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Mazda
PREMACY
Training
Manual
FOREWORD
This manual explains each component or
system operation and function for
the Mazda PREMACY.
For proper repair and maintenance,
a thorough familiarization with this manual
is important, and it should always be kept
in a handy place for quick and easy
reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up to date.
Mazda Motor Corporation reserves
the right to alter the specifications and
contents of this manual without obligation
or advance notice.
All rights reserved. No part of this book
may be reproduced or used in any form or
by any means, electronic or
mechanical including photocopying and
recording and the use of any kind of
information storage and retrieval
system without 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.
CONTENTS
Title
General Information
Engine
Lubrication System
Cooling System
Fuel and Emission
Control Systems
Engine Electrical System
Clutch
Manual Transaxle
Automatic Transaxle
Front and Rear Axles
Steering System
Braking System
Suspension
Body
Body Electrical System
Heater and Air Conditioner Systems
2001 Mazda Motor Corporation
PRINTED IN AUSTRALIA, JANUARY 2001
3351-1A-01A
Section
GI
B1
FP
D
E
FP
F1
G
H
F25M-R
J1
K
M
N
P
R
S
T
U

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   Summary of Contents for Mazda premacy

  • Page 1

    As modifications affecting repair or Suspension maintenance occur, relevant information supplementary to this volume will be made Body available at Mazda dealers. This manual should be kept up to date. Body Electrical System Mazda Motor Corporation reserves Heater and Air Conditioner Systems...

  • Page 2

    VEHICLE IDENTIFICATION NUMBERS (VIN) Australian specs. JM0 CP10P100 100001 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) .

  • Page 3: General Information

    1 0 P 1 0 0 1 0 0 0 0 1 Serial No. 100001 No Significance 00 (Dummy) Model Change Code Engine Type P= FP Body Style 10= Closed body Vehicle Type CP= PREMACY World Manufacturer Identification JM0= Mazda (Australian specs.) GI-1...

  • Page 4

    UNITS The actual converted values for 2.7 kgf/cm 265 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom Electric current A (ampere) specification, 2.7 is used as a lower limit, so its Electric power...

  • Page 5: New Standards

    NEW STANDARDS Following is a comparison of the previous standard and the new standard. New Standard Previous Standard Remark Abbrevi Abbrevi Name Name ation ation Accelerator Pedal Accelerator Pedal Air Cleaner Air Cleaner Air Conditioning Air Conditioning BARO Barometric Pressure Atmospheric Pressure Battery Positive Voltage Battery Voltage...

  • Page 6

    New Standard Previous Standard Remark Abbrevi Abbrevi Name Name ation ation Injection Pump Fuel Injection Pump Input/Turbine Speed Sensor Pulse Generator Intake Air Temperature Intake Air Thermo Knock Sensor Knock Sensor Malfunction Indicator Lamp Malfunction Indicator Light Manifold Absolute Pressure Intake Air Pressure Mass Air Flow Sensor Airflow Sensor...

  • Page 7

    New Standard Previous Standard Remark Abbrevi Abbrevi Name Name ation ation Volume Air Flow Sensor Air flow Sensor sensor Warm Up Three Way Catalytic WU TWC Catalytic Converter Converter Wide Open Throttle Fully Open #5: Directly connected to exhaust manifold GI-5...

  • Page 8

    ENGINE (FP) ABBREVIATIONS ......B1-1 SPECIFICATIONS ..... . . B1-1 OUTLINE .

  • Page 9

    ENGINE MECHANISM CYLINDER HEAD COVER 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. Ignition coil installation position Boss for ignition coil B1-2...

  • Page 10: Lubrication System

    LUBRICATION SYSTEM ABBREVIATIONS ......SPECIFICATIONS ......OUTLINE .

  • Page 11

    LUBRICATION MECHANISM STRUCTURAL VIEW AND LUBRICATION FLOW DIAGRAM Oil pan Main bearing Oil strainer Crankshaft Oil pump Connecting rod bearing Oil filter Oil jet Oil pressure switch Piston Orifice Cylinder head Camshaft Cylinder block...

  • Page 12: Cooling System

    COOLING SYSTEM ABBREVIATIONS ......COOLING MECHANISM ..... OUTLINE .

  • Page 13

    COOLING MECHANISM STRUCTURAL VIEW AND COOLANT FLOW DIAGRAM Coolant reservoir Cylinder block Radiator Cylinder head Thermostat Heater unit Water pump...

  • Page 14

    RADIATOR To increase the coolant capacity, the height of the radiator core has been increased approx. 25 mm {0.98 in}. Radiator cap Lower tank Upper tank Radiator drain plug Core Integrated with ATF cooler...

