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1985 Mazda RX-7 (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Code: FC Model Variant: 2nd Generation Year: 1985 👋 Introduction Market Position Market Position: The 1985 Mazda RX-7 (FC generation) was...
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Sku: 458825
1985 Mazda RX-7 (2nd gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Model Code:
FC
Model Variant:
2nd Generation
Year:
1985
👋 Introduction
Market Position
Market Position:
The 1985 Mazda RX-7 (FC generation) was positioned as a stylish, sporty, and engaging rear-wheel-drive coupe, challenging established competitors in the sports car segment with its unique rotary engine and balanced chassis.
Competitive Analysis
Competitive Analysis:
Competed against vehicles like the Toyota Supra, Nissan 300ZX (Z31), Chevrolet Camaro/Pontiac Firebird, and Ford Mustang. The RX-7 distinguished itself with its lightweight design and the distinctive character of its Wankel rotary engine.
Key Features
Key Features:
Lightweight construction, advanced independent suspension, optional turbocharged engine, sophisticated styling (often described as 'Gandolfi' design), and excellent weight distribution.
Manual Value Proposition
Manual Value Proposition:
This manual is an indispensable tool for RX-7 owners and independent mechanics, providing the exact factory-level information needed for accurate diagnostics, maintenance, and repair, ensuring the longevity and optimal performance of this unique sports car.
📋 Manual Details
Coverage Areas
Model Year Coverage:
1985
Trim Level Coverage:
All trims (e.g., GS, GSL, Turbo II - if applicable for the specific year)
Regional Coverage:
Likely North American market focus, but essential repair procedures are universal.
Page Count
Page Count:
Estimate: 800-1200 pages (typical for comprehensive factory service manuals of this era)
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Likely printed physical copy. If digital, specify PDF.
📖 Manual Coverage
Systems Covered
Engine:
Rotary Engine (13B), including theory of operation, disassembly, inspection, assembly, troubleshooting, and repair of all components (rotor housing, rotors, apex seals, side seals, eccentric shaft, oil metering, cooling, lubrication).
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulator, fuel lines, fuel tank, and related sensors.
Ignition System
Ignition System:
Ignition timing, spark plugs, ignition coils, distributor (if applicable), igniter, and related wiring.
Transmission
Transmission:
Manual Transmission (5-speed) and Automatic Transmission (4-speed) overhaul, repair, clutch service, drive shafts, and differential.
Brakes
Brakes:
Front and rear disc brakes, ABS (if equipped), hydraulic system, calipers, rotors, brake pads, parking brake, and bleeding procedures.
Suspension
Suspension:
Front struts, rear shocks, control arms, bushings, ball joints, stabilizer bars, and alignment specifications.
Steering
Steering:
Power steering system, steering rack, tie rods, steering column, and alignment.
Electrical System
Electrical System:
Battery, charging system (alternator), starting system (starter motor), fuses, relays, lighting, horn, wipers, power windows, mirrors, and detailed wiring diagrams.
Hvac
HVAC:
Air conditioning system (refrigerant, compressor, condenser, evaporator), heater core, blower motor, and climate control unit.
Body And Interior
Body And Interior:
Body panel removal/installation, doors, hood, trunk, bumpers, interior trim, seats, and glass replacement.
Diagnostic Troubleshooting
Diagnostic Troubleshooting:
Systematic troubleshooting guides, fault diagnosis, error codes (if applicable), and diagnostic procedures for all major systems.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks and changes, belt adjustments.
Repair:
Detailed step-by-step repair instructions for all mechanical and electrical components, including engine rebuilds, transmission overhauls, brake system repairs, and electrical component replacement.
Inspection:
Component inspection guidelines, wear limits, and specifications for proper operation.
Diagnostics:
Advanced diagnostic routines for identifying and resolving complex issues.
Specifications:
Torque specifications for all fasteners, clearances, tolerances, and fluid capacities.
Technical Depth
Technical Depth:
Comprehensive from basic fluid changes to complete engine and transmission rebuilds. Includes detailed diagrams, exploded views, and schematics.
📊 Manual Specifications
File Format
File Format:
If digital: PDF. If printed: High-quality paper for durability.
Print Quality
Print Quality:
Professional printing with clear text and high-resolution diagrams.
Binding Type
Binding Type:
If printed: Spiral-bound or perfect-bound for ease of use and durability in a workshop environment.
Paper Type
Paper Type:
If printed: Durable paper, possibly with a gloss finish for diagrams.
