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Mazda RX7 RX-7 1992-2002 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Chassis Code: FD3S Generation: Third Generation (FD) 👋 Introduction Market Position Market Segment: Sports Car, Grand Tourer Key Selling Points: Rotary Engine,...
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类型: Car
厂商:
斯库: 86548
Mazda RX7 RX-7 1992-2002 WSM Service Manual RepairMazda RX7 RX-7 1992-2002 WSM Service Manual RepairMazda RX7 RX-7 1992-2002 WSM Service Manual RepairMazda RX7 RX-7 1992-2002 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Chassis Code:
FD3S
Generation:
Third Generation (FD)
👋 Introduction
Market Position
Market Segment:
Sports Car, Grand Tourer
Key Selling Points:
Rotary Engine, Lightweight Chassis, Balanced Handling, Iconic Design
Competitive Analysis
Primary Competitors:
Nissan 300ZX (Z32), Toyota Supra (Mk4), Mitsubishi 3000GT/GTO, Porsche 968, Chevrolet Corvette (C4/C5)
Key Features
Design Philosophy:
Jinba Ittai (Horse and Rider as One), emphasizing driver connection and agility.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual (WSM)
Language:
English
Format:
PDF Download
Intended Audience:
Professional Technicians and Advanced DIY Enthusiasts
📖 Manual Coverage
Systems Covered
Engine:
13B-REW Twin-Turbo Rotary Engine (All Configurations, Maintenance, Troubleshooting, Rebuild)
Fuel System:
Fuel Injection, Fuel Pump, Injectors, Fuel Pressure Regulator, Emissions Control (including secondary air injection)
Ignition System:
Ignition Coils, Spark Plugs, ECU Control, Timing
Cooling System:
Radiator, Water Pump, Thermostat, Fan Control, Intercooler System
Lubrication System:
Oil Pump, Oil Cooler, Oil Filter, Oil Capacity Specifications
Exhaust System:
Catalytic Converter, Mufflers, Exhaust Manifolds, O2 Sensors
Transmission:
R154 5-Speed Manual Transmission (Disassembly, Assembly, Repair, Fluid Specs)
Drivetrain:
Driveshaft, Differential, Axles, Wheel Bearings
Suspension:
Front and Rear Suspension Components, Bushings, Shocks/Struts, Springs, Alignment Specifications
Steering:
Power Steering System, Steering Rack, Tie Rods, Column
Brakes:
Front and Rear Disc Brakes, ABS System, Brake Lines, Master Cylinder, Rotor and Pad Specifications
Electrical System:
Battery, Alternator, Starter, Wiring Diagrams, Fuses, Relays
Body And Chassis:
Body Panels, Doors, Hood, Trunk, Chassis Structure, Corrosion Prevention
Interior:
Seats, Dashboard, Trim, HVAC Controls, Airbags
HVAC:
Air Conditioning System, Heater Core, Blower Motor, Refrigerant Type and Capacity
Lighting:
Headlights, Taillights, Interior Lights, Bulb Types and Specifications
Diagnostics:
OBD-II Codes, Diagnostic Procedures, Troubleshooting Guides
Procedures Included
Maintenance:
Scheduled Maintenance Intervals, Oil Changes, Filter Replacements, Spark Plug Service, Fluid Checks and Replacements
Troubleshooting:
Systematic Diagnostic Flows for Common and Complex Issues, Symptom-Based Troubleshooting
Repair:
Component Removal, Installation, Reassembly, Adjustment Procedures for All Major Systems
Rebuild:
Detailed Engine Rebuild Procedures (Apex Seals, Rotor Housings, Rotors), Transmission Rebuild Procedures
Electrical Diagnostics:
Wiring Harness Repair, Sensor Testing, ECU Diagnosis
Specifications And Tolerances:
Torque Specifications, Gapping Specifications, Clearance Measurements
Component Testing:
Testing of Sensors, Actuators, Relays, and Electronic Control Units
Technical Depth
Engine Rebuild:
Comprehensive, including apex seal replacement, rotor housing inspection, and port timing adjustments.
Transmission Overhaul:
Detailed steps for gearbox disassembly, gearset inspection, synchro ring replacement, and reassembly.
Electrical Diagnostics:
In-depth, with full color wiring diagrams, connector pinouts, and diagnostic trouble tree (DTT) charts.
Suspension Tuning:
Includes alignment specifications, camber, caster, and toe adjustments for optimal handling.
Intercooler System:
Specific details on the sequential twin-turbo system and its intercooler airflow management.
