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 ina handy place for quick and easy reference, Al 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 Section General Information Engine FP Lubrication System Cooling System Fuel and Emission Control Systems. FP Engine Electrical System Clutch Manual Transaxle F25M-R 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 3351-18-01,VEHICLE IDENTIFICATION NUMBERS (VIN) Australian specs. JMO CP10P100 100001 — RELATED MATERIALS 323 Training Manual (Australia, General (R.H.D. LHD.) ... - 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. LH.D.)) . 3304-10-87F 626, 626 Station Wagon Workshop M Manual ‘Supplement (Europe) . 1614-10-98DGENERAL INFORMATION VIN CODE GI NEWSTANDARDS ..... Gre UNITS ... VIN CODE ‘Australian specs, smo cP10P 1 00 100004 Seri Na, 100001 No Signfeance 00 Dummy) Mosel Change Coa Engine Type Por Body Style 10= Closed body Verine Typ P= PREMACY ‘World Manufacture entiation .IMO~ Mazda (Australian specs) Gl-1UNITS + The actual converted values for 2.7 kgm? are 265 kPa and 38.4 psi In the top specication, 2.7 is used as an upper limi, so ils converted values Elec curent | A ampere) are rounded down to 260 and 38. In the bottom loci power ——] W twat specication, 2.7 used as a lower limit, £0 is eT) converted values are rounded up to 270 and 39 Electric voltage V (volt) rm (ier) Lenath in chy kPa (kilo pascal) Nogatve pressure [-mmtig miimoters of mercuy) inkg (inches of mercury) Positive pressure kPa (iio pascal) ‘gem? (kilogram foree per square centimeter) si (pounds per square inch) Number of revolutons ‘pm (revolutions por minuto) Torque Tem (Newion meter) ‘kgf (logram force meter) ‘rafem (llogram force contimetor) ‘Ribt (oot pound force) ‘inibt (inch pound force) Volume Len US gt (US. quart) Imp af (imperial quart) (rite cc (cubic contimetor) uti (cubic inch) oz (uid ounce) Weight (orem) ‘oz (ounce) Conversion to SI Units (Systéme Intern: d'Unités) ‘© All numerical values in this manual are based on Sl units. Numbers shown in conventional units are Converted from these values. Rounding off '* Converted values are rounded of to the same umber of places as the SI unit value. For example, ifthe 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 ‘© When the data indicates upper and lower limits, the converted values are rounded down if the St 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 katcm? in the following specifications: 210-260 kPa 2. |—2.7 kgt/em?, 30—38 psi} 270-310 kPa {2.73.2 kglicm?, 39—85 psi} Gl-2NEW STANDARDS. «¢ Following is a comparison of the previous standard and the new standard. Hew Sandee Previous Standard ‘Aabre Name Abbe Name ear AP | Aca Pa = per Pea ‘ct [Ar arer = Tar clenor ‘nc | Ar Conon = Tar contin BAR| Baromene Presse = [amoepnne resis 3 | Gator Poeive voage Ye Baton Vota [Brake Sen = Sept Ste = ceatireton Resa = Teorecie esiance 7% Ga camara Poston Sener — [crank Anale sensor ca —| Charge Ar Cone [rrr CLS | Glsed Loop Syn = Feetioc Sen P| closed Tone Postan = ry Gosea — | Cie Tvl Poston Sch = Tie Sach ce Ghach Pol Poston ——[revach Peston iS | Contos Fut jecian Sten | —EGI | Elecrone Gnroie hiecan Sytem SS SS [contr iooe Poston Soreor | #6 GE _| crameran Poston Sener — | cranking soneora 0.6 — | ata Erk Gomcr = risa Conese Dra | Dagnste Txt ade = Prost td ni DIC | Dagrste Tawi Como = [sere cose 1 | Bator anton = Soercanton BL Bates gion = Toren 1 | Biocon ion = [econ Saigon m2 EGT | Engine Coat Tepes = [Water Teo | Ee oicaton =—[Fenaie watcaon = [ena Speer nt Sra = enaine mPa Sra EWAP | Evaporaive Emon = [evaportve Enis EGR | Exhaust Gas Rosen = Testis Gas Recieiaton Fo | Fan Con = [ran cone FF Fede Ful = ene Fl aR [ Forth Goer =—Toverie — [Fut Pup Ray = crest Opera Raley B FS, | Fuels Salen rov | Fucicuvane ‘6 GEN | Gonorar = Paar xo | Grew =—[eceundearn 700s — | Hesiod Opgor Sonar =—Tongen sere Wino TAC —[ ie Ar Gon = [te Seo Cont = —[ncorect Gee Fao = #77, Diagnoslic rouble codes depend on the diagnostic test mode #2; Conirolied by the PCM 3: In some models, there is @ fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed) 46: Part name of diesel engine GI-3Tew Stnord Previous Standard breve = Remark bbrev Name ‘bore Name — | ton Bam iP | Funston Pap % =| npurturone Speed Sensor =| Pulse Generator Tat irae ir temperate [ake ar Tera S| Knock Sensor — [nook Sensor ML | Manton nar Lam =| wattinton ator att WAP | Manols Absolute Pressure [ake ar Pressure (MAE ass Ai Fow Sensor — | ftom Sensor wart pon Ft acon = renipor Foarijecion (080 | On-Board Diagnostic =| Diagnoss6or Diagnosis (OL | Open L209 =| Open Looe — | Outpt Sp0ed Sone = [Wohi speed Sensor (06 [ Oxteaton Caray Convener = cata Convener (28 [ Orygen Sensor —osgen Sensor PuP__| ParkNeutra Postion = [areal Range — | POM Conta Ray =| main Ry a PSP | Power Steering Pressure =| Powe Steeing Pressure Pom | Powerrain Gontol Module EGU [Engine Coot Unt = — | Pressure Con! Selena — | tie