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1990 Mazda 121 Werkstatt-Service-Reparaturhandbuch

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🏷️ Basic Information Identification Make: Mazda Model: 121 Year: 1990 Codes Chassis Code: DA Engine Code: B3 (1.3L) 👋 Introduction Market Position Segment: Subcompact hatchback, known for its affordability, fuel...
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Art.-Nr: 585521
Stichworte: 121 1990 Car Cars Mazda
1990 Mazda 121 Werkstatt-Service-Reparaturhandbuch1990 Mazda 121 Werkstatt-Service-Reparaturhandbuch1990 Mazda 121 Werkstatt-Service-Reparaturhandbuch1990 Mazda 121 Werkstatt-Service-Reparaturhandbuch
🏷️ Basic Information
Identification
Make:
Mazda
Model:
121
Year:
1990
Codes
Chassis Code:
DA
Engine Code:
B3 (1.3L)
👋 Introduction
Market Position
Segment:
Subcompact hatchback, known for its affordability, fuel efficiency, and practicality.
Competitive Analysis
Key Competitors 1990:
Ford Festiva, Honda Civic, Toyota Tercel, Nissan Sentra, Suzuki Swift.
Key Features
Design Philosophy:
Compact, fuel-efficient, reliable transportation. Often praised for its surprisingly spacious interior for its size.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
Page Count
Estimated Page Count:
Approx. 800-1200 pages (typical for comprehensive workshop manuals of this era)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, repair, timing belt, cylinder head, pistons, crankshaft, camshaft, lubrication system, cooling system.
Fuel System:
Fuel pump, injectors, fuel filter, fuel tank, fuel lines, carburetor (if applicable, though likely EFI for 1990).
Ignition System:
Distributor, ignition coils, spark plugs, wiring, ignition timing.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, pipes, emissions control.
Transmission Manual:
Gearbox assembly, disassembly, clutch, shifting mechanism, gear ratios, maintenance, repair.
Transmission Automatic:
Automatic transmission operation, overhaul, fluid types, control systems (if applicable).
Drivetrain:
Front-wheel drive system, driveshafts, CV joints, differential.
Suspension Front:
MacPherson struts, control arms, ball joints, bushings, wheel bearings, alignment specifications.
Suspension Rear:
Torsion beam axle, shock absorbers, springs, bushings, alignment specifications.
Steering System:
Steering rack, tie rods, power steering pump (if applicable), steering column, maintenance, repair.
Brake System:
Front disc brakes, rear drum brakes (typical for this model), hydraulic system, master cylinder, brake lines, calipers, wheel cylinders, parking brake.
Electrical System Charging:
Alternator, battery, voltage regulator, wiring diagrams.
Electrical System Starting:
Starter motor, starter solenoid, ignition switch, wiring diagrams.
Lighting System:
Headlights, taillights, interior lights, turn signals, wiring diagrams.
Instrument Panel:
Gauges, warning lights, switches, wiring diagrams.
Body Interior:
Trim removal and installation, seat adjustment, dashboard components, door panels, headliner.
Body Exterior:
Bumpers, fenders, hood, trunk lid, doors, glass, seals, body panel removal and installation.
HVAC System:
Heating, ventilation, air conditioning (A/C) system components, refrigerant, operation, repair.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all systems.
Procedures Included
Preventative Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common fault diagnosis.
Engine Repair:
Complete engine rebuild procedures, head gasket replacement, piston ring replacement, bearing replacement.
Transmission Overhaul:
Detailed steps for disassembling and reassembling manual and automatic transmissions.
Brake Service:
Brake pad replacement, rotor resurfacing/replacement, brake caliper rebuilding, brake bleeding.
Suspension Component Replacement:
Strut replacement, shock absorber replacement, control arm bushings, ball joint replacement.
Electrical Component Diagnosis:
Testing of sensors, actuators, fuses, relays, and control modules.
Body Panel Repair:
Alignment and replacement of doors, fenders, hood, and trunk.
HVAC Repair:
A/C compressor replacement, refrigerant recharging, heater core replacement.
