Mazda RX-7 1992-2002 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Chassis Code: FD3S (3rd Generation) Production Years Covered: 1992-2002 👋 Introduction Market Position Segment: Front-engine, Rear-wheel-drive, Sports Car, Rotary-powered GT Competitive Analysis Key Rivals: Nissan 300ZX (Z32), Toyota Supra (JZA70/JZA80), Mitsubishi 3000GT (Z16A), Porsche 968, Chevrolet Corvette (C4) Key Features Rotary Engine: Unique sequential twin-turbocharged 13B-REW rotary engine, offering high-revving performance and compact design. Chassis Dynamics: Advanced chassis design, lightweight construction, near 50/50 weight distribution, sophisticated suspension geometry for exceptional handling. Design: Iconic, aerodynamic 'Kiyoku' (clean) design language, featuring pop-up headlights (early models) and a sleek profile. 📋 Manual Details Coverage Areas Covered Regions: Global (Japanese Domestic Market, North American Spec, European Spec variants generally covered) Page Count Estimated Pages: Thousands (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English (Primary, though variations might exist depending on source) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine System: Rotary engine (13B-REW), lubrication, cooling, fuel injection, ignition, emissions control, starting, charging Transmission System: Manual transmission (R154 for some markets, Mazda M015/M016), clutch, driveline, limited-slip differential (LSD) Brake System: Hydraulic system, ABS, front and rear disc brakes, parking brake Suspension System: Front (double wishbone), Rear (multi-link), springs, shock absorbers, bushings, steering linkage Electrical System: Battery, alternator, starter, wiring diagrams, lighting, fuses, relays, ECUs, sensors, immobilizer Body And Interior: Body panels, chassis structure, doors, windows, seats, HVAC, dashboard, trim, sound system Fuel System: Fuel tank, pump, lines, injectors, fuel pressure regulator, emissions canister Cooling System: Radiator, fans, water pump, thermostat, hoses, coolant specifications Exhaust System: Exhaust manifolds, catalytic converters, mufflers, emissions control components (e.g., air pump, EGR) Air Conditioning: Compressor, condenser, evaporator, refrigerant, system servicing Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks/replacement, fluid checks and top-offs, belt...

Type: Car

Sku: 457250

Collections: ALL Mazda

Tags: 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Car Cars Mazda Misc RX-7

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Chassis Code:

FD3S (3rd Generation)

Production Years Covered:

1992-2002

👋 Introduction

Market Position

Segment:

Front-engine, Rear-wheel-drive, Sports Car, Rotary-powered GT

Competitive Analysis

Key Rivals:

Nissan 300ZX (Z32), Toyota Supra (JZA70/JZA80), Mitsubishi 3000GT (Z16A), Porsche 968, Chevrolet Corvette (C4)

Key Features

Rotary Engine:

Unique sequential twin-turbocharged 13B-REW rotary engine, offering high-revving performance and compact design.

Chassis Dynamics:

Advanced chassis design, lightweight construction, near 50/50 weight distribution, sophisticated suspension geometry for exceptional handling.

Design:

Iconic, aerodynamic 'Kiyoku' (clean) design language, featuring pop-up headlights (early models) and a sleek profile.

📋 Manual Details

Coverage Areas

Covered Regions:

Global (Japanese Domestic Market, North American Spec, European Spec variants generally covered)

Page Count

Estimated Pages:

Thousands (typical for comprehensive factory service manuals)

Manual Type

Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language

Language:

English (Primary, though variations might exist depending on source)

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine System:

Rotary engine (13B-REW), lubrication, cooling, fuel injection, ignition, emissions control, starting, charging

Transmission System:

Manual transmission (R154 for some markets, Mazda M015/M016), clutch, driveline, limited-slip differential (LSD)

Brake System:

Hydraulic system, ABS, front and rear disc brakes, parking brake

Suspension System:

Front (double wishbone), Rear (multi-link), springs, shock absorbers, bushings, steering linkage

Electrical System:

Battery, alternator, starter, wiring diagrams, lighting, fuses, relays, ECUs, sensors, immobilizer

