Musso

General information
Electronic control unit (ECU) incorporates self-diagnosis function.

ABS warning lamp will illuminate in the event of system failure.
Trouble codes can be accessed with suitable code reader or a voltmeter connected to the data link connector (DLC) or
diagnostic socket Fig. 1 .
For DLC or diagnostic socket location refer to System layout and components.
Accessing trouble codes
Ensure ignition switched OFF.

Bridge data link connector (DLC) terminals TBS and GND Fig. 2 .
Connect analogue voltmeter between DLC terminal FBS and vehicle battery Fig. 2 .
Switch ignition ON.
Voltmeter needle will deflect to indicate trouble code(s).
After a 3 second deflection the voltmeter indicates trouble code(s).
A 1,2 second deflection indicates the 'tens' of the trouble code Fig. 3 [A].
A 0,4 second deflection indicates the 'units' of the trouble code Fig. 3 [D].
A 0,4 second pause separates each deflection Fig. 3 [B].
A 1 second pause separates each group of deflections Fig. 3 [C].
A 4 second pause separates each trouble code Fig. 3 [E].
For example: Trouble code 22 displayed Fig. 3 .
Count voltmeter needle deflections.
Compare with trouble code table.
Switch ignition OFF.
Remove bridge wire and voltmeter.
Erasing trouble codes

Bridge data link connector (DLC) terminals TBS and GND Fig. 2 .
Connect analogue voltmeter between DLC terminal FBS and vehicle battery Fig. 2 .
Switch ignition ON.
Any stored trouble codes should be indicated.
Depress and release brake pedal 10 times within 10 seconds.
Warning lamp will illuminate for 2-3 seconds.
Lamp extinguishes.
Remove bridge wire and voltmeter.
Trouble code identification
Trouble code Fault location

11 Wheel speed sensor, right front
12 Wheel speed sensor, left front
13 Wheel speed sensor, right rear
14 Wheel speed sensor, left rear
15 Wheel speed sensors
22 Solenoid valve, RH front
24 Solenoid valve, LH front
26 Solenoid valve, RH rear
28 Solenoid valve, LH rear
51 System relay
53 Pump motor
53 Pump motor relay
Electronic control unit (ECU)
Manufacturer: Mazda Model: 323 (BA) 2,0 © Autodata Limited 2004

Engine code: KF Output: 106 (144) 6000 26.03.2007
Tuned for: R-Cat Year: 1994-98 V5.500-
ABS warning lamp
Correct operating sequence
Switch ignition ON.

Lamp illuminates.
Start engine.
Lamp extinguishes after 3 seconds.
General test procedures
NOTE: Due to small size of ECU harness multi-plug pins it is advisable to use a breakout box.
Warning lamp circuit
Checking - Fig. 4
Switch ignition ON.

Check warning lamp illuminates.
If not: Switch ignition OFF.
Check fuses.
Disconnect ECU multi-plugs.
Connect breakout box to 18-pin harness multi-plug.
Bridge breakout box terminal 2L and earth.
Switch ignition ON.
Check warning lamp illuminates.
If not: Switch ignition OFF.
Check bulb and wiring.
Wheel speed sensors
Preparatory conditions
Check wheel bearings for excessive play. Adjust or replace as necessary.

Check wheel speed sensors for mechanical security.
Inspect wheel speed sensor rings visually for damage and cleanliness.
Checking
Technical Data
Air gap Not specified
Tightening torque 19-25 Nm
No adjustment of wheel speed sensor air gaps is possible.

If removed or replaced: Tighten fixing to specified torque.
Checking resistance - front - Fig. 5 & Fig. 6
Technical Data
Terminals Wheel speed sensor Resistance
2O & 2P Left hand 1600-2000 Ω
2N & 2M Right hand 1600-2000 Ω

Check resistance between breakout box terminals Fig. 5 .
If resistance not as specified:
Disconnect relevant wheel speed sensor multi-plug.
Check resistance between wheel speed sensor terminals Fig. 6 .
If resistance as specified: Check wiring.
If resistance not as specified: Suspect faulty wheel speed sensor.
Repeat test for other wheel speed sensor.
Checking resistance - rear - Fig. 5 & Fig. 6
Technical Data
Terminals Wheel speed sensor Resistance
2R & 2Q Left hand 1600-2000 Ω
2S & 2T Right hand 1600-2000 Ω

Check resistance between breakout box terminals Fig. 5 .
If resistance not as specified:
Check resistance between wheel speed sensor terminals Fig. 6 .
If resistance as specified: Check wiring.
If resistance not as specified: Suspect faulty wheel speed sensor.
Checking voltage - front - Fig. 7 & Fig. 8
Technical Data
Terminals Wheel speed sensor Voltage
2O & 2P Left hand 0,25-3,0 V ac
2N & 2M Right hand 0,25-3,0 V ac

Raise vehicle.
Adjust voltmeter to measure alternating current.
Turn road wheel at 60 rpm.
Check voltage between breakout box terminals Fig. 7 .
If voltage not as specified:
Check voltage between wheel speed sensor terminals Fig. 8 .
If voltage as specified: Check wiring.
If voltage not as specified: Suspect faulty wheel speed sensor.
Checking voltage - rear - Fig. 7 & Fig. 8

Technical Data
Terminals Wheel speed sensor Voltage
2R & 2Q Left hand 0,25-3,0 V ac
2S & 2T Right hand 0,25-3,0 V ac

Raise vehicle.
Check voltage between breakout box terminals Fig. 7 .
If voltage not as specified:
Check voltage between wheel speed sensor terminals Fig. 8 .
If voltage as specified: Check wiring.
If voltage not as specified: Suspect faulty wheel speed sensor.
Checking wave form - front - Fig. 9
Technical Data
Terminals Wheel speed sensor
2O & 2P Left hand
2N & 2M Right hand