Pressure Solna Vaio pan | Pulsed Secondary Ar jection — | seconsary ancien system | Pubed =| Panp Seed Sensor = [RE Sensor 6 fn | Secondary Arneson — | Seconaary Arneson sytem | Sh SAPY_| Secondary A Puss ave = Resavane SFI_—_| Sequential Mutpont Fue injesion | — | Sequel Fut injeoton — | oMelay = sive ray 6 — Tein sono a = [1-2 shit Solna vate Selene =| sina Soro Vane = [a sn Solera vane — Shit Solenoie 6 = ‘Shift B Solenoid Valve Se = [e-1sni Solenea vane ag | Thea Gear — [acer TWO | Three way Caayie Conerer —~T cata Convener Te [Troe Boxy = [rivet Boy “sensor | Tirole Postion Sensor = [vate Sensor Tov _[tner Contr vale TOV _[ ining Gono Vabeo % Tc | Trae Converter Gach =| Leckeup Poston Tear | fasion ranaviyCoa ——T car cont une —_ | Bgnamssion Crane) ud —_| AIF Themosonsor “TA ranamislon ansaia) Range = [itor Poaton To | Tuecarger = Trbochargr ss | Veni Speed Sensor — [Won Spee Sonor va | Votage Rogultr = Te equator ‘7 Device that controls engine and powertrain #6: Part name of diesel engineaw Sina Fravone andar Aare ‘bre mark ation Name ation. Name [Votan A ow Scr — | Artow Soeor a Up Tee Way Cala se Gone wows | earmoe —_| ca Conan 6 WOT | Wie Open Ti = Tray one 5: Directly connected to exhaust manifold GI-5ENGINE (FP) Cy OUTLINE ..eeeeel cine ueeeeseseees BIT ENGINE MECHANISM 02000000 000IIIIT pra ‘OUTLINE OF CONSTRUCTION’ Bit ‘CYLINDER HEAD COVER | B12 ABBREVIATIONS ‘ABDC _| Afr botiom dead center DOHG_| Double over head camshaft ‘ATDC_| Alter top dead center Ex | Exhaust 'BBDC_| Before bottom dead center IN _| Intake BTDG_| Belore top dead center = = OUTLINE OUTLINE OF CONSTRUCTION '* The construction and operation of the FP engine models for Australian specs are the same as those of the current 323 (B.) FP engine model for each respective specification. (Refer to 323 Training Manual 3927-10-98.) Exceptions are as follows: — As the ignition coil is installed on the cylinder head, the shape of the cylinder head cover has been changed. SPECIFICATIONS: ‘Specification FP Type Gasoline, ovale (Gylinder arrangement and number Inline, cylinders ‘Combustion chamber Peniroot Valve system DONG, Timing belt driven, 16 valves Displacement (wifes cup 1.840 (1,840, 112.2) Bore X stroke (com (a) 85.0 85,0 (827 x3.35) ‘Gompression ratio eat ‘Gompression pressure _ (kPa thao? psi pmb 1, 180-120, 1719 300) wy LObet_ BTCC) 2 (GioseABDG ) 35 Valve ting ex [Open _BBDC (7 ny Giose ATG) 6 Prey 0.225—0.285 {0.000.011 Valve clearance [Engine cold 9.260085 (90100001) x (nin 0.225 0.295 (0.000.011) (026 + 0.035 0.010 0.001)) Bi-1ENGINE MECHANISM CYLINDER HEAD COVER “e 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. Tonion col instalation poston’ 2 | Boss forigntion col Bi-2LUBRICATION SYSTEM coves DA SPECIFICATIONS ...00..0s+00 eves D1 LUBRICATION MECHANISM... pat ABBREVIATIONS . OUTLINE «......5 Bon ‘OUTLINE OF CONSTRUCTION’? ABBREVIATIONS RH | Righthand drive OUTLINE OUTLINE OF CONSTRUCTION '* 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 won Specification Labrcaion sya Force-ted ype Oil cooler — Tipe “Trecho gear of Pump | Retief pressure _WPa Ration? pal 50500 (455.5, 64 TO) Tie Fallow, paper element otter | Bypass pressure >a igen? ps 79-110 (0.812, 12-17) Ol pressure Wa ton? ps om) 400490 (40-56, 5771} 000) ‘Oi replacemont (Approximato quantity) TL{US ah np at 8965.29 ‘and oF mer repiacoment (Approximate quantiy) 3567.30 Ot capacity L{US gt imp at “otal (ry engine) (Appronimata quanty) 3799.9) L{US at imp at Engine a ‘AP leona SG, SH or SI Above 30°C 15 FD SAE 40 0°C—40°0 (92 F104 FP SAED0 ~10°0—20°C (14 *F—68 °F} SAE 20W-20 =15 °0—40°0 (5 °F—104°F} — ve ‘Above 10°C (14°F) ‘SAE D0W-40, 20W-50 ‘SAE 100-20) ‘Above -25°C (13°F) Cae TOW 20. Below 10°C 60-7 = 30 "037 °C (22 F—98-FY SAE SW-0 Below 20°C 54°F) SAE SW-20 D-1LUBRICATION MECHANISM STRUCTURAL VIEW AND LUBRICATION FLOW DIAGRAM Oipan | Main bearing Oilstraner 9 | Crankshaft Oilpump 10__| Connecting rod bearing Outer nt_| onjer Oil pressure switch 72_| Piston Calico 18_| Gylinder head Camshaft 14_| Gyiindor blockCOOLING ABBREVIATIONS ..... OUTLINE... cs. ‘OUTLINE OF CONSTRUCTION’? SPECIFICATIONS ABBREVIATIONS ATF ‘Aulomatis wansane uid OUTLINE OUTLINE OF CONSTRUCTION FP, FP (Hi-power) SYSTEM COOLING MECHANISM ............ ‘STRUCTURAL VIEW AND COOLANT FLOW DIAGRAM . RADIATOR ‘The construction and operation of the cooling system for Australian specs. are the same as those of the current 323 (Bu) FP engine model for each respective specification. (Refer to 323 Training Manual cesses ED -E2 3827-10-98G,) Due to the change in vehicle body shape, the radiator shape has also been changed from the current 323 ®) SPECIFICATIONS: em Specification FP. ‘Cooling system ‘Water cooled, freed eirculation ‘Goolant capacity (Approximate quantity) (CUS at. Imp at) 7547.9, 66} Water pump Type Centrifugal, V-ribbed belt driven Type ‘Wax, boltom-bypase “thermostat Initial opening temparatwe (CFF) 8084 {176183} Ful-opening temperature Corry 95 203) Ful-opening tft (ram fn) 85 (0.33) min Radiator Tyee. ‘Comugated fn Radiator cap opening pressure (Pa (eaten, ps) 4122 (0951.25, 196-17 7) Type Eicorical cooing fan agg [Number 4 (Outer damater nm fn} 300 (11.6) E-1COOLING MECHANISM STRUCTURAL VIEW AND COOLANT FLOW DIAGRAM 2 1_| Coolant reservar 3] Ovinder block 2_| Radiator 6_| Gylinderhead 3_| Thermostat 7_[ Heater unit 4 [Water pumpRADIATOR, ‘¢ To increase the coolant capacity, the height of the radiator core has been increased approx. 