🏷️ Basic Information

Make:

Mazda

Model:

RX-7

Year:

1999

Chassis Code:

FD3S

Engine Code:

13B-REW

👋 Introduction

Positioning:

The Mazda RX-7 (FD) is a legendary JDM icon, celebrated for its groundbreaking twin-rotor rotary engine, sophisticated chassis, and striking design. It occupied a niche in the sports car market, competing with cars like the Nissan 300ZX, Toyota Supra, and Mitsubishi 3000GT.

Competitors:

Nissan 300ZX (Z32), Toyota Supra (Mk. IV), Mitsubishi 3000GT VR-4, Porsche 968, Chevrolet Corvette.

Unique Selling Points:

Naturally aspirated rotary engine (13B-REW) with sequential twin-turbocharging, lightweight construction, exceptional handling and balance, iconic styling, rear-wheel drive. This manual provides the in-depth knowledge required to maintain and repair this complex and performance-oriented vehicle.

📋 Manual Details

General Coverage:

Comprehensive repair, maintenance, rebuild, refurbish, and restoration of the 1999 Mazda RX-7.

Estimated Page Count:

Extensive, likely over 1000 pages based on typical full service manuals for performance vehicles.

Type:

Full Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine System:

Rotary engine (13B-REW), including theory of operation, disassembly, assembly, inspection, troubleshooting, and component replacement for apex seals, rotor housings, rotors, eccentric shaft, oil metering, cooling, lubrication, and ignition systems.

Fuel System:

Fuel injection system (sequential twin-turbo), fuel pump, fuel injectors, fuel pressure regulator, fuel lines, evaporative emissions control (EVAP).

Exhaust System:

Catalytic converter, mufflers, exhaust manifold, oxygen sensors, emission control components.

Intake:

Air intake system, air filter, mass airflow sensor (MAF), intake manifold, intercooler system, twin-turbocharger operation and diagnosis.

Cooling:

Radiator, cooling fans, coolant hoses, thermostat, water pump, coolant flow, temperature sensor.

Lubrication:

Engine oil sump, oil pump, oil filter, oil cooler, oil metering system (premix or separate injection).

Ignition:

Ignition coils, spark plugs, ignition timing, ECU control of ignition.

Electrical:

Wiring diagrams, battery, alternator, starter motor, fuses, relays, lighting systems, horn, wipers, power windows, power locks, instrument cluster, dashboard warning lights.

Transmission:

Manual transmission (R154 or similar, if applicable to specific FD market or variant), clutch system, clutch hydraulics, flywheel, driveshaft, differential, axle shafts, gearbox overhaul and repair.

Brakes:

Front and rear disc brakes, ABS system, brake calipers, brake rotors, brake pads, brake lines, brake fluid specifications, parking brake, bleeding procedure.

Steering:

Power steering system, steering rack, steering column, steering wheel, tie rods, power steering fluid.

Suspension:

Front and rear suspension (double wishbone), shock absorbers, springs, anti-roll bars, bushings, ball joints, wheel alignment specifications.

Body:

Chassis structure, body panels, doors, hood, trunk, bumpers, glass, seals, rust prevention and repair, paint codes.

Interior:

Seating systems, dashboard, instrument panel, center console, door panels, headliner, seat belts, airbag system (if equipped).

HVAC:

Air conditioning system, heater core, blower motor, evaporator, condenser, refrigerant type and capacity, climate control unit.

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical diagnostic procedures, component testing.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, air filter replacement, belt inspection and replacement.

Engine Rebuild:

Complete engine disassembly, cleaning, inspection, measurement, part replacement (apex seals, O-rings, gaskets), and reassembly procedures for the 13B-REW rotary engine.

Turbocharger Service:

Inspection, repair, and replacement of the sequential twin-turbocharger system.

Transmission Overhaul:

Step-by-step instructions for disassembling, inspecting, and reassembling the manual transmission.

Brake System Repair:

Brake pad and rotor replacement, caliper service, bleeding the brake system, ABS component diagnosis.

Suspension Component Replacement:

Replacement of shock absorbers, springs, bushings, and ball joints.

Electrical Diagnostics:

Tracing electrical faults using wiring diagrams, testing components, and repairing wiring harnesses.

Body Panel Alignment:

Adjustments and replacement of body panels for proper fit and finish.

Interior Trim Removal:

Instructions for removing and reinstalling interior components for access to underlying systems.

Engine Management Tuning:

Information on ECU parameters, sensor inputs, and potentially tuning parameters (though advanced tuning might be separate).