Raise vehicle.
Connect oscilloscope between breakout box terminals.
Turn road wheel at approximately 60 rpm.
Check wave form of wheel speed sensor.
If wave form not as specified:
Check wave form between wheel speed sensor terminals.
If wave form as specified: Check wiring.
If wave form not as specified: Suspect faulty wheel speed sensor.
Checking wave form - rear - Fig. 9
Technical Data
Terminals Wheel speed sensor
2R & 2Q Left hand
2S & 2T Right hand

Raise vehicle.
Connect oscilloscope between breakout box terminals.
Check wave form of wheel speed sensor.
If wave form not as specified:
Check wave form between wheel speed sensor terminals.
If wave form as specified: Check wiring.
If wave form not as specified: Suspect faulty wheel speed sensor.
Relays
Checking operation - system relay - Fig. 10
Technical Data
Terminals Condition Resistance
E&C Battery voltage disconnected
F&C Battery voltage disconnected Zero
E&C Battery voltage connected Zero
F&C Battery voltage connected
Battery + to terminal A
Battery - to terminal B
NOTE: Ensure battery voltage supply is connected correctly. Otherwise relay could be damaged.

Remove relay.
Check resistance between relay terminals.
Connect battery voltage supply to specified relay terminals.
Checking resistance - system relay - Fig. 10
Technical Data
Terminals Resistance
A&B 60-100 Ω

Remove relay.
Checking supply voltage - system relay - Fig. 11
Technical Data
Terminals Condition Voltage
E & earth Ignition OFF Battery voltage
A & earth Ignition ON Battery voltage

Remove relay.
Check voltage between relay base terminal and earth.
Switch ignition ON.
If voltage not as specified: Check wiring and fuses.
Checking earth connection - system relay - Fig. 11
Technical Data
F & earth Zero

Remove relay.
Check resistance between relay base terminal and earth.
If resistance not as specified: Check wiring.
Checking operation - pump motor relay - Fig. 12
Technical Data
Terminals Condition Resistance
C&D Battery voltage disconnected
C&D Battery voltage connected Zero
Battery + to terminal A
Battery - to terminal B
NOTE: Ensure battery voltage supply is connected correctly. Otherwise relay could be damaged.

Remove relay.
Connect battery voltage supply to specified relay terminals.
Checking resistance - pump motor relay - Fig. 12
Technical Data
A&B 50-90 Ω

Remove relay.
Checking supply voltage - pump motor relay - Fig. 13
Technical Data
C & earth Ignition OFF Battery voltage
A & earth Ignition ON Battery voltage

Remove relay.

Switch ignition ON.
Electronic control unit (ECU)
Checking supply voltage - Fig. 14
61 Technical Data
Terminals Voltage
1H & earth Battery voltage

Connect breakout box to harness multi-plugs.
Switch ignition ON.
Check voltage between breakout box terminal and earth.
Checking earth connection - Fig. 14
Technical Data
1E & earth Zero
1F & earth Zero

Connect breakout box to harness multi-plugs.
Check resistance between breakout box terminals and earth.
If resistance not as specified: Check wiring.
Hydraulic modulator solenoid valves
Checking - Fig. 15
Technical Data
Terminals Solenoid valve Resistance
C&G LH front 3 Ω approx.
D&H RH front 3 Ω approx.
A&E LH rear 3 Ω approx.
B&F RH rear 3 Ω approx.

Disconnect hydraulic modulator 8-pin multi-plug.
Check resistance between hydraulic modulator terminals.
Checking supply voltage - Fig. 16

Technical Data
Terminals Voltage
E & earth Battery voltage
F & earth Battery voltage
G & earth Battery voltage
H & earth Battery voltage

Switch ignition ON.
Check voltage between harness multi-plug terminals and earth.
Pump motor
Checking resistance - Fig. 17
Technical Data
A&B 1 Ω max.

Check resistance between hydraulic modulator terminals.
Checking operation - Fig. 18
NOTE: DO NOT allow pump motor to run for more than 2 seconds.

Remove pump motor relay.
Bridge relay base terminals C and D with a switched lead.
Operate switch.
Pump motor should run.
If not: Suspect faulty pump motor.
Brake pedal position (BPP) switch
Checking - Fig. 19
Technical Data
1M & earth Pedal released Zero
1M & earth Pedal depressed Battery voltage

Depress brake pedal.
If voltage not as specified: Check wiring and fuses.

Vehicle speed sensor (VSS)
Checking - Fig. 20
Technical Data
2F & 1F Vehicle stationary Zero
2F & 1F Vehicle moving 0,1-0,2 V ac

Connect breakout box between ECU and harness multi-plugs.
Start engine.
Check voltage between breakout box terminals.
Drive the vehicle at approximately 12 mph (20 km/h).
Check voltage between breakout box terminals.
Hydraulic system
Bleeding

Ensure reservoir topped up to MAX.
Bleed in sequence: RH rear, LH rear, RH front, LH front.
Connect tube to bleed screw and immerse end in jar of clean fluid.
Depress brake pedal firmly two or three times.
Open bleed screw.
Depress brake pedal fully.
Close bleed screw. Tightening torque: 6,9-9,8 Nm (front), 5,9-8,8 Nm (rear).
Allow brake pedal to return.
Repeat process until fluid is air free.
Maintain fluid level in reservoir during bleeding procedure.
Top up reservoir to MAX.
1 2

3 3
4 5
6 6
7 8

8 9
10 11
12 13
14 15

16 17
18 19
20

Adjustment Data
MAZDA - 323 - 2.0i V6 24V - KF
Engine (general)
Item Values Units

Engine code KF
Capacity 1995 (cc)
Idle speed 800 ± 50 (rpm)
Valve clearance
Hydraulic
Compression pressure
Normal 10.8 - 14.7 (bar)
Normal (bar)
Minimum (bar)
Oil pressure 3.4 - 5.0/3000 (bar / rpm)
Fuel system (make & type) Mazda EGI
Adjustment screws (A = idle speed B = CO) A
Firing order 1-2-3-4-5-6

