The Mazda RX-7, specifically the 1994 model of the FD (Third Generation) chassis code FD3S, represents a pinnacle of Japanese sports car engineering. Powered by the distinctive 13B-REW twin-rotor rotary engine, this rear-wheel-drive vehicle is renowned for its exceptional handling, balanced chassis, and unique styling. Introduced to the market as a pure sports car, the RX-7 was designed to offer enthusiasts unparalleled driving engagement and performance, often competing with prestigious marques such as Nissan, Toyota, Mitsubishi, and Porsche. Its legacy is built upon Mazda's long-standing commitment to rotary engine technology, delivering a driving experience characterized by smooth power delivery and a high-revving nature, making it an icon among automotive enthusiasts.
This comprehensive factory service manual provides in-depth guidance for the maintenance, repair, and diagnostics of the 1994 Mazda RX-7. It covers a vast array of systems, including the rotary engine, fuel, ignition, cooling, lubrication, exhaust, clutch, manual transmission, driveshaft, differential, suspension, steering, brakes, ABS, body electrical systems, and HVAC. The manual details routine maintenance procedures, step-by-step diagnostic flowcharts for troubleshooting common issues like apex seal wear and turbocharger problems, and instructions for major repairs and rebuilds. With detailed technical specifications, torque values, clearances, and wiring diagrams, this resource empowers owners, mechanics, and technicians to accurately maintain and preserve the performance and longevity of this remarkable sports car.
Generation:
FD (Third Generation)
Segment:
Sports Car / Grand Tourer
Target Audience:
Enthusiasts, performance drivers, and owners seeking in-depth knowledge for maintenance and repair.
Key Competitors:
Nissan 300ZX (Z32), Toyota Supra (MkIV), Mitsubishi 3000GT VR-4, Porsche 968.
Vehicle Selling Points:
Unique twin-rotor rotary engine, balanced chassis, exceptional handling, distinctive styling, rear-wheel drive platform.
Value To Owner:
Empowers owners to perform complex maintenance and repairs, diagnose issues accurately, and maintain the iconic RX-7's performance and longevity.
Systems Covered:
Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Clutch, Transmission (Manual), Driveshaft, Differential, Axles, Suspension (Front & Rear), Steering System, Brakes (Front & Rear), ABS, Body Electrical System, HVAC, Body Panels, Interior Trim, Wiring Diagrams, Diagnostic Procedures, Troubleshooting
Page Count:
Detailed information typically ranges from 1500-2500+ pages for a complete factory service manual set, this PDF likely consolidates significant portions.
Manual Type:
Factory Service Manual / Repair Manual
Engine Systems:
Rotary engine (13B-REW) operation, apex seal wear diagnosis, oil metering system, fuel injection system, twin-turbocharger operation and diagnosis, ignition timing, compression testing, emission control systems.
Drivetrain Systems:
Manual transmission (R154 or similar depending on market) repair, clutch assembly replacement, driveshaft balancing, differential inspection and rebuild, axle shaft maintenance.
Suspension Steering Brakes:
Double wishbone suspension geometry, shock absorber and spring replacement, steering rack service, brake caliper overhaul, ABS system diagnostics, rotor and pad replacement specifications.
Electrical Coverage:
Complete wiring diagrams, fuse and relay identification, starter, alternator, battery service, lighting systems, power windows, central locking, instrument cluster repair, ECU troubleshooting.
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter servicing, coolant flush, brake fluid replacement, belt inspection and adjustment, tire rotation.
Diagnostic Troubleshooting:
Step-by-step diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems. Includes diagnostic trouble codes (DTCs) and their meanings.
Major Repairs Rebuilds:
Detailed instructions for engine disassembly and reassembly, transmission overhaul, suspension component replacement, brake system repairs, and body panel alignment.
Depth Of Coverage:
Comprehensive, covering everything from basic owner-level maintenance to advanced engine rebuilds and electrical system diagnostics. Includes torque specifications, clearances, and critical tolerances.
File Format Type:
PDF (Portable Document Format)
Image Resolution:
High-resolution scans of original diagrams and photographs, ensuring clarity for visual aids. Recommended to view with Adobe PDF Reader for optimal display.
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
Engine Type:
Rotary (Wankel)
Displacement:
1308cc (654cc x 2 rotor faces)
Aspiration:
Twin-Turbocharged Sequential
Horsepower:
255 hp @ 6500 rpm (approx.)
