Mazda RX7 RX-7 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 2002 Generation Generation: FD (Third Generation) Codes Chassis Code: FD3S 👋 Introduction Market Position Positioning: Iconic Japanese sports car, celebrated for...

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斯库: 80702

标签: 2002 Car Cars Mazda Misc RX-7 RX7

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Year:

Generation

Generation:

FD (Third Generation)

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

Iconic Japanese sports car, celebrated for its rotary engine and exceptional handling.

Competitive Analysis

Competitors:

Nissan 300ZX (Z32), Toyota Supra (JZA80), Mitsubishi 3000GT VR-4

Key Features

Defining Features:

Twin-rotor sequential turbocharger, lightweight chassis, near 50/50 weight distribution, sophisticated suspension tuning.

Target Audience

Audience:

Enthusiast owners, DIY mechanics, restoration specialists, performance tuners.

Manual Purpose

Purpose:

To provide comprehensive guidance for the repair, maintenance, and restoration of the 2002 Mazda RX-7 FD3S.

📋 Manual Details

Coverage Areas

Engine:

13B-REW (Twin-Rotary Turbocharged)

Transmission:

R154 (Mazda 5-Speed Manual)

Chassis:

All components including suspension, steering, brakes, body

Electrical:

Wiring diagrams, ECU, lighting, accessories

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Full Service & Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel injection, ignition, lubrication, cooling, exhaust, emissions, turbocharger system

Drivetrain:

Clutch, transmission, driveshafts, differential, axles

Suspension Steering:

Front and rear suspension components, shock absorbers, springs, sway bars, power steering system

Brakes:

Front and rear disc brakes, ABS, parking brake, hydraulic system

Body Chassis:

Body panels, doors, windows, interior trim, chassis structure, underbody components

Electrical Electronics:

Starter, alternator, battery, lighting system, instrument cluster, climate control, power accessories, immobilizer system, ECU diagnostics

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, inspections, lubrication

Repair Rebuild:

Engine rebuilds (apex seals, rotor housings, oil seals), transmission overhaul, suspension component replacement, brake caliper overhaul, turbocharger rebuild

Diagnostics Troubleshooting:

Component testing, fault code interpretation, symptom-based troubleshooting guides, electrical system diagnostics

Installation Adjustment:

Component installation, alignment procedures, timing adjustments, electrical component replacement

Technical Depth

Depth:

Comprehensive: From basic fluid checks and filter changes to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format

Format:

Searchability:

Text-searchable PDF

Print Quality

Quality:

High-resolution, printable pages

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

13B-REW

Engine Type:

Twin-Rotor, Wankel, Sequential Turbocharged

Displacement:

1308 cc (1.3 L)

Performance

Horsepower:

255 hp @ 6500 rpm (approx.)

Torque:

217 lb-ft @ 5000 rpm (approx.)

Redline:

8000 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane Recommended)

Ignition

Ignition System:

Distributorless Ignition System (DIS) with twin ignition coils per rotor

Cooling Lubrication

Cooling System Type:

Water-cooled, pressurized system

Oil System:

Forced lubrication with oil cooler

🔧 Transmission

Standard

Type:

Mazda R154 5-speed Manual

Optional

Type:

None for 2002 model year

Features

Clutch Type:

Hydraulically actuated, multi-plate clutch

Gear Ratios

1St Gear:

3.483

2Nd Gear:

2.015

3Rd Gear:

1.317

4Th Gear:

1.000

5Th Gear:

0.797

Reverse:

3.150

Final Drive Ratio:

4.300

Fluid Specifications

Transmission Fluid Type:

GL-4 SAE 75W-90 (Manual Transmission Fluid)

Fluid Capacities

Transmission Fluid Capacity:

2.1 L (2.2 US qt)

📐 Dimensions

Exterior

Length:

4275 mm (168.3 in)

Width:

1750 mm (68.9 in)

Height:

1230 mm (48.4 in)

Wheelbase:

2505 mm (98.6 in)

Front Track:

1470 mm (57.9 in)

Rear Track:

1475 mm (58.1 in)

Weights

Curb Weight:

1300 kg (2866 lbs) approx.

Weight Distribution:

Near 50/50 front/rear

Cargo

Trunk Volume:

N/A (Limited trunk space, typical for sports coupes)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

Not rated or comparable to modern standards. Emphasis on structural integrity.

IIHS Impact:

Not rated or comparable to modern standards.

Active Features

Standard Anti-lock Braking System

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags:

Driver and Passenger Frontal Airbags

Seatbelts:

3-point seatbelts with pretensioners

Body Structure:

Reinforced safety cage and crumple zones

💡 Technology Features

Infotainment

Audio System:

Factory premium audio system (e.g., Bose) with AM/FM, cassette, and CD player.

Display:

Analog gauges and basic climate control displays.

Driver Assistance

Cruise Control:

Standard cruise control

Lighting:

Pop-up Headlights, halogen headlights, fog lights (optional)

Connectivity

Original Connectivity:

Limited to basic audio and power accessories. No Bluetooth or USB connectivity in stock form.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles or 3 months, whichever comes first, due to rotary engine characteristics. More frequent for spirited driving.

Spark Plug Replacement:

Consult manual; typically around 30,000 miles. Specific plugs required for rotary engines.

Air Filter Replacement:

Every 15,000 miles or annually.

Coolant Flush:

Every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil Type:

API SG or higher, viscosity typically 10W-30 or 5W-30. Rotary-specific oil additives recommended.

Engine Oil Capacity:

4.4 L (4.7 US qt) with filter change

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid Type:

Dexron II or equivalent ATF

Coolant Type:

Ethylene glycol-based coolant (Mazda long-life coolant recommended)

Known Issues

Common Problems:

Apex seal wear, oil seal degradation, vacuum hose leaks, turbocharger failure (especially with improper maintenance), ignition system issues, difficult cold starts if not properly maintained.

Apex Seal Life:

Highly dependent on maintenance and driving style. Rebuild often required between 60,000-100,000 miles if not meticulously cared for.

Preventative Maintenance

Importance:

Crucial for rotary engines to ensure longevity. Regular oil changes with quality oil, correct oil level, and avoiding prolonged idling are paramount.

📚 Vehicle History

Brand Heritage

Mazda Rotary History:

Mazda's long-standing commitment to and pioneering development of the Wankel rotary engine, starting with the Cosmo.

Model Evolution

Rx7 Generations:

SA/FB (1st Gen), FC (2nd Gen), FD (3rd Gen). The FD represents the pinnacle of rotary sports car evolution.

Production

Production Years Fd:

1992-2002

Manufacturing Location:

Japan

Notable Variants:

Type R, Type RZ, Spirit R (limited editions for Japan market)

🏆 Awards & Recognition

Recognitions

Car And Driver Alist:

Car and Driver's Ten Best list multiple times during its production run.

Iconic Status:

Widely recognized as one of the greatest Japanese sports cars of all time.

Motor Trend Car Of The Year:

Nominated but did not win.