1989 Mazda RX-7 (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 1989 Codes Chassis Code: FC3S Generation Designation: Second Generation (FC) 👋 Introduction Market Position Market Segment: Sports Car, Rear-Wheel Drive Coupe...

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标签: 1989 Car Cars Mazda Misc RX-7 (2nd gen)

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Year:

Codes

Chassis Code:

Generation Designation:

Second Generation (FC)

👋 Introduction

Market Position

Market Segment:

Sports Car, Rear-Wheel Drive Coupe

Design Philosophy:

Focus on lightweight design, balanced handling, and innovative rotary engine technology.

Competitive Analysis

Primary Competitors:

Nissan 300ZX (Z31), Toyota Supra (MkII/MkIII), Porsche 944, Chevrolet Camaro/Pontiac Firebird

Key Features

Rotary Engine:

The signature Wankel rotary engine, offering a unique power delivery and high-revving character.

Handling:

Renowned for its balanced chassis, sophisticated suspension, and predictable handling characteristics.

Styling:

Sleek, aerodynamic design with pop-up headlights, a hallmark of 1980s sports cars.

📋 Manual Details

Coverage Areas

Coverage Scope:

All models and all repairs A-Z

Information Type:

Vehicle Specific (not generic)

Target Audience:

Dealership Technicians, Professional Mechanics, Enthusiasts

Page Count

Estimated Page Count:

Over 1500 pages (typical for comprehensive factory service manuals of this era)

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Printed Book (Original Factory Publication)

Print Quality:

High-quality original factory printing with clear diagrams and text.

Binding Type:

Original factory binding (typically hardcover or sturdy softcover with professional binding).

Paper Type:

Durable, high-quality paper designed for workshop use.

📖 Manual Coverage

Systems Covered

Engine Systems:

Rotary Engine (13B), Lubrication, Cooling, Fuel Injection, Ignition, Emissions Control

Drivetrain:

Manual Transmission, Automatic Transmission, Clutch, Driveshaft, Differential, Axles

Suspension Steering:

Front Suspension (MacPherson Strut), Rear Suspension (Independent Multi-link), Power Steering System, Steering Gear

Brakes:

Front Disc Brakes, Rear Disc Brakes, Anti-lock Braking System (ABS), Parking Brake

Electrical Electronics:

Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Fuses, Relays, ECU (Engine Control Unit), Immobilizer (if equipped), Audio System

Body Chassis:

Body Construction, Exterior Trim, Interior Trim, Doors, Hood, Trunk, Seats, Glass

HVAC:

Air Conditioning System, Heater System, Ventilation

Procedures Included

Maintenance Procedures:

Scheduled Maintenance, Oil Changes, Filter Replacements, Tune-ups, Fluid Level Checks and Replacements

Repair Procedures:

Engine Overhaul/Rebuild (Rotary Specific), Transmission Overhaul, Brake Caliper Rebuild, Suspension Component Replacement, Electrical Component Diagnosis and Repair, Body Panel Repair

Troubleshooting:

Diagnostic Flowcharts, Symptom-based Troubleshooting Guides, Error Code Explanations (for ECU)

Diagnostics:

Wiring Diagrams, Component Testing Procedures, Specifications for Measurement

Special Tools:

Identification and usage of specialized Mazda tools required for specific repairs

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and assembly instructions.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Rotary (Wankel)

Engine Code:

Configuration:

Naturally Aspirated (NA) and Turbocharged (Turbo)

Displacement:

1.3 Liters (654cc x 2 rotors)

Performance

Horsepower Na:

Approx. 145-160 hp (depending on specific market and minor revisions)

Torque Na:

Approx. 130-140 lb-ft

Horsepower Turbo:

Approx. 200 hp (Turbo II model)

Torque Turbo:

Approx. 200-210 lb-ft (Turbo II model)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

Unleaded Gasoline (Octane rating specified in manual, typically 91+ for optimal performance)

Cooling System

Cooling Type:

Liquid-cooled

Lubrication System

Lubrication Type:

Oil sump with oil injection system for apex seals.

