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Mazda 121 (3) (1996-2003) Mazda BT-50 (1) (2006-2011)

Precautions when working with body parts (Mazda 121 (3))

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Since sparks are generated during the welding process, it is necessary to completely disconnect the battery during work (both wires) and securely insulate the removed wires. When working near the battery, it must be removed. For instructions on removal, see Chapter "Electrical equipment".

For body parts, especially those damaged by corrosion, galvanized metal is used. There is no need to remove the zinc layer before welding (clean only when soldering). Increase welding current by 10-30%, use hardened copper electrodes.

Precautions: When welding galvanized steel, toxic zinc oxide is produced, so ensure good ventilation of the workplace.


Neither welding nor soldering may be performed on parts of a charged air conditioning system. This also applies to welding and soldering work on those parts of the vehicle that may heat up the parts of the air conditioning system.

Caution: The refrigerant circuit of the air conditioning system must not be opened. If the refrigerant comes into contact with the skin, frostbite may occur.


When painting in a drying chamber or in a heated area, the vehicle must not be heated above 80°C, otherwise the vehicle's electronic control units may be damaged.

Plastic body protection should be removed in places using a rotating steel brush or it should be heated with a special hair dryer to approximately +180°C and scraped off with a spatula. It should be borne in mind that when burning or heating a material based on polyvinyl chloride, hydrochloric acid is formed, which strongly promotes corrosion, and in addition, harmful vapors are released.

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Mazda 121 (3) » Exterior (external elements)
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General information about the car body
Removal and installation the front bumper and radiator grille
Removal and installation the rear bumper
Removal and installation the inner parts of the front fenders
Removal and installation the front wing
Removal and installation the hood
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Mazda BT-50 (1) (2006-2011) 
  • General information
  • Introduction to guide
  • User manual
  • Maintenance
  • Power unit
  • Engine repair (diesel)
  • Cooling and lubrication system
  • Fuel injection system
  • Intake and exhaust system
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  • Clutch
  • Mechanical gearbox
  • All-wheel drive system
  • Transfer case and gearboxes
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Heating and air conditioning
  • Security system SRS
  • Electrical equipment
  • Equipment and devices
  • Electrical circuits
Mazda 121 (3) (1996-2003) 
  • General information
  • User manual
  • Maintenance
  • Power unit
  • Petrol engine 1.3 l
  • Petrol engine 1.25/1.4 l
  • Diesel engine
  • Lubrication system
  • Cooling system
  • Ignition system
  • Supply system
  • Fuel injection (gasoline)
  • Fuel injection (diesel)
  • Exhaust system
  • Transmission
  • Clutch
  • Car gearbox
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Wheels and tires
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Doors, windows and locks
  • Heating system
  • Electrical equipment
  • Troubleshooting
  • Equipment and devices
  • Lighting system
  • Power devices
  • Electrical circuits
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