Mazda RX2 1970-1978 All Service Manual Repair

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The Mazda RX-2, produced between 1970 and 1978, represents a significant chapter in automotive history, distinguished by its innovative Wankel rotary engine. This compact sports sedan and coupe offered a unique driving experience, characterized by smooth power delivery and a distinctive engine note, setting it apart from its contemporaries. The RX-2's sleek, sporty styling, often drawing praise for its European-influenced aesthetics, further cemented its appeal to enthusiasts seeking performance and individuality in the compact car segment. The brand's pioneering commitment to rotary engine technology, evident in models like the RX-2, established the brand's reputation for engineering prowess and a focus on driving dynamics. This comprehensive service and repair manual provides essential information for the maintenance and restoration of your RX-2 (S102A). Covering the period from 1970 to 1978, this manual details the operation, disassembly, and assembly of the 10A rotary engine, along with its fuel, ignition, and cooling systems. It also includes procedures for the transmission, drivetrain, suspension, steering, braking systems, and electrical components, as well as body and interior work. With in-depth troubleshooting guides, diagnostic procedures, torque specifications, and detailed wiring diagrams, this manual is an indispensable resource for owners and technicians aiming to preserve the unique character and performance of their classic rotary vehicle. 🏷️ Basic Information Identification Make: Mazda Model: RX-2 Model Code: S102A (Coupe/Sedan) Generation Generation Designation: First Generation Codes Chassis Codes: S102A Engine Codes: 10A 👋 Introduction Market Position Market Segment: Compact sports sedan/coupe, targeting a more performance-oriented buyer than typical mainstream sedans of the era. Unique Selling Proposition: Wankel rotary engine offering smooth power delivery and a distinctive engine note, coupled with Mazda's characteristic sporty handling. Competitive Analysis Key Competitors: Toyota Corolla Levin/Sprinter Trueno, Datsun Sunny/1200, Honda Civic (later in the period), European compact sports cars. Key Features Vehicle Rotary Engine Advantage: Compact size, fewer moving parts than piston engines, high power-to-weight ratio, smooth operation. Styling: Sleek, sporty coupe and sedan designs, often praised for their European-influenced aesthetics. Key Features Manual Manual Value Proposition: Empowers owners to maintain and repair their classic rotary Mazda, preserving its unique character and value. 📋 Manual Details Coverage Areas Years Covered: 1970-1978 Body Styles Covered: Coupe, Sedan Regions Covered: Global (primarily for markets where RX-2 was sold) Page Count Estimated Page Count: Likely extensive, typical service manuals for this era exceed 500 pages. Manual Type Manual Type: Comprehensive Service and Repair Manual Language Language: English (assuming based on product description context) Format Format: Downloadable Digital Format (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Rotary engine (10A) operation, disassembly, assembly, troubleshooting, component specifications, cooling system, lubrication system. Fuel System: Carburetor(s) (e.g., Hitachi), fuel pump, fuel lines, fuel tank, emission control systems. Ignition System: Distributor, ignition coils, spark plugs, timing specifications, electronic ignition components (if applicable to later models). Transmission Manual: Manual gearbox (e.g., 4-speed or 5-speed), clutch operation, disassembly, assembly, fluid specifications. Transmission Automatic: Optional automatic transmission (if available), operation, service procedures, fluid specifications. Drivetrain: Rear-wheel drive system, driveshaft, differential, axle shafts, wheel bearings. Suspension: Front suspension (e.g., independent strut), rear suspension (e.g., leaf springs or live axle), shock absorbers, springs, bushings, alignment specifications. Steering: Steering column, steering gear (e.g., recirculating ball), tie rods, power steering system (if equipped), lubrication. Brakes Front: Disc brakes (common for this era), brake calipers, pads, rotors, brake lines, master cylinder. Brakes Rear: Drum brakes, brake shoes, drums, wheel cylinders, brake lines, master cylinder. Electrical System Charging: Alternator, voltage regulator, battery, wiring diagrams for charging circuit. Electrical System Starting: Starter motor, starter solenoid, ignition switch, wiring diagrams for starting circuit. Lighting System: Headlights, taillights, brake lights, turn signals, interior lights, wiring diagrams. Instrumentation: Dashboard instruments, gauges, warning lights, speedometer, tachometer, wiring. Body Exterior: Body panel removal/installation, doors, hood, trunk lid, bumpers, glass, seals, trim. Body Interior: Seat removal/installation, dashboard removal, interior trim panels, carpeting, headliner. HVAC: Heating system, ventilation, defroster, air conditioning (if equipped), blower motor, controls. Emission Controls: PCV system, exhaust gas recirculation (EGR), air injection system (if applicable), troubleshooting emission-related issues. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, fluid level checks and top-offs, lubrication points. Major Engine Repairs: Engine overhaul, apex seal replacement, rotor housing machining, porting inspection. Transmission Overhaul: Disassembly, inspection, repair, and reassembly of manual and automatic transmissions. Brake System Service: Brake pad/shoe replacement, rotor/drum resurfacing or replacement, brake line bleeding, master cylinder overhaul. Suspension Component Replacement: Shock absorber, strut, ball joint, tie rod end, control arm bushing replacement. Steering System Repair: Steering gear adjustment and repair, power steering pump and hose replacement. Electrical Troubleshooting: Diagnosis and repair of common electrical faults using wiring diagrams. Body Panel Alignment: Adjustment of doors, hood, and trunk for proper fit and sealing. Interior Trim Restoration: Removal and reinstallation of interior components for cleaning or repair. Carburetor Adjustment And Rebuild: Detailed procedures for cleaning, rebuilding, and adjusting the...

