1989 Mazda RX-7 Service Repair Factory Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 1989 Chassis Code: FC3S 👋 Introduction Market Position Segment: Sports Car / Grand Tourer Target Audience: Enthusiasts, DIY Mechanics, Restoration Shops...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Year:

Chassis Code:

👋 Introduction

Market Position

Segment:

Sports Car / Grand Tourer

Target Audience:

Enthusiasts, DIY Mechanics, Restoration Shops

Competitive Analysis

Key Competitors:

Nissan 300ZX (Z32), Toyota Supra (Mk3), Porsche 944

Key Features

Unique Selling Proposition:

Mazda's signature rotary engine, balanced chassis, and driver-focused design.

Manual Value:

Essential resource for maintaining and repairing the iconic FC generation RX-7, particularly the complex rotary engine.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Wiring Diagrams

Page Count

Estimated Pages:

Approximately 1500-2000 (typical for full factory service manuals of this era)

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Electronic (PDF)

📖 Manual Coverage

Systems Covered

Engine System:

Rotary Engine (13B) - Disassembly, Assembly, Rebuild, Tuning, Lubrication, Cooling, Fuel Injection (EFI)

Transmission System:

Manual (5-speed) and Automatic Transmission - Overhaul, Shifting Mechanisms, Fluid Specifications

Drivetrain System:

Rear-Wheel Drive, Differential, Driveshafts, Axles

Suspension System:

Front and Rear Suspension (Independent), Bushings, Ball Joints, Shock Absorbers, Springs

Braking System:

Front and Rear Disc Brakes, ABS (if equipped), Hydraulic System, Brake Pad/Rotor Replacement

Steering System:

Power Steering System, Steering Rack, Tie Rods

Electrical System:

Battery, Alternator, Starter, Ignition System, Lighting, Fuses, Relays, Body Electrical, ECU Pinouts

Fuel System:

Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Pressure Regulator, Emission Control Systems

Exhaust System:

Exhaust Manifolds, Catalytic Converter, Muffler, Oxygen Sensors

Cooling System:

Radiator, Water Pump, Thermostat, Hoses, Coolant Specifications

HVAC System:

Air Conditioning, Heater, Blower Motor, Climate Control

Body And Interior:

Body Panels, Doors, Windows, Seats, Trim, Upholstery

Procedures Included

General Maintenance:

Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Spark Plug Replacement (Rotary Specific)

Engine Repair:

Apex Seal Replacement, Rotor Housing Resurfacing, Eccentric Shaft Reassembly, Engine Mounts

Transmission Repair:

Clutch Replacement, Gearbox Overhaul, Synchronizer Replacement

Brake Service:

Brake Pad/Rotor Replacement, Caliper Rebuild, Brake Fluid Flush

Suspension Service:

Strut/Shock Replacement, Bushing Replacement, Alignment Specifications

Electrical Diagnostics:

Troubleshooting Fault Codes, Wiring Harness Repair, Component Testing

Fuel System Diagnostics:

Fuel Injector Cleaning, Fuel Pump Testing, Fuel Pressure Adjustments

Troubleshooting Guides:

Systematic Diagnosis for Common Problems (e.g., starting issues, rough idle, poor performance)

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic preventative maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system troubleshooting.

Diagnostic Tools:

Details on required special tools and diagnostic equipment for specific procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (depending on OCR quality of original scan)

Print Quality

Image Resolution:

Varies based on original scan quality, but aims for clarity of diagrams and text.

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Quality:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Rotary (Wankel)

Engine Code:

Displacement:

1.3 L (654cc x 2 rotors)

Performance

Horsepower Naturally Aspirated:

160 hp @ 6500 rpm (GTUs, GXL)

Horsepower Turbocharged:

200 hp @ 6500 rpm (Turbo II)

Torque Naturally Aspirated:

150 lb-ft @ 3500 rpm

Torque Turbocharged:

200 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (91 Octane Recommended)

Engine Components

Rotary Specifics:

Apex seals, side seals, corner seals, rotor housing coating, eccentric shaft.

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual

Optional

Transmission Type:

4-Speed Automatic

Features

Clutch Type:

Hydraulic Actuation

Fluid Specifications

Manual Transmission Fluid:

GL-4 SAE 75W-90 (or equivalent)

Automatic Transmission Fluid:

Dexron III (or equivalent)

📐 Dimensions

Exterior

Wheelbase:

99.4 inches (2525 mm)

Length:

175.6 inches (4460 mm)

Width:

69.1 inches (1755 mm)

Height:

49.6 inches (1260 mm)

Weights

Curb Weight:

Approx. 2800 - 3000 lbs (depending on trim and transmission)

Gross Vehicle Weight Rating:

Not explicitly stated, but typically around 3500 lbs

Wheel And Tire

Standard Wheel Size:

15-inch

Standard Tire Size:

205/60R15 (non-turbo), 225/50R15 (Turbo II)

Bolt Pattern:

5x114.3 mm (5x4.5 inches)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

Not rated or not tested under modern standards.

Active Features

Available on some models (e.g., Turbo II, GT Limited)

Passive Features

Seat Belts:

Three-point retractable front seat belts.

Airbags:

Driver-side airbag became standard in later years of this generation, check specific vehicle.

Crumple Zones:

Designed with front and rear crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette player, optional CD player on higher trims.

Driver Assistance

Anti-lock Braking System available on select models.

Climate Control

HVAC Features:

Manual climate control, optional automatic climate control on some models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 - 5,000 miles or 6 months (recommended, especially for rotary engines).

Spark Plug Replacement:

Refer to manual for specific interval and type (two spark plugs per rotor).

Timing Belt Replacement:

Not applicable (Rotary engines do not have timing belts; they use a timing chain/tensioner system).

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-30 or 10W-40 recommended. Rotary engines require specific oil consumption through the fuel system.

Coolant Type:

Ethylene Glycol based coolant, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Rotary Engine Wear:

Apex seal wear, carbon buildup, potential for flooding, oil consumption management is critical.

Fuel System Issues:

Clogged fuel injectors, weak fuel pump, vacuum leaks.

Suspension Component Wear:

Worn bushings, ball joints, and tie rod ends.

Electrical Gremlins:

Corroded grounds, failing relays, aging wiring harnesses.

📚 Vehicle History

Brand Heritage

Mazda Rotary Development:

Mazda's long-standing commitment to rotary engine technology, starting with the Cosmo Sport.

Model Evolution

Fc Generation:

Second generation RX-7 (1986-1991), known as the FC. Successor to the SA22C and predecessor to the FD.

Design Influence:

Influenced by the Porsche 944, featuring a front-engine, rear-wheel-drive layout and a more refined chassis.

Production

Production Years:

1985-1992 (for the FC generation globally), 1989 model year falls within this range.

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.