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Mazda RX7 RX-7 1989-1991 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Code: FC3S Generation Generation Name: Second Generation Generation Code: FC Codes Production Years Covered: 1989, 1990, 1991 👋 Introduction Market Position...
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Type: Car
Vendor:
Sku: 94624
Mazda RX7 RX-7 1989-1991 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Model Code:
FC3S
Generation
Generation Name:
Second Generation
Generation Code:
FC
Codes
Production Years Covered:
1989, 1990, 1991
👋 Introduction
Market Position
Segment:
Sports Car / Grand Tourer
Target Audience:
Enthusiasts, performance-oriented drivers, owners seeking in-depth knowledge for maintenance and repair.
Competitive Analysis
Key Competitors:
Nissan 300ZX (Z32), Toyota Supra (Mk3), Mitsubishi Starion, Porsche 944
Key Features
Defining Characteristic:
Rotary Engine (13B-T), Balanced Chassis, Lightweight Construction, Distinctive Styling
Trim Levels Overview:
Base, GT, GXL, Turbo-R (JDM specific)
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Regional Variants Covered:
North American Market (Likely, based on common manual offerings)
Page Count
Estimated Page Count:
1500-2000+ (Typical for comprehensive factory service manuals)
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine System:
Rotary Engine (13B-T), Engine Mechanical, Lubrication, Cooling, Fuel Injection (Bosch L-Jetronic/EGI), Ignition System, Emission Control Systems, Turbocharger System (CT26), Engine Management (ECU/DTCs)
Drivetrain System:
Manual Transmission (Type R/M, FS5C71A), Automatic Transmission (Optional, JATCO), Clutch System, Driveshafts, Rear Axle Assembly, Differential
Chassis System:
Suspension (Front MacPherson Strut, Rear Independent), Steering System (Power Rack and Pinion), Brakes (Front Ventilated Discs, Rear Discs, ABS), Wheels and Tires
Electrical System:
Wiring Diagrams, Battery, Charging System, Starting System, Lighting, Instrumentation, Power Windows, Mirrors, Audio System, Cruise Control, HVAC Controls, ECU Pinouts, Diagnostic Trouble Codes (DTCs)
Body And Interior:
Body Panels, Doors, Hood, Trunk, Bumpers, Seats, Dashboard, Trim, Sound Deadening, HVAC Ducts, Exterior Trim, Weatherstripping
Procedures Included
Maintenance Procedures:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Coolant Flush, Brake Fluid Flush, Transmission Fluid Change, Differential Fluid Change, Belt Replacement
Diagnostic Procedures:
Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Code (DTC) Retrieval and Interpretation, Sensor Testing, Actuator Testing
Repair Procedures:
Engine Overhaul (Apex Seals, Rotor Housing Inspection), Turbocharger Rebuild, Transmission Overhaul, Clutch Replacement, Brake System Repair, Suspension Component Replacement, Steering Rack Rebuild, Electrical Component Replacement, Body Panel Repair
Special Procedures:
Turbocharger Boost Adjustment, Fuel Injection Calibration, Ignition Timing Adjustment, Compression Testing (Rotary), Engine Reassembly Torque Specifications
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and drivetrain overhauls. Includes detailed diagrams, specifications, and step-by-step instructions suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely Searchable Text (depends on original scan quality)
Print Quality
Resolution:
High Resolution Scan (Typical for quality digital manuals)
Clarity:
Clear text and legible diagrams
Binding Type
Binding Type:
Not Applicable (Digital PDF)
Paper Type
Paper Type:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
13B-T
Engine Type:
Rotary (Wankel), Twin Distributor, Twin Spark Ignition
Displacement:
1.3L (1308cc)
Performance
Horsepower Hp:
200 hp @ 6500 rpm (Base Turbo), 210 hp @ 6500 rpm (Later models/GT)
Torque Lb Ft:
190 lb-ft @ 3500 rpm (Base Turbo), 200 lb-ft @ 3500 rpm (Later models/GT)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Bosch EGI)
Fuel Type:
Unleaded Gasoline (91 Octane or higher recommended)
Induction
Forced Induction:
Turbocharged (Single Turbocharger, Hitachi/Garrett CT26 type)
