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Mazda RX-7 1978 1979 1980 Workshop Service Manual for Repair

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The Mazda RX-7 First Generation (SA22C) is a compact sports car produced from 1978 to 1980, celebrated for its distinctive rotary engine technology, lightweight chassis, and sporty handling. This iconic model established Mazda's reputation in the performance car segment, offering a unique driving experience that set it apart from contemporaries like the Datsun Z-series and Toyota Celica. Engineered with a two-rotor Wankel engine (12A) producing approximately 100-110 horsepower, the RX-7 provided an engaging and spirited ride, making it a favorite among enthusiasts and a significant entry in automotive history. This workshop service and repair manual provides comprehensive technical guidance for the Mazda RX-7 First Generation (SA22C) models from 1978, 1979, and 1980. It covers a wide array of systems, including the rotary engine, fuel, ignition, transmission, drivetrain, suspension, steering, brakes, and electrical systems, as well as body and chassis components. The manual details routine maintenance procedures, in-depth diagnostic and troubleshooting guides, and instructions for component repair and overhaul, supported by essential specifications and data. Its purpose is to assist owners, mechanics, and technicians in effectively maintaining, repairing, and understanding this classic vehicle. 🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: First Generation (SA/FB) Codes Chassis Code: SA22C 👋 Introduction Market Position Segment: Compact Sports Car Target Audience: Enthusiasts, DIY Mechanics, Restoration Specialists Competitive Analysis Key Competitors: Datsun Z-series, Toyota Celica, Ford Capri, Fiat X1/9 Key Features Distinguishing Factor: Rotary Engine technology, lightweight chassis, sporty handling Value Proposition: Provides in-depth technical guidance for maintaining and repairing the iconic first-generation RX-7 📋 Manual Details Coverage Areas Model Years Covered: 1978, 1979, 1980 Region Specific Coverage: General (assumed global, specific regional variations may exist) Page Count Total Pages: 155 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English (presumed, standard for most workshop manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Rotary Engine (12A) - Theory of Operation, Disassembly, Assembly, Troubleshooting, Diagnostics, Lubrication, Cooling System Fuel System: Carburetion (Nikki or similar), Fuel Pump, Fuel Lines, Fuel Tank, Emission Control Systems (Air Injection, EGR) Ignition System: Distributor, Ignition Coils, Spark Plugs, Ignition Timing, Electronic Ignition Components Drivetrain: Driveshaft, Rear Axle, Differential, Wheel Bearings Suspension: Front Suspension (MacPherson Struts), Rear Suspension (Multi-link), Shock Absorbers, Springs, Bushings, Alignment Specifications Steering: Steering Gear, Steering Column, Power Steering System (if equipped), Tie Rods, Ball Joints Brakes: Front Disc Brakes, Rear Drum Brakes (typically), Brake Lines, Master Cylinder, Calipers, Wheel Cylinders, Parking Brake System, Brake Fluid Specifications Electrical System: Wiring Diagrams, Battery, Alternator, Starter Motor, Lighting System, Fuses, Relays, Gauges, Horn, Wiper System Body And Chassis: Body Panel Repair, Doors, Hood, Trunk, Glass, Bumpers, Interior Trim, Chassis Frame, Corrosion Protection HVAC: Heating System, Ventilation, Air Conditioning (if equipped), Refrigerant Type, Service Procedures Transmission Manual Transmission: Removal, Installation, Disassembly, Assembly, Fluid Specifications, Troubleshooting Automatic Transmission: If applicable for the model years covered - Removal, Installation, Troubleshooting, Fluid Specifications Procedures Included Maintenance: Oil Changes, Filter Replacements, Spark Plug Service, Fluid Top-offs, Belt Adjustments, Inspection Procedures Diagnostics Troubleshooting: Step-by-step diagnostic flowcharts for common problems, symptom-based troubleshooting guides Repair Overhaul: Detailed instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation Specifications Data: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters Technical Depth Depth: Comprehensive, covering routine maintenance to major component overhauls and troubleshooting 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if OCR'd properly Print Quality Quality: Variable (depends on original scan quality), typically clear for text and diagrams Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Mazda Rotary (Wankel) Engine Engine Code: 12A Rotor Displacement: 573 cc per rotor (total 1.15 liters equivalent) Configuration: Two-Rotor Performance Horsepower: Approx. 100-110 hp (varies slightly by year and market) Torque: Approx. 