valve actuator
5 IAC valve 13 VICS solenoid valve
6 MAF sensor 14 VICS vacuum chamber (builtĆin intake manifold)
7 Air cleaner 15 VICS check valve (oneĆway)
8 IAT sensor
F1-9
FUEL SYSTEM
OUTLINE
D The fuel system is the same as that of the current 323 (BJ) FP engine model. (Refer to 323 Training Manual
3327-10-98G.) A comparison of major parts for the PREMACY FP engine model and the 323 (BJ) FP engine
models is as follows:
: Applicable
Fuel tank Same as 323 (BJ) FP engine model
Quick release
connector and plastic Same as 323 (BJ) FP engine model
fuel hose
Fuel pump Same as 323 (BJ) FP engine model
Fuel filter
Same as 323 (BJ) FP engine model
(highĆpressure)
Fuel injector Same as 323 (BJ) FP engine model
Pressure regulator Same as 323 (BJ) FP engine model
PRC solenoid valve Same as 323 (BJ) FP engine model
Pulsation damper Same as 323 (BJ) FP engine model
STRUCTURAL VIEW
Engine Room Side
1 Pulsation damper 5 Quick release connector

2 Fuel injector 6 Fuel pump relay
3 Pressure regulator 7 To fuel tank
4 PRC solenoid valve 8 From fuel tank
F1-10
Fuel Tank Side
1 Fuel pump unit 4 To pulsation damper

2 Nonreturn valve 5 From pressure regulator
3 Quick release connector
SYSTEM DIAGRAM
1 Fuel tank 6 Fuel injector

2 Fuel filter (lowĆpressure) 7 Pressure regulator
3 Fuel pump 8 PRC solenoid valve
4 Fuel filter (highĆpressure) 9 To PCM
5 Pulsation damper
F1-11
EXHAUST SYSTEM
OUTLINE
D The exhaust system is the same as that of the current 323 (BJ) FP engine model. (Refer to 323 Training
Manual 3327-10-98G.)
STRUCTURAL VIEW
1 Exhaust manifold 4 Presilencer

2 Front pipe 5 Main silencer
3 TWC
F1-12
EMISSION SYSTEM
OUTLINE
D The emission system is the same as that of the current 323 (BJ) FP engine model. (Refer to 323 Training
Manual 3327-10-98G.) A comparison of major parts for the PREMACY FP engine model and the 323 (BJ) FP
engine models is as follows:
: Applicable
Ċ: Not applicable
Rollover valve Same as 323 (BJ) FP engine model
Evaporative gas check
valve (twoĆway)
Charcoal canister Same as 323 (BJ) FP engine model
Evaporative gas check
Ċ Same as 323 (BJ) FP engine model
valve (oneĆway)
Purge solenoid valve Same as 323 (BJ) FP engine model
PCV valve Same as 323 (BJ) FP engine model
TWC Same as 323 (BJ) FP engine model
STRUCTURAL VIEW
Engine Room Side
1 Charcoal canister 4 PCV valve

2 Purge solenoid valve 5 TWC
3 EGR valve 6 From fuel tank
F1-13
Fuel Tank Side
1 Rollover valve (builtĆin fuel tank)
SYSTEM DIAGRAM
1 Rollover valve (evaporative gas check valve (twoĆ 4 EGR valve

