Positioning:
The Mazda RX-7 (FD) is a legendary Japanese sports car renowned for its rotary engine, performance, and iconic styling.
Competitors:
Competed with other high-performance sports cars of its era such as the Nissan 300ZX (Z32), Toyota Supra (Mk4), Mitsubishi 3000GT/GTO, and Porsche 968.
Rotary Engine:
The 13B-REW twin-rotor engine is the defining characteristic, offering high revving capability and a unique power delivery.
Design:
Sleek, aerodynamic 'spirit of speed' design language, often cited as one of the most beautiful Japanese cars.
Handling:
Exceptional handling due to its balanced chassis, lightweight construction, and sophisticated suspension geometry.
Twin Turbo:
Sequential twin-turbocharging system providing a broad power band and improved low-end torque.
Covered Model Years:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
Estimated Page Count:
Extensive (typical for full workshop manuals, often 1000+ pages)
Type:
Workshop Service Repair Manual
Engine Mechanical:
Rotary engine (13B-REW) operation, disassembly, inspection, assembly, troubleshooting.
Engine Management:
Fuel injection, ignition system, emissions control, ECU diagnostics, sensors, actuators.
Transmission:
Manual transmission (R154, RX-8 6-speed optional), clutch system, driveline, differentials.
Brakes:
Hydraulic system, ABS, caliper, rotor, and pad inspection/replacement, bleeding procedures.
Suspension:
Front and rear suspension components, alignment specifications, shock absorbers, springs.
Steering:
Power steering system, steering rack, linkage inspection and repair.
Electrical:
Wiring diagrams, charging system, starting system, lighting, accessories, power windows, mirrors.
Body And Chassis:
Body panel removal/installation, interior trim, doors, glass, frame repair, rust prevention.
HVAC:
Air conditioning system, heater, ventilation, climate control operation and repair.
Exhaust:
Catalytic converter, mufflers, pipe inspection and replacement.
Fuel System:
Fuel tank, fuel pump, fuel lines, injectors, fuel pressure testing.
Preventive Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, inspections.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for common issues.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation.
Diagnostic Procedures:
OBD-II diagnostics, specific sensor testing, system checks.
Technical Data And Specs:
Torque specifications, clearances, fluid capacities, electrical specifications.
Depth:
Comprehensive (covers everything from basic oil changes to complete engine rebuilds and diagnostics).
Diagnostic Tools:
Information on using diagnostic tools and scanners relevant to the era.
Engine Type:
654cc x 2 (1308cc) Rotary, Twin Sequential Turbocharged
Bore Stroke:
100 mm x 63 mm (per rotor)
Horsepower Early:
255 hp @ 6500 rpm (1992-1995 models)
Horsepower Late:
280 hp @ 6500 rpm (1996-2002 models, often referred to as Series 7 and 8)
Torque Early:
217 lb-ft @ 5000 rpm (1992-1995 models)
Torque Late:
231 lb-ft @ 5000 rpm (1996-2002 models)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Premium Unleaded Gasoline (91 Octane or higher)
Oil Type Recommendation:
API SG/SH or higher, SAE 10W-30/10W-40 Recommended (with specific rotary oil considerations)
Length:
Approx. 4295 mm (169.1 in)
Width:
Approx. 1750 mm (68.9 in)
Height:
Approx. 1230 mm (48.4 in)
Wheelbase:
Approx. 2505 mm (98.6 in)
Curb Weight:
Approx. 1270-1300 kg (2800-2866 lbs) depending on trim and year
Weight Distribution:
Near 50/50 front/rear for optimal handling
Niosh Ratings:
N/A (Crash test ratings vary by region and year; generally good for its class).
ABS:
Anti-lock Braking System (ABS) standard on most models.
Traction Control:
Traction control system (TCS) available on later models (e.g., Series 8).
Airbags:
Driver and passenger airbags standard.
Body Structure:
Reinforced safety cell and crumple zones.
Audio System:
Factory premium audio systems (e.g., Bose) were available, often with cassette and CD players.
Climate Control:
Automatic climate control on higher trims.
Cruise Control:
Standard cruise control system.
Connectivity Features:
Limited by era; primarily focused on audio connectivity, no modern Bluetooth or USB integration from factory.
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (highly recommended for rotary engines).
Spark Plug Replacement:
Typically every 30,000-60,000 miles, depending on plug type and driving conditions (use specific rotary plugs).
Timing Belt Replacement:
N/A (Rotary engines do not have timing belts; they use chains or a direct drive system for the rotors.)
Coolant Flush:
Every 2-3 years or 30,000 miles.
Engine Oil Capacity:
Approx. 4.7 Liters (4.9 US quarts) with filter (check manual for exact type).
Transmission Fluid Type:
API GL-4 SAE 75W-90 (or specified manual transmission fluid).
Differential Fluid Type:
API GL-5 SAE 80W-90 or 85W-140 (hypoid gear oil).
Coolant Type:
Mazda Genuine Super Long Life Coolant or equivalent ethylene glycol-based coolant with corrosion inhibitors.
Apex Seals:
Wear of apex seals can lead to loss of compression and poor engine performance. Requires engine rebuild.
Oil Injection System:
Failure of the oil metering pump or its lines can starve the engine of essential lubrication.
Vacuum Lines:
Aging and cracking of numerous vacuum hoses can cause boost leaks and drivability issues.
Intercooler System:
Turbocharger and intercooler systems can be prone to leaks and heat soak if not maintained.
Electrical Gremlins:
Can be susceptible to various electrical issues due to complex wiring harnesses and age.
Rotary Specific Care:
Regularly check oil levels (engine oil and 2-stroke oil for oil injection), perform compression tests, and use appropriate high-quality lubricants.
Rotary History:
Mazda has a long history with the rotary engine, dating back to the Cosmo Sport.
Previous Generations:
Preceded by the SA/FB (1978-1985) and FC (1985-1991) generations.
Design Influence:
The FD's design was heavily influenced by the 'spirit of speed' concept, aiming for aerodynamic efficiency and a pure sports car feel.
Production Period:
October 1991 - August 2002
Production Locations:
Mazda's Hofu Plant, Yamaguchi Prefecture, Japan.
Series Designations:
Series 1 (1992-1995), Series 2 (1996-1998), Series 3 (1999-2002) with significant updates to engine management, suspension, and aerodynamics.
