Mazda 121 1991 Instruction manual

JMOOB103t00

Mazda
121
Workshop
Manual
Vofume1of2
FOREWORD
Thisworkshop
manual
isintended
foruse
bv servicetechnicians
of Authorized
Mazda
D-ealersto helpthemservice
Mazda
vehicles.
It
canalsobe uselul
to ownersandoperators
of Mazda vehicles in diagnosingsome
problems
and performing
limited
repair
and
maintenanceon Mazdavehicles.
For proper repair and maintenance,
a
thorough
lamiliarization
withthis
manual
isim-
portant,
anditshouldalways
bekept
ina han-
dy place
forquick andeasy
reterence.
Allthe contentsof thismanual,
including
drawingsandspecifications,
arethe
latestavail-
ableat the time of printing.
As modifications
affecting
repair
ormaintenance
occur,
relevant
informationsupplementary
tothisvolume
will
be made available at Authorized Mazda
Dealers.This manualshould be kept up-
to-date.
Mazda
MotorCorporation
reserves
theright
to alter
the specifications
andcontentsofthis
manual
withoutobligation
oradvance
notice.
Allrights
reserved.Nopart
ofthis
book
may
bereproducedor usedinany
formorby any
means,electronic
or mechanical-including
photocopying
and recordingand the useof
any kindoJ
information
storageand retrieval
system-without permission
in writing.
Mazda Motor Corporation
HIROSHIMA.
JAPAN
APPLICATION:
Thismanual
isapplicable
tovehicles
beginning
withtheVehicleldentification
Numbers
(VlN)
shownon thefollowing
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
Frontand RearAxles
SteeringSystem
BrakingSyslem
Wheels
and Tires
Suspension
Body
BodyElectricalSystem
Heater
and AarConditioner
Systems
Technical
Data
Special
Tools
wiringDiasram Sili:.|Tj|:'"''""'0"''
Thesection
Z is published
separate
lrom this manual.

vEHlcLE
IDENTIFICATION
NUMBERS
(VlN)
JMo
D81031
00100001
-

GI
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
AWORD
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_
7
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
of
serviceoperations
onMazda
vehiclesand
that
youknowhowtousethem
properly.
It
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
toreducethe
risk
ofpersonal
injurytoyourself orothers
andtherisk ofimproperservice
thatmaydamagethe
vehicleorrenderitunsafe.
lfthere
isnosuch information
inregard
toanyspectfic
service
method,this
doesnotmean
thereisnopossibility
that
personal
safetyor vehiclesafety
will
be
jeopardized
bytheuseoJ
incorrectmethodsortools.
POSSIBLELOSSOF
WARRANTY
Themanufacturer'swarranty
onMazdavehiclesand
engines
canbevoidedifimproperservice
orrepairs
are
performed
bypersons other
thanthoseatanAuthorized
MazdaDealer.
WARNINGON
LUBRICANTSANDGREASES
Avoidallprolonged andrepeatedcontactwithmineral
oils,
especiallyusedoils.Usedoilscontaminated
during
service
(e.g.,
enginesump
oils)aremoreirritating
and
morelikelytocauseseriouseffects,
including
skincancer,intheeventofgross
andprolonged
skincontact.
Washskinthoroughlyafter
workinvolvingoil.
Protective
handcleanersmaybeof
value
provided
theycanberemoved
fromtheskinwithwater.
Donot
use
gasoline,
paraffin,
orothersolvents
lo removeoil
fromtheskin.
Lubricantsandgreases
maybeslightly
irritatingtotheeyes.
Bepeatedor
prolonged
skincontactshould
beavoided
by
wearing
protective
clothing
if
necessary.
Particu-
lar
care
shouldbetaken
withusedoilsand
greases
containing
lead.Donotallow
workclothingtobecon-
taminated
withoil.Drycleanorlaundersuchclothing
atregularintervals. sMuGrx_oo2
Gl-z

HOWTOUSE
THISMANUAL GI
HOW
TOUSE
THISMANUAL
F[rtFf#rtifiirointsouttheneededspeciat
serviceTool
(ssT)
fortheserviceoperation
matit
pro-
E
ceeds.Gather
allnecessarySSTbeforebeginning
work.
Example:
SSTNUMBER
SSTNAME SST ILLUSTRATION 03uGtx-@6
REPAIBPROCEDURE
1.
Most
repairoperationsbeginwith
anoverviewillustration.
ltidentifiesthecomponents,shows
howthe
parts
fit
together,
and
visual
parts
lnspections.lfadamaged orworn
part
isfound,
repair
orreplaceit
asnecessary.
2.Expendable
parts,
tighteningtorques,andsymbolsforoil,
grease,
andsealantare
shownintheoverview
illustration.
3.Pagesrelated
toservice
procedures
areshownunder
theillustration.Befer
tothisinformation
whenser-
vicingthe
related
part.
Example:
SHOWSTIGHTENING
TOROUEUNIT
sHows
RELATED
PAGEFOR
SERVICE
"1: Thenumbering
(ex.@)
showsservice
procedure.
Unitsshown
inNm (m-kg, ftJb)unlessotherwisespecified.
9MUGIX.O34
Gt-3
MANUAL
STEERING
PREPARATION
ssT
490118850C
Pullef,ball
joinl
17 Spacer
18 Drive
pinion
Bemoval pageM-2'l
rpecl splinesand leelh fot weat or damage

