Positioning:
The 1991 Mazda RX-7 (FC) represented the pinnacle of affordable Japanese sports car performance in its era, competing with cars like the Nissan 300ZX (Z32) and Toyota Supra (Mk3).
Competition:
Distinguished itself with its unique rotary engine technology, offering a compact, high-revving powerplant with a distinct character and sound, unlike the inline-six and V6 engines of its primary competitors.
Features:
Pop-up headlights, sophisticated independent suspension, powerful rotary engine, rear-wheel-drive layout, and a focus on driver engagement and handling.
Coverage:
All models and all repairs A-Z for the 1991 Mazda RX-7 (2nd Gen)
Pages:
Over 1,000 pages (estimated typical for dealership service manuals of this era)
Type:
Factory Service Manual / Workshop Manual
Format:
Print (typically spiral-bound or case-bound)
Engine:
Rotary engine (13B), lubrication, cooling, fuel, ignition, emissions, starting, charging
Transmission:
Manual (Type-R), Automatic (4-speed), clutch, drivetrain, driveshafts, differentials
Brakes:
Front ventilated discs, rear discs, ABS system (if equipped), hydraulic system, parking brake
Suspension:
Front McPherson struts, rear independent multi-link, steering system, power steering
Electrical:
Wiring diagrams, battery, alternator, starter, lighting, instrumentation, body electrical, ECU, sensors
Body:
Exterior panels, interior trim, doors, windows, seats, HVAC system, body structural repairs
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement (rotary specific), coolant flushes, belt inspections/replacement
Repair:
Engine rebuild (apex seals, rotor housing inspection), transmission overhaul, brake caliper rebuild, suspension component replacement, electrical component diagnosis and repair, body panel replacement
Troubleshooting:
Diagnostic procedures for engine performance issues, electrical gremlins, braking system faults, and drivetrain problems using specific Mazda diagnostic charts and flowcharts.
Special Tools:
Identification and usage of required Mazda special tools for specific repair procedures.
Depth:
Comprehensive, from basic fluid checks to complete engine and transmission teardowns and rebuilds, including torque specifications, clearances, and diagnostic fault codes.
Format:
Printed (typically on high-quality paper suitable for workshop environments)
Quality:
High-resolution diagrams, clear text, and professional layout typical of factory publications.
Binding:
Likely spiral-bound or case-bound for durability and ease of use in a workshop setting.
Paper:
Durable, possibly coated paper to withstand workshop conditions and repeated use.
Engine Type:
Naturally Aspirated Rotary (Wankel)
Displacement:
1.3 Liters (654cc x 2 rotor faces)
Configuration:
Two-rotor, naturally aspirated
Rotor Design:
Reuleaux triangle rotor within an epitrochoid housing
Rotary Specifics:
Requires specific oil metering for lubrication of apex and side seals.
Horsepower Hp:
160 HP @ 6,500 RPM (approximate)
Torque Lb Ft:
150 LB-FT @ 4,000 RPM (approximate)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Ignition System:
Distributorless Ignition System (DIS) with twin ignition coils per rotor (typically) for enhanced combustion.
Federal Crash Tests:
Information not readily available for specific year/model in standardized formats like modern NHTSA ratings. Focus was on passive safety for the era.
ABS:
Anti-lock Braking System (ABS) was an available option on higher trim levels.
Seatbelts:
Three-point seatbelts, potentially with pretensioners depending on market and trim.
Airbags:
Driver's side airbag was a late addition or optional feature for this model year in some markets.
Chassis Design:
Unibody construction with crumple zones designed for the era.
Audio System:
Factory AM/FM stereo cassette player with optional CD player, typically 4-6 speakers.
Climate Control:
Manual or automatic climate control systems with air conditioning.
Cruise Control:
Standard on most models, providing highway driving convenience.
ABS:
As mentioned in safety, ABS was available.
Connectivity:
Limited by 1991 standards; primarily focused on the in-car audio experience.
Oil Change:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions. Use of a quality synthetic oil is highly recommended for rotary engines.
Spark Plugs:
Replace at recommended intervals (refer to manual for exact mileage), as rotary plugs are critical for proper combustion.
Coolant Flush:
Typically every 2 years or 30,000 miles.
Belt Inspection:
Regular inspection of accessory belts and timing belt (if applicable for specific engine components) for wear and tension.
Engine Oil:
Refer to manual for specific API service classification and viscosity grade (e.g., 10W-30, 10W-40). Synthetic oils are preferred for rotary engines.
Coolant:
Mazda-recommended antifreeze/coolant (typically ethylene glycol-based) with a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
GL-4 manual transmission fluid (e.g., 75W-90).
Transmission Fluid Automatic:
Dexron-III (or equivalent) automatic transmission fluid.
Power Steering Fluid:
Mazda-specific power steering fluid or Dexron-III ATF.
Engine:
Apex seal wear, carbon build-up in exhaust ports and combustion chambers, oil seal degradation, intake manifold vacuum leaks, and the need for regular decarb procedures.
Electrical:
Degradation of wiring harnesses, intermittent electrical issues due to age, failure of power window motors, and corrosion in connectors.
Suspension:
Worn bushings, strut failure, and early signs of rust in critical suspension mounting points.
Heritage:
Mazda's long history with sports cars, including the iconic Cosmo and the preceding RX-7 (SA/FB) generation, established its reputation for unique engineering and performance.
Fc Generation:
The FC generation (1986-1991) marked a significant evolution from the FB, featuring more modern styling, advanced suspension, and the introduction of turbocharging.
Performance Variants:
Included naturally aspirated and turbocharged models, with the Turbo II (FC3S Turbo) offering significantly enhanced performance.
Production Period:
1985-1992 (FC generation globally)
Car And Driver:
The FC RX-7 was frequently featured on Car and Driver's '10Best' lists in various iterations during its production run, acknowledging its performance and value.
Performance Benchmarks:
Consistently praised for its handling dynamics, balanced chassis, and the unique character of its rotary engine, making it a darling of automotive journalists.
