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Mazda RX-2 RX2 616 SEDAN COUPE Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-2 / 616 Body Styles Covered: Sedan, Coupe Codes Internal Model Codes: FA (Coupe), FB (Sedan) 👋 Introduction Market Position Segment: Compact/Subcompact Sports Sedan and Coupe Target Audience: Enthusiasts, DIY mechanics, restoration specialists Competitive Analysis Key Competitors: Datsun (Nissan) 510, Toyota Corolla, Honda Civic (early generations) Key Features Unique Selling Proposition: Rotary engine technology offering a unique driving experience and distinctive sound Design Philosophy: Sporty, compact, and reliable Japanese automotive engineering 📋 Manual Details Coverage Areas Primary Coverage: Full Workshop/Service Manual Page Count Page Count: 230 Manual Type Manual Type: Factory Workshop Manual Language Language: English Format Format: Printed Document File Format: Likely physical print (as described), potentially scanned PDF for digital versions Print Quality: Factory original print quality (typically good clarity) Binding Type: Typically perfect bound or stapled for factory manuals Paper Type: Durable paper stock suitable for workshop environments 📖 Manual Coverage Systems Covered Engine System: Rotary Engine (12A) - Theory of Operation, Disassembly, Assembly, Troubleshooting, Specifications Fuel System: Carburetor (likely Hitachi or Mikuni), Fuel Pump, Lines, Tank, Specifications, Adjustment, Troubleshooting Ignition System: Distributor, Ignition Coils, Spark Plugs, Timing Adjustment, Troubleshooting Cooling System: Radiator, Water Pump, Thermostat, Hoses, Fan, Specifications, Troubleshooting Exhaust System: Manifolds, Pipes, Muffler, Emission Controls (if applicable), Troubleshooting Transmission Manual: 4-Speed and 5-Speed Manual Transmissions - Disassembly, Assembly, Fluid Specifications, Troubleshooting Transmission Automatic: Automatic Transmission (if applicable) - Disassembly, Assembly, Fluid Specifications, Troubleshooting Drivetrain: Driveshaft, Universal Joints, Rear Axle, Differential - Disassembly, Assembly, Fluid Specifications, Troubleshooting Suspension Front: MacPherson Struts, Control Arms, Bushings, Springs, Shock Absorbers, Specifications, Alignment Procedures Suspension Rear: Leaf Springs or Coil Springs, Trailing Arms, Panhard Rod (depending on model), Shock Absorbers, Specifications Steering System: Steering Gearbox, Tie Rods, Steering Column, Power Steering (if equipped), Specifications, Troubleshooting Brake System: Front Disc Brakes, Rear Drum Brakes, Master Cylinder, Brake Lines, Parking Brake, Specifications, Bleeding Procedures Electrical System: Battery, Alternator, Starter Motor, Wiring Diagrams, Fuses, Relays, Lights, Switches, Gauges, Troubleshooting Body And Chassis: Body Panel Removal/Installation, Doors, Hood, Trunk, Glass, Seats, Interior Trim, Chassis Components, Specifications HVAC System: Heater Core, Blower Motor, Controls, Air Ducts, Specifications, Troubleshooting Procedures Included Routine Maintenance: Oil Changes, Filter Replacements, Spark Plug Gapping/Replacement, Fluid Level Checks, Lubrication Engine Overhaul: Complete engine disassembly, inspection, component replacement, and reassembly procedures Transmission Repair: Manual and automatic transmission rebuilds, clutch replacement, gear selection adjustments Suspension And Steering Repair: Ball joint replacement, tie rod end replacement, shock/strut replacement, steering gearbox overhaul Brake System Overhaul: Brake pad/shoe replacement, caliper/wheel cylinder rebuild, master cylinder replacement, brake line replacement Electrical Troubleshooting: Diagnosis of electrical faults using wiring diagrams, component testing, and circuit analysis Bodywork And Trim: Replacement of