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Mazda 121 1990-1998 Workshop Service Manual for Repair

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The Mazda 121, specifically the DA (DB) generation produced from 1990 to 1998, represents a practical and economical subcompact hatchback. Designed with efficiency and everyday usability in mind, this model...
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SKU: 57868
Mazda 121 1990-1998 Workshop Service Manual for RepairMazda 121 1990-1998 Workshop Service Manual for RepairMazda 121 1990-1998 Workshop Service Manual for RepairMazda 121 1990-1998 Workshop Service Manual for Repair
The Mazda 121, specifically the DA (DB) generation produced from 1990 to 1998, represents a practical and economical subcompact hatchback. Designed with efficiency and everyday usability in mind, this model aimed to provide reliable transportation for individuals and small families, often competing with vehicles like the Ford Fiesta and Volkswagen Polo. Its engineering emphasizes Mazda's commitment to delivering engaging driving dynamics, or "Zoom-Zoom," even within the constraints of its class. This generation, known in some markets as the Autozam Revue, was primarily manufactured in Japan and offered a straightforward yet capable package, typically featuring a 1.3-liter inline 4-cylinder engine coupled with either a 5-speed manual or an optional 4-speed automatic transmission. This comprehensive Workshop Service Manual for Repair provides essential guidance for maintaining and repairing the Mazda 121 (DB) generation. Covering a wide array of systems, including the engine, fuel, cooling, lubrication, ignition, exhaust, transmission, drivetrain, suspension, steering, brakes, and electrical systems, this manual is an invaluable resource. It details periodic maintenance schedules, fluid specifications, and common issues such as rust and engine idling problems, offering systematic troubleshooting procedures and step-by-step repair instructions. With 771 pages of detailed information, including technical specifications, torque values, special tool requirements, and clear diagrams, this English-language manual is designed to assist owners, mechanics, and technicians in ensuring the longevity and optimal performance of their vehicle.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
121
Generation
Generation Code:
DA (DB)
Codes
Chassis Code:
DB129
👋 Introduction
Market Position
Vehicle Segment:
Subcompact hatchback.
Competitive Analysis
Key Competitors:
Ford Fiesta, Volkswagen Polo, Honda Civic (early models), Toyota Starlet.
Key Features
Target Audience:
Economical, reliable, and practical transportation for individuals and small families.
Design Philosophy:
Focus on efficiency, practicality, and Mazda's hallmark of 'Zoom-Zoom' driving dynamics adapted for the subcompact class.
📋 Manual Details
Coverage Areas
Applicable Years:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Page Count
Total Pages:
771
Manual Type
Type:
Workshop Service Manual for Repair
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage of engine mechanicals, including disassembly, assembly, inspection, and repair of major components.
Fuel System:
Details on fuel delivery, injection systems, fuel pump, injectors, and related components.
Cooling System:
Information on radiator, water pump, thermostat, hoses, and coolant specifications.
Lubrication System:
Oil pump, oil filter, oil pressure, and lubrication system maintenance.
Ignition System:
Spark plugs, ignition coils, distributor (if applicable), and timing adjustments.
Exhaust System:
Catalytic converter, muffler, exhaust manifold, and pipe repair and replacement.
Transmission:
Both manual and automatic transmission overhaul, maintenance, clutch service, and gear selection.
Drivetrain:
Front-wheel drive system, CV joints, axles, and differential service.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, and alignment procedures.
Steering:
Power steering system, steering rack, tie rods, and steering column repair.
Brakes:
Disc and drum brake systems, brake pads, rotors, calipers, master cylinder, and bleeding procedures.
Electrical System:
Wiring diagrams, starter motor, alternator, battery, lighting, fuses, relays, and control modules.
Body And Chassis:
Body panel removal/installation, interior trim, glass replacement, door mechanisms, and structural repairs.
Heating And Air Conditioning:
HVAC system components, refrigerant handling, blower motor, and climate control adjustments.
Body Electrical:
Wipers, power windows, door locks, mirrors, and instrument cluster diagnostics.