Timing stroboscopic (before TDC) 10 ± 1/800 (° / rpm)
Ignition-coil resistance, primary 0.49 - 0.73 (ohms)
Ignition-coil resistance, secondary 20000 - 31000 (ohms)
Spark plugs (make & type) NGK BPR6ES11
Champion RC7YCC4
Spark-plug gap 1.0 - 1.1 (mm)
Fuel-pump pressure 5.0 - 6.3 (bar)
Injection pressure / system pressure 2.7 - 3.2 (bar)
CO exhaust gas < 0.5 (%)
CO2 14.5 - 16.0 (%)
HC 100 (ppm)
O2 0.1 - 0.5 (%)
Lambda 0.97 - 1.03
Lambda change (Delta Lambda) 0.03
Oil temperature during test 60 (°C)
Fast-idle speed 2500-2800 (rpm)
CO at fast-idle speed < 0.3 (%)
Cooling system
Item Values Units

Cap pressure 0.75 - 1.05 (bar)
Thermostat opens at 84 - 89 (°C)
Fan on at 97 (°C)
Electrical
Item Values Units

Battery 80 (Ah)
Alternator 95 (A)
Brakes
Item Values Units

Disc thickness, front, min. 20 (mm)
Disc thickness, rear, min. 8.0 (mm)
Steering and wheel alignment
Item Values Units

Toe-in, front 2±4 (mm)
Camber, front -44' ± 1° (°)
Castor, front 1° 55' ± 1° (°)
K.P.I., front 13° 22' (°)
Toe-in, rear 2±4 (mm)
Camber, rear 49' ± 1° (°)
Wheels and tyres
Item Values Units

Tyre size 205/50R16
Optional
Front tyre pressure 2.0 (bar)
Rear tyre pressure 1.8 (bar)
Capacities
Item Values Units

Engine sump, incl. filter 4.0 (l)
Gearbox refill 2.7 (l)
Cooling system 5.0 (l)
Air-conditioner refrigerant 700 - 750 (g)
Air-conditioner compressor oil 150 (ml)
Torque settings
Item Values Units

Cylinder head
Stage 1 23 - 26 (Nm)
Stage 2 90° (°)
Stage 3 90° (°)
Front hub 235 (Nm)
Rear hub 177 - 235 (Nm)
Wheel nuts 118 (Nm)
Spark plugs 15 - 23 (Nm)
© Copyright, Wessels + Mьller AG

System description
Optional driver's and front passenger's airbags.

Airbag locations identified by the inscription 'SRS'.
SRS control module mounted separately.
Optional pyrotechnic pretensioners on front seat belts.
Special attention
To prevent personal injury, expansion area of all airbags MUST remain clear.
Steering wheel spiral cable has limited rotary movement.
Centralise steering before disconnecting steering column. To prevent damage, ensure steering wheel and spiral cable DO
NOT rotate before or during reassembly.
Pyrotechnic pretensioners are electrically triggered by SRS control module.
SRS warning lamp
Operation
Switch ignition ON.

SRS warning lamp illuminates.
If warning lamp does not illuminate: Suspect wiring or SRS warning lamp.
Lamp extinguishes after approximately 4-8 seconds.
If not: Suspect wiring or SRS control module.
If warning lamp flashes:
3 flashes: Suspect open/short circuit or SRS control module.
6 flashes: Suspect driver's airbag.
7 flashes: Suspect passenger's airbag.
Disarm the system
When
Fascia/instrument panel removal or replacement.

Front seat belt removal or replacement.
Front seat repair or replacement.
Repair work around SRS components, especially airbags and pretensioners.
SRS component removal or replacement.
Steering wheel/column repair or replacement.
Welding operations.
How

Disconnect battery earth lead. Make sure accidental reconnection is not possible.
Disconnect SRS control module.
Disconnect pyrotechnic pretensioners.
Arm the system
How

Reconnect SRS control module.
Reconnect pyrotechnic pretensioners.
Ensure vehicle interior is unoccupied.
Reconnect battery earth lead.
Switch ignition ON.
Check SRS warning lamp operation.
After deployment
Check
All mounting brackets for SRS components.

Fascia/instrument panel.
Seat assemblies.
Seat belts, including buckles and anchorage points.
Steering wheel and column.
Surrounding components and trims.
SRS wiring harness and multi-plugs for charred or damaged areas.
Renew
All airbags.
Fascia/instrument panel, if damaged.
Front seat belts.
Mounting brackets, if damaged.
Seat components, if damaged.
Spiral cable, if damaged or noisy.
Steering column, if damaged.
Steering wheel, if damaged.
Surrounding components and trims, if damaged.
SRS control module.
SRS wiring harness and multi-plugs, if charred or damaged areas found.
Disposal
Vehicle manufacturer suggests that deployed SRS components are sealed in a plastic bag and disposed of in accordance
with local regulations.
Steering wheel removal and installation
Special attention
Disarm system and remove driver's airbag.

Centralise steering and disconnect spiral cable multi-plug before removing steering wheel.
Spiral cable should not be allowed to rotate once steering wheel removed.
To centralise spiral cable, slowly rotate clockwise until resistance is felt and then rotate approximately 2turns anti-
clockwise until alignment marks aligned.
Ensure spiral cable remains centralised during reassembly.
Steering wheel and airbag assembly Fig. 1

Spiral cable alignment marks Fig. 2
Tightening torques

Driver's airbag 8-12 Nm
Front passenger's airbag 16-22 Nm
Front seat 39-63 Nm
Front seat belt inertia reel 38-78 Nm
Front seat belt inertia reel bracket 18-26 Nm
Front seat belt buckle 39-78 Nm
Front seat belt upper anchorage point 38-78 Nm
Steering wheel 40-49 Nm
SRS control module 7-10 Nm
1 2

CANISTER PURGE SOLENOID
Function
The evaporative gases produced in the fuel tank are absorbed by the activated charcoal in the
carbon canister. As The purge control solenoid valve opens these gases are delivered to the
intake manifold for combustion purposes. The purge control solenoid valve is controlled by the
control unit. The control unit operates this valve during the time the lambda control loop is
active.
Specifications
RESISTANCE:
resistance: ± 50 ohms
supply voltage: 12 Volts
current: ± 250 mA
Electrical control
Most solenoids are normally closed. This means

that the connection between the canister and the
intake manifold is closed. The solenoid has a
connector with two terminals. On one of those
terminals is connected to the battery voltage.
This supply-voltage is often switched with a
relay. The other terminal leads directly to the
control unit. The current through the solenoid is
switched on during the time the control unit
connects this terminal to ground. The voltage on
this terminal is during this time 0 Volts. During
the time the solenoid is switched off, the voltage
on this terminal is 12 Volts. Some
motormanagement systems control the amount
gases delivered to the intake manifold switching
the solenoid on and of with a certain duty cycle.
In this case the duty-cycle depends on engine
RPM and engine load.
Electrical diagnosis
STATIC
General
To perform this measurements the relay switching the power to the solenoid
should be closed. Short circuit the switch in the relay if necessary.
Measurements
Measure the voltage on the control unit. Use the pin which switches the
solenoid.
result: 12 V
solenoid and wiring are electrically OK
0V
check the relay switching the power to the solenoid

check the wiring between the relay and the solenoid
check the solenoid resistance
check the wiring between the solenoid and the control unit
check the control unit
Capacities
MAZDA - 323 - 2.0i V6 24V - KF
Item Values Units

Engine sump, incl. filter 4.0 (l)
Gearbox refill 2.7 (l)
Cooling system 5.0 (l)
Air-conditioner refrigerant 700 - 750 (g)
Air-conditioner compressor oil 150 (ml)

System information
Control system Manual temperature control

System layout Single evaporator - single zone
Refrigerant circuit type Expansion valve
General information
Self-diagnosis
No AC self-diagnosis function applicable to this model range.
System control
Compressor operation controlled by refrigerant pressure switch.

Compressor will not operate if refrigerant level is low.
System incorporates an AC evaporator temperature sensor.
System repairs
Access to evaporator housing from vehicle interior. Removal of fascia panel not required.
Access to AC/heater blower motor from vehicle interior. Removal of fascia panel not required.
System service
Refrigerant sight glass located in receiver/drier.

Renew pollen filter every 36,000 miles or 48 months, whichever occurs first. Fig. 1
Refrigerant charging
NOTE: Running the engine with the high pressure service connector valve open is dangerous.
Charging with vapour:

Ensure refrigerant circuit is evacuated for a minimum of 15 minutes prior to charging.
Charge via high pressure service connector.
After 50% of refrigerant has entered system:
Charge via low pressure service connector.
Start engine.
Air conditioning switched ON.
Continue to charge until recommended quantity has entered system.
System fault diagnosis
For information regarding system and component diagnosis refer to 'General test procedures' in the front section of this
manual.
Fuse box/relay plates
Fascia Fig. 2
5-door

Fuse (Amps) Circuit
F9 (10A) - 1,5 AC condenser blower motor relay, AC compressor clutch relay
F15 (10A) - AC amplifier, AC/heater function control panel, heater blower relay, AC/heater
except 2,0 recirculation flap motor
AC condenser blower motor relay, AC compressor clutch relay, AC amplifier,
F15 (10A) -
AC/heater function control panel, heater blower relay, AC/heater recirculation
2,0
flap motor
F23 (40A) -
AC/heater blower motor
10/96
F29 (15A) AC/heater function control panel
10/96 3/4-door
Fuse
Circuit
(Amps)
F9 (10A) AC condenser blower motor relay, AC compressor clutch relay
AC amplifier, AC/heater function control panel, heater blower relay, AC/heater
F15 (10A)
recirculation flap motor
F23 (40A) AC/heater blower motor
Fascia - 11/96 3/4-door Fig. 3
Fuse (Amps) Circuit

F4 (15A) AC amplifier, AC/heater function control panel, heater blower relay
F10 (10A) AC condenser blower motor relay, AC compressor clutch relay
F11 (10A) AC compressor clutch relay
F14 (15A) - 2,0TD AC condenser blower motor relay II
Underbonnet Fig. 4
Fuse (Amps) Circuit

F4 (40A) - 11/96 AC/heater blower motor
F4 (30A) - 5-door 10/96 AC condenser blower motor relay I
F9 (10A) - 10/96 AC compressor clutch relay
F9 (30A) - 11/96 AC condenser blower motor relay I
F10 (30A) - 3/4-door 10/96 AC condenser blower motor relay I
F14 (30A) - 2,0TD AC condenser blower motor relay II
Location Component Circuit diagram code
2 - 11/96 Engine coolant blower motor relay K12
Refrigerant pressures
Engine at normal operating temperature.

Pollen filter installed and in good condition.

All windows and doors closed.
Ambient temperature above 15°C.
Engine idling.
AC/heater blower motor switch set to position 4.
AC/heater recirculation flap set to recirculation position.
AC/heater temperature control(s) set to maximum cold position.
Fascia ventilation outlets fully open.
Checking
Run engine at 1500 rpm.
Ambient temperature High pressure Low pressure

15°C 10,3-11,4 bar 1,3-1,5 bar
20°C 11,7-12,7 bar 1,4-1,6 bar
25°C 13,1-14,9 bar 1,45-1,65 bar
30°C 15-17 bar 1,5-1,8 bar
35°C 16,5-19 bar 1,6-1,9 bar
Delivery temperature
Engine at normal operating temperature.

