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Mazda RX 7 Service Repair Workshop Manual 1989-1991

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: FC Product Type: Service Repair Workshop Manual Codes Chassis Codes: FC3S, FC3C 👋 Introduction Market Position Positioning: Iconic Japanese sports car,...
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Mazda RX 7 Service Repair Workshop Manual 1989-1991
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
FC
Product Type:
Service Repair Workshop Manual
Codes
Chassis Codes:
FC3S, FC3C
👋 Introduction
Market Position
Positioning:
Iconic Japanese sports car, known for its rotary engine and handling prowess
Competitive Analysis
Competitors:
Nissan 300ZX (Z32), Toyota Supra (MK3), Mitsubishi Starion/Chrysler Conquest
Key Features
Handling:
Renowned for its balanced chassis, independent suspension, and excellent weight distribution
Powertrain Uniqueness:
Exclusive use of Mazda's Wankel rotary engine, offering a unique power delivery and sound
Manual Value
Value Proposition:
Essential for owners and technicians seeking accurate, detailed information for maintenance and repair of the FC RX-7.
Original Source:
Factory-issued technical documentation used by dealership technicians
📋 Manual Details
Coverage Areas
Model Years Covered:
1989, 1990, 1991
Models Covered:
All RX-7 models (Coupe, Convertible)
Repair Scope:
A-Z (Comprehensive)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Rotary Engine (13B), Turbocharger, Fuel System, Ignition System, Cooling System, Exhaust System
Drivetrain:
Transmission (Manual & Automatic), Clutch, Driveshafts, Differential, Axles
Chassis:
Suspension (Front & Rear), Steering System, Brakes (Front & Rear, ABS), Wheels, Tires
Electrical:
Wiring Diagrams, Lighting, Instruments, Audio System, Power Accessories, Starting & Charging System, Engine Control Module (ECM)
Body:
Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System, Convertible Top Mechanism (if applicable)
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Spark Plug Replacement
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnostics, DTC Code Interpretation, Test Procedures
Repair:
Engine Overhaul, Transmission Rebuild, Brake Caliper Replacement, Suspension Component Replacement, Electrical Component Diagnosis and Repair
Special Procedures:
Rotary Engine Apex Seal Inspection/Replacement, Turbocharger Overhaul, ABS Bleeding, Convertible Top Adjustment
Technical Depth
Depth:
Comprehensive (from basic inspection to complete engine rebuild)
Precision:
Vehicle/Model Specific (not generic)
📊 Manual Specifications
File Format
Compatibility:
PDF Reader (Adobe Acrobat or similar)
Searchability:
Text-searchable for quick information retrieval
Print Quality
Printability:
Printable for offline use
Binding Type
Digital Format:
N/A (Digital product)
Paper Type
Digital Format:
N/A (Digital product)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotary (Wankel)
Engine Code:
13B
Configuration:
Two-rotor, naturally aspirated and turbocharged variants
Displacement:
1.3 L (654 cc x 2)
Performance
Naturally Aspirated Hp:
Approx. 145-160 hp (depending on market and specific variant)
Turbocharged Hp:
Approx. 180-200 hp (Turbo II models)
Torque Turbocharged:
Approx. 190-205 lb-ft (Turbo II models)
Fuel System
Injection Type:
Electronic Fuel Injection (EFI)
Fuel Grade:
Premium Unleaded Gasoline
Cooling System
Type:
Liquid-cooled
Coolant Type:
Mazda Long Life Coolant (or equivalent ethylene glycol-based coolant)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual
Optional
Transmission Type:
4-speed Automatic
Features
Clutch Type:
Hydraulic, single-plate dry
Transmission Fluid:
Dexron III (or equivalent ATF for automatic) / Manual Transmission Fluid (API GL-4, SAE 75W-90 for manual)
📐 Dimensions
Exterior
Wheelbase:
2500 mm (98.4 inches)
Length:
4365 mm (171.9 inches)
Width:
1750 mm (68.9 inches)
Height:
1295 mm (51.0 inches)
Weights
Curb Weight:
Approx. 1250-1350 kg (2750-2980 lbs) depending on trim and options
Gross Vehicle Weight Rating:
Typically around 1700 kg
Wheel Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official data available for this era, but known for robust construction.
Active Features
Brakes:
Four-wheel disc brakes (ventilated front), optional Anti-lock Braking System (ABS) on Turbo II and Convertible models
Suspension Dynamics:
Independent front and rear suspension contributing to active safety through handling stability
Passive Features
Seat Belts:
3-point inertia reel seat belts
Airbags:
Driver's airbag optional on later models, not standard
Body Structure:
Reinforced passenger cabin
💡 Technology Features
Infotainment
Audio System:
Factory-provided AM/FM stereo with cassette player, optional CD player on later models.
Climate Control:
Manual climate control with A/C standard on most models.
Driver Assistance
ABS:
Available Anti-lock Braking System (ABS) on select trims, particularly Turbo II and Convertible.
Cruise Control:
Standard on most models.
Connectivity
Connectivity Features:
Limited by era; primarily analog systems.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 miles or 6 months (whichever comes first)
Air Filter:
Inspect every 15,000 miles, replace as needed
Spark Plugs:
Replace every 30,000 miles (specific rotary spark plugs recommended)
Fuel Filter:
Replace every 30,000 miles
Timing Belt:
N/A (Rotary engine does not use a timing belt, utilizes a timing chain/chain system)
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5-5.0 liters (4.7-5.3 US Quarts) with filter change (refer to manual for precise fill)
Engine Oil Viscosity:
10W-30 or 10W-40 (check manual for specific recommendations based on climate)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
ATF (Automatic Transmission Fluid)
Known Issues
Rotary Engine Apex Seals:
Wear or failure of apex seals leading to compression loss and poor running condition is a common concern. Regular maintenance and proper engine warm-up are crucial.
Oil Consumption:
Rotary engines naturally consume a small amount of oil as part of lubrication; however, excessive consumption can indicate seal wear.
Vacuum Leaks:
Degradation of vacuum hoses and seals can lead to rough idle and performance issues.
Turbocharger Reliability:
Early turbo models can experience turbocharger wear if not maintained properly (e.g., oil changes, allowing turbo to cool).
Rotary Specific Maintenance:
Requires specific knowledge regarding apex seal lubrication and engine break-in procedures.
📚 Vehicle History
Brand Heritage
Rotary Legacy:
Continuation of Mazda's pioneering work with the Wankel rotary engine, dating back to the Cosmo Sport.
Model Evolution
Fc Generation Introduction:
Introduced in 1985 as the successor to the SA22C RX-7.
Fc Facelift:
Significant styling and mechanical updates in 1989 (Series 5), including revised engine management, body kit, and interior.
Fc End Of Production:
Production ceased in 1991, succeeded by the FD generation RX-7.
Production
Manufacturing Location:
Hiroshima, Japan
Global Sales:
Sold globally, with significant markets in Japan, North America, and Europe.
🏆 Awards & Recognition
Recognitions
Car And Driver:
Car and Driver Ten Best list for 1986 and 1987.
Road And Track:
Frequently featured and praised in automotive publications for its driving dynamics.
Certifications
Automotive Journalism:
Widely recognized as a benchmark for sports car handling and rotary engine technology of its time.
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