Timing Belt Replacement:
Critical procedure for B3 engine, including tensioner and water pump recommendations.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and transmission overhauls.
📊 Manual Specifications
File Format
File Type:
Likely PDF, potentially scanned images of original pages. Searchable text is a bonus.
Print Quality
Image Resolution:
Variable, depending on the source of the digital conversion. Aim for clear, legible scans.
Binding Type
Original Binding:
Likely perfect bound or spiral bound for professional workshop manuals.
Paper Type
Original Paper Quality:
Durable, often glossy paper to withstand shop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, SOHC (Single Overhead Camshaft)
Displacement:
1.3 Liters (1324 cc)
Bore X Stroke:
71.0 mm x 83.6 mm (typical for B3)
Compression Ratio:
9.3:1 (typical)
Performance
Horsepower:
Approx. 62-70 hp @ 5500-6000 rpm (depending on market and tune)
Torque:
Approx. 70-78 lb-ft @ 3000-3500 rpm (depending on market and tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Unleaded gasoline, 87 octane (or as per local market specifications)
Maintenance
Spark Plugs:
NGK BKR5E-11 or equivalent (check manual for exact part number)
Timing Belt Replacement Interval:
60,000 miles or 5 years (critical, non-interference engine not guaranteed)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
3-speed Automatic Transmission
Features
Manual Gear Ratios:
Specific ratios provided in manual (e.g., 1st: 3.583, 2nd: 2.000, 3rd: 1.367, 4th: 1.000, 5th: 0.821, Reverse: 3.583)
Maintenance
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 (or specific Mazda recommendation)
Automatic Transmission Fluid Type:
Dexron II or equivalent
📐 Dimensions
Exterior
Length:
Approx. 3755 mm (147.8 inches)
Width:
Approx. 1615 mm (63.6 inches)
Height:
Approx. 1395 mm (54.9 inches)
Wheelbase:
Approx. 2310 mm (90.9 inches)
Weights
Curb Weight:
Approx. 800-900 kg (1760-1980 lbs), depending on trim and options
Gross Vehicle Weight Rating:
Refer to vehicle placard or manual
🛡️ Safety Features
Ratings
NHTSA Crash Test Results:
Data limited for this era and model; early models generally had less stringent testing.
Passive Features
Seat Belts:
3-point front, 2-point rear (typical)
Body Structure:
Unibody construction with crumple zones (basic for the era)
Driver Airbag:
Optional or standard on higher trims for 1990 (verify by model variant)
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player. Single-DIN aftermarket upgrades common.
Driver Assistance
ABS:
Optional on some models, often front-wheel ABS only.
Connectivity
Original Connectivity:
None by modern standards; relies on analog systems.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 miles or 6 months, whichever comes first.
Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000 miles or 1 year.
Coolant Flush:
Every 30,000 miles or 2 years.
Fluid Specifications
Engine Oil Type:
API SG, SAE 10W-30 or 10W-40 (check manual for seasonal recommendations)
Engine Oil Capacity:
Approx. 3.0 Liters (3.2 US Quarts) with filter change.
Coolant Type:
Ethylene glycol based, Mazda blue or equivalent.
Known Issues
Engine Wear:
Piston ring wear leading to oil consumption can occur with high mileage.
Suspension Components:
Wear in bushings, ball joints, and tie rod ends is common due to age and mileage.
Electrical Corrosion:
Corrosion in connectors and grounds, especially in humid climates.
Rust:
Can be an issue on older vehicles, particularly in areas exposed to salt.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Known for sporty driving dynamics (Zoom-Zoom) and reliable, efficient vehicles.
Model Evolution
Generation 1 Da:
Launched in 1989, based on the Ford Festiva platform (developed in collaboration with Mazda and Kia).
Rebadging Notes:
Also sold as the Ford Festiva in North America and other markets.
Production
Manufacturing Location:
Japan and South Korea (Kia)
🏆 Awards & Recognition
Recognitions
Industry Standing:
Recognized for its value and fuel economy in its segment during its production run. Often a reliable first car.
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