Pollen filter installed and in good condition.
Doors open.
Engine idling.
Passenger compartment air temperature 15-40°C.
Fascia ventilation outlets fully open.
AC/heater blower motor switch set to position 4.
AC/heater recirculation flap set to recirculation position.
AC/heater temperature control(s) set to maximum cold position.
Checking
Run engine at 1500 rpm.

Measure ambient temperature in passenger footwell.
Position temperature probe in fascia ventilation centre outlet.
Wait for delivery temperature to stabilise.
Measure temperature.
At 50% relative humidity
Ambient temperature Delivery temperature

25°C 0-2°C
30°C 3-7°C
35°C 8-12°C
40°C 13-17°C
At 70% relative humidity

Ambient temperature Delivery temperature
25°C 4-8°C
30°C 9-13°C
35°C 14-18°C
40°C 19-23°C
Technical data
Refrigerant
Type R134a
Type Refer to engine bay label
Quantity - except 3HB/4SD 11/96 750 grams
Quantity - 3HB/4SD 11/96 700 grams
Refrigerant oil
Type Atmos GU10
Viscosity ISO 46
Quantities:
Compressor Replace quantity drained + 10-20 ml
Condenser - 3/4-door 15 ml
Condenser - 5-door 30 ml
Evaporator - 3/4-door 50 ml
Evaporator - 5-door 60 ml
Line (general) 10 ml
Receiver/drier 10 ml
System - 10/96 175 ml
System - 11/96 150 ml
Compressor clutch
Adjustment type Shim
Clearance 0,4-0,6 mm
Resistance Not specified
AC evaporator temperature sensor

Resistance Not specified

1

4
3

Accessing trouble codes

Bridge data link connector (DLC) terminals GND and TEN Fig. 1 .
Connect LED test lamp between terminals FEN and B+ Fig. 1 .
NOTE: Connect LED test lamp positive connection to DLC terminal B+.
Switch ignition ON.

Count LED flashes. Note trouble codes. Compare with trouble code table.
Long flashes indicate the LH digit.
Short flashes indicate the RH digit.
The ECM fault memory can also be checked using suitable diagnostic equipment connected to the data link connector
(DLC).
Erasing trouble codes

Disconnect battery earth lead.
Depress brake pedal for 3 seconds.
Reconnect battery earth lead.
Repeat checking procedure to ensure no data remains in ECM fault memory.
WARNING: Disconnecting the battery may erase memory from electronic units (e.g. radio, clock).
Trouble code identification
Trouble code Fault location

01 Ignition pulse
02 Engine speed (RPM) sensor/crankshaft position (CKP) sensor - Ne-signal
03 Camshaft position (CMP) sensor - G-signal
04 Camshaft position (CMP) sensor - G-signal
05 Knock sensor (KS)
06 Vehicle speed sensor (VSS)
08 Mass air flow (MAF) sensor/volume air flow (VAF) sensor
09 Engine coolant temperature (ECT) sensor
10 Intake air temperature (IAT) sensor
11 Intake air temperature (IAT) sensor
12 Throttle position (TP) sensor
14 Barometric pressure (BARO) sensor
15 Heated oxygen sensor (HO2S) - LH
16 Exhaust gas recirculation (EGR) sensor
17 Oxygen sensor (O2S)/heated oxygen sensor (HO2S)
23 Heated oxygen sensor (HO2S) - RH
24 Heated oxygen sensor (HO2S) - RH
25 Fuel pressure regulator control solenoid
26 Evaporative emission (EVAP) canister purge valve
28 Exhaust gas recirculation (EGR) solenoid - vacuum
29 Exhaust gas recirculation (EGR) solenoid - vent
34 Idle air control (IAC) valve
35 Fuel pressure regulator control solenoid 2

41 Intake manifold air control solenoid 1
46 Intake manifold air control solenoid 2
55 Speed sensor - AT torque converter
56 Temperature sensor - AT
60 Solenoid valve - 1-2 shift AT
63 Solenoid valve - lock-up AT
64 Engine coolant blower motor relay - K8-DOHC
65 Lock-up control solenoid valve (AT)
66 Line pressure solenoid (AT)
67 Engine coolant blower motor relay - 1/low temperature
68 Engine coolant blower motor relay - high temperature
69 Engine coolant blower motor temperature sensor

Environmental Data
MAZDA - 323 - 2.0i V6 24V - KF
Item Values Units

Engine code KF
Idle speed 800 ± 50 (rpm)
Fuel system (make & type) Mazda EGI
Adjustment screws (A = idle speed B = CO) A
Timing stroboscopic (before TDC) 10 ± 1/800 (° / rpm)

Fuel-pump pressure 5.0 - 6.3 (bar)
Injection pressure / system pressure 2.7 - 3.2 (bar)
CO exhaust gas < 0.5 (%)
CO2 14.5 - 16.0 (%)
HC 100 (ppm)
O2 0.1 - 0.5 (%)
Lambda 0.97 - 1.03
Lambda change (Delta Lambda) 0.03
Oil temperature during test 60 (°C)
Fast-idle speed 2500-2800 (rpm)
CO at fast-idle speed < 0.3 (%)

Notes Specified value Measured value
Vehicle identification
No. of cylinders Type 6/DOHC
Capacity (Fiscal) cc 1995
Compression ratio :1 9,5
Suitable for unleaded petrol Yes
Minimum octane rating RON 91
Ignition system Type ESA
Ignition system Description Map-i
Trigger location Distributor/ 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
Primary resistance Ohm 0,49-0,73
Secondary resistance Ohm 20000-31000
Firing order 1-2-3-4-5-6
Tuning and emissions
7 Tuning conditions
Ignition timing - basic BTDC °Engine/rpm 10±1/800
Ignition advance checks °Engine/rpm ECM Controlled
Idle speed rpm 800±50
Oil temperature for CO test °C 60
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
Spark plugs
Spark plugs Original equipment NGK
Spark plug Type BKR6E-11
Electrode gap mm 1,1
Spark plugs Make Autolite
Spark plug Type APP3923
Spark plugs Make Beru
Spark plug Type 14FR-7DUX
Spark plugs Make Bosch
Spark plug Type FR78X
Spark plugs Make Champion
Spark plug Type RC8YCC4
Spark plugs Make NGK
Spark plug Type BKR6E-11
Fuel system
Fuel pump delivery pressure bar 5,0-6,3
System pressure without vacuum bar 2,8-3,1
Regulated pressure with vacuum bar 2,0-2,4
Engine coolant temperature (ECT) sensor Ohm/°C 280-350/80

