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Mazda RX-7 1978 1979 1980 Workshop Repair Service Manual

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The Mazda RX-7 First Generation (SA/FB), produced from 1978 to 1980, stands as a testament to innovative automotive engineering, most notably featuring Mazda's pioneering rotary engine. Designed as an affordable sports coupe, it offered a compelling blend of lightweight construction, balanced handling, and a driver-focused experience that set it apart from contemporaries like the Datsun 240Z and Toyota Celica Supra. This iconic vehicle, manufactured in Japan, was celebrated for its unique Wankel engine technology, providing a distinct driving character and performance that appealed to automotive enthusiasts. This comprehensive workshop repair service manual, written in English and covering global markets primarily North America and Japan, provides in-depth information for the maintenance and repair of the Mazda RX-7 First Generation. With over 700 pages of detailed content, it covers all essential systems, including the 12A rotary engine, fuel, ignition, cooling, lubrication, and exhaust systems, as well as the transmission, drivetrain, suspension, steering, brakes, electrical systems, body, and interior. The manual includes general maintenance procedures, detailed engine and transmission rebuilds, electrical troubleshooting, and crucial technical specifications, serving as an indispensable resource for owners, mechanics, and technicians. 🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: First Generation (SA/FB) Production Years Covered: 1978-1980 👋 Introduction Market Position Original Market Segment: Affordable Sports Coupe Target Audience: Enthusiasts seeking performance and unique rotary engine experience Competitive Analysis Key Competitors: Datsun 240Z/260Z/280Z, Toyota Celica Supra, Porsche 924 Key Features Distinctive Feature: Rotary Engine (Wankel) Design Philosophy: Lightweight, balanced chassis, driver-focused 📋 Manual Details Coverage Areas Language: English Regions Covered: Global (primarily North America and Japan) Page Count Estimated Page Count: 700+ Manual Type Manual Type: Workshop Repair Service Manual Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Rotary Engine (12A) Fuel System: Carburetor (likely Hitachi/Keihin), Fuel Pump, Lines Ignition System: Distributor, Ignition Coils, Spark Plugs Cooling System: Radiator, Fan, Water Pump, Hoses, Thermostat Lubrication System: Oil Pump, Oil Pan, Oil Filter, Oil Cooler (if equipped) Exhaust System: Manifold, Catalytic Converter (if applicable by region), Muffler Transmission: Manual Transmission (4-speed and 5-speed), Clutch Drivetrain: Rear-Wheel Drive, Driveshaft, Differential, Axles Suspension: Front (MacPherson Strut), Rear (Live Axle with Watt's Linkage), Springs, Shocks, Bushings Steering: Rack and Pinion, Steering Column, Tie Rods Brakes: Front Disc Brakes, Rear Drum Brakes (typically), Master Cylinder, Lines, Parking Brake Electrical System: Battery, Alternator, Starter Motor, Wiring Diagrams, Lighting, Fuses, Relays Body And Frame: Body Panels, Chassis, Doors, Hood, Trunk, Bumpers, Glass Interior: Seats, Dashboard, Trim, HVAC Controls HVAC: Heating, Ventilation, Air Conditioning (if factory equipped) Procedures Included General Maintenance: Oil Changes, Filter Replacements, Spark Plug Checks/Replacement, Belt Adjustments Engine Overhaul: Apex Seal Replacement, Rotor Housing Machining, Rebuild Procedures Transmission Repair: Clutch Replacement, Gearbox Disassembly and Reassembly Brake Service: Pad/Shoe Replacement, Rotor/Drum Machining, Bleeding Electrical Troubleshooting: Wiring Diagram Interpretation, Component Testing, Fault Diagnosis Suspension And Steering Repair: Bushings, Ball Joints, Tie Rod Ends, Strut Replacement Fuel System Diagnostics: Carburetor Adjustment, Fuel Filter Replacement Engine Tune Up: Ignition Timing, Carburetor Synchronization Troubleshooting Guides: Common Problems and Solutions, Diagnostic Flowcharts Technical Depth Diagnostics: Advanced Diagnostics, Fault Code Interpretation (if applicable) Rebuild Procedures: Complete Engine Rebuild, Transmission Rebuild, Differential Rebuild Specifications And Tolerances: Torque Values, Clearances, Wear Limits Wiring Diagrams: Comprehensive Electrical Schematics for All Systems Special Tools: Identification and Usage of Mazda Specific Tools 📊 Manual Specifications File Format PDF Quality: High Resolution, Searchable Text Printable: Yes, all pages are printable Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 12A Engine Type: Naturally Aspirated Rotary (Two-Rotor Wankel) Displacement: 1146 cc (69.9 cu in) Rotor Housing Material: Chrome-plated aluminum