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Typ: Car

Anbieter:

Art.-Nr: 94067

Sammlungen: ALL Mazda

Verfügbarkeit: Auf Lager

Stichworte: 1970 1971 1972 1973 1974 1975 1976 1977 1978 Car Cars Mazda Misc RX2

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Model Code:

S102A (Coupe/Sedan)

Generation

Generation Designation:

First Generation

Codes

Chassis Codes:

S102A

Engine Codes:

👋 Introduction

Market Position

Market Segment:

Compact sports sedan/coupe, targeting a more performance-oriented buyer than typical mainstream sedans of the era.

Unique Selling Proposition:

Wankel rotary engine offering smooth power delivery and a distinctive engine note, coupled with Mazda's characteristic sporty handling.

Competitive Analysis

Key Competitors:

Toyota Corolla Levin/Sprinter Trueno, Datsun Sunny/1200, Honda Civic (later in the period), European compact sports cars.

Key Features Vehicle

Rotary Engine Advantage:

Compact size, fewer moving parts than piston engines, high power-to-weight ratio, smooth operation.

Styling:

Sleek, sporty coupe and sedan designs, often praised for their European-influenced aesthetics.

Key Features Manual

Manual Value Proposition:

Empowers owners to maintain and repair their classic rotary Mazda, preserving its unique character and value.

📋 Manual Details

Coverage Areas

Years Covered:

1970-1978

Body Styles Covered:

Coupe, Sedan

Regions Covered:

Global (primarily for markets where RX-2 was sold)

Page Count

Estimated Page Count:

Likely extensive, typical service manuals for this era exceed 500 pages.

Manual Type

Manual Type:

Comprehensive Service and Repair Manual

Language

Language:

English (assuming based on product description context)

Format

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Rotary engine (10A) operation, disassembly, assembly, troubleshooting, component specifications, cooling system, lubrication system.

Fuel System:

Carburetor(s) (e.g., Hitachi), fuel pump, fuel lines, fuel tank, emission control systems.

Ignition System:

Distributor, ignition coils, spark plugs, timing specifications, electronic ignition components (if applicable to later models).

Transmission Manual:

Manual gearbox (e.g., 4-speed or 5-speed), clutch operation, disassembly, assembly, fluid specifications.

Transmission Automatic:

Optional automatic transmission (if available), operation, service procedures, fluid specifications.

Drivetrain:

Rear-wheel drive system, driveshaft, differential, axle shafts, wheel bearings.

Suspension:

Front suspension (e.g., independent strut), rear suspension (e.g., leaf springs or live axle), shock absorbers, springs, bushings, alignment specifications.

Steering:

Steering column, steering gear (e.g., recirculating ball), tie rods, power steering system (if equipped), lubrication.

Brakes Front:

Disc brakes (common for this era), brake calipers, pads, rotors, brake lines, master cylinder.