RPM/TDC sensor Ohm 520-580
Idle speed control valve Ohm 10,7-12,3
Oxygen sensor heater Ohm 6
Service checks and adjustments
Valve clearance -INLET mm Hydraulic
Valve clearance -EXHAUST mm Hydraulic
Compression pressure bar 10,8-14,7
Oil pressure bar/rpm 3,3-4,9/3000
Lubricants and capacities
Engine oil grade - cold climate SAE 5W/30
Engine oil grade - moderate climate SAE 10W/40
Engine oil grade - hot climate SAE 20W/40
Engine oil classification API/ACEA SJ/A2-96
Engine oil grade - alternative - moderate climate SAE 10W/40
Engine oil classification - alternative - moderate climate API/ACEA SJ/A2-96
Engine with filter litres 4,0
Gearbox oil grade SAE 75W/90
Gearbox 4/5 speed litres 2,7
Automatic transmission fluid Type Dexron II
Cooling system litres 7,5
Brake fluid Type DOT 3/4
Power steering fluid Type Dexron II
Power steering fluid litres 1,3-1,4
Tightening torques
Cylinder head instructions
Cylinder head
Maximum bolt length 135 mm
Stage 1 Tighten 23-26 Nm
Stage 2 Tighten 85°-90°
Stage 3 Tighten 85°-90°
Other tightening torques
16 Big end bearings Stage 1
61 Sump bolts
Sump drain bolt 30-40 Nm
Flywheel/driveplate 64 Nm/64 Nm
Clutch to flywheel 18-26 Nm
Crankshaft pulley/damper 157-166 Nm
Camshaft sprocket/gear 123-140 Nm
Camshaft carrier/cap 11-14 Nm
Camshaft/rocker cover 7-10 Nm
Inlet manifold to cylinder head 20-25 Nm
Exhaust manifold to cylinder head 15-25 Nm
Spark plugs 15-22 Nm
Oxygen sensor (Lambda) 30-49 Nm
26 Front hub
27 Rear hub
Steering track rod end 43-56 Nm
Brake caliper to carrier Front 88 Nm
Brake caliper carrier to hub Front 90 Nm
Brake caliper to carrier Rear 54 Nm
Brake caliper carrier to hub Rear 54 Nm
ABS sensor Front 20 Nm
ABS sensor Rear 20 Nm
Road wheels 89-127 Nm
Starting and charging
Battery V/RC(Ah) 12/80 (55)
Minimum starting voltage V 8,0
Maximum cranking amps A 149-182

Alternator/Regulator Make Mitsubishi
Alternator output at engine speed A/V/rpm 95/14/2000
Regulated voltage V 14,1-14,7
Brake disc and drum dimensions
Minimum disc thickness - ventilated Front 20 mm
Minimum disc thickness Rear 8 mm
Disc runout Front 0,10 mm
Disc runout Rear 0,10 mm
Minimum pad thickness Front 1 mm
Minimum pad thickness Rear 1 mm
Minimum shoe thickness Rear 1 mm
Handbrake travel No. of notches 5-7
Air conditioning
Air conditioning refrigerant Type R134a
71 Air conditioning refrigerant quantity grams 750
Air conditioning oil Type Atmos GU10
51 Air conditioning oil quantity cmі 175
Cylinder layout Timing mark
Idle speed adjustment (A) Tightening sequence

ID Location 1/1
MAZDA - 323 - 2.0i V6 24V - KF
1 Identification plate
2 VIN
3 Engine code B3 / B5 / B6 / PN
4 Engine code BP / FP / FS
5 Manual transmission code
© Copyright, Wessels + Mьller AG 26.03.2007

IDLE SPEED CONTROL VALVE
Function
The idle control valve is located in a tube bypassing the throttle. The control unit controls this
device to ensure stable idling in all operating conditions.
Specifications
resistance coil(s): ± 20 ohms
supply voltage: 12 Volts
A rotary slide valve attached to the armature is turned to open the air bypass until the
desired idle speed is obtained. The position of the armature is controlled by the force of
an internal spring opposing the force of a solenoid (types with to terminals) or controlled
by two solenoids energised alternately which exerts opposing forces on the armature
(types with three terminals).
Electrical control
Types with two terminals
As a current flows through the coil the armature

is turned against the spring force. As the current
increases the airflow and the idle speed increases.
If the current through the coil is switched off due
to a mall functioning system, the valve is forced
into a position which results in a (too) high idle
speed.
The idle control valve has a connector with two

terminals. On one of those terminals is connected
to the battery voltage. This supply-voltage is
often switched with a relay. The other terminal
leads directly to the control unit. The current
through the coil is switched on during the time the
control unit connects this terminal to ground. The
voltage on this terminal is during this time 0
Volts. During the time the current through the coil
is switched off, the voltage on this terminal is 12
Volts.
The control unit controls the current through the
coil switching the current on and off with a certain
duty cycle. The current increases as the
duty-cycle increases. The duty cycle varies
between approx. 35% (valve closed) and 85%
(valve opened). Nominal idle speed is obtained
when slightly open.
Three terminal types
The two coils inside this type of idle speed control

