Mazda 121 Instruction manual

JMOOB103t00

Mazda

121

Workshop

Manual

Vofume1 of

FOREWORD

Thisworkshop

manual

is intended

for

use

bv servicetechnicians

of Authorized

Mazda

D-ealersto helpthem service

Mazda

vehicles.

can also

be uselul

to ownersand operators

of Mazda vehicles in diagnosing

some

problems

and performing

limited

repair

and

maintenanceon Mazda

vehicles.

For proper repair and maintenance,

thorough

lamiliarization

withthis

manual

isim-

portant,

and itshouldalways

be kept

ina han-

dy place

for

quick

and

easy

reterence.

All

the contentsof this manual,

including

drawingsand

specifications,

arethe

latestavail-

able at the time of printing.

As modifications

affecting

repair

or maintenance

occur,

relevant

informationsupplementary

thisvolume

will

be made available at Authorized Mazda

Dealers.This manual should be kept up-

to-date.

Mazda

MotorCorporation

reserves

the right

to alter

the specifications

and contentsof

this

manual

withoutobligation

or advance

notice.

All rights

reserved.No part

ofthis

book

may

reproducedor used

in any

form or by any

means,electronic

or mechanical-including

photocopying

and recordingand the use of

any kind oJ

information

storageand retrieval

system-without permission

in writing.

Mazda Motor Corporation

HIROSHIMA.

JAPAN

APPLICATION:

Thismanual

isapplicable

tovehicles

beginning

withthe

Vehicleldentification

Numbers

(VlN)

shownon the

following

page.

o 1990MazdaMotor

Corporation

ocT. '90

1249-10-90J

CONTENTS

Tirle Secti

General

lnformation

Pre-Delivery

Inspection

and

Scheduled

MaintenanceService

Engine

Lubrication

System

Cooling

System

Fuel

andEmission

C,onttolSystem

I EGI-S

Engine

ElectricalSystem

Clutch

Manual

Transaxle

Automatic

Transaxle

Front and RearAxles

Steering

System

BrakingSyslem

Wheels

and Tires

Suspension

Body

Body ElectricalSystem

Heater

and AarConditioner

Systems

Technical

Data

Special

Tools

wiringDiasram Sili:.|Tj|:'"''""'0"''

The section

Z is published

separate

lrom this manual.

vEHlcLE

IDENTIFICATION

NUMBERS

(VlN)

JMo

D81031

00100001

GENERAL

INFORMATION

TMPORTANTTNFORMATION.....................

Gl- 2

BAS|CASSUMPT|ONS............................Gl- 2

sAFEry

H1SK............... ...Gl- 2

POSSIBLE

LOSSOFWARRANry.....,,......GI- 2

WARNINGON

LUBRICANTS

ANDGREASES. .............Gl- 2

HOWTOUSETH|S

MANUAL....................Gt- 3

PREPARATTON ................Gl- 3

REpAtR

PROCEDURE.............................Gl- 3

SYMBOLS........ ...............Gl- 4

NOTES.

CAUTIONS.

ANDWARNINGS.......

GI- 4

FUNDAMENTALPROCEDURES.................GI- 4

PROTECTIONOF

THE

VEHICLE

..,...........GI- 4

A WORD

ABOUTSAFETY.......................Gl- 5

PREPARATIONOF

TOOLS

ANDMEASURING

EQUIPMENT.............GI_5

SPEC|ALTOO1S............ .. Gl- 5

REMOVALOF

PARTS.............................Gl- s

DTSASSEMBLY ................Gl- 5

REASSEMBLY .................GI- 6

ADJUSTMENTS ..,....,..,,...GI- 7

RUBBERPARTS

ANDTUBING.............,..GI_

JACK

ANDSAFETYSTAND

POSITIONS....GI- 8

VEHICLELIFT

(2.SUPPORT

TYPE)

postTtoNs..... .................

Gl- I

TOW|NG......... ...................Gl- 9

IDENTIFICATION

NUMBERLOCATIONS.,...GI-10

uNtTs............. ..................Gl-l0

ABBREVTATTONS

.....................................Gl-l0

CAUT|ON ....

Gl-ll

INSTALLATIONOF

A MOBILE

TWO-WAY

FAD|O

SYSTEM....................

Gl-l1

REMOVALOF

IGNITIONKEYON

AUTOMATIC

TRANSAXLEMODE1..........GI-11

ELECTRICALTROUBLESHOOTING

TOOLSGI-12

CAUTION

WITHELECTRICAL

PARTS........

