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1991 Mazda 121 (2nd gen) Service and Repair Manual

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$133.00
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$133.00
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🏷️ Basic Information Identification Make: Mazda Model: 121 Generation Generation: Second Generation (DB) Codes Model Codes: DB1 👋 Introduction Market Position Market Position: The 1991 Mazda 121 (DB) was positioned as a compact, economical subcompact car, often competing in the supermini segment in various global markets. It emphasized affordability, fuel efficiency, and practicality for urban driving. Competitive Analysis Competitive Analysis: Competed against vehicles like the Ford Fiesta, Volkswagen Polo, Fiat Uno, Opel Corsa, and Nissan Micra, often favored for its distinctive styling and respectable handling characteristics for its class. Key Features Key Features: Distinctive wedge-shaped styling, available with efficient 4-cylinder engines, front-wheel drive, compact dimensions for urban maneuverability, practical interior layout. Target Audience Target Audience: DIY mechanics, professional automotive technicians, and Mazda enthusiasts seeking to maintain or repair their 1991 Mazda 121. 📋 Manual Details Coverage Areas Coverage Areas: Full service, repair, and diagnostic coverage for all mechanical and electrical systems. Page Count Page Count: Approximately 800+ Manual Type Manual Type: Factory Service Manual (FSM) Language Language: English Format Format: Printed Manual 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, engine management, fuel system, cooling system, exhaust system, ignition system, drivetrain, transmission (manual & automatic), steering, suspension, brakes (front & rear disc/drum), ABS (if equipped), electrical systems (lighting, ignition, charging, starting, instruments, accessories, body electrical), climate control, body and chassis, interior trim, exterior body panels, diagnostic procedures, troubleshooting. Procedures Included Procedures Included: Routine maintenance, lubrication, engine tune-up, component removal/installation, rebuilding procedures, diagnostic trouble codes (DTCs), electrical circuit diagrams, torque specifications, tightening sequences, component testing, fluid capacities and specifications, replacement procedures for all major components. Technical Depth Technical Depth: Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, advanced electrical diagnostics, and body repair. Diagnostic Procedures Diagnostic Procedures: Includes specific diagnostic procedures for engine, transmission, and electrical faults, including troubleshooting flowcharts and component testing. Wiring Diagrams Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle systems, including engine control, lighting, instrumentation, and accessories. Torque Specifications Torque Specifications: Comprehensive list of torque specifications for all critical fasteners, including cylinder head bolts, main bearing caps, suspension components, etc. Rebuilding Procedures Rebuilding Procedures: Detailed instructions for the overhaul and rebuilding of engines, transmissions, carburetors (if applicable), and other major mechanical components. Body And Chassis Body And Chassis: Detailed procedures for body panel alignment, repair of rust damage, interior trim removal/installation, glass replacement, and chassis component maintenance. 📊 Manual Specifications File Format File Format: N/A (Printed) Print Quality Print Quality: Professional-grade printing with clear diagrams and text. Binding Type Binding Type: Perfect Bound or Spiral Bound (typical for FSMs) Paper Type Paper Type: Durable, high-quality paper suitable for workshop use. ⚙️ Engine Specifications Primary Engine Primary Engine: 1.1L (1139cc) Inline-4 (E11), 1.3L (1339cc) Inline-4 (B3-M, B3-E) Performance Horsepower 1 1L: Approx. 60-63 PS (59-62 hp; 44-46 kW) Horsepower 1 3L: Approx. 72-75 PS (71-74 hp; 53-55 kW) Fuel System Fuel System: Carbureted (typical for 1.1L and early 1.3L models), Electronic Fuel Injection (EFI) for later 1.3L models. Engine Codes 1 1L Engine Codes 1 1L: E11 Engine Codes 1 3L Engine Codes 1 3L: B3-M, B3-E Engine Layout Engine Layout: Inline 4-cylinder, front-mounted, transverse Bore Stroke 1 3L Bore Stroke 1 3L: 71 mm x 83 mm (approx.) Compression Ratio 1 3L Compression Ratio 1 3L: 9.3:1 (typical) Fuel Delivery 1 1L Fuel Delivery 1 1L: Downdraft Carburetor (e.g., Hitachi) Fuel Delivery 1 3L Efi Fuel Delivery 1 3L Efi: Electronic Fuel Injection (EFI) with throttle body injection (TBI) or multi-point fuel injection (MPFI) depending on specific market/trim. 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission Optional Optional Transmission: 3-speed Automatic Transmission Features Transmission Features: Front-wheel drive (FWD). Gear Ratios Manual Gear Ratios Manual: Refer to manual for specific ratios (vary by model and engine). Gear Ratios Automatic Gear Ratios Automatic: Refer to manual for specific ratios (3-speed unit). 📐 Dimensions Exterior Length: Approx. 3,740 mm (147.2 in) Width: Approx. 1,600 mm (63.0 in) Height: Approx. 1,370 mm (53.9 in) Weights Curb Weight: Approx. 770-850 kg (1,698-1,874 lbs) depending on configuration. Wheelbase Wheelbase: Approx. 2,300 mm (90.6 in) Wheels Tires Wheel Size: 13-inch or 14-inch wheels common. Tire Sizes: Common sizes include 155/70R13, 165/70R13, 175/65R14. Refer to vehicle placard for exact specification. Bolt Pattern: 4x100 mm 🛡️ Safety Features Ratings Safety Ratings: No specific official crash test ratings readily available for this generation from major bodies like Euro NCAP or NHTSA due to the era and market segment. Designed to meet prevailing safety standards of the early 1990s. Active Features Active Features: Front disc brakes, rear drum brakes, power-assisted brakes (optional on some trims). Passive Features Passive Features: Seat belts (front and rear), reinforced body structure. Brakes Front Brakes Front: Ventilated Disc Brakes Brakes Rear Brakes Rear: Drum Brakes 💡 Technology Features Infotainment Infotainment System: Basic factory fitted radio/cassette player. Options may...
