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Mazda RX-7 1978 1979 1980 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: First Generation (SA/FB) Codes Chassis Code: SA22C 👋 Introduction Market Position Segment: Compact Sports Car Target Audience: Enthusiasts, DIY Mechanics, Restoration...
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Mazda RX-7 1978 1979 1980 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
First Generation (SA/FB)
Codes
Chassis Code:
SA22C
👋 Introduction
Market Position
Segment:
Compact Sports Car
Target Audience:
Enthusiasts, DIY Mechanics, Restoration Specialists
Competitive Analysis
Key Competitors:
Datsun Z-series, Toyota Celica, Ford Capri, Fiat X1/9
Key Features
Distinguishing Factor:
Rotary Engine technology, lightweight chassis, sporty handling
Value Proposition:
Provides in-depth technical guidance for maintaining and repairing the iconic first-generation RX-7
📋 Manual Details
Coverage Areas
Model Years Covered:
1978, 1979, 1980
Region Specific Coverage:
General (assumed global, specific regional variations may exist)
Page Count
Total Pages:
155
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English (presumed, standard for most workshop manuals)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Rotary Engine (12A) - Theory of Operation, Disassembly, Assembly, Troubleshooting, Diagnostics, Lubrication, Cooling System
Fuel System:
Carburetion (Nikki or similar), Fuel Pump, Fuel Lines, Fuel Tank, Emission Control Systems (Air Injection, EGR)
Ignition System:
Distributor, Ignition Coils, Spark Plugs, Ignition Timing, Electronic Ignition Components
Drivetrain:
Driveshaft, Rear Axle, Differential, Wheel Bearings
Suspension:
Front Suspension (MacPherson Struts), Rear Suspension (Multi-link), Shock Absorbers, Springs, Bushings, Alignment Specifications
Steering:
Steering Gear, Steering Column, Power Steering System (if equipped), Tie Rods, Ball Joints
Brakes:
Front Disc Brakes, Rear Drum Brakes (typically), Brake Lines, Master Cylinder, Calipers, Wheel Cylinders, Parking Brake System, Brake Fluid Specifications
Electrical System:
Wiring Diagrams, Battery, Alternator, Starter Motor, Lighting System, Fuses, Relays, Gauges, Horn, Wiper System
Body And Chassis:
Body Panel Repair, Doors, Hood, Trunk, Glass, Bumpers, Interior Trim, Chassis Frame, Corrosion Protection
HVAC:
Heating System, Ventilation, Air Conditioning (if equipped), Refrigerant Type, Service Procedures
Transmission
Manual Transmission:
Removal, Installation, Disassembly, Assembly, Fluid Specifications, Troubleshooting
Automatic Transmission:
If applicable for the model years covered - Removal, Installation, Troubleshooting, Fluid Specifications
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Fluid Top-offs, Belt Adjustments, Inspection Procedures
Diagnostics Troubleshooting:
Step-by-step diagnostic flowcharts for common problems, symptom-based troubleshooting guides
Repair Overhaul:
Detailed instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters
Technical Depth
Depth:
Comprehensive, covering routine maintenance to major component overhauls and troubleshooting
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable if OCR'd properly
Print Quality
Quality:
Variable (depends on original scan quality), typically clear for text and diagrams
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Mazda Rotary (Wankel) Engine
Engine Code:
12A
Rotor Displacement:
573 cc per rotor (total 1.15 liters equivalent)
Configuration:
Two-Rotor
Performance
Horsepower:
Approx. 100-110 hp (varies slightly by year and market)
Torque:
Approx. 105-115 lb-ft (varies slightly by year and market)
Fuel System
Carburetion:
Single or Twin Downdraft Carburetors (e.g., Nikki, Solex)
Fuel Type:
Unleaded Gasoline (Octane rating appropriate for performance)
Lubrication
Oil Type:
Specific Rotary Engine Oil (e.g., API SG/SH or equivalent, consult manual for exact specs and viscosity)
Cooling System
Coolant Type:
Ethylene Glycol based antifreeze/coolant mixture (50/50)
🔧 Transmission
Standard
Type:
4-Speed Manual Transmission (early models), 5-Speed Manual Transmission (later models)
Optional
Type:
3-Speed Automatic Transmission
Features
Clutch Type:
Dry Single Plate Clutch
Fluid Specifications
Manual Transmission Fluid:
API GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, consult manual for specific viscosity and capacity)
Automatic Transmission Fluid:
Dexron II or equivalent
📐 Dimensions
Exterior
Body Style:
2-Door Coupe, 2-Door Fastback
Wheelbase:
Approx. 95.7 inches (2430 mm)
Length:
Approx. 163.0 inches (4140 mm)
Width:
Approx. 65.2 inches (1655 mm)
Height:
Approx. 50.6 inches (1285 mm)
Weights
Curb Weight:
Approx. 2200-2400 lbs (1000-1090 kg)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official data available for this era, rely on contemporary automotive reviews and general safety practices of the time.
Active Features
Brakes:
Front ventilated disc brakes, Rear drum brakes
Steering:
Recirculating ball steering (some models with power steering)
Passive Features
Seat Belts:
Three-point seat belts (front)
Construction:
Unibody construction with front and rear crumple zones (design principles of the era)
💡 Technology Features
Infotainment
Radio:
AM/FM radio, often with cassette player (optional or aftermarket)
Gauges:
Tachometer, speedometer, oil pressure, water temperature, voltmeter
Driver Assistance
Features:
Minimal by modern standards; focus on basic driver controls and feedback.
Connectivity
Features:
None (pre-dates modern connectivity)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 3,000-5,000 miles or 6 months, consult manual for specific interval and type of oil
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection
Spark Plugs Service:
Rotary engines require specific plugs, check manual for interval and type (e.g., platinum)
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (consult manual)
Coolant Capacity:
Approx. 5.5-6.0 quarts (5.2-5.7 liters), consult manual
Known Issues
Apex Seals:
Wear and failure of apex seals is a common rotary engine issue; proper maintenance and break-in procedures are critical.
Carburetor Issues:
Tuning difficulties, diaphragm wear, clogging, especially with age.
Oil Consumption:
Rotary engines naturally consume a small amount of oil for lubrication, but excessive consumption can indicate seal wear.
Chassis Corrosion:
Common for vehicles of this age, especially in rust-prone climates.
Electrical Gremlins:
Aging wiring harnesses and components can lead to intermittent electrical faults.
📚 Vehicle History
Brand Heritage
Mazda Rotary:
Mazda's pioneering and continued development of the Wankel rotary engine
Model Evolution
Rx-7 Lineage:
First generation (SA22C) introduced in 1978, established Mazda's reputation in the sports car market.
Production
Production Years:
1978-1985 (SA/FB generation)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Automotive Press:
Praised by automotive journalists for its handling and unique rotary powertrain, contributing to Mazda's performance image.
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