Mazda 121 - User Manual

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Contents2
Vehicle Identification Numbers (VIN)3
General Information4
Table of Contents4
POSSIBLE LOSS of Warranry5
Warning on Lubricants and Greases5
Repair Procedure6
How to Use Th|S Manual6
Fundamental Procedures7
Symbols7
Notes, Cautions and Warnings7
Protection of the Vehicle7
A Word about Safety8
Preparation of Tools and Measuring Equipment8
Special Tools8
Removal of Parts8
Reassembly9
Inspection of Parts9
Arrangement of Parts9
Adjustments10
Rubber Parts and Tubing10
Jack and Safety Stand Positions11
Vehicle Lift (2-Support Type) Positions11
Front/Rear End11
Jack Position11
Towing12
Identification Number Locations13
Units13
Abbreviations13
Automatic Transaxle Mode113
Installation of Mobile Two-Way Radio System14
Removal of Ignition Key on Automatic Transaxle Model14
Electrical Troubleshooting Tools15
Test Light15
Jumper Wire15
Voltmeter15
Caution with Electrical Parts16
Battery Cable16
Removal of Connector16
Locking of Connector16
Terminals Inspection17
Replacement of Terminals17
Sensors, Switches and Relays17
Fuse Replacement18
Wiring Harness18
Wiring Color Codes18
Pre-Delivery Inspection and Scheduled Maintenance Services19
Pre-Delivery Inspection Table20
Scheduled Maintenance Services21
Adjustment of Engine Valve Clearance23
Tightening Intake Manifold Bolts and Nuts23
Tightening Exhaust Manifold Nuts23
Replacement Timing Belt23
Inspection and Adjustment of Drive Belts24
Replacement of Engine Oil25
Replacement of Engine Oil Filter25
Recommended SAE Viscosity Numbers25
Inspection of Cooling System26
Coolant Level (Engine Cold)26
Coolant Quality26
Coolant Leakage26
Replacement of Engine Coolant27
Adjustment of Idle Speed28
Replacement of Air Cleaner Element29
Replacement of Fuel Filter29
Inspection of Fuel Lines and Hoses29
Adjustment of Ignition Timing30
Inspection of Spark Plugs31
Inspection of Throttle Sensor31
Inspection of Dashpot32
Inspection of Evaporative System33
Inspection of Battery33
Inspection of All Electrical System33
Inspection of Clutch Pedal34
Inspection of Brake Lines, Hoses and Connections34
Inspection of Brake Fluid34
Replacement of Brake Fluid Air Bleeding35
Inspection of Parking Brake35
Inspection of Power Brake Unit and Hoses35
Inspection of Disc Brake36
Inspection of Drum Brake36
Inspection of Steering and Front Suspension36
Inspection of Power Steering Fluid and Lines36
Replacement of Manual Transaxle Oil37
Inspection of Automatic Transaxle Fluid Level37
Replacement of Front Wheel Bearing Greases37
Inspection of Drive Shaft Dust Boots38
Tightening of Bolts and Nuts on Chassis and Body38
Inspection of Exhaust System Heat Shield38
Engine39
Parts39
Index40
Outline41
Troubleshooting Guide41
Specifications41
Engine Tune-Up Procedure43
Engine Oil Inspection43
Engine Coolant43
Drive Belt43
Valve Clearance Inspection/Adjustment45
Ignition Timing, Idle Speed46
Compression48
On-Vehicle Maintenance49
Timing Belt Removal/Installation50
Pulley Lock Bolt51
Timing Belt52
Cylinder Head Gasket55
Harnesses57
Cylinder Head Bolt57
Front Oil Seal Replacement59
Rear Oil Seal Replacement61
Driveshaft68
Engine Mount Member68
Engine and Transaxle Assembly69
Engine Stand Mounting71
Auxiliary Parts75
Cylinder Head78
Rocker Arm and Rocker Shaft Assembly79
Camshaft Pulley79
Valve Keeper79
Valve Seal79
Cylinder Block (External Parts)80
Main Bearing Support Plate82
Front/Rear Oil Seal82
Cylinder Block (Internal Parts)83
Connecting Rod Cap84
Connecting Rod84
Piston Ring/Pin84
Main Bearing Cap85
Valve Mechanism87
Valve and Valve Guide87
Valve Seat89
Camshaft90
Valve Spring90
Cylinder Block92
Rocker Arm and Rocker Arm Shaft92
Cylinder Bore93
Piston, Piston Ring, and Piston Pin94
Crankshaft96
Main Bearing and Connecting Rod Bearing96
Tensioner, Idler97
Tensioner Spring97
Pulley97
Assembly98
Cylinder Block (Internal Parts) Torque Specifications99
Piston Ring100
Oil Filter Joint101
Oil Clearance Inspection101
Cylinder Block (External Parts) Torque Specifications105
Rear Cover105
Oil Pump106
Oil Strainer106
Oil Pan107
End Plate107
Flywheel (MTX)107
Clutch Disc and Clutch Cover (MTX)108
Drive Plate108
Timing Belt Pulley109
Water Pump109
Cylinder Head Torque Specifications110
Valve and Valve Spring111
Camshaft Oil Seal111
Valve Clearance Adjustment112
Temperature Gauge Unit113
Thermostat and Thermostat Cover113
Cylinder Head Cover113
Timing Belt Torque Specifications114
Timing Belt Tensioner114
Timing Belt Cover116
Crankshaft Pulley116
Water Pump Pulley116
Auxiliary Parts Torque Specifications117
Engine Hanger117
Spark Plug118
Oil Dipstick118
Oil Pressure Switch118
Oil Filter118
Intake Manifold Assembly119
Distributor and High-Tension Lead119
Engine Stand Dismounting120
Water Inlet Pipe120
Exhaust Pipe Bracket121
A/C Compressor Bracket121
Exhaust Manifold121
Exhaust Manifold Insulator121
Clutch Cable125
Shift Control Cable (ATX)125
Speedometer Cable126
Exhaust Pipe126
P/S Oil Pump and Bracket129
Radiator and Cooling Fan Assembly129
Accelerator Cable130
Battery Duct, Battery Carrier, and Battery130
Lubrication System131
Oil Pressure134
Engine Oil135
Oil Pan Removal/Installation137
Oil Pum Disassembly/Assembly141
Oil Pump Inspection142
Pressure Spring142
Rotor Clearance142
Cooling System143
Engine Coolant Replacement147
Coolant Protection147
Antifreeze Solution Mixture Percentage147
Coolant Capacity147
Radiator Cap Inspection148
Radiator Cap Valve148
Radiator Removal/Installation149
Radiator Inspection149
Thermostat Removal/Installation150
Thermostat Inspection151
Thermostat Gasket151
Water Pump Removal/Installation152
Electric Cooling Fan System Circuit153
Electric Cooling Fan System Inspection153
Fan Motor Inspection154
Fan Motor Replacement154
Water Thermoswitch Removal/Installation155
Water Thermoswitch Inspection155
Fan Relay Removal/Installation156
Fan Relay Inspection156
Fuel and Emission Control Systems (Egi-S)157
Description of Drivability171
Fuel Pressure Release and Servicing Fuel System172
Pinching Hose172
Symptom Troubleshooting173
Cranks Normally but will Not Start173
Cranks Normally but will Not Start (Partial Combustion) - When Engine Cold175
Cranks Normally but will Not Start - after Warm-Up177
Cranks Normally but Hard to Start - Always179
Cranks Normally but Hard to Start - When Engine Cold181
Cranks Normally but Hard to Start - after Warm-Up183
Rough Idle/Engine Stalls at Idle - Always185
Rough Idle/Engine Stalls at Idle - before Warm-Up187
Rough Idle/Engine Stalls at Idle - after Warm-Up189
Rough Idle/Engine Stalls at Idle - When A/C, P/S, E/L on191
Rough Idle/Engine Stalls Just after Starting192
High Idle Speed after Warm-Up194
Idle Moves up and Down/Idle Hunting195
Engine Stalls on Deceleration197
Hesitates/Stumbles on Acceleration199
Surges While Cruising201
Lack of Power203
Poor Acceleration206
Runs Rough on Deceleration/Backfire209
Knocking211
Fuel Odor213
Exhaust Sulfer Smell214
High Oil Consumption214
Poor Fuel Economy215
Engine Tune-Up217
Air Cleaner Element218
Engine Tune-Up Adjustment218
Ignition Timing Inspection/Adjustment219
Idle Speed219
Idle-Up Speed220
Self-Diagnosis Function222
Malfunction Code Number223
Principle of Code Cycle224
Code Cycle Break224
Second Digit of Malfunction Code224
First Digit of Malfunction Code224
Code Numbers225
Circuit Diagram226
Switch Monitor Function236
Neutral and Clutch Switches (MTX)237
Stoplight Switch237
Blower Switch238
Headlight Switch238
Water Thermoswitch Circuit238
Rear Defroster Switch238
Intake Air System Component Parts239
Injection Body Inspection240
Fuel Pressure Release240
Fast-Idle240
Baffle/Intake Manifold Inspection242
Accelerator Pedal242
Fuel System Description243
Fuel Pressure Hold Inspection244
Fuel Line Pressure Inspection245
Fuel Tank Removal/Inspection/Installation246
Fuel Pump Inspection247
Fuel Pump Operation Sound248
Circuit Opening Relay249
Fuel Filter Replacement249
Low/High Pressure Side249
Pressure Regulator250
Fuel Line Pressure250
Fuel Leakage Test252
Exhaust System Component Parts253
Outline of Emission Control System Structural View254
Positive Crankcase Ventilation (PCV) System Description255
PCV Valve Inspection255
Evaporative Emission Control System Description256
Solenoid Valve (Purge Control)257
Check Valve Inspection258
Charcoal Canister258
Catalytic Converter System Description259
Catalytic Converter Inspection259
Deceleration Control System Description260
Dashpot Inspection260
A/C Cut-Off System Description261
A/C Cut-Off System Operation261
Dechoke Control System Description262
Dechoke Control System Operation262
