Positioning:
A highly sought-after sports car, the FD RX-7 is known for its unique rotary engine and exceptional handling, making an accurate service manual indispensable.
Competitors:
Competed against other performance coupes of its era, such as the Nissan 300ZX (Z32), Toyota Supra (MkIV), and Mitsubishi 3000GT.
Distinguishing Features:
Twin-rotor Wankel engine (13B-REW), lightweight chassis, near 50/50 weight distribution, advanced aerodynamics, iconic styling.
Engine Mechanical:
Rotary engine (13B-REW) teardown, inspection, assembly, timing, lubrication, cooling.
Fuel System:
Fuel injection, fuel pump, fuel injectors, fuel pressure regulator, EVAP system.
Ignition System:
Ignition timing, spark plugs, ignition coils, igniter.
Transmission:
Manual transmission (R154/Type 318 etc.), clutch system, driveline.
Brakes:
Hydraulic system, ABS, brake pads, rotors, calipers, parking brake.
Suspension:
Front and rear suspension components, struts, springs, bushings, alignment specifications.
Steering:
Power steering system, steering rack, tie rods, steering column.
Electrical System:
Battery, charging system, starter, lighting, accessories, wiring diagrams.
HVAC:
Air conditioning, heating, ventilation, climate control system.
Body And Trim:
Exterior panels, interior trim, doors, windows, seats, bumpers.
Chassis And Frame:
Frame components, body structure, corrosion protection.
Emissions Control:
Catalytic converter, O2 sensors, EGR system, PCV system.
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement intervals.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation (OBD-I).
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair.
Diagnostic Procedures:
Testing of sensors, actuators, control modules, and electrical circuits.
Rebuild Procedures:
Detailed instructions for rebuilding the rotary engine and major components.
Depth:
Expert level, covering complete overhauls, diagnostics, and specialized procedures.
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, using appropriate synthetic oil for rotary engines.
Spark Plug Replacement:
Refer to manual; typically around 30,000-60,000 miles depending on plug type and driving conditions.
Timing Belt Replacement:
N/A (Rotary engines do not have timing belts; they have internal timing gears).
Engine Oil:
API SG or higher, SAE 10W-30 or 5W-30 recommended, specifically formulated or suitable for rotary engines (e.g., less detergent).
Coolant:
Mazda Genuine FL22 Coolant or equivalent; typically a 50/50 mix of antifreeze and distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid:
Mazda GL-5 75W-90 synthetic gear oil.
Apex Seal Wear:
Apex seals are a wear item; improper maintenance, overheating, or detonation can accelerate wear.
Pre Mix Oil System:
The sequential twin-turbo system can be sensitive; proper maintenance of lubrication and cooling is critical.
Catalytic Converter:
Can become clogged, especially with poor maintenance or engine issues.
Vacuum Lines:
Aging rubber vacuum lines can degrade, leading to boost leaks and performance issues.
Rotary Legacy:
Mazda has a long history with the Wankel rotary engine, dating back to the Cosmo series, culminating in the performance-oriented RX series.
Generations:
The FD generation (1992-2002) is the third and final generation of the RX-7.
Production Years:
1992-2002 (FD generation)
Manufacturing Location:
Mazda Hiroshima Plant, Japan.
