Mazda2001–2003Technical specifications

323 1.6: Technical specifications

Workshop data for the 1.6-litre petrol (engine code ZM). Covers engine, fluids, brakes, service, torques and air conditioning: the figures to check before a job or a parts order.

Common faults & fixes

Summary

Match the engine code (ZM) to the vehicle before ordering parts or applying these figures.

Vehicle specifications

Overview

Make: Mazda
Model: 323
Years: 2001–2003
Fuel: Petrol
Engine code: ZM

Performance & efficiency

Power: 72 kW (98 hp)
Engine size: 1,598 cc
Cylinders: 4 · DOHC
Compression ratio: 9.7:1
Fuel system: Mazda

Fluids & capacities

Engine oil (with the filter): 2.9 litres

All 129 specifications below

Engine & identification

Vehicle identification

No. of cylinders Type	4/DOHC
Capacity (Fiscal) cc	1598
Compression ratio :1	9,7
Suitable for unleaded petrol	Yes
Minimum octane rating RON	95
Ignition system Make	Mazda
Ignition system Type	EGI
Ignition system Description	Map-DIS
Trigger location	Cam/Crankshaft
Fuel system Make	Mazda
Fuel system Type	EGI
Fuel system Description	MFI-s
Air metering Type	Mass
Combined ignition and fuel ECM	Yes
Diagnostic socket	Yes

Ignition system

Ignition coil supply voltage + with ballast V	12,0
Secondary resistance Ohm	7000-11000

Firing order

The firing order for the Mazda 323 1.6 (2001–2003) is 1-3-4-2.

Firing order	1-3-4-2

Valve clearances

Valve clearances for the Mazda 323 1.6 (2001–2003) are 0,25-0,31 mm inlet and 0,25-0,31 mm exhaust, measured cold.

Valve clearance - INLET mm	0,25-0,31 cold
Valve clearance - EXHAUST mm	0,25-0,31 cold

Engine oil & fluids

Engine oil

The Mazda 323 1.6 (2001–2003) takes 2.9 litres of engine oil with the filter.

See the reference table for the complete engine oil entries and their conditions.

Manual gearbox

See the reference table for the complete manual gearbox entries and their conditions.

Coolant

See the reference table for the complete coolant entries and their conditions.

Grades, filling conditions and capacities

Lubricants and capacities — complete reference
Engine oil options
Ambient temperature range	➞40°C
Engine oil grade SAE	5W-30
Engine oil classification API/ACEA	SJ/A1, A3
Ambient temperature range	-25°C➞45°C
Engine oil grade SAE	10W-30
Engine oil classification API/ACEA	SJ/A2
Ambient temperature range	-25°C➞45°C
Engine oil grade SAE	10W-40
Engine oil classification API/ACEA	SJ/A3
Engine with filter(s) litres	2.9
Other lubricants and capacities
Manual transmission oil grade SAE	—
Manual transmission oil grade
Manual transmission oil classification	GL-4/5
Manual transmission litres	2.7
Automatic transmission fluid Type	Dexron II
Automatic transmission (dry fill) litres	7.2
Cooling system - total capacity litres	6.0
Brake fluid Type	DOT 3/4
Power steering fluid Type	Dexron II
Power steering fluid litres	0.8-1.0

Brakes & wear limits

Brake disc thickness

Brake discs on the Mazda 323 1.6 (2001–2003) are replaced at a minimum thickness of 20 mm (ventilated) front and 8 mm rear.

Minimum disc thickness for replacement - ventilated Front	20 mm
Minimum disc thickness for replacement Rear	8 mm
Maximum drum diameter for replacement Rear	201,5 mm

Brake disc and drum dimensions

Disc thickness variation Front	0,015 mm
Disc thickness variation Rear	0,015 mm
Disc runout Front	0,05 mm
Disc runout Rear	0,05 mm
Minimum pad thickness Front	1,5 mm
Minimum pad thickness Rear	1 mm
Minimum shoe thickness Rear	1 mm
Parking brake travel No. of notches	5-7

Service & electrical

Tuning and emissions

Ignition timing and idle speed
Tuning conditions	—
View more information	—
Ignition timing - basic BTDC °Engine/rpm	9-11/700
Ignition advance checks °Engine/rpm	ECM Controlled
Idle speed rpm	700±50
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	2500-2800
CO content at increased idle speed Vol. %	0,3
Lambda at increased idle λ	0,97-1,03

