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Mazda RX-7 1989 1.3L 202-215 hp (151-160 kW)Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: FC (Second Generation) Model Year: 1989 Codes Chassis Code: FC3S Engine Code: 13B (Rotary) 👋 Introduction Market Position Market Position: Performance...
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Mazda RX-7 1989 1.3L 202-215 hp (151-160 kW)Service Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
FC (Second Generation)
Model Year:
1989
Codes
Chassis Code:
FC3S
Engine Code:
13B (Rotary)
👋 Introduction
Market Position
Market Position:
Performance Sports Coupe; the RX-7 FC generation represented Mazda's continued commitment to rotary engine technology and a driver-focused sports car experience in the late 1980s.
Competitive Analysis
Competitive Analysis:
Competed against iconic sports cars of the era such as the Nissan 300ZX (Z32), Toyota Supra (MkIII), Porsche 944, and Chevrolet Camaro/Pontiac Firebird. Differentiated itself with its unique rotary engine and balanced handling.
Key Features
Key Features:
Rotary Engine, Rear-Wheel Drive, Independent Suspension, Sophisticated Aerodynamics, Optional Turbocharging, Lightweight Construction, Driver-Oriented Cockpit
📋 Manual Details
Coverage Areas
Coverage Areas:
Complete Service and Repair
Page Count
Page Count:
Over 1000 pages (estimated for comprehensive official manual)
Manual Type
Manual Type:
Official Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine (Rotary 13B Turbo), Drivetrain (Transmission, Differential, Driveshafts), Suspension (Front & Rear), Steering System, Braking System, Fuel System, Ignition System, Cooling System, Exhaust System, Electrical System (Wiring Diagrams, Components), HVAC System, Body & Chassis, Interior Components, Diagnostics & Troubleshooting, Emissions Control System
Procedures Included
Procedures Included:
Routine Maintenance, Engine Tune-up, Component Removal & Installation, Disassembly & Reassembly, Troubleshooting Faults, Electrical Diagnosis, Brake System Overhaul, Suspension Adjustments, Clutch Replacement, Turbocharger Service, Fuel Injector Testing, Cooling System Flushing, Emissions System Checks, Body Panel Repair, Interior Trim Replacement
Technical Depth
Technical Depth:
Comprehensive; includes detailed specifications, diagnostic procedures, torque values, special tool requirements, and exploded views for most components. Suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
Digital PDF
Print Quality
Print Quality:
High-resolution scans, ensuring clarity of diagrams and text for printing
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotary (Wankel)
Engine Configuration:
Two-Rotor (13B)
Displacement:
1.3L (1308cc)
Performance
Horsepower:
202-215 hp (SAE Net)
Torque:
196-202 lb-ft (SAE Net)
Redline:
Approx. 7000 RPM
Fuel System
Fuel Delivery:
Fuel Injection (Electronic Port Injection - EGI)
Fuel Type:
Unleaded Premium Gasoline (91+ Octane)
Induction
Forced Induction:
Turbocharged (Single Turbocharger, intercooled)
Cooling System
Cooling Type:
Water-Cooled
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual
Optional
Optional Transmission:
4-Speed Automatic
Features
Clutch Type:
Hydraulically Actuated Single Dry-Plate
Differential Type:
Viscous Coupling Limited Slip Differential (LSD) on some models/trims
📐 Dimensions
Exterior
Length:
170.1 inches (4320 mm)
Width:
67.1 inches (1705 mm)
Height:
49.4 inches (1255 mm)
Wheelbase:
95.7 inches (2430 mm)
Front Track:
56.7 inches (1440 mm)
Rear Track:
56.1 inches (1425 mm)
Weights
Curb Weight:
Approx. 2860-3000 lbs (1297-1361 kg)
Weight Distribution:
Near 50/50 balance
Cargo
Cargo Volume:
Minimal, typical for a sports coupe
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not rated or standard for the era
Active Features
Active Features:
Anti-lock Braking System (ABS)
Passive Features
Passive Features:
Three-point Seatbelts, Collapsible Steering Column, Reinforced Passenger Cabin
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM Stereo Cassette Player with optional CD player. Analog gauges.