body panels, door mechanisms, glass sealing, interior trim panel removal and installation Wheel Alignment: Detailed specifications and procedures for adjusting camber, caster, and toe angles Carburetor Adjustment: Idle speed, air-fuel mixture, and choke adjustments for optimal performance and emissions Diagnostic Procedures: Step-by-step guides for identifying and resolving common and complex issues Technical Depth Depth Of Coverage: Comprehensive - from basic maintenance to complete engine and drivetrain rebuilds Diagnostic Capability: Advanced diagnostic trees and troubleshooting flowcharts for identifying root causes of problems Rebuild Procedures: Detailed instructions with torque specifications and clearances for rebuilding major components Wiring Diagrams: Complete, often color-coded, wiring schematics for all vehicle systems Schematics: Hydraulic, pneumatic, and vacuum schematics where applicable ⚙️ Engine Specifications Primary Engine Engine Type: Mazda Rotary (Wankel) Engine Code: 12A Displacement: 1146 cc (approx. 2 x 573 cc rotor chambers) Performance Horsepower Gross: Approx. 90-100 HP (depending on market and emissions controls) Torque Gross: Approx. 90-100 lb-ft (depending on market and emissions controls) Fuel System Fuel Delivery: Single or Twin Carburetor (e.g., Hitachi DCAS, Mikuni Solex) Fuel Type: Unleaded gasoline (depending on year and market regulations) Technical Details Rotor Housing Material: Typically aluminum alloy with chrome plating Apex Seals: Crucial wear item, typically made of ceramic or carbon composites Oil Injection: Separate oil injection system for lubrication of apex and side seals 🔧 Transmission Standard Transmission Type: 4-speed manual Optional Transmission Type Optional: 5-speed manual, 3-speed automatic (less common) Features Clutch Type: Single dry plate Fluid Specifications Manual Transmission Fluid: API GL-4 SAE 75W-90 or SAE 80W-90 gear oil (check manual for exact specification) Automatic Transmission Fluid: Dexron II or equivalent (if equipped with automatic transmission) 📐 Dimensions Exterior Wheelbase: Approx. 97.0 inches (2465 mm) Length: Approx. 166.7 inches (4235 mm) for Coupe, 168.7 inches (4285 mm) for Sedan Width: Approx. 64.0 inches (1625 mm) Height: Approx. 52.0 inches (1320 mm) for Coupe, 53.7 inches (1365 mm) for Sedan Weights Curb Weight: Approx. 2100-2300 lbs (950-1045 kg) depending on body style and equipment Gross Vehicle Weight Rating: Check vehicle specific placard, typically around 3000 lbs (1360 kg) 🛡️ Safety Features Ratings Crash Test Data: Limited data available for this era; modern safety standards not applicable. 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Mazda RX-2 RX2 616 SEDAN COUPE Workshop Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-2 / 616
Body Styles Covered:
Sedan, Coupe
Codes
Internal Model Codes:
FA (Coupe), FB (Sedan)
👋 Introduction
Market Position
Segment:
Compact/Subcompact Sports Sedan and Coupe
Target Audience:
Enthusiasts, DIY mechanics, restoration specialists
Competitive Analysis
Key Competitors:
Datsun (Nissan) 510, Toyota Corolla, Honda Civic (early generations)
Key Features
Unique Selling Proposition:
Rotary engine technology offering a unique driving experience and distinctive sound
Design Philosophy:
Sporty, compact, and reliable Japanese automotive engineering
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Workshop/Service Manual
Page Count
Page Count:
230
Manual Type
Manual Type:
Factory Workshop Manual
Language
Language:
English
Format
Format:
Printed Document
File Format:
Likely physical print (as described), potentially scanned PDF for digital versions
Print Quality:
Factory original print quality (typically good clarity)
Binding Type:
Typically perfect bound or stapled for factory manuals