25 mm {0.98 in}. 7_| Radiator cap 7] Lower tank 2 | Unper tank '5_| Radiator drain pg 3 [Core 6 | Integrated with ATF cooler E-3FUEL AND EMISSION CONTROL SYSTEMS (FP) ABBREVIATIONS . FUEL AND EMISSION CONTROL ‘SYSTEMS OUTLINE, ‘OUTLINE FEATURES ‘SPECIFICATIONS CONTROL SYSTEM DIAGRAM INTAKE-AIR SYSTEM ‘OUTLINE .. STRUCTUAAL VIEW SYSTEM DIAGRAM FUEL SYSTEM : ‘OUTLINE STRUCTUAAL VIEW - SYSTEM DIAGRAM EXHAUST SYSTEM 2 OUTLINE .. STRUCTURAL VIEW - EMISSION SYSTEM . FIR FIR DFR 2 FIR 2 FIR CONTROL SYSTEM WIRING DIAGRAM 2 FIR 2 FIR DFR DFR Fi Fi CemDnaEnNn F110 *FI-10 DFI-t0 Dern Fi-12 2 I-12 D2 Drs QUTLINE . STRUCTURAL VIEW .- SYSTEM DIAGRAM CONTROL SYSTEM ‘OUTLINE STRUCTURAL VIEW |. BLOCK DIAGRAM ‘CONTROL DEVICES AND CONTROL RELATIONSHIP CHART . IDLE AIR CONTROL (IAC) ..- 2.2 ‘OUTLINE : EGR CONTROL . 2 ‘OUTLINE : ‘OPERATION CONDITIONS .... ON-BOARD DIAGNOSTIC SYSTEM ‘OUTLINE . pte PID/DATA MONITOR AND RECORD .. SIMULATION TEST FI3 Fi-13 214 SEAS ae FI-t7 2 F118 - F120 Theta crit DEt21 Fi-2t c FA-24 1 Ft-22 I Ft22 Fi-22 2 FA-24 D125 Fi-1ABBREVIATIONS. ‘AG _| Aireondtionr TAT__| Tntake air temperature ‘ABS _| Antlook brake system IC _| Integrated circu ‘ACC _| Accessories 16_| Ignition ‘ATF _| Automatic transando fuid M_| Motor ‘ATX__| Automatic transaxle MAF _| Mass air flow sensor 8 | eatery MTX _| Manual ransaxie Bs _| Battery positive voltage NOx_| Nitrogen oxide ‘CKP_| Crankshaft postion ‘028 | Oxygon sensor ‘€M__| Control medule PCM _| Powertrain control module ‘MP _| Camshaft position PCV _| Posie crankcase vontiation (CO | Carbon monoxide PAC_| Pressure regulator contro! (COz_| Carbon dioxide PSP_| Power sieering pressure DLC_| Data fink connector STA_| Start DTC | Diagnostic trouble code TOS _| Traction control system ECT _| Engine coolant temperatura TP _| Thratte position EGR | Exhaust gas recireulation TR | Transaxle range ESA _| Electronic spark advance TWC_| Theo way catalytic convertor HC _| Hydrocarbon VICS_| Variable inartia charging system HO2S_ | Hoatod oxygon sensor ‘vss | Vonicio speed sensor TAG _| Ide air control FUEL AND EMISSION CONTROL SYSTEMS OUTLINE ‘OUTLINE '* The {uel and emission control systems are essentially carried over from those 323 (BJ) FP engine models, except for the following features. (lefer to 323 Training Manual 3327-10-98.) FEATURES Improved serviceability ‘* The OBD tester has been changed from the NGS tester to WDS. Modification to match vehicle characteristics '* Idle speed has been changad to match the vehicle characteristics. ‘¢ The operation condition of EGR control has been modified to match the vehicle characteristic. F1-2SPECIFICATIONS: Item FP, FP (Hi-power) “Seana emer Te Paper cement (ol peresied) TAG va we Duty contra Tye ohmic Fuente Type afar sever Topees Type of ave Votage opultng pressir Pressure equator eating rasa 200 29,41 Fuel puro we Ter fan Capaciy : Fuctark ra impo) 58,61, 517 Fuel ‘Specification Unleaded (RON 90 or higher) Catalyst Type TWC (monolythic) ER coil Tye Stepping moor pe Evaporative emission contol ayaten | Type Canister ype POV ays ee Gooses ype F1-3‘CONTROL SYSTEM DIAGRAM [TAT sensor 17_| Pulsation dumper 2_| MAF sensor 18_| Purge solenoid valve 3_[ TP sensor 19_| EGR valve 4_[ EGT sensor 20_| VIOS solenoid valve | CMP sensor 21_| VICS vacuum chamber 6 _| CKP sensor '22__| VIGS chock valve (one-way) 7_| Kook sensor 23_| VICS actuator 8 HO2S (intograted with O25 heater) 24 | Charcoal canister 2 [IAC vaio 125 | Rollover valvo (evaporative gas check valve 10_| Fuel injector two-way) integrated) T1_| PRC solenoid valve 26 [two 12 | Pressure regulator 27 _| Ignition coll No.t 13_| Fuel iter dow-pressure) 28_| Ignition collNo2 14_| Fuel pump 20 | Generator 15 | Fuet tank 30_| Pou 16 | Fuel iter thigh pressure) a1 | ToPcM F1-4CONTROL SYSTEM WIRING DIAGRAM Fi-5e oor ls : : . | ee ae. FH af EH ——l| ee ; | *8 ® F1-6[Pow 36] GRP soncor 2 _| Battery 37_| CMP sensor 3_| MAIN fase 38_| VICS solenoid valve @_[eGi tase 32_| PRC solenoid valve &_[ Hanon switch 40_| Purge solenoid valve @_| Starter “41_| Fuolinjoctor Not 7_| Generator 42_| Fuel injector No2 '8_| Generator wamning ight 43_| Fuel injector Nos | Fuel pump relay ‘44_| Fuelinjector Noa 70 | Main ratay 45_| Condenser 11_| Fuel pump 46_ | Ignition col No-t 12 | DLC 447_| To spark plug No-t, No 13 | HOLD switch ‘48_| Jgniton coil No2 14_[ HOLD indicator ight 49_| To spark plug No2, No 15 | Backcup light 50_| Knock sensor 16 | TRewich 51_| PSP