Mazda RX7 RX-7 1989-1991 Factory Service Repair Manual

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Type: Car

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Sku: 58833

Tags: 1989 1990 1991 Car Cars Mazda Misc RX-7 RX7

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Description

The Mazda RX-7 FC3S, produced from 1989 to 1991, represents the second generation of Mazda's iconic rotary-powered sports coupe. Engineered with a focus on lightweight construction, balanced weight distribution, and the unique performance characteristics of its 13B rotary engine, this rear-wheel-drive vehicle offered exhilarating driving dynamics. Available in coupe and convertible body styles, with both naturally aspirated and twin-turbocharged variants, the RX-7 was celebrated for its driver-focused ergonomics and sporty handling, earning accolades such as consistent appearances on Car and Driver's Ten Best lists. Its design and engineering philosophy emphasized a pure driving experience, making it a standout in the sports coupe segment. This comprehensive Factory Service Repair Manual provides in-depth information for the Mazda RX-7 FC3S, covering model years 1989, 1990, and 1991. It details all major systems, including the rotary powertrain, chassis, and electrical components, offering essential guidance on maintenance, repair, and troubleshooting. Within its extensive pages, owners and technicians will find detailed procedures for scheduled maintenance, engine and transmission overhauls, brake and suspension work, and electrical system diagnostics. Crucial technical specifications, torque values, fluid capacities, and wiring diagrams are also included, ensuring accurate and effective upkeep and repair of this performance-oriented vehicle.

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Generation:

FC3S (Second Generation)

Codes

Chassis Code:

Engine Code Primary:

13B (Rotary)

👋 Introduction

Market Position

Segment:

Sports Coupe/Convertible

Competitive Analysis

Key Competitors:

Nissan 300ZX (Z32), Toyota Supra (MkIII), Porsche 944, Chevrolet Camaro/Pontiac Firebird (late 3rd gen)

Key Features

Engineering Philosophy:

Lightweight chassis, balanced weight distribution, rotary engine technology, driver-focused ergonomics.

Model Variants:

Coupe, Convertible, Turbo II (performance variant), Non-Turbo models.

📋 Manual Details

Coverage Areas

Years Covered:

1989, 1990, 1991

Regions Covered:

Global (North American and Japanese specifications are typically included in comprehensive factory manuals)

Page Count

Estimated Pages:

Hundreds (Specific count varies by exact edition, but typically exceeds 1000 pages for a complete factory service manual)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (Rotary 13B, twin-turbo and naturally aspirated), Fuel System, Cooling System, Exhaust System, Drivetrain (RWD)

Chassis:

Suspension (Front & Rear), Steering, Brakes (ABS available), Driveline

Electrical:

Wiring Diagrams, Lighting, Instrumentation, Audio System, Power Accessories, ECU and Sensors

Body:

Exterior Body Panels, Interior Trim, Doors, Windows, HVAC System

Procedures Included

Maintenance:

Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks and Replacements

Repair:

Engine Overhaul, Transmission Repair, Brake System Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair

Troubleshooting:

Diagnostic Flowcharts, Symptom-Based Troubleshooting Guides, Diagnostic Trouble Codes (DTCs)

Specifications:

Torque Specifications, Clearances, Tolerances, Fluid Capacities, Electrical Specifications

Technical Depth

Depth:

Comprehensive factory-level repair and diagnostic information, suitable for professional technicians and advanced enthusiasts.

📊 Manual Specifications

File Format

Quality:

High-resolution scans or original digital files, ensuring clarity of text and diagrams.

Searchability:

Typically includes searchable text (OCR) for quick information retrieval.

Print Quality

Print Readability:

Designed for clear printing, with legible diagrams and text.

Binding Type

For Print:

Digital PDF allows for printing individual sections or the entire manual, suitable for various binding methods (e.g., binder, comb binding).

Paper Type

For Print:

N/A (Digital Format), but original manuals typically used durable, coated paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Type:

Rotary (Wankel)

Displacement:

1.3 Liters (654cc x 2 rotor equivalent)

Configuration:

Twin-Rotor

Performance

Turbo Ii Horsepower:

200 hp @ 6500 rpm (approx.)