Paper Type:
Durable paper stock suitable for workshop environments
📖 Manual Coverage
Systems Covered
Engine System:
Rotary Engine (12A) - Theory of Operation, Disassembly, Assembly, Troubleshooting, Specifications
Fuel System:
Carburetor (likely Hitachi or Mikuni), Fuel Pump, Lines, Tank, Specifications, Adjustment, Troubleshooting
Ignition System:
Distributor, Ignition Coils, Spark Plugs, Timing Adjustment, Troubleshooting
Cooling System:
Radiator, Water Pump, Thermostat, Hoses, Fan, Specifications, Troubleshooting
Exhaust System:
Manifolds, Pipes, Muffler, Emission Controls (if applicable), Troubleshooting
Transmission Manual:
4-Speed and 5-Speed Manual Transmissions - Disassembly, Assembly, Fluid Specifications, Troubleshooting
Transmission Automatic:
Automatic Transmission (if applicable) - Disassembly, Assembly, Fluid Specifications, Troubleshooting
Drivetrain:
Driveshaft, Universal Joints, Rear Axle, Differential - Disassembly, Assembly, Fluid Specifications, Troubleshooting
Suspension Front:
MacPherson Struts, Control Arms, Bushings, Springs, Shock Absorbers, Specifications, Alignment Procedures
Suspension Rear:
Leaf Springs or Coil Springs, Trailing Arms, Panhard Rod (depending on model), Shock Absorbers, Specifications
Steering System:
Steering Gearbox, Tie Rods, Steering Column, Power Steering (if equipped), Specifications, Troubleshooting
Brake System:
Front Disc Brakes, Rear Drum Brakes, Master Cylinder, Brake Lines, Parking Brake, Specifications, Bleeding Procedures
Electrical System:
Battery, Alternator, Starter Motor, Wiring Diagrams, Fuses, Relays, Lights, Switches, Gauges, Troubleshooting
Body And Chassis:
Body Panel Removal/Installation, Doors, Hood, Trunk, Glass, Seats, Interior Trim, Chassis Components, Specifications
HVAC System:
Heater Core, Blower Motor, Controls, Air Ducts, Specifications, Troubleshooting
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Spark Plug Gapping/Replacement, Fluid Level Checks, Lubrication
Engine Overhaul:
Complete engine disassembly, inspection, component replacement, and reassembly procedures
Transmission Repair:
Manual and automatic transmission rebuilds, clutch replacement, gear selection adjustments
Suspension And Steering Repair:
Ball joint replacement, tie rod end replacement, shock/strut replacement, steering gearbox overhaul
Brake System Overhaul:
Brake pad/shoe replacement, caliper/wheel cylinder rebuild, master cylinder replacement, brake line replacement
Electrical Troubleshooting:
Diagnosis of electrical faults using wiring diagrams, component testing, and circuit analysis
Bodywork And Trim:
Replacement of body panels, door mechanisms, glass sealing, interior trim panel removal and installation
Wheel Alignment:
Detailed specifications and procedures for adjusting camber, caster, and toe angles
Carburetor Adjustment:
Idle speed, air-fuel mixture, and choke adjustments for optimal performance and emissions
Diagnostic Procedures:
Step-by-step guides for identifying and resolving common and complex issues
Technical Depth
Depth Of Coverage:
Comprehensive - from basic maintenance to complete engine and drivetrain rebuilds
Diagnostic Capability:
Advanced diagnostic trees and troubleshooting flowcharts for identifying root causes of problems
Rebuild Procedures:
Detailed instructions with torque specifications and clearances for rebuilding major components
Wiring Diagrams:
Complete, often color-coded, wiring schematics for all vehicle systems
Schematics:
Hydraulic, pneumatic, and vacuum schematics where applicable
⚙️ Engine Specifications
Primary Engine
Engine Type:
Mazda Rotary (Wankel)
Engine Code:
12A
Displacement:
1146 cc (approx. 2 x 573 cc rotor chambers)
Performance
Horsepower Gross:
Approx. 90-100 HP (depending on market and emissions controls)
