Mazda 121 1991 Gebrauchsanweisung

JMOOB103t00

Mazda

121

Workshop

Manual

Vofume1of2

FOREWORD

Thisworkshop

manual

isintended

foruse

bv servicetechnicians

of Authorized

Mazda

D-ealersto helpthemservice

Mazda

vehicles.

canalsobe uselul

to ownersandoperators

of Mazda vehicles in diagnosingsome

problems

and performing

limited

repair

and

maintenanceon Mazdavehicles.

For proper repair and maintenance,

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

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_

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

youknowhowtousethem

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

toreducethe

risk

ofpersonal

injurytoyourself

orothers

andtherisk

ofimproperservice

thatmaydamagethe

vehicleorrenderitunsafe.

lfthere

isnosuch

information

inregard

toanyspectfic

service

method,this

doesnotmean

thereisnopossibility

that

personal

safetyor vehiclesafety

will

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

wearing

protective

clothing

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-

ceeds.Gather

allnecessarySSTbeforebeginning

work.

Example:

SSTNUMBER

SSTNAME SST ILLUSTRATION 03uGtx-@6

REPAIBPROCEDURE

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

part.

Example:

SHOWSTIGHTENING

TOROUEUNIT

sHows

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

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

thoseareas

where

carelessness

can

cause

Per'

sonat

iniury.

The

followingliltcontains

some

general

WARNINGS

you

should

when

you

workon

a vehicle olA.,x-oo2

FUNDAMENTAL

PROCEDURES

PROTECTION

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

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,

tryalsoto determine

its

cause.

Beginwork

only

afterfirstlearning

which

parts

andsubassem-

b esmust

beremovedanddisassembled

forreplacement

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

carefully

inspected

for

malfunctioning,

detormation,

damage,

and

other

problems'

Arrangement

of Parts

AlldisJssembledoarts

should

carefully

arranged

iorre-

assembly.

Besureioseparate

orotherwise

identify

theparts

to be

reolaced

fromthose

that

will

bereused

Cleaning

parts

tor reuse

Alloarts'iobereused

should

carefully

and

thoroughly

cleaned

intheappropriate

method.

REASSEMBLY

Standard

values,

such

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

.Oil

seals

3.O-rings

5.Cotter

pins

Gaskets

4.Lock

washers

Nylon

nuts

)ffi

Gt-6

Depending

onlocation:

1.Sealant

should

beapplied

to gaskets.

2.Oilshould

beapplied

themoving

components

parts'

3.Specified

oilor

gieaseshould

beapplied

the

prescribed

locations

(such

asoil

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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