Procedures Included
Maintenance:
Detailed periodic maintenance schedules, fluid changes, filter replacements, and inspections.
Troubleshooting:
Systematic diagnostic procedures, fault code interpretation, and common problem solutions.
Repair:
Step-by-step instructions for removal, disassembly, inspection, repair, and reassembly of all major vehicle components.
Installation:
Guidance on the correct installation of new or replacement parts.
Adjustments:
Specific procedures for adjusting systems such as brakes, clutch, and ignition timing.
Technical Depth
Depth:
Comprehensive, from basic maintenance and adjustments to complete engine and transmission rebuilds.
Diagrams And Illustrations:
Features detailed step-by-step procedures with pictorial diagrams, exploded views, and photographs for clarity.
Special Tools:
Identification and usage instructions for specific Mazda service tools required for certain procedures.
Torque Specifications:
Precise tightening torque values for all critical fasteners and components.
Service Data:
Includes essential service data, specifications, allowable limits, and reference values for accurate diagnostics and repairs.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, printable, and searchable.
Print Quality
Pages Printable:
Yes
Binding Type
Binding:
Digital Download (PDF)
Paper Type
Paper Type:
N/A (Digital)
Software Requirements
Reader:
Adobe Reader
Compatibility
Operating Systems:
Windows, Mac, and Linux OS
⚙️ Engine Specifications
Primary Engine
Engine Code:
B3-ME (common for this era)
Displacement:
1.3 Liters (1300 cc)
Configuration:
Inline 4-cylinder, SOHC (Single Overhead Cam)
Performance
Horsepower:
Approximately 70-75 hp (varies by market and specific engine tune)
Torque:
Approximately 95-100 Nm (varies by market and specific engine tune)
Fuel System
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type:
5-speed Manual
Optional
Transmission Type:
4-speed Automatic (optional)
Features
Drivetrain:
Front-Wheel Drive (FWD)
📐 Dimensions
Exterior
Length:
Approx. 3800-3900 mm (varies slightly by body style)
Width:
Approx. 1600-1650 mm
Height:
Approx. 1350-1400 mm
Weights
Curb Weight:
Approx. 850-950 kg (varies by configuration)
🛡️ Safety Features
Ratings
Crash Test Results:
Limited standardized crash test data available for this model's era and market segment. Manual provides guidance on structural repair.
Active Features
ABS:
Anti-lock Braking System (optional on some models/trims)
Passive Features
Airbags:
Driver airbag may be standard or optional depending on market and trim. Passenger airbag generally not available.
Seatbelts:
Front and rear seat belts.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, often with optional CD player. Manual covers speaker replacement and head unit installation.
Driver Assistance
Cruise Control:
Rarely equipped; typically not a standard feature on this model.
Connectivity
Bluetooth:
Not available from the factory.
🔧 Maintenance
Service Intervals
Oil Change:
Recommended every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first (refer to manual for specific recommendations).
Air Filter Replacement:
Typically every 15,000 - 30,000 miles (24,000 - 48,000 km).
Spark Plug Replacement:
Refer to manual; often in the 30,000 - 60,000 mile range.
Fluid Specifications
Engine Oil:
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for precise viscosity based on climate).
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron II or equivalent automatic transmission fluid.
Coolant:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Consult manual for specific type and capacity.
Known Issues
Rust And Corrosion:
Common in older vehicles, particularly around wheel arches, sills, and door bottoms. Manual provides guidance on structural repair.
Engine Idling Problems:
Can sometimes be related to vacuum leaks, dirty throttle body, or ignition system issues, all covered in the manual.
Gearbox Synchromesh Wear:
In manual transmissions, wear can lead to difficult shifting, which the manual addresses through internal inspection and repair.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Mazda's commitment to driver enjoyment and innovative engineering, even in its more budget-friendly models.
Model Evolution
Generations:
The DB generation of the Mazda 121 (also known as Autozam Revue in Japan) was a key part of Mazda's global subcompact offering.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with some production or assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Vehicle Accolades:
While specific awards are less common for this segment and era, the 121 was recognized for its affordability and practicality in its markets.
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