Mazda RX-7 Service & Repair Manual (1989 1990 1991)-PDF

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation Code: FC3S (Third Generation RX-7) Production Years Covered: 1989, 1990, 1991 👋 Introduction Market Position Segment: Sports Car, Grand Tourer Target...

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标签: 1989 1990 1991 Car Cars Mazda Misc RX-7

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Generation Code:

FC3S (Third Generation RX-7)

Production Years Covered:

1989, 1990, 1991

👋 Introduction

Market Position

Segment:

Sports Car, Grand Tourer

Target Audience:

Enthusiasts, DIY Mechanics, Professional Technicians

Competitive Analysis

Key Rivals:

Nissan 300ZX (Z32), Toyota Supra (MkIII), Mitsubishi Starion/Chrysler Conquest

Key Features Vehicle

Distinctive Powertrain:

Rotary Engine (13B-T) known for its smooth power delivery and unique sound

Handling Dynamics:

Renowned for excellent handling, balanced chassis, and independent rear suspension

Key Features Manual

Value Proposition:

Comprehensive, authoritative resource for maintaining and repairing the FC RX-7

Diagnostic Aid:

Essential for diagnosing and resolving common and complex issues specific to the rotary engine and chassis

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair

Model Variants Covered:

All models, all engines

Page Count

Estimated Page Count:

Extensive (typically 2000+ pages for comprehensive factory manuals)

Manual Type

Manual Type:

Official Factory Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain Engine:

Rotary (13B-T, 13B-FC Turbo II)

Powertrain Transmission:

Manual (M5, M5X) and Automatic Transmissions

Chassis Suspension:

Front and Rear Suspension, Steering System

Chassis Brakes:

Brake System (including ABS on applicable models)

Electrical System:

Full Electrical System, Wiring Diagrams, ECUs

Body And Trim:

Body Panels, Doors, Interior Trim, Seating

Heating And Cooling:

HVAC System, Climate Control

Fuel System:

Fuel Injection, Fuel Pump, Lines, Tank

Cooling System:

Radiator, Water Pump, Hoses, Thermostat

Exhaust System:

Exhaust Manifolds, Catalytic Converter, Mufflers

Procedures Included

Routine Maintenance:

Oil Changes, Filter Replacements, Spark Plug/Apex Seal Checks, Fluid Top-offs

Engine Overhaul:

Complete Engine Rebuild Procedures for Rotary Engine

Transmission Repair:

Transmission Removal, Disassembly, Reassembly, and Installation

Brake Service:

Brake Pad Replacement, Rotor Machining/Replacement, Caliper Service, ABS Bleeding

Electrical Diagnostics:

Troubleshooting Faults, Component Testing, Wiring Harness Repair

Suspension And Steering Repair:

Component Replacement (Shocks, Struts, Bushings, Tie Rods), Alignment Specifications

Body And Trim Repair:

Panel Alignment, Door Hinge/Latch Adjustment, Interior Component Replacement

Diagnostic Troubleshooting:

Systematic Fault Finding, Diagnostic Trouble Codes (DTCs) and Solutions

Technical Depth

Diagnostic Capabilities:

Advanced Diagnostics, Component Level Troubleshooting

Repair Scope:

Comprehensive Rebuilds, Component Replacements, Adjustments

Technical Illustrations:

Detailed Diagrams, Exploded Views, Torque Specifications

Specification Data:

Exact Tolerances, Clearances, Fluid Capacities, Part Numbers

📊 Manual Specifications

File Format

File Type:

Digital PDF

Searchability:

Searchable Text Content

Printability:

Printable Pages

Print Quality

Image Resolution:

High Resolution for Clear Diagrams and Text

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Rotary (Wankel)

Engine Code:

13B-T (Turbocharged)

Displacement:

1.3 Liters (equivalent to approx. 2.6L reciprocating)

Performance

Horsepower:

Approx. 200 hp (US Spec Turbo II)

Torque:

Approx. 203 lb-ft (US Spec Turbo II)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (Premium Recommended)

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with Direct Ignition (Igniter/Coil)