Cooling System
Type:
Liquid-Cooled
Lubrication System
Type:
Wet Sump
Engine Management
ECU Type:
Engine Control Unit (ECU) with diagnostics
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Manual Transmission Model:
FS5C71A
Optional
Transmission Type:
4-Speed Automatic
Automatic Transmission Model:
JATCO 4E55
Features
Clutch Type:
Hydraulic, Dry Single Plate
Drivetrain:
Rear-Wheel Drive (RWD)
📐 Dimensions
Exterior
Length:
175.2 inches (4450 mm)
Width:
69.1 inches (1755 mm)
Height:
49.2 inches (1250 mm)
Wheelbase:
95.7 inches (2430 mm)
Front Track:
57.7 inches (1465 mm)
Rear Track:
57.7 inches (1465 mm)
Weights
Curb Weight Lbs:
2950-3100 lbs (Approximate, depending on trim and options)
Gross Vehicle Weight Rating Gvwr Lbs:
Approx. 3700 lbs
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
Not Specifically Rated for this Era (Pre-dates extensive standardized testing)
IIHS Crash Test Results:
Not Available for this Era
Active Features
ABS:
Anti-lock Braking System (Optional on some models, standard on Turbo II later)
Passive Features
Seat Belts:
3-Point Inertial Reel Seatbelts
Airbags:
Driver Side Airbag (Optional/Late Models)
Body Construction:
Unibody with Front and Rear Crumple Zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Stereo Cassette Player with optional CD Player (rare). Speaker configurations varied by trim level.
Driver Assistance
ABS:
Available as an option, typically on higher trims or turbo models.
Connectivity
OBD System:
Pre-OBDII (On-Board Diagnostics). Diagnosis typically involves reading flash codes or using specific diagnostic tools for the era.
🔧 Maintenance
Service Intervals
Oil Change Interval Miles:
Every 3,000-5,000 miles or 3-6 months (whichever comes first)
Coolant Flush Interval Miles:
Every 30,000 miles or 2 years
Spark Plug Replacement Interval Miles:
Every 30,000 miles (Specific rotary spark plugs)
Transmission Fluid Change Interval Miles:
Every 30,000-60,000 miles (Manual/Automatic)
Fluid Specifications
Engine Oil Type:
API SG/SH, SAE 10W-30 or 10W-40 (Check manual for specific viscosity recommendations, often with an emphasis on higher zinc content for rotary engines)
Coolant Type:
Mazda Super Long Life Coolant (Blue) or equivalent ethylene glycol-based antifreeze
Brake Fluid Type:
DOT 3 or DOT 4
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 or 80W-90
Automatic Transmission Fluid Type:
Mazda ATF-Type T-IV or equivalent
Differential Fluid Type:
API GL-5, SAE 80W-90
Known Issues
Rotary Engine Wear:
Apex seal wear, rotor housing scoring, oil seal degradation are common concerns for high-mileage rotary engines. Regular oil changes and proper warm-up/cool-down are crucial.
Turbocharger Reliability:
Early turbocharger designs could be prone to failure if not properly maintained or if consistently driven hard without adequate cooling. Oil supply and filtration are critical.
Fuel Injector Clogging:
Can occur due to poor fuel quality or age, affecting performance and idle stability.
Electrical Gremlins:
As with many cars of this era, aging wiring harnesses, relays, and sensors can lead to intermittent electrical issues.
Vacuum Leaks:
Degradation of rubber vacuum hoses and seals can lead to vacuum leaks, affecting engine performance and drivability.
📚 Vehicle History
Brand Heritage
Mazda Rotary Legacy:
Mazda's long-standing commitment to rotary engine technology, beginning with the Cosmo Sport.
Model Evolution
Fc Generation Introduction:
Introduced in 1985 for the 1986 model year, replacing the SA22C (FB) RX-7.
Fc Facelift:
Received a significant facelift for the 1989 model year, including revised styling, improved aerodynamics, updated interior, and a more powerful 13B-T engine.
Production
Production Period:
1985-1992
Manufacturing Plant:
Mazda's Hofu Plant, Yamaguchi Prefecture, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
The FC RX-7 was named to Car and Driver's Ten Best list multiple times, including for 1989.
Motor Trend Import Car Of The Year:
Nominee / Contender
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