Engine & identification
Vehicle identification
| No. of cylinders Type | 4/DOHC |
|---|---|
| Capacity (Fiscal) cc | 1596 |
| Compression ratio :1 | 11,0 |
| Suitable for unleaded petrol | Yes |
| Minimum octane rating RON | 95 |
| Ignition system Make | Siemens |
| Ignition system Type | EDIS |
| Ignition system Description | Map-DIS |
| Trigger location | Cam/Crankshaft |
| Fuel system Make | Siemens |
| Fuel system Description | MFI-s |
| Air metering Type | MAP |
| Combined ignition and fuel ECM | Yes |
| Diagnostic socket | Yes |
Ignition system
| Ignition coil supply voltage + with ballast V | 12,0 |
|---|
Firing order
The firing order for the Mazda 2 1.6 (2002–2007) is 1-3-4-2.
| Firing order | 1-3-4-2 |
|---|
Valve clearances
Valve clearances for the Mazda 2 1.6 (2002–2007) are 0,17-0,23 mm inlet and 0,31-0,37 mm exhaust, measured cold.
| Valve clearance - INLET mm | 0,17-0,23 cold |
|---|---|
| Valve clearance - EXHAUST mm | 0,31-0,37 cold |
Engine oil & fluids
Engine oil
The Mazda 2 1.6 (2002–2007) takes 4.25 litres of engine oil with the filter.
See the reference table for the complete engine oil entries and their conditions.
Manual gearbox
The manual gearbox has a listed capacity of 2.3 litres. The specified oil is SAE 75W-90, with classification WSD-M2C200-C.
Coolant
The listed total cooling-system capacity is 5.0 litres.
Grades, filling conditions and capacities
| Engine oil options | |
|---|---|
| Ambient temperature range | All temperatures |
| Engine oil grade SAE | 5W-30 |
| Engine oil classification API/ACEA | SJ/A1, A3 |
| Ambient temperature range | All temperatures |
| Engine oil grade SAE | 5W-40 |
| Engine oil classification API/ACEA | SJ/A1, A3 |
| Ambient temperature range | All temperatures |
| Engine oil grade SAE | 10W-40 |
| Engine oil classification API/ACEA | SJ/A1, A3 |
| Engine with filter(s) litres | 4.25 |
| Other lubricants and capacities | |
| Manual transmission oil grade SAE | 75W-90 |
| Manual transmission oil classification | WSD-M2C200-C |
| Manual transmission litres | 2.3 |
| Cooling system - total capacity litres | 5.0 |
| Brake fluid Type | DOT 3/4 |
| Power steering fluid Type | WSA-M2C195-A |
Brakes & wear limits
Brake disc thickness
Brake discs on the Mazda 2 1.6 (2002–2007) are replaced at a minimum thickness of 20 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 204 mm.
| Minimum disc thickness for replacement - ventilated Front | 20 mm |
|---|---|
| Maximum drum diameter for replacement Rear | 204 mm |
Brake disc and drum dimensions
| Disc thickness variation Front | 0,025 mm |
|---|---|
| Minimum pad thickness Front | 1,5 mm |
| Minimum shoe thickness Rear | 1 mm |
| Parking brake travel No. of notches | 4 |
Service & electrical
Ignition timing
The ignition timing on the Mazda 2 1.6 (2002–2007) is not adjustable.
| Ignition timing - basic BTDC °Engine/rpm | Not adjustable |
|---|
Battery
The Mazda 2 1.6 (2002–2007) uses a 12 V, 43 Ah battery.
| Battery V/RC(Ah) | 12 (43) |
|---|
Spark plugs
The Mazda 2 1.6 (2002–2007) uses Motorcraft AYFS-22C spark plugs with a 1,3 mm electrode gap.
| Spark plugs Original equipment | Motorcraft |
|---|---|
| Spark plug Type | AYFS-22C |
| Electrode gap mm | 1,3 |
| Spark plugs Make | NGK |
| Spark plug Type | TR5A-10 |
| Electrode gap mm | 1,3 |
Tuning and emissions
| Ignition advance checks °Engine/rpm | ECM Controlled |
|---|---|
| Idle speed rpm | 750±100 Not adjustable |
| Oil temperature °C | 80 |
| CO level at idle speed - tailpipe Vol. % CO | 0,5 Max Not adjustable |
| HC level at idle speed ppm | 100 |
| CO2 level at idle speed Vol. % CO2 | 14,5-16 |
| O2 level at idle speed Vol. % O2 | 0,1-0,5 |
| Increased idle speed for CO test rpm | 2800-3100 |
| CO content at increased idle speed Vol. % | 0,3 |
| Lambda at increased idle λ | 0,98-1,02 |
Starting and charging
| Maximum cranking amps A | 116-172 |
|---|
Service checks and adjustments
| Oil pressure bar/rpm | 2,5/2000 |
|---|---|
| Radiator cap bar | 1,30 |
Fuel system
| Regulated pressure with vacuum bar | 3,8 |
|---|
Tightening torques
Cylinder head bolt torque
The cylinder head bolts on the Mazda 2 1.6 (2002–2007) are tightened in 3 stages: 15 Nm, then 30 Nm, then a final 90°.