way) integrated) 5 PCV valve
2 Charcoal canister 6 TWC
3 Purge solenoid valve 7 To PCM
F1-14
CONTROL SYSTEM
OUTLINE
D The control system is essentially carried over from the 323 (BJ) FP engine model, except for the following:
Ċ Operation condition of EGR control has been modified. (Refer to 323 Training Manual 3327-10-98G.)
Input Device
: Applicable
Ċ: Not applicable
Item SIgnal PREMACY FP 323 (BJ) FP Remark
IAT sensor IAT Same as 323 (BJ) FP engine model
MAF sensor MAF Same as 323 (BJ) FP engine model
TP sensor TP Same as 323 (BJ) FP engine model
ECT sensor ECT Same as 323 (BJ) FP engine model
Cylinder
CMP sensor Same as 323 (BJ) FP engine model
identification
Engine
CKP sensor Same as 323 (BJ) FP engine model
revolution
Knock sensor Knocking Same as 323 (BJ) FP engine model
Oxygen
HO2S Same as 323 (BJ) FP engine model
concentration
Neutral switch (for Load/no load
MTX) detection
Clutch switch Load/no load
(for MTX) detection
TR switch Load/no load
(for ATX) detection
Power steering
PSP switch oil pump load Same as 323 (BJ) FP engine model
condition
VSS Vehicle speed Same as 323 (BJ) FP engine model
Brake pedal
Brake switch Same as 323 (BJ) FP engine model
condition
A/C switch,
refrigerant pressure
A/C operational Same as 323 (BJ) FP engine model
switch (high, low
pressure)
Refrigerant Refrigerant
pressure switch pressure (middle Ċ Ċ
(middle pressure) pressure)
DLC Diagnostic test
(TEN terminal) mode switching
BackĆup power
Battery Same as 323 (BJ) FP engine model
supply
Generator
Generator
(terminal P: output Same as 323 (BJ) FP engine model
output voltage
voltage)
Torque
ABS/TCS CM reduction Ċ Same as 323 (BJ) FP engine model
request
Immobilizer
Immobilizer unit system Same as 323 (BJ) FP engine model
communication
F1-15
Output Device
: Applicable
Ċ: Not applicable
Output device Control item PREMACY FP 323 (BJ) FP Remark
IAC valve IAC Same as 323 (BJ) FP engine model
VICS solenoid
VICS Same as 323 (BJ) FP engine model
valve
Fuel injection
Fuel injector Same as 323 (BJ) FP engine model
control
PRC solenoid
PRC Same as 323 (BJ) FP engine model
valve
Fuel pump Fuel pump
relay control
Ignition coil ESA control Same as 323 (BJ) ZL engine model
EGR valve EGR control In EGR control, operation conditions
have been changed.
Purge solenoid
Purge control Same as 323 (BJ) FP engine model
valve
O2S heater
O2S heater Same as 323 (BJ) FP engine model
control
Generator
Generator
(terminal D: Same as 323 (BJ) FP engine model
control
field coil)
Cooling fan
relay Electrical fan
Condenser fan control
relay (for ATX)
A/C relay
A/C cutĆoff
Condenser fan Same as 323 (BJ) FP engine model
control
relay (for MTX)
Traction
ABS/TCS CM Ċ Ċ
control
OnĆboard
DLC (terminal
diagnostic Same as 323 (BJ) FP engine model
KLN, FEN)
system
F1-16
STRUCTURAL VIEW
1 PCM 17 VSS (for MTX)

2 IAT sensor 18 VSS (for ATX)
3 MAF sensor 19 IAC valve
4 TP sensor 20 VICS solenoid valve
5 ECT sensor 21 Fuel injector
6 CMP sensor 22 Fuel pump relay
7 CKP sensor 23 Ignition coil
8 Knock sensor 24 O2S heater (integrated with HO2S)
9 HO2S (integrated with HO2S heater) 25 PRC solenoid valve
10 Clutch switch (for MTX) 26 Cooling fan relay
11 Neutral switch (for MTX) 27 Condenser fan relay
12 TR switch (for ATX) 28 Purge solenoid valve
13 PSP switch 29 EGR valve
14 Brake switch 30 A/C relay
15 Battery 31 Generator
16 DLC 32 Main relay
F1-17
BLOCK DIAGRAM
F1-18
1 IAT sensor 25 Fuel pump relay
2 MAF sensor 26 O2S heater (integrated with HO2S)
3 TP sensor 27 EGR valve
4 CMP sensor 28 Purge solenoid valve
5 CKP sensor 29 A/C relay
6 ECT sensor 30 Condenser fan relay (for MTX)
7 Knock sensor 31 Cooling fan relay
8 HO2S 32 Condenser fan relay (for ATX)
9 VSS 33 Generator (terminal D: field coil)
10 Clutch switch (for MTX) 34 Generator warning light (integrated with instrument
11 Neutral switch (for MTX) cluster)
12 TR switch (for ATX) 35 IAC system
13 PSP switch 36 VICS
14 Brake switch 37 Fuel injection control
15 A/C switch, refrigerant pressure switch (high, low 38 Immobilizer system

