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1989-1991 Mazda RX-7 RX7 Workshop Service Repair Manual 1989 1990 1991

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Code: FC3S Generation: Second Generation Codes Chassis Codes: FC3S (Rotary Turbo), FC3S (Naturally Aspirated) 👋 Introduction Market Position Segment: Sports Car, Grand Tourer Target Audience: Enthusiasts, DIY Mechanics, Professional Technicians Competitive Analysis Key Competitors: Nissan 300ZX (Z32), Toyota Supra (Mk3), Porsche 944, Chevