Mazda RX-7 Service & Repair Manual (1986 1987 1988)-PDF

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: FC (Second Generation) Production Years Covered: 1986, 1987, 1988 👋 Introduction Market Position Vehicle Segment: Sports car, Personal luxury car Target...

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类型: Car

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标签: 1986 1987 1988 Car Cars Mazda Misc RX-7

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Generation:

FC (Second Generation)

Production Years Covered:

1986, 1987, 1988

👋 Introduction

Market Position

Vehicle Segment:

Sports car, Personal luxury car

Target Audience:

Enthusiasts, owners seeking to perform their own maintenance and repairs

Competitive Analysis

Key Competitors:

Nissan 300ZX, Toyota Supra, Chevrolet Camaro, Pontiac Firebird

Key Features

Vehicle Highlights:

Rotary engine, rear-wheel drive, balanced chassis, sporty handling, distinctive styling

Manual Value Proposition

Manual Benefit:

Enables DIY repairs, enhances vehicle understanding, aids in troubleshooting, preserves vehicle value

📋 Manual Details

Coverage Areas

Manual Type:

Complete Official Service and Repair Manual

Language:

English

Format:

Coverage Scope:

All models and all engines for the specified years

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Rotary engine (13B) internal components, rebuild procedures, timing, lubrication, cooling, intake, exhaust

Engine Management:

Fuel injection system (EFI), ignition system, sensors, actuators, ECU diagnosis and troubleshooting

Transmission:

Manual (5-speed) and Automatic transmission overhaul, diagnosis, and repair

Drivetrain:

Clutch, driveshaft, differential, axles, wheel bearings

Suspension:

Front and rear suspension components, alignment specifications, shock absorbers, springs, bushings

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

Front and rear disc brakes, ABS system (if equipped), brake fluid specifications, caliper and rotor service

Electrical System:

Battery, charging system, starter, lighting, horn, wipers, power windows, mirrors, audio system wiring diagrams

HVAC:

Heating, ventilation, and air conditioning system diagnosis and service

Body And Chassis:

Body panel removal and installation, interior trim, glass replacement, chassis components

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement (rotary equivalent), belt inspections

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems, fault code interpretation

Major Repairs:

Engine overhaul, transmission rebuild, suspension component replacement, brake system service

Component Rebuilds:

Detailed instructions for rebuilding specific components like the alternator, starter, fuel injectors, etc.

Wiring Diagrams:

Comprehensive electrical system wiring schematics for all major systems

Technical Depth

Depth Level:

Factory-level repair and diagnostic information

Diagnostic Tools:

Information on required specialized tools and diagnostic equipment

Specifications Data:

Torque values, clearances, fluid capacities, electrical resistances, pressure readings

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (depending on original source scan quality)

Printability:

Printable pages for workshop use

Digital Quality:

Comprehensive, high-detail digital reproduction of original factory manual content

Print Quality

Source Material:

Official Mazda factory service manual

Resolution:

High-resolution scans for clarity of text and diagrams

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Rotary (Wankel)

Engine Code:

Rotor Displacement:

654cc per rotor (1308cc total displacement equivalent)

Aspirated Variant Power:

Approximately 145-160 hp (depending on market and specific model year)

Turbocharged Variant Power:

Approximately 182-200 hp (for Turbo II models)

Turbocharged Variant Torque:

Approximately 183-200 lb-ft (for Turbo II models)

Performance

Redline:

Typically around 7000-7500 RPM

Special Characteristics:

Smooth operation, high-revving nature, unique sound, compact size

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Octane Rating:

Premium unleaded (91+ octane recommended, especially for turbocharged models)

Maintenance Considerations

Apex Seals:

Critical wear item requiring careful monitoring and potential replacement

Oil Consumption:

Rotary engines consume a small amount of oil as part of their lubrication system; this is normal and needs monitoring.