Brakes Rear:

Drum brakes, brake shoes, drums, wheel cylinders, brake lines, master cylinder.

Electrical System Charging:

Alternator, voltage regulator, battery, wiring diagrams for charging circuit.

Electrical System Starting:

Starter motor, starter solenoid, ignition switch, wiring diagrams for starting circuit.

Lighting System:

Headlights, taillights, brake lights, turn signals, interior lights, wiring diagrams.

Instrumentation:

Dashboard instruments, gauges, warning lights, speedometer, tachometer, wiring.

Body Exterior:

Body panel removal/installation, doors, hood, trunk lid, bumpers, glass, seals, trim.

Body Interior:

Seat removal/installation, dashboard removal, interior trim panels, carpeting, headliner.

HVAC:

Heating system, ventilation, defroster, air conditioning (if equipped), blower motor, controls.

Emission Controls:

PCV system, exhaust gas recirculation (EGR), air injection system (if applicable), troubleshooting emission-related issues.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, fluid level checks and top-offs, lubrication points.

Major Engine Repairs:

Engine overhaul, apex seal replacement, rotor housing machining, porting inspection.

Transmission Overhaul:

Disassembly, inspection, repair, and reassembly of manual and automatic transmissions.

Brake System Service:

Brake pad/shoe replacement, rotor/drum resurfacing or replacement, brake line bleeding, master cylinder overhaul.

Suspension Component Replacement:

Shock absorber, strut, ball joint, tie rod end, control arm bushing replacement.

Steering System Repair:

Steering gear adjustment and repair, power steering pump and hose replacement.

Electrical Troubleshooting:

Diagnosis and repair of common electrical faults using wiring diagrams.

Body Panel Alignment:

Adjustment of doors, hood, and trunk for proper fit and sealing.

Interior Trim Restoration:

Removal and reinstallation of interior components for cleaning or repair.

Carburetor Adjustment And Rebuild:

Detailed procedures for cleaning, rebuilding, and adjusting the Hitachi carburetors used on the 10A engine.

Rotary Engine Specific Procedures:

Apex seal lubrication, side seal checks, rotor housing lapping (if applicable), intake/exhaust port timing checks.

Technical Depth

Depth Of Information:

Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts.

Diagnostic Procedures:

Step-by-step troubleshooting guides for various systems, including common symptoms and their causes.

Torque Specifications:

Detailed torque values for critical fasteners throughout the vehicle.

Clearances And Tolerances:

Precise measurements for engine components, bearings, and other critical areas.

Wiring Diagrams:

Complete and detailed wiring diagrams for all electrical systems, color-coded for clarity.

Special Tools:

Identification and usage instructions for any specialized tools required for specific repairs.

📊 Manual Specifications

File Format

File Format:

PDF Quality:

High-resolution scans suitable for digital viewing and printing.

Searchable Text:

Likely includes OCR (Optical Character Recognition) for text searchability.

Print Quality

Print Suitability:

Printable pages for offline use in a workshop environment.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Wankel Rotary Engine

Engine Code:

Displacement Cc:

491 cc per rotor (total 982 cc equivalent displacement)

Displacement Ci:

60.0 cu in per rotor (total 120.0 cu in equivalent displacement)

Rotor Configuration:

Two-rotor

Performance

Horsepower Hp Ps:

Approximately 110-120 hp (SAE Gross) depending on year and market.

Torque Lb-Ft:

Approximately 120-130 lb-ft (SAE Gross) depending on year and market.

Fuel System

Carburetion:

Twin Hitachi downdraft carburetors (e.g., HMB-32/32)

Fuel Type:

Unleaded gasoline (early models may have been designed for leaded).

Oil Type Recommendation:

Special rotary engine oil (e.g., API SF or SG rated, with specific additive packages to combat apex seal wear).