Oil Type Specification:

API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for specific ambient temperature ranges).

Rotary Specifics

Apex Seals:

Critical wear components requiring specific lubrication and maintenance.

Oil Metering Pump:

Responsible for injecting lubricating oil into the combustion chambers.

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

4-Speed Automatic Transmission

Features

Clutch Type:

Hydraulically Actuated, Single Dry Plate (Manual)

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (refer to manual for specific viscosity recommendations based on temperature).

Transmission Fluid Automatic:

Dexron III or equivalent ATF (Automatic Transmission Fluid)

📐 Dimensions

Exterior

Length:

Approx. 172.0 inches (4369 mm)

Width:

Approx. 68.7 inches (1745 mm)

Height:

Approx. 49.8 inches (1265 mm)

Wheelbase:

Approx. 95.7 inches (2430 mm)

Weights

Curb Weight:

Approx. 2800-3100 lbs (1270-1406 kg) depending on trim and options

Gross Vehicle Weight Rating:

Refer to vehicle's compliance plate (typically around 3700 lbs)

Cargo

Trunk Capacity:

Limited, typical for a sports coupe. Specific volume not readily available but functional for weekend luggage.

🛡️ Safety Features

Ratings

NHTSA Ratings:

As an older vehicle, specific NHTSA ratings from that era may be limited or unavailable in modern databases. The structure was designed for sporty performance.

Active Features

Available on higher trims and Turbo models (Anti-lock Braking System)

Passive Features

Seatbelts:

3-point inertia reel seatbelts

Airbags:

Driver-side airbag may have been optional or standard on later 1989 models, but not universally equipped as in modern vehicles.

Body Structure:

Reinforced chassis and crumple zones typical for the period.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player, often with multiple speakers. Optional premium sound systems available.

Instrumentation:

Comprehensive analog gauges including speedometer, tachometer, oil pressure, water temperature, and voltage meter. Turbo models feature boost gauge.

Driver Assistance

Cruise Control:

Available on most models.

Connectivity

Connectivity Features:

Limited by era; primarily focused on basic vehicle operation and entertainment. No advanced connectivity or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first. High-performance rotary engines may benefit from more frequent changes.

Spark Plug Replacement:

Refer to manual; typically around 30,000 miles for standard plugs. Rotary engines often use specific long-life plugs.

Coolant Flush:

Every 2-3 years or 30,000 miles.

Timing Belt Or Chain:

Not applicable; rotary engines do not have timing belts or chains in the conventional sense.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for exact specification).

Power Steering Fluid:

Dexron II or equivalent power steering fluid.

Coolant:

50/50 mix of ethylene glycol antifreeze and distilled water.

Known Issues

Apex Seal Wear:

Degradation of apex seals leading to compression loss, rough idle, and reduced power. Regular proper maintenance is key.

Carbon Buildup:

Accumulation of carbon in the rotor housings and exhaust ports, potentially affecting performance and emissions. Requires periodic cleaning.

Oil Consumption:

Rotary engines naturally consume a small amount of oil for lubrication. Excessive consumption indicates potential seal wear.

O2 Sensor Failure:

Common on many vehicles of this era, affecting fuel mixture and emissions.

Vacuum Lines:

Aging rubber vacuum lines can crack and leak, leading to vacuum leaks and drivability issues.

📚 Vehicle History

Brand Heritage

Mazda Rotary Legacy:

Mazda's long and dedicated history with the Wankel rotary engine, starting with the Cosmo Sport and continuing with the RX series.

Model Evolution

Fc Generation:

Introduced in 1985, the FC RX-7 was a significant departure from the first generation (SA/FB), featuring a more modern and aerodynamic design influenced by the Porsche 944.

1989 Updates:

Minor cosmetic updates and potential refinements to the engine and suspension were common for the late FC generation.

Production

Production Years Fc:

1985-1992

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

The RX-7 (FC generation) was named to Car and Driver's Ten Best list multiple times during its production run.