Body And Interior:

Body panels, chassis structure, doors, windows, seats, HVAC, dashboard, trim, sound system

Fuel System:

Fuel tank, pump, lines, injectors, fuel pressure regulator, emissions canister

Cooling System:

Radiator, fans, water pump, thermostat, hoses, coolant specifications

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, emissions control components (e.g., air pump, EGR)

Air Conditioning:

Compressor, condenser, evaporator, refrigerant, system servicing

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks/replacement, fluid checks and top-offs, belt inspections

Engine Repair:

Apex seal replacement, rotor housing inspection/lapping, seal kit installation, engine disassembly/assembly, balancing

Transmission Repair:

Gearbox overhaul, synchro ring replacement, bearing replacement, clutch assembly

Suspension And Steering Repair:

Shock absorber replacement, bushing replacement, wheel alignment, power steering system service

Brake System Repair:

Brake pad/rotor replacement, caliper overhaul, brake bleeding, ABS sensor diagnosis

Electrical Troubleshooting:

Wiring harness repair, sensor diagnostics, ECU flashing, component testing

Body And Frame Repair:

Panel replacement, dent repair, rust treatment, door and window glass replacement

Fuel System Service:

Fuel injector cleaning/replacement, fuel pump testing, fuel filter replacement

Cooling System Service:

Radiator flush, thermostat replacement, water pump replacement

Diagnostics And Troubleshooting:

Fault code retrieval (OBD-I/II dependent on year), symptom analysis, component testing procedures

Technical Depth

Depth:

Comprehensive (covers basic maintenance to complete engine and transmission rebuilds, full electrical schematics, and bodywork)

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable (depending on scan quality and OCR processing)

Print Quality

Quality:

High-resolution scans of original factory documentation

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

13B-REW

Engine Type:

Rotary, Wankel, Twin-Rotor

Aspiration:

Twin-Turbocharged (Sequential)

Displacement:

1.3L (654cc per rotor x 2)

Bore X Stroke:

N/A (Rotary engine dimensions differ from piston engines; effective displacement quoted)

Performance

Horsepower Range:

Approx. 255-280 hp (varies by year and market, e.g., 255 hp for early US models, 280 hp for later JDM models)

Torque Range:

Approx. 217-231 lb-ft (varies by year and market)

Redline:

7,500 RPM (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane recommended)

Fuel Injectors:

Side-feed or Top-feed injectors (e.g., 550cc primary, 750cc secondary on some later models)

Ignition System

Ignition Type:

Direct Ignition System (DIS) with trailing and leading spark plugs per rotor

Lubrication System

Oil Type Recommendation:

High-quality synthetic oil, API SG or higher, viscosity 10W-30 or 5W-30 (refer to specific manual for precise recommendations)

Oil Capacity:

Approx. 5.5-6.0 US Quarts (with filter)

Oil Pump:

Engine-driven oil pump with a dedicated oil metering pump (OMP) for 2-stroke oil injection into intake ports

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission (Mazda M015/M016) on most models. Some early models or specific markets may have used different transmissions.

Optional

Transmission Type:

4-speed Automatic Transmission (R4A-EL) was optional on some markets.

Features

Gear Ratios:

Specific ratios vary by model year and market; manual transmissions generally feature close-ratio gearing for sporty performance.

Clutch Type:

Hydraulically actuated, multi-plate clutch (typically dry, single-plate for manual; wet multi-plate on some earlier rotary engines).

Driveshaft:

One-piece or two-piece driveshaft depending on year and specific configuration.

Driveshaft

Differential:

Standard Limited-Slip Differential (LSD) on most performance variants.