🔧 Transmission

Standard

Type Std:

5-speed manual transaxle

Optional

Type Opt:

4-speed automatic transaxle

Features

Drivetrain Layout:

Rear-wheel drive (RWD)

Clutch Type:

Hydraulically actuated single-plate dry clutch

Fluid Specifications

Manual Transmission Fluid:

GL-5 75W-90 gear oil (Mazda recommends specific grades, check manual for exact spec)

Automatic Transmission Fluid:

Dexron II or equivalent (Mazda specifies type, consult manual)

📐 Dimensions

Exterior

Wheelbase:

Approximately 95.7 inches (2430 mm)

Length:

Approximately 168.7 inches (4285 mm)

Width:

Approximately 67.7 inches (1720 mm)

Height:

Approximately 49.2 inches (1250 mm)

Weights

Curb Weight:

Approximately 2800-3100 lbs (1270-1406 kg) depending on trim and equipment

🛡️ Safety Features

Ratings

Crash Test Data:

Limited public crash test data available for this era, but known for robust chassis construction for its time.

Active Features

Braking System:

Front and rear disc brakes; ABS available on some higher trims/models

Suspension Tuning:

Designed for excellent handling and stability

Passive Features

Seat Belts:

3-point seat belts

Body Structure:

Reinforced safety cell structure

💡 Technology Features

Infotainment

Audio System:

Factory-equipped radio with cassette player, often with optional graphic equalizer or CD player on higher trims.

Dashboard Features:

Analog gauges, including tachometer, speedometer, oil pressure, water temperature, and voltage meter.

Driver Assistance

Anti-lock Braking System available as an option or standard on certain models/trims.

Limited Slip Differential:

Optional on some models for improved traction.

Connectivity

Connectivity Features:

Basic analog connectivity; no modern smartphone integration or Bluetooth.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months (depending on driving conditions and oil used).

Spark Plug Replacement:

Check and replace as per manual recommendations; often requires specific platinum or iridium plugs for rotary engines, with a periodic change of the leading and trailing plugs.

Coolant Flush:

Every 2-3 years or 30,000 miles.

Timing Belt Replacement:

N/A (Rotary engines do not have timing belts; they use a chain or gears internally for rotor timing, which is part of engine rebuild).

Fluid Specifications

Engine Oil Type:

API SG or higher, viscosity 10W-30 or 10W-40 recommended (check manual for specific OEM recommendations).

Engine Oil Capacity:

Approximately 5.1 quarts (4.8 L) with filter change.

Coolant Type:

Ethylene glycol-based antifreeze (e.g., Mazda FL22 or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Apex Seal Wear:

Premature wear or failure leading to loss of compression and starting issues.

Oil Seals:

Rotary oil seals (especially front and rear main seals) can degrade over time, leading to oil leaks or internal oil consumption.

Cooling System:

Overheating due to inefficient radiator or coolant leaks; specific rotary cooling system design can be sensitive.

Turbocharger Reliability:

Early turbo models can be susceptible to turbocharger failure if not properly maintained or if pushed too hard without proper warm-up/cool-down.

Ignition System:

Degradation of ignition coils, wires, or distributors can lead to misfires and poor performance.

📚 Vehicle History

Brand Heritage

Mazda Rotary Legacy:

Mazda's pioneering and continued development of the Wankel rotary engine, starting with the Cosmo.

Model Evolution

Rx-7 Generations:

The FC generation (1986-1992) followed the FB (SA/FB) and preceded the highly acclaimed FD generation.

Fc Development:

Styled partly by Satoru Tomonaga and designed with input from Porsche consultants, featuring a more sophisticated and aerodynamic design than its predecessor.

Production

Manufacturing Plant:

Mazda Hiroshima Plant, Japan

Sales Performance:

Popular sports car globally, particularly in the late 1980s and early 1990s, contributing to Mazda's performance image.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The FC RX-7 was named to Car and Driver's Ten Best list in 1986 and 1987.

Motor Trend Import Car Of The Year:

While the first generation RX-7 won this award, the FC continued to build Mazda's reputation for sporty, well-engineered vehicles.