Positioning:
The Mazda RX-7 (FD generation) is renowned as a halo sports car, celebrated for its unique rotary engine, balanced chassis, and iconic styling. This manual targets owners and mechanics who need in-depth information for maintaining, repairing, and restoring this enthusiast-focused vehicle.
Competitors:
Competed against other performance coupes of its era, such as the Nissan 300ZX (Z32), Toyota Supra (Mk IV), Mitsubishi 3000GT VR-4, and Porsche 968. Its rotary engine offered a distinct performance characteristic.
Distinguishing Factors:
Unique twin-rotor 13B-REW engine, lightweight construction, near-perfect weight distribution, advanced sequential twin-turbo system (on most models), sophisticated suspension design.
Engine Mechanical:
Rotary engine (13B-REW), apex seals, rotor housing, eccentric shaft, lubrication system, cooling system, fuel injection, emissions control, ignition system, engine management.
Transmission:
Manual transmission (R154 or equivalent), clutch system, driveshaft, differential, transmission fluid specifications.
Brakes:
Front and rear disc brakes, ABS system, hydraulic system, brake fluid specifications, pad and rotor replacement.
Suspension Steering:
Front and rear independent suspension, shock absorbers, springs, bushings, power steering system, steering rack, alignment specifications.
Electrical Electronics:
Battery, charging system, starter motor, lighting system, instrument cluster, ECU, sensors, wiring diagrams, fuse box layout.
Body Chassis:
Body panel removal and installation, interior trim, doors, windows, convertible top (if applicable), chassis components, rust prevention.
Maintenance:
Oil changes, filter replacements, spark plug replacement (specific to rotary), coolant checks, belt inspections, fluid top-offs, brake inspections.
Repair:
Engine rebuild, transmission overhaul, brake system repair, suspension component replacement, electrical diagnostics and repair, bodywork repairs.
Troubleshooting:
Diagnosis of common drivability issues, electrical faults, starting problems, overheating, fuel system issues, with diagnostic charts and procedures.
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, diagnostic procedures, and component-specific instructions.
Engine Type:
Rotary (Wankel)
Displacement:
1.3 Liters (654cc x 2 chambers)
Horsepower:
252 hp @ 6500 rpm (early models), 276 hp @ 6500 rpm (later models)
Torque:
217 lb-ft @ 3500 rpm (early models), 247 lb-ft @ 5000 rpm (later models)
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (91 octane or higher recommended)
Turbo Configuration:
Sequential Twin-Turbo
Oil Type Capacity:
API SG/SH SAE 10W-30 or 10W-40, 4.8 US quarts (4.5 Liters) with filter change.
Coolant Type Capacity:
Mazda FL22 or equivalent (long-life silicate-free coolant), 8.4 US quarts (7.9 Liters).
Transmission Type:
5-speed Manual (Type R154 variant or similar)
Optional Transmission:
4-speed Automatic (less common, primarily for specific markets)
Clutch Type:
Hydraulic Twin-Plate or Single-Plate Clutch
Transmission Fluid:
API GL-4 SAE 75W-90 Gear Oil, 2.4 US quarts (2.3 Liters).
Length:
170.1 inches (4320 mm)
Width:
69.1 inches (1755 mm)
Height:
48.2 inches (1225 mm)
Wheelbase:
95.5 inches (2425 mm)
Curb Weight:
Approx. 2,800-3,000 lbs (1270-1360 kg), depending on trim and options.
Gross Vehicle Weight:
Approx. 3,800 lbs (1725 kg)
Trunk Volume:
Approx. 5.7 cubic feet (161 Liters)
NHTSA Rating:
Not officially rated by NHTSA for 1993 model year in the same way as modern vehicles. Focus was on passive safety features.
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Traction Control:
Optional or standard depending on trim/market (e.g., Torsen LSD often included).
Airbags:
Driver and passenger airbags.
Seat Belts:
Three-point inertia-reel seat belts with pretensioners.
Body Structure:
Reinforced safety cage, crumple zones.
Audio System:
Factory Bose or Clarion audio system with AM/FM stereo, cassette player, and optional CD player. Limited digital integration by modern standards.
ABS:
Standard Anti-lock Braking System (ABS).
Cruise Control:
Standard electronic cruise control.
Factory Options:
Minimal connectivity by today's standards. Primarily focused on the driving experience.
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first. Frequent oil analysis is recommended for rotary engines.
Spark Plug Replacement:
Every 30,000 miles (48,000 km). Requires specific platinum-tipped, two-electrode spark plugs (e.g., NGK PFR7A or equivalent).
Fuel Filter Replacement:
Every 60,000 miles (96,000 km).
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Dexron II or equivalent ATF.
Apex Seal Wear:
Degradation of apex seals due to poor lubrication, overheating, or detonation. Symptoms include loss of compression, rough idle, and poor performance. Requires engine rebuild.
Oil Metering Pump:
Failure or clogging of the OMP can lead to premature apex seal wear. Regular checks and proper maintenance are crucial.
Sequential Turbo System:
Issues with the solenoids, actuators, or vacuum lines controlling the sequential turbos can lead to reduced boost or incorrect boost delivery.
Fuel Injector Clogging:
Especially common with aftermarket modifications or poor fuel quality, leading to misfires and lean conditions.
Ignition System:
Coil packs and ignition wires can degrade over time, affecting spark quality and leading to misfires.
Mazda Rotary:
Mazda's long history and unique commitment to the rotary engine, dating back to the Cosmo and RX series (RX-2, RX-3, RX-4, RX-7 SA/FB, RX-7 FC).
Third Generation:
The FD RX-7 represents the third and final generation of the RX-7, launched in 1992 for the 1993 model year. It featured a completely new chassis and design, moving away from the previous RX-7 FC.
Production Period:
1992-2002 (for the FD generation). The 1993 model year marks the initial release of the FD RX-7.
Manufacturing Location:
Hiroshima, Japan.
