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Mazda RX2 RX3 1970-1978 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Mazda Model: RX-2 / RX-3 Common Name: Mazda Familia Rotary / Mazda Savanna Rotary Generation Applicable Years: 1970-1978 Codes Chassis Code Rx2: S102A, S124A, S132A Chassis Code Rx3: S124A, S132A, S133A, S134A 👋 Introduction Market Position Positioning: The Mazda RX-2 and RX-3 were significant models in Mazda's early history, establishing their reputation for rotary-powered vehicles. They competed in the compact and subcompact segments with a focus on performance and unique engineering. Competitive Analysis Competitors: Ford Escort, Toyota Corolla, Datsun 510, Honda Civic, Mitsubishi Lancer. Key Features Engine Technology: The primary differentiator was the Wankel rotary engine, offering a smooth, high-revving power delivery. Design Philosophy: Sporty styling, lightweight construction, and a focus on driver engagement. Manual Value Proposition Value: Essential for owners and mechanics looking to maintain, repair, or restore these classic rotary Mazdas. Provides factory-accurate procedures and specifications. 📋 Manual Details Coverage Areas Manual Type: Factory Workshop Service Manual (WSM) Primary Language: English (translated from original Japanese) Format: PDF Download Page Count Estimated Pages: High (Typically 500-1000+ pages for factory WSMs of this era, exact count varies by specific revision) 📖 Manual Coverage Systems Covered Engine: Rotary (12A, 13B) - detailed disassembly, assembly, lubrication, cooling, ignition, fuel, emissions control, rotary specific component theory Transmission: Manual (4-speed, 5-speed) and Automatic - overhaul, adjustments, fluid specifications, clutch system Drivetrain: Rear-wheel drive, driveshaft, differential, axles Suspension: Front (MacPherson strut), Rear (Live axle with leaf springs or coil springs) - component replacement, alignment specifications, shock absorber and spring service Steering: Manual and Power Steering systems - components, adjustments, overhaul Brakes: Front Disc, Rear Drum - hydraulic system, calipers, master cylinder, brake lines, parking brake Electrical: Charging system, ignition system, lighting, starting system, instruments, wiring diagrams, fuse/relay locations Fuel System: Fuel tank, pump, lines, carburetor (single barrel and twin barrel Zenith Stromberg or Hitachi variations) service Exhaust System: Mufflers, pipes, catalytic converter (later models) where applicable Body: Body construction, doors, windows, trim, interior components, seat adjustment, panel gaps Chassis: Frame construction, mounting points, corrosion protection Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, lubrication points, battery maintenance, coolant checks Troubleshooting: Diagnostic flowcharts for common symptoms, engine performance issues, electrical faults Repair: Component replacement (engine, transmission, brakes, suspension), gasket and seal replacement, body panel repair Overhaul: Complete engine rebuild, transmission rebuild, carburetor overhaul, brake caliper and master cylinder rebuild Adjustments: Carburetor idle speed and mixture, ignition timing, valve clearance (if applicable, though rotary engines don't have traditional valves), clutch pedal, brake adjustments Torque Specifications: Detailed torque values for all critical fasteners and engine components Technical Depth Depth: Comprehensive factory-level detail, covering routine maintenance to full engine and drivetrain rebuilds. Diagnostic Capabilities: Includes diagnostic procedures and specifications for identifying and resolving mechanical and electrical issues. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Likely, depending on the OCR quality of the original scan. Print Quality Quality: Variable (dependent on the scan quality of the original document). Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Wankel Rotary Displacement Liter: 1.1 L (12A) for RX-2, 1.1 L (12A) and 1.3 L (13B) for RX-3 Performance Horsepower 12A: Approx. 110-130 hp (depending on variant and emissions controls) Torque 12A: Approx. 110-130 lb-ft (depending on variant) Horsepower 13B: Approx. 135-145 hp (depending on variant) Torque 13B: Approx. 130-150 lb-ft (depending on variant) Fuel System Carburetion: Single-barrel or twin-barrel Zenith Stromberg, Hitachi, or Mikuni carburetors. Fuel Type: Unleaded Gasoline (Octane rating as specified by Mazda, typically high) Cooling System Type: Water-cooled, with a dedicated rotary engine cooling system design (often with multiple thermostats). Lubrication Oil System: Rotary engines require a specific oil injection system (REI) for apex seals, in addition to the sump oil. Rotor Design Rotor Housing Material: Chrome-plated housing or cast iron with special coatings. Rotary Specifics Apex Seals: Critical wear item, manual covers inspection and replacement procedures. 🔧 Transmission Standard Type Rx2: 4-speed manual Type Rx3: 4-speed manual, 5-speed manual Optional Type Rx2: 3-speed automatic Type Rx3: 3-speed automatic Features Fluid Type: API GL-4 gear oil (specific viscosity to be confirmed in manual, likely 75W-90 or 80W-90) Clutch System Type: Dry single-plate, hydraulically operated 📐 Dimensions Exterior Rx2 Length Mm: Approx. 4,000 - 4,100 mm Rx2 Width Mm: Approx. 1,550 - 1,600 mm Rx2 Height Mm: Approx. 1,350 - 1,400 mm Rx3 Length Mm: Approx. 3,900 - 4,050 mm Rx3 Width Mm: Approx. 1,560 - 1,600 mm Rx3 Height Mm: Approx. 1,340 - 1,380 mm Wheelbase Mm Rx2: Approx. 2,400 mm Rx3: Approx. 2,320 - 2,360 mm Weights Curb Weight Kg: Approx. 950 - 1,100 kg (varies by model and specification) Gross Vehicle Weight Kg: Not typically specified in detail for this era but can be inferred from payload capacity. Wheel Bolt Pattern: 4x110 mm Tire Sizes: Common sizes include...
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Mazda RX2 RX3 1970-1978 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-2 / RX-3
Common Name:
Mazda Familia Rotary / Mazda Savanna Rotary
Generation
Applicable Years:
1970-1978
Codes
Chassis Code Rx2:
S102A, S124A, S132A
Chassis Code Rx3:
S124A, S132A, S133A, S134A
👋 Introduction
Market Position
Positioning:
The Mazda RX-2 and RX-3 were significant models in Mazda's early history, establishing their reputation for rotary-powered vehicles. They competed in the compact and subcompact segments with a focus on performance and unique engineering.
Competitive Analysis
Competitors:
Ford Escort, Toyota Corolla, Datsun 510, Honda Civic, Mitsubishi Lancer.
Key Features
Engine Technology:
The primary differentiator was the Wankel rotary engine, offering a smooth, high-revving power delivery.
Design Philosophy:
Sporty styling, lightweight construction, and a focus on driver engagement.
Manual Value Proposition
Value:
Essential for owners and mechanics looking to maintain, repair, or restore these classic rotary Mazdas. Provides factory-accurate procedures and specifications.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Workshop Service Manual (WSM)
Primary Language:
English (translated from original Japanese)
Format:
PDF Download
Page Count
Estimated Pages:
High (Typically 500-1000+ pages for factory WSMs of this era, exact count varies by specific revision)
📖 Manual Coverage
Systems Covered
Engine:
Rotary (12A, 13B) - detailed disassembly, assembly, lubrication, cooling, ignition, fuel, emissions control, rotary specific component theory
Transmission:
Manual (4-speed, 5-speed) and Automatic - overhaul, adjustments, fluid specifications, clutch system
Drivetrain:
Rear-wheel drive, driveshaft, differential, axles
Suspension:
Front (MacPherson strut), Rear (Live axle with leaf springs or coil springs) - component replacement, alignment specifications, shock absorber and spring service
Steering:
Manual and Power Steering systems - components, adjustments, overhaul
Brakes:
Front Disc, Rear Drum - hydraulic system, calipers, master cylinder, brake lines, parking brake
Electrical:
Charging system, ignition system, lighting, starting system, instruments, wiring diagrams, fuse/relay locations
Fuel System:
Fuel tank, pump, lines, carburetor (single barrel and twin barrel Zenith Stromberg or Hitachi variations) service
Exhaust System:
Mufflers, pipes, catalytic converter (later models) where applicable
Body:
Body construction, doors, windows, trim, interior components, seat adjustment, panel gaps
Chassis:
Frame construction, mounting points, corrosion protection
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug service, lubrication points, battery maintenance, coolant checks
Troubleshooting:
Diagnostic flowcharts for common symptoms, engine performance issues, electrical faults
Repair:
Component replacement (engine, transmission, brakes, suspension), gasket and seal replacement, body panel repair
Overhaul:
Complete engine rebuild, transmission rebuild, carburetor overhaul, brake caliper and master cylinder rebuild
Adjustments:
Carburetor idle speed and mixture, ignition timing, valve clearance (if applicable, though rotary engines don't have traditional valves), clutch pedal, brake adjustments
Torque Specifications:
Detailed torque values for all critical fasteners and engine components
Technical Depth
Depth:
Comprehensive factory-level detail, covering routine maintenance to full engine and drivetrain rebuilds.
