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 AutomaticTransaxle K in a handy place for quick and easy reference. Front and Rear Axles M
All the contents of this manual, including Steering System N 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.
Form No.3351-1A-01A 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A NEW STANDARDS
D Following is a comparison of the previous standard and the new standard. GI New Standard Previous Standard 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
Form No.3351-1A-01A New Standard Previous Standard AbbreviĆ AbbreviĆ Remark 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 NESensor #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
Form No.3351-1A-01A New Standard Previous Standard AbbreviĆ AbbreviĆ Remark 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
Form No.3351-1A-01A 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 modelfor 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A 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 OUTLINE OF CONSTRUCTION D The construction and operation ofthe FP engine lubrication system forAustralian specs. models are the same as those ofthe current 323 (BJ) models. (Referto 323 Training Manual 3327-10-98G.)
SPECIFICATIONS Specification Item FP Lubrication system ForceĆfed type Oil cooler Ċ Type Trochoid gear Oil pump Reliefpressure kPa {kgf/cm 2, 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A 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 OUTLINE OF CONSTRUCTION FP, FP (HiĆpower) D The construction and operation ofthe cooling system forAustralian specs. are the same as those ofthe 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A RADIATOR D To increase the coolant capacity, the height ofthe radiator core has been increased approx. 25 mm {0.98 in}.
E
1 Radiator cap 4 Lower tank 2 Upper tank 5 Radiator drain plug 3 Core 6 Integrated with ATF cooler
E-3
Form No.3351-1A-01A 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
Form No.3351-1A-01A 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 Manualtransaxle B+ Battery positive voltage NOx Nitrogen oxide CKP Crankshaft position O2S Oxygen sensor CM Controlmodule PCM Powertrain controlmodule 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 controlsystem 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 controlhas been modified to match the vehiclecharacteristic.
F1-2
Form No.3351-1A-01A SPECIFICATIONS Item FP, FP (HiĆpower) Air cleaner element Type Paper element (oil permeated) IAC valve Type Duty control Type HiĆohmic Fuelinjector Type of fueldelivery TopĆfeed Type of drive Voltage Regulating pressure Pressure regulator 280 {2.9, 41} (kPa {kgf/cm2, psi}) Fuelpump Type Impeller (inĆtank) F1 Capacity Fueltank 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 controlsystem Type Canister type PCV system Type Closed type
F1-3
Form No.3351-1A-01A 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 Charcoalcanister 9 IAC valve 25 Rollover valve (evaporative gas check valve 10 Fuelinjector (twoĆway) integrated) 11 PRC solenoid valve 26 TWC 12 Pressure regulator 27 Ignition coilNo.1 13 Fuel filter (lowĆpressure) 28 Ignition coilNo.2 14 Fuelpump 29 Generator 15 Fueltank 30 PCM 16 Fuelfilter(highĆpressure) 31 To PCM
F1-4
Form No.3351-1A-01A CONTROL SYSTEM WIRING DIAGRAM
B AC TEN KLN FEN AB AT5 AT10 F1 BH 1V 1F 1L 1E 1D 4M 4O 3H 3J 1V 1F 1L 1E 1D 4M 4O 3H 3J C 2E G 2H F 2G