  • Page 15: Table Of Contents

    FUEL AND EMISSION CONTROL SYSTEMS (FP) ABBREVIATIONS ......F1- 2 OUTLINE ......F1-13 FUEL AND EMISSION CONTROL STRUCTURAL VIEW...

  • Page 16: Abbreviations

    ABBREVIATIONS Air conditioner Intake air temperature Antilock brake system Integrated circuit Accessories Ignition Automatic transaxle fluid Motor Automatic transaxle Mass air flow sensor Battery Manual transaxle Battery positive voltage Nitrogen oxide Crankshaft position Oxygen sensor Control module Powertrain control module Camshaft position Positive crankcase ventilation Carbon monoxide...

  • Page 17: Specifications

    SPECIFICATIONS Item FP, FP (Hi power) Air cleaner element Type Paper element (oil permeated) IAC valve Type Duty control Type Hi ohmic Fuel injector Type of fuel delivery Top feed Type of drive Voltage Regulating pressure Pressure regulator 280 {2.9, 41} (kPa {kgf/cm , psi}) Fuel pump...

  • Page 18: Control System Diagram

    CONTROL SYSTEM DIAGRAM IAT sensor Pulsation dumper MAF sensor Purge solenoid valve TP sensor EGR valve ECT sensor VICS solenoid valve CMP sensor VICS vacuum chamber CKP sensor VICS check valve (one way) Knock sensor VICS actuator HO2S (integrated with O2S heater) Charcoal canister IAC valve Rollover valve (evaporative gas check valve...

  • Page 19: Control System Wiring Diagram

    CONTROL SYSTEM WIRING DIAGRAM 1T 1O 3I 4E 4F 4Q 4R 4S 4U 4V 4K 4I 1M 2L 2K 1T 1O 3I 4E 4F B F A C G I D E H A B C B ACC IG1 IG2 STA LOCK F1-5...

  • Page 20

    3M 3N 3O 3P 3M 3N 3O 3P F1-6...

  • Page 21

    CKP sensor Battery CMP sensor MAIN fuse VICS solenoid valve EGI fuse PRC solenoid valve Ignition switch Purge solenoid valve Starter Fuel injector No.1 Generator Fuel injector No.2 Generator warning light Fuel injector No.3 Fuel pump relay Fuel injector No.4 Main relay Condenser Fuel pump...

  • Page 22: Intake Air System

    The intake air 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:...

  • Page 23: System Diagram

    SYSTEM DIAGRAM Intake manifold Fresh air duct To PRC solenoid valve Resonance chamber To purge solenoid valve EGR valve Throttle body VICS shutter valve actuator IAC valve VICS solenoid valve MAF sensor VICS vacuum chamber (built in intake manifold) Air cleaner VICS check valve (one way) IAT sensor F1-9...

  • Page 24: Fuel System

    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:...

  • Page 25: System Diagram

    Fuel Tank Side Fuel pump unit To pulsation damper Nonreturn valve From pressure regulator Quick release connector SYSTEM DIAGRAM Fuel tank Fuel injector Fuel filter (low pressure) Pressure regulator Fuel pump PRC solenoid valve Fuel filter (high pressure) To PCM Pulsation damper F1-11...

  • Page 26: Exhaust System

    EXHAUST SYSTEM OUTLINE 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 Exhaust manifold Presilencer Front pipe Main silencer F1-12...

  • Page 27: Emission System

    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:...

  • Page 28: System Diagram

    Fuel Tank Side Rollover valve (built in fuel tank) SYSTEM DIAGRAM Rollover valve (evaporative gas check valve (two EGR valve way) integrated) PCV valve Charcoal canister Purge solenoid valve To PCM F1-14...

  • Page 29: Control System

    Operation condition of EGR control has been modified. (Refer to 323 Training Manual 3327-10-98G.) Input Device : Applicable : Not applicable Item Item SIgnal SIgnal PREMACY FP PREMACY FP 323 (BJ) FP 323 (BJ) FP Remark Remark IAT sensor Same as 323 (BJ) FP engine model...

  • Page 30

    Output Device : Applicable : Not applicable Output device Output device Control item Control item PREMACY FP PREMACY FP 323 (BJ) FP 323 (BJ) FP Remark Remark IAC valve Same as 323 (BJ) FP engine model VICS solenoid VICS Same as 323 (BJ) FP engine model...

  • Page 31: Structural View

    STRUCTURAL VIEW VSS (for MTX) IAT sensor VSS (for ATX) MAF sensor IAC valve TP sensor VICS solenoid valve ECT sensor Fuel injector CMP sensor Fuel pump relay CKP sensor Ignition coil Knock sensor O2S heater (integrated with HO2S) HO2S (integrated with HO2S heater) PRC solenoid valve Clutch switch (for MTX) Cooling fan relay...