Diagnostic Capabilities:
Includes diagnostic procedures and specifications for identifying and resolving mechanical and electrical issues.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely, depending on the OCR quality of the original scan.
Print Quality
Quality:
Variable (dependent on the scan quality of the original document).
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
Wankel Rotary
Displacement Liter:
1.1 L (12A) for RX-2, 1.1 L (12A) and 1.3 L (13B) for RX-3
Performance
Horsepower 12A:
Approx. 110-130 hp (depending on variant and emissions controls)
Torque 12A:
Approx. 110-130 lb-ft (depending on variant)
Horsepower 13B:
Approx. 135-145 hp (depending on variant)
Torque 13B:
Approx. 130-150 lb-ft (depending on variant)
Fuel System
Carburetion:
Single-barrel or twin-barrel Zenith Stromberg, Hitachi, or Mikuni carburetors.
Fuel Type:
Unleaded Gasoline (Octane rating as specified by Mazda, typically high)
Cooling System
Type:
Water-cooled, with a dedicated rotary engine cooling system design (often with multiple thermostats).
Lubrication
Oil System:
Rotary engines require a specific oil injection system (REI) for apex seals, in addition to the sump oil.
Rotor Design
Rotor Housing Material:
Chrome-plated housing or cast iron with special coatings.
Rotary Specifics
Apex Seals:
Critical wear item, manual covers inspection and replacement procedures.
🔧 Transmission
Standard
Type Rx2:
4-speed manual
Type Rx3:
4-speed manual, 5-speed manual
Optional
Type Rx2:
3-speed automatic
Type Rx3:
3-speed automatic
Features
Fluid Type:
API GL-4 gear oil (specific viscosity to be confirmed in manual, likely 75W-90 or 80W-90)
Clutch System
Type:
Dry single-plate, hydraulically operated
📐 Dimensions
Exterior
Rx2 Length Mm:
Approx. 4,000 - 4,100 mm
Rx2 Width Mm:
Approx. 1,550 - 1,600 mm
Rx2 Height Mm:
Approx. 1,350 - 1,400 mm
Rx3 Length Mm:
Approx. 3,900 - 4,050 mm
Rx3 Width Mm:
Approx. 1,560 - 1,600 mm
Rx3 Height Mm:
Approx. 1,340 - 1,380 mm
Wheelbase Mm
Rx2:
Approx. 2,400 mm
Rx3:
Approx. 2,320 - 2,360 mm
Weights
Curb Weight Kg:
Approx. 950 - 1,100 kg (varies by model and specification)
Gross Vehicle Weight Kg:
Not typically specified in detail for this era but can be inferred from payload capacity.
Wheel Bolt Pattern:
4x110 mm
Tire Sizes:
Common sizes include 165 SR 13, 175/70 HR 13, 185/70 SR 13. Specific sizes depend on trim and factory options.
🛡️ Safety Features
Ratings
Era Safety Standards:
As per 1970s automotive safety standards. No modern crash test ratings apply.
Active Features
Braking System:
Front disc brakes, rear drum brakes. Power assist may be optional on some trims.
Parking Brake:
Mechanical, acting on rear wheels.
