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Mazda RX-7 1978-1985 FB Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: FB (First Generation) Model Years Covered: 1978-1985 Codes Chassis Code: SA/FB 👋 Introduction Market Position Target Audience: Do-it-yourselfers (DIY), home mechanics, professional technicians, Mazda enthusiasts Competitive Analysis Value Proposition: Inexpensive alternative to professional repair services, empowers owners to maintain and repair their vehicle Key Features Content Richness: Hundreds of photos, illustrations, diagrams, exploded views, and step-by-step instructions Usability: Easy-to-read text, numbered instructions, bold figure numbers for quick cross-referencing Accessibility: Downloadable PDF format, accessible across multiple devices and operating systems 📋 Manual Details Coverage Areas Primary Coverage: Workshop/Factory Service Repair Secondary Coverage: Maintenance, Diagnostics, Troubleshooting, Repair, Overhaul Page Count Estimated Page Count: Varies by specific edition, but generally comprehensive Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, assembly, component inspection, and rebuilding of the rotary engine (12A and 13B variations) Cooling System: Radiator, water pump, thermostat, coolant flow, hoses, and fan operation Starting And Charging: Battery, starter motor, alternator, wiring, and charging system diagnostics Ignition System: Spark plugs, ignition coils, distributor (if applicable), timing, and electronic ignition components Emission Controls: Air injection system, EGR, catalytic converter, and emissions-related sensors and actuators Engine Controls: Carburetor (various models), fuel injection (later models), ECU, and sensor inputs/outputs Transmission Manual: Clutch, gearbox disassembly, assembly, gear ratios, and maintenance Transmission Automatic: Disassembly, assembly, hydraulic control, and maintenance (if applicable to specific models) Driveline: Driveshaft, differential, rear axle, and universal joints Suspension: Front and rear suspension components, struts, shocks, bushings, and alignment specifications Steering: Steering gear, steering column, power steering system (if equipped), and tie rod ends Brakes: Disc and drum brake systems, hydraulic lines, master cylinder, calipers, wheel cylinders, and brake pad/shoe replacement Wheels And Tires: Tire pressure, rotation, wheel installation, and specifications Fuel System: Fuel tank, fuel pump, fuel lines, fuel filters, and carburetor/injection system components Exhaust System: Exhaust manifold, pipes, muffler, and catalytic converter replacement HVAC: Heating, Ventilation, and Air Conditioning system components, refrigerant, and operation Instrumentation And Warning Systems: Dashboard gauges, warning lights, sensors, and indicator functionality Lighting: Headlights, taillights, interior lights, and wiring diagrams for lighting circuits Electrical: Complete electrical system, wiring diagrams, fuses, relays, switches, and component testing Body Interior: Interior trim, seats, dashboard, door panels, and related components Body Exterior: Body panels, doors, hood, trunk, bumpers, glass, and trim removal/installation Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, lubrication Tune Up Procedures: Spark plug replacement, ignition timing adjustment, carburetor adjustment Troubleshooting: Systematic diagnosis of common and uncommon problems with symptom-cause-effect tables Repair Procedures: Step-by-step instructions for component replacement, repair, and adjustment Disassembly And Assembly: Detailed instructions for taking apart and reassembling major vehicle systems and components Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, multimeter testing, and component diagnosis Technical Depth Depth: Comprehensive: Covers from basic maintenance to complete engine rebuilds and complex electrical diagnostics Detail Level: High: Features detailed exploded views, diagrams, photographs, and step-by-step instructions 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Compatibility: Compatible with all PC-based Windows operating systems and Mac OS Searchability: Generally searchable text within the PDF for quick information retrieval Print Quality Printable: All pages are printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Rotary (Wankel) Engine Displacement: 1146cc (12A) for most early models, 1308cc (13B) for later models Induction System: Carbureted (e.g., Hitachi, Mikuni) for most models, Fuel Injection (Bosch L-Jetronic) on some later/performance variants Performance Horsepower Range: Approximately 100-135 hp (12A) and 135-160 hp (13B), depending on model and emissions equipment Torque Range: Approximately 110-120 lb-ft (12A) and 130-140 lb-ft (13B), depending on model Fuel System Fuel Type: Unleaded gasoline (typically 87-91 octane recommended) Fuel Delivery: Dual downdraft carburetors (common) or multi-point fuel injection (later models) 🔧 Transmission Standard Type: 5-speed manual transmission Optional Type: 3-speed automatic transmission Features Clutch: Hydraulically actuated single dry plate clutch Final Drive: Rear-wheel drive with a limited-slip differential (LSD) often optional or standard on performance models 📐 Dimensions Exterior Body Styles: 2-door Coupe, 2-door Fastback/Liftback Length: Approx. 161.8 inches (4110 mm) Width: Approx. 65.2 inches (1656 mm) Height: Approx. 49.6 inches (1260 mm) Weights Curb Weight: Approx. 2300-2600 lbs (1043-1179 kg), varies by model and equipment 🛡️ Safety Features Ratings Crash Test Data: Limited data available from modern comprehensive crash testing; era-appropriate safety features Active Features Braking: Front disc brakes, rear drum brakes (later models may have rear discs) Passive Features Seatbelts: Standard three-point seatbelts Body Construction: Reinforced safety cage, crumple zones (early designs) 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM radio, often with cassette player; basic speaker setup Driver Assistance None: No modern driver assistance systems (e.g., ABS, traction control, airbags were not standard or widespread in early models)...