Driver Assistance
Driver Assistance:
None typical for this era beyond ABS.
Connectivity
Connectivity:
N/A
Lighting
Lighting Type:
Halogen Headlights, Incandescent Taillights and Turn Signals.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months (depending on oil type and driving conditions)
Spark Plug Replacement:
Refer to manual; typically around 30,000 miles, but varies for rotary plugs.
Timing Belt Replacement:
N/A (Rotary engines do not have a timing belt; they use a timing chain/sprockets).
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 (check manual for specific viscosity under temperature variations)
Engine Oil Capacity:
Approx. 5.5 quarts (5.2 liters) with filter
Coolant Type:
Mazda FL22 Long Life Coolant or equivalent (50/50 mix with distilled water)
Transmission Fluid Manual:
API GL-4 or GL-5 SAE 75W-90 gear oil
Transmission Fluid Automatic:
Dexron III ATF or equivalent
Brake Fluid Type:
DOT 3 or DOT 4
Differential Fluid Type:
API GL-5 SAE 90 gear oil (limited slip requires specific additive if not factory specified)
Known Issues
Known Issues:
Apex seal wear, rotor housing wear, oil metering injection issues, vacuum hose deterioration, exhaust manifold cracking (turbo models), alternator bearing failure, cooling system leaks, ECU capacitor failure.
Rotary Specific Maintenance:
Importance of regular oil changes with correct oil, use of 'easy start' or pre-mix fuel additives for cold starts, monitoring oil level and consumption closely.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mazda has a long history of producing innovative and driver-focused vehicles, with a particular legacy in rotary engine technology pioneered by NSU.
Model Evolution
Model Evolution:
The FC generation RX-7 (1985-1992) succeeded the SA/FB generation. It featured a more aerodynamic design, independent rear suspension, and the introduction of turbocharging for increased performance. The 1989 model year saw minor updates (S5).
Production
Production Period:
1985-1992
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Recognitions:
Consistently praised by automotive journalists for its handling, balance, and unique rotary powerplant. Recognized as a benchmark Japanese sports car of its time.
Ratings
Ratings:
Often featured in 'Best of' lists for sports cars, particularly for driver engagement.
Certifications
Certifications:
N/A (Emissions certifications specific to region and model year would be detailed in the manual).
📄 Performance Data
Acceleration
Zero To Sixty Mph:
Approximately 6.5 - 7.5 seconds (depending on transmission and driver)
Top Speed
Top Speed:
Approximately 135-145 mph (217-233 km/h)
📄 Chassis Suspension
Suspension Front
Suspension Front:
Independent, MacPherson Struts with Coil Springs and Stabilizer Bar
Suspension Rear
Suspension Rear:
Independent, Semi-Trailing Arm with Watt's Linkage, Coil Springs, and Stabilizer Bar
📄 Brakes
Front Brakes
Front Brakes:
Ventilated Disc Brakes
Rear Brakes
Rear Brakes:
Solid Disc Brakes
Brake Actuation
Brake Actuation:
Hydraulic with ABS
📄 Wheels Tires
Wheel Size
Wheel Size:
15x6.5 inches (standard), 16x7 inches (optional on Turbo II)
Bolt Pattern
Bolt Pattern:
4x114.3mm (4x4.5 inches)
Tire Size Front
Tire Size Front:
205/60R15 (standard), 225/50R16 (optional Turbo II)
Tire Size Rear
Tire Size Rear:
205/60R15 (standard), 225/50R16 (optional Turbo II)
📄 Electrical
Battery
Battery Voltage:
12V
Alternator
Alternator Output:
Approx. 80-100 Amps (check manual for exact specification)
📄 Diagnostic Tools
Obd Type
OBD Type:
Pre-OBD-II (OBDI). Diagnostic codes accessed via flashing LED on ECU or specific diagnostic connectors. The manual will detail these procedures.
📄 Manual Addendum
Special Tools
Special Tools Required:
The manual will list specific tools required for rotary engine maintenance and repair, such as rotor housing alignment tools, apex seal insertion tools, and specific diagnostic equipment.
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