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Mazda RX7 RX-7 1978-1980 Workshop Service Repair Manual

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The Mazda RX-7 (SA/FB chassis code) represents the first generation of Mazda's iconic rotary-powered sports car, produced from 1978 to 1980. This compact, rear-wheel-drive coupe revolutionized the affordable sports car segment with its unique Wankel rotary engine, offering a smooth, high-revving power delivery that set it apart from its contemporaries. Praised for its balanced weight distribution and driver-focused design, the RX-7 earned accolades such as being named one of Car and Driver's 'Ten Best' cars in 1979. Its distinctive styling and pioneering use of rotary technology cemented its status as a significant and engaging sports car of its era. This comprehensive Factory Service Manual provides detailed guidance for the maintenance, repair, and diagnostics of the 1978-1980 Mazda RX-7. It covers all major systems, including the rotary engine (12A), drivetrain, suspension, brakes, and electrical components. Within its hundreds of pages, you will find step-by-step procedures for routine maintenance, engine and transmission overhauls, component replacement, and in-depth troubleshooting. This manual is an essential resource for owners and technicians seeking to preserve the performance and longevity of this classic vehicle, offering insights into its unique rotary technology and common service considerations. 🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Code: SA/FB Generation Generation Name: First Generation Generation Code: SA22C (Initial) Codes Chassis Code Prefix: SA22C 👋 Introduction Market Position Segment: Compact Sports Car / Grand Touring Coupe Era Context: Pioneering affordable rotary-powered sports car in the late 1970s Competitive Analysis Key Competitors: Datsun Z-cars (240Z, 260Z, 280Z), Toyota Celica, Honda Prelude, Porsche 924 Key Features Unique Selling Proposition: Compact size, lightweight, rear-wheel drive, and a unique Wankel rotary engine offering a smooth, high-revving power delivery. Design Philosophy: Balanced weight distribution, driver-focused cockpit, and distinctive styling. 📋 Manual Details Coverage Areas Covered Years: 1978, 1979, 1980 Page Count Estimated Pages: Hundreds of pages Manual Type Type: Workshop Service Repair Manual Official Designation: Factory Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Rotary Engine (12A), Engine Mechanical, Cooling System, Lubrication System, Fuel System, Ignition System, Emission Control System Drivetrain: Clutch, Transmission (Manual), Driveshaft, Rear Axle Assembly Suspension: Front Suspension, Rear Suspension, Steering System Brakes: Front Disc Brakes, Rear Drum Brakes, Hydraulic System, Parking Brake Electrical: Wiring Diagrams, Charging System, Starting System, Lighting System, Instruments and Gauges, Ignition System, Power Distribution, Exterior and Interior Electrical Components Body And Chassis: Body Panels, Doors, Hood, Trunk, Glass, Seats, Interior Trim, Chassis Frame Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement (Rotary Specific), Fluid Checks and Replacements Repair: Engine Rebuilds, Transmission Overhaul, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Repair, Body Panel Repair Diagnostics: Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Specifications, Component Testing Technical Depth Depth: Comprehensive (from basic maintenance to full engine rebuilds and diagnostics) Diagnostic Tools: Information on required specialized tools for rotary engines and general automotive repair 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (depending on scan quality) Print Quality Printability: Printable in its entirety or specific sections Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Wankel Rotary (Two-Rotor) Engine Code: 12A Displacement: 1146 cc (approx. 69.9 cu in.) Rotor Housing Design: Epitrochoidal Performance Horsepower Early Models: Approx. 100-110 hp @ 6000-6500 rpm (depending on market and emissions controls) Torque Early Models: Approx. 105-115 lb-ft @ 3500-4000 rpm Fuel System Carburetion: Nikki downdraft 2-barrel carburetor (for 1978-1980 models) Fuel Type: Unleaded gasoline (Premium recommended) Cooling System Cooling Method: Water-cooled Lubrication System Oil Type Recommendation: API SG or SH, SAE 10W-30 or 10W-40 (refer to manual for exact specifications) Oil Capacity: Approx. 5.5 US quarts (5.2 Liters) with filter change Oil Injection: Separate oil metering system for apex seals 🔧 Transmission Standard Transmission Type: 4-speed manual transmission Optional Transmission Type: 3-speed automatic transmission (less common) Features Clutch Type: Dry single plate clutch Transmission Fluid Type: GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, check manual) 📐 Dimensions Exterior Length: Approx. 162.8 inches (4135 mm) Width: Approx. 65.2 inches (1656 mm) Height: Approx. 50.0 inches (1270 mm) Wheelbase: Approx. 95.7 inches (2430 mm) Weights Curb Weight: Approx. 2300-2500 lbs (1043-1134 kg) Gross Vehicle Weight Rating: Refer to vehicle placard 🛡️ Safety Features Ratings Crash Test Ratings: NHTSA and IIHS ratings from this era are not directly comparable to modern standards, but the vehicle was designed with crumple zones. Active Features Braking System: Power-assisted front disc brakes and rear drum brakes Steering: Recirculating ball, power steering optional on some models Passive Features Seat Belts: 3-point front seat belts Windshield: Laminated safety glass 💡 Technology Features Infotainment Radio: AM/FM radio, optional cassette player Speakers: Typically 2 or 4 speaker system Driver Assistance Cruise Control: Optional on higher trim levels Headlights: Halogen headlights, pop-up mechanism Connectivity Connectivity Features: None (pre-dates modern...