E 2F I 2A D 2C A 1Q1T 1O 3I 4E 4F 4P 4Q 4R 4S 4U 4V 4K 4I 1M 2L 2K 1Q1T 1O 3I 4E 4F 4P 4D AT1 a
BFACGIDEH AB
ABC
b F/P c
d AT1 e f
AB B ACC IG1 IG2 STA CE LOCK
ACC AT5 ON STA
AT10 AB CD
M PB B PD D A C
F1-5
Form No.3351-1A-01A IG- A B C B A E ACB F D AB AB AB AB AB AB AB
3F 3D 3K3A 1I 3M 3N 3O 3P 4N 4T 4L 4W 4X 4Y 4Z 3F 3D 3K 1M3M 3N 3O 3P 4N 4T 4L 4W 4X 4Y 4Z
3E3B 3L 1B 1A 3C 1P 1S 1J 1R 1G 3G 4B 4A 4C 4G 4H 3E3B 3L 1B 1A 3C 1P 1S 1J 4J 1R 1G 3G 4B 4A 4C 4G 4H
a
A B A B A
A B BA A BC D BC A C BC A
b c
d e f
C A C A M
D B D B
M
M
F1-6
Form No.3351-1A-01A 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 Fuelinjector No.1 7 Generator 42 Fuelinjector No.2 8 Generator warning light 43 Fuelinjector No.3 9 Fuelpump relay 44 Fuelinjector No.4 F1 10 Main relay 45 Condenser 11 Fuelpump 46 Ignition coilNo.1 12 DLC 47 To spark plug No.1, No.4 13 HOLD switch 48 Ignition coilNo.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 controlsolenoid 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 Neutralswitch 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
Form No.3351-1A-01A INTAKEĆAIR SYSTEM OUTLINE D The intakeĆair system is the same as that of the current 323 (BJ) FP engine model(Refer to 323 Training Manual3327-10-98G.) A comparison of major parts for the PREMACY FP engine modeland 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A FUEL SYSTEM OUTLINE D The fuelsystem 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 modeland the 323 (BJ) FP engine models is as follows: : Applicable Item PREMACY FP 323 (BJ) FP Remark Fueltank Same as 323 (BJ) FP engine model Quick release connector and plastic Same as 323 (BJ) FP engine model fuelhose Fuelpump Same as 323 (BJ) FP engine model Fuelfilter Same as 323 (BJ) FP engine model (highĆpressure) Fuelinjector 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 Fuelinjector 6 Fuelpump relay 3 Pressure regulator 7 To fueltank 4 PRC solenoid valve 8 From fueltank
F1-10
Form No.3351-1A-01A Fuel Tank Side
1 Fuelpump unit 4 To pulsation damper 2 Nonreturn valve 5 From pressure regulator 3 Quick release connector
SYSTEM DIAGRAM
1 Fueltank 6 Fuelinjector 2 Fuel filter (lowĆpressure) 7 Pressure regulator 3 Fuelpump 8 PRC solenoid valve 4 Fuelfilter(highĆpressure) 9 To PCM 5 Pulsation damper
F1-11
Form No.3351-1A-01A EXHAUST SYSTEM OUTLINE D The exhaust system is the same as that of the current 323 (BJ) FP engine model. (Refer to 323 Training Manual3327-10-98G.)
STRUCTURAL VIEW
1 Exhaust manifold 4 Presilencer 2 Front pipe 5 Main silencer 3 TWC
F1-12
Form No.3351-1A-01A EMISSION SYSTEM OUTLINE D The emission system is the same as that of the current 323 (BJ) FP engine model. (Refer to 323 Training Manual3327-10-98G.) A comparison of major parts for the PREMACY FP engine modeland the 323 (BJ) FP engine models is as follows: : Applicable Ċ: Not applicable Item PREMACY FP 323 (BJ) FP Remark Rollover valve Same as 323 (BJ) FP engine model Evaporative gas check Same as 323 (BJ) FP engine model valve (twoĆway) Charcoalcanister 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 Charcoalcanister 4 PCV valve 2 Purge solenoid valve 5 TWC 3 EGR valve 6 From fueltank
F1-13
Form No.3351-1A-01A 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 Charcoalcanister 6 TWC 3 Purge solenoid valve 7 To PCM
F1-14
Form No.3351-1A-01A 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 controlhas been modified. (Refer to 323 Training Manual3327-10-98G.)
