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Mazda 121 Manuals
Manuals and User Guides for Mazda 121. We have
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Mazda 121 manual available for free PDF download: Workshop Manual
Mazda 121 Workshop Manual (391 pages)
Brand:
Mazda
| Category:
Automobile
| Size: 64.18 MB
Table of Contents
Contents
2
Vehicle Identification Numbers (VIN)
3
General Information
4
Table of Contents
4
POSSIBLE LOSS of Warranry
5
Warning on Lubricants and Greases
5
Repair Procedure
6
How to Use Th|S Manual
6
Fundamental Procedures
7
Symbols
7
Notes, Cautions and Warnings
7
Protection of the Vehicle
7
A Word about Safety
8
Preparation of Tools and Measuring Equipment
8
Special Tools
8
Removal of Parts
8
Reassembly
9
Inspection of Parts
9
Arrangement of Parts
9
Adjustments
10
Rubber Parts and Tubing
10
Jack and Safety Stand Positions
11
Vehicle Lift (2-Support Type) Positions
11
Front/Rear End
11
Jack Position
11
Towing
12
Identification Number Locations
13
Units
13
Abbreviations
13
Automatic Transaxle Mode1
13
Installation of Mobile Two-Way Radio System
14
Removal of Ignition Key on Automatic Transaxle Model
14
Electrical Troubleshooting Tools
15
Test Light
15
Jumper Wire
15
Voltmeter
15
Caution with Electrical Parts
16
Battery Cable
16
Removal of Connector
16
Locking of Connector
16
Terminals Inspection
17
Replacement of Terminals
17
Sensors, Switches and Relays
17
Fuse Replacement
18
Wiring Harness
18
Wiring Color Codes
18
Pre-Delivery Inspection and Scheduled Maintenance Services
19
Pre-Delivery Inspection Table
20
Scheduled Maintenance Services
21
Adjustment of Engine Valve Clearance
23
Tightening Intake Manifold Bolts and Nuts
23
Tightening Exhaust Manifold Nuts
23
Replacement Timing Belt
23
Inspection and Adjustment of Drive Belts
24
Replacement of Engine Oil
25
Replacement of Engine Oil Filter
25
Recommended SAE Viscosity Numbers
25
Inspection of Cooling System
26
Coolant Level (Engine Cold)
26
Coolant Quality
26
Coolant Leakage
26
Replacement of Engine Coolant
27
Adjustment of Idle Speed
28
Replacement of Air Cleaner Element
29
Replacement of Fuel Filter
29
Inspection of Fuel Lines and Hoses
29
Adjustment of Ignition Timing
30
Inspection of Spark Plugs
31
Inspection of Throttle Sensor
31
Inspection of Dashpot
32
Inspection of Evaporative System
33
Inspection of Battery
33
Inspection of All Electrical System
33
Inspection of Clutch Pedal
34
Inspection of Brake Lines, Hoses and Connections
34
Inspection of Brake Fluid
34
Replacement of Brake Fluid Air Bleeding
35
Inspection of Parking Brake
35
Inspection of Power Brake Unit and Hoses
35
Inspection of Disc Brake
36
Inspection of Drum Brake
36
Inspection of Steering and Front Suspension
36
Inspection of Power Steering Fluid and Lines
36
Replacement of Manual Transaxle Oil
37
Inspection of Automatic Transaxle Fluid Level
37
Replacement of Front Wheel Bearing Greases
37
Inspection of Drive Shaft Dust Boots
38
Tightening of Bolts and Nuts on Chassis and Body
38
Inspection of Exhaust System Heat Shield
38
Engine
39
Parts
39
Index
40
Outline
41
Troubleshooting Guide
41
Specifications
41
Engine Tune-Up Procedure
43
Engine Oil Inspection
43
Engine Coolant
43
Drive Belt
43
Valve Clearance Inspection/Adjustment
45
Ignition Timing, Idle Speed
46
Compression
48
On-Vehicle Maintenance
49
Timing Belt Removal/Installation
