Mazda 323 1,8 F/ S 323 [1998 - 2003]

A16 Imobilizer
A18 Automatic transmission
A19 Speedometer
A20 Tachometer
A22 A/C
A23 ABS-ECU
A24 Instrument cluster
A65 ECU
B10 Knock sensor
B16 Inductive crankshaft position sensor
B18 Inductive camshaft position sensor
B19 Turbine speed sensor, gearbox
B22 Coolant temperature sensor
B23 Air temperature sensor
B30 MAF sensor
B40 Transmission oil temperature sensor
B48 O2-sensor with pre-heater
F- Fuse
G13 Alternator-Signal
K18 Pump relay
K22 System relay
M11 Fuel pump
M18 Cooling fan
R17 Throttle valve potentiometer
S13 Power steering pressure switch
S16 Stop light switch
S18 Gear position sensor
T27 Ignition coil with high stage cyl. 1 and 4
T28 Ignition coil with high stage cyl. 2 and 3
X11 Diagnostic connector
X14 Ground connection
X15 Cable screen
Y11 Injector cyl. 1
Y12 Injector cyl. 2
Y13 Injector cyl. 3
Y14 Injector cyl. 4
Y34 Canister purge valve
Y37 Inlet control valve
Y40 Idling control valve
Y50 Fuel pressure regulator vacuum valve
Y53 EGR valve
 Technical data on the vehicle
Make Mazda Date: 15-08-2016
Model 323 1,8 F/ S Owner
Year 1998-2001 Registration No.
Engine FP VIN
Variant 1. Reg. Date

Technical item Data

Engine
Engine ID code FP
Number of cylinders R4
Number of valves 16, DOHC
Capacity/ (bore/ stroke) 1840 cm³ (83,0/ 85,0)
Compression ratio (RON) 9.7: 1 (95 unleaded)
Max. output kW (din hp)/ rpm 84 (114)/ 6000
Max. torque NM/ rpm 161/ 4000
Engine code location Engine block left side by flywheel
Vehicle Identification Number location Fire wall right side
Valve clearance, inlet (cold/ hot) 0.260 ± 0.035 cold i
Valve clearance, exhaust (cold/ hot) 0.26 ± 0.035 cold i
Compression pressure, bar 14.0 (Min. 11.0) Max. difference 2.0
Oil pressure/ rpm, bar 4,0 - 5,0/ 3000
Radiator cap, bar/ thermostat °C 0,95 - 1,25/ 80° - 84° C
Thermostat gap at test temperature 8.5 mm at 95° C
Clutch freeplay, mm (Hydraulic) (0.7 - 3.5 at pedal)
Timing belt: Renewal interval 90,000 km i
Noise measurement, dB(A) at rpm 86/ 4500
Drive belt i
Engine management
Engine management system Mazda EGI
Spark plug Champion RC10 YC4/ NGK BKR 5E - 11
Electrode gap, mm 0.7 - 0.8 mm
Firing order 1 - 3 - 4 - 2 (Cylinder 1 at timing gear) i
Ignition timing (BTDC) 9° - 11°/ idle speed i
Diagnostic connector In engine room i
Max. timing advance (max. rpm) (Electronic)
Timing mark location Belt pulley
Ignition coil: Primary/ secondary resistance / 8,0 - 14,0 kohm
Fuel pressure, w/wo vacuum, bar 2,1 - 2,5/ 2,7 - 3,1
Holding pressure, bar Min. 3.4 after 5 minutes
Injector resistance, ohm 12,0 - 16,0
Min. idle manifold vacuum, mbar 590
Coolant temperature sensor 20°/ 80°C 2,20 - 2,80 kohm/ 0,29 - 0,40 kohm
Intake air temperature sensor 20°/ 80°C 2,2 - 2,7 kohm/
TPS voltage, volt Closed 0.1 - 1.1/ Open 2.8 - 4.5
Fuel pump pressure, bar 5,0 - 6,3 bar
Electrical system
Battery 12 V - 40/ 52 Ah
Starter motor current (cranking), A Max. 90 A/ 11 V (Unloaded)
Voltage relay, Volt at/ amp. 14,1 - 14,7/
Terminal definitions DIN 72 552
Alternator max, A 80
Wheel alignment
Load Unloaded
Toe-in, ° 0° 12' ± 24'
 Technical item Data