Turbo Ii Torque:

196 lb-ft @ 3500 rpm (approx.)

Naturally Aspirated Horsepower:

145 hp @ 6000 rpm (approx.)

Naturally Aspirated Torque:

135 lb-ft @ 4000 rpm (approx.)

Fuel System

Induction Turbo:

Bosch L-Jetronic Fuel Injection with Twin Turbochargers (Sequential on later models)

Induction Naturally Aspirated:

Bosch L-Jetronic Fuel Injection

Engine Management

Engine Control Unit (ECU) managing fuel, ignition, and boost pressure.

🔧 Transmission

Standard

Type:

5-speed Manual

Optional

Type:

4-speed Automatic

Features

Drive Layout:

Rear-Wheel Drive (RWD)

Clutch:

Hydraulic clutch system

📐 Dimensions

Exterior

Length:

4370 mm (approx. for Coupe)

Width:

1690 mm (approx.)

Height:

1265 mm (approx. for Coupe)

Wheelbase:

2500 mm (approx.)

Weights

Curb Weight Turbo Ii:

1350 kg (approx.)

Curb Weight Naturally Aspirated:

1260 kg (approx.)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not explicitly rated by NHTSA for this model year in all configurations, but designed with safety crumple zones and reinforcing structures.

Active Features

Anti-lock Braking System (ABS) available on select models and trims.

Brake Bias:

Adjustable brake proportioning valve (manual adjustment on some models).

Passive Features

Airbags:

Driver-side airbag standard on most models from 1990 onwards, passenger airbag optional or standard on later models/markets.

Seatbelts:

Three-point inertia reel seatbelts

Chassis Reinforcement:

Integrated roll-over protection structure in convertible models, chassis reinforcement in coupes.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player, optional CD player on later models. Speakers integrated into doors and rear deck.

Driver Assistance

Cruise Control:

Standard on many models, providing long-distance driving comfort.

Connectivity

Interior Features:

Driver-oriented cockpit, adjustable steering column, power windows, power locks, and climate control.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000 miles or 6 months, whichever comes first. Use synthetic oil recommended for rotary engines.

Spark Plugs:

Replace every 30,000 miles. Specific platinum-tipped or iridium spark plugs are crucial for rotary engines.

Coolant Flush:

Every 2 years or 30,000 miles.

Fluid Specifications

Engine Oil:

API SG or higher, SAE 10W-30 or 10W-40 (Synthetic recommended for rotary engines). Specific rotary-specific oils are ideal.

Transmission Fluid Manual:

GL-5 75W-90 gear oil

Transmission Fluid Automatic:

Dexron II or equivalent

Coolant:

Mazda Long Life Coolant (or equivalent ethylene glycol-based coolant, 50/50 mix with distilled water)

Brake Fluid:

DOT 3 or DOT 4

Known Issues

Apex Seals:

Wear of apex seals is a common rotary engine issue, leading to loss of compression. Regular oil changes and proper engine warm-up/cool-down are critical.

Oil Consumption:

Rotary engines naturally consume some oil as part of their lubrication system. The manual details the expected consumption and how to monitor it.

Turbo Charger Reliability:

Turbocharger wear can occur, especially if not properly maintained or if heat management is poor. The manual covers inspection and maintenance.

Cooling System:

Potential for coolant leaks and radiator issues due to age. The manual provides diagnostic steps.

📚 Vehicle History

Brand Heritage

Motorsport Connection:

Mazda's strong heritage in motorsports, particularly with rotary engines in endurance racing (e.g., Le Mans).

Model Evolution

Fc Generation:

The FC generation (1986-1991) was a significant evolution from the SA22C, featuring a more sophisticated independent rear suspension and more powerful engine options.

Updates 1989-1991:

Facelift in 1989 included revised bumpers, lights, hood, and interior styling. Turbo II models received larger intercoolers and improved engine management.

Production

Manufacturing Plant:

Hofu, Yamaguchi, Japan

Production Years:

1985–1992 (FC generation)

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

The FC RX-7 was a consistent nominee and winner of Car and Driver's Ten Best list during its production run, particularly the Turbo II models.