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1990-1996 Mazda 121 Workshop Service Repair Manual

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$17.99
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🏷️ Basic Information Identification Make: Mazda Model: 121 Generation: DB (Second Generation) Production Years Covered: 1990-1996 Codes Chassis Code: DB 👋 Introduction Market Position Vehicle Segment: Subcompact car, often marketed...
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1990-1996 Mazda 121 Workshop Service Repair Manual1990-1996 Mazda 121 Workshop Service Repair Manual1990-1996 Mazda 121 Workshop Service Repair Manual1990-1996 Mazda 121 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
121
Generation:
DB (Second Generation)
Production Years Covered:
1990-1996
Codes
Chassis Code:
DB
👋 Introduction
Market Position
Vehicle Segment:
Subcompact car, often marketed as an affordable and reliable city car.
Target Audience:
First-time car buyers, urban commuters, budget-conscious consumers.
Competitive Analysis
Key Competitors:
Ford Fiesta, Volkswagen Polo, Toyota Starlet, Honda City, Opel Corsa.
Key Features
Design Philosophy:
Practicality, fuel efficiency, maneuverability, and straightforward mechanicals.
Unique Selling Points:
Compact dimensions for urban driving, good fuel economy, relatively low running costs, surprising interior space for its size.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital (PDF)
Page Count:
Comprehensive (Exact count not specified, implies extensive detail)
Coverage Scope:
Detailed repair and maintenance procedures for all major vehicle systems.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (including disassembly, inspection, and reassembly), fuel system, ignition system, cooling system, exhaust system, lubrication system.
Drivetrain:
Transmission (manual and automatic), clutch system, drive shafts, differentials.
Suspension And Steering:
Front and rear suspension components, steering gear, power steering system.
Brakes:
Front and rear brake systems (disc and drum), hydraulic system, parking brake.
Electrical System:
Battery, charging system (alternator), starting system, lighting system, ignition system, instrumentation, wiring diagrams, fuses, relays.
Body And Chassis:
Body panels, doors, windows, interior trim, seats, chassis components, frame, noise reduction.
Heating Ventilation And Air Conditioning:
HVAC system operation, components, and service.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and tensioning, tire rotation.
Troubleshooting:
Diagnostic procedures for common faults and symptoms across all systems, fault code interpretation (where applicable).
Component Repair:
Detailed step-by-step instructions for the removal, repair, overhaul, and installation of engine components, transmission, brakes, suspension, steering, and electrical parts.
System Diagnostics:
In-depth diagnostic trees and procedures for identifying and resolving issues within various vehicle systems.
Wiring Diagrams:
Comprehensive electrical system wiring diagrams for accurate fault diagnosis and component identification.
Technical Depth
Depth Of Coverage:
Expert level, covering complete overhauls, complex diagnostics, and component-level repairs. Suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Tools:
Mentions required special tools and equipment for various procedures.
Torque Specifications:
Detailed torque specifications for all critical fasteners.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval.
Print Quality:
High-resolution, suitable for printing individual pages or sections.
Interactivity:
Often includes clickable links to sections or cross-references.
Binding Type
Binding Style:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
B3, B5
Displacement Common 1:
1.3 Liters (1340 cc)
Displacement Common 2:
1.5 Liters (1498 cc)
Configuration:
Inline 4-cylinder
Valvetrain:
SOHC (Single Overhead Camshaft)
Performance
Horsepower 1 3L:
Approx. 62-73 PS (depending on market and tune)
Horsepower 1 5L:
Approx. 72-88 PS (depending on market and tune)
Torque 1 3L:
Approx. 90-105 Nm
Torque 1 5L:
Approx. 105-120 Nm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) or Carburetor (early models/markets)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Electronic Control Unit (ECU) for fuel injection and ignition timing.
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
3-Speed or 4-Speed Automatic Transmission (market dependent)
Features
Clutch Type:
Dry, single-plate, diaphragm spring type (Manual)
Transmission Fluid:
Refer to manual for specific API GL-4 or equivalent gear oil specifications.
📐 Dimensions
Exterior
Length:
Approx. 3,845 mm (Varies slightly by body style)
Width:
Approx. 1,600 mm
Height:
Approx. 1,360 mm (Hatchback)
Wheelbase:
Approx. 2,300 mm
Weights
Curb Weight:
Approx. 800-900 kg (Varies by model and equipment)
🛡️ Safety Features
Ratings
Crash Test Performance:
N/A (Limited official crash test data available for this era and segment)
Active Features
Braking System:
Front ventilated discs, rear drum brakes. ABS available on some higher trims/markets.
Passive Features
Seatbelts:
Three-point inertia reel seatbelts in front, two-point lap belts in rear.
Airbags:
Driver airbag generally not standard, may be optional on later models/specific markets.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player. Optional CD player may be found on higher trims/later models.
Instrumentation:
Analog gauges for speedometer, tachometer (optional), fuel level, and engine temperature. Warning lights for critical systems.
Driver Assistance
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature, not standard across all models and years.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil used. Consult manual for exact recommendation.
Air Filter Replacement:
Every 20,000-30,000 km or as needed based on inspection.
Spark Plug Replacement:
Typically every 40,000-60,000 km, depending on plug type.
Timing Belt Replacement:
Critical for interference engines; typically recommended every 80,000-100,000 km or 5-7 years. Consult manual for specific engine.
Fluid Specifications
Engine Oil Type:
API SG or higher; Viscosity typically 5W-30 or 10W-30. Check manual for exact specification and capacity.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4, depending on vehicle specification.
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, exhaust system corrosion, radiator leaks, starter motor reliability.
Electrical Gremlins:
Flickering lights, issues with power windows or central locking can occur due to age and wiring degradation.
Engine Performance Degradation:
Carbon buildup in combustion chambers and on intake valves can affect performance and fuel economy over time.
📚 Vehicle History
Brand Heritage
Mazda Heritage:
Mazda, a Japanese automaker with a long history dating back to 1920, known for its innovative technologies and engaging driving dynamics, even in smaller vehicles.
Model Evolution
Previous Generation:
The first-generation Mazda 121 (DA) was produced from 1985-1990 and was essentially a rebadged Ford Festiva.
Second Generation Distinction:
The DB generation (1990-1996) marked a departure, being more of an independent Mazda design, although it shared some platform elements with Ford's European operations.
Subsequent Generation:
The Mazda 121 was replaced by the Mazda Demio (later known as Mazda 2) in many markets.
Production
Manufacturing Locations:
Primarily manufactured in Japan and also in other Mazda or Ford-affiliated plants globally depending on market.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 1990-1996 121 are not prominently documented, the model was generally recognized for its value and reliability in the subcompact segment, contributing to Mazda's reputation for dependable small cars.
Ratings
Fuel Efficiency Ratings:
Generally good fuel economy for its era, making it an economical choice for everyday driving.
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