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1991 Mazda 121 (2nd gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
121
Generation
Generation:
Second Generation (DB)
Codes
Model Codes:
DB1
👋 Introduction
Market Position
Market Position:
The 1991 Mazda 121 (DB) was positioned as a compact, economical subcompact car, often competing in the supermini segment in various global markets. It emphasized affordability, fuel efficiency, and practicality for urban driving.
Competitive Analysis
Competitive Analysis:
Competed against vehicles like the Ford Fiesta, Volkswagen Polo, Fiat Uno, Opel Corsa, and Nissan Micra, often favored for its distinctive styling and respectable handling characteristics for its class.
Key Features
Key Features:
Distinctive wedge-shaped styling, available with efficient 4-cylinder engines, front-wheel drive, compact dimensions for urban maneuverability, practical interior layout.
Target Audience
Target Audience:
DIY mechanics, professional automotive technicians, and Mazda enthusiasts seeking to maintain or repair their 1991 Mazda 121.
📋 Manual Details
Coverage Areas
Coverage Areas:
Full service, repair, and diagnostic coverage for all mechanical and electrical systems.
Page Count
Page Count:
Approximately 800+
Manual Type
Manual Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Printed Manual
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, engine management, fuel system, cooling system, exhaust system, ignition system, drivetrain, transmission (manual & automatic), steering, suspension, brakes (front & rear disc/drum), ABS (if equipped), electrical systems (lighting, ignition, charging, starting, instruments, accessories, body electrical), climate control, body and chassis, interior trim, exterior body panels, diagnostic procedures, troubleshooting.
Procedures Included
Procedures Included:
Routine maintenance, lubrication, engine tune-up, component removal/installation, rebuilding procedures, diagnostic trouble codes (DTCs), electrical circuit diagrams, torque specifications, tightening sequences, component testing, fluid capacities and specifications, replacement procedures for all major components.
Technical Depth
Technical Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, advanced electrical diagnostics, and body repair.
Diagnostic Procedures
Diagnostic Procedures:
Includes specific diagnostic procedures for engine, transmission, and electrical faults, including troubleshooting flowcharts and component testing.
Wiring Diagrams
Wiring Diagrams:
Detailed electrical wiring diagrams for all vehicle systems, including engine control, lighting, instrumentation, and accessories.
Torque Specifications
Torque Specifications:
Comprehensive list of torque specifications for all critical fasteners, including cylinder head bolts, main bearing caps, suspension components, etc.
Rebuilding Procedures
Rebuilding Procedures:
Detailed instructions for the overhaul and rebuilding of engines, transmissions, carburetors (if applicable), and other major mechanical components.
Body And Chassis
Body And Chassis:
Detailed procedures for body panel alignment, repair of rust damage, interior trim removal/installation, glass replacement, and chassis component maintenance.
📊 Manual Specifications
File Format
File Format:
N/A (Printed)
Print Quality
Print Quality:
Professional-grade printing with clear diagrams and text.
Binding Type
Binding Type:
Perfect Bound or Spiral Bound (typical for FSMs)
Paper Type
Paper Type:
Durable, high-quality paper suitable for workshop use.
⚙️ Engine Specifications
Primary Engine
Primary Engine:
1.1L (1139cc) Inline-4 (E11), 1.3L (1339cc) Inline-4 (B3-M, B3-E)
Performance
Horsepower 1 1L:
Approx. 60-63 PS (59-62 hp; 44-46 kW)
Horsepower 1 3L:
Approx. 72-75 PS (71-74 hp; 53-55 kW)
Fuel System
Fuel System:
Carbureted (typical for 1.1L and early 1.3L models), Electronic Fuel Injection (EFI) for later 1.3L models.
Engine Codes 1 1L
Engine Codes 1 1L:
E11
Engine Codes 1 3L
Engine Codes 1 3L:
B3-M, B3-E
Engine Layout
Engine Layout:
Inline 4-cylinder, front-mounted, transverse
Bore Stroke 1 3L
Bore Stroke 1 3L:
71 mm x 83 mm (approx.)
