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Mazda RX-7 S5 1989-1991 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: Third Generation (FC) - Series 5 Production Years Covered: 1989, 1990, 1991 Codes Chassis Code: FC3S (Coupe), FC3C (Convertible) Engine Code...
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Mazda RX-7 S5 1989-1991 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Generation:
Third Generation (FC) - Series 5
Production Years Covered:
1989, 1990, 1991
Codes
Chassis Code:
FC3S (Coupe), FC3C (Convertible)
Engine Code Primary:
13B-FC (Rotary)
👋 Introduction
Market Position
Vehicle Class:
Compact Sports Car / Grand Tourer
Target Audience For Manual:
Enthusiast owners, DIY mechanics, professional repair shops specializing in rotary Mazdas
Competitive Analysis
Key Competitors At Launch:
Nissan 300ZX (Z32), Toyota Supra (MkIII), Porsche 944, Chevrolet Camaro/Pontiac Firebird
Key Features
Vehicle Selling Points:
Rotary engine performance, lightweight chassis, balanced handling, distinctive styling, rear-wheel drive
Manual Value Proposition:
Enables owners to maintain and repair their complex rotary engine and sports car systems, saving money and preserving the vehicle's performance.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual / Repair Manual
Language:
English
Format:
Digital PDF (Instant Download)
Page Count
Estimated Page Count:
~1000-1500 pages (typical for full factory service manuals, actual may vary for condensed versions)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (Rotary), Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System, Transmission (Manual and Automatic), Drivetrain, Differential
Chassis:
Suspension (Front and Rear), Steering System, Brakes (Front and Rear), Wheels and Tires
Electrical:
Wiring Diagrams, Lighting System, Instrumentation, Audio System, Power Accessories, Engine Control Module (ECM), Anti-lock Braking System (ABS), Air Conditioning System
Body:
Body Panels, Doors, Hood, Trunk, Interior Trim, Exterior Trim, Seats, Glass
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Spark Plug Replacement, Belt Inspection/Replacement
Diagnostics And Troubleshooting:
Fault Code Diagnosis, Symptom-based Troubleshooting Guides, Diagnostic Procedures for all major systems
Repair And Rebuild:
Engine Overhaul (Apex Seals, Rotor Housings), Transmission Rebuild, Brake Caliper Overhaul, Suspension Component Replacement, Electrical Component Repair
Specifications And Tolerances:
Torque Specifications, Clearances, Dimensions, Electrical Resistance Values, Performance Data
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams)
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Searchable Text (typically, depending on scan quality)
Print Quality
Resolution:
High-resolution scans suitable for digital viewing and printing
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Mazda Rotary (Wankel)
Engine Code:
13B-FC
Rotor Design:
Naturally Aspirated (Standard) or Turbocharged (GTX, GT-X Turbo models)
Performance
Displacement Equivalent:
2.6 Liters (2 x 654cc rotors)
Horsepower Na:
160 hp @ 6,500 rpm (approx.)
Torque Na:
153 lb-ft @ 3,500 rpm (approx.)
Horsepower Turbo:
200 hp @ 6,500 rpm (approx.) for 200PS / 210 hp @ 6,500 rpm (approx.) for 210PS models
Torque Turbo:
193 lb-ft @ 3,500 rpm (approx.) for 200PS / 203 lb-ft @ 3,500 rpm (approx.) for 210PS models
Fuel System
Fuel Delivery Na:
Electronic Fuel Injection (EFI)
Fuel Delivery Turbo:
Electronic Fuel Injection (EFI) with Turbocharger (intercooled on later models)
Recommended Fuel:
Premium Unleaded Gasoline (91+ octane)
Engine Management
ECU Type:
Engine Control Unit (ECU) managing fuel, ignition, and emissions
Rotary Specifics
Apex Seals:
Critical wear component, regular inspection and replacement as per manual recommendations
Oil Metering Pump:
Injects 2-stroke oil into the combustion chambers for lubrication, requires specific rotary-specific oil
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission
Features
Clutch Type:
Hydraulic Actuated Single Dry Plate Clutch
Fluid Specifications
Manual Transmission Fluid:
GL-5 Gear Oil, SAE 75W-90 (check manual for exact Mazda specification)
Automatic Transmission Fluid:
Dexron II or equivalent (check manual for exact Mazda specification)
📐 Dimensions
Exterior
Length:
Approx. 4,390 mm (172.8 in)
Width:
Approx. 1,755 mm (69.1 in)
Height:
Approx. 1,295 mm (51.0 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Weights
Curb Weight Manual:
Approx. 1,250-1,350 kg (2,756-2,976 lbs) depending on trim
Curb Weight Automatic:
Approx. 1,300-1,400 kg (2,866-3,086 lbs) depending on trim
Wheel Bolt Pattern:
5 x 114.3 mm (4.5 in)
🛡️ Safety Features
Ratings
Fedor Rating At Launch:
Not widely available for this era, but generally considered a safe sports car with a strong chassis.