50
Pulley Lock Bolt
51
Timing Belt
52
Cylinder Head Gasket
55
Harnesses
57
Cylinder Head Bolt
57
Front Oil Seal Replacement
59
Rear Oil Seal Replacement
61
Driveshaft
68
Engine Mount Member
68
Engine and Transaxle Assembly
69
Engine Stand Mounting
71
Auxiliary Parts
75
Cylinder Head
78
Rocker Arm and Rocker Shaft Assembly
79
Camshaft Pulley
79
Valve Keeper
79
Valve Seal
79
Cylinder Block (External Parts)
80
Main Bearing Support Plate
82
Front/Rear Oil Seal
82
Cylinder Block (Internal Parts)
83
Connecting Rod Cap
84
Connecting Rod
84
Piston Ring/Pin
84
Main Bearing Cap
85
Valve Mechanism
87
Valve and Valve Guide
87
Valve Seat
89
Camshaft
90
Valve Spring
90
Cylinder Block
92
Rocker Arm and Rocker Arm Shaft
92
Cylinder Bore
93
Piston, Piston Ring, and Piston Pin
94
Crankshaft
96
Main Bearing and Connecting Rod Bearing
96
Tensioner, Idler
97
Tensioner Spring
97
Pulley
97
Assembly
98
Cylinder Block (Internal Parts) Torque Specifications
99
Piston Ring
100
Oil Filter Joint
101
Oil Clearance Inspection
101
Cylinder Block (External Parts) Torque Specifications
105
Rear Cover
105
Oil Pump
106
Oil Strainer
106
Oil Pan
107
End Plate
107
Flywheel (MTX)
107
Clutch Disc and Clutch Cover (MTX)
108
Drive Plate
108
Timing Belt Pulley
109
Water Pump
109
Cylinder Head Torque Specifications
110
Valve and Valve Spring
111
Camshaft Oil Seal
111
Valve Clearance Adjustment
112
Temperature Gauge Unit
113
Thermostat and Thermostat Cover
113
Cylinder Head Cover
113
Timing Belt Torque Specifications
114
Timing Belt Tensioner
114
Timing Belt Cover
116
Crankshaft Pulley
116
Water Pump Pulley
116
Auxiliary Parts Torque Specifications
117
Engine Hanger
117
Spark Plug
118
Oil Dipstick
118
Oil Pressure Switch
118
Oil Filter
118
Intake Manifold Assembly
119
Distributor and High-Tension Lead
119
Engine Stand Dismounting
120
Water Inlet Pipe
120
Exhaust Pipe Bracket
121
A/C Compressor Bracket
121
Exhaust Manifold
121
Exhaust Manifold Insulator
121
Clutch Cable
125
Shift Control Cable (ATX)
125
Speedometer Cable
126
Exhaust Pipe
126
P/S Oil Pump and Bracket
129
Radiator and Cooling Fan Assembly
129
Accelerator Cable
130
Battery Duct, Battery Carrier, and Battery
130
Lubrication System
131
Oil Pressure
134
Engine Oil
135
Oil Pan Removal/Installation
137
Oil Pum Disassembly/Assembly
141
Oil Pump Inspection
142
Pressure Spring
142
Rotor Clearance
142
Cooling System
143
Engine Coolant Replacement
147
Coolant Protection
147
Antifreeze Solution Mixture Percentage
147
Coolant Capacity
147
Radiator Cap Inspection
148
Radiator Cap Valve
148
Radiator Removal/Installation
149
Radiator Inspection
149
Thermostat Removal/Installation
150
Thermostat Inspection
151
Thermostat Gasket
151
Water Pump Removal/Installation
152
Electric Cooling Fan System Circuit
153
Electric Cooling Fan System Inspection
153
Fan Motor Inspection
154
Fan Motor Replacement
154
Water Thermoswitch Removal/Installation
155
Water Thermoswitch Inspection
155
Fan Relay Removal/Installation
156
Fan Relay Inspection
156
Fuel and Emission Control Systems (Egi-S)
157
Description of Drivability
171
Fuel Pressure Release and Servicing Fuel System
172
Pinching Hose
172
Symptom Troubleshooting
173
Cranks Normally but will Not Start
173
Cranks Normally but will Not Start (Partial Combustion) - When Engine Cold
175
Cranks Normally but will Not Start - after Warm-Up
177