Wheel alignment
Camber° ÷ 0° 48' ± 1°
Camber, max. difference on R and L side 1° 30'
Caster° 1° 50' ± 1° i
Caster, max. difference on R and L side 1° 00'
KPI/SAI° 12° 35'
Toe-out on turns, inner wheel° 37° ± 2°
Toe-out on turns, outer wheel° 33° ± 2°
Rear camber° ÷ 0° 30' ± 1° i
Rear camber, max. difference on R and L side 1° 30'
Rear toe-in ° 0° 12' ± 24' i
Tyre size 185/ 65 R 14 86 T (195/ 55 R 15 85 V)
Tyre pressure, front/ rear, bar 2,1 - 2,2/ 2,1 - 2,8
Free play in suspension parts Factory data i
Wheel offset, mm 5½JJ x 14 = 45 mm (6JJ x 15 = 45 mm)
Tightening torques
Tightening, NM Torque standards
Cylinder head bolts, stage 1, Nm 17.5 - 22.5 Nm oiled i
Cylinder head bolts, stage 2, Nm + 85° - 95°
Cylinder head bolts, stage 3, Nm + 85° - 95°
Cylinder head bolts, stage 4, Nm (No retightening)
Cylinder head bolts, stage 5, Nm (Max. bolt length without head 105.5 mm)
Main bearings, Nm 17,2 Nm - 22,0 Nm + 85° - 95°
Connection rod bearings, Nm 22 - 27 Nm + 85° - 95°
Flywheel, Nm 97 - 102 with Loctite
Crankshaft pulley/ vibration damp. Nm 157 - 166/
Camshaft pulley/ bearings, Nm 50 - 60/ 11,3 - 14,2
Timing belt tensioner, Nm 38 - 51
Spark plugs, Nm 15 - 22
Wheel nuts/ bolts, Nm 89 - 117
Wheel hub, front/ rear, Nm 236 - 318 new/ 177 - 235 new
Brakes
Front, min. thickness (new) 22,0 mm (24,0 mm)
Rear, min. thickness (new) 8.0 mm (10.0 mm)
Min. brake lining thickness, front, mm 2.0 mm
Min. brake lining thickness, rear, mm 2.0 mm
Capacities
Engine oil/ - incl. filter, litre 3,3/ 3,5 (APi. SG, SH, SAE 10W30)
Manual transmission, litre 2,68 (APi. GL-4/ 5 SAE 75W/ 90)
Automatic transmission, litre 7,2 (ATF M - III/ Dexron II) i
Power steering, litre 1,0 (ATF M-III/ Dexron II)
Cooling system, litre 7,5
Fuel tank, litre 55
A/C fluid, type/ gram R134a/ 600
A/C oil, type/ cm³ / 150
Environmental parametres
Idle speed, rpm 750 ± 50
Min. oil temperature at test °C 60
Heating time for catalyst, minutes 3.0
Idling speed in heating period 2750 ± 250
CO% at idle speed Max. 0,5 i
Increased idle speed 2650 ± 150
CO% at Increased idle speed Max. 0.3
HC idling, ppm (CO²) Max. 100
Lambda 1,00 ± 0,03
 Troubleshooting-data
Model: 323 1,8 F/ S Motor: FP / Sumitomo

Component: From: To: Condition: Value Measured:

Pic.
. . . Connector seen from wire side .
Battery (earth) AA Batt. - Ignition on 0V
Battery (earth) AD Batt. - Ignition on 0V
ABS indicator lamp W Batt. - Idle, lamp off 11 - 14 V
ABS indicator lamp W Batt. - Idle, light on 0-2V
Battery (possitive) AB Batt. - Ignition off 11 - 14 V
Battery (possitive) AC Batt. - Ignition off 11 - 14 V
Ignition Z Batt. - Ignition on 11 - 14 V
Ignition Z Batt. - Ignition off 0V
Stop light switch Y Batt. - Ignition on, pedal activated 11 - 14 V
Stop light switch Y Batt. - Ignition on, brake pedal 0V
released
Wheelspeed sensor F.L. I E Ignition off, ECU connector 1300 - 1700
dismantled ohm
Wheelspeed sensor F.L. I E Spin wheel at approx. 60 rpm 0,3 ~ 1 V 1050
Wheelspeed sensor F.R. G D Ignition off, ECU connector 1300 - 1700
dismantled ohm
Wheelspeed sensor F.R. G D Spin wheel at approx. 60 rpm 0,3 ~ 1 V 1050
Wheelspeed sensor R.L. C F Ignition off, ECU connector 1300 - 1700
dismantled ohm
Wheelspeed sensor R.L. C F Spin wheel at approx. 60 rpm 0,3 ~ 1 V 1050
Wheelspeed sensor R.R. A B Ignition off, ECU connector 1300 - 1700
dismantled ohm
Wheelspeed sensor R.R. A B Spin wheel at approx. 60 rpm 0,3 ~ 1 V 1050
Diagnostic connector Flash code:

FEN = Test socket Code example: 22

TEN = Activation of DTC's
+B = Battery +
GND = Chassis
FBS = Read ABS DTC's using a diode test lamp
TBS = Activation of ABS DTC's
IG÷ = RPM signal
F/P = Activation of fuel pump
TAB = Deleting airbag trouble codes
Procedure
Faultcode read-out:
1. Connect a diode test lamp between the battery's positive terminal and FEN in the diagnostic
connector.
2. Connect TEN in the diagnostic connector to ground.
3. Ignition on.
4. Faultcodes are shown on the diode test lamp.
5. Test completed.

Resetting the ECU:

1. Ignition off.
2. Disconnect the battery's negative terminal from ground.
3. Activate the brake pedal for at least 20 seconds.
4. Re-connect the battery's negative terminal to ground.
5. Check that there are no more faultcodes shown.
 Fault-codes
Model: 323 1,8 F/ S Motor: FP / EGI Aut.

Faultcode Possible cause(s)

01, Ignition module Missing signal,
02, TDC sensor cylinder 1 Missing signal,
03, Hall sensor Missing signal,
04, TDC sensor cylinder 1 Missing signal,
05, Knock sensor 1 Fault in circuit,
06, Vehicle speed sensor Fault in circuit,
08, Air swirl meter Fault in circuit,
09, Coolant temperature sensor Fault in circuit,
10, Air temperature sensor Fault in circuit,
11, Air temperature sensor Fault in circuit,
12, Throttle valve potentiometer Fault in circuit,
14, Altitude sensor Fault in circuit,
15, O2 sensor Missing signal,
16, EGR valve position sensor Fault in circuit,
17, O2 sensor Signal incorrect,
18, Injection quantity regulator Fault in circuit,
19, Fuel adjustment sensor Fault in circuit,
22, Shut-off valve Fault in circuit,
23, Fuel temperature sensor Fault in circuit,
24, O2 sensor Signal incorrect,
25, Control valve Fault in circuit,
26, Canister purge valve Fault in circuit,
28, EGR valve Faulty vacuum signal,
29, EGR valve Flow incorrect,
34, Idle control valve Fault in circuit,
35, Control valve (Number 2),
36, Glow plug Relay control circuit electrical,
41, Inlet control valve Fault in circuit,
43, Injection timing valve Fault in circuit,
46, Inlet control valve (Number 2),
49, ECU Defective,
52, ECU Diagnostic connector, Defective,
55, Automatic transmission Fault in circuit,
56, ECU Voltage too low,
57, Relay Injection/ ignition/ ECU,
60, Automatic transmission Two-way valve # 1,
61, Automatic transmission Two-way valve # 2,
62, Automatic transmission Two-way valve 3rd/ 4th gear,
63, Automatic transmission Fault in circuit,
64, Automatic transmission Fault in circuit,
65, Automatic transmission Fault in circuit,
66, Automatic transmission Fault in circuit,
67, Cooling fan relay Temperature too low,
68, Cooling fan relay Overtemperature condition,
69, Cooling fan thermo switch Fault in circuit,
71, Immobilizer Wrong signal,
72, Immobilizer Key,
73, Immobilizer Key,
74, Immobilizer Key,
75, ECU ROM error,
76, Immobilizer Key,
77, Immobilizer Wrong signal,
Mazda 323 1,8 F/ S 1998
Diagnostic connector

Diagnostic connector

Pic. 1