Mazda RX-2 RX2 616 SEDAN COUPE Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-2 / 616 Body Styles Covered: Sedan, Coupe Codes Internal Model Codes: FA (Coupe), FB (Sedan) 👋 Introduction Market Position Segment: Compact/Subcompact Sports...

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Type: Car

Vendor:

Sku: 251218

Tags: 616 COUPE 616 SEDAN Car Cars Mazda RX Models RX-2 RX2

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

RX-2 / 616

Body Styles Covered:

Sedan, Coupe

Codes

Internal Model Codes:

FA (Coupe), FB (Sedan)

👋 Introduction

Market Position

Segment:

Compact/Subcompact Sports Sedan and Coupe

Target Audience:

Enthusiasts, DIY mechanics, restoration specialists

Competitive Analysis

Key Competitors:

Datsun (Nissan) 510, Toyota Corolla, Honda Civic (early generations)

Key Features

Unique Selling Proposition:

Rotary engine technology offering a unique driving experience and distinctive sound

Design Philosophy:

Sporty, compact, and reliable Japanese automotive engineering

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Workshop/Service Manual

Page Count

Page Count:

Manual Type

Manual Type:

Factory Workshop Manual

Language

Language:

English

Format

Format:

Printed Document

File Format:

Likely physical print (as described), potentially scanned PDF for digital versions

Print Quality:

Factory original print quality (typically good clarity)

Binding Type:

Typically perfect bound or stapled for factory manuals

Paper Type:

Durable paper stock suitable for workshop environments

📖 Manual Coverage

Systems Covered

Engine System:

Rotary Engine (12A) - Theory of Operation, Disassembly, Assembly, Troubleshooting, Specifications

Fuel System:

Carburetor (likely Hitachi or Mikuni), Fuel Pump, Lines, Tank, Specifications, Adjustment, Troubleshooting

Ignition System:

Distributor, Ignition Coils, Spark Plugs, Timing Adjustment, Troubleshooting

Cooling System:

Radiator, Water Pump, Thermostat, Hoses, Fan, Specifications, Troubleshooting

Exhaust System:

Manifolds, Pipes, Muffler, Emission Controls (if applicable), Troubleshooting

Transmission Manual:

4-Speed and 5-Speed Manual Transmissions - Disassembly, Assembly, Fluid Specifications, Troubleshooting

Transmission Automatic:

Automatic Transmission (if applicable) - Disassembly, Assembly, Fluid Specifications, Troubleshooting

Drivetrain:

Driveshaft, Universal Joints, Rear Axle, Differential - Disassembly, Assembly, Fluid Specifications, Troubleshooting

Suspension Front:

MacPherson Struts, Control Arms, Bushings, Springs, Shock Absorbers, Specifications, Alignment Procedures

Suspension Rear:

Leaf Springs or Coil Springs, Trailing Arms, Panhard Rod (depending on model), Shock Absorbers, Specifications

Steering System:

Steering Gearbox, Tie Rods, Steering Column, Power Steering (if equipped), Specifications, Troubleshooting

Brake System:

Front Disc Brakes, Rear Drum Brakes, Master Cylinder, Brake Lines, Parking Brake, Specifications, Bleeding Procedures

Electrical System:

Battery, Alternator, Starter Motor, Wiring Diagrams, Fuses, Relays, Lights, Switches, Gauges, Troubleshooting

Body And Chassis:

Body Panel Removal/Installation, Doors, Hood, Trunk, Glass, Seats, Interior Trim, Chassis Components, Specifications

HVAC System:

Heater Core, Blower Motor, Controls, Air Ducts, Specifications, Troubleshooting

Procedures Included

Routine Maintenance:

Oil Changes, Filter Replacements, Spark Plug Gapping/Replacement, Fluid Level Checks, Lubrication

Engine Overhaul:

Complete engine disassembly, inspection, component replacement, and reassembly procedures

Transmission Repair:

Manual and automatic transmission rebuilds, clutch replacement, gear selection adjustments

Suspension And Steering Repair:

Ball joint replacement, tie rod end replacement, shock/strut replacement, steering gearbox overhaul

Brake System Overhaul:

Brake pad/shoe replacement, caliper/wheel cylinder rebuild, master cylinder replacement, brake line replacement

Electrical Troubleshooting:

Diagnosis of electrical faults using wiring diagrams, component testing, and circuit analysis

Bodywork And Trim:

Replacement of body panels, door mechanisms, glass sealing, interior trim panel removal and installation

Wheel Alignment:

Detailed specifications and procedures for adjusting camber, caster, and toe angles

Carburetor Adjustment:

Idle speed, air-fuel mixture, and choke adjustments for optimal performance and emissions

Diagnostic Procedures:

Step-by-step guides for identifying and resolving common and complex issues

Technical Depth

Depth Of Coverage:

Comprehensive - from basic maintenance to complete engine and drivetrain rebuilds

Diagnostic Capability:

Advanced diagnostic trees and troubleshooting flowcharts for identifying root causes of problems

Rebuild Procedures:

Detailed instructions with torque specifications and clearances for rebuilding major components

Wiring Diagrams:

Complete, often color-coded, wiring schematics for all vehicle systems

Schematics:

Hydraulic, pneumatic, and vacuum schematics where applicable

⚙️ Engine Specifications

Primary Engine

Engine Type:

Mazda Rotary (Wankel)

Engine Code:

Displacement:

1146 cc (approx. 2 x 573 cc rotor chambers)

Performance

Horsepower Gross:

Approx. 90-100 HP (depending on market and emissions controls)

Torque Gross:

Approx. 90-100 lb-ft (depending on market and emissions controls)

Fuel System

Fuel Delivery:

Single or Twin Carburetor (e.g., Hitachi DCAS, Mikuni Solex)

Fuel Type:

Unleaded gasoline (depending on year and market regulations)

Technical Details

Rotor Housing Material:

Typically aluminum alloy with chrome plating

Apex Seals:

Crucial wear item, typically made of ceramic or carbon composites

Oil Injection:

Separate oil injection system for lubrication of apex and side seals

🔧 Transmission

Standard

Transmission Type:

4-speed manual

Optional

Transmission Type Optional:

5-speed manual, 3-speed automatic (less common)

Features

Clutch Type:

Single dry plate

Fluid Specifications

Manual Transmission Fluid:

API GL-4 SAE 75W-90 or SAE 80W-90 gear oil (check manual for exact specification)

Automatic Transmission Fluid:

Dexron II or equivalent (if equipped with automatic transmission)

📐 Dimensions

Exterior

Wheelbase:

Approx. 97.0 inches (2465 mm)

Length:

Approx. 166.7 inches (4235 mm) for Coupe, 168.7 inches (4285 mm) for Sedan

Width:

Approx. 64.0 inches (1625 mm)

Height:

Approx. 52.0 inches (1320 mm) for Coupe, 53.7 inches (1365 mm) for Sedan

Weights

Curb Weight:

Approx. 2100-2300 lbs (950-1045 kg) depending on body style and equipment

Gross Vehicle Weight Rating:

Check vehicle specific placard, typically around 3000 lbs (1360 kg)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited data available for this era; modern safety standards not applicable.

Active Features

Braking:

Front disc, rear drum with single-circuit hydraulic system (dual circuit introduced later)

Passive Features

Seatbelts:

Standard lap belts, optional shoulder belts in some markets/trims

Body Structure:

Unibody construction with integrated safety cage elements

💡 Technology Features

Infotainment

Radio:

Basic AM/FM radio, potentially with cassette player in later models.

Gauges:

Speedometer, tachometer, fuel gauge, coolant temperature, oil pressure (basic analogue)

Driver Assistance

Braking Assist:

Traction Control:

Connectivity

Auxiliary Inputs:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 miles (5,000 km) or 3 months, whichever comes first.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Spark Plugs:

Inspect every 15,000 miles, replace as needed. Specific rotary plugs required.

Transmission Fluid Change:

Every 30,000 miles (48,000 km) or 24 months.

Rear Axle Fluid Change:

Every 30,000 miles (48,000 km) or 24 months.

Fluid Specifications

Engine Oil Capacity:

Approx. 4.0 - 4.5 US quarts (3.8 - 4.3 liters) with filter change (check manual for exact)

Engine Oil Viscosity:

10W-30 or 20W-50, depending on climate (check manual for exact recommendation).

Coolant Capacity:

Approx. 5.5 - 6.0 US quarts (5.2 - 5.7 liters)

Brake Fluid:

DOT 3 or DOT 4 glycol-based brake fluid

Known Issues

Rotary Engine Wear:

Apex seal wear and housing scoring are common due to the nature of the rotary design; requires careful maintenance and proper oiling.

Carburetor Issues:

Degradation of rubber components, clogging, and tuning difficulties.

Chassis Corrosion:

Rust and corrosion can be prevalent in areas exposed to salt and moisture.

Electrical Gremlins:

Aging wiring and connectors can lead to intermittent issues in lighting and accessories.

📚 Vehicle History

Brand Heritage

Mazda Rotary Pioneering:

Mazda's commitment to rotary engine development, starting with the Cosmo Sport.

Model Evolution

Predecessor:

Mazda R100 (Cosmo Sport)

Successor:

Mazda RX-3 (Savy), Mazda RX-4 (Capella)

Production

Production Years:

1971-1978 (approximate, varies by market)

Manufacturing Location:

Japan

Model Notes

Popularity:

Gained a niche following for its sporty handling and unique rotary powertrain.