Cranks Normally but Hard to Start - Always
179
Cranks Normally but Hard to Start - When Engine Cold
181
Cranks Normally but Hard to Start - after Warm-Up
183
Rough Idle/Engine Stalls at Idle - Always
185
Rough Idle/Engine Stalls at Idle - before Warm-Up
187
Rough Idle/Engine Stalls at Idle - after Warm-Up
189
Rough Idle/Engine Stalls at Idle - When A/C, P/S, E/L on
191
Rough Idle/Engine Stalls Just after Starting
192
High Idle Speed after Warm-Up
194
Idle Moves up and Down/Idle Hunting
195
Engine Stalls on Deceleration
197
Hesitates/Stumbles on Acceleration
199
Surges While Cruising
201
Lack of Power
203
Poor Acceleration
206
Runs Rough on Deceleration/Backfire
209
Knocking
211
Fuel Odor
213
Exhaust Sulfer Smell
214
High Oil Consumption
214
Poor Fuel Economy
215
Engine Tune-Up
217
Air Cleaner Element
218
Engine Tune-Up Adjustment
218
Ignition Timing Inspection/Adjustment
219
Idle Speed
219
Idle-Up Speed
220
Self-Diagnosis Function
222
Malfunction Code Number
223
Principle of Code Cycle
224
Code Cycle Break
224
Second Digit of Malfunction Code
224
First Digit of Malfunction Code
224
Code Numbers
225
Circuit Diagram
226
Switch Monitor Function
236
Neutral and Clutch Switches (MTX)
237
Stoplight Switch
237
Blower Switch
238
Headlight Switch
238
Water Thermoswitch Circuit
238
Rear Defroster Switch
238
Intake Air System Component Parts
239
Injection Body Inspection
240
Fuel Pressure Release
240
Fast-Idle
240
Baffle/Intake Manifold Inspection
242
Accelerator Pedal
242
Fuel System Description
243
Fuel Pressure Hold Inspection
244
Fuel Line Pressure Inspection
245
Fuel Tank Removal/Inspection/Installation
246
Fuel Pump Inspection
247
Fuel Pump Operation Sound
248
Circuit Opening Relay
249
Fuel Filter Replacement
249
Low/High Pressure Side
249
Pressure Regulator
250
Fuel Line Pressure
250
Fuel Leakage Test
252
Exhaust System Component Parts
253
Outline of Emission Control System Structural View
254
Positive Crankcase Ventilation (PCV) System Description
255
PCV Valve Inspection
255
Evaporative Emission Control System Description
256
Solenoid Valve (Purge Control)
257
Check Valve Inspection
258
Charcoal Canister
258
Catalytic Converter System Description
259
Catalytic Converter Inspection
259
Deceleration Control System Description
260
Dashpot Inspection
260
A/C Cut-Off System Description
261
A/C Cut-Off System Operation
261
Dechoke Control System Description
262
Dechoke Control System Operation
262
Air Bypass Control System Description
263
Operation of Air Bypass Solenoid Valve
263
Air Bypass Solenoid Valve
265
Control System
266
Control System Structural View
267
Engine Control Unit Replacement
268
Engine Control Unit Inspection
268
2. Ecu
268
I N S P E C L I O N
268
Terminal Voltage
270
Crank Angle Sensor Inspection
276
Crank Angle Sensor Specification
276
Airflow Sensor (Bypass Hot-Wire Type) Inspection
277
Water Thermosensor Removal
277
Water Thermosensor Inspection
277
Throttle Sensor Inspection
278
Throttle Sensor Specification
278
Throttle Sensor Adjustment
278
Throttle Sensor Removal/Installation
278
Oxygen Sensor
279
Main Relay Replacement
280
Main Relay Inspection of Continuity
280
Clutch Switch Inspection
280
Clutch Switch Replacement
280
Neutral Switch Inspection
281
Neutral Switch Replacement
281
Power Steering Pressure Switch Inspection
281
Engine Electrical
282
Engine Electrical Index