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Mazda RX7 RX-7 1978-1980 Workshop Service Repair ManualMazda RX7 RX-7 1978-1980 Workshop Service Repair ManualMazda RX7 RX-7 1978-1980 Workshop Service Repair ManualMazda RX7 RX-7 1978-1980 Workshop Service Repair Manual
The Mazda RX-7 (SA/FB chassis code) represents the first generation of Mazda's iconic rotary-powered sports car, produced from 1978 to 1980. This compact, rear-wheel-drive coupe revolutionized the affordable sports car segment with its unique Wankel rotary engine, offering a smooth, high-revving power delivery that set it apart from its contemporaries. Praised for its balanced weight distribution and driver-focused design, the RX-7 earned accolades such as being named one of Car and Driver's 'Ten Best' cars in 1979. Its distinctive styling and pioneering use of rotary technology cemented its status as a significant and engaging sports car of its era. This comprehensive Factory Service Manual provides detailed guidance for the maintenance, repair, and diagnostics of the 1978-1980 Mazda RX-7. It covers all major systems, including the rotary engine (12A), drivetrain, suspension, brakes, and electrical components. Within its hundreds of pages, you will find step-by-step procedures for routine maintenance, engine and transmission overhauls, component replacement, and in-depth troubleshooting. This manual is an essential resource for owners and technicians seeking to preserve the performance and longevity of this classic vehicle, offering insights into its unique rotary technology and common service considerations.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Model Code:
SA/FB
Generation
Generation Name:
First Generation
Generation Code:
SA22C (Initial)
Codes
Chassis Code Prefix:
SA22C
👋 Introduction
Market Position
Segment:
Compact Sports Car / Grand Touring Coupe
Era Context:
Pioneering affordable rotary-powered sports car in the late 1970s
Competitive Analysis
Key Competitors:
Datsun Z-cars (240Z, 260Z, 280Z), Toyota Celica, Honda Prelude, Porsche 924
Key Features
Unique Selling Proposition:
Compact size, lightweight, rear-wheel drive, and a unique Wankel rotary engine offering a smooth, high-revving power delivery.
Design Philosophy:
Balanced weight distribution, driver-focused cockpit, and distinctive styling.
📋 Manual Details
Coverage Areas
Covered Years:
1978, 1979, 1980
Page Count
Estimated Pages:
Hundreds of pages
Manual Type
Type:
Workshop Service Repair Manual
Official Designation:
Factory Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Rotary Engine (12A), Engine Mechanical, Cooling System, Lubrication System, Fuel System, Ignition System, Emission Control System
Drivetrain:
Clutch, Transmission (Manual), Driveshaft, Rear Axle Assembly
Suspension:
Front Suspension, Rear Suspension, Steering System
Brakes:
Front Disc Brakes, Rear Drum Brakes, Hydraulic System, Parking Brake
Electrical:
Wiring Diagrams, Charging System, Starting System, Lighting System, Instruments and Gauges, Ignition System, Power Distribution, Exterior and Interior Electrical Components
Body And Chassis:
Body Panels, Doors, Hood, Trunk, Glass, Seats, Interior Trim, Chassis Frame
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement (Rotary Specific), Fluid Checks and Replacements
Repair:
Engine Rebuilds, Transmission Overhaul, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Repair, Body Panel Repair
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Specifications, Component Testing
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and diagnostics)
Diagnostic Tools:
Information on required specialized tools for rotary engines and general automotive repair
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (depending on scan quality)
Print Quality
Printability:
Printable in its entirety or specific sections
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Wankel Rotary (Two-Rotor)
Engine Code:
12A
Displacement:
1146 cc (approx. 69.9 cu in.)