pressure) 39 ESA control
16 Generator (terminal P: output voltage) 40 PRC
17 DLC (terminal TEN) 41 Fuel pump control
18 Battery 42 O2S heater control
19 Immobilizer unit 43 EGR control
20 IAC valve 44 Purge control
21 VICS solenoid valve 45 A/C cutĆoff control
22 Fuel injectors 46 Electrical fan control
23 Ignition coil 47 Generator control
24 PRC solenoid valve 48 PCM
F1-19
CONTROL DEVICES AND CONTROL RELATIONSHIP CHART
: Applicable
Control item
PURGE CONTROL
FUEL INJECTION
EGR CONTROL
FAN CONTROL
IMMOBILIZER
A/C CUTĆOFF
ELECTRICAL
O2S HEATER
GENERATOR
FUEL PUMP
CONTROL
CONTROL
CONTROL
CONTROL
CONTROL
SYSTEM
VICS
PRC
ESA
IAC
IAT sensor
MAF sensor
TP sensor
CMP sensor
CKP sensor
ECT sensor
Knock sensor
HO2S
vice
VSS
Input dev
Neutral/Clutch switch*1
TR switch*2
PSP switch
Brake switch
A/C switch, refrigerant pressure
switch (high, low pressure)
Generator (terminal P: output
voltage)
DLC (terminal TEN)
Battery
Immobilizer unit
IAC valve
VICS solenoid valve
Fuel injector
Fuel pump relay
PRC solenoid valve
vice
Ignition coil
O tput dev
O2S heater
Purge solenoid valve
Outp
EGR valve
A/C relay
Cooling fan relay *2
Condenser fan relay *1
Generator (terminal D: field coil)
Generator warning light
*1: For MTX
*2: For ATX
F1-20
IDLE AIR CONTROL (IAC)
OUTLINE
D The IAC of the PREMACY FP engine model is the same as that of the 323 (BJ) FP engine models.
Idle Speed
D A comparison of the idle speeds for PREMACY FP engine model and the 323 (BJ) FP engine models is as
shown in the following table.
Idle speed (rpm)