Starting and charging

Battery V/RC(Ah)	12

Service checks and adjustments

Compression pressure bar	9,8-14,0
Oil pressure bar/rpm	2,9-3,9/3000
Radiator cap bar	0,94-1,22
Thermostat opens °C	86-89

Fuel system

Fuel pump delivery pressure bar	5,0-6,3
System pressure bar	2,7-3,1
Regulated pressure with vacuum bar	2,1-2,5
Engine coolant temperature (ECT) sensor Ohm/°C	290-400/80
Injector Ohm	12,0-16,0
Idle air control (IAC) valve/idle speed control (ISC) actuator Ohm	7,7-9,3
Lambda sensor (Oxygen) heater Ohm	6,0

Spark plugs

Spark plugs Original equipment	Denso
Spark plug Type	SKJ16CR-A8
Electrode gap mm	1,0-1,1
Spark plugs Make	Champion
Spark plug Type	RC10YC4
Electrode gap mm	1,0-1,1

Tightening torques

Cylinder head
Cylinder head instructions	—
Maximum bolt length	100,5 mm
Tighten	10±2 Nm
Tighten	20±2 Nm
Tighten	90°±5°
Tighten	90°±5°
Other engine tightening torques
Main bearings Renew bolts/nuts	No
Main bearings Stage 1	28±1 Nm
Main bearings Stage 2	56±2 Nm
Big end bearings Renew bolts/nuts	No
Big end bearings Stage 1	25 Nm
Big end bearings Stage 2	49±1 Nm
Oil pump to cylinder block	22±3 Nm
Sump bolts	10±1 Nm
Sump drain bolt	16-20 Nm
Flywheel/driveplate	100±2 Nm
Clutch pressure plate	22±4 Nm
Crankshaft pulley/damper centre bolt	15±2 Nm/162±4 Nm
Camshaft sprocket/gear	55±5 Nm
Camshaft carrier/cap	12±1 Nm
Camshaft/rocker cover	9±2 Nm
Inlet manifold to cylinder head	25±5 Nm
Exhaust manifold to cylinder head	20±2 Nm
Exhaust downpipe to manifold	44±6 Nm
Water pump	22±3 Nm
Spark plugs	19±3 Nm
Fuel rail	22±3 Nm
Crankshaft position (CKP) sensor/engine speed (RPM) sensor	10±1 Nm
Lambda sensor (Oxygen)	40±9 Nm
Knock sensor (KS)	27±7 Nm
Engine oil pressure switch	15±2 Nm
Chassis tightening torques
Front hub	—
Front hub
Rear hub	—
Rear hub
Steering wheel	46±6 Nm
Steering rack/box mounting	90±14 Nm
Steering track rod end	38±6 Nm
Brake caliper to carrier Front	47±2 Nm
Brake caliper/carrier to hub Front	90±10 Nm
Brake caliper to carrier Rear	20±3 Nm
Brake caliper/carrier to hub Rear	56±10 Nm
Back plate to hub Rear	59±9 Nm
ABS sensor Front	22±3 Nm
ABS sensor Rear	22±3 Nm
Road wheels	102±15 Nm

Air conditioning

Refrigerant quantity
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	600
Air conditioning oil group	PAG
Air conditioning oil Type	Atmos GU 10
Air conditioning oil quantity cm³	150
Air conditioning oil viscosity ISO	46

Frequently asked questions

What is the firing order of the Mazda 323 1.6?

The firing order for the Mazda 323 1.6 (2001–2003) is 1-3-4-2.

How much oil does the Mazda 323 1.6 take?

The Mazda 323 1.6 (2001–2003) takes 2.9 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 323 1.6?

Valve clearances for the Mazda 323 1.6 (2001–2003) are 0,25-0,31 mm inlet and 0,25-0,31 mm exhaust, measured cold.

What is the minimum brake disc thickness for the Mazda 323 1.6?

Brake discs on the Mazda 323 1.6 (2001–2003) are replaced at a minimum thickness of 20 mm (ventilated) front and 8 mm rear.