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Mazda RX-7 Complete Workshop Repair Manual 1980-1985

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: First Generation (SA/FB) Model Years Covered: 1980, 1981, 1982, 1983, 1984, 1985 👋 Introduction Market Position Segment: Compact Sports Car Target...
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Mazda RX-7 Complete Workshop Repair Manual 1980-1985
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
First Generation (SA/FB)
Model Years Covered:
1980, 1981, 1982, 1983, 1984, 1985
👋 Introduction
Market Position
Segment:
Compact Sports Car
Target Audience:
Enthusiasts, DIY mechanics, classic car owners
Competitive Analysis
Key Competitors:
Datsun Z-car series, Toyota Supra, Porsche 944, Fiat X1/9
Key Features
Unique Selling Proposition:
Rotary engine technology, lightweight chassis, sporty handling, distinctive styling
Manual Benefit:
Empowers owners to perform comprehensive maintenance and repairs, saving significant costs and preserving vehicle value.
📋 Manual Details
Coverage Areas
Countries Of Sale:
Global (primarily North America and Japan)
Regional Variants Covered:
US, Canadian, European, and Japanese specifications
Page Count
Estimated Pages:
Thousands (Digital format allows for extensive detail)
Manual Type
Type:
Workshop Service & Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PC, Mac, Tablets, Smartphones)
📖 Manual Coverage
Systems Covered
Engine:
Rotary Engine (12A, 13B), Lubrication, Cooling, Fuel Injection (early models may have Carburetion), Ignition, Emissions Control
Transmission:
Manual Transmission (4-speed, 5-speed), Automatic Transmission (optional), Drivetrain, Clutch
Brakes:
Front Disc Brakes, Rear Drum Brakes (later models may have rear discs), Parking Brake System, Hydraulic System
Suspension:
Front MacPherson Struts, Rear Watt's Linkage or Live Axle (depending on specific model/year), Steering System (Power Steering optional)
Electrical:
Battery, Charging System, Starting System, Lighting, Instrumentation, Wiper System, Horn, Fuses and Relays, Wiring Diagrams
Body:
Body Structure, Exterior Panels, Doors, Hood, Trunk, Glass, Interior Trim, Seats, Safety Belts
HVAC:
Heating, Ventilation, Air Conditioning (if equipped)
Fuel:
Fuel Tank, Fuel Lines, Fuel Pump, Fuel Filter (Carburetor or Fuel Injection)
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Spark Plug Replacement, Belt Adjustments, Battery Care
Troubleshooting:
Diagnostic Procedures, Common Faults, Symptom Analysis, Error Code Interpretation (if applicable)
Repair:
Engine Rebuilds, Transmission Overhaul, Brake System Repairs, Suspension Component Replacement, Electrical Component Repair, Body Panel Repair
Adjustment:
Carburetor Tuning, Ignition Timing, Clutch Adjustment, Brake Adjustment
Disassembly Assembly:
Component Removal and Installation for all major systems
Technical Depth
Depth:
Comprehensive Professional Level (from basic maintenance to complete engine/transmission rebuilds)
Diagnostic Tools:
Procedures for using basic diagnostic tools and interpreting system feedback
Special Tools:
Identification and usage of specialized tools required for specific procedures
📊 Manual Specifications
File Format
File Type:
PDF (Searchable, Printable)
Print Quality
Quality:
High-resolution scans, clear diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Mazda Wankel Rotary
Engine Codes:
12A, 13B (for later models within the range, though 12A is more prevalent in early SA/FB)
Displacement Cc:
1146cc (12A), 1308cc (13B)
Rotor Housing Design:
Unique epitrochoid shape
Performance
Horsepower Hp Approx:
100-135 hp (12A variations)
Torque Lb Ft Approx:
105-115 lb-ft (12A variations)
Fuel System
Fuel Delivery Early:
Carbureted (e.g., Hitachi, Mikuni twin-choke)
Fuel Delivery Late:
Electronic Fuel Injection (EFI) introduced on some models (e.g., GSL-SE with 13B)
Fuel Type:
Unleaded gasoline
Engine Management
Ignition System:
Distributor-based, CDI (Capacitor Discharge Ignition) on later models
Oil System:
Integrated oil metering pump (often requires premixing with fuel in some regions/years for apex seal lubrication)
🔧 Transmission
Standard
Type Standard:
4-speed manual (early), 5-speed manual (later)
Optional
Type Optional:
3-speed automatic
Features
Drivetrain:
Rear-Wheel Drive (RWD)
Clutch Type:
Single dry plate, hydraulically operated
Gear Ratios:
Specific ratios vary by transmission model and year, detailed in manual.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or 80W-90 (check specific model recommendations)
📐 Dimensions
Exterior
Length Mm:
Approx. 4200-4300 mm
Width Mm:
Approx. 1650-1700 mm
Height Mm:
Approx. 1280-1310 mm
Wheelbase Mm:
Approx. 2400 mm
Weights
Curb Weight Kg Approx:
1050-1200 kg
Gross Vehicle Weight Rating Kg:
Refer to vehicle plate or manual
Cargo
Cargo Volume Liters:
Not a primary focus, but includes rear storage area.
🛡️ Safety Features
Ratings
Safety Standards Era:
Designed to meet safety regulations of the late 1970s and early 1980s.
Active Features
Brakes:
Front-ventilated disc brakes, Rear drum brakes (power assisted)
Suspension Handling:
Focus on balanced handling for active safety
Passive Features
Seat Belts:
3-point front seat belts, lap belts in rear (if applicable)
Rollover Protection:
Reinforced A-pillars and roof structure
Crash Structure:
Energy-absorbing front and rear crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with cassette player (optional features like equalizers or multiple speakers may have been available).
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not a standard feature and became more common on later models or performance variants (e.g., GSL-SE).
Cruise Control:
Optional on higher trim levels.
Connectivity
Connectivity Features:
None (This era predates modern infotainment and connectivity)
🔧 Maintenance
Service Intervals
Oil Change Interval Km Miles:
Every 5,000-7,500 km or 3,000-5,000 miles (recommend checking manual for specific model and oil type)
Air Filter Replacement Km Miles:
Every 15,000-25,000 km or 10,000-15,000 miles
Spark Plug Replacement Km Miles:
Every 30,000-50,000 km or 20,000-30,000 miles (depending on plug type)
Timing Belt Replacement Km Miles:
N/A (Rotary engines do not have timing belts, they use a chain or gear drive for rotor drive)
Fluid Specifications
Engine Oil Type:
Rotary-specific oil or high-quality synthetic/conventional oil meeting Mazda specifications (e.g., SAE 10W-30, 10W-40, 20W-50 depending on climate).
Engine Oil Capacity Liters:
Approx. 4.5-5.5 liters (including filter)
Coolant Type:
Ethylene Glycol based antifreeze, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific recommendation)
Power Steering Fluid Type:
ATF Dexron II or equivalent (if equipped with power steering)
Known Issues
Rotary Apex Seals:
Wear or failure of apex seals, leading to compression loss and rough running. Crucial for rotary engine health.
Carburetor Issues:
Clogging, vacuum leaks, and adjustment drift in carbureted models.
Oil Consumption:
Normal for rotary engines, but excessive consumption can indicate seal issues.
Chassis Rust:
Common on older vehicles, particularly in areas exposed to salt and moisture.
Electrical Gremlins:
Age-related issues with wiring, connectors, and grounds.
📚 Vehicle History
Brand Heritage
Mazda Rotary Pioneer:
Mazda's long-standing commitment to rotary engine technology, dating back to the Cosmo.
Model Evolution
Rx-7 Lineage:
First generation (SA/FB) established the RX-7 as Mazda's premier sports coupe.
Design Inspiration:
Influenced by classic European sports cars, with a focus on aerodynamics and weight distribution.
Production
Production Years:
1978-1985 (SA/FB generation)
Production Locations
Assembly Plants:
Japan
Sales Figures
Global Sales Approx:
Over 470,000 units for the SA/FB generation.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The RX-7 (including the FB generation) was frequently recognized by automotive publications like Car and Driver for its performance and handling.
Ratings
Handling Reputation:
Consistently praised for its balanced chassis and engaging driving dynamics.
Certifications
Automotive Journalism Mentions:
Widely featured in automotive magazines for its unique rotary engine and sporting credentials.
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