Compression Ratio 1 3L
Compression Ratio 1 3L:
9.3:1 (typical)
Fuel Delivery 1 1L
Fuel Delivery 1 1L:
Downdraft Carburetor (e.g., Hitachi)
Fuel Delivery 1 3L Efi
Fuel Delivery 1 3L Efi:
Electronic Fuel Injection (EFI) with throttle body injection (TBI) or multi-point fuel injection (MPFI) depending on specific market/trim.
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
3-speed Automatic Transmission
Features
Transmission Features:
Front-wheel drive (FWD).
Gear Ratios Manual
Gear Ratios Manual:
Refer to manual for specific ratios (vary by model and engine).
Gear Ratios Automatic
Gear Ratios Automatic:
Refer to manual for specific ratios (3-speed unit).
📐 Dimensions
Exterior
Length:
Approx. 3,740 mm (147.2 in)
Width:
Approx. 1,600 mm (63.0 in)
Height:
Approx. 1,370 mm (53.9 in)
Weights
Curb Weight:
Approx. 770-850 kg (1,698-1,874 lbs) depending on configuration.
Wheelbase
Wheelbase:
Approx. 2,300 mm (90.6 in)
Wheels Tires
Wheel Size:
13-inch or 14-inch wheels common.
Tire Sizes:
Common sizes include 155/70R13, 165/70R13, 175/65R14. Refer to vehicle placard for exact specification.
Bolt Pattern:
4x100 mm
🛡️ Safety Features
Ratings
Safety Ratings:
No specific official crash test ratings readily available for this generation from major bodies like Euro NCAP or NHTSA due to the era and market segment. Designed to meet prevailing safety standards of the early 1990s.
Active Features
Active Features:
Front disc brakes, rear drum brakes, power-assisted brakes (optional on some trims).
Passive Features
Passive Features:
Seat belts (front and rear), reinforced body structure.
Brakes Front
Brakes Front:
Ventilated Disc Brakes
Brakes Rear
Brakes Rear:
Drum Brakes
💡 Technology Features
Infotainment
Infotainment System:
Basic factory fitted radio/cassette player. Options may include upgraded speakers.
Driver Assistance
Driver Assistance Features:
Minimal. Primarily standard braking systems. ABS was an option on higher trims or specific markets.
Connectivity
Connectivity Options:
None (pre-dating modern connectivity standards).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 km (4,500 - 6,000 miles) or 6-12 months, depending on driving conditions and oil type. Check manual for specific recommendation.
Air Filter Replacement:
Recommended every 15,000 - 20,000 km (9,000 - 12,000 miles) or as needed based on inspection.
Spark Plug Replacement:
Typically every 30,000 - 40,000 km (18,000 - 24,000 miles).
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 is common. Refer to manual for precise viscosity and API service classification.
Coolant Type:
Ethylene Glycol based, typically a 50/50 mix with distilled water. Ensure it meets Mazda specifications for this era.
Brake Fluid Type:
DOT 3 or DOT 4.
Transmission Fluid Type Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Type Automatic:
Dexron II or equivalent automatic transmission fluid (ATF).
Known Issues
Known Issues:
Corrosion on body panels (especially wheel arches and sills), minor electrical gremlins, potential wear in suspension bushings and ball joints, aging cooling system components (radiator, hoses), clutch wear on manual transmissions, carburetor issues on older models.
Fluid Capacities
Engine Oil Capacity:
Approx. 3.5 - 4.0 Liters (3.7 - 4.2 US Quarts) with filter change. Refer to manual.
Coolant Capacity:
Approx. 5.0 Liters (5.3 US Quarts). Refer to manual.
Fuel Tank Capacity:
Approx. 40 Liters (10.6 US Gallons).
Filter Part Numbers
Oil Filter Part Number:
Commonly Mazda part numbers such as B6S7-14-302 or equivalent aftermarket.
Air Filter Part Number:
Commonly Mazda part numbers such as B25D-13-215 or equivalent aftermarket.
Timing Belt Replacement
Timing Belt Replacement:
Recommended replacement interval is typically around 90,000-100,000 km (56,000-62,000 miles). Crucial for B-series engines.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mazda has a long history of producing reliable and often driver-focused vehicles, known for innovation in compact car design and rotary engine technology (though not present in the 121).
Model Evolution
Model Evolution:
The second generation (DB) Mazda 121, also known as the Mazda Autozam Revue in Japan, marked a significant design departure from its predecessor. It featured a more modern, albeit distinctive, wedge-shaped hatchback body style.
Production
Production Years:
1990-1995
Manufacturing Locations:
Primarily manufactured in Japan and also assembled in other Mazda facilities globally.
Design Era
Design Era:
Early 1990s compact car design language, known for its aerodynamic wedge profile and distinctive front grille/headlight treatment.
Chassis Code
Chassis Code:
DB1
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