alloy Lubrication System Type: Rotary engine specific oil injection system (RE-I) and sump lubrication Performance Horsepower Peak: 100-110 hp (approx.) Torque Peak: 110-120 lb-ft (approx.) Redline Rpm: 7000 RPM Fuel System Carburetor Type: Two-Barrel Downdraft (e.g., Hitachi DCAS 3140 or Keihin) Fuel Type: Unleaded Gasoline (87 Octane or higher recommended) 🔧 Transmission Standard Standard Transmission: 4-Speed Manual Optional Optional Transmission: 5-Speed Manual (introduced later in the generation/model years) Features Clutch Type: Single Dry Plate Clutch Transmission Fluid Type: API GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90) 📐 Dimensions Exterior Wheelbase: 2400 mm (94.5 in) Length: 4215 mm (165.9 in) Width: 1650 mm (65.0 in) Height: 1280 mm (50.4 in) Weights Curb Weight: Approx. 1000-1100 kg (2200-2425 lbs) Gross Vehicle Weight Rating: Approx. 1350 kg (2976 lbs) Cargo Trunk Volume: Limited (typical for sports coupes) 🛡️ Safety Features Ratings Crash Test Ratings: Not extensively tested by modern standards; primarily focused on occupant protection for its era. Active Features Active Safety Features: Standard braking system, limited electronic aids (if any) Passive Features Passive Safety Features: Seatbelts, reinforced chassis construction 💡 Technology Features Infotainment Infotainment System: Basic AM/FM radio with optional cassette player, manual climate controls. Driver Assistance Driver Assistance Features: None (pre-dates modern driver...
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Mazda RX-7 1978 1979 1980 Workshop Repair Service ManualMazda RX-7 1978 1979 1980 Workshop Repair Service ManualMazda RX-7 1978 1979 1980 Workshop Repair Service ManualMazda RX-7 1978 1979 1980 Workshop Repair Service Manual
The Mazda RX-7 First Generation (SA/FB), produced from 1978 to 1980, stands as a testament to innovative automotive engineering, most notably featuring Mazda's pioneering rotary engine. Designed as an affordable sports coupe, it offered a compelling blend of lightweight construction, balanced handling, and a driver-focused experience that set it apart from contemporaries like the Datsun 240Z and Toyota Celica Supra. This iconic vehicle, manufactured in Japan, was celebrated for its unique Wankel engine technology, providing a distinct driving character and performance that appealed to automotive enthusiasts. This comprehensive workshop repair service manual, written in English and covering global markets primarily North America and Japan, provides in-depth information for the maintenance and repair of the Mazda RX-7 First Generation. With over 700 pages of detailed content, it covers all essential systems, including the 12A rotary engine, fuel, ignition, cooling, lubrication, and exhaust systems, as well as the transmission, drivetrain, suspension, steering, brakes, electrical systems, body, and interior. The manual includes general maintenance procedures, detailed engine and transmission rebuilds, electrical troubleshooting, and crucial technical specifications, serving as an indispensable resource for owners, mechanics, and technicians.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
First Generation (SA/FB)
Production Years Covered:
1978-1980
👋 Introduction
Market Position
Original Market Segment:
Affordable Sports Coupe
Target Audience:
Enthusiasts seeking performance and unique rotary engine experience
Competitive Analysis
Key Competitors:
Datsun 240Z/260Z/280Z, Toyota Celica Supra, Porsche 924
Key Features
Distinctive Feature:
Rotary Engine (Wankel)
Design Philosophy:
Lightweight, balanced chassis, driver-focused
📋 Manual Details
Coverage Areas
Language:
English
Regions Covered:
Global (primarily North America and Japan)
Page Count
Estimated Page Count:
700+
Manual Type
Manual Type:
Workshop Repair Service Manual
Format
File Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Rotary Engine (12A)
Fuel System:
Carburetor (likely Hitachi/Keihin), Fuel Pump, Lines
Ignition System:
Distributor, Ignition Coils, Spark Plugs
Cooling System:
Radiator, Fan, Water Pump, Hoses, Thermostat
Lubrication System:
Oil Pump, Oil Pan, Oil Filter, Oil Cooler (if equipped)
Exhaust System:
Manifold, Catalytic Converter (if applicable by region), Muffler
Transmission:
Manual Transmission (4-speed and 5-speed), Clutch
Drivetrain:
Rear-Wheel Drive, Driveshaft, Differential, Axles
Suspension:
Front (MacPherson Strut), Rear (Live Axle with Watt's Linkage), Springs, Shocks, Bushings
Steering:
Rack and Pinion, Steering Column, Tie Rods
Brakes:
Front Disc Brakes, Rear Drum Brakes (typically), Master Cylinder, Lines, Parking Brake
Electrical System:
Battery, Alternator, Starter Motor, Wiring Diagrams, Lighting, Fuses, Relays
Body And Frame:
Body Panels, Chassis, Doors, Hood, Trunk, Bumpers, Glass
Interior:
Seats, Dashboard, Trim, HVAC Controls
HVAC:
Heating, Ventilation, Air Conditioning (if factory equipped)
Procedures Included
General Maintenance:
Oil Changes, Filter Replacements, Spark Plug Checks/Replacement, Belt Adjustments
Engine Overhaul:
Apex Seal Replacement, Rotor Housing Machining, Rebuild Procedures
Transmission Repair:
Clutch Replacement, Gearbox Disassembly and Reassembly
Brake Service:
Pad/Shoe Replacement, Rotor/Drum Machining, Bleeding
Electrical Troubleshooting:
Wiring Diagram Interpretation, Component Testing, Fault Diagnosis
Suspension And Steering Repair:
Bushings, Ball Joints, Tie Rod Ends, Strut Replacement
Fuel System Diagnostics:
Carburetor Adjustment, Fuel Filter Replacement
Engine Tune Up:
Ignition Timing, Carburetor Synchronization
Troubleshooting Guides:
Common Problems and Solutions, Diagnostic Flowcharts
Technical Depth
Diagnostics:
Advanced Diagnostics, Fault Code Interpretation (if applicable)
Rebuild Procedures:
Complete Engine Rebuild, Transmission Rebuild, Differential Rebuild
Specifications And Tolerances:
Torque Values, Clearances, Wear Limits
Wiring Diagrams:
Comprehensive Electrical Schematics for All Systems
Special Tools:
Identification and Usage of Mazda Specific Tools
📊 Manual Specifications
File Format
PDF Quality:
High Resolution, Searchable Text
Printable:
Yes, all pages are printable
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
12A
Engine Type:
Naturally Aspirated Rotary (Two-Rotor Wankel)
Displacement:
1146 cc (69.9 cu in)
Rotor Housing Material:
Chrome-plated aluminum alloy
Lubrication System Type:
Rotary engine specific oil injection system (RE-I) and sump lubrication
Performance
Horsepower Peak:
100-110 hp (approx.)
Torque Peak:
110-120 lb-ft (approx.)
Redline Rpm:
7000 RPM
Fuel System
Carburetor Type:
Two-Barrel Downdraft (e.g., Hitachi DCAS 3140 or Keihin)
Fuel Type:
Unleaded Gasoline (87 Octane or higher recommended)
🔧 Transmission
Standard
Standard Transmission:
4-Speed Manual
Optional
Optional Transmission:
5-Speed Manual (introduced later in the generation/model years)
Features
Clutch Type:
Single Dry Plate Clutch
Transmission Fluid Type:
API GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90)
📐 Dimensions
Exterior
Wheelbase:
2400 mm (94.5 in)
Length:
4215 mm (165.9 in)
Width:
1650 mm (65.0 in)
Height:
1280 mm (50.4 in)
Weights
Curb Weight:
Approx. 1000-1100 kg (2200-2425 lbs)
Gross Vehicle Weight Rating:
Approx. 1350 kg (2976 lbs)
Cargo
Trunk Volume:
Limited (typical for sports coupes)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not extensively tested by modern standards; primarily focused on occupant protection for its era.
Active Features
Active Safety Features:
Standard braking system, limited electronic aids (if any)
Passive Features
Passive Safety Features:
Seatbelts, reinforced chassis construction
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio with optional cassette player, manual climate controls.
Driver Assistance
Driver Assistance Features:
None (pre-dates modern driver assistance systems).
Connectivity
Connectivity Options:
None
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles or 3 months, whichever comes first
Air Filter Replacement:
Every 12,000 miles or 12 months
Spark Plug Replacement:
Every 15,000 miles
Coolant Flush:
Every 24,000 miles or 24 months
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 10W-30 or 10W-40 (check owner's manual for specific recommendations)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Apex Seal Wear:
Premature wear of apex seals due to improper break-in, overheating, or detonation. Requires engine rebuild.
Carburetor Issues:
Clogging, vacuum leaks, difficult synchronization leading to poor running.
Oil Consumption:
Natural characteristic of rotary engines requiring oil injection; excessive consumption can indicate seal wear.
Rust And Corrosion:
Common in older vehicles, particularly in salt-prone regions, affecting body panels and undercarriage.
📚 Vehicle History
Brand Heritage
Mazda Rotary Development:
Mazda's pioneering and successful implementation of the Wankel rotary engine in mass production vehicles.
Model Evolution
Rx-7 Initial Launch:
Launched in 1978 as a successor to the RX-3, aimed at offering sports car performance with compact dimensions and a unique engine.
Generation Codes:
SA for 1978-1980, FB for 1981-1985
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Iconic Status:
Considered a classic sports car and an icon of rotary engine technology.
Ratings
Car And Driver Ranking:
Frequently listed in 'Ten Best Cars' lists for its respective years due to performance and value.
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