Mazda 121 Instruction manual

JMOOB103t00

Mazda
121
Workshop
Manual
Vofume1 of
2
FOREWORD
Thisworkshop
manual
is intended
for
use
bv servicetechnicians
of Authorized
Mazda
D-ealersto helpthem service
Mazda
vehicles.
It
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,
a
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
to
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
be
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
-

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
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_
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
you
knowhowto
usethem
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
to reducethe
risk
of personal
injuryto
yourself
or others
andthe
risk
of
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
be
jeopardized
by
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
by
wearing
protective
clothing
if
necessary.
Particu-
lar
care
shouldbetaken
withusedoilsand
greases
containing
lead.Donotallow
workclothingto becon-
taminated
withoil.Drycleanor laundersuchclothing
at
regularintervals. sMuGrx_oo2
Gl-z

HOWTO USE
THISMANUAL GI
HOW
TOUSE
THISMANUAL
F[rtFf#rtifiirointsouttheneededspeciat
serviceTool
(ssT)
fortheserviceoperation
matit
pro-
E
ceeds.Gather
allnecessarySSTbeforebeginning
work.
Example:
SST
NUMBER
SST NAME SST ILLUSTRATION
03uGtx-@6
REPAIBPROCEDURE
1.
Most
repairoperationsbeginwith
an overviewillustration.
lt identifiesthecomponents,shows
howthe
parts
fit
together,
and
visual
parts
lnspections.lf
a damaged
or
worn
part
isfound,
repair
or replaceit
as
necessary.
2.Expendable
parts,
tighteningtorques,andsymbolsforoil,
grease,
andsealantare
shownintheoverview
illustration.
3. Pagesrelated
to
service
procedures
areshownunder
theillustration.Befer
tothisinformation
whenser-
vicingthe
related
part.
Example:
SHOWSTIGHTENING
TOROUEUNIT
sHows
RELATED
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
TO
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
As
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
a
particularprocedrire.
GAUTIbNS
are
given
to
pri:vent
you
from
making
anerror
thatcould
damage
the
vdhicle.
WARNINGS
remind
you
to beespeciallycareful
in
thoseareas
where
carelessness
can
cause
Per'
sonat
iniury.
The
followinglilt contains
some
general
WARNINGS
you
should
follow
when
you
workon
a vehicle olA.,x-oo2
FUNDAMENTAL
PROCEDURES
PROTECTION
OF
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
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,
try alsoto
determine
its
cause.
Beginwork
only
afterfirstlearning
which
parts
andsubassem-
b esmust
be
removedanddisassembled
for replacement
or
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
be
performed
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.
Be sureio separate
or otherwise
identify
the
parts
to be
reolaced
fromthose
that
will
be reused
3.
Cleaning
parts
tor reuse
Alloarts'iobe
reused
should
be
carefully
and
thoroughly
cleaned
inthe
appropriate
method.
REASSEMBLY
Standard
values,
such
as
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
be
replaced
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
on
location:
1.Sealant
should
be
applied
to gaskets.
2.Oilshould
beapplied
to
themoving
components
of
parts'
3.Specified
oilor
gieaseshould
beapplied
at
the
prescribed
locations
(such
as
oil
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