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Mazda RX4 Workshop Engine Service Repair Manual

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The Mazda RX4, produced from 1972 to 1977, represents a significant chapter in automotive history, showcasing Mazda's pioneering spirit with its rotary (Wankel) engine technology. Available in sedan, coupe, and wagon body styles, with chassis codes S124A and LA2VS respectively, the RX4 was engineered to deliver a unique driving experience powered by the compact yet potent 12A rotary engine. This engine, displacing 654 cc per rotor, offered an equivalent displacement of 1308 cc and produced between 100-135 horsepower, providing smooth power delivery and a distinct engine note. Its innovative design and performance capabilities helped establish Mazda's reputation for engineering excellence and cemented the rotary engine's place in the automotive landscape. This comprehensive workshop service repair manual provides in-depth technical information essential for the maintenance, diagnosis, and repair of your Mazda RX4. It covers critical systems including the rotary engine (12A), fuel system, ignition, cooling, and lubrication. Detailed procedures for routine maintenance, troubleshooting common issues such as apex seal wear and carburetor problems, and complete engine rebuilds are included. Furthermore, the manual offers vital specifications, torque values, and tolerances, making it an indispensable resource for owners and mechanics alike to ensure the optimal performance and longevity of this iconic rotary-powered vehicle. 🏷️ Basic Information Identification Make: Mazda Model: RX4 Model Codename: S124A (Sedan/Coupe), LA2VS (Wagon) Codes Chassis Codes: S124A, LA2VS 👋 Introduction Market Position Target Audience: Owners and mechanics of Mazda RX4 vehicles seeking in-depth repair and maintenance knowledge. Competitive Analysis Manual Value: Provides essential technical data often unavailable in owner's manuals, crucial for maintaining rotary engines. Key Features Comprehensiveness: Focuses specifically on the engine service and repair, offering detailed procedures for the unique rotary powerplant. 📋 Manual Details Coverage Areas Engine: Rotary (12A) Fuel System: Carburetor and Injection (depending on market/variant) Ignition System: Electronic Cooling System: Water-cooled Lubrication System: Wet sump Page Count Estimated Pages: 300-500 (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, inspection, assembly, timing, seals, gaskets, rotor housings, apex seals, eccentric shaft, oil pump, water pump, intake manifold, exhaust manifold. Fuel And Emission Control: Carburetor adjustment and overhaul (e.g., Hitachi, Mikuni), fuel pump, fuel filter, emissions control systems (e.g., EGR, thermal reactor). Ignition System: Distributor, ignition coils, spark plugs, wiring, timing adjustments, electronic control unit (ECU) if applicable. Cooling System: Radiator, coolant hoses, thermostat, water pump, fan, coolant specifications. Lubrication System: Engine oil, oil filter, oil pan, oil pump, oil cooler, oil specifications. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, coolant flushes, lubrication points. Troubleshooting: Diagnosis of common engine problems, electrical issues, starting problems, performance issues, diagnostic charts. Repair And Overhaul: Detailed step-by-step instructions for engine rebuilds, component replacement (e.g., seals, bearings, ignition components), carburetor overhauls. Specifications And Tolerances: Torque values, clearances, measurements, rebuild specifications for critical engine components. Technical Depth Depth: Comprehensive engine rebuild and diagnostic procedures, including internal component specifications and tolerances. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF with clear diagrams and text. Print Quality Scalability: Optimized for printing, with sharp lines and legible text for diagrams. Binding Type Digital Format Advantage: Instant download, easily accessible on multiple devices, printable pages. Paper Type Digital Equivalent: No physical paper; delivered as a digital file. ⚙️ Engine Specifications Primary Engine Engine Type: Mazda 13B Rotary (Wankel) Engine Code: 12A Rotor Displacement: 654 cc per rotor (total 1308 cc equivalent displacement) Rotor Housing Material: Cast iron or similar durable alloy Apex Seal Material: Historically, carbon or phenolic resin, later variations used metal composites. Performance Horsepower Range: Approximately 100-135 hp (depending on market and emission controls) Torque Range: Approximately 110-130 lb-ft Fuel System Carburetion: Twin-choke downdraft carburetors (e.g., Hitachi SH20, Mikuni PHH) Fuel Type: Unleaded gasoline (91 RON or higher recommended) Ignition System Ignition Timing: Typically specified in degrees Before Top Dead Center (BTDC), adjustable via distributor. Cooling System Coolant Type: Ethylene glycol based antifreeze/coolant mixture (50/50 recommended). Lubrication System Oil Capacity: Approximately 5.5-6.0 quarts (5.2-5.7 liters) with filter change. Oil Viscosity Recommendation: API SG or higher, SAE 10W-30 or 10W-40 commonly recommended for varying temperatures. Other Emissions Control Systems: Thermal reactor, EGR (Exhaust Gas Recirculation), air injection (depending on market and year). 🔧 Transmission Standard Transmission Type: 4-speed Manual Optional Transmission Type: 3-speed Automatic (TorqueFlite based or Mazda's own design) Features Gear Ratios Manual: Specific ratios for 1st, 2nd, 3rd, 4th, and Reverse gears would be detailed in the manual. Automatic Transmission Fluid Type: Dexron II or equivalent automatic transmission fluid (ATF). 📐 Dimensions Exterior Length: Sedan/Coupe: ~4250 mm (167.3 in) Width: Sedan/Coupe: ~1600 mm (63.0 in) Height: Sedan/Coupe: ~1375 mm (54.1 in) Weights Curb Weight: Approximately 1150-1250 kg (2535-2755 lbs) 🛡️ Safety Features Ratings Crash Test Data: Limited comprehensive modern crash test data...
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Mazda RX4 Workshop Engine Service Repair ManualMazda RX4 Workshop Engine Service Repair ManualMazda RX4 Workshop Engine Service Repair ManualMazda RX4 Workshop Engine Service Repair Manual
The Mazda RX4, produced from 1972 to 1977, represents a significant chapter in automotive history, showcasing Mazda's pioneering spirit with its rotary (Wankel) engine technology. Available in sedan, coupe, and wagon body styles, with chassis codes S124A and LA2VS respectively, the RX4 was engineered to deliver a unique driving experience powered by the compact yet potent 12A rotary engine. This engine, displacing 654 cc per rotor, offered an equivalent displacement of 1308 cc and produced between 100-135 horsepower, providing smooth power delivery and a distinct engine note. Its innovative design and performance capabilities helped establish Mazda's reputation for engineering excellence and cemented the rotary engine's place in the automotive landscape. This comprehensive workshop service repair manual provides in-depth technical information essential for the maintenance, diagnosis, and repair of your Mazda RX4. It covers critical systems including the rotary engine (12A), fuel system, ignition, cooling, and lubrication. Detailed procedures for routine maintenance, troubleshooting common issues such as apex seal wear and carburetor problems, and complete engine rebuilds are included. Furthermore, the manual offers vital specifications, torque values, and tolerances, making it an indispensable resource for owners and mechanics alike to ensure the optimal performance and longevity of this iconic rotary-powered vehicle.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX4
Model Codename:
S124A (Sedan/Coupe), LA2VS (Wagon)
Codes
Chassis Codes:
S124A, LA2VS
👋 Introduction
Market Position
Target Audience:
Owners and mechanics of Mazda RX4 vehicles seeking in-depth repair and maintenance knowledge.
Competitive Analysis
Manual Value:
Provides essential technical data often unavailable in owner's manuals, crucial for maintaining rotary engines.
Key Features
Comprehensiveness:
Focuses specifically on the engine service and repair, offering detailed procedures for the unique rotary powerplant.
📋 Manual Details
Coverage Areas
Engine:
Rotary (12A)
Fuel System:
Carburetor and Injection (depending on market/variant)
Ignition System:
Electronic
Cooling System:
Water-cooled
Lubrication System:
Wet sump
Page Count
Estimated Pages:
300-500 (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Disassembly, inspection, assembly, timing, seals, gaskets, rotor housings, apex seals, eccentric shaft, oil pump, water pump, intake manifold, exhaust manifold.
Fuel And Emission Control:
Carburetor adjustment and overhaul (e.g., Hitachi, Mikuni), fuel pump, fuel filter, emissions control systems (e.g., EGR, thermal reactor).
Ignition System:
Distributor, ignition coils, spark plugs, wiring, timing adjustments, electronic control unit (ECU) if applicable.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, fan, coolant specifications.
Lubrication System:
Engine oil, oil filter, oil pan, oil pump, oil cooler, oil specifications.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, coolant flushes, lubrication points.
Troubleshooting:
Diagnosis of common engine problems, electrical issues, starting problems, performance issues, diagnostic charts.
Repair And Overhaul:
Detailed step-by-step instructions for engine rebuilds, component replacement (e.g., seals, bearings, ignition components), carburetor overhauls.
Specifications And Tolerances:
Torque values, clearances, measurements, rebuild specifications for critical engine components.