| Cylinder head | |
|---|---|
| Renew bolts | No |
| Tighten | 15 Nm |
| Tighten | 30 Nm |
| Tighten | 90° |
| Cylinder head instructions | — |
|---|---|
| View more information | — |
| Other engine tightening torques | |
| Main bearings Stage 1 | — |
| Measurement of bearing clearance is not possible by normal methods and should not be attempted, as this will result in damage to the cylinder block and crankshaft. If the bearing bolts have been loosened the entire cylinder block and crankshaft must be replaced. | |
| Big end bearings Stage 1 | — |
| Oil pump to cylinder block | 9 Nm |
| Sump bolts | 1)10 Nm 2)20 Nm |
| Sump drain bolt | 28 Nm |
| Flywheel/driveplate | 1)30 Nm 2)80° |
| Bolts/nuts | |
| Clutch pressure plate | 29 Nm |
| Crankshaft pulley/damper centre bolt | 1)45 Nm 2)90° |
| View more information | — |
| Crankshaft pulley/damper centre bolt | |
| Camshaft sprocket/gear | 60 Nm |
| Camshaft carrier/cap | — |
| View more information | — |
| Camshaft carrier/cap | |
| Camshaft/rocker cover | — |
| View more information | — |
| Camshaft/rocker cover | |
| Inlet manifold to cylinder head | 18 Nm |
| Exhaust manifold to cylinder head | 54 Nm |
| Exhaust downpipe to manifold | 44 Nm |
| Water pump | 9 Nm |
| Spark plugs | 15 Nm |
| Fuel rail | 15 Nm |
| Crankshaft position (CKP) sensor/engine speed (RPM) sensor | 9 Nm |
| Camshaft position (CMP) sensor | 9 Nm |
| Engine coolant temperature (ECT) sensor | 20 Nm |
| Lambda sensor (Oxygen) | 47 Nm |
| Knock sensor (KS) | 20 Nm |
| Engine oil pressure switch | 15 Nm |
| Chassis tightening torques | |
| Front hub | 290 Nm |
| Rear hub | 235 Nm |
| Steering wheel | 47 Nm |
| Steering rack/box mounting | 48 Nm |
| Steering track rod end | 48 Nm |
| Brake caliper to carrier Front | 30 Nm |
| Brake caliper/carrier to hub Front | 70 Nm |
| ABS sensor Front | 9 Nm |
| ABS sensor Rear | 9 Nm |
| Road wheels | 85 Nm |
Air conditioning
| No. of AC service connectors | 2 |
|---|---|
| Air conditioning restrictor type | Expansion valve |
| Compressor clutch/magnetic coupling | Yes |
| Compressor variable displacement solenoid | No |
| Air conditioning refrigerant Type | R134a |
| Air conditioning refrigerant quantity grams | 650±13 |
| Air conditioning oil group | PAG |
| Air conditioning oil Type | WSH-M1C231-B |
| Air conditioning oil quantity cm³ | 207 |
| Air conditioning oil viscosity ISO | 46 |
Frequently asked questions
What is the firing order of the Mazda 2 1.6?
The firing order for the Mazda 2 1.6 (2002–2007) is 1-3-4-2.
What spark plugs does the Mazda 2 1.6 use?
The Mazda 2 1.6 (2002–2007) uses Motorcraft AYFS-22C spark plugs with a 1,3 mm electrode gap.
How much oil does the Mazda 2 1.6 take?
The Mazda 2 1.6 (2002–2007) takes 4.25 litres of engine oil with the filter. See the reference table for the complete engine oil entries and their conditions.
What are the valve clearances for the Mazda 2 1.6?
Valve clearances for the Mazda 2 1.6 (2002–2007) are 0,17-0,23 mm inlet and 0,31-0,37 mm exhaust, measured cold.
What is the cylinder head torque for the Mazda 2 1.6?
The cylinder head bolts on the Mazda 2 1.6 (2002–2007) are tightened in 3 stages: 15 Nm, then 30 Nm, then a final 90°.
What is the ignition timing for the Mazda 2 1.6?
The ignition timing on the Mazda 2 1.6 (2002–2007) is not adjustable.