1986-1991 Mazda RX-7 Workshop Repair Service Manual Best

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Generation: FC3S Model Years Covered: 1986-1991 Chassis Code: FC3S 👋 Introduction Market Position Description: The Mazda RX-7 (FC generation) was positioned...

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类型: Car

斯库: 358450

标签: 1986 1987 1988 1989 1990 1991 Car Cars Mazda RX Models RX-7

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Model Generation:

Model Years Covered:

1986-1991

Chassis Code:

👋 Introduction

Market Position

Description:

The Mazda RX-7 (FC generation) was positioned as a stylish, sporty, and technologically advanced rear-wheel-drive coupe and convertible, competing with cars like the Toyota Supra, Nissan 300ZX, and Chevrolet Camaro/Pontiac Firebird.

Competitive Analysis

Competitors:

Toyota Supra (MkII/MkIII), Nissan 300ZX (Z31), Datsun 280ZX, Chevrolet Camaro/Pontiac Firebird (3rd Gen), Porsche 944.

Key Features

Notable Features:

Rotary engine (Wankel), sophisticated suspension, distinctive styling, available as coupe and convertible, often turbocharged (GXL, GTU, Turbo II trims).

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Repair and Service

Diagnostic Coverage:

Comprehensive diagnostic procedures

Maintenance Coverage:

All preventative maintenance procedures

Repair Coverage:

All mechanical and electrical repair procedures

Rebuild Coverage:

Engine and transmission rebuild procedures

Restoration Coverage:

Procedures for refurbishing and restoring vehicle components

Page Count

Estimated Page Count:

Not specified in product info, typically 1000+ pages for this era/depth

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, inspection, and reassembly

Engine Lubrication:

Oil pump, oil passages, oil filter, oil cooler operation and service

Engine Cooling:

Radiator, water pump, thermostat, coolant flow, fan operation and service

Engine Control:

ECU, sensors (MAP, TPS, O2), ignition timing, fuel injection control

Fuel System:

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

Exhaust System:

Manifold, catalytic converter, muffler, exhaust pipe service and replacement

Clutch:

Clutch disc, pressure plate, release bearing, hydraulic system service

Manual Transmission:

Gearbox disassembly, inspection, repair, fluid specifications

Automatic Transmission:

Transmission disassembly, inspection, repair, fluid specifications, control systems

Front Axle:

CV joints, wheel bearings, hub assembly service

Rear Axle:

Differential, half-shafts, wheel bearings, hub assembly service

Front Suspension:

Struts, control arms, ball joints, bushings, sway bar service

Rear Suspension:

Multi-link suspension components, bushings, shock absorbers, sway bar service

Road Wheels And Tires:

Tire pressure, rotation, balancing, wheel specifications

Brake System:

Disc brake service (pads, rotors), hydraulic lines, fluid specifications

Parking Brake:

Parking brake mechanism, cables, adjustment procedures

Brake Control:

ABS system (if equipped), proportioning valves, brake booster service

Power Steering:

Pump, rack and pinion, hydraulic fluid, steering linkage service

Steering System:

Steering column, tie rods, alignment specifications

Seat Belts:

Seat belt inspection, replacement, and functionality checks

Supplemental Restraint System (Airbag) diagnostics and service (cautionary notes)

Body Lock Security:

Door locks, ignition lock, key replacement, alarm systems (if equipped)

Glasses Windows Mirrors:

Window regulators, glass replacement, mirror adjustment and repair

Roof:

Targa top removal/installation, seals, headliner service

Exterior Interior:

Bumpers, fenders, trim pieces, seat upholstery, dashboard repair

Instrument Panel:

Gauge cluster, warning lights, sensor integration, dashboard illumination

Air Conditioner:

Refrigerant system, compressor, condenser, evaporator, climate control operation

Wiring Diagrams:

Complete vehicle electrical system schematics

Starting Charging:

Battery, starter motor, alternator service and testing

Lighting System:

Headlights, taillights, interior lighting, bulb replacement, circuit diagnostics

Driver Information:

Instrument cluster indicators, warning lights, trip computer (if equipped)

Wiper Washer Horn:

Wiper motor, washer pump, horn circuit service

Body Control System:

Central locking, power windows, mirror controls, interior lighting circuits

Lan System:

Local Area Network (LAN) for diagnostic communication (on later models)

Audio Visual Navigation Telephone:

Factory radio, speaker replacement, antenna systems (navigation/telephone likely not standard)

Auto Cruise Control:

Cruise control system diagnosis and repair

Power Supply Ground Circuit Elements:

Battery, fuses, relays, grounding points, circuit protection

Procedures Included

General Procedures:

Vehicle identification, safety precautions, jacking and lifting points, torque specifications

Engine Procedures:

