Positioning:
The Mazda RX-7 FC generation, particularly the S4 Turbocharged models, represented Mazda's commitment to performance and rotary engine technology in the sports car segment. It competed against established rivals with a unique powertrain and sporty styling.
Competitors:
Toyota Supra (Mk III), Nissan 300ZX (Z31), Porsche 944, Chevrolet Camaro/Pontiac Firebird.
Features:
Rotary engine, lightweight chassis, balanced handling, rear-wheel drive, iconic pop-up headlights, sporty coupe design.
Value Proposition:
This manual is invaluable for owners and technicians seeking to maintain, diagnose, and repair the complex rotary engine and associated systems of the 1989 RX-7. It provides the factory-level detail essential for preserving this enthusiast vehicle.
Engine:
13B Rotary (Naturally Aspirated and Turbocharged variants), Lubrication, Cooling, Fuel, Ignition, Emissions Control, Engine Mechanical (Disassembly/Assembly), Engine Electrical.
Transmission:
Manual (Type M030/M032), Automatic (Type G4A-EL) - Diagnosis, Repair, Overhaul.
Drivetrain:
Clutch System, Driveshaft, Rear Axle Assembly (Differential, Axle Shafts).
Suspension:
Front and Rear Suspension Systems (MacPherson Struts, Independent Rear), Bushings, Ball Joints, Control Arms, Shock Absorbers, Springs.
Steering:
Power Steering System (Pump, Rack and Pinion), Steering Column.
Brakes:
Front and Rear Disc Brakes, ABS (Anti-lock Braking System), Brake Booster, Master Cylinder, Calipers, Lines, Parking Brake.
Electrical:
Battery, Charging System (Alternator), Starting System (Starter Motor), Ignition System, Lighting System, Fuses, Relays, Wiring Diagrams, Instrument Cluster, Gauges, Audio System, Power Accessories (Windows, Locks).
Body:
Exterior Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Seals, Interior Trim, Seats, HVAC (Heating, Ventilation, and Air Conditioning) System.
Emissions:
Emissions Control System Components, Diagnosis, and Service.
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks and Replenishment, Belt Inspections and Adjustments, Brake Pad Replacement, Tire Rotation.
Repair:
Engine Rebuilds (Rotary Apex Seals, Side Seals, Rotor Housing Inspection), Transmission Overhaul, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Replacement, HVAC System Repairs, Body Panel Repair and Alignment.
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Troubleshooting Guides for various systems (engine performance, electrical faults, transmission issues).
Diagnostics:
On-Board Diagnostics (OBD) information (if applicable for the era), Test Procedures for Sensors and Actuators, Special Tool Requirements.
Specifications:
Torque Specifications for critical fasteners, Clearances, Tolerances, Electrical Resistance values.
Depth:
Comprehensive. Covers routine maintenance, in-depth diagnostics, component overhaul, and complete vehicle disassembly/reassembly.
Engine Type:
Rotary (Wankel)
Displacement:
1.3L (654cc per rotor x 2 = 1308cc equivalent)
Aspirated Type:
Turbocharged
Horsepower:
182 hp (136 kW) @ 6500 rpm
Torque:
190 lb-ft (258 Nm) @ 3500 rpm
Fuel Delivery:
Fuel Injection (Multi-point)
Fuel Type:
Unleaded Gasoline
Ignition Type:
Distributorless Ignition System (DIS) with dual ignition coils.
Oil Type:
API SG or higher, Viscosity: SAE 10W-30 (Consult manual for seasonal variations and specific recommendations).
Coolant Type:
Ethylene Glycol based coolant (50/50 mixture with distilled water). Consult manual for specific Mazda coolant part numbers.
Apex Seals:
Critical wear component. Manual will detail inspection, replacement procedures, and clearance specifications.
Transmission Type:
5-speed Manual Transmission (M030/M032).
Transmission Type:
4-speed Automatic Transmission (G4A-EL).
Clutch Type:
Hydraulically operated, single dry plate clutch.
Manual Transmission Fluid:
API GL-4, Viscosity: SAE 75W-90 (Consult manual for specific Mazda part numbers or approved alternatives).
Automatic Transmission Fluid:
Dexron III or equivalent. Consult manual for specific Mazda part numbers.
Length:
Approx. 4,365 mm (171.9 in)
Width:
Approx. 1,690 mm (66.5 in)
Height:
Approx. 1,265 mm (49.8 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Curb Weight:
Approx. 1,270 - 1,350 kg (2,800 - 2,976 lbs) depending on trim and transmission.
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first. Consult manual for specific turbocharger considerations.
Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plug Replacement:
Every 30,000 miles. Special platinum-tipped plugs are often recommended.
Coolant Flush:
Every 24 months or 30,000 miles.
Brake Fluid:
DOT 3 or DOT 4. Consult manual for specific Mazda part numbers or recommendations.
Power Steering Fluid:
ATF (Automatic Transmission Fluid) or specific power steering fluid. Consult manual.
Rotary Engine Wear:
Apex seal wear, carbon build-up, oil seal degradation leading to compression loss and oil consumption.
Turbocharger Issues:
Turbo seal failure, wastegate issues, intercooler leaks, especially with high mileage or lack of proper maintenance.
Cooling System:
Radiator leaks, fan clutch failure, and occasional coolant seal failures on the engine housing. Proper flushing and maintenance are critical.
Fuel System:
Clogged fuel injectors, weak fuel pump, and issues with the emissions control system (e.g., EGR valve, air pump).
Electrical Systems:
Aging wiring harnesses, corrosion in connectors, and failures in specific sensors or control modules.
Mazda Rotary History:
Mazda has a long and unique history with the rotary engine, debuting it in the Cosmo Sport in 1967. The RX-7 lineage is synonymous with this innovative powerplant.
Fc Generation Overview:
The FC generation (1986-1991) introduced a more sophisticated chassis, independent rear suspension, and improved aerodynamics over its predecessor (FB). The 1989 model year (S4 update) featured styling refinements and powertrain enhancements.
Production Period:
1986-1991 (FC Generation).
Manufacturing Plant:
Mazda's Hofu Plant, Yamaguchi Prefecture, Japan.