🔧 Transmission

Standard

Transmission Type Standard:

4-speed Manual Transmission

Optional

Transmission Type Optional:

3-speed Automatic Transmission (Mazda's own design or potentially sourced)

Features

Clutch Type:

Dry single-plate clutch

Transmission Fluid Type:

API GL-4 gear oil (e.g., SAE 80W-90)

📐 Dimensions

Exterior

Length Mm:

Approx. 4050-4100 mm (Coupe/Sedan)

Width Mm:

Approx. 1600-1620 mm

Height Mm:

Approx. 1350-1380 mm (Coupe), 1390-1410 mm (Sedan)

Wheelbase Mm:

Approx. 2300-2320 mm

Front Track Mm:

Approx. 1300 mm

Rear Track Mm:

Approx. 1290 mm

Weights

Curb Weight Kg:

Approx. 950-1050 kg

Gross Vehicle Weight Rating Kg:

Approx. 1300-1400 kg

🛡️ Safety Features

Ratings

Crash Test Ratings:

No official crash test ratings available from modern agencies for this era and model.

Active Features

Braking System:

Front disc brakes, rear drum brakes. Dual-circuit hydraulic system.

Steering Design:

Recirculating ball steering system, often with manual assist.

Passive Features

Seat Belts:

Standard lap belts, optional shoulder belts depending on year and market.

Body Construction:

Unitized body construction with reinforced pillars and doors for the era.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio, often with an optional 8-track player or cassette deck.

Speaker Configuration:

Typically two or four speakers.

Driver Assistance

Anti-lock Braking System (ABS) was not a standard feature on most RX-2 models of this era.

Power Steering:

Optional on many models, not standard across the board.

Connectivity

Connectivity Features:

No modern connectivity features (Bluetooth, USB, etc.) are present.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-5,000 miles or 3-6 months (Rotary engines require more frequent oil changes and often consume oil by design).

Oil Filter Replacement:

With every oil change.

Spark Plug Check And Replacement:

Check every 15,000 miles, replace as needed (rotary-specific plugs may be required).

Air Filter Cleaning Or Replacement:

Check every 15,000 miles, replace as needed.

Transmission Fluid Change:

Every 20,000-30,000 miles or 2-3 years.

Rear Axle Fluid Change:

Every 20,000-30,000 miles or 2-3 years.

Brake Fluid Flush:

Every 2-3 years to prevent moisture absorption and corrosion.

Fluid Specifications

Engine Oil Capacity Liters:

Approx. 4.5-5.0 liters (including oil injection system, if applicable).

Transmission Fluid Capacity Liters:

Approx. 2.0-2.5 liters (manual), 4.0-4.5 liters (automatic).

Rear Axle Fluid Capacity Liters:

Approx. 1.0-1.3 liters.

Coolant Type:

Ethylene glycol-based antifreeze mixed with water (50/50 ratio).

Known Issues

Apex Seal Wear:

Premature wear or failure of apex seals can lead to loss of compression, rough running, and smoking. Proper maintenance and engine warm-up are crucial.

Carburetor Issues:

Carburetors can be prone to clogging and require regular cleaning and adjustment, especially with fuel quality variations over time.

Rotary Oil Consumption:

Rotary engines inherently consume some oil for lubrication of apex seals; excessive consumption can indicate seal wear.

Thermal Issues:

Rotary engines can be sensitive to overheating. Ensuring the cooling system is in perfect condition is vital.

Electrical Gremlins:

As with many cars of this era, age-related degradation of wiring and components can lead to intermittent electrical issues.

📚 Vehicle History

Brand Heritage

Mazda Rotary Pioneering:

Mazda's commitment to the Wankel rotary engine, starting with the Cosmo Sport and continuing with models like the RX-2, RX-3, RX-4, and RX-7.

Model Evolution

Introduction Year:

Facelifts And Updates:

Minor cosmetic and feature updates throughout its production run, with some grille and trim changes.

Production

Production Years:

1970-1978

Manufacturing Location:

Japan

Sales Performance Context:

While not a global blockbuster, the RX-2 was a significant model in establishing Mazda's performance credentials and showcasing the rotary engine's potential in the compact car segment.

🏆 Awards & Recognition

Recognitions

Rotary Engine Recognition:

The Wankel rotary engine itself has received numerous accolades over its development and production for its innovative design and performance characteristics.

Ratings

Consumer Reports Era:

Reviews from the period often highlighted the RX-2's spirited performance and unique engine, while also noting the learning curve for maintenance and potential for higher running costs compared to piston-engined rivals.

Certifications

Emission Certifications:

Met the emission standards of the respective markets for the years of production, often utilizing early forms of emission control technology.