105-115 lb-ft (varies slightly by year and market) Fuel System Carburetion: Single or Twin Downdraft Carburetors (e.g., Nikki, Solex) Fuel Type: Unleaded Gasoline (Octane rating appropriate for performance) Lubrication Oil Type: Specific Rotary Engine Oil (e.g., API SG/SH or equivalent, consult manual for exact specs and viscosity) Cooling System Coolant Type: Ethylene Glycol based antifreeze/coolant mixture (50/50) 🔧 Transmission Standard Type: 4-Speed Manual Transmission (early models), 5-Speed Manual Transmission (later models) Optional Type: 3-Speed Automatic Transmission Features Clutch Type: Dry Single Plate Clutch Fluid Specifications Manual Transmission Fluid: API GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, consult manual for specific viscosity and capacity) Automatic Transmission Fluid: Dexron II or equivalent 📐 Dimensions Exterior Body Style: 2-Door Coupe, 2-Door Fastback Wheelbase: Approx. 95.7 inches (2430 mm) Length: Approx. 163.0 inches (4140 mm) Width: Approx. 65.2 inches (1655 mm) Height: Approx. 50.6 inches (1285 mm) Weights Curb Weight: Approx. 2200-2400 lbs (1000-1090 kg) 🛡️ Safety Features Ratings Crash Test Data: Limited official data available for this era, rely on contemporary automotive reviews and general safety practices of the time. 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Sku: 64719
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Mazda RX-7 1978 1979 1980 Workshop Service Manual for RepairMazda RX-7 1978 1979 1980 Workshop Service Manual for RepairMazda RX-7 1978 1979 1980 Workshop Service Manual for Repair
The Mazda RX-7 First Generation (SA22C) is a compact sports car produced from 1978 to 1980, celebrated for its distinctive rotary engine technology, lightweight chassis, and sporty handling. This iconic model established Mazda's reputation in the performance car segment, offering a unique driving experience that set it apart from contemporaries like the Datsun Z-series and Toyota Celica. Engineered with a two-rotor Wankel engine (12A) producing approximately 100-110 horsepower, the RX-7 provided an engaging and spirited ride, making it a favorite among enthusiasts and a significant entry in automotive history. This workshop service and repair manual provides comprehensive technical guidance for the Mazda RX-7 First Generation (SA22C) models from 1978, 1979, and 1980. It covers a wide array of systems, including the rotary engine, fuel, ignition, transmission, drivetrain, suspension, steering, brakes, and electrical systems, as well as body and chassis components. The manual details routine maintenance procedures, in-depth diagnostic and troubleshooting guides, and instructions for component repair and overhaul, supported by essential specifications and data. Its purpose is to assist owners, mechanics, and technicians in effectively maintaining, repairing, and understanding this classic vehicle.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
First Generation (SA/FB)
Codes
Chassis Code:
SA22C
👋 Introduction
Market Position
Segment:
Compact Sports Car
Target Audience:
Enthusiasts, DIY Mechanics, Restoration Specialists
Competitive Analysis
Key Competitors:
Datsun Z-series, Toyota Celica, Ford Capri, Fiat X1/9
Key Features
Distinguishing Factor:
Rotary Engine technology, lightweight chassis, sporty handling
Value Proposition:
Provides in-depth technical guidance for maintaining and repairing the iconic first-generation RX-7
📋 Manual Details
Coverage Areas
Model Years Covered:
1978, 1979, 1980
Region Specific Coverage:
General (assumed global, specific regional variations may exist)
Page Count
Total Pages:
155
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English (presumed, standard for most workshop manuals)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Rotary Engine (12A) - Theory of Operation, Disassembly, Assembly, Troubleshooting, Diagnostics, Lubrication, Cooling System
Fuel System:
Carburetion (Nikki or similar), Fuel Pump, Fuel Lines, Fuel Tank, Emission Control Systems (Air Injection, EGR)
Ignition System:
Distributor, Ignition Coils, Spark Plugs, Ignition Timing, Electronic Ignition Components
Drivetrain:
Driveshaft, Rear Axle, Differential, Wheel Bearings
Suspension:
Front Suspension (MacPherson Struts), Rear Suspension (Multi-link), Shock Absorbers, Springs, Bushings, Alignment Specifications
Steering:
Steering Gear, Steering Column, Power Steering System (if equipped), Tie Rods, Ball Joints
Brakes:
Front Disc Brakes, Rear Drum Brakes (typically), Brake Lines, Master Cylinder, Calipers, Wheel Cylinders, Parking Brake System, Brake Fluid Specifications
Electrical System:
Wiring Diagrams, Battery, Alternator, Starter Motor, Lighting System, Fuses, Relays, Gauges, Horn, Wiper System
Body And Chassis:
Body Panel Repair, Doors, Hood, Trunk, Glass, Bumpers, Interior Trim, Chassis Frame, Corrosion Protection
