Mazda premacy Installation guide

Form No.3351-1A-01A
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 ith this manual
is important, and it should al ays be kept
in a handy place for quick and easy
reference.
All the contents of this manual, including
dra ings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume ill be made
available at Mazda dealers. This manual
should be kept upĆtoĆdate.
Mazda Motor Corporation reserves
the right to alter the specifications and
contents of this manual ithout 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
mechanicalĊincluding photocopying and
recording and the use of any kind of
information storage and retrieval
systemĊ ithout permission in riting.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning ith the Vehicle Identification
Numbers (VIN), and related materials
sho n on the follo ing page.
Title Se tion
General Information GI
Engine B1
Lubri ation System D
Cooling System E
FP F1
Engine Ele tri al System G
Clut h H
Manual Transaxle J1
2001 Mazda Motor Corporation
PRINTED IN AUSTRALIA, JANUARY 2001
3351-1A-01A
Fuel and Emission
Control Systems
CONTENTS
Steering System N
Braking System P
Suspension R
Body S
Body Ele tri al System T
UHeater and Air Conditioner Systems
M
Front and Rear Axles
FP
KAutomati Transaxle
F25M-R

Form No.3351-1A-01A
VEHICLE IDENTIFICATION NUMBERS (VIN)
Australian spe s.
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
GI
GI-1
GENERAL INFORMATION
VIN CODE GI-1................................
UNITS GI-2....................................
NEW STANDARDS GI-3........................
VIN CODE
Australian sp cs.
JM0 CP 00 100001
JM0= Mazda (Australian specs.)
100001Ċ
10 P 1
Serial No.
1
P= FP
Model Change Code
ngine Type
10= Closed body
CP= PR MACY
Vehicle Type
World Manufacturer Identification
Body Style
No Significance 00 (Dummy)

Form No.3351-1A-01A
GI-2
UNITS
lectric current A (ampere)
lectric power W (watt)
lectric resistance Ω(ohm)
lectric voltage V (volt)
Length
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure kgf/cm2(kilogram force per
square centimeter)
psi (pounds per square inch)
Number of
revolutions rpm (revolutions per minute)
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)
Weight
g (gram)
Weight
oz (ounce)
Conv rsion to SI Units (Systèm Int rnational
d'Unités)
DAll numerical values in this manual are based on
SI units. Numbers shown in conventional units are
converted from these values.
Rounding off
DConverted 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.
Upp r and low r limits
DWhen 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/cm2in
the following specifications:
210Ċ260 kPa {2.1Ċ2.7 kgf/cm2, 30Ċ38 psi}
270Ċ310 kPa {2.7Ċ3.2 kgf/cm2, 39Ċ45 psi}
DThe actual converted values for 2.7 kgf/cm2are
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
specification, 2.7 is used as a lower limit, so its
converted values are rounded up to 270 and 39.

Form No.3351-1A-01A
GI
GI-3
NEW STANDARDS
DFollowing is a comparison of the previous standard and the new standard.
N w Standard Pr vious Standard
Abbr viĆ
ation Nam Abbr viĆ ation Nam R mark
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 VBBattery Voltage
Ċ Brake Switch Ċ Stoplight Switch
Ċ Calibration Resistor Ċ Corrected Resistance #6
CMP
sensor Camshaft Position Sensor Ċ Crank Angle 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 GI lectronic Gasoline Injection System
CS sensor Control Sleeve Sensor CSP
sensor Control Sleeve Position Sensor #6
CKP
sensor Crankshaft Position Sensor Ċ Crank Angle Sensor 2
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
I lectronic Ignition Ċ lectronic Spark Ignition #2
CT ngine Coolant Temperature Ċ Water Thermo
M ngine Modification Ċ ngine Modification
Ċ ngine Speed Input Signal Ċ ngine RPM Signal
VAP vaporative mission Ċ vaporative mission
GR xhaust Gas Recirculation Ċ xhaust 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
solenoid Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
G N Generator Ċ Alternator
GND Ground Ċ Ground/ arth
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

Form No.3351-1A-01A
GI-4
N w Standard Pr vious Standard
Abbr viĆ
ation Nam Abbr viĆ ation Nam R mark
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
sensor Mass Air Flow Sensor Ċ Airflow 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 CU ngine Control Unit #4
Ċ Pressure Control Solenoid Ċ Line Pressure Solenoid Valve
PAIR Pulsed Secondary Air Injection Ċ Secondary Air Injection System Pulsed
injection
Ċ Pump Speed Sensor Ċ N Sensor #6
AIR Secondary Air Injection Ċ Secondary Air Injection System Inject with
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
Shift Solenoid A
Ċ 1-2 Shift Solenoid Valve
Ċ
Shift Solenoid A
Ċ Shift A Solenoid Valve
Shift Solenoid B
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
TCM Transmission (Transaxle) Control
Module Ċ CĆAT Control Unit
ĊTransmission (Transaxle) Fluid
Temperature Sensor Ċ ATF Thermosensor
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