Torque:
217 lb-ft @ 5000 rpm (approx.)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Premium Gasoline (91 octane or higher recommended)
Oil Type Specification:
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for specific Mazda recommendations)
Coolant Type:
Mazda Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors)
Transmission Type:
5-Speed Manual
Transmission Model:
R154 (common for US models, other variants exist globally)
Transmission Type:
4-Speed Automatic (available in certain markets/trims)
Clutch Type:
Hydraulically actuated, single dry plate
Transmission Fluid Specification:
GL-4 or GL-5 Gear Oil (refer to manual for specific viscosity and type)
Length:
4295 mm (169.1 in)
Height:
1230 mm (48.4 in)
Wheelbase:
2425 mm (95.5 in)
Front Track:
1480 mm (58.3 in)
Rear Track:
1475 mm (58.1 in)
Curb Weight:
Approx. 1310-1370 kg (2888-3020 lbs) depending on trim and options.
Gross Vehicle Weight Rating:
Refer to vehicle VIN plate or manual for exact GVWR.
NHTSA Frontal Crash Rating:
Not consistently available or applicable for this era's reporting standards. Mazda focused on structural integrity and active safety.
Anti Lock Brakes:
Standard on most models, providing enhanced control during braking.
Traction Control:
Available on some higher trims, referred to as 'TCS'.
Airbags:
Driver's side airbag standard.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners.
Body Structure:
Reinforced safety cell, crumple zones.
Audio System:
Factory AM/FM/Cassette player with optional CD changer. Premium sound systems often included Bose components.
Climate Control:
Manual or automatic climate control systems.
Cruise Control:
Standard feature on most models.
Power Features:
Power windows, power mirrors, power door locks.
Diagnostics Port:
OBD-I (On-Board Diagnostics I) system, requiring specific diagnostic tools or procedures for fault code retrieval.
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first. Frequent oil checks are critical for rotary engines.
Spark Plug Replacement:
Refer to manual; typically around 30,000-60,000 miles, depending on plug type and driving conditions. Specific platinum or iridium plugs may have longer intervals.
Timing Belt Replacement:
N/A (Rotary engines do not have timing belts; they use a timing chain/sprocket system for the eccentric shaft and rotor housing alignment).
Engine Oil Capacity:
Approximately 4.8 liters (5.1 US quarts) with filter change. Always verify with dipstick.
Transmission Fluid Capacity:
Approximately 2.5 liters (2.6 US quarts). Refer to manual for exact capacity and fill level.
Differential Fluid Type:
API GL-5 Hypoid Gear Oil, SAE 80W-90 recommended.
Brake Fluid Specification:
DOT 3 or DOT 4, High-Temperature Brake Fluid.
Apex Seal Wear:
Premature apex seal wear can occur due to poor lubrication, overheating, or engine abuse. Regular oil checks and proper engine warm-up are crucial. The manual details diagnostic methods.
Sequential Turbo Failure:
Issues with the secondary turbocharger or its control system can lead to a loss of power. The manual provides troubleshooting for this complex system.
Cooling System Overheating:
Rotary engines generate more heat. Maintaining the cooling system (radiator, hoses, thermostat, water pump) is critical. The manual details flush and fill procedures.
Oil Metering Pump Failure:
Failure of the OMP leads to insufficient lubrication of the apex seals. The manual describes its function and troubleshooting.
Mazda Rotary Legacy:
Mazda's long-standing commitment to the rotary engine, dating back to the Cosmo Sport 110S.
Rx-7 Generations:
First Generation (SA/FB), Second Generation (FC), Third Generation (FD).
Fd Development Philosophy:
Designed as a pure sports car, emphasizing lightweight construction, balanced weight distribution, and advanced rotary engine technology. Often referred to as the 'clean-sheet' design.
Production Years Fd:
1992-2002
Manufacturing Location:
Hiroshima, Japan
Key Market Introduction:
Japan (1991), North America (1993), Europe (1992).
Car And Driver Ten Best:
Named to Car and Driver's '10 Best Cars' list multiple times during its production run.
Motor Trend Car Of The Year:
While not a winner, it was a strong contender and recognized for its engineering.
Road And Track Reviews:
Consistently praised for its handling, engine performance, and driver engagement.