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Mazda RX-7 1978-1985 FB Workshop Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
FB (First Generation)
Model Years Covered:
1978-1985
Codes
Chassis Code:
SA/FB
👋 Introduction
Market Position
Target Audience:
Do-it-yourselfers (DIY), home mechanics, professional technicians, Mazda enthusiasts
Competitive Analysis
Value Proposition:
Inexpensive alternative to professional repair services, empowers owners to maintain and repair their vehicle
Key Features
Content Richness:
Hundreds of photos, illustrations, diagrams, exploded views, and step-by-step instructions
Usability:
Easy-to-read text, numbered instructions, bold figure numbers for quick cross-referencing
Accessibility:
Downloadable PDF format, accessible across multiple devices and operating systems
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop/Factory Service Repair
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Repair, Overhaul
Page Count
Estimated Page Count:
Varies by specific edition, but generally comprehensive
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full disassembly, assembly, component inspection, and rebuilding of the rotary engine (12A and 13B variations)
Cooling System:
Radiator, water pump, thermostat, coolant flow, hoses, and fan operation
Starting And Charging:
Battery, starter motor, alternator, wiring, and charging system diagnostics
Ignition System:
Spark plugs, ignition coils, distributor (if applicable), timing, and electronic ignition components
Emission Controls:
Air injection system, EGR, catalytic converter, and emissions-related sensors and actuators
Engine Controls:
Carburetor (various models), fuel injection (later models), ECU, and sensor inputs/outputs
Transmission Manual:
Clutch, gearbox disassembly, assembly, gear ratios, and maintenance
Transmission Automatic:
Disassembly, assembly, hydraulic control, and maintenance (if applicable to specific models)
Driveline:
Driveshaft, differential, rear axle, and universal joints
Suspension:
Front and rear suspension components, struts, shocks, bushings, and alignment specifications
Steering:
Steering gear, steering column, power steering system (if equipped), and tie rod ends
Brakes:
Disc and drum brake systems, hydraulic lines, master cylinder, calipers, wheel cylinders, and brake pad/shoe replacement
Wheels And Tires:
Tire pressure, rotation, wheel installation, and specifications
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filters, and carburetor/injection system components
Exhaust System:
Exhaust manifold, pipes, muffler, and catalytic converter replacement
HVAC:
Heating, Ventilation, and Air Conditioning system components, refrigerant, and operation
Instrumentation And Warning Systems:
Dashboard gauges, warning lights, sensors, and indicator functionality
Lighting:
Headlights, taillights, interior lights, and wiring diagrams for lighting circuits
Electrical:
Complete electrical system, wiring diagrams, fuses, relays, switches, and component testing
Body Interior:
Interior trim, seats, dashboard, door panels, and related components
Body Exterior:
Body panels, doors, hood, trunk, bumpers, glass, and trim removal/installation
Procedures Included
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Tune Up Procedures:
Spark plug replacement, ignition timing adjustment, carburetor adjustment
Troubleshooting:
Systematic diagnosis of common and uncommon problems with symptom-cause-effect tables
Repair Procedures:
Step-by-step instructions for component replacement, repair, and adjustment
Disassembly And Assembly:
Detailed instructions for taking apart and reassembling major vehicle systems and components
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, multimeter testing, and component diagnosis
Technical Depth
Depth:
Comprehensive: Covers from basic maintenance to complete engine rebuilds and complex electrical diagnostics
Detail Level:
High: Features detailed exploded views, diagrams, photographs, and step-by-step instructions