swich 17_| Shift solenoid A 52_| Immobiizer unit 16 _| Shift solenoid B 53 | Hoes 19_| Shit solanoia © 54_| EGR vale 20__| Shift solenod D 55_| Cooling fan relay 21_| Shift solenod E '56__| Cooling fan motor 22_| Prossuro control solenaid '57_| Condenser fan rotay 28 _| ATF temperature sensor '58_| Condenser fan motor 24_| Inputurbine speed sensor 59 | AC relay 25._| TP sensor 60_| AIC compressor 26_| ECT sensor 61_| Refrigerant pressure switch (high, low pressue) 27_| Speadometer sensor 2_| AC switch 28_| vss 63_| ACampiner 29_| Sposdometer 4_| Fan switch 30 | Brake switch 25 _| Blowor motor 3t_| Neural switch 6_| AIC equiped 32_| Cuutoh switch 7_| For Mix 33_ | TAC valve 8_| ForATX 34_[ IAT sensor 69__| To instrument user '35_| MAF sensor Fi-7INTAKE-AIR SYSTEM OUTLINE '¢ The intake-air system is the same as that of the current 323 (Bu) FP engine model (Refer to 328 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: x: Applicable = Not applicable Tem PREMACY FP. 33 BFP, Remark Fresh-air duct * ‘Same as 929 (BJ) FP engine model Resonance chamber x ‘Same as 323 (BJ) FP engine model Ar leaner ™ ‘Same as 323 (Bd) FP engine model Throitle body | a ‘Same as 323 (BJ) FP engine model ‘ir valve = ‘Same as 323 (BJ) FP engine model TAG vane x ‘Same as 323 (BJ) FP engine modal Tntake manifols x ‘Same as 323 (BJ) FP engine model Dynamic chamber x ‘Same as 423 (BJ) FP engine model VICS solonoia valve x ‘Same as 323 (64) FP engine model ‘STRUCTURAL VIEW —~8) 7 [intake mani a | Arcane 2_[ WIGS solenoid valve 5 _| Resonanoe chamber 3 | Theotle body 6 | Frostvair duct F1-8SYSTEM DIAGRAM Fi-9 1_[ intake mantra | Freshair duct 2_| Te PRO solenoid valve 10_| Resonance chamber '3_| To purge solenoid valve 1t_| EGR vale 4 Thttle body 12_| VIGS shutter valve actuator [IAC vale 13_| VIGS solenoid valve 6 _| MAF sensor 14_| VICS vacuum chamber (bultin intake manos) 7_| Aircleaner 45 | WIGS chock valve (one-way) [IAT sensorFUEL SYSTEM (OUTLINE '¢ 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 fol x: Applicable Hem PREMACY FP. 323 (8) FP Remark Fuel tank ‘Same as 323 (BJ) FP engine modal ‘Quick release ‘connector and plastic fuot hase. ‘Same as 323 (BJ) FP engine model Fuel puns x See S29 FP ne now ee P Samo a8 325 (8) FP ange mode Fuk cor Samo a 523 FP ino moda Pressure rogulator ‘Same as 423 (BJ) FP engine model PRC solenoid valve ‘Same as 329 (BJ) FP engine model Pulsation damper ‘Same as 323 (BJ) FP engine model ‘STRUCTURAL VIEW Engine Room Side 1_| Palsation damper 3] Quick release connector 2_| Fuel injector | Fuel pump relay 2_| Pressure ragulator 7_| To fuel tank 4_[ PRC solenoid valve | From Wve tank F1-10Fuel Tank Side 1_[ Fuei pump unit “4_| Te pulsation dampor 2_[ Noneeturn valve 5_| From pressure regulator 3_| Quick release connector aa SYSTEM DIAGRAM Fuel tani Fuel injector Fug iter dow pressure) Pressure regulator Fuel pump PRC soloncid valve Fuel iter (high pressure) To POM Pulsation damper Fi-11EXHAUST SYSTEM (OUTLINE '¢ The exhaust system is the same as that of the current 323 (Eu) FP engine model. (Refer to 323 Training Manual 3327-10-98G.) STRUCTURAL VIEW 1_[ Exhaust manor 4] Presiencer 2_| Front pipe | Main silencer 3_ [we F1-12EMISSION SYSTEM OUTLINE '¢ 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: x: Applicable = Not applicable Tem ‘PREMACY FP. 323 (BFP, Remark Rollover valve * ‘Same as 029 (Bu) FP engine mode! Evaporative gas check x ‘Same as 223 (Bu) FP engine mode! valve (two-way) (8) FP engi ‘Charcoal eanister x ‘Same as 323 (BU) FP engine model Evaporative gas check eee Cae = ‘Same as 923 (BU) FP engine mode! Purge solenoid valve =z ‘Same as 823 (BU) FP engine model POV vaive x ‘Same as 323 (BU) FP engine mode! Two x ‘Same as 323 (BN) FP engine model STRUCTURAL VIEW Engine Room Side T_| Charcoal canister 4] Pov vane 2_| Purge solenoid valve 5 | Two 3 [EGR valve 6 _| From fuel tank F1-13Fuel Tank Side 1 _[ Rolover valve (bult-in fuel tank) ‘SYSTEM DIAGRAM 1] Rollover valve (evaporative gas check valve (hwo way) integrated) 2_| Charcoal canistor 3 [Purge solenoid valve F1-14 EGR valve POV valve Two To POMCONTROL SYSTEM OUTLINE '¢ The control system is essentially carried over from the 323 (BJ) FP engine modal, except for the following: — Operation condition of EGR control has been modified. (Refer to 323 Training Manual 3327-10-98G.) Input Device x: Applicable Not applicable Tem Siena PREMAGY FP a6 Tlemark Tat sensor ar Same 38 323 (.) FP ongne mel MAF sensor [MAF = Same a8 323 (.) FP ongne med TP sensor [TP x Same a5 329 (.) FP engne model ECT sensor [ECT x Same os 823 (4) FP engine model sensor | Oinder x ame 08 engine model our icenttetion Same as 229 (8 FP engine model xP sensor [ERIE x Sama 28 323 (4) FP ongine model reo sensor —[enockng z Same as 323 (6) FP engine nae 028 Onygen ~ Sa 8929 (8) FP ena mode Neutra wich (or | Load oad : Gmowe cngne ve and Same 28 323 (8) FP engine medel Cush swich | Ladin oad Guts ‘tno x Same as 323 (64) FP engine model TRewich Londo oad Tews teen x Sama 28 323 (8) FP ongine dl Power ssaing sp wien | pump toad x Same 08 329 (.) FP engine model conciton vss Vehicle peed z Same ws 32 (BD) FP engine model ake rake paca x ame as engine Brake anten | KE Pe Same as 29 (8) FP engine model AG och ‘eget peseure ‘eters presse | yc cpaatonal x Sama 2s 323 (8) FP engine mod wer) Regent | Feigart pressure evien | preesure (ro - x _ (rss resi) | posse) oe Diagreste wat . — ome (TENteminay | mode ewiching Sarno oo 22 (FP engine mace watery Seep pve x Same a5 58) FP engine model eneraioe Generator (erminalP: output | Serer x Same as 323 (8) FP engine medel vtage) pavolage Torque posircscm — | reducton - x Same 08 329 (.) FP engine model request tmmobiizr Immotizorunt | system x Same os 323 (4) FP engine mode! F1-15Output Device x: ppt —:netapptase Saige vce | Conarnem | PRENACYRP [aaa BFP co TaGvane [AC x Sao os (i FP ong node Ws steed | vicg x Sar a 29) FP engine mode ‘uel injector Fuel injection x same as: ‘engine Fuetinecor | ust Sa a 325 (8) FP nga mode AC std rae Pac x Same a8 929 (8) FP engine model Foatpare | Folpare cmoas canoes ry conte ar a 23.) FP ong ce Tgnton cal ESA ona x San a 25 (G) A eng mal Sao a 23.) FP ong ose convane | go contol x ImEGH contol open condor avo been sarge Pages | Page cond x Sar a 25.) FP engine mode os ear | Oe Fear x Sao a 29 (2) FP ongna mode termina: | Sener x Same a5 929 (8) FP engine mal foiseo oni fn rey eters! an . 1 ertan | Scat sae 0 320 (.) FP engine ese rly (or 9) 7G ry Condarsrten | AC oot x sae a 25.) FP engine mode rly for Tan aasresem | Tas - x — On oad DLC (terminal ynost x same as: ‘engine eager | Sag Sao a 29.) FP engine ode F1-16STRUCTURAL VIEW 7_[ Pow 17_] VSS (for MIX) 2_[ IAT sensor 18_| VSS (for ADO) 3_| MAF sensor 19_[ AG vave 4 [TP sensor 20_| VICS solenoid valve 5_[ ET sensor 21_| Fuel injector 6_| CMP sensor 22_| Fuel pump relay 7_| KP sensor 23 | lgnition cit @_| Knock sensor 24 _| 028 hoator (ntogratod with HO2S) 8 HO2S (iniogratod with HO2S heater) 25 _| PRC solenoid valve 10_[ Citen switch (lor MTX) 26 | Cooling fan roiay 11_| Neutral switch (for MS) 27_| Condenser fan relay 12_ | TReswich (or ADO, 28_| Purge solenoid valve 13_[ PSP switch 20_| EGR valve 14_| Brake switch 90_| ACrelay 15 | Banery 31_| Generator 16 | DLC. 32_| Main rea F1-17BLOCK DIAGRAM F1-181 [aT sensor 25_| Fuel pump relay 2_| MAF sensor 26 | 025 heater (tegrated with HO2S) 3_| TP sensor 27_| EGR valve @_[ CMP sensor 28_| Purge solenoid vane © _| CKP sensor 2o_| AC relay @_| ECT sensor '30_| Condenser fan relay or MTX) 7_| Knock sensor 31_| Cooling fan relay | Hoes 82_| Condenser fan relay (for ATX) @ [vss 2_| Generator (erminal D: fel coi) 10 | Cutch switen (or MTX) 34 | Generator waring ight (rtegrated with instumant 11_| Neutealswitoh for MTX) cluster 12 | TReswiten (or ADO) 36 | IAC system 13_[ PSP swe 96_| vies 14 | Brake switch '37_| Fuel injection control 15 | AC switch, refigerant pressure switch (righ, ow 38_[ tmmotitzer systom pressure) 30_| ESA control 16 | Gonerator (erninal P: output vokage) 40_| PRC 17_[ DLC (eminal TEN) 41_| Fuel pump contol 1¢_[ Battory 42_| 028 neater contro! 18_[ Immobilizer unit 43_| EGR control 20_| TAC valve 44_| Purge control 21_| VICS solenoid valve 45__| AC out-of control 22_| Fuel injectors 46_| Electrical fan control, 23 _| Ignition coi 47_| Generator control 24_| PAC solenoid valve ae_| POM F1-19‘CONTROL DEVICES AND CONTROL RELATIONSHIP CHART x: Applicable Control tem FUEL INJECTION CONTROL FUEL PUMP CONTROL ‘035 HEATER CONTROL PURGE CONTROL FAN CONTROL ‘GENERATOR CONTROL IMMOBILIZER ‘NG CUT-OFF SYSTEM vies PRC ESA CONTROL ELECTRICAL lac x | EGR CONTROL TAT sensor MAF sensor TP sensor [EMP sensor ‘CKP sensor, ECT sensor x Knock sensor HOZS vss NeuivalOlutch switerr™ TTR switon"= Tnput device PSP switch Brake switch ‘AC switch, refrigerant pressure switch (high, low pressure) ‘Generator (terminal P: output voltage) DLC (terminal TEN) 5 x 5 x Battery x x x x Immobilizer unit x TAG vane x VICS soloncid valve = Fuelinjector| x 3 Fuel pump relay x PRC solenoid valve x Ignition coi x x (025 healer x Purge solonoid valve a ‘Output device EGR valve * AIG relay x ‘Cooling fan relay = ‘Condenser fan relay xa] x ‘Generator (terminal Dold coll) “Generator waming light ST For MTX *2: For ATX F1-20IDLE AIR CONTROL (IAC) OUTLINE '¢ The IAC of the PREMACY FP engine model is the same as that of the 323 (BJ) FP engine models. Idle Speed '* A.comparison of the idle speeds for PREMACY FP engine model and the $23 (BJ) FP engine madels is as. shown in the following table. Tale speed (om) Coneition PREWAGY 323 MTX ATX, (8) Novoad a NG's operating” = Etecrical oad is on. | Within S0A—408 750 700 40h or above"? 