Mazda RX7 RX-7 1999 Repair Service Manual

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标签: 1999 Car Cars Mazda Misc RX-7 RX7

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Description

The 1999 Mazda RX-7 (FD3S) stands as an iconic Japanese sports car, celebrated for its unique twin-rotor 13B-REW engine with sequential twin-turbocharging, delivering exhilarating performance. This generation is renowned for its lightweight chassis, near 50/50 weight distribution, and advanced suspension geometry, all contributing to its exceptional handling dynamics and driver feedback. Developed with a focus on aerodynamics and chassis dynamics, the RX-7 has earned accolades, including being named to Car and Driver's Ten Best list, solidifying its reputation as a high-revving, performance-oriented machine. This comprehensive Factory Service Manual provides in-depth guidance for the repair and maintenance of your 1999 Mazda RX-7 (FD3S). It covers all essential systems, including the rotary engine, drivetrain, suspension, braking, electrical, and body components. Detailed procedures for scheduled maintenance, complex repairs, and diagnostics are included, along with critical technical specifications, torque values, and information on specialized tools. This manual serves as an indispensable resource for owners, mechanics, and technicians aiming to preserve the integrity and performance of this celebrated sports car.

🏷️ 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.