Description:
The Mazda RX-7 (FD) is an iconic Japanese sports car, renowned for its rotary engine and exceptional handling. This manual caters to enthusiasts and mechanics who maintain and repair this highly specialized vehicle, often sought after for its performance and unique engineering.
Competitors:
Competed against sports cars like the Nissan 300ZX (Z32), Toyota Supra (Mk4), and Mitsubishi 3000GT VR-4 during its production run.
Design:
Sleek, aerodynamic design with a low-slung profile and iconic pop-up headlights (early models) and fixed headlights (later models).
Engine Type:
Unique twin-rotor, sequential twin-turbocharged Wankel rotary engine (13B-REW).
Handling:
Renowned for its balanced chassis, near-perfect weight distribution, and agile handling characteristics.
Regions Covered:
Global (primarily North American and Japanese market specifications where applicable)
Trim Levels Covered:
All trim levels including Base, Touring, R1, R2, Spirit R, Bathurst R (where applicable to the model years)
Estimated Page Count:
1500+ pages (aggregate from a comprehensive service manual)
Type:
Comprehensive Service and Repair Manual
Powertrain:
Engine (Rotary), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Transmission (Manual & Automatic), Drivetrain (Rear Wheel Drive)
Chassis:
Suspension (Front & Rear), Steering, Brakes (Front & Rear Disc, ABS), Wheels & Tires
Electrical:
Body Electrical, Powertrain Control Module (PCM), Lighting, Instruments & Gauges, Audio System, Air Conditioning System, Power Accessories (Windows, Locks, Mirrors), Anti-theft System, SRS (Airbag) System
Body And Interior:
Body Panels, Doors, Hood, Trunk, Bumpers, Interior Trim, Seats, Upholstery, Glass & Seals
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug (Apex Seal) Inspection/Replacement, Coolant Flush, Brake Fluid Flush, Belt Adjustments/Replacement
Diagnostics:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Wiring Diagrams, Component Testing Procedures, On-Board Diagnostics (OBD-I/OBD-II)
Repair And Rebuild:
Engine Rebuild (Apex Seal Replacement, Rotor Housing Inspection), Transmission Overhaul, Brake System Overhaul, Suspension Component Replacement, Electrical Component Repair, Body Panel Repair/Replacement
Installation:
Component Installation, Aftermarket Part Integration Guidance (where applicable to factory setup)
Depth:
Expert-level, covering detailed disassembly, assembly, diagnosis, and repair procedures for all major vehicle systems. Includes torque specifications, diagnostic flowcharts, and component specifications.
Engine Type:
Naturally Aspirated, Sequential Twin-Turbocharged Rotary (Wankel)
Displacement:
1.3 Liters (654cc x 2 rotors)
Bore X Stroke:
100 mm x 61.5 mm (per rotor)
Horsepower Early Models:
252 hp @ 6500 rpm
Horsepower Later Models:
276 hp @ 6500 rpm (for facelifted models)
Torque Early Models:
217 lb-ft @ 5000 rpm
Torque Later Models:
246 lb-ft @ 5000 rpm (for facelifted models)
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Type:
Direct Ignition System (DIS) with trailing and leading spark plugs per rotor
NHTSA Front Impact:
Not explicitly rated by NHTSA for these specific years, but generally considered structurally sound for its era.
IIHS Side Impact:
Not explicitly rated by IIHS for these specific years.
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS) on some later models
Airbags:
Driver and Passenger SRS Airbags
Seatbelts:
3-point front seatbelts with pretensioners
Body Structure:
Reinforced safety cell with crumple zones
Audio System:
Factory AM/FM/CD player with 4 or 6 speaker system, optional Bose premium audio on select trims.
Climate Control:
Manual or automatic climate control systems.
Cruise Control:
Standard cruise control system.
OBD Port:
OBD-I port (1992-1995), transitioning to OBD-II (1996 onwards) for diagnostics.
Oil Change Engine:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions. Use of specific rotary oil is critical.
Oil Filter Replacement:
At every engine oil change. Mazda Genuine Part Number: Y601-14-302A
Spark Plug Inspection Replacement:
Every 30,000 miles (leading plugs) and 60,000 miles (trailing plugs). Specific plugs required, e.g., NGK BUR7EQP (trailing) and NGK BUR6EQP (leading).
Coolant Flush:
Every 2 years or 30,000 miles. Use of Mazda FL22 coolant or equivalent.
Transmission Fluid Change:
Manual: Every 60,000 miles. Automatic: Every 30,000-50,000 miles. Refer to manual for specific fluid types.
Engine Oil:
API SG or higher, SAE 10W-30 recommended for rotary engines. Mazda Genuine Rotary Engine Oil or equivalent is crucial for lubrication and sealing. Do not use conventional engine oil designed for piston engines.
Coolant:
Mazda FL22 Long Life Coolant (Pink) or equivalent ethylene glycol-based coolant with deionized water.
Brake Fluid:
DOT 3 or DOT 4 Brake Fluid.
Transmission Fluid Manual:
GL-4 SAE 75W-90 Gear Oil (e.g., Castrol SYNTRANS FE 75W-90)
Transmission Fluid Automatic:
Mazda ATF JWS3317 or equivalent.
Apex Seal Wear:
Apex seals are a common wear item in rotary engines, leading to compression loss and performance degradation. Regular checks and proper oiling are vital.
Vacuum Lines:
Aging rubber vacuum lines can crack and cause vacuum leaks, affecting engine performance and emissions.
Sequential Turbo System:
The sequential turbo system's actuators and solenoids can fail, leading to loss of boost or incorrect boost delivery.
Cooling System:
Overheating can be a significant issue if the cooling system (radiator, fans, coolant) is not maintained, due to the high thermal load of the rotary engine.
Catalytic Converter:
Can become clogged over time, especially if the engine is burning oil or running rich.
Mazda Rotary:
Mazda's long-standing association with the Wankel rotary engine, dating back to the Mazda Cosmo.
Rx Series:
Successor to the RX-3, RX-4, and RX-7 (FC) generations, representing the pinnacle of Mazda's rotary sports car development.
Fd Development:
Designed by the renowned automotive designer Tom Matano.
Production Period:
1992-2002 (model years)
Manufacturing Location:
Hiroshima, Japan
Facelifts:
Major facelift in 1995 (1996 model year) with revised aerodynamics, suspension, and powertrain.