Condition PREMACY
323 (BJ)
MTX ATX
No load 700
A/C is operating.*1 750
Within 30AĊ40A 750 700
Electrical load is on.
on
40A or above*2 750 700
P/S is operating.
750
(Steering wheel is rotating.)
*1: A/C switch and fan switch are on.
*2: Headlight is on, Fan switch is above 1st, Cooling fan is operating, and Rear window defroster is on.
EGR CONTROL
OUTLINE
D The EGR control of the PREMACY FP engine model is essentially carried over from the 323 (BJ) FP engine
models except for operation conditions.
D The EGR control of the PREMACY FP engine model is the same as that of the 323 (BJ) FP engine models.
OPERATION CONDITIONS
D The EGR control carries out the EGR operation when all of the following conditions are satisfied:
(1) Except cranking
(2) Except idling
(3) Engine speed is between 1000 rpm and 4093 rpm.
(4) Except heavy load volume increase zone (fuel injection control)
(5) Vehicle speed is above 3.8 km/h {2.4 MPH}.
F1-21
ONĆBOARD DIAGNOSTIC SYSTEM
OUTLINE
D The DTCs and simulation items of the PREMACY FP engine model are the same as those of the 323(BJ) FP
engine models.
D The monitoring item has been added for the PREMACY FP engine model compared to the 323 (BJ) FP
engine models.
DTC
DTC Table
: Applicable
-: Not applicable
Diagnosed Memory
DTC Detection condition FailĆsafe
circuit function
Input voltage from MAF sensor is below 0.86 V D Adjusts charging efficiency to
P0102
when ignition switch is turned to ON position. set value
MAF sensor
Input voltage from MAF sensor is above 4.90 V D Adjusts ignition timing to fixed
P0103 ignition (6°CA)
when ignition switch is turned to ON position.
Input voltage from IAT sensor is below 0.16 V D Sets IAT for engine control
P0112
when ignition switch is turned to ON position. 20°C {68°F}
{ }
IAT sensor
Input voltage from IAT sensor is above 4.84 V D Illuminates generator warning
P0113 light
D Sets ECT for engine control
Input voltage from ECT sensor is below 0.20 V
P0117 40°C {104°F}
D Sets ECT for IAC 80°C
ECT sensor
{176°F}
Input voltage from ECT sensor is above 4.94 V D Operates cooling fan (and
P0118
when ignition switch is turned to ON position. condenser fan*1)
D Sets throttle opening angle
Input voltage from TP sensor is below 0.10 V for engine control closed
P0122
when ignition switch is turned to ON position. D Fixes closed throttle position
TP sensor learning value to set value
D Inhibits dechoke control
Input voltage from TP sensor is above 4.90 V
P0123 D Inhibits dashpot correction for
IAC
When HO2S signal does not exceed 0.55 V
after engine is started or stays below 0.55 V for D Stops feedback control of fuel
P0134 HO2S
120 seconds after engine has reached normal injection control
operating temperature
Input voltage from knock sensor is below 0.90
P0327 D Stops fuel cutĆoff at shifting
V when ignition switch is turned to ON position.
Knock sensor D Ignition retard of knocking is
Input voltage from knock sensor is above 3.98 canceled.
P0328
V when ignition switch is turned to ON position.
No NE signal is inputted from CKP sensor while
P0335 CKP sensor D Stops fuel injection control
engine is running.
Purge Open or short circuit is observed in purge
P0443 solenoid solenoid valve system when ignition switch is - -
valve turned to ON position.
When HO2S signal stays above 0.55 V or beĆ
D Stops feedback control of fuel
P1170 HO2S low 0.55 V for 42.8 seconds after engine has
injection control
reached normal operating temperature.
Open or short circuit is observed in PRC
PRC solenoid
P1250 solenoid valve system when ignition switch is - -
valve
turned to ON position.
No SGC signal input from CMP sensor for 12
P1345 CMP sensor D Stops fuel injection control
engine rotations.
*1: For ATX
F1-22
: Applicable
-: Not applicable
Diagnosed Memory
DTC Detection condition FailĆsafe
circuit function
Open or short circuit is observed in EGR valve
P1496 (stepping motor 1 coil) system when ignition - -
switch is turned to ON position.
EGR valve
If PCM detects that PCM terminal 4M voltage is
above threshold*2 or below threshold*2 when
IAC duty target is above 18%, PCM determines
that IAC valve circuit has malfunction.
P1504 IAC valve D Stops IAC
If PCM detects that PCM terminal 4O voltage is
above 2 V or IAC target control duty valve is
below threshold*2, PCM determines that IAC
valve circuit has malfunction.
Open or short circuit is observed in VICS
VICS soleĆ
P1523 solenoid valve system when ignition switch is - -
noid valve
turned to ON position.
Commanded transmission from PCM to
P1602 immobilizer unit exceeds limit. - -
Immobilizer No response from immbilizer unit.
system
t
P1603 Key ID numbers are not registered in PCM. - -
P1604 Code word is not resistered in PCM. - -
P1608 PCM PCM does not read DTC from output device. - -
Code words stored in PCM and immobilizer unit
P1621 -
do not match.
ID numbers stored in immobilizer unit and PCM
P1622 Immobilizer do not match. (stored after immobilizer unit was -
system
y replaced and key ID number reĆregistered.)
P1623 Internal PCM EEPROM malfunction -
PCM detected immobilizer system malfunction
P1624 -
more than three times.
When PCM needs more than 19 A from generĆ
P1631 Generator ator, and judges generator output voltage to be -
below 8.5 V.
When PCM judges generator output voltage is
P1633 Battery -
above 18.4 V or B+ is above 15.9 V.
When PCM judges generator output voltage is
P1634 Generator -
above 16.9 V and B+ is below 11.0 V.
*2: When detected, the threshold value depends on battery voltage and IAC signal duty value.
F1-23
PID/DATA MONITOR AND RECORD
D The PID monitoring items of the PREMACY FP engine model for fuel and emission control systems are in the
following table.
PID/DATA Monitor Table