  • Page 32: Block Diagram

    BLOCK DIAGRAM F1-18...

  • Page 33

    IAT sensor Fuel pump relay MAF sensor O2S heater (integrated with HO2S) TP sensor EGR valve CMP sensor Purge solenoid valve CKP sensor A/C relay ECT sensor Condenser fan relay (for MTX) Knock sensor Cooling fan relay HO2S Condenser fan relay (for ATX) Generator (terminal D: field coil) Clutch switch (for MTX) Generator warning light (integrated with instrument...

  • Page 34: Control Devices And Control Relationship Chart

    CONTROL DEVICES AND CONTROL RELATIONSHIP CHART : Applicable Control item IAT sensor MAF sensor TP sensor CMP sensor CKP sensor ECT sensor Knock sensor HO2S Neutral/Clutch switch* TR switch* PSP switch Brake switch A/C switch, refrigerant pressure switch (high, low pressure) Generator (terminal P: output voltage) DLC (terminal TEN)

  • Page 35: Idle Air Control (iac)

    The EGR control of the PREMACY FP engine model is essentially carried over from the 323 (BJ) FP engine models except for operation conditions. The EGR control of the PREMACY FP engine model is the same as that of the 323 (BJ) FP engine models. OPERATION CONDITIONS...

  • Page 36: On Board Diagnostic System

    ON BOARD DIAGNOSTIC SYSTEM OUTLINE The DTCs and simulation items of the PREMACY FP engine model are the same as those of the 323(BJ) FP engine models. The monitoring item has been added for the PREMACY FP engine model compared to the 323 (BJ) FP engine models.

  • Page 37

    : Applicable -: Not applicable Diagnosed Memory Detection condition Fail safe 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. Open or short circuit is observed in EGR valve (stepping motor 2 coil) system when ignition P1497 switch is turned to ON position.

  • Page 38: Pid/data Monitor And Record

    PID/DATA MONITOR AND RECORD 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)

  • Page 39: Simulation Test

    Input/turbine speed signal 2K, 2L VPWR Vehicle speed km/h : ATX only : MTX only SIMULATION TEST The simulation items of the PREMACY FP engine model are in the following table. : Applicable -: Not applicable Test condition Simulation Definition Definition Operation...

  • Page 40

    ENGINE ELECTRICAL SYSTEM ABBREVIATIONS ......SPECIFICATIONS ......OUTLINE .

  • Page 41

    STRUCTURAL VIEW Battery Spark plug Generator High tension lead Ignition coil Starter...

  • Page 42

    CLUTCH OUTLINE ........SPECIFICATIONS ......OUTLINE OF CONSTRUCTION .

  • Page 43: Manual Transaxle

    MANUAL TRANSAXLE (F25M-R) OUTLINE ....... . . J1-2 SPECIFICATIONS ..... . . J1-2 OUTLINE OF CONSTRUCTION .

  • Page 44

    OUTLINE OUTLINE OF CONSTRUCTION FP engine models are equipped with the F25M-R manual transaxle. 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 Item...

  • Page 45

    AUTOMATIC TRANSAXLE (FN4A-EL) ABBREVIATIONS ......K- 1 CONSTRUCTION ......K- 9 OUTLINE .

  • Page 46: Outline

    OUTLINE OUTLINE OF CONSTRUCTION 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).

  • Page 47: Specifications

    SPECIFICATIONS Item Australian specs. Transaxle type FN4A-EL 2.816 1.497 Gear ratio 1.000 0.725 Reverse 2.648 Final gear ratio 4.147 Type ATF M-III or equivalent (e.g. DexronR II) Capacity (L {US qt, lmp qt}) 7.2 {7.6, 6.3} Torque converter stall torque ratio 2.120 Forward clutch (number of drive/driven plates)

  • Page 48: Automatic Transaxle

    AUTOMATIC TRANSAXLE OUTLINE The FN4A EL type automatic transaxle is used. The construction and operation of the automatic transaxle is the same as that of the current 323 (BJ). CROSS SECTIONAL VIEW Torque converter 2-4 brake band Oil pump Low and reverse brake Forward clutch One way clutch Front planetary gear...

  • Page 49: Outline Of Operation

    OUTLINE OF OPERATION 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: Electronic control mechanism 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...

  • Page 50

    EC-AT OPERATION CHART Shift pattern Transaxle Operation of shift solenoid Solenoid Solenoid valve brake valve (ON/ (duty cycle type) band OFF type) Mode Gear position – – – – – – – – Reverse 2.648 – OPEN OPEN OPEN – –...

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