Mazda RX7 RX-7 1999 All Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Generation: FD (Third Generation) Model Year Covered: 1999 Codes Chassis Code: FD3S 👋 Introduction Market Position Positioning: Iconic Japanese sports car,...

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Sku: 105292

Tags: 1999 Car Cars Mazda Misc RX-7 RX7

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Model Generation:

FD (Third Generation)

Model Year Covered:

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

Iconic Japanese sports car, revered for its rotary engine and distinctive styling.

Competitive Analysis

Competitors:

Toyota Supra (Mk4), Nissan 300ZX (Z32), Mitsubishi 3000GT VR-4

Key Features

Rotary Engine:

Unique sequential twin-turbocharged 13B-REW rotary engine renowned for its high-revving nature and compact size.

Design:

Sleek, aerodynamic coupe design with a focus on weight distribution and handling.

Performance:

Exceptional power-to-weight ratio, precise handling, and a visceral driving experience.

Manual Value

Purpose:

Essential resource for owners and technicians seeking to maintain, diagnose, and repair the 1999 Mazda RX-7 FD.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Electrical Schematics, Bodywork, Specifications

Page Count

Estimated Pages:

Approximately 1500+

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Rotary engine (13B-REW) teardown, assembly, lubrication, cooling, fuel injection, ignition, emissions control, turbocharging system

Engine Performance:

Twin-turbo system operation, intercooling, boost control, power delivery characteristics

Transmission Manual:

Mazda R154 (RX-7 specific 5-speed manual) - clutch, gearbox, driveline, driveshaft, differential

Transmission Automatic:

N/A for this model year/variant (refer to specific manual if applicable)

Brakes:

ABS system, hydraulic components, parking brake, front and rear brake caliper service, rotor replacement

Suspension And Steering:

Front and rear suspension (double wishbone), shock absorbers, springs, bushings, steering rack, power steering system

Electrical System:

Battery, charging system, starter, lighting, horn, wipers, power windows, power seats, central locking, fuse box diagrams, relay locations

Body And Frame:

Chassis structure, body panel removal/installation, door mechanisms, hood and trunk operation, interior trim, glass replacement

HVAC:

Air conditioning system diagnosis and repair, heater core, blower motor, controls

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel injectors, fuel pressure regulator

Exhaust System:

Catalytic converter, mufflers, exhaust manifold, O2 sensors

Procedures Included

Routine Maintenance:

Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid change, transmission fluid change

Major Repairs:

Engine rebuild (rotary apex seal replacement, rotor housing machining), transmission overhaul, turbocharger rebuild, differential service

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit testing, component testing

Diagnostics:

OBD-II system, scan tool usage, sensor data interpretation, actuator testing

Alignment And Balancing:

Wheel alignment specifications, tire balancing procedures

Component Replacement:

Detailed instructions for replacing major and minor components across all systems

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.

Diagnostic Tools:

Information on using factory-specific diagnostic tools and general automotive diagnostic equipment.

Torque Specifications:

Detailed torque specifications for all critical fasteners and components.

Clearances:

Engine component clearances, bearing tolerances, and other critical measurements for engine assembly.

Manual Specifications

File Format:

📊 Manual Specifications

Print Quality

Quality:

High-resolution, printable pages with clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

13B-REW

Engine Type:

Rotary, Twin-Rotor, Twin-Turbocharged

Displacement:

1.3L (1308cc)

Performance

Horsepower Ps:

280 PS (276 hp) at 6500 RPM

Torque Nm:

314 Nm (232 lb-ft) at 5000 RPM

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Twin-Turbo System

Fuel Type:

Unleaded Gasoline (Octane Rating 91 or higher recommended)

Cooling System

Cooling Type:

Water-Cooled

Lubrication System

Oil Type:

API SG/SH, ACEA A2/B2 specification, viscosity SAE 10W-30 recommended for rotary engines.

Turbocharging

Turbo System:

Sequential Twin-Turbo System (Primary turbo activates at lower RPM, secondary turbo activates at higher RPM)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual

Transmission Model:

Mazda R154 (RX-7 specific variant)

Optional

Automatic Option:

N/A for 1999 models in most markets.

Features

Clutch Type:

Hydraulic Operated, Single Dry Plate Clutch

Final Drive Ratio:

4.30:1 (typical, may vary by market)

Fluid Capacity

Manual Transmission Fluid Type:

GL-4 API rating, viscosity SAE 75W-90 or 80W-90.

Manual Transmission Fluid Capacity:

Approx. 2.3 Liters (2.4 US Quarts)

📐 Dimensions

Exterior

Length Mm:

4295 mm

Width Mm:

1750 mm

Height Mm:

1230 mm

Wheelbase Mm:

2425 mm

Weights

Curb Weight Kg:

Approximately 1270 kg (depending on trim and options)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not rated directly for this specific model year in the US, but general FD chassis is known for good structural integrity.

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags:

Driver and Passenger Front Airbags

Seatbelts:

3-Point Inertial Reel Seatbelts with Pretensioners

Chassis Design:

Reinforced safety cell, crumple zones

💡 Technology Features

Infotainment

Audio System:

Bose premium audio system (optional), CD player, cassette deck.

Display:

Digital climate control display, analog gauges for tachometer, speedometer, boost gauge, oil temp, water temp.

Driver Assistance

Cruise Control:

Standard cruise control.

Connectivity

Phone Integration:

N/A (Analog era technology)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (using quality synthetic oil for rotary engines is highly recommended).

Spark Plug Replacement:

Every 30,000 miles for trailing plugs, trailing plugs have a longer service life. Consult manual for specific recommendations.

Coolant Flush:

Every 2 years or 30,000 miles.

Fluid Specifications

Engine Oil Spec:

API SG/SH, ACEA A2/B2, SAE 10W-30 recommended.

Brake Fluid Spec:

DOT 3 or DOT 4.

Power Steering Fluid Spec:

Dexron III ATF or equivalent.

Known Issues

Apex Seal Wear:

Premature wear of apex seals can occur due to poor maintenance, overheating, or improper break-in procedures. This is the most critical and common concern for rotary engines.

Oil Consumption:

Rotary engines naturally consume a small amount of oil for lubrication of the seals. Excessive consumption may indicate seal issues.

Sequential Turbo Failure:

Issues with the vacuum lines, solenoids, or actuators controlling the sequential turbo system can lead to performance degradation.

Cooling System Reliability:

Overheating can exacerbate apex seal wear. Regular coolant checks and system maintenance are vital.

Fuel Injector Clogging:

Can lead to rough idling or misfires.

📚 Vehicle History

Brand Heritage

Rotary Legacy:

Mazda's long history and pioneering work with the Wankel rotary engine, dating back to the Cosmo Sport.

Model Evolution

Generation Three:

The FD RX-7 represents the zenith of the RX-7 lineage, known for its advanced engineering and stunning design.

Production

Production Years:

1992-2002

Manufacturing Location:

Hiroshima, Japan

Motorsport

Racing Heritage:

Successful in various motorsport disciplines, including IMSA GTU and sports car racing.

🏆 Awards & Recognition

Recognitions

Car And Driver:

Car and Driver's 10Best list multiple times.

Road And Track:

Frequently featured and lauded by automotive publications for its driving dynamics and performance.

Certifications

Jdm Status:

Highly sought after by JDM enthusiasts worldwide.