Torque Gross:
Approx. 90-100 lb-ft (depending on market and emissions controls)
Fuel System
Fuel Delivery:
Single or Twin Carburetor (e.g., Hitachi DCAS, Mikuni Solex)
Fuel Type:
Unleaded gasoline (depending on year and market regulations)
Technical Details
Rotor Housing Material:
Typically aluminum alloy with chrome plating
Apex Seals:
Crucial wear item, typically made of ceramic or carbon composites
Oil Injection:
Separate oil injection system for lubrication of apex and side seals
🔧 Transmission
Standard
Transmission Type:
4-speed manual
Optional
Transmission Type Optional:
5-speed manual, 3-speed automatic (less common)
Features
Clutch Type:
Single dry plate
Fluid Specifications
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or SAE 80W-90 gear oil (check manual for exact specification)
Automatic Transmission Fluid:
Dexron II or equivalent (if equipped with automatic transmission)
📐 Dimensions
Exterior
Wheelbase:
Approx. 97.0 inches (2465 mm)
Length:
Approx. 166.7 inches (4235 mm) for Coupe, 168.7 inches (4285 mm) for Sedan
Width:
Approx. 64.0 inches (1625 mm)
Height:
Approx. 52.0 inches (1320 mm) for Coupe, 53.7 inches (1365 mm) for Sedan
Weights
Curb Weight:
Approx. 2100-2300 lbs (950-1045 kg) depending on body style and equipment
Gross Vehicle Weight Rating:
Check vehicle specific placard, typically around 3000 lbs (1360 kg)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited data available for this era; modern safety standards not applicable.
Active Features
Braking:
Front disc, rear drum with single-circuit hydraulic system (dual circuit introduced later)
Passive Features
Seatbelts:
Standard lap belts, optional shoulder belts in some markets/trims
Body Structure:
Unibody construction with integrated safety cage elements
💡 Technology Features
Infotainment
Radio:
Basic AM/FM radio, potentially with cassette player in later models.
Gauges:
Speedometer, tachometer, fuel gauge, coolant temperature, oil pressure (basic analogue)
Driver Assistance
Braking Assist:
None
Traction Control:
None
Connectivity
Auxiliary Inputs:
None
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 miles (5,000 km) or 3 months, whichever comes first.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or annually.
Spark Plugs:
Inspect every 15,000 miles, replace as needed. Specific rotary plugs required.
Transmission Fluid Change:
Every 30,000 miles (48,000 km) or 24 months.
Rear Axle Fluid Change:
Every 30,000 miles (48,000 km) or 24 months.
Fluid Specifications
Engine Oil Capacity:
Approx. 4.0 - 4.5 US quarts (3.8 - 4.3 liters) with filter change (check manual for exact)
Engine Oil Viscosity:
10W-30 or 20W-50, depending on climate (check manual for exact recommendation).
Coolant Capacity:
Approx. 5.5 - 6.0 US quarts (5.2 - 5.7 liters)
Brake Fluid:
DOT 3 or DOT 4 glycol-based brake fluid
Known Issues
Rotary Engine Wear:
Apex seal wear and housing scoring are common due to the nature of the rotary design; requires careful maintenance and proper oiling.
Carburetor Issues:
Degradation of rubber components, clogging, and tuning difficulties.
Chassis Corrosion:
Rust and corrosion can be prevalent in areas exposed to salt and moisture.
Electrical Gremlins:
Aging wiring and connectors can lead to intermittent issues in lighting and accessories.
📚 Vehicle History
Brand Heritage
Mazda Rotary Pioneering:
Mazda's commitment to rotary engine development, starting with the Cosmo Sport.
Model Evolution
Predecessor:
Mazda R100 (Cosmo Sport)
Successor:
Mazda RX-3 (Savy), Mazda RX-4 (Capella)
Production
Production Years:
1971-1978 (approximate, varies by market)
Manufacturing Location:
Japan
Model Notes
Popularity:
Gained a niche following for its sporty handling and unique rotary powertrain.
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