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 Neutralswitch (for Load/no load Same as 323 (BJ) FP engine model MTX) detection Clutch switch Load/no load Same as 323 (BJ) FP engine model (for MTX) detection TR switch Load/no load Same as 323 (BJ) FP engine model (for ATX) detection Power steering PSP switch oilpump 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 Same as 323 (BJ) FP engine model (TEN terminal) mode switching BackĆup power Battery Same as 323 (BJ) FP engine model supply Generator Generator (terminalP: 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
Form No.3351-1A-01A 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 Fuelinjection Fuelinjector Same as 323 (BJ) FP engine model control PRC solenoid PRC Same as 323 (BJ) FP engine model valve Fuelpump Fuelpump Same as 323 (BJ) FP engine model relay control Ignition coil ESA control Same as 323 (BJ) ZL engine model Same as 323 (BJ) FP 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 (terminalD: Same as 323 (BJ) FP engine model control field coil) Cooling fan relay Electrical fan Same as 323 (BJ) FP engine model 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
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Form No.3351-1A-01A 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 Fuelinjector 6 CMP sensor 22 Fuelpump 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 Neutralswitch (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
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Form No.3351-1A-01A BLOCK DIAGRAM
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Form No.3351-1A-01A 1 IAT sensor 25 Fuelpump 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 Neutralswitch (for MTX) cluster) 12 TR switch (for ATX) 35 IAC system 13 PSP switch 36 VICS 14 Brake switch 37 Fuelinjection control 15 A/C switch, refrigerant pressure switch (high, low 38 Immobilizer system pressure) 39 ESA control 16 Generator (terminalP: output voltage) 40 PRC 17 DLC (terminalTEN) 41 Fuelpump 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 Fuelinjectors 46 Electrical fan control 23 Ignition coil 47 Generator control 24 PRC solenoid valve 48 PCM
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Form No.3351-1A-01A CONTROL DEVICES AND CONTROL RELATIONSHIP CHART : Applicable Control item IAC VICS FUEL INJECTION CONTROL FUEL PUMP CONTROL PRC ESA O2S HEATER CONTROL PURGE CONTROL EGR CONTROL A/C CUTĆOFF CONTROL ELECTRICAL FAN CONTROL GENERATOR CONTROL IMMOBILIZER SYSTEM IAT sensor MAF sensor TP sensor CMP sensor CKP sensor ECT sensor Knock sensor HO2S VSS ice v Neutral/Clutch switch*1 de TR switch*2 put
In PSP switch Brake switch A/C switch, refrigerant pressure
switch (high, low pressure) Generator (terminalP: output
voltage) DLC (terminalTEN) Battery Immobilizer unit IAC valve VICS solenoid valve Fuelinjector Fuelpump relay PRC solenoid valve Ignition coil ice v O2S heater dev Purge solenoid valve put p t EGR valve Out O 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
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Form No.3351-1A-01A IDLE AIR CONTROL (IAC) OUTLINE D The IAC of the PREMACY FP engine modelis 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. 40A or above*2 750 700 P/S is operating. 750 (Steering wheelis 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 controlof the PREMACY FP engine modelis 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}.
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Form No.3351-1A-01A 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 modelcompared 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 P0102 D Adjusts charging efficiency to 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 when ignition switch is turned to ON position. ignition (6°CA) Input voltage from IAT sensor is below 0.16 V P0112 D Sets IAT for engine control 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 when ignition switch is turned to ON position. light Sets ECT for engine control Input voltage from ECT sensor is below 0.20 V D P0117 40°C {104°F} when ignition switch is turned to ON position. Sets ECT for IAC 80°C ECT sensor D {176°F} Input voltage from ECT sensor is above 4.94 V P0118 D Operates cooling fan (and 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 P0122 for engine controlclosed when ignition switch is turned to ON position. D Fixes closed throttle position TP sensor learning value to set value Input voltage from TP sensor is above 4.90 V D Inhibits dechoke control P0123 when ignition switch is turned to ON position. D Inhibits dashpot correction for IAC When HO2S signaldoes not exceed 0.55 V after engine is started or stays below 0.55 V for D Stops feedback controlof fuel P0134 HO2S 120 seconds after engine has reached normal injection control operating temperature Input voltage from knock sensor is below 0.90 P0327 V when ignition switch is turned to ON position. D Stops fuelcutĆoff at shifting Knock sensor D Ignition retard of knocking is Input voltage from knock sensor is above 3.98 P0328 canceled. V when ignition switch is turned to ON position. No NE signalis inputted from CKP sensor while P0335 CKP sensor D Stops fuelinjection 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 signalstays above 0.55 V or beĆ D Stops feedback controlof fuel P1170 HO2S low 0.55 V for 42.8 seconds after engine has injection control reached normaloperating 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 signalinput from CMP sensor for 12 P1345 CMP sensor D Stops fuelinjection control engine rotations. *1: For ATX
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Form No.3351-1A-01A : 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. Open or short circuit is observed in EGR valve P1497 (stepping motor 2 coil) system when ignition - - switch is turned to ON position. EGR valve Open or short circuit is observed in EGR valve P1498 (stepping motor 3 coil) system when ignition - - switch is turned to ON position. Open or short circuit is observed in EGR valve P1499 (stepping motor 4 coil) system when ignition - - switch is turned to ON position. If PCM detects that PCM terminal4M voltageis 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 terminal4O voltageis above2VorIACtarget controlduty valveis 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. systemt 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 - systemy replaced and key ID number reĆregistered.) P1623 InternalPCM 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.