Rotary Specifics:
Unique procedures for rotary engine maintenance, including oil metering pump adjustments and two-stroke oil considerations.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Fully searchable text for quick information retrieval.
Printability:
Printable pages for offline use in the workshop.
Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Page Count
Estimated Page Count:
~2000+ pages (estimated for a complete WSM)
⚙️ Engine Specifications
Primary Engine
Engine Code:
13B-REW
Engine Type:
Twin-Rotary, Naturally Aspirated (Early models), Sequential Twin-Turbocharged (Later models)
Displacement:
1.3L (654cc x 2 rotors)
Performance
Horsepower Range:
255-280 hp (depending on year and market)
Torque Range:
217-231 lb-ft (depending on year and market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
91+ Octane Unleaded Gasoline
Other Specs
Oil Type And Capacity:
API SG or SH, SAE 10W-30 / 10W-40 (Capacity: 5.1 L / 5.4 US qt without filter change)
🔧 Transmission
Standard
Transmission Type:
Mazda R154 5-Speed Manual Transmission
Optional
Optional Transmission:
BorgWarner T-5 5-Speed Manual (some markets, earlier years); 4-Speed Automatic (less common)
Features
Transmission Fluid:
Dexron III or equivalent ATF (Capacity: 2.3 L / 2.4 US qt)
📐 Dimensions
Exterior
Wheelbase:
2545 mm (100.2 in)
Length:
4295 mm (169.1 in)
Width:
1750 mm (68.9 in)
Height:
1230 mm (48.4 in)
Weights
Curb Weight:
1250-1300 kg (2756-2866 lbs) depending on trim and options
Gross Vehicle Weight Rating:
Approx. 1650 kg (3638 lbs)
Wheel Specs
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Size Range:
16-inch and 17-inch alloy wheels
Tire Size Range
Tire Sizes:
225/50R16 (front), 245/45R16 (rear) for 16-inch wheels; 225/45R17 (front), 245/40R17 (rear) for 17-inch wheels
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not extensively tested by NHTSA for this era; owner reports and professional reviews highlight excellent balance.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS) on later models
Passive Features
Airbags:
Driver and Passenger Airbags standard on most models within the covered range.
Seatbelts:
3-point inertia reel seatbelts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Stereo with Cassette Player, Optional CD Player, Bose Speaker System (on select trims).
Climate Control:
Manual or Automatic Climate Control (ACC) depending on trim.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Connectivity
Original Connectivity:
Limited to analog systems; no modern Bluetooth or USB connectivity from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first.
Spark Plug Replacement:
Every 30,000 miles (refer to manual for specific plug type and gap).
Coolant Flush:
Every 2 years or 30,000 miles.
Timing Belt Replacement:
N/A (Rotary engines use timing chains or gears, not belts)
Fluid Specifications
Engine Oil:
API SG/SH, SAE 10W-30 or 10W-40
Transmission Fluid:
Dexron III ATF
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
Dexron II or equivalent ATF
Coolant:
Mazda Genuine Long Life Coolant or equivalent (50/50 mix with distilled water)
Known Issues
Apex Seal Wear:
A known wear item in rotary engines, requiring careful maintenance and occasional rebuilds. Pre-mix oil can help.
Oil Metering Pump:
Can fail, leading to increased engine wear. Manual covers inspection and adjustment.
Vacuum Lines:
Degradation of rubber vacuum lines can cause boost leaks and rough running. Manual details routing and inspection.
Catalytic Converter:
Can become clogged with age and mileage, affecting performance. Manual provides diagnostic procedures.
Part Numbers
Oil Filter Part Number:
Mazda OEM: B6Y1-14-302 (or equivalent aftermarket like Wix 51348)
Spark Plug Part Number:
NGK BUR9EQP (Trailing) and BUR7EQP (Leading) are common replacements; consult manual for precise fitment.
📚 Vehicle History
Brand Heritage
Rotary Legacy:
Continuation of Mazda's pioneering work with the Wankel rotary engine, dating back to the Cosmo Sport.
Model Evolution
Previous Generations:
SA22C (1978-1985), FC3S (1986-1991)
Production
Production Years:
1992-2002
Manufacturing Location:
Hofu, Yamaguchi Prefecture, Japan
Key Milestones:
Introduction of the FD chassis, sequential twin-turbo system, and refined aerodynamic styling.
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Car and Driver's '10Best' list multiple times during its production run, lauded for its handling and performance.
Motor Trend Car Of The Year:
Was a contender for Motor Trend Car of the Year upon its release.
Ratings
Handling Reputation:
Universally praised for its exceptional balance, steering feel, and track-capable performance.
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