GI-13

03uGtx-001

GI IMPORTANT

INFORMATION

IMPORTANT

INFORMATION

BASICASSUMPTIONS

This

workshopmanualassumes

that

you

have

certainspecial

toolsthatare

necessaryforthesafeandetfi-

cient

perlormance

serviceoperations

onMazda

vehiclesand

that

you

knowhowto

usethem

properly.

also

assumesthat

you

are

familiarwithautomobile

systems

andbasic

serviceandrepair

procedures.

You

should

not

attempt

tousethis

manualunless

theseassumptions

arecorrecl

and

you

understandtheconse-

quences

described

below.

SAFETY

RISK

This

manualcontainscertain

notes,warnings,

andother

precautionary

information

that

you

shouldcarefully

readand

iollow

to reducethe

risk

of personal

injuryto

yourself

or others

andthe

risk

improperservice

thatmaydamagethe

vehicleor renderit unsafe.

lf there

isno

such

information

in regard

to anyspectfic

service

method,this

doesnotmean

thereis no

possibility

that

personal

safetyor vehiclesafety

will

jeopardized

theuseoJ

incorrectmethodsor

tools.

POSSIBLELOSSOF

WARRANTY

Themanufacturer'swarranty

on Mazdavehiclesand

engines

canbevoidedifimproperservice

or repairs

are

performed

by persons

other

thanthoseat an

Authorized

MazdaDealer.

WARNINGON

LUBRICANTSANDGREASES

Avoidall

prolonged

and

repeatedcontactwithmineral

oils,

especiallyusedoils.Usedoilscontaminated

during

service

(e.g.,

enginesump

oils)aremoreirritating

and

morelikelytocauseseriouseffects,

including

skincancer,in

theeventof

gross

and

prolonged

skincontact.

Washskinthoroughlyafter

workinvolvingoil.

Protective

handcleanersmaybeof

value

provided

theycanberemoved

fromtheskinwithwater.

Donot

use

gasoline,

paraffin,

or othersolvents

lo removeoil

fromtheskin.

Lubricantsand

greases

maybe slightly

irritatingto theeyes.

Bepeatedor

prolonged

skincontactshould

beavoided

wearing

protective

clothing

necessary.

Particu-

lar

care

shouldbetaken

withusedoilsand

greases

containing

lead.Donotallow

workclothingto becon-

taminated

withoil.Drycleanor laundersuchclothing

regularintervals. sMuGrx_oo2

Gl-z

HOWTO USE

THISMANUAL GI

HOW

TOUSE

THISMANUAL

F[rtFf#rtifiirointsouttheneededspeciat

serviceTool

(ssT)

fortheserviceoperation

matit

pro-

ceeds.Gather

allnecessarySSTbeforebeginning

work.

Example:

SST

NUMBER

SST NAME SST ILLUSTRATION

03uGtx-@6

REPAIBPROCEDURE

Most

repairoperationsbeginwith

an overviewillustration.

lt identifiesthecomponents,shows

howthe

parts

fit

together,

and

visual

parts

lnspections.lf

a damaged

worn

part

isfound,

repair

or replaceit

necessary.

2.Expendable

parts,

tighteningtorques,andsymbolsforoil,

grease,

andsealantare

shownintheoverview

illustration.

3. Pagesrelated

service

procedures

areshownunder

theillustration.Befer

tothisinformation

whenser-

vicingthe

part.

Example:

SHOWSTIGHTENING

TOROUEUNIT

sHows

PAGEFOR

SERVICE

"1: Thenumbering

(ex.@)

showsservice

procedure.

Unitsshown

in Nm (m-kg,

ftJb)unlessotherwisespecified.

9MUGIX.O34

Gt-3

MANUAL

STEERING

PREPARATION

ssT

490118850C

Pullef,ball

joinl

17 Spacer

18 Drive

pinion

Bemoval page

M-2'l

rpecl splines and leelh fot weat or damage

GI HOW

USE

THISMANUAL/FUNDAMENTAL

PROCEDURES

SYMBOLS

if,er" uresi*

symbols

indicating

oil,

grease,

and

sealant.

Thesesymbols

show

the

points

ofapplying

such

materials

during

service.

