Mazda RX7 RX-7 1999 Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Designation: FD3S Year: 1999 Codes Chassis Code: FD3S 👋 Introduction Market Position Positioning: Iconic Japanese sports car, celebrated for its rotary...

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标签: 1999 Car Cars Mazda Misc RX-7 RX7

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Model Designation:

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

Iconic Japanese sports car, celebrated for its rotary engine and performance capabilities

Competitive Analysis

Competitors:

Nissan 300ZX (Z32), Toyota Supra (Mk IV), Mitsubishi 3000GT VR-4, Porsche 968

Key Features

Rotary Engine:

Unique twin-rotor 13B-REW engine with sequential twin-turbocharging

Chassis Design:

Lightweight chassis, near 50/50 weight distribution, advanced suspension geometry

Performance Focus:

Tuned for high-revving performance and exceptional handling

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive repair and service for 1999 Mazda RX-7 (FD3S)

Page Count

Estimated Page Count:

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

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

Rotary engine (13B-REW), lubrication, cooling, fuel injection, ignition, emissions control, engine mechanicals, troubleshooting, diagnostics

Drivetrain System:

Transmission (R154/Type 6A), clutch, driveshaft, differential, axles, troubleshooting, repair

Suspension System:

Front and rear suspension, steering system, wheel alignment, troubleshooting, repair

Braking System:

Front and rear brakes (including ABS), brake fluid, hydraulic system, troubleshooting, repair

Electrical System:

Starting and charging system, lighting, instrumentation, power accessories, body electrical, ECU, wiring diagrams, troubleshooting

Body And Chassis:

Body construction, interior trim, exterior trim, doors, windows, seats, HVAC, chassis components, troubleshooting, repair

Fuel System:

Fuel tank, fuel pump, fuel lines, injectors, fuel pressure regulation, emissions components (e.g., EVAP)

Cooling System:

Radiator, thermostat, water pump, cooling fans, coolant specifications

Lubrication System:

Oil pump, oil cooler, oil filter, oil specifications, oil change intervals

Emissions Control System:

Air pump, catalytic converter, EGR system, O2 sensors, PCV system

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspection and replacement

Repair Procedures:

Engine rebuild (apex seals, rotor housing inspection), transmission overhaul, brake caliper rebuild, suspension component replacement, electrical component diagnosis and replacement

Diagnostic Procedures:

Troubleshooting charts, symptom-based diagnostics, use of diagnostic tools (e.g., OBD-II scanner), specific fault code explanations

Installation Procedures:

Component replacement, timing belt/chain installation (where applicable, though rotary is different), accessory installation

Technical Depth

Depth Level:

In-depth, suitable for professional technicians and advanced DIY enthusiasts

Diagnostic Capabilities:

Detailed diagnostic flowcharts, component testing specifications, wiring diagrams for accurate troubleshooting

Torque Specifications:

Comprehensive torque values for all critical fasteners and components

Special Tools:

Identification and usage of specialized Mazda tools required for certain procedures

📊 Manual Specifications

File Format

Format Details:

Searchable PDF with high-resolution scans of original documentation

Print Quality

Quality Description:

Clear, legible text and diagrams, suitable for printing individual pages or sections

Binding Type

Digital Binding:

N/A (Digital format)

Paper Type

Digital Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

13B-REW

Engine Type:

Twin-Rotor, Wankel, Rotary

Aspiration:

Sequential Twin-Turbocharged

Displacement Cc:

Displacement Ci:

Performance

Horsepower Hp:

280 PS (276 bhp / 206 kW) at 6500 RPM

Torque Lb Ft:

294 lb-ft (400 Nm) at 5000 RPM

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with sequential twin-turbo control

Fuel Type:

Unleaded Gasoline (91 Octane or higher recommended)

Ignition System:

Electronic ignition with trailing and leading spark plugs per rotor

Lubrication System

Oil Capacity Liters:

Approximately 4.5 Liters (including oil cooler)

Cooling System

Coolant Capacity Liters:

Approximately 7.5 Liters (with reservoir)

🔧 Transmission

Standard

Transmission Type:

6-speed Manual Transmission

Optional

Transmission Type Optional:

4-speed Automatic Transmission (less common, typically for non-performance variants)

Features

Gear Ratios Manual:

Specific ratios provided in manual for each gear and final drive.

Transmission Fluid Spec:

Dexron III ATF or equivalent for automatic; API GL-4 or GL-5 gear oil for manual.

📐 Dimensions

Exterior

Length Mm:

Width Mm:

Height Mm:

Wheelbase Mm:

Weights

Curb Weight Kg:

Approximately 1300-1350 kg (depending on trim and options)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Specific ratings from official bodies for 1999 model not widely published; designed with safety cage and crumple zones.

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS) on certain trims

Passive Features

Airbags:

Driver and passenger airbags

Seatbelts:

Three-point seatbelts with pre-tensioners

Structural Reinforcement:

Reinforced chassis structure, side-impact door beams

💡 Technology Features

Infotainment

Audio System:

Factory radio/cassette/CD player with optional premium sound system.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Connectivity

Diagnostics Port:

OBD-II compliant diagnostic port for engine management and fault code retrieval.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (using appropriate synthetic oil).

Spark Plug Replacement:

Refer to manual; typically every 30,000-60,000 miles depending on plug type.

Coolant Flush Interval:

Every 2 years or 30,000 miles.

Transmission Fluid Interval:

Manual: Every 60,000 miles or 4 years. Automatic: Every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil Spec:

API SG/SH or higher, SAE 5W-30 or 10W-30 (check manual for precise recommendations based on climate).

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Spec:

Mazda Genuine ATF or Dexron III equivalent.

Known Issues

Apex Seal Wear:

Degradation of apex seals leading to compression loss is a known long-term concern with rotary engines. Proper maintenance and avoiding overheating are crucial.

Oil Metering System:

Potential issues with the automatic oil metering system; manual addresses inspection and adjustment.

Turbocharger Reliability:

Sequential turbo system requires precise operation; early models had some issues addressed in later revisions. Manual provides diagnostic steps.

Cooling System Maintenance:

Rotary engines generate significant heat, emphasizing the importance of a clean and efficient cooling system.

📚 Vehicle History

Brand Heritage

Mazda Rotary History:

Mazda's long-standing commitment to rotary engine technology, dating back to the Cosmo.

Model Evolution

Rx7 Generations:

This manual covers the third generation (FD) RX-7, known for its advanced engineering and styling.

Fd Development:

Developed with input from Porsche, focusing on aerodynamics and chassis dynamics.

Production

Production Years Fd:

1992-2002

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver Best:

Named to Car and Driver's Ten Best list multiple times during its production run.

Motor Trend Car Of The Year:

While not a winner, it was a strong contender and highly regarded by automotive journalists.

Ratings

Handling Reviews:

Universally praised for its exceptional handling dynamics and driver feedback.