HVAC:
Heating System, Ventilation, Air Conditioning (if equipped), Refrigerant Type, Service Procedures
Transmission
Manual Transmission:
Removal, Installation, Disassembly, Assembly, Fluid Specifications, Troubleshooting
Automatic Transmission:
If applicable for the model years covered - Removal, Installation, Troubleshooting, Fluid Specifications
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Fluid Top-offs, Belt Adjustments, Inspection Procedures
Diagnostics Troubleshooting:
Step-by-step diagnostic flowcharts for common problems, symptom-based troubleshooting guides
Repair Overhaul:
Detailed instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters
Technical Depth
Depth:
Comprehensive, covering routine maintenance to major component overhauls and troubleshooting
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable if OCR'd properly
Print Quality
Quality:
Variable (depends on original scan quality), typically clear for text and diagrams
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Mazda Rotary (Wankel) Engine
Engine Code:
12A
Rotor Displacement:
573 cc per rotor (total 1.15 liters equivalent)
Configuration:
Two-Rotor
Performance
Horsepower:
Approx. 100-110 hp (varies slightly by year and market)
Torque:
Approx. 105-115 lb-ft (varies slightly by year and market)
Fuel System
Carburetion:
Single or Twin Downdraft Carburetors (e.g., Nikki, Solex)
Fuel Type:
Unleaded Gasoline (Octane rating appropriate for performance)
Lubrication
Oil Type:
Specific Rotary Engine Oil (e.g., API SG/SH or equivalent, consult manual for exact specs and viscosity)
Cooling System
Coolant Type:
Ethylene Glycol based antifreeze/coolant mixture (50/50)
🔧 Transmission
Standard
Type:
4-Speed Manual Transmission (early models), 5-Speed Manual Transmission (later models)
Optional
Type:
3-Speed Automatic Transmission
Features
Clutch Type:
Dry Single Plate Clutch
Fluid Specifications
Manual Transmission Fluid:
API GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90, consult manual for specific viscosity and capacity)
Automatic Transmission Fluid:
Dexron II or equivalent
📐 Dimensions
Exterior
Body Style:
2-Door Coupe, 2-Door Fastback
Wheelbase:
Approx. 95.7 inches (2430 mm)
Length:
Approx. 163.0 inches (4140 mm)
Width:
Approx. 65.2 inches (1655 mm)
Height:
Approx. 50.6 inches (1285 mm)
Weights
Curb Weight:
Approx. 2200-2400 lbs (1000-1090 kg)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official data available for this era, rely on contemporary automotive reviews and general safety practices of the time.
Active Features
Brakes:
Front ventilated disc brakes, Rear drum brakes
Steering:
Recirculating ball steering (some models with power steering)
Passive Features
Seat Belts:
Three-point seat belts (front)
Construction:
Unibody construction with front and rear crumple zones (design principles of the era)
💡 Technology Features
Infotainment
Radio:
AM/FM radio, often with cassette player (optional or aftermarket)
Gauges:
Tachometer, speedometer, oil pressure, water temperature, voltmeter
Driver Assistance
Features:
Minimal by modern standards; focus on basic driver controls and feedback.
Connectivity
Features:
None (pre-dates modern connectivity)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 3,000-5,000 miles or 6 months, consult manual for specific interval and type of oil
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection
Spark Plugs Service:
Rotary engines require specific plugs, check manual for interval and type (e.g., platinum)
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (consult manual)
Coolant Capacity:
Approx. 5.5-6.0 quarts (5.2-5.7 liters), consult manual
Known Issues
Apex Seals:
Wear and failure of apex seals is a common rotary engine issue; proper maintenance and break-in procedures are critical.
Carburetor Issues:
Tuning difficulties, diaphragm wear, clogging, especially with age.
Oil Consumption:
Rotary engines naturally consume a small amount of oil for lubrication, but excessive consumption can indicate seal wear.
Chassis Corrosion:
Common for vehicles of this age, especially in rust-prone climates.
Electrical Gremlins:
Aging wiring harnesses and components can lead to intermittent electrical faults.
📚 Vehicle History
Brand Heritage
Mazda Rotary:
Mazda's pioneering and continued development of the Wankel rotary engine
Model Evolution
Rx-7 Lineage:
First generation (SA22C) introduced in 1978, established Mazda's reputation in the sports car market.
Production
Production Years:
1978-1985 (SA/FB generation)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Automotive Press:
Praised by automotive journalists for its handling and unique rotary powertrain, contributing to Mazda's performance image.
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