Symbol Meaning Kind

gApply oil Newengine

oil or gear

oil as

appropriate

@Apply

brake

fluid Only

brakefluid

EApply automatic

transmission

fluid Only

ATF

€

Apply

grease Appropriate

grease

(@[ Apply sealant Appropriate

sealant

eApply

petroleum

jelly Appropriate

petroleum

jellY

osuctx005

Note

. Whenspecial

oil or grease

is needed,this is shown

in the illustration.

NOTES,CAUTIONS,

AND

WARNINGS

you

iead

through

ihe

procedures,you

willcomeacross

NOTES,

CAUTIONS,

and

WARNINGS.

Each

one

istherefore

a ipecific

purpose.

NOTES

giveyou

added

information

that

willhelp

you

to complete

particularprocedrire.

GAUTIbNS

are

given

pri:vent

you

from

making

anerror

thatcould

damage

the

vdhicle.

WARNINGS

remind

you

to beespeciallycareful

thoseareas

where

carelessness

can

cause

Per'

sonat

iniury.

The

followinglilt contains

some

general

WARNINGS

you

should

when

you

workon

a vehicle olA.,x-oo2

FUNDAMENTAL

PROCEDURES

PROTECTION

THEVEHICLE

Alwaysbe

sureto cover

fenders,

seats,and

floor

areas

be-

forestartino

work.

Gt-4 9MUGIX.O37

FUNDAMENTAL

PROCEDURES GI

9MUGtX-003

9[,{UGtX-038

47UOGX-005

47U0GX-006

SMUGIX,O39

A WORD

ABOUTSAFETY

The

following

precautions

mustbe

followedwhen

jacking

thevehicle.

1. Block

the

wheels.

2.Useonly

thespecified

jacking

positions.

3.Support

the

vehicle

withsafetystands.

Startthe

engine

onlyafter

makingcertain

theenginecompart-

mentisclear

toolsand

people.

PREPARATION

TOOLSAND

MEASURING

EOUTPMENT

sure

that

all

necessarytoolsand

measuringequipment

are

available

before

starting

any

work.

SPECIAL

TOOLS

Usespecial

tools

whenthey

arerequired.

REMOVAL

OF PARTS

Whilecorrecting

a problem,

try alsoto

determine

its

cause.

Beginwork

only

afterfirstlearning

which

parts

andsubassem-

b esmust

removedanddisassembled

for replacement

repair.

DISASSEMBLY

lfthedisassembly

procedure

iscomplex,

requiringmany

parts

to bedisassembled,

all

parts

shouldbe

disassembled

ina

way

that

willnot affect

their

performance

or external

appearance

and

identifiedso

that

reassemblycan

performed

easilyand

efficiently.

Gr-5

GI FUNDAMENTAL

PROCEDURES

1.lnsoectlon

of Parts

Whbn

removed,-each

part

should

carefully

inspected

for

malfunctioning,

detormation,

damage,

and

other

problems'

Arrangement

of Parts

AlldisJssembledoarts

should

carefully

arranged

iorre-

assembly.

Be sureio separate

or otherwise

identify

the

parts

to be

reolaced

fromthose

that

will

be reused

Cleaning

parts

tor reuse

Alloarts'iobe

reused

should

carefully

and

thoroughly

cleaned

inthe

appropriate

method.

REASSEMBLY

Standard

values,

such

torques

and

certain

ad.iustments'

mustbe strictlv

observed

inthe

reassembly

of all

parts'

NEIErtOSTNUONRD

BOLT

AND

NUT

TIGHTENING

TORQUE

inSection

TDfortightening

torques

hot

mentioned

inthe

main

text.

lf removed,

these

parts

should

replaced

with

newones:

9MUGtX-040

9MUGIX.O41

9MUGIX-OM

Oil

seals

3.O-rings

5.Cotter

pins

Gaskets

4. Lock

washers

Nylon

nuts

)ffi

Gt-6

Depending

location:

1.Sealant

should

applied

to gaskets.

2.Oilshould

beapplied

themoving

components

parts'

3.Specified

oilor

gieaseshould

beapplied

the

prescribed

locations

(such

oil

seals)

before

reassembly'

9MUGIX{42

FUNDAMENTAL

PROCEDURES GI

9MUGIX.OOs

ADJUSTMENTS

Usesuitable

gauges

and/ortesters

when

makingadiustments.

RUBBER

PARTS

AND

TUBING

Prevent

gasoline

oroilfrom

getting

rubber

parts

ortubing.

57UoGX-002

Gt-7

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