valve are connected with the supply voltage using
one common terminal. The other two terminals
lead directly to the control unit. The control unit
switches the current through the solenoid on and
off alternately with a duty cycle between 35 and
85%.
STATIC DYNAMIC TESTS THREE TERMINAL TYPES
To perform this measurements the Remove the idle control valve

relay switching the power to the idle but leave the electrical
control valve should be closed. connections in place. Fully
Short circuit the switch in the relay open or close the rotating
if necessary. plunger. Switch on the
ignition.
Measurements:
Disconnect the connector and

measure the resistance of the
coil(s). The nominal value is app. 20
ohms.
Check the relay switching the power result: Switch on the ignition. The
to the idle control valve rotating plunger must move
Check the wiring between the relay to a position equivalent to
and the idle control valve app. 50% opening, and
Check the wiring between the idle remain there.
control valve and the control unit
Check the control unit
Mechanical diagnosis
Check the air chamber on air leakage.
Check engine on air leaks into the intake system.
Remove the idle control valve. The plunger should rotate or move easily.
Clean if necessary.
IGNITION MODULE
Function
The ignition module switches the current through the primary ignition coil on and off. The
ignition module charges the ignition coil during the time the current is switched on. The
moment the ignition module switches the current 'off' the ignition coil induces an induction
voltage which causes the spark.
An ignition module switches the current on and off according to an input signal. This input is
delivered by the control unit. On older systems the input signal is delivered by an inductive,
Hall or opto-coupled sensor mounted in the distributor.
Specifications
resistance -
supply voltage -
Electrical control
The connector of the ignition module has
several terminals. The following terminals are
used on common ignition modules.
a terminal connected with the ignition coil.

By this terminal the current through the
ignition coil is switched on and of.
a terminal connected with the supply
voltage ( 12 Volts)
a terminal connected with ground.
terminal(s) to receive the input signal. If
the input signal is delivered by an
inductive sensor two terminals are
needed.
The output voltage of an inductive sensor is

delivered by an internal coil. This coil induces
an almost sine wave output voltage. If the input
signal is delivered by an Hall-sensor or
opto-coupler three terminals are needed. Two
of those three terminals are used to supply the
sensor. The supply voltage is either 5 or 12
Volts. The third terminal receives the output
signal from the sensor. The output voltage of
these sensors is a square wave signal.
Addition terminals are possible. For example to
send out a RPM signal to the revolution counter.
Sometimes the input signal is delivered by a
sensor while the ignition timing is controlled by
the control unit. In this case the received input
signal from the sensor is converted into a
square wave signal by the ignition module and
send out to the control unit. The control unit
receiving this signal computes this input
information and other input information from
various engine parameters and sends out a new
square wave signal to the ignition module. This
signal is used by the ignition module to switch
the current through the primary ignition coil on
and off.
During the time the input signal for the ignition

module is 'high' the current is switched 'on'. The
moments this input signals falls to 'low' the
current is switched 'off'. This moment the spark
will appear
Start the engine and measure (using an oscilloscope) the input signal
delivered by the control unit or input sensor. The square wave signal or
sine wave signal from a inductive sensor should be visible.
signal Disconnect the ignition module's connector and check the wiring between
not OK: the ignition module and the control unit or input sensor.
replace the ignition module if the signal appears on the disconnected
connector and disappears on the connected connector.
If the output signal remains invisible the failure is not in the component.
signal check the power supply of the ignition module.

OK: check the primary voltage using an ignition oscilloscope or normal
oscilloscope with a suitable probe.
check the wiring between the ignition module and the ignition coil.
The voltage should be nearly 0 Volt during the period the ignition
module receives an 'high' input voltage from the sensor or control unit.
Mechanical diagnosis
Remove the auxiliary air valve without disconnecting the connector.

Turn the ignition on and make sure that the valve closes as the heating element
heats-up the bi-metallic strip.
Lubricants and Fluids 1/1
MAZDA - 323 - 2.0i V6 24V - KF
Engine
Motor oil API SG Below 0 °C SAE 5W-30
Motor oil API SG From -25 °C to 30 °C SAE 10W-30
Motor oil API SG Above -25 °C SAE 10W-40
Cooling system
Coolant All temperatures
Manual transmission (2WD)

ATF Dexron II All temperatures
ATF M-III All temperatures
Manual transmission (4WD)

Gear oil API GL-4 All temperatures SAE 75W-90
Gear oil API GL-5 All temperatures SAE 75W-90
Automatic transmission
Transfer box
Gear oil API GL-5 Above -15 °C SAE 90
Gear oil API GL-5 Below -1 °C SAE 80W
Differential, rear (4WD)

Gear oil API GL-5 Above -15 °C SAE 90
Gear oil API GL-5 Below -1 °C SAE 80W
Power steering
Brakes system
Brake fluid DOT 3 All temperatures
Air conditioning
Refrigerant R134a
Compressor oil PAG, ISO 46
© Copyright, Wessels + Mьller AG 26.03.2007

Timing
MAZDA - 323 - 2.0i V6 24V - KF
General
Item Note
Always check the timing marks before timing belt removal
Before disconnecting the battery cable, check the audio system security code
Removal
Item Note
Disconnect the battery
Remove the right front wheel
Remove the engine lower covers
Remove the ancillary drive belt
Remove the water pump pulley
Remove the ancillary pulley bracket
Remove the power steering pump
Remove the crankshaft pulley
Use a special tool: 49 EO11 1A1 / 49 S120 710
Remove the dipstick

Remove the crankshaft sensor
Place the wiring loom to one side
Note: Use a hoist to support the engine
Remove the engine mount

Remove all the timing-belt covers
Turn the crankshaft to TDC for cylinder 1
Align the timing marks
Remove the tensioner
Remove the idler pulley
Remove the timing belt
Check the tensioner and idler pulleys, renew if necessary
Measure the piston protrusion
If out of specification, replace with a new one 14 - 16 mm
Check for leaks
Compress the tensioner
Lock the tensioner, use a locking pin
Installation
Item Note
Check the timing marks
Fit the locked tensioner
Fit the timing belt anti-clockwise, starting at the crankshaft gearwheel
Refit the idler pulley 32 - 46 Nm
Remove the locking pin
Turn the engine 2 rotations by hand
Check the timing marks
Measure the timing belt deflection
The tension is set at a deflection of: 6 - 8 mm / 98 N

