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2002 Mazda RX-7 (3rd gen) Service and Repair Manual

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$16.99
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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 2002 Generation Generation: 3rd Generation (FD3S) Codes Chassis Code: FD3S 👋 Introduction Market Position Market Position: Iconic Japanese sports car, renowned...
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2002 Mazda RX-7 (3rd gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Year:
2002
Generation
Generation:
3rd Generation (FD3S)
Codes
Chassis Code:
FD3S
👋 Introduction
Market Position
Market Position:
Iconic Japanese sports car, renowned for its rotary engine technology and handling characteristics.
Competitive Analysis
Competitors:
Toyota Supra (Mk IV), Nissan 300ZX (Z32), Mitsubishi 3000GT VR-4, Porsche 911 (996).
Key Features
Key Features:
Twin-sequential turbocharged rotary engine, lightweight chassis, near 50/50 weight distribution, sophisticated suspension, stylish design.
📋 Manual Details
Coverage Areas
Coverage Areas:
All models and all repairs A-Z
Page Count
Page Count:
Estimated 1500-2000+ pages (typical for comprehensive dealer service manuals)
Manual Type
Manual Type:
Official Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Printed Manual (likely bound)
📖 Manual Coverage
Systems Covered
Engine Systems:
Rotary engine (13B-REW), fuel injection, ignition system, cooling system, lubrication system, emissions control, forced induction (twin-turbo)
Drivetrain Systems:
Transmission (manual R154/Mazda equivalent), clutch, driveshaft, differential, axles
Suspension Steering:
Front and rear suspension (double wishbone), steering system (power assisted), alignment specifications
Brake Systems:
Front and rear brakes (disc), ABS (Anti-lock Braking System), parking brake
Electrical Systems:
Battery, charging system, starting system, lighting, power windows, power locks, audio system, instrument cluster, ECU (Engine Control Unit), wiring diagrams
Body And Chassis:
Body panels, interior trim, chassis structure, door mechanisms, glass, weatherstripping
HVAC Systems:
Air conditioning, heating, ventilation
Wheel Tire Specs:
Wheel bolt pattern (4x114.3), recommended tire sizes (e.g., 225/50R16 front, 245/40R17 rear for some trims).
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement (specific apex seals and ignition system maintenance), fluid checks and changes
Diagnostic Procedures:
Troubleshooting guides, fault code interpretation, diagnostic connector access, circuit testing
Repair Procedures:
Engine mechanical repairs, transmission overhaul, brake system repairs, suspension component replacement, electrical component repair, bodywork repair
Special Procedures:
Rotary engine apex seal replacement, twin-turbo system diagnostics and repair, ECU remapping considerations (if applicable to factory specs), fuel system pressure testing and cleaning
Performance Tuning Guidelines:
Factory specifications for optimal performance, potential baseline for modifications.
Component Torque Specs:
Detailed torque values for all critical fasteners (engine, chassis, suspension, brakes).
Technical Depth
Technical Depth:
Complete rebuilds and overhauls, detailed diagnostic routines, wiring schematics, torque specifications, special tool requirements
Diagnostic Flowcharts:
Step-by-step diagnostic flowcharts for troubleshooting specific symptoms.
📊 Manual Specifications
File Format
File Format:
Likely printed paper, but digital versions (PDF) are common aftermarket.
Print Quality
Print Quality:
High quality, professional printing with clear diagrams and illustrations.
Binding Type
Binding Type:
Likely spiral-bound or hardcover for durability in a workshop environment.
Paper Type
Paper Type:
Durable, possibly glossy or semi-gloss paper for longevity and clarity of images.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotary (Wankel)
Engine Code:
13B-REW
Displacement:
1.3L (654cc x 2 rotor chambers)
Performance
Horsepower Us Spec:
255 hp @ 6500 rpm (for 2002 model)
Torque Us Spec:
217 lb-ft @ 5000 rpm (for 2002 model)
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Induction
Forced Induction:
Twin sequential turbochargers (Hitachi HT07-4A/HT06-21S)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission:
None for the 2002 model year in most markets.
Features
Clutch Type:
Hydraulic clutch, single plate dry.
Fluid Spec
Transmission Fluid Type:
API GL-4 or GL-5, SAE 75W-90 gear oil (check manual for specific Mazda recommendation).
📐 Dimensions
Exterior
Length:
167.9 inches (4265 mm)
Width:
69.1 inches (1755 mm)
Height:
48.2 inches (1225 mm)
Wheelbase:
95.5 inches (2425 mm)
Front Track:
58.3 inches (1480 mm)
Rear Track:
58.5 inches (1485 mm)
Weights
Curb Weight:
Approx. 2,844 lbs (1290 kg) for US spec.
Gross Vehicle Weight Rating:
Not typically highlighted, but essential for load capacity.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars (Driver), 4 Stars (Passenger) for earlier FD models, specific 2002 ratings may vary but generally consistent.
IIHS Side Impact:
Good (for models equipped with side airbags, though not standard on all trims).
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Traction Control System (TCS - on some models).
Passive Features
Passive Safety Features:
Driver and passenger front airbags, side-impact door beams, crumple zones, 3-point seat belts with pre-tensioners.
💡 Technology Features
Infotainment
Infotainment System:
Factory cassette/CD player, optional Bose premium audio system.
Driver Assistance
Driver Assistance Features:
Limited by modern standards; primarily ABS and TCS.
Connectivity
Connectivity Features:
None by modern standards; basic audio connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (recommended for rotary engines).
Spark Plug Interval:
Refer to manual; specialized platinum or iridium plugs are crucial. Intervals vary based on plug type and driving style.
Coolant Flush Interval:
Every 30,000 miles (48,000 km) or 2 years.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 recommended. Consider synthetic for optimal rotary lubrication. Two-stroke oil injection for oil metering pump is also critical.
Coolant Type:
Mazda Super Long Life Coolant (or equivalent ethylene glycol-based coolant with pink/red color) - typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific DOT rating).
Power Steering Fluid Type:
Mazda Genuine ATF-III or equivalent Dexron III H/Mercon. Check manual for exact specification.
Known Issues
Common Issues Rotary:
Apex seal wear/failure, oil seal failure, thermal issues (overheating), vacuum line deterioration, ignition coil failure, turbocharger issues (especially oil seals).
Common Issues Chassis:
Catalytic converter failure (especially with lean conditions), fuel pump issues, suspension bushings wear, electrical gremlins, interior plastic brittleness.
📚 Vehicle History
Brand Heritage
Mazda Rotary Heritage:
Mazda is the sole major manufacturer to successfully mass-produce the rotary engine, dating back to the Cosmo.
Model Evolution
Rx-7 Generations:
SA22C (1st gen), FC3S (2nd gen), FD3S (3rd gen). The 3rd gen represents a significant leap in performance and design.
Production
Production Years:
1992-2002 (globally).
Assembly Location:
Hofu, Yamaguchi, Japan.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
Named to Car and Driver's 10Best list multiple times, including for the 3rd generation.
Ratings
Road And Track Contributor Mention:
Often praised by automotive journalists for its driving dynamics and unique engineering.
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