Form No.3351-1A-01A
GI
GI-5
N w Standard Pr vious Standard
Abbr viĆ
ation Nam Abbr viĆ ation Nam R mark
VAF
sensor Volume Air Flow Sensor Ċ Air flow Sensor
WUĆTWC Warm Up Three Way Catalytic
Converter Ċ Catalytic Converter #5
WOT Wide Open Throttle Ċ Fully Open
#5: Directly connected to exhaust manifold

Form No.3351-1A-01A
B1
B1-1
ENGINE (FP)
ABBREVIATIONS B1-1..........................
OUTLINE B1-1.................................
OUTLINE OF CONSTRUCTION B1-1...........
SPECIFICATIONS B1-1.......................
ENGINE MECHANISM B1-2.....................
CYLINDER HEAD COVER B1-2................
ABBREVIATIONS
ABDC After bottom dead center
ATDC After top dead center
BBDC Before bottom dead center
BTDC Before top dead center
DOHC Doub e over head camshaft
EX Exhaust
IN Intake
Ċ Ċ
OUTLINE
OUTLINE OF CONSTRUCTION
DThe construction and operation of the FP engine mode s for Austra ian specs are the same as those of the
current 323 (BJ) FP engine mode for each respective specification. (Refer to 323 Training Manua
3327-10-98G.)
Exceptions are as fo ows:
Ċ As the ignition coi is insta ed on the cy inder head, the shape of the cy inder head cover has been
changed.
SPECIFICATIONS
Item
Specific tion
Item
FP
Type Gaso ine, 4Ćcyc e
Cy inder arrangement and number InĆ ine, 4Ćcy inders
Combustion chamber Pentroof
Va ve system DOHC, Timing be t driven, 16 va ves
Disp acement (m {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]
IN
Open BTDC (°) 0
Va ve timing
IN
C ose ABDC (°) 45
Va ve timing
EX
Open BBDC (°) 44
EX
C ose ATDC (°) 6
Va ve c earance [Engine co d]
IN (mm {in}) 0.225Ċ0.295 {0.009Ċ0.011}
(0.26"0.035 {0.010"0.001})
Va ve c earance [Engine co d]
EX (mm {in}) 0.225Ċ0.295 {0.009Ċ0.011}
(0.26"0.035 {0.010"0.001})

Form No.3351-1A-01A
B1-2
ENGINE MECHANISM
CYLINDER HEAD COVER
DBosses for ignition coi insta ation are insta ed at the spark p ug ho es for the No.2 and No.4 cy inders on the
cy inder head cover.
1 Ignition coi insta ation position 2 Boss for ignition coi

Form No.3351-1A-01A
D
D-1
LUBRICATION SYSTEM
ABBREVIATIONS D-1...........................
OUTLINE D-1..................................
OUTLINE OF CONSTRUCTION D-1............
SPECIFICATIONS D-1........................
LUBRICATION MECHANISM D-2................
ABBREVIATIONS
R.H.D. Right hand drive
OUTLINE
OUTLINE OF CONSTRUCTION
DThe construction and operation o the FP engine lubrication system or Australian specs. models are the same
as those o the current 323 (BJ) models. (Re er to 323 Training Manual 3327-10-98G.)
SPECIFICATIONS
Item
Specificati n
Item
FP
Lubrication system ForceĆ ed type
Oil cooler Ċ
Oil pump
Type Trochoid gear
Oil pump
Relie pressure kPa {kg /cm2, psi} 450Ċ530 {4.5Ċ5.5, 64Ċ78}
Type FullĆ low, paper element
Oil ilter Bypass pressure
kPa {kg /cm2, psi} 79Ċ110 {0.8Ċ1.2, 12Ċ17}
Oil pressure kPa {kg /cm2, psi} [rpm] 400Ċ490 {4.0Ċ5.0, 57Ċ71} [3,000]
Oil replacement (Approximate quantity)
L {US qt, lmp qt} 3.3 {3.5, 2.9}
Oil capacity
Oil and oil ilter replacement
(Approximate quantity)
L {US qt, lmp qt}
3.5 {3.7, 3.1}
Total (dry engine)
(Approximate quantity)
L {US qt, lmp qt}
3.7 {3.9, 3.3}
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
Viscosity
Above -10 °C {14 °F} SAE 20W-40, 20W-50
Viscosity
Above -25 °C {-13 °F} SAE 10W-30,
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