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5 gear oil, viscosity typically 75W-90 (refer to manual for exact specifications and capacity)

📐 Dimensions

Exterior

Length:

Approx. 4,280-4,315 mm (168.5-170.0 inches)

Width:

Approx. 1,750 mm (68.9 inches)

Height:

Approx. 1,230-1,250 mm (48.4-49.2 inches)

Wheelbase:

Approx. 2,445 mm (96.3 inches)

Front Track:

Approx. 1,470-1,480 mm (57.9-58.3 inches)

Rear Track:

Approx. 1,460-1,470 mm (57.5-57.9 inches)

Weights

Curb Weight:

Approx. 1,250-1,350 kg (2,755-2,976 lbs), varies by trim and equipment

Gross Vehicle Weight Rating Gvwr:

Refer to vehicle placard for specific GVWR

🛡️ Safety Features

Ratings

NHTSA Ratings:

Variable and often not directly comparable to modern standards due to testing methodologies of the era. Focus on passive safety features.

Active Features

Anti-lock Braking System (ABS) standard on most models from introduction.

Traction Control:

Traction Control System (TCS) available on later models.

Passive Features

Airbags:

Driver and passenger airbags standard on most models.

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners.

Body Structure:

Reinforced safety cage, crumple zones designed for energy absorption.

💡 Technology Features

Infotainment

Audio System:

Bose premium audio system with CD player and AM/FM radio was an option on some models. Factory cassette players were common.

Climate Control:

Manual or automatic climate control systems depending on trim level.

Driver Assistance

Cruise Control:

Standard cruise control system.

Connectivity

Navigation:

Very limited or non-existent factory navigation systems during this era. Aftermarket solutions were common.

Lighting

Headlights:

Pop-up (retractable) headlights on early models, fixed halogen or HID headlights on later models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles or 3-6 months (often shorter intervals recommended by enthusiasts due to rotary engine characteristics).

Air Filter Replacement:

Check every 15,000 miles, replace as needed. Specific interval varies.

Spark Plug Replacement:

Replace every 30,000 miles (using appropriate platinum or iridium plugs). Rotary engines use two plugs per rotor.

Timing Belt Replacement:

N/A (Rotary engines do not have timing belts; they use a chain or gear-driven eccentric shaft).

Coolant Flush:

Every 30,000 miles or 2-3 years.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 brake fluid (refer to manual for precise type and capacity).

Power Steering Fluid:

ATF (Automatic Transmission Fluid) or specific power steering fluid as per Mazda recommendations.

Coolant Type:

Ethylene glycol-based coolant (50/50 mix with distilled water). Mazda's 'FL22' coolant or equivalent is often recommended for later models.

Known Issues

Apex Seals:

Wear and failure of apex seals is a common concern in high-mileage rotary engines, leading to compression loss. Requires engine rebuild.

Oil Seals:

Eccentric shaft oil seals and corner seals can degrade over time, leading to oil consumption and potential engine damage if not addressed.

Cooling System:

Overheating can be a significant issue due to the rotary engine's high heat output. Ensuring proper cooling system maintenance is critical.

Fuel System:

Fuel pump failure and clogged fuel injectors can affect performance.

Turbocharger Issues:

Wear and failure of turbochargers and associated plumbing (e.g., wastegate, boost control solenoids) can occur.

Vacuum Lines:

Degradation of vacuum hoses can lead to vacuum leaks, causing drivability issues and engine misfires.

Emissions System:

Problems with the air pump system, O2 sensors, and catalytic converters can arise, especially on high-mileage vehicles.

📚 Vehicle History

Brand Heritage

Rotary Legacy:

Mazda's pioneering and continued commitment to rotary engine technology, beginning with the Cosmo and RX series.

Model Evolution

Generations:

The FD3S represents the third and final generation of the RX-7, succeeding the FC3S (2nd gen) and SA22C/FB (1st gen).

Development Philosophy:

Focused on light weight, advanced chassis dynamics, and a unique, high-revving rotary power plant.

Production

Manufacturing Plant:

Mazda's Fuchu Plant in Hiroshima, Japan.

Production End Date:

August 2002

🏆 Awards & Recognition

Recognitions

Car And Driver:

Car and Driver's 'Ten Best' list multiple times during its production run, highlighting its exceptional driving dynamics and performance.

Road And Track:

Frequently praised by automotive journalists and publications like Road & Track for its handling, engine, and overall sports car appeal.

Ratings

Enthusiast Appreciation:

Highly regarded by enthusiasts and considered a modern classic in the sports car community.