Depth:

Deep technical detail, covering everything from basic maintenance to complete engine rebuilds and component-level diagnostics. Suitable for both DIY enthusiasts and professional mechanics.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Typically text-searchable PDF for easy information retrieval.

Quality:

High-resolution scans or digitally created documents, suitable for printing individual pages or the entire manual.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Rotary (Wankel)

Engine Code:

13B-REW

Displacement:

1.3L (654cc x 2 rotor faces)

Aspiration:

Twin-Turbocharged (Sequential)

Horsepower:

Approximately 255 hp (JDM) to 280 hp (later USDM/JDM) at 6500 rpm

Torque:

Approximately 217 lb-ft (JDM) to 231 lb-ft (later USDM/JDM) at 5000 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Twin-Turbo

Recommended Fuel:

Premium Unleaded Gasoline (91 octane or higher)

Oil Capacity:

Approximately 4.9 US quarts (4.6 liters) with filter change.

Coolant Capacity:

Approximately 8.5 US quarts (8.0 liters).

🔧 Transmission

Type:

5-Speed Manual Transmission

Type:

4-Speed Automatic Transmission (less common)

Clutch Type:

Hydraulically actuated, multi-plate clutch (typical for performance applications, though specific FD might vary).

Transmission Fluid Type:

Refer to manual for specific API GL-4 or GL-5 rated gear oil (e.g., Mazda specifies 75W-90 synthetic).

Differential Fluid Type:

Refer to manual for specific API GL-5 rated gear oil (e.g., Mazda specifies 80W-90).

📐 Dimensions

Length:

Approximately 169.1 inches (4300 mm)

Width:

Approximately 69.1 inches (1755 mm)

Height:

Approximately 48.2 inches (1225 mm)

Wheelbase:

Approximately 95.5 inches (2425 mm)

Curb Weight:

Approximately 2844 - 2976 lbs (1290 - 1350 kg) depending on trim and options.

🛡️ Safety Features

NHTSA Ratings:

Vehicle safety ratings vary by region and specific testing protocols of the era. Consult official sources for specific crash test data.

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS) on some models.

Airbags:

Driver and passenger front airbags (standard on later models).

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners.

💡 Technology Features

Audio System:

Factory fitted AM/FM stereo with cassette player and CD player (optional). Speaker configuration typically includes front door and rear cabin speakers.

Climate Control Unit:

Manual or automatic climate control systems.

Cruise Control:

Standard cruise control system.

OBD Ii:

On-Board Diagnostics II (OBD-II) port for diagnostic scanning.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions and oil used. Rotary engines require diligent oil maintenance.

Spark Plug Replacement:

Recommended every 30,000 miles (48,000 km), often using specialized ignition components for rotary engines.

Timing Belt Replacement:

N/A (Rotary engines do not have timing belts; they use chains or direct drive for the eccentric shaft).

Coolant Flush:

Every 2 years or 30,000 miles (48,000 km).

Engine Oil Type:

API SG or SH, SAE 10W-30 or 10W-40 synthetic recommended for rotary engines.

Brake Fluid Type:

DOT 3 or DOT 4 (consult manual for specific recommendation).

Power Steering Fluid Type:

ATF Dexron II or equivalent.

Apex Seal Wear:

The primary concern with rotary engines. Regular maintenance, proper lubrication, and avoiding engine lugging are crucial. The manual will detail inspection and replacement procedures.

Oil Metering System:

Potential issues with the oil injection system can lead to increased wear. Manual provides diagnostic and repair steps.

Sequential Turbo Failure:

Early turbocharger issues can occur. The manual offers troubleshooting guides.

Vacuum Lines:

Numerous vacuum lines can degrade over time, leading to boost leaks and running issues. The manual aids in identifying and replacing these.

📚 Vehicle History

Mazda Rotary:

Mazda has a long and unique history with the rotary engine, starting with the Cosmo in the late 1960s. The RX-7 line is the pinnacle of their rotary sports car development.

Generations:

The 1999 model is part of the third generation (FD) of the RX-7, produced from 1992 to 2002. The FD generation is renowned for its significant improvements in chassis stiffness, aerodynamics, and the evolution of the 13B engine.

Production Years:

1992-2002

Assembly Location:

Hiroshima, Japan

🏆 Awards & Recognition

Car And Driver Ten Best:

The RX-7 FD was a consistent recipient of Car and Driver's 'Ten Best' list for its performance and handling.

Iconic Status:

Widely regarded as one of the greatest sports cars of its era, maintaining a strong enthusiast following and collector value.