Air Bypass Control System Description263
Operation of Air Bypass Solenoid Valve263
Air Bypass Solenoid Valve265
Control System266
Control System Structural View267
Engine Control Unit Replacement268
Engine Control Unit Inspection268
2. Ecu268
I N S P E C L I O N268
Terminal Voltage270
Crank Angle Sensor Inspection276
Crank Angle Sensor Specification276
Airflow Sensor (Bypass Hot-Wire Type) Inspection277
Water Thermosensor Removal277
Water Thermosensor Inspection277
Throttle Sensor Inspection278
Throttle Sensor Specification278
Throttle Sensor Adjustment278
Throttle Sensor Removal/Installation278
Oxygen Sensor279
Main Relay Replacement280
Main Relay Inspection of Continuity280
Clutch Switch Inspection280
Clutch Switch Replacement280
Neutral Switch Inspection281
Neutral Switch Replacement281
Power Steering Pressure Switch Inspection281
Engine Electrical282
Engine Electrical Index283
Charging System Circuit Diagram287
Charging System Troubleshooting288
Battery Inspection289
Electrolyte Level289
Specific Gravity of Electrolyte289
Voltage Test289
Terminal and Cable290
Recharging290
Slow-Charging290
Alternator Removal/Installation291
R E P L a C E M E N T291
Alternator Disassembly/Assembly292
Rotor Inspection293
Stator Inspection293
Bearings Inspection293
Rectifier294
Brush294
Brush Spring294
Drive Belt Inspection295
Drive Belt Tension295
Drive Belt Deflection295
Drive Belt Adjustment295
Drive Belt Replacement296
Ignition System Circuit Diagram297
Ignition System Troubleshooting298
Ignition Timing Adjustment299
Spark Plugs Removal/Installation300
Spark Plugs Inspection300
Ignition Coil Inspection301
Ignition Coil Replacement301
Distributor Spark Test301
Electronic Advance Inspection301
Ignition Coil Removal/Installation302
Ignition Coil Disassembly/Assembly303
Cap and Rotor Inspection304
Igniter Inspection304
Igniter Replacement304
High-Tension Lead Inspection304
Starting System Circuit Diagram305
Starter Inspection306
Starter Removal/Installation306
Mtx307
Starting System Performance Inspection308
Magnetic Switch308
Pull-In Test308
Hold-On Test308
Starting System Disassembly/Assembly309
Drive Pinion310
Brush and Brush Holder311
Field Coil311
Armature312
Clutch313
Clutch Index314
Clutch Specifications315
Clutch Troubleshooting Guide315
Clutch Pedal Adjustment316
Clutch Pedal Free Play316
Clutch Pedal Removal/Inspection/Installation317
Clutch Cable Removal/Inspection/Installation318
Adjustment318
Clutch Unit319
Clutch Unit Removal/Installation320
Clutch Cover and Disc321
Pilot Bearing321
Flywheel321
Clutch Disc322
Clutch Cover Inspection323
Clutch Disc Inspection323
Release Collar Inspection324
Pilot Bearing Inspection324
Flywheel Inspection324
Manual Transaxle325
Manual Transaxle Index326
Manual Transaxle Specifications327
Manual Transaxle Structural View328
Manual Transaxle Powerflow329
Manual Transaxle Troubleshooting Guide330
Transaxle Oil Inspection331
Transaxle Oil Replacement331
Oil Seal Replacement331
Transaxle333
Transaxle Removal335
Engine Mounting Member336
Transaxle Disassembly338
Shift Rod340
Interlock Pin340
Clutch Housing and Transaxle Case Components341
Oil Seal342
Funnel and Bearing Outer Race (Secondary Shaft)342
Funnel343
Bearing Outer Race343
Bearing Outer Race and Adjustment Shim (Differential)343
Bearing Outer Race and Adjustment Shim344
Primary Shaft Assembly345
3Rd/4Th Gear Thrust Clearance346
Secondary Shaft Assembly348
Clutch Hub Assembly350
Bearing Inner Race (1St), Pinion Gear, 1St Gear350
Synchronizer Ring350
Clutch Release Collar351
Shift Fork, Clutch Hub Sleeve351
Primary Shaft352
3Rd Gear, 4Th Gear352
Secondary Shaft353
1St Gear, 2Nd Gear, 5Th Gear353
Transaxle Assembly354
2Nd Gear, Synchronizer Ring356
Retaining Ring357
Steel Ball, Spacer361
Adjustment Shim Selection363
Adjustment Shim Thickness363
Transaxle Installation380
Extension Bar and Control Rod382
Differential383
Differential Disassembly/Inspection/Assembly384
Backlash of Pinion Gears385
Roll Pin385
Side Bearing Inner Race385
Shift Mechanism Overhaul388
Spring390
Extension Bar390
Control Rod390

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Mazda 121 Specifications

General

Brand	Mazda
Model	121
Category	Automobile
Language	English

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