Engine removal/installation, seal replacement, component testing, rebuild procedures

Transmission Procedures:

Transmission removal/installation, clutch replacement, gear synchro replacement, fluid changes

Suspension Procedures:

Shock absorber replacement, bushing replacement, alignment procedures

Brake Procedures:

Brake pad/rotor replacement, caliper overhaul, brake bleeding, ABS diagnostics

Electrical Procedures:

Component testing, wiring harness repair, diagnostic trouble code (DTC) retrieval and interpretation

Body Procedures:

Panel alignment, dent repair, seal replacement, interior trim removal/installation

Air Conditioning Procedures:

Refrigerant recharge, component replacement, leak detection

Technical Depth

Depth:

Comprehensive; covers basic maintenance to complete rebuilds and advanced diagnostics

Diagnostic Capability:

Detailed troubleshooting guides and symptom-based diagnostics

Rebuild Detail:

Includes detailed internal component specifications for engine and transmission

📊 Manual Specifications

File Format

Format:

Compatibility:

All Windows, Mac, and Linux versions

Readability:

Requires PDF Reader

Searchability:

Likely text-searchable PDF (depending on original scanning/creation)

Print Quality

Quality Description:

High Quality; contains high quality photos, illustrations, and diagrams

Binding Type

Type:

Digital Download (no physical binding)

Paper Type

Type:

Not applicable (digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Rotary (Wankel)

Engine Code Examples:

13B (Naturally Aspirated and Turbocharged variants)

Performance

Naturally Aspirated Hp:

Approx. 145-160 hp (depending on market and specific engine variant)

Turbocharged Hp:

Approx. 182-200 hp (Turbo II models)

Turbocharged Torque:

Approx. 183-200 lb-ft (Turbo II models)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (Premium recommended, especially for Turbo models)

Other

Rotor Housing Type:

Dual rotor (13B)

🔧 Transmission

Standard

Manual Transmission:

5-speed manual

Optional

Automatic Transmission:

4-speed automatic (availability varied by trim level)

Features

Differential Type:

Limited-Slip Differential (LSD) often standard or optional on performance models (e.g., Turbo II)

📐 Dimensions

Exterior

Length:

Approx. 167.9 inches (4265 mm)

Width:

Approx. 68.9 inches (1750 mm)

Height:

Approx. 49.6 inches (1260 mm)

Wheelbase:

Approx. 95.7 inches (2430 mm)

Weights

Curb Weight:

Approx. 2800-3200 lbs (1270-1450 kg), depending on trim and options

🛡️ Safety Features

Ratings

Safety Ratings:

NHTSA/IIHS ratings for this era are often dated; emphasis on passive restraint systems available at the time.

Active Features

Active Safety:

Anti-lock Braking System (ABS) available on some models, powerful disc brakes, responsive steering.

Passive Features

Passive Safety:

3-point seat belts, reinforced chassis, optional airbag (driver-side on later models).

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player, often with equalizer and amplifier options.

Driver Assistance

Cruise Control:

Available on select trims.

Connectivity

Connectivity Features:

Limited by era; no modern Bluetooth or USB connectivity unless aftermarket.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles or 6 months (check manual for specific recommendation based on oil type and driving conditions).

Spark Plug Replacement:

Specific intervals for rotary plugs, often around 30,000 miles, but check manual.

Timing Belt Replacement:

Not applicable (rotary engines do not have timing belts; they use a chain or gears for apex seal timing).

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-30 or 10W-40 often recommended. Rotary-specific oil additives are sometimes used.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil (specific viscosity depends on ambient temperature, e.g., 75W-90).

Transmission Fluid Automatic:

Dexron II or equivalent ATF.

Coolant:

Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Apex Seal Wear:

A common concern with rotary engines; regular maintenance, proper warm-up/cool-down, and avoiding detonation are crucial.

Oil Consumption:

Rotary engines naturally consume some oil to lubricate apex seals; excessive consumption can indicate seal wear.

Cooling System:

Overheating can be an issue if the cooling system is not properly maintained.

Vacuum Lines:

Age-related degradation of vacuum hoses can lead to vacuum leaks and drivability issues.

Exhaust System Rust:

Common for vehicles of this age, especially in corrosive climates.

📚 Vehicle History

Brand Heritage

Brand Focus:

Mazda has a long history of producing engaging and innovative driver-focused vehicles, often with unique engineering solutions.

Model Evolution

Previous Generation:

First generation RX-7 (SA22C/FB, 1978-1985).

Next Generation:

Third generation RX-7 (FD, 1992-2002).

Production

Production Period:

1985-1991

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Automotive Journalism Awards:

Car and Driver's Ten Best list in 1986. Frequently praised for its handling and rotary engine technology.