750 700 PIS operang. (Steering whee s rotating) 750 "AVC switch and fan swilch are on. "2; Headlight is on, Fan switch is above 1st, Cooling fan is operating, and Rear window defroster is on. EGR CONTROL OUTLINE ‘* The EGR control of the PREMACY FP engine model is essentially carried over from the 323 (Bu) FP engine models except for operatian conditions. ‘* The EGR control of the PREMACY FP engine model is the same as that of the 323 (BJ) FP engine models. OPERATION CONDITIONS '¢ The EGR control carries out the EGR operation when all of the following conditions are satisfied: (1) Except cranking (2) Except idling {@) Engine speed is between 1000 rpm and 4093 rpm. (@) Except heavy load volume increase zone ({uel injaction control) (6) Vehicle speed is above 3.8 km/h {2.4 MPH}. F1-21ON-BOARD DIAGNOSTIC SYSTEM (OUTLINE '¢ The DTCs and simulation items of the PREMACY FP engine madel are the same as thase of the 323(6) FP engine modes. ‘* The monitoring item has been added for the PREMACY FP engine model compared to the 323 (BJ) FP engine models pre DTC Table 2: Applicable ~:Not applicable Diagnosed ‘on condition mea Memory ore] Plagnose Detection condi Fallsate Memery pow input volago tom MAF sonsorisbolow 0.86V | » Adjusts charging effcencyto | war. when ignition swrch is med to ON postion. |" set valve P0103 Sense [input voltage from MAF sensor is above 4.90V | * Adjusts ignition ting to fixed | when ignition switch is turned to ON position. ignition (6°CA) pone Input votago trom IAT sensor is below 0.16 V | Sets IAT for angi contol x vn coneor Lthonigniion swich suned ON positon |” 20°C arr) pone | "°°" [input votage trom IAT sensoris above «ea v | * luminates generator waming | when ignition switch is turned to ON position. light Input voltage from ECT sensor is below 0.20 v | * Sets ECT for engine control pour when ignition switch is turned to ON position. orc toa} “ ect + Sets ECT for AG 80°C Sensor {176°F} Input votage rom ECT sensoris above sony | U7 . pone wong suite ume o ON postin. | * OPeraes. cong fan end Sets trate opening angie pote Input votage trom TP sensors below 0.10 |” for engine cortrl cised “ won ignition sui is turned to ON postion. | 4 fee tosed tee postion TP sensor foaming valuo to sot value « Innis dechoke contol Input voltage tram TP sensor is above 4.90 V . Pores ‘when ignition switch i tured to ON position. | * bits dashpot corrction for When HO2S signal does nat oxcoed 0.58 V alter engine is started or stays below 0.55 V for | « Stops feedback contrat ttuel | Pois4 | Ho2s, 120 seconds after engine has reached normal, injection control operating temperatura Input votlage tom knock sensor below 0.90 . POS” | knock soneor |W NER anton switch is tuned to ON positon, | St fuel cu-of at siting came Senso" [put voltage fom knock sensoris above a.0e | * /an#n 9 7 \Vwhen ignition switch is tured to ON poston. posse | Gx censor | NONE sionals nputed tom OKP sensor while | sp ner wjoauon conrad y engine ie runaing. cone Purge ‘pen oF shortcuts observed in purge P23. | solenoid | solenoid valve system when ignition swatch is - - vane tuned to ON pasion, When HO28 signal stays above 0.55 Vor b= prize | Hoes | wass\foraad seconds ater eng hes | * Slope feedback contol otto! | reached normal operating temperature. Wegectir ‘pen or short ecuitis observed in PRC praso | PRC sola | Sora vave oft wnen ton such - - “ turned to ON position. vrais | cuPcomor | NSC Smalmpatom cuPsesortrT2 |. sopsivtinectn otal |< T Fora F1-22x: Applicable =: Net applicable Diagnosed circuit Detection condition sate ‘Memory function Prag ‘Open or short Greultis observed in EGR valve {stepping motor 1 col) system when ignition Switch is tumed to ON postion. prao7 EGR valve ‘Open or short circuit is observed in EGR valve (stopping motor 2 co) systom when ignition Switch is tumed to ON position. Praga ‘Open or short circuit is observed in EGR valve {etepping motor 3 col) systom when ignition switch i tumed to ON position. Praga ‘Open or short circuit is observed in EGR valve (stepping motor 4 co) system when ignition Switch is tumed to ON position. Pisos ac vale PCM detects that PCM terminal 4M voltage is ‘above threshold or below threshola*? when IAC duty target is above 18%, PCM determines tha IAC valve circut has malfunction ITPCM detects that PCM terminal 40 voltage is, above 2 V or IAC target control duty valve is below thrashols"2, PCM determines that IAC valve crcuithas maltunction, Stops IAC Prs23. VICS cole- roid valve ‘Open or short circuits observed in VICS solenoid valve system when ignition switch is turned to ON postion. Pre02 Immobilizer ‘Commanded transmission from POM to Immobilizer unt excoeds lina, No response from immbiizer unit P1603 system Koy 1D numbers are not registered in POM. P1604 ‘Code word isnot resistored in PCM. P1608 Pow POM does not read DTC from output device. Prezt ‘Code words stored in POM and immoblizer unit do not match, Pre22 Immobilizer system TD numbers stored i immobilizer unitand POM do not match, (sored after immobilizer unit was replaced and key 1D number te-registered.) Pies Tnlemal PCM EEPROM mallunetion Pre24 PCM detected