Cooling System

Cooling Type:

Liquid Cooled

🔧 Transmission

Standard

Standard Transmission:

5-Speed Manual (M5/M5X)

Optional

Optional Transmission:

4-Speed Automatic

Features

Differential:

Viscous Coupling Limited Slip Differential (LSD) often standard on Turbo II models

📐 Dimensions

Exterior

Body Style:

2-door Coupe, Convertible

Wheelbase:

Approx. 95.4 inches (2423 mm)

Overall Length:

Approx. 167.7 inches (4257 mm)

Overall Width:

Approx. 69.1 inches (1755 mm)

Overall Height:

Approx. 49.2 inches (1250 mm)

Weights

Curb Weight:

Approx. 2900-3200 lbs (1315-1451 kg) depending on trim and options

🛡️ Safety Features

Ratings

Crash Test Results:

NHTSA and IIHS data for this era may be limited, but generally considered a safe vehicle for its time.

Active Features

Anti-lock Braking System (ABS) available on many models, particularly Turbo II

Traction Control:

Traction Control System (TCS) available on some later models

Passive Features

Airbags:

Driver's side airbag standard on most models within this range; Passenger airbag became more common later in the generation.

Seatbelts:

Three-point inertia-reel seatbelts

Rollover Protection:

Reinforced A-pillars and structural bracing for convertible models

💡 Technology Features

Infotainment

Audio System:

Factory premium audio system with cassette player and AM/FM radio. Optional CD player.

Climate Control:

Manual or automatic climate control systems depending on trim level.

Driver Assistance

Cruise Control:

Standard cruise control on most models

Connectivity

Bluetooth Connectivity:

Not available from the factory; aftermarket solutions exist.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles or 6 months, using high-quality synthetic oil is recommended for rotary engines.

Air Filter Replacement:

Every 15,000 miles or annually

Spark Plug Inspection:

Inspect every 15,000 miles. Rotary-specific spark plugs are critical.

Fluid Specifications

Engine Oil Type:

API SG or higher, viscosity typically 10W-30 or 10W-40 (refer to manual for exact recommendation). High-quality synthetic is strongly advised.

Coolant Type:

Ethylene Glycol based coolant (e.g., Mazda FL22 or equivalent)

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, viscosity 75W-90 or 80W-90 (consult manual for specific grade)

Transmission Fluid Automatic:

Dexron III/Mercon or equivalent ATF

Differential Fluid:

API GL-5 gear oil, viscosity 80W-90

Known Issues

Rotary Engine Apex Seals:

Wear of apex seals can lead to loss of compression, hard starting, and decreased power. Regular maintenance and proper operating temperatures are crucial.

Oil Consumption:

Rotary engines naturally consume some oil for lubrication. Ensuring proper oil levels is vital.

Turbocharger Reliability:

Early turbochargers could be susceptible to heat soak and failure if not properly maintained.

E-Shaft Bearing Wear:

Potential wear on the eccentric shaft bearings, especially on high-mileage or poorly maintained engines.

Cooling System Overheating:

Proper coolant levels and radiator condition are essential to prevent overheating.

📚 Vehicle History

Brand Heritage

Mazda Rotary Legacy:

Continuation of Mazda's pioneering work with the Wankel rotary engine, dating back to the Cosmo Sport.

Model Evolution

Generation Context:

The FC generation (1986-1991) was the second iteration of the RX-7, evolving from the FB (SA/FB) model. It featured a more modern, sleek design and significant chassis improvements.

Mk1 Vs Mk2 Fc:

The FC moved away from the initial lightweight sports car ethos to a more capable, powerful, and refined grand touring sports car, especially with the Turbo II variant.

Production

Manufacturing Location:

Mazda's Hofu Plant, Japan

Production End Year:

1991 for the FC generation, succeeded by the FD RX-7

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The RX-7, in various generations, was a frequent recipient of Car and Driver's '10Best' list, highlighting its performance and handling prowess.

Motor Trend Car Of The Year:

While specific FC awards may vary, the RX-7 line has consistently been recognized for its engineering and performance.