Monitor item (Display on Condition/
Monitoring item PCM terminal
WDS or equivalent) Unit
ACCS A/C relay ON/OFF 1S
ACSW A/C switch ON/OFF 1P
ALTF Generator field coil control duty value % 1O
ALTT V Generator output voltage V 1T
ARPMDES Target engine speed rpm -
BOO Brake switch ON/OFF 1F
CHRGLP Generator warning light ON/OFF 1Q
ECT °C 3E
ECT
ECT signal voltage V 3E
EVAPCP Purge solenoid valve duty value % 4L
FAN2*1 Condenser fan control ON/OFF 4J
FAN3 Cooling fan control ON/OFF 1R
FP Fuel pump relay ON/OFF 4P
FPRC Pressure regulator control ON/OFF 4T
FUELPW1 Fuel injection duration ms 4W, 4X, 4Y, 4Z
First gear 1/2/3/4 -
Second gear 1/2/3/4 -
GEAR
Third gear 1/2/3/4 -
Fourth gear 1/2/3/4 -
IAC IAC valve ms 4M, 4O
IAT °C 3B
IAT
IAT signal voltage V 3B
IVC VICS solenoid valve ON/OFF 4N
KNOCK 1 Knocking retard degree 3G
Change target line pressure according to throttle opening
LINEDES kPa -
angle
LPS*1 Pressure control solenoid A 4I, 4K
MAF MAF signal voltage V 3L
O2S11 HO2S V 3C
PNP*1 Load/no load condition signal ON/OFF 1V
PNP*2 Load/no load condition signal ON/OFF 1V
PSP PSP switch ON/OFF 1G
RPM Engine speed rpm 3H, 3J
SEGRP EGR valve stepping motor position step 3M, 3N, 3O, 3P
SSA/SS1*1 Shift solenoid A % 4S
SSB/SS2*1 Shift solenoid B % 4U
SSC/SS3*1 Shift solenoid C % 4V
SSD/SS4*1 Shift solenoid D ON/OFF 4Q
SSE/SS5*1 Shift solenoid E ON/OFF 4R
SPARKADV Ignition timing BTDC 3D, 3F
TCIL HOLD indicator light ON/OFF 2A
TCS HOLD switch ON/OFF 2C
*1: ATX only
*2: MTX only
F1-24
Monitor item (Display on Condition/
Monitoring item PCM terminal
WDS or equivalent) Unit
TEST TEN terminal in DLC
TFT*1 TFT °C 1M
TFTV*1 TFT sensor signal voltage V 1M
TP TP signal voltage V 4E
TPOD TP % 4E
TRL*1 TR switch (L range) ON/OFF 2F
TROD*1 TR switch (D range) ON/OFF 2H
TRR*1 TR switch (R position) ON/OFF 2E
TRD*1 TR switch (S range) ON/OFF 2G
TSS*1 Input/turbine speed signal rpm 2K, 2L
VPWR B+ V 1B
VSS Vehicle speed km/h 3A
*1: ATX only
*2: MTX only
SIMULATION TEST
D The simulation items of the PREMACY FP engine model are in the following table.
: Applicable
-: Not applicable
Simulation Test condition
Definition Operation PCM terminal
item IG ON IDLE
ACCS A/C relay ON/OFF 1S
ALTF Generator field coil control duty value OFF ɝ 1O
CHRGLP Generator warning light ON/OFF 1Q
EVAPCP Purge solenoid valve duty value % 4L
FAN2*1 Condenser fan control ON/OFF 4J
FAN3 Cooling fan control ON/OFF 1R
FP Fuel pump relay ON/OFF 4P
FPRC Pressure regulator control ON/OFF 4T
FUELPW1 Fuel injection duration % ɝ 4W, 4X, 4Y, 4Z
IAC IAC valve % 4M, 4O
INJ_1 Fuel injector No.1 OFF ɝ 4W
INJ_2 Fuel injector No.2 OFF ɝ 4X
INJ_3 Fuel injector No.3 OFF ɝ 4Y
NJ_4 Fuel injector No.4 OFF ɝ 4Z
IVC VICS solenoid valve ON/OFF 4N
SEGRP EGR valve stepping motor position STEP 3M, 3N, 3O, 3P
*1: ATX only
*2: MTX only
F1-25
ENGINE ELECTRICAL SYSTEM
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . G-1
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . G-2
OUTLINE OF CONSTRUCTION . . . . . . . . . . . . G-1
ABBREVIATIONS
DLI Distributorless ignition R.H.D. Right hand drive
G
OUTLINE
D The construction and operation of the engine electrical systems for the FP engines are the same as those of
the current 323 (BJ) FP respectively. (Refer to 323 Training Manual 3327-10-98G, However, the following
item has been changed in accordance with engine electrical system installation condition.
Ċ The ignition coils for FP engines are placed in the No.2 and No.4 cylinders on the upside of the cylinder
head cover. They are the same types as those of the current 323 (BJ) ZL and ZM engines.
SPECIFICATIONS
Specification
Item
FP
Voltage (V) 12
Battery Type and capacity
50D20L (40)
(5Ćhour rate) (A·h)
Output (V-A) 12Ċ80
Generator Regulated voltage (V) Controlled by PCM
SelfĆdiagnosis function Integrated in PCM
Type DLI
Spark advance Electronic
Ignition system
1Ċ3Ċ4Ċ2(1·4-3·2-4·1-2·3)
Firing order
Two cylinders fire simultaneously for each.
NGK BKR5E-11*1, BKR6E-11*2
Spark plug Type DENSO K16PR-U11*1, K20PR-U11*2
CHAMPION RC10YC4*3, RC8YC4*2
Type Coaxial reduction
Starter
Output (kW) 1.0
*1: Standard plug
*2: Cold type plug
*3: Hot type plug
G-1
STRUCTURAL VIEW
1 Battery 4 Spark plug