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Compatibility:
Compatible with all PC-based Windows operating systems and Mac OS
Searchability:
Generally searchable text within the PDF for quick information retrieval
Print Quality
Printable:
All pages are printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotary (Wankel)
Engine Displacement:
1146cc (12A) for most early models, 1308cc (13B) for later models
Induction System:
Carbureted (e.g., Hitachi, Mikuni) for most models, Fuel Injection (Bosch L-Jetronic) on some later/performance variants
Performance
Horsepower Range:
Approximately 100-135 hp (12A) and 135-160 hp (13B), depending on model and emissions equipment
Torque Range:
Approximately 110-120 lb-ft (12A) and 130-140 lb-ft (13B), depending on model
Fuel System
Fuel Type:
Unleaded gasoline (typically 87-91 octane recommended)
Fuel Delivery:
Dual downdraft carburetors (common) or multi-point fuel injection (later models)
🔧 Transmission
Standard
Type:
5-speed manual transmission
Optional
Type:
3-speed automatic transmission
Features
Clutch:
Hydraulically actuated single dry plate clutch
Final Drive:
Rear-wheel drive with a limited-slip differential (LSD) often optional or standard on performance models
📐 Dimensions
Exterior
Body Styles:
2-door Coupe, 2-door Fastback/Liftback
Length:
Approx. 161.8 inches (4110 mm)
Width:
Approx. 65.2 inches (1656 mm)
Height:
Approx. 49.6 inches (1260 mm)
Weights
Curb Weight:
Approx. 2300-2600 lbs (1043-1179 kg), varies by model and equipment
🛡️ Safety Features
Ratings
Crash Test Data:
Limited data available from modern comprehensive crash testing; era-appropriate safety features
Active Features
Braking:
Front disc brakes, rear drum brakes (later models may have rear discs)
Passive Features
Seatbelts:
Standard three-point seatbelts
Body Construction:
Reinforced safety cage, crumple zones (early designs)
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM radio, often with cassette player; basic speaker setup
Driver Assistance
None:
No modern driver assistance systems (e.g., ABS, traction control, airbags were not standard or widespread in early models)
Connectivity
None:
No integrated connectivity features like Bluetooth or USB
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 miles or 3 months (crucial for rotary engines)
Spark Plugs:
Check/replace every 15,000-20,000 miles (specific types for rotary engines)
Coolant Flush:
Every 24,000 miles or 24 months
Fluid Specifications
Engine Oil:
API SG or higher, SAE 20W-50 or 10W-30 recommended (rotary-specific oils sometimes preferred)
Coolant:
Ethylene glycol-based coolant, 50/50 mix with distilled water
Transmission Fluid Manual:
API GL-4 SAE 75W-90 gear oil
Transmission Fluid Automatic:
Dexron III (or equivalent)
Brake Fluid:
DOT 3 or DOT 4 brake fluid
Known Issues
Apex Seals:
Wear or failure of apex seals leading to compression loss and poor performance
Oil Consumption:
Rotary engines inherently consume a small amount of oil for lubrication; excessive consumption indicates a problem
Carburetor Issues:
Deterioration of gaskets, diaphragms, and vacuum leaks in older carburetors
Thermal Reliance:
Rotary engines are sensitive to overheating; cooling system maintenance is critical
Wiring Harness Deterioration:
Aging electrical components and wiring can lead to intermittent faults
📚 Vehicle History
Brand Heritage
Rotary Pioneering:
Mazda's long history and commitment to the rotary engine technology
Model Evolution
Generation Introduction:
Introduced as the RX-7 in 1978, replacing the RX-3, focusing on sportiness and lightweight design
Styling Changes:
Initial SA22C model with pop-up headlights and classic sports car lines. The FB designation refers to the later 1981-1985 facelift with more integrated bumpers and revised styling.
Production
Production Period:
1978-1985
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Automotive Press:
Widely praised by automotive press for its handling, performance, and unique rotary engine, contributing to Mazda's sporty image.
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