GI HOW
TOUSE
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
gApplyoil Newengine
oilor gearoilasappropriate
@Applybrake
fluid Only
brakefluid
EApplyautomatic
transmission
fluid Only
ATF
€Apply
grease Appropriate
grease
(@[ Applysealant Appropriate
sealant
eApplypetroleum
jelly Appropriate
petroleum
jellY
osuctx005
Note
. Whenspecial
oil or grease
is needed,this is shownin the illustration.
NOTES,CAUTIONS,
AND
WARNINGS
As
you
iead
through
iheprocedures,you
willcomeacross
NOTES,
CAUTIONS,
and
WARNINGS.
Each
one
istherefore
aipecific
purpose.
NOTES
giveyou
added
information
that
willhelp
you
tocomplete
aparticularprocedrire.
GAUTIbNS
are
given
topri:vent
you
from
making
anerror
thatcould
damage
the
vdhicle.
WARNINGS
remind
you
tobeespeciallycareful
in
thoseareas
where
carelessness
can
cause
Per'
sonat
iniury.
The
followingliltcontains
some
general
WARNINGS
you
should
follow
when
you
workon
a vehicle olA.,x-oo2
FUNDAMENTAL
PROCEDURES
PROTECTION
OF
THEVEHICLE
Alwaysbe
suretocover
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
up
thevehicle.
1.Block
the
wheels.
2.Useonly
thespecified
jacking
positions.
3.Support
the
vehicle
withsafetystands.
Startthe
engine
onlyafter
makingcertain
theenginecompart-
mentisclear
of
toolsand
people.
PREPARATION
OF
TOOLSAND
MEASURING
EOUTPMENT
Be
sure
that
all
necessarytoolsand
measuringequipment
are
available
before
starting
any
work.
SPECIAL
TOOLS
Usespecial
tools
whenthey
arerequired.
REMOVAL
OF PARTS
Whilecorrecting
a problem,
tryalsoto determine
its
cause.
Beginwork
only
afterfirstlearning
which
parts
andsubassem-
b esmust
beremovedanddisassembled
forreplacement
or
repair.
DISASSEMBLY
lfthedisassembly
procedure
iscomplex,
requiringmany
parts
tobedisassembled,
all
parts
shouldbe
disassembled
inaway
thatwillnotaffect
their
performance
or external
appearance
andidentifiedso
that
reassemblycan
beperformed
easilyand
efficiently.
Gr-5

GI FUNDAMENTAL
PROCEDURES
1.lnsoectlon
of Parts
Whbn
removed,-each
part
should
be
carefully
inspected
for
malfunctioning,
detormation,
damage,
and
other
problems'
2.
Arrangement
of Parts
AlldisJssembledoarts
should
be
carefully
arranged
iorre-
assembly.
Besureioseparate
orotherwise
identify
theparts
to be
reolaced
fromthose
that
will
bereused
3.
Cleaning
parts
tor reuse
Alloarts'iobereused
should
be
carefully
and
thoroughly
cleaned
intheappropriate
method.
REASSEMBLY
Standard
values,
such
as
torques
and
certain
ad.iustments'
mustbestrictlv
observed
inthereassembly
ofallparts'
NEIErtOSTNUONRD
BOLT
AND
NUT
TIGHTENING
TORQUE
inSection
TDfortightening
torques
hot
mentioned
inthe
main
text.
lfremoved,
these
parts
should
bereplaced
with
newones:
9MUGtX-040
9MUGIX.O41
9MUGIX-OM
'1
.Oil seals
3.O-rings
5.Cotter
pins
2.
Gaskets
4.Lock
washers
6.
Nylon
nuts
)ffi
Gt-6
Depending
onlocation:
1.Sealant
should
beapplied
to gaskets.
2.Oilshould
beapplied
to
themoving
components
of
parts'
3.Specified
oilor
gieaseshould
beapplied
at
the
prescribed
locations
(such
asoil
seals)
before
reassembly'
9MUGIX{42

FUNDAMENTAL
PROCEDURES GI
9MUGIX.OOs
ADJUSTMENTS
Usesuitable
gauges
and/ortesters
when
makingadiustments.
E
RUBBER
PARTS
AND
TUBING
Prevent
gasoline
oroilfrom
getting
on
rubber
parts
ortubing.
57UoGX-002
Gt-7