⚙️ Engine Specifications
Primary Engine
Engine Code:
13B
Engine Type:
Naturally Aspirated Rotary (Wankel) Engine
Rotor Displacement:
654 cc per rotor (x2 = 1308 cc effective displacement)
Induction System:
Naturally Aspirated (EFI)
Horsepower Na:
Approximately 146 hp @ 6500 rpm (for non-turbo models)
Torque Na:
Approximately 138 lb-ft @ 3500 rpm (for non-turbo models)
Compression Ratio Na:
9.7:1
Optional Engine
Optional Engine Type:
Turbocharged Rotary (Wankel) Engine
Optional Horsepower:
Approximately 182 hp @ 6500 rpm (for Turbo II models)
Optional Torque:
Approximately 183 lb-ft @ 3500 rpm (for Turbo II models)
Optional Compression Ratio:
8.5:1
Fuel System
Fuel Injection Type:
Electronic Fuel Injection (EFI) - Rotary Fuel Injection (RFI)
Fuel Type:
Unleaded gasoline (Premium recommended)
Cooling System
Cooling System Type:
Water-cooled, pressurized system
Lubrication System
Lubrication System Type:
Forced lubrication with an oil metering system for apex seals
Oil Type Recommendation:
API SG or higher, SAE 10W-30 or 10W-40 (refer to manual for specific conditions)
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission
Optional
Optional Transmission:
4-speed automatic transmission
Features
Clutch Type:
Hydraulically operated, single dry plate
Drive Type:
Rear-wheel drive (RWD)
Transmission Fluid Type
Manual Transmission Fluid:
GL-5 SAE 75W-90 gear oil (check manual for exact specification)
Automatic Transmission Fluid:
Dexron II (check manual for exact specification)
Differential Type
Differential Fluid Type:
GL-5 SAE 75W-90 gear oil (check manual for exact specification)
📐 Dimensions
Exterior
Wheelbase:
Approx. 95.7 inches (2430 mm)
Length:
Approx. 170.1 inches (4320 mm)
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 49.8 inches (1265 mm)
Weights
Curb Weight Approx:
Approx. 2750 - 3050 lbs (1247 - 1383 kg) depending on trim and options
Wheels Tires
Standard Tire Size:
195/60R15 (Non-turbo), 205/55R16 (Turbo II - common)
Wheel Bolt Pattern:
4x114.3 mm (4x4.5 inches)
Wheel Size:
15x6.5J or 16x7J (common)
🛡️ Safety Features
Ratings
Safety Ratings Era:
Safety standards of the mid-1980s. Specific crash test ratings from agencies like NHTSA might be limited or not directly comparable to modern standards.
Active Features
Active Features:
Four-wheel disc brakes, advanced suspension for handling stability.
Passive Features
Passive Features:
Seat belts, padded dashboard and interior surfaces.
Optional Safety Features
Optional Safety Features:
Anti-lock Braking System (ABS) became available later in the FC generation, though availability for the specific 1985 model year may vary by market and trim.
💡 Technology Features
Infotainment
Infotainment Features:
Factory-installed AM/FM stereo with cassette player, manual or automatic climate control, analog gauges with tachometer.
Driver Assistance
Driver Assistance Features:
Limited by era. Primarily focused on vehicle dynamics and handling. ABS was an optional feature later in the generation.
Connectivity
Connectivity Features:
None by modern standards. Primarily mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles or 3-6 months, whichever comes first (refer to manual for specific conditions and oil type).
Spark Plug Replacement:
Rotor-specific spark plugs require regular inspection and replacement. Intervals vary; consult the manual.
Timing Belt Replacement:
Rotary engines do not have a timing belt; they utilize a timing chain or direct ignition system.
Fuel Filter Replacement:
Typically recommended every 30,000-60,000 miles.
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil Capacity:
Approximately 5.4 US quarts (5.1 Liters) with filter change (refer to manual).
Coolant Capacity:
Approximately 7.5 US quarts (7.1 Liters) (refer to manual).
Brake Fluid Type:
DOT 3 (check manual for exact specification)
Known Issues
Known Issues:
Apex seal wear (leading to loss of compression), carbon buildup in exhaust ports, potential oil seal degradation, ignition system issues, and older fuel injection components can be prone to failure.
Rotary Engine Maintenance:
Regularly checking oil levels is critical due to the oil metering system. Periodic 'bouncing' or 'de-carbonizing' procedures might be recommended. Frequent short trips can exacerbate carbon buildup.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mazda has a long history of engineering innovation, particularly with its rotary engine technology, which began with the Cosmo in the late 1960s.
Model Evolution
Model Evolution:
The 1985 model marks the introduction of the second generation (FC) RX-7, succeeding the popular SA22C (FB) generation. The FC received a significant redesign with a more modern, aerodynamic profile and a focus on improved handling and refinement.
Production
Production Years Fc:
1985-1992
Notable Variants
Notable Variants:
The Turbo II model, introduced for the 1987 model year, significantly boosted performance and became a highly sought-after variant.
🏆 Awards & Recognition
Recognitions
Recognitions:
Car and Driver magazine's Ten Best list for multiple years during its production run. Praised for its handling, styling, and rotary engine innovation.
Ratings
Ratings:
Consistently well-regarded by automotive journalists for its driving dynamics and sporty appeal.
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