283
Charging System Circuit Diagram
287
Charging System Troubleshooting
288
Battery Inspection
289
Electrolyte Level
289
Specific Gravity of Electrolyte
289
Voltage Test
289
Terminal and Cable
290
Recharging
290
Slow-Charging
290
Alternator Removal/Installation
291
R E P L a C E M E N T
291
Alternator Disassembly/Assembly
292
Rotor Inspection
293
Stator Inspection
293
Bearings Inspection
293
Rectifier
294
Brush
294
Brush Spring
294
Drive Belt Inspection
295
Drive Belt Tension
295
Drive Belt Deflection
295
Drive Belt Adjustment
295
Drive Belt Replacement
296
Ignition System Circuit Diagram
297
Ignition System Troubleshooting
298
Ignition Timing Adjustment
299
Spark Plugs Removal/Installation
300
Spark Plugs Inspection
300
Ignition Coil Inspection
301
Ignition Coil Replacement
301
Distributor Spark Test
301
Electronic Advance Inspection
301
Ignition Coil Removal/Installation
302
Ignition Coil Disassembly/Assembly
303
Cap and Rotor Inspection
304
Igniter Inspection
304
Igniter Replacement
304
High-Tension Lead Inspection
304
Starting System Circuit Diagram
305
Starter Inspection
306
Starter Removal/Installation
306
Mtx
307
Starting System Performance Inspection
308
Magnetic Switch
308
Pull-In Test
308
Hold-On Test
308
Starting System Disassembly/Assembly
309
Drive Pinion
310
Brush and Brush Holder
311
Field Coil
311
Armature
312
Clutch
313
Clutch Index
314
Clutch Specifications
315
Clutch Troubleshooting Guide
315
Clutch Pedal Adjustment
316
Clutch Pedal Free Play
316
Clutch Pedal Removal/Inspection/Installation
317
Clutch Cable Removal/Inspection/Installation
318
Adjustment
318
Clutch Unit
319
Clutch Unit Removal/Installation
320
Clutch Cover and Disc
321
Pilot Bearing
321
Flywheel
321
Clutch Disc
322
Clutch Cover Inspection
323
Clutch Disc Inspection
323
Release Collar Inspection
324
Pilot Bearing Inspection
324
Flywheel Inspection
324
Manual Transaxle
325
Manual Transaxle Index
326
Manual Transaxle Specifications
327
Manual Transaxle Structural View
328
Manual Transaxle Powerflow
329
Manual Transaxle Troubleshooting Guide
330
Transaxle Oil Inspection
331
Transaxle Oil Replacement
331
Oil Seal Replacement
331
Transaxle
333
Transaxle Removal
335
Engine Mounting Member
336
Transaxle Disassembly
338
Shift Rod
340
Interlock Pin
340
Clutch Housing and Transaxle Case Components
341
Oil Seal
342
Funnel and Bearing Outer Race (Secondary Shaft)
342
Funnel
343
Bearing Outer Race
343
Bearing Outer Race and Adjustment Shim (Differential)
343
Bearing Outer Race and Adjustment Shim
344
Primary Shaft Assembly
345
3Rd/4Th Gear Thrust Clearance
346
Secondary Shaft Assembly
348
Clutch Hub Assembly
350
Bearing Inner Race (1St), Pinion Gear, 1St Gear
350
Synchronizer Ring
350
Clutch Release Collar
351
Shift Fork, Clutch Hub Sleeve
351
Primary Shaft
352
3Rd Gear, 4Th Gear
352
Secondary Shaft
353
1St Gear, 2Nd Gear, 5Th Gear
353
Transaxle Assembly
354
2Nd Gear, Synchronizer Ring
356
Retaining Ring
357
Steel Ball, Spacer
361
Adjustment Shim Selection
363
Adjustment Shim Thickness
363
Transaxle Installation
380
Extension Bar and Control Rod
382
Differential
383
Differential Disassembly/Inspection/Assembly
384
Backlash of Pinion Gears
385
Roll Pin
385
Side Bearing Inner Race
385
Shift Mechanism Overhaul
388
Spring
390
Extension Bar
390
Control Rod
390
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