Rotor Housing Design:
Epitrochoidal
Performance
Horsepower Early Models:
Approx. 100-110 hp @ 6000-6500 rpm (depending on market and emissions controls)
Torque Early Models:
Approx. 105-115 lb-ft @ 3500-4000 rpm
Fuel System
Carburetion:
Nikki downdraft 2-barrel carburetor (for 1978-1980 models)
Fuel Type:
Unleaded gasoline (Premium recommended)
Cooling System
Cooling Method:
Water-cooled
Lubrication System
Oil Type Recommendation:
API SG or SH, SAE 10W-30 or 10W-40 (refer to manual for exact specifications)
Oil Capacity:
Approx. 5.5 US quarts (5.2 Liters) with filter change
Oil Injection:
Separate oil metering system for apex seals
🔧 Transmission
Standard
Transmission Type:
4-speed manual transmission
Optional
Transmission Type:
3-speed automatic transmission (less common)
Features
Clutch Type:
Dry single plate clutch
Transmission Fluid Type:
GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, check manual)
📐 Dimensions
Exterior
Length:
Approx. 162.8 inches (4135 mm)
Width:
Approx. 65.2 inches (1656 mm)
Height:
Approx. 50.0 inches (1270 mm)
Wheelbase:
Approx. 95.7 inches (2430 mm)
Weights
Curb Weight:
Approx. 2300-2500 lbs (1043-1134 kg)
Gross Vehicle Weight Rating:
Refer to vehicle placard
🛡️ Safety Features
Ratings
Crash Test Ratings:
NHTSA and IIHS ratings from this era are not directly comparable to modern standards, but the vehicle was designed with crumple zones.
Active Features
Braking System:
Power-assisted front disc brakes and rear drum brakes
Steering:
Recirculating ball, power steering optional on some models
Passive Features
Seat Belts:
3-point front seat belts
Windshield:
Laminated safety glass
💡 Technology Features
Infotainment
Radio:
AM/FM radio, optional cassette player
Speakers:
Typically 2 or 4 speaker system
Driver Assistance
Cruise Control:
Optional on higher trim levels
Headlights:
Halogen headlights, pop-up mechanism
Connectivity
Connectivity Features:
None (pre-dates modern connectivity standards)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles (5,000 km) or 3 months, whichever comes first (typical recommendation)
Air Filter Replacement:
Refer to manual, typically every 15,000-30,000 miles (24,000-48,000 km)
Spark Plug Replacement:
Specific rotary plugs, interval varies, consult manual (e.g., every 15,000-20,000 miles)
Coolant Flush:
Every 2 years or 30,000 miles (48,000 km)
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Coolant:
Ethylene glycol-based coolant (50/50 mix with distilled water)
Known Issues
Rotary Specific Wear:
Apex seal wear, carbon seal buildup, potential for rotor housing scoring if maintenance is neglected.
Carburetor Issues:
Tuning difficulties, gumming of fuel passages, choke issues.
Electrical Gremlins:
Corrosion in connectors, aging wiring harnesses, and failing relays are common in older vehicles.
Rust And Corrosion:
Common on body panels and chassis components due to age and environmental exposure.
📚 Vehicle History
Brand Heritage
Mazda Rotary Introduction:
Mazda pioneered the Wankel rotary engine in passenger cars, starting with the Mazda Cosmo Sport 110S in 1967.
Model Evolution
Rx-7 Debut:
The RX-7 (SA22C) debuted in 1978 as a successor to the RX-3, aiming to compete with established sports cars.
First Generation Facelift:
A minor facelift occurred for the 1981 model year (transitioning to FB designation), with updated styling and potentially improved emissions.
Production
Manufacturing Plant:
Mazda's plants in Japan
Production Period Fa:
1978-1981 (SA22C chassis code)
🏆 Awards & Recognition
Recognitions
Car And Driver Best Driver Car:
Recognized by Car and Driver as one of its 'Ten Best' cars in 1979.
Motor Trend Import Car Of The Year:
Often cited in discussions of seminal Japanese sports cars of the era.
Certifications
Emission Standards Compliance:
Designed to meet US emissions standards of the late 1970s, requiring careful tuning.
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