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Form No.3351-1A-01A PID/DATA MONITOR AND RECORD D The PID monitoring items of the PREMACY FP engine modelfor fueland emission controlsystems 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 fieldcoilcontrolduty 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 signalvoltage 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 Fuelpump relay ON/OFF 4P FPRC Pressure regulator control ON/OFF 4T FUELPW1 Fuelinjection 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 signalvoltage 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 controlsolenoid A 4I, 4K MAF MAF signalvoltage 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
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Form No.3351-1A-01A Monitor item (Display on Condition/ Monitoring item PCM terminal WDS or equivalent) Unit TEST TEN terminalin DLC TFT*1 TFT °C 1M TFTV*1 TFT sensor signalvoltage V 1M TP TP signalvoltage 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 fieldcoilcontrolduty 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 Fuelpump relay ON/OFF 4P FPRC Pressure regulator control ON/OFF 4T FUELPW1 Fuelinjection duration % ɝ 4W, 4X, 4Y, 4Z IAC IAC valve % 4M, 4O INJ_1 Fuelinjector No.1 OFF ɝ 4W INJ_2 Fuelinjector No.2 OFF ɝ 4X INJ_3 Fuelinjector No.3 OFF ɝ 4Y NJ_4 Fuelinjector 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
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Form No.3351-1A-01A 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 handdrive G OUTLINE OUTLINE OF CONSTRUCTION D The construction andoperation 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 headcover. They are the same types as those of the current 323 (BJ) ZL andZM engines.
SPECIFICATIONS Specification Item FP Voltage (V) 12 Battery Type andcapacity 50D20L (40) (5Ćhour rate) (A·h) Output (V-A) 12Ċ80 Generator Regulatedvoltage (V) Controlledby PCM SelfĆdiagnosis function Integratedin 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 StarterStarter Output (kW) 1.0 *1: Standard plug *2: Coldtype plug *3: Hot type plug
G-1
Form No.3351-1A-01A STRUCTURAL VIEW
1 Battery 4 Spark plug 2 Generator 5 HighĆtension lead 3 Ignition coil 6 Starter
G-2
Form No.3351-1A-01A CLUTCH
OUTLINE...... H-1 SPECIFICATIONS ...... H-1 OUTLINE OF CONSTRUCTION ...... H-1
OUTLINE OUTLINE OF CONSTRUCTION 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
Form No.3351-1A-01A MANUAL TRANSAXLE (F25M-R)
OUTLINE...... J1-2 SPECIFICATIONS ...... J1-2 OUTLINE OF CONSTRUCTION ...... J1-2
J1
J1-1
Form No.3351-1A-01A OUTLINE OUTLINE OF CONSTRUCTION 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A OUTLINE OUTLINE OF CONSTRUCTION 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
Form No.3351-1A-01A 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) Hydraulic system K Reverse clutch 2/2 (number of drive/driven plates) Low and reverse brake 5/5 (number of drive/driven plates) Servo diameter Band servo 64.6 {2.54} (piston outer dia.) (mm {in}) Front sun gear 49 FrontFront p planetarlanetary gear Front pinion gear 20 (number of teeth) Front internal gear 89 Rear sun gear 37 RearRear pplanetarlanetary 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A 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
Form No.3351-1A-01A EC-AT OPERATION CHART Shift pattern Transaxle Operation of shift solenoid 2-4 Solenoid valve Solenoid brake (dutyĆcycle type) valve (ON/ band
h OFF type) brake h ch ge g c c c c t t e ModeMd GearG position iti e Applied Released Shift solenoid A Shift solenoid B Shift solenoid C Shift solenoid D Shift solenoid E Position/Ran Low and reverse Shift TCC Engine brak Forward clut 3-4 clutch Reverse clut OneĆway clu 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 POWĆ
ER/ 3GR 1.000 OPEN OPEN OPEN OFF OFF 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
D 3GR 1.000 OPEN OPEN OPEN OFF OFF 4GR*3 0.725 CLOSE OPEN OPEN ON OFF 1GR 2.816 Ě OPEN CLOSE CLOSE OFF OFF NNonĆ 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 3 D 3GR* 1.000 OPEN OPEN OPEN OFF OFF 4GR*3 0.725 CLOSE OPEN OPEN ON OFF 1GR 2.816 Ě OPEN CLOSE CLOSE OFF OFF NNonĆ 2GR 1.497 OPEN OPEN CLOSE OFF OFF HOL D 3GR*3 1.000 OPEN OPEN OPEN OFF OFF 4GR*3 0.725 CLOSE OPEN OPEN ON 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 4GR*3 0.725 CLOSE OPEN OPEN ON 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
Form No.3351-1A-01A