2 Generator 5 HighĆtension lead
3 Ignition coil 6 Starter
G-2
CLUTCH
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . H-1
OUTLINE OF CONSTRUCTION . . . . . . . . . . . . H-1
OUTLINE
D The clutch mechanism is the same as that of the current 323 (BJ) models. (Refer to 323 Training Manual
3327-10-98G.)
SPECIFICATIONS H
Engine
Item
FP
Clutch control Hydraulic
Spring type Diaphragm
Clutch cover
Set load (N {kgf, lbf}) 4,805 {490, 1,080)
Outer diameter (mm {in}) 200 {7.87}
Clutch disc
Inner diameter (mm {in}) 130 {5.12}
Type Suspended
Clutch pedal Pedal ratio 6.66
Full stroke (mm {in}) 137 {5.39}
Clutch master cylinder inner diameter (mm {in}) 15.87 {0.625}
Clutch release cylinder inner diameter (mm {in}) 19.05 {0.750}
Clutch fluid type SAE J1703, FMVSS 116 DOTĆ3
H-1
MANUAL TRANSAXLE
(F25M-R)
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J1-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . J1-2
OUTLINE OF CONSTRUCTION . . . . . . . . . . . J1-2
J1
J1-1
OUTLINE
D FP engine models are equipped with the F25M-R manual transaxle.
D The construction and operation of the transaxle are the same as those of the current F25M-R type manual
transaxle. (Refer to 323 Training Manual 3327-10-98G)
SPECIFICATIONS
Engine
Item
FP
Transaxle type F25M-R
Transaxle control FloorĆshift
Operation system Rod
Forward Synchromesh
Shift assist
Reverse Selective sliding and synchromesh
1st 3.416
2nd 1.842
3rd 1.290
Gear ratio
4th 0.972
5th 0.731
Reverse 3.214
Final gear ratio 4.105
Grade API service GL-4 or GL-5
All season SAE 75W-90
Oil Viscosity
Above 10°C {50°F} SAE 80W-90
Capacity (L {US qt, lmp qt}) 2.68 {2.83, 2.36}
J1-2
AUTOMATIC TRANSAXLE
(FN4A-EL)
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . K-ă1 CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . K-ă9
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-ă2 BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . K-10
OUTLINE OF CONSTRUCTION . . . . . . . . . . . K-ă2 ELECTRONIC CONTROL ITEMS AND
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-ă2 CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-11
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . K-ă3 COMPONENT DESCRIPTIONS
AUTOMATIC TRANSAXLE . . . . . . . . . . . . . . . . . K-ă4 (ELECTRONIC CONTROL) . . . . . . . . . . . . . . K-11
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-ă4 INPUT/OUTPUT SIGNALS AND RELATED
CROSSĆSECTIONAL VIEW . . . . . . . . . . . . . . . K-ă4 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . K-12
OUTLINE OF OPERATION . . . . . . . . . . . . . . . . K-ă5 SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . K-13
ECĆAT OPERATION CHART . . . . . . . . . . . . . . K-ă6 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-13
POWERFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . K-ă7 STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . K-13
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . K-ă9 SHIFTĆLOCK SYSTEM . . . . . . . . . . . . . . . . . . . K-14
K
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-ă9
ABBREVIATIONS
ATF Automatic transaxle fluid 1GR First gear
ECĆAT Electronically controlled automatic transaxle 2GR Second gear
PCM Powertrain control module 3GR Third gear
TCC Torque converter clutch 4GR Fourth gear
K-1
OUTLINE
D The construction and operation of the automatic transaxle is the same as that of the current 323 (BJ) (Refer to
Mazda 323 Training Manual 3327-10-98G).
K-2
SPECIFICATIONS
Item Australian specs.
Transaxle type FN4A-EL
1GR 2.816
2GR 1.497
Gear ratio 3GR 1.000
4GR 0.725
Reverse 2.648
Final gear ratio 4.147
Type ATF M-III or equivalent (e.g. DexronR II)
ATF
Capacity (L {US qt, lmp qt}) 7.2 {7.6, 6.3}
Torque converter stall torque ratio 2.120
Forward clutch
4/4
(number of drive/driven plates)
3Ċ4 clutch
3/3
(number of drive/driven plates) K
Hydraulic system
Reverse clutch
2/2
Low and reverse brake
5/5
Servo diameter
Band servo 64.6 {2.54}
(piston outer dia.) (mm {in})
Front sun gear 49
Front planetary
planetar gear
Front pinion gear 20
(number of teeth)
Front internal gear 89
Rear sun gear 37
Rear planetary
planetar gear
Rear pinion gear 30
(number of teeth)
Rear internal gear 98
Primary gear (number of teeth) 86
Secondary gear (number of teeth) 82
Output gear (number of teeth) 20
Ring gear (number of teeth) 87
K-3
AUTOMATIC TRANSAXLE
OUTLINE
D The FN4AĆEL type automatic transaxle is used.
D The construction and operation of the automatic transaxle is the same as that of the current 323 (BJ).
CROSSĆSECTIONAL VIEW
1 Torque converter 8 2-4 brake band

