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Mazda RX-7 Service Repair Manual 1989 1990 1991
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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: FC Production Years Covered: 1989, 1990, 1991 Codes Chassis Codes: FC3S (Coupe), FC3C (Convertible) Engine Codes: 13B (Naturally Aspirated and Turbocharged)...
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🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
FC
Production Years Covered:
1989, 1990, 1991
Codes
Chassis Codes:
FC3S (Coupe), FC3C (Convertible)
Engine Codes:
13B (Naturally Aspirated and Turbocharged)
👋 Introduction
Market Position
Positioning:
Performance sports car, known for its unique rotary engine and balanced chassis
Target Audience:
Enthusiasts, DIY mechanics, and professional workshops working on the FC generation RX-7
Competitive Analysis
Key Competitors:
Toyota Supra (MkIII), Nissan 300ZX (Z31), Porsche 944
Key Features
Vehicle Signature:
Rotary engine, rear-wheel drive, excellent weight distribution, pop-up headlights
Manual Value Proposition:
Provides comprehensive technical data essential for maintaining the performance and longevity of the RX-7
📋 Manual Details
Coverage Areas
Full Vehicle Coverage:
All models and engines for 1989-1991 RX-7
Diagnostic Coverage:
Detailed troubleshooting procedures and diagnostic flowcharts
Electrical System Coverage:
Complete wiring diagrams, component locations, and testing procedures
Powertrain Coverage:
Engine, transmission, driveline, and fuel system repair and overhaul
Suspension Steering Brakes:
Comprehensive repair and adjustment for all suspension, steering, and brake systems
Body And Interior:
Body panel repair, trim, seats, and climate control system details
Page Count
Estimated Pages:
Over 1500 pages (typical for complete factory service manuals)
Manual Type
Type:
Complete Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Management:
ECU functions, sensor diagnostics, fuel injection, ignition timing
Rotary Engine Specifics:
Apex seal inspection, rotor housing clearance, oil metering system, cooling system for rotary engine
Drivetrain:
Clutch, transmission, differential, driveshafts, and hub assemblies
Fuel System:
Fuel pump operation, injector testing, fuel pressure regulation, evaporative emission control
Cooling System:
Radiator, water pump, thermostat, hoses, and coolant types
Exhaust System:
Catalytic converter, mufflers, pipes, and emission control components
Power Steering System:
Hydraulic pump, steering rack, fluid specifications, and bleeding procedures
Anti Lock Braking System:
ABS control unit, wheel speed sensors, hydraulic modulator, and bleeding procedures
Climate Control System:
HVAC operation, refrigerant, compressor, and control panel diagnostics
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug (rotary equivalent) checks, fluid top-offs
Engine Rebuild:
Complete disassembly, inspection, and reassembly of the 13B rotary engine
Transmission Overhaul:
Manual and automatic transmission disassembly, repair, and adjustment
Brake System Service:
Pad and rotor replacement, caliper overhaul, fluid flush, and ABS bleeding
Electrical Troubleshooting:
Step-by-step diagnostic guides for common electrical faults
Suspension Component Replacement:
Shock absorber, strut, ball joint, and bushing replacement
Fuel Injector Service:
Testing, cleaning, and replacement of fuel injectors
Turbocharger Diagnosis:
Testing turbocharger operation, wastegate, and blow-off valve adjustment
Body Panel Alignment And Repair:
Guidelines for door, hood, and trunk alignment, as well as dent repair
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Diagnostic Tools:
Information on using a multimeter, vacuum gauge, and other essential diagnostic tools
Torque Specifications:
All critical torque specifications for engine, chassis, and drivetrain components
Clearances And Tolerances:
Specific clearances for rotary engine internals and other critical wear components
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval
Printability:
Printable pages for workshop use
Image Quality:
High-resolution images and diagrams
Print Quality
Quality Description:
Digital format ensures consistent quality, unlike older scanned manuals
Binding Type
Binding:
Not applicable (Digital PDF)
Paper Type
Paper Type:
Not applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotary (Wankel)
Engine Code:
13B
Configuration:
Two-rotor, naturally aspirated or turbocharged
Displacement Equivalent:
1.3L (Rotary displacement calculation differs from piston engines)
Performance
Naturally Aspirated Hp:
160 hp @ 6500 rpm (approx.)
Naturally Aspirated Torque:
150 lb-ft @ 4000 rpm (approx.)
Turbocharged Hp:
200 hp @ 6500 rpm (Turbo II models)
Turbocharged Torque:
196 lb-ft @ 3500 rpm (Turbo II models)
Fuel System
Injection Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (91 octane or higher recommended)
Oil Metering:
Two-stroke oil injection system (manual covers servicing)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual
Optional
Transmission Type:
4-speed Automatic
Features
Clutch Type:
Hydraulically operated single-plate dry clutch
Differential:
Limited-Slip Differential (LSD) often standard on Turbo models
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90
Automatic Transmission Fluid:
Dexron II (or equivalent)
📐 Dimensions
Exterior
Length:
170.7 inches (Coupe), 171.7 inches (Convertible)
Width:
69.1 inches
Height:
50.4 inches (Coupe), 51.2 inches (Convertible)
Wheelbase:
95.7 inches
Weights
Curb Weight Approx:
2,800 - 3,100 lbs (depending on model and options)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited specific official ratings from modern standards, but generally considered robust for its era.
Active Features
ABS:
Available Anti-lock Braking System (ABS)
Traction Control:
Available on some later Turbo II models (TCS)
Passive Features
Airbags:
Driver's airbag standard on later models, passenger airbag optional/unavailable depending on market and year.
Seatbelts:
3-point inertia-reel seatbelts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player on later models.
Climate Control:
Manual or automatic climate control systems.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Connectivity Features:
Limited to basic audio connectivity, no modern Bluetooth or USB ports from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles or 6 months (depending on driving conditions)
Spark Plug Inspection Interval:
Every 15,000 - 30,000 miles (rotary spark plug specific)
Timing Belt Replacement:
Not applicable (Rotary engine uses a timing chain/gears)
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 recommended (check manual for exact specs)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
Dexron II (or equivalent)
Known Issues
Apex Seal Wear:
Degradation of apex seals leading to loss of compression and engine performance; a common concern with high-mileage rotaries.
Oil Consumption:
Higher oil consumption is normal for rotary engines, but excessive consumption can indicate seal issues.
Vacuum Hose Cracking:
Aging rubber vacuum hoses can crack, leading to vacuum leaks and rough idling.
Cooling System Maintenance:
Overheating can be critical for rotaries; regular coolant checks and radiator maintenance are vital.
Turbocharger Reliability:
Early turbo failures can occur if maintenance is neglected or if the engine is abused when cold.
📚 Vehicle History
Brand Heritage
Mazda Rotary Legacy:
Mazda's long history of developing and perfecting the rotary engine, starting with the Cosmo.
Model Evolution
Fc Generation Introduction:
Introduced in 1985, replacing the SA22C generation. Known as the 'second generation' RX-7.
Fc Facelift:
Received a significant facelift in 1989, featuring updated styling, suspension, and improved Turbo II performance.
Fc Special Editions:
Various trim levels and special editions, including the Turbo II (FC3S) which was the performance flagship.
Production
Production Period:
1985-1992
Manufacturing Location:
Hiroshima, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
RX-7 (specifically the Turbo II) was a frequent nominee and winner on Car and Driver's '10Best' list during its production run.
Motor Trend Import Car Of The Year:
RX-7 was awarded Motor Trend's Import Car of the Year for 1986.