Passive Features
Seatbelts:
Lap belts standard, 3-point belts optional or standard on higher trims/later models.
Body Construction:
Unitary body construction, with crumple zones and safety cage design typical of the era.
Steering Column:
Collapsible steering column (design varies by year and market).
💡 Technology Features
Infotainment
Era Entertainment System:
Basic AM/FM radio, optional AM/FM with 8-track player or cassette player on higher trims or later models.
Driver Assistance
Active Safety Features:
Limited to basic safety engineering of the era. No electronic stability control, ABS, or traction control.
Passive Safety Features:
Collapsible steering column, safety glass, basic body structure reinforcement.
Connectivity
Connectivity Options:
N/A for this era. No onboard computers or digital connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 - 5,000 miles or 6 months, whichever comes first. Manual will specify exact interval and oil type.
Spark Plug Replacement:
Intervals vary for rotary plugs; manual provides specifics.
Coolant Flush:
Typically every 2 years or 30,000 miles, but specific rotary cooling system recommendations apply.
Ignition Timing Check:
Recommended at regular service intervals, especially if performance issues arise.
Fluid Specifications
Engine Oil Type:
Mazda specifically recommended API SE, SF rated oils. Viscosity like 10W-30 or 10W-40 would be common. Crucially, it must be suitable for rotary engines, which may have different additive packages than standard automotive oils of the era.
Coolant Type:
Ethylene glycol-based antifreeze, mixed with distilled water (typically 50/50 ratio).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Fluid Type:
Manual: Gear oil API GL-4. Automatic: DEXRON II or equivalent.
Known Issues
Apex Seal Wear:
The most common and critical issue. Symptoms include loss of compression, increased oil consumption, rough idle, and difficulty starting. Requires engine rebuild.
Oil Seal Failure:
Corner seals and side seals can degrade, leading to oil leaks and internal damage.
Carburetor Issues:
Wear and tear on carburetors can lead to idle instability, poor fuel economy, and tuning difficulties.
Cooling System Performance:
Rotary engines run hotter and require a well-maintained cooling system. Overheating can exacerbate apex seal wear.
Ignition System:
Points and condenser ignition systems require regular maintenance. Distributor wear can affect timing.
Part Numbers
Example Oil Filter:
Specific part numbers would be in the manual, but aftermarket equivalents exist (e.g., Fram PH series, Wix 51049, Mann W 712/20).
📚 Vehicle History
Brand Heritage
Rotary Pioneering:
Mazda's commitment to the rotary engine began with the Cosmo Sport and continued with mass-produced models like the RX-2 and RX-3, defining their performance image.
Model Evolution
Rx2 Introduction:
Introduced in 1970 as the Mazda Capella Rotary (RX-2 in export markets). Available as a 2-door coupe and 4-door sedan.
Rx3 Introduction:
Introduced in 1971 as the Mazda Savanna Rotary (RX-3 in export markets). Offered in coupe and wagon (estate) body styles, with a sportier focus.
Updates And Facelifts:
Both models received minor styling updates and engine enhancements throughout their production runs, including chassis code variations reflecting these changes.
Production End
Production Years:
RX-2: 1970-1978 (market dependent, often superseded by RX-4/RX-5 later). RX-3: 1971-1978 (often superseded by Mazda MAZDA ROADSTER Coupe in some markets).
Motorsport Legacy
Racing History:
The RX-2 and RX-3, particularly the RX-3, were successful in various motorsport disciplines, including circuit racing and rallying, showcasing the durability and performance of the rotary engine.
🏆 Awards & Recognition
Recognitions
Rotary Engine Impact:
Mazda's rotary engines, showcased in models like the RX-2 and RX-3, were revolutionary and earned significant recognition for innovation and performance in their time.
Ratings
Road Test Period Accolades:
Contemporary road tests praised the smooth power delivery, handling, and sporty aesthetics of the RX-2 and RX-3, often highlighting their unique appeal against conventional piston-engined rivals.
Certifications
Manufacturing Standards:
Built to Mazda's Japanese manufacturing standards of the period.
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