immobilizer system malfunction move than tree times, Presi Generator \When PCM noeds more than 19 A from ganer- ator, and judges generator output voltage to be below 8.5 V. Press Battory When PCM judges generator output voRage 5 above 18.4 V or B+ is above 15.9 V. P1634 Generator \When PCM judges generator output voltage is above 16.9 V and Br is below 11.0 ‘When detected, the threshold value depends on baitery volage and IAC signal duly value. F1-23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 PIDDATA Monitor Table MONOS ce aanesten Monitoring item Condon! | pce terminal ‘ACCS NG relay ONOFF 1s ACSW ‘NG switch ‘ON/OFF iP ALTE ‘Gonorator fd coi corral day value % 10 ALT Generator output votage Vv 7 'ARPMOES, Target engine speed om - B00) Brake switch ON/OFF 1 (GHRGLP Generator warning Hah (ON/OFF 10 cor ECT “c 3E ECT signal votage v 3e EVAPOP Purge solenoid valve day value % a FANE ‘Condon fan contol ‘ONOFF a FANS Coating fan contol ‘ON/OFF in P Fuel pump relay ‘ONIOFF 2 FPRC Pressure regulator control ONOFF aT FUELPWI Fuel injection duration me | AWA AY AZ First gear ‘relat = ‘Second gear 172134 = orn Third goar 2)34 = Fourth goar 12134 = TAG TAG valve ms aM. 40 var TAT “c 38 TAT signal votiage Vv 3 we VIGS solenoid vate ‘ON/OFF an KNOOK T Knocking retar degree 3G Linens Chane tage ine resis acid et ceig a - upset Pressure contol solenoid A MAF MAF signal votiage Vv ‘o2stt HOS v PNPET Loadino load condition signal ‘ON/OFF v PNP Loadino load condition signal ON/OFF v PSP PSP wich ‘ON/OFF 1G RPM Engine speed om HD ‘SEGAP. EGR vate stepping moter postion step | SM 2N.90. 3° SSASSI Shif'solenod A % 4s SSBSS™7 Shit solenod B % w SSCISSo7 Shit solenod © % av SSDISSI" Shit soienod © ‘ONIOFF 20 SSESSST Shit solonod E ‘ON/OFF aR 'SPARKADV ignition timing BTDC 30.3 ToL HOLD indicator ight ONIOFF 2A cs HOLD swich ON/OFF 20 T ATX only MTX only F1-24Honor Tom Bey on Monitoring Hem ono peu erminal Test Teoma WUE ert ii % Tm TV TT soar Sonal ea v iT a TP sa votoge v = 7205 7 = Tat TR ‘owore | ar 7A007 Tse range) oworr [a Tar TR postin oworr_| 2 TA TR swioh (rage) ‘oworr [a6 T337 Tape speed ea om | ea ve er v 8 9 veri ee i oe AT ATK only, +2. MITX only SIMULATION TEST "The emulation Kem ofthe PAEMACY FP engine model are inte following lable. amie Never Timaaton Test conaion nat Detnton Operation PSRERPAENT cy cermin noes | Roy ONO a ALF neato fal ot corre aya OFF es iRNGLP | Generator warning ight ONO oe EVAPCP | Purge soled vane dita = opt Fann | Condos fan con ONO ps Fana——| Colin en cova ONOFF =p fa im Fuel un ey ONO a FERE [Prose rguno Soe ONOFF a FUELPWT | Pet recon drain % aa ae Tac TAC va % aio Tt | Footer a OFF ee Tha [Footer no OFF =o x Ta [Poets OFF oy Ws Fuster No OF p= Ne VIS ela va ONO a SEGRP ER wave sipping aa potion STEP so Pa 20 AT ATK only, *2 MTX only F1-25ENGINE ELECTRICAL SYSTEM ABBREVIATIONS .... seeeeeeeeeeeseeees Gat SPECIFICATIONS .....+ OUTLINE .oeeeee ste cetelilliicscnsees @-4 STRUCTURALVIEW 21. OUTLINE OF CONSTRUCTION G4 ABBREVIATIONS Du | Disiibutoress ignition RHO. | Aighthand ave OUTLINE OUTLINE OF CONSTRUCTION ‘¢ 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 systam installation conaition. — The ignition cols for FP engines are placed in the No.2 and No.‘ cylinders on the upside ofthe cylinder head cover. They are the same types as those of the current 323 (Bu) ZL and ZM engines. SPECIFICATIONS, tem Specification FP Votage w 2 Battery “Type and eapaaty (S-hour rate) ) 500201. (40) Output vA 280 Generator [Regulated vonage (V1 Controlled by POM ‘Soa diagnosis function Integrated in POM “Type Du Ignition sytem | SParkaavance Bleconie Fring order 13—4-2(14-32-41-29) 0 ‘Two cylinders fire simultaneously for each. NGK ‘BKASE-11), BKAGE-117 Sparkpug | Type [ DENSO Ki6PR-UNT, KOOPR-UIT? (CHAMPION RCIOYCA®, ABYC? Type axial reduction ‘suaner ie Coaxial reduct ‘Ouput (wy 10 “7 Standard plog 2: Gold type plug °S: Hot type plug‘STRUCTURAL VIEW 1 | Batery | Spark plog 2_| Generator 5 _| High-tonsion lead) 3 [anion coi 6 | StarterCLUTCH OUTLINE oo. essesssssecsseseesesesessseses HAL SPECIFICATIONS ‘OUTLINE OF CONSTRUCTION. HA OUTLINE OUTLINE OF CONSTRUCTION '¢ The clutch mechanism is the same as that of the current 323 (BJ) models. (Refer to 323 Training Manual 3927-10-98G.) SPECIFICATIONS: tom Engine FP ‘Giutch contra! Hyaraule ‘cunch cover [Seen Be Diaphragm Set load (Wie, 74,808 (490, 1,080), Guach ane | Outer dlamator (en fn) 2007.87) Inner dlamotor (nm fn) 190 (6.12) Type Suspended ‘Clutch pedal [Pedal ratio 6.66 Fal stroke (onto) 187 5.39) ‘Clutch master eyinder inner diameter (eam fin) 15.87 {0.625} ‘Gute release cylinder inner diametor (nm fn) 18,05 {0-760} ‘Clutch fuid type ‘SAE J1703, FMVSS 116 DOTS H-1OUTLIN' MANUAL TRANSAXLE (F25M-R) IE OUTLINE OF CONSTRUCTION’ SPECIFICATIONS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, Tom Engine P Transase ype Fa5M-A Teansawe control Floor svt ‘Operation system Rod ‘sit aseh Forward ‘Synetwomesh Reverse Seleatve sliding and synchromesh ist 3416 2nd) 182 Gearrato | SS 1280 ‘ath osre th o7s1 Reverse 3214 Final gear rao 2.105 Grade ‘API sonice GL-4 or GL-6 on Vieonty PAtseason SAE 75W-90) ‘Above 10°C (50°F) SAE 80W-90 Capaiy (CUS, imp a) 2.68 (283,296) Ji-2AUTOMATIC TRANSAXLE (FN4A-EL) ABBREVIATIONS . K-41 ‘CONSTRUCTION Ko OUTLINE : TK 2 BLOCK DIAGRAM K-10 ‘OUTLINE OF CONSTRUCTION K-2 ELECTRONIC CONTROL ITEMS AND) FEATURES .. K2 (CONTENTS: Kt SPECIFICATIONS K-3 COMPONENT DESCRIPTIONS AUTOMATIC TRANSAXLE 2 fk 4 (ELECTRONIC CONTROL) Kent ‘OUTLINE: kK 4 INPUT/OUTPUT SIGNALS AND RELATED CROSS-SECTIONAL VIEW Ka CONTROLS. K-12 OUTLINE OF OPERATION K- 5 — SHIFTMECHANISH K-43 EC-AT OPERATION CHART K-6 OUTLINE. K-43 POWERFLOW .... K7 STRUCTURAL VIEW | K-43 ELECTRONIC CONTR\ Ko SHIFT-LOCK SYSTEM . Ka OUTLINE: : Tk9 ABBREVIATIONS AIF | Automatic vancado Fuld TGR __| Fret gear EC-AT_| Electronically controled automatic vansene 2GR_| Second gear POM | Powertrain con madule 3GR__| Third gear TOC __| Torque converter cuich 4GR_| Fourth gear K-1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). K-2SPECIFICATIONS: tom Taran specs Tanase pe FNAA-EL eA 286 26h 1497 Gear rao 36h 00 ac 0785 Tova 28 Final goarrato a7 - Te TATE WC or ewhelot fg Doon W Copaciy CS a mp at) 72178.63) Tiqie coer argue ao 120 Forward Gah ia (number a vedeven plates) 34h Hyoraulic system {number of drive/driven plates) se Rovere catch oe Chubor a tvtdven plats) Tow end revere brake {number of drive/driven plates) 58 Servo ameter Band servo (piston outer dia) (mm fin) mapa Front planetary gear Front sun gear * manor 206 Frnt pin ger 20 Frontnemal goa ry 7 Par un goar a7 arpa asa" erin ge 20 Rear internal gear 98 Prana gear (cuba ea 6 Secondary gear (rubra w ‘Out gear (ruer acer 20 Fang gear (cunbor aco m7 K-3AUTOMATIC TRANSAXLE (OUTLINE '@ The FNAA-EL type automatic transaxle is used, ‘* The construction and operation of the automatic transaxle is the same as that of the current 323 (BY). (CROSS-SECTIONAL VIEW 1 [Torque convertor @_] 2a brake band 2_| Oilpump 9 | Low and reverse brake 3 | Forwara auton 70 | One-way luten @_| Front planetary gear 11_| Primary gear 5 _| Rear planetary gear 12 | Seoondary gear | 3-4 clutch 43 | Output gear 7_[ Reverse euih 14_| Diftorenval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 and the duty-cycle type solenoids in the hydraulic pressure control mechanism. — Hydraulic pressure control mechanism '* According to the signals from the PCM, each solenoid operates to switch the hydraulic passages in the control valve body and controls the cluich engagement pressure. ‘* 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 contralled by the duty-cycle type solenoids (shift solenoids A, B, and C). — Powertrain mechanism ‘* The driving force from the engine is transmitted through the torque converter to the transaxle, ‘* The transmitted driving force operates each clutch and brake according to the clutch engagement pressure from the duty-cycle 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 tres, la 3 ® 2 t ® ® 3 >® we) | a {i >a =| =a _| Powertrain mechanism 72] Orpune 2 _[ Hydraulic pressure convol mechanism 13 | Pom 3 | Eleewonic contol mechanism “4 _| Vehicle speed [Torque converter 15_| ATF temperature | Cutches, brakes 16 | Forward cuich cram revoion speed 6_| Planetary gear 17_| Engine revolution speed 7_[ itera 18__| Oiches, brakes engageren ease pressure 8 _| Cont vave boxy 19_| Powertow | Shit scienod 0, (ONOFF ype) 20_| Hysaute pressure contol signal 10 | Pressure control slendi (near type) 21_| Electronic signal “1 [ shit solenoid A, 8 G (cu cyto type) 2 [we K-5EC-AT OPERATION CHART Sa pao Oparalon of a eolonotd ‘sound : vane 3 5 Sls OFF type) 8) ode | aor position 23 #|§ £|2\5 i\3 5 2\E\s 28 A e/g |B) E| 2 Pa 2 5\8 [|b |s als a] [Room [ew] TT x [orn [eee [aT % | omen [cose [RSE “ =e z OPEN | OPEN [CLOSE mR x{x]™ x |x ‘OPEN | OPEN | OPEN non. xP TeL Te CLOSE FEN [ OFEN | MAL x |x x x CLOSE | OPEN | OPEN | ON | ON ; z x Oran | Oren [ce [OFF [OF Hot 4 pec open [ oven | oven [ore [Orr x x cose oven [open | OW [OFF 7 z Boren [oxose [ose [or Torr MOL 1 x * ‘OPEN [CLOSE | OFF | OFF i" Hope epee crEN | oFEN [OFF [OFF s Lee oreN | Oren | on [OFF Tore x omen [cose OFF [OF Ho t ca ee ‘EN | OPEN | OFF | OFF x x a , A z | omen [ose [ouose [ort Torr on HoT x ren [cLose [orF [OFF roe pore cE a xP te [x Oren oven Pon [OF ‘ Tor [280], x x{|e@ ‘OPEN [oLOsE | ON | ON no. [2oR" [eT |g x ‘OPEN | oLOSE | OFF | OFF ae [os et bet Tx ren [oven | on [arr “1: Automatically switches between POWER and NORMAL modes according to accelerator pedal depressing speed. +2 Perform TCC operation in NORMAL mode. =: To prevent engine overspeed, inhibits downshift until the engine speod is reduced to the preset speed. + Operating @: Transmits the torque only when driving. ‘OPEN: Engages the line pressure tothe 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 por).