Active Features
Anti Lock Brakes:
Optional ABS (Anti-lock Braking System) available on higher trims
Traction Control:
Not typically available on Series 5 models
Passive Features
Airbags:
Driver-side airbag standard on most models, passenger airbag optional or standard on later models
Seatbelts:
3-point inertia reel seatbelts
Chassis Construction:
Rigid unibody construction with front and rear crumple zones
💡 Technology Features
Infotainment
Audio System:
Mazda ETR/AM/FM stereo with cassette player, optional CD player on later models. Speakers typically located in doors and rear deck.
Instrumentation:
Full analog gauges including tachometer (with redline starting higher for turbo models), speedometer, oil pressure, coolant temperature, voltmeter, and turbo boost gauge (on turbo models).
Driver Assistance
Cruise Control:
Standard on most models
Connectivity
Early Electronic Features:
Power windows, power door locks, power mirrors, cruise control, pop-up headlights, optional ABS.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles (5,000 km) or 3-6 months, whichever comes first (crucial for rotary engines).
Spark Plug Replacement Interval:
Refer to manual, typically every 15,000 - 30,000 miles due to rotary engine design, use of correct plug type is vital.
Air Filter Replacement Interval:
Refer to manual, typically every 15,000 miles or annually.
Fluid Specifications
Engine Oil Type:
Rotary-specific 2-stroke oil for oil metering pump (e.g., Idemitsu Racing Rotary Oil, Mobil 1 Racing 2T, or equivalent), and conventional or synthetic engine oil for oil sump (e.g., 10W-30 or 10W-40, consult manual for precise viscosity and API rating).
Coolant Type:
Ethylene Glycol based antifreeze with demineralized water (typically a 50/50 mix). Refer to manual for Mazda specification.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for specific Mazda recommendation).
Known Issues
Rotary Engine Maintenance:
Apex seal wear, carbon build-up, oil seal failure, OMP function, over-revving can cause significant damage. Requires specialized knowledge.
Common Turbo Issues:
Turbocharger seal failure, intercooler leaks, boost leaks, exhaust manifold cracking (especially on earlier turbo models).
Electrical Gremlins:
Aging wiring harnesses, corroded connectors, and failing sensors can cause various electrical issues.
Part Numbers Reference
Spark Plug Part Number Example:
NGK BUR7EQP (example for turbocharged models, verify with manual)
📚 Vehicle History
Brand Heritage
Mazda Rotary Legacy:
Mazda's pioneering development and successful implementation of the Wankel rotary engine, starting with the Cosmo Sport.
Model Evolution
Rx-7 Generations:
First Gen (SA22C), Second Gen (FC), Third Gen (FD)
Fc Generation Introduction:
Introduced in 1985, the FC generation (RX-7 II) marked a significant departure with more sophisticated styling and performance.
S5 Updates:
The Series 5 (1989-1991) featured revised styling, improved aerodynamics, upgraded interior, more powerful engine options (especially turbo), and revised suspension tuning.
Production
Manufacturing Location:
Japan
Production Period For S5:
August 1988 - December 1991
🏆 Awards & Recognition
Recognitions
Car And Driver Award:
Car and Driver Ten Best list for 1989
Motor Trend Award:
Motor Trend Import Car of the Year nominee
Ratings
Handling Reputation:
Consistently praised by automotive media for its exceptional handling, balance, and driver engagement.
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