2 Oil pump 9 Low and reverse brake
3 Forward clutch 10 OneĆway clutch
4 Front planetary gear 11 Primary gear
5 Rear planetary gear 12 Secondary gear
6 3-4 clutch 13 Output gear
7 Reverse clutch 14 Differential
K-4
OUTLINE OF OPERATION
D The operation of the electronic automatic transaxle is classified into three systems: the electronic control
mechanism, the hydraulic pressure control mechanism, and the powertrain mechanism (includes the torque
converter mechanism.) The operation of each system is as follows:
Ċ Electronic control mechanism
D According to the signals from the switches and sensors in the input system, the PCM outputs the
signal which matches the present driving condition to the linear type solenoid, ON/OFF type solenoids
and the dutyĆcycle type solenoids in the hydraulic pressure control mechanism.
Ċ Hydraulic pressure control mechanism
D According to the signals from the PCM, each solenoid operates to switch the hydraulic passages in the
control valve body and controls the clutch engagement pressure.
D The line pressure is adjusted by the linear type pressure control solenoid. The hydraulic passages are
switched by the ON/OFF type solenoids (shift solenoids D and E.) And the clutch engagement
pressure is controlled by the dutyĆcycle type solenoids (shift solenoids A, B, and C).
Ċ Powertrain mechanism
D The driving force from the engine is transmitted through the torque converter to the transaxle.
D The transmitted driving force operates each clutch and brake according to the clutch engagement
pressure from the dutyĆcycle type solenoid, and the planetary gears change the gear ratio to the
optimal driving force. The changed driving force is transmitted through the differential to the axle shaft
and then the tires. K
1 Powertrain mechanism 12 Oil pump

2 Hydraulic pressure control mechanism 13 PCM
3 Electronic control mechanism 14 Vehicle speed
4 Torque converter 15 ATF temperature
5 Clutches, brakes 16 Forward clutch drum revolution speed
6 Planetary gear 17 Engine revolution speed
7 Differential 18 Clutches, brakes engagement, relase pressure
8 Control valve body 19 Powerflow
9 Shift solenoid D, E (ON/OFF type) 20 Hydraulic pressure control signal
10 Pressure control solenoid (linear type) 21 Electronic signal
11 Shift solenoid A, B, C (dutyĆcycle type) 22 Tire
K-5
EC-AT OPERATION CHART
Shift pattern Transaxle Operation of shift solenoid
2-4 Solenoid
Solenoid valve
Low and reverse brake

brake valve (ON/
(dutyĆcycle type)
band OFF type)
OneĆway cluttch
ge
ch
ch
Position/Rang
Forward clutc
Reverse clutc
M d
Mode G
Gear iti
position
e
Engine brake
solenoid A
solenoid B
solenoid C
solenoid D
solenoid E
3-4 clutch
Released
Applied
Shift
Shift
Shift
Shift
Shift
Shift
TCC
P – – – – – – – ON OFF
R – Reverse 2.648 – OPEN OPEN OPEN OFF OFF
N – – – – – – – ON OFF
1GR 2.816 Ě OPEN CLOSE CLOSE OFF OFF
*1 2GR 1.497 OPEN OPEN CLOSE OFF OFF
POW
POWĆ
3GR 1.000 OPEN OPEN OPEN OFF OFF
ER/
NORĆ 4GR 0.725 CLOSE OPEN OPEN ON OFF
D MAL 4GR *2
0.725 CLOSE OPEN OPEN ON ON
TCC ON
2GR 1.497 OPEN OPEN CLOSE OFF OFF
HOL
3GR 1.000 OPEN OPEN OPEN OFF OFF
D
4GR*3 0.725 CLOSE OPEN OPEN ON OFF
NonĆ
N 2GR 1.497 OPEN OPEN CLOSE OFF OFF
HOL
D 3GR 1.000 OPEN OPEN OPEN OFF OFF
S 4GR*3 0.725 CLOSE OPEN OPEN ON OFF
2GR 1.497 OPEN OPEN CLOSE OFF OFF
HOL
3GR*3 1.000 OPEN OPEN OPEN OFF OFF
D
NonĆ
N 2GR 1.497 OPEN OPEN CLOSE OFF OFF
HOL
D 3GR*3 1.000 OPEN OPEN OPEN OFF OFF
L
1GR 2.816 Ě OPEN OPEN CLOSE ON ON
HOL 2GR*3 1.497 OPEN OPEN CLOSE OFF OFF
D 3GR*3 1.000 OPEN OPEN OPEN OFF OFF
*1: Automatically switches between POWER and NORMAL modes according to accelerator pedal depressing
speed.
*2: Perform TCC operation in NORMAL mode.
*3: To prevent engine overspeed, inhibits downshift until the engine speed is reduced to the preset speed.
: Operating
Ě: Transmits the torque only when driving.
OPEN: Engages the line pressure to the clutch pressure.
CLOSE: Drains the clutch pressure.
ON: Engages the output port and the supply port (Solenoid reducing pressure).
OFF: Engages the output port and the drain port (Drains the output port).
K-6

Mazda Premacy Training Manual: GI B1 D E F1 G H J1 K

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Mazda CONTENTS

PREMACY Title Section

Manual Lubrication System D

For proper repair and maintenance, Manual Transaxle F25M-R J1

Mazda Motor Corporation reserves Heater and Air Conditioner Systems U

Mazda Motor Corporation

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VIN CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-1 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI-3

JM0 CP10 P 1 00 100001

Model Change Code 1

Body Style 10= Closed body

Vehicle Type CP= PREMACY

World Manufacturer Identification

Upper and lower limits

210Ċ260 kPa {2.1Ċ2.7 kgf/cm2, 30Ċ38 psi}

1 Ignition coil installation position 2 Boss for ignition coil

1 Oil pan 8 Main bearing

1 Coolant reservoir 5 Cylinder block

1 Radiator cap 4 Lower tank

FUEL AND EMISSION CONTROL SYSTEMS OUTLINE

Modification to match vehicle characteristics

1 IAT sensor 17 Pulsation dumper

12 Pressure regulator 27 Ignition coil No.1

13 Fuel filter (lowĆpressure) 28 Ignition coil No.2

14 Fuel pump 29 Generator

15 Fuel tank 30 PCM

16 Fuel filter (highĆpressure) 31 To PCM

1 Intake manifold 4 Air cleaner

1 Intake manifold 9 FreshĆair duct

1 Pulsation damper 5 Quick release connector

1 Fuel pump unit 4 To pulsation damper

1 Fuel tank 6 Fuel injector

1 Exhaust manifold 4 Presilencer

1 Charcoal canister 4 PCV valve

1 Rollover valve (builtĆin fuel tank)

1 Rollover valve (evaporative gas check valve (twoĆ 4 EGR valve

1 PCM 17 VSS (for MTX)

13 PSP switch 36 VICS

14 Brake switch 37 Fuel injection control

15 A/C switch, refrigerant pressure switch (high, low 38 Immobilizer system

Idle speed (rpm)

PID/DATA Monitor Table

1 Battery 4 Spark plug

1 Torque converter 8 2-4 brake band

1 Powertrain mechanism 12 Oil pump

Low and reverse brake

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