Technical Depth
Depth:
Comprehensive engine rebuild and diagnostic procedures, including internal component specifications and tolerances. Suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF with clear diagrams and text.
Print Quality
Scalability:
Optimized for printing, with sharp lines and legible text for diagrams.
Binding Type
Digital Format Advantage:
Instant download, easily accessible on multiple devices, printable pages.
Paper Type
Digital Equivalent:
No physical paper; delivered as a digital file.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Mazda 13B Rotary (Wankel)
Engine Code:
12A
Rotor Displacement:
654 cc per rotor (total 1308 cc equivalent displacement)
Rotor Housing Material:
Cast iron or similar durable alloy
Apex Seal Material:
Historically, carbon or phenolic resin, later variations used metal composites.
Performance
Horsepower Range:
Approximately 100-135 hp (depending on market and emission controls)
Torque Range:
Approximately 110-130 lb-ft
Fuel System
Carburetion:
Twin-choke downdraft carburetors (e.g., Hitachi SH20, Mikuni PHH)
Fuel Type:
Unleaded gasoline (91 RON or higher recommended)
Ignition System
Ignition Timing:
Typically specified in degrees Before Top Dead Center (BTDC), adjustable via distributor.
Cooling System
Coolant Type:
Ethylene glycol based antifreeze/coolant mixture (50/50 recommended).
Lubrication System
Oil Capacity:
Approximately 5.5-6.0 quarts (5.2-5.7 liters) with filter change.
Oil Viscosity Recommendation:
API SG or higher, SAE 10W-30 or 10W-40 commonly recommended for varying temperatures.
Other
Emissions Control Systems:
Thermal reactor, EGR (Exhaust Gas Recirculation), air injection (depending on market and year).
🔧 Transmission
Standard
Transmission Type:
4-speed Manual
Optional
Transmission Type:
3-speed Automatic (TorqueFlite based or Mazda's own design)
Features
Gear Ratios Manual:
Specific ratios for 1st, 2nd, 3rd, 4th, and Reverse gears would be detailed in the manual.
Automatic Transmission Fluid Type:
Dexron II or equivalent automatic transmission fluid (ATF).
📐 Dimensions
Exterior
Length:
Sedan/Coupe: ~4250 mm (167.3 in)
Width:
Sedan/Coupe: ~1600 mm (63.0 in)
Height:
Sedan/Coupe: ~1375 mm (54.1 in)
Weights
Curb Weight:
Approximately 1150-1250 kg (2535-2755 lbs)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited comprehensive modern crash test data available due to era of production.
Active Features
Brakes:
Front disc brakes, rear drum brakes. Power assist typically standard.
Passive Features
Seatbelts:
Front lap and shoulder belts. Rear lap belts.
💡 Technology Features
Infotainment
Entertainment System:
Basic AM/FM radio, optional cassette player.
Driver Assistance
Features:
No electronic driver assistance features typical of modern vehicles.
Connectivity
Features:
No integrated connectivity features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, whichever comes first.
Spark Plug Inspection Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. Rotary spark plugs are critical.
Air Filter Replacement:
Inspect every 7,500 miles (12,000 km), replace as needed or annually.
Coolant Flush Interval:
Every 2 years or 30,000 miles (48,000 km).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Manual Transmission Fluid:
API GL-4 gear oil, SAE 75W-90 or 80W-90 (capacity approx. 1.8-2.0 liters).
Known Issues
Apex Seal Wear:
Common issue with high-mileage rotary engines, leading to loss of compression, poor starting, and rough running. Requires engine rebuild.
Carburetor Issues:
Deterioration of rubber components, vacuum leaks, and tuning challenges common with older carburetors.
Oil Consumption:
Rotary engines inherently consume some oil for lubrication; the manual will detail normal consumption rates and how to monitor.
Cooling System Leaks:
Aging hoses, seals, and potential corrosion in the cooling system. Overheating can be detrimental to rotary engines.
📚 Vehicle History
Brand Heritage
Mazda Rotary Pioneering:
Mazda's commitment to rotary engine technology, pioneered by Felix Wankel and developed extensively by Mazda.
Model Evolution
Development Context:
Introduced as Mazda's entry into the global market, showcasing the performance and unique characteristics of the rotary engine.
Production
Production Years:
1972-1977
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Rotary Engine Prowess:
The RX4 itself was a significant model that helped establish Mazda's reputation for performance and innovation with the rotary engine.
Ratings
Performance Reviews:
Praised for its smooth power delivery and unique engine characteristics by period automotive journalists.
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