Refit the timing belt covers
Refit the engine mount

Remove the hoist
Remove the dipstick

Fit the crankshaft sensor
Refit the crankshaft pulley 157 - 166 Nm
Use a special tool: 49 E011 1A1 / 49 S120 710

Refit the power steering pump
Refit the water pump pulley

Fit the ancillary drive belt
Refit the engine lower covers
Refit the right front wheel
Reconnect the battery earth cable
Torque settings
Item Note
Tensioner: 19 - 25 Nm
Crankshaft pulley: 157 - 166 Nm
Water pump pulley: 10 Nm
Idler pulley: 32 - 46 Nm
Special tools
Item Note
Engine hoist: 49 G017 5AO
Crankshaft pulley: 49 EO11 1A1 / 49 S120 710

Dimensions
Wheelbase mm 2605
Track - front/rear mm 1460/1460
Tightening torques
Tightening torque - steel wheels 89-127 Nm
Tightening torque - alloy wheels 89-127 Nm
Trackrod locknut/clamp 35-50 Nm
Checking range - Front wheels
Load positioning unladen
Fuel tank - percentage full % 100
Toe-in (N = negative, toe-out) mm 2N - 4P
Toe-in deg 0°12'N - 0°36'P
Toe-in deg-1/100 0,20N - 0,60P
Camber deg 1°52'N - 0°8'P
Camber deg-1/100 1,87N - 0,13P
Castor deg 1°4' - 3°4'
Castor deg-1/100 1,07 - 3,07
Setting data - Four wheels
Load positioning unladen
Fuel tank - percentage full % 100
Toe-in (N = negative, toe-out) mm 1±3
Toe-in deg 0°12'±24'
Toe-in deg-1/100 0,20±0,40
Camber deg 0°52'N±1°
Camber deg-1/100 0,87N±1
Tolerance left/right deg 1°30'
Tolerance left/right deg-1/100 1,50
Camber adjustment $ADJ
Castor deg 2°4'±1°
Castor deg-1/100 2,07±1
Tolerance left/right deg 1°30'
Tolerance left/right deg-1/100 1,50
Castor adjustment Not adjustable
KPI (SAI) deg 13°22'
KPI (SAI) deg-1/100 13,37
Included angle deg 12°30'
Included angle deg-1/100 12,50
Lock angles - max. inner deg 38°±3°
Lock angles - max. inner deg-1/100 38±3
Lock angles - max. outer deg 32°±3°
Lock angles - max. outer deg-1/100 32±3
Rear toe-in mm 1±3
Rear toe-in deg 0°12'±24'
Rear toe-in deg-1/100 0,20±0,40
Rear toe-in adjustment $ADJ
Rear camber deg 0°56'N±1°
Rear camber deg-1/100 0,93N±1
Rear tolerance left/right deg 1°30'
Rear tolerance left/right deg-1/100 1,50
Rear camber adjustment Not adjustable

Camber adjustment Rear toe-in adjustment


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General information

Electronic control unit (ECU) incorporates self-diagnosis function.

Accessing trouble codes

Ensure ignition switched OFF.

Erasing trouble codes

Ensure ignition switched OFF.

Trouble code identification

Trouble code Fault location

Manufacturer: Mazda Model: 323 (BA) 2,0 © Autodata Limited 2004

Correct operating sequence

Switch ignition ON.

General test procedures

Warning lamp circuit

Switch ignition ON.

Wheel speed sensors

Check wheel bearings for excessive play. Adjust or replace as necessary.

No adjustment of wheel speed sensor air gaps is possible.

Checking resistance - front - Fig. 5 & Fig. 6

Ensure ignition switched OFF.

Manufacturer: Mazda Model: 323 (BA) 2,0 © Autodata Limited 2004

Checking resistance - rear - Fig. 5 & Fig. 6

Ensure ignition switched OFF.

Checking voltage - front - Fig. 7 & Fig. 8

Ensure ignition switched OFF.

Checking voltage - rear - Fig. 7 & Fig. 8

Manufacturer: Mazda Model: 323 (BA) 2,0 © Autodata Limited 2004

Ensure ignition switched OFF.

Checking wave form - front - Fig. 9

Ensure ignition switched OFF.

Checking wave form - rear - Fig. 9

Ensure ignition switched OFF.

Checking operation - system relay - Fig. 10

Ensure ignition switched OFF.

Checking resistance - system relay - Fig. 10

Ensure ignition switched OFF.

Checking supply voltage - system relay - Fig. 11

Ensure ignition switched OFF.

Checking earth connection - system relay - Fig. 11

Ensure ignition switched OFF.

Checking operation - pump motor relay - Fig. 12

Ensure ignition switched OFF.

Checking resistance - pump motor relay - Fig. 12

Ensure ignition switched OFF.

Checking supply voltage - pump motor relay - Fig. 13

Ensure ignition switched OFF.

Manufacturer: Mazda Model: 323 (BA) 2,0 © Autodata Limited 2004

Electronic control unit (ECU)

Checking supply voltage - Fig. 14

Ensure ignition switched OFF.

Checking earth connection - Fig. 14

Ensure ignition switched OFF.

Hydraulic modulator solenoid valves

Ensure ignition switched OFF.

Checking supply voltage - Fig. 16

Manufacturer: Mazda Model: 323 (BA) 2,0 © Autodata Limited 2004

Ensure ignition switched OFF.

Checking resistance - Fig. 17

Ensure ignition switched OFF.

Checking operation - Fig. 18

Ensure ignition switched OFF.