Mazda RX7 RX-7 1992-2002 Workshop Service Manual for Repair
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๐ท๏ธ Basic Information Identification Make: Mazda Model: RX-7 Generation: FD (Third Generation) Codes Chassis Code: FD3S Engine Code: 13B-REW ๐ Introduction Market Position Vehicle Segment: Sports Car / Grand Tourer Target Audience: Enthusiasts, performance drivers, owners seeking to maintain and repair their RX-7. Competitive Analysis Key Competitors: Nissan 300ZX (Z32), Toyota Supra (JZA80), Mitsubishi 3000GT/GTO, Porsche 968. Key Features Engine Layout: Front-engine, Rear-wheel drive with a compact rotary engine. Design Philosophy: Lightweight chassis, balanced weight distribution, aerodynamic styling, rotary engine performance. Unique Selling Proposition: The 13B-REW twin-rotor engine with sequential turbocharging, delivering high power from a small displacement, and the iconic FD chassis design. ๐ Manual Details Coverage Areas Years Covered: 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Page Count Total Pages: 1093 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download ๐ Manual Coverage Systems Covered Powertrain: Engine (Rotary Wankel), Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System, Transmission (Manual & Automatic) Chassis: Suspension (Front & Rear), Steering System, Brakes (ABS, Power Assist), Wheels & Tires Electrical: Battery, Charging System, Starting System, Lighting, Instruments & Gauges, Wiper & Washer System, Audio System, Power Windows, Power Locks, Immobilizer Body: Body Panels, Doors, Hood, Trunk Lid, Interior Trim, Seats, HVAC System Procedures Included Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their interpretation. Maintenance: Routine maintenance procedures, fluid changes, filter replacements, lubrication, inspection schedules. Repair: Component removal, disassembly, inspection, repair, and reassembly for engine, transmission, suspension, brakes, electrical, and body components. Adjustment: Torque specifications for all fasteners, alignment procedures, clutch adjustment, idle speed adjustment. Rebuilds: Detailed instructions for engine rebuilds (rotary apex seals, housings), transmission overhauls. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds. Includes detailed diagrams, schematics, and specifications. ๐ Manual Specifications File Format File Type: PDF Searchable: Yes (typically, depending on scan quality) Printable: Yes Print Quality Resolution: High-resolution scans suitable for viewing on screen and printing. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) โ๏ธ Engine Specifications Primary Engine Engine Type: Rotary (Wankel) Twin-Rotor, Twin-Turbocharged Displacement: 1308 cc (2 x 654 cc rotors) Performance Horsepower Early Models: 255 PS (252 hp) @ 6500 rpm Horsepower Later Models: 280 PS (276 hp) @ 6500 rpm (post-1995 facelift, Japanese domestic market) Torque Early Models: 314 Nm (231 lb-ft) @ 4000 rpm Torque Later Models: 333 Nm (246 lb-ft) @ 5000 rpm (post-1995 facelift, Japanese domestic market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Twin Turbochargers Fuel Type: Unleaded Premium Gasoline (91+ Octane) Lubrication Oil Type: API SG or SH, SAE 10W-30 or 10W-40 (Check manual for specific viscosity) Oil Capacity: Approx. 4.5 liters (with filter) Cooling Coolant Type: Ethylene Glycol based antifreeze (50/50 mix with distilled water) Coolant Capacity: Approx. 8.5 liters ๐ง Transmission Standard Transmission Type: 6-Speed Manual Transmission (Mazda R154 equivalent in principle, specific Mazda code) Optional Transmission Type: 4-Speed Automatic Transmission (optional on some markets/trims) Features Clutch Type: Hydraulically Actuated, Single Dry Plate Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 or 75W-85 (Refer to manual for exact specification) ๐ Dimensions Exterior Length: 4295 mm (169.1 in) Width: 1750 mm (68.9 in) Height: 1230 mm (48.4 in) Wheelbase: 2500 mm (98.4 in) Weights Curb Weight Manual: Approx. 1250-1300 kg (2755-2866 lbs) Wheel Bolt Pattern: 5x114.3 mm Wheel Size: 16-inch or 17-inch alloy wheels (std/optional) Tire Size Front: 225/50 R16 or 235/40 R17 Tire Size Rear: 245/45 R16 or 255/40 R17 ๐ก๏ธ Safety Features Ratings Crash Test Ratings: Varies by region and testing authority. Historically, many sports cars of this era had less stringent testing than modern vehicles. Active Features ABS: Anti-lock Braking System (ABS) standard on most models. Traction Control: Traction Control System (TCS) available on some later models and higher trims. Passive Features Airbags: Driver and passenger airbags standard. Seatbelts: 3-point inertia-reel seatbelts with pre-tensioners. Chassis Design: Designed for rigidity and crash energy management with a focus on driver safety and handling. ๐ก Technology Features Infotainment Audio System: Bose premium audio system available on higher trims, with CD player and cassette deck. Climate Control: Automatic climate control with electronic controls on some models. Driver Assistance Cruise Control: Standard cruise control system. Adjustable Suspension: Some later models featured electronically adjustable suspension (e.g., 'Active' variants). Connectivity Connectivity Features: Limited by era; primarily focused on the vehicle's internal systems. Aftermarket upgrades for Bluetooth/USB are common. ๐ง Maintenance Service Intervals Oil Change Interval: Every 5,000 miles (8,000 km) or 6 months, whichever comes first. More frequent changes are recommended for spirited driving. Air Filter Replacement: Every 15,000 miles (24,000 km) or as needed based on driving conditions. Spark Plug Replacement: Refer to manual; often platinum or iridium plugs with longer intervals. Typically around 30,000-60,000 miles. Timing Belt Replacement: N/A (Rotary engines do not have...
Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds. Includes detailed diagrams, schematics, and specifications.
๐ Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (typically, depending on scan quality)
Printable:
Yes
Print Quality
Resolution:
High-resolution scans suitable for viewing on screen and printing.
API SG or SH, SAE 10W-30 or 10W-40 (Check manual for specific viscosity)
Oil Capacity:
Approx. 4.5 liters (with filter)
Cooling
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Coolant Capacity:
Approx. 8.5 liters
๐ง Transmission
Standard
Transmission Type:
6-Speed Manual Transmission (Mazda R154 equivalent in principle, specific Mazda code)
Optional
Transmission Type:
4-Speed Automatic Transmission (optional on some markets/trims)
Features
Clutch Type:
Hydraulically Actuated, Single Dry Plate
Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 75W-85 (Refer to manual for exact specification)
๐ Dimensions
Exterior
Length:
4295 mm (169.1 in)
Width:
1750 mm (68.9 in)
Height:
1230 mm (48.4 in)
Wheelbase:
2500 mm (98.4 in)
Weights
Curb Weight Manual:
Approx. 1250-1300 kg (2755-2866 lbs)
Wheel Bolt Pattern:
5x114.3 mm
Wheel Size:
16-inch or 17-inch alloy wheels (std/optional)
Tire Size Front:
225/50 R16 or 235/40 R17
Tire Size Rear:
245/45 R16 or 255/40 R17
๐ก๏ธ Safety Features
Ratings
Crash Test Ratings:
Varies by region and testing authority. Historically, many sports cars of this era had less stringent testing than modern vehicles.
Active Features
ABS:
Anti-lock Braking System (ABS) standard on most models.
Traction Control:
Traction Control System (TCS) available on some later models and higher trims.
Passive Features
Airbags:
Driver and passenger airbags standard.
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners.
Chassis Design:
Designed for rigidity and crash energy management with a focus on driver safety and handling.
๐ก Technology Features
Infotainment
Audio System:
Bose premium audio system available on higher trims, with CD player and cassette deck.
Climate Control:
Automatic climate control with electronic controls on some models.
Driver Assistance
Cruise Control:
Standard cruise control system.
Adjustable Suspension:
Some later models featured electronically adjustable suspension (e.g., 'Active' variants).
Connectivity
Connectivity Features:
Limited by era; primarily focused on the vehicle's internal systems. Aftermarket upgrades for Bluetooth/USB are common.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first. More frequent changes are recommended for spirited driving.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Refer to manual; often platinum or iridium plugs with longer intervals. Typically around 30,000-60,000 miles.
Timing Belt Replacement:
N/A (Rotary engines do not have a timing belt; they use a chain or oil pump drive system.)
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4, low-viscosity.
Power Steering Fluid:
ATF DEXRON II or equivalent.
Known Issues
Rotary Engine Apex Seals:
Wear or failure of apex seals is a known potential issue, often exacerbated by poor maintenance, overheating, or detonation. This manual is crucial for proper diagnosis and repair.
Sequential Turbo System:
Reliability of the sequential turbo system (especially the smaller primary turbo and its control solenoids) can be a concern. This manual details its operation and troubleshooting.
Oil Consumption:
Rotary engines naturally consume oil as part of their lubrication system. Owners must monitor and top up oil regularly.
Cooling System Performance:
Efficient cooling is vital for rotary engines. Overheating can lead to premature wear. This manual covers the cooling system in detail.
๐ Vehicle History
Brand Heritage
Brand Identity:
Mazda is known for its engineering innovation, particularly its development of the rotary engine, and a heritage of sporty, driver-focused vehicles.
Model Evolution
Previous Generations:
SA/FB (1978-1985), FC (1985-1992). The FD represented a significant leap in performance, design, and technology.
Design Inspiration:
Designed by Tom Matano, with styling cues from the Porsche 944 and Chevrolet Camaro.
Key Facelifts:
Significant updates in 1995 (Japanese market) and 1999 (US market) addressed reliability concerns and refined performance and styling.
Production
Production Years:
1991-2002
Production Locations:
Hiroshima, Japan
Production Numbers:
Approximately 71,000 units globally.
๐ Awards & Recognition
Recognitions
Car And Driver 10 Best:
Car and Driver named the RX-7 to its '10Best' list multiple times during its production run.
Iconic Status:
Widely regarded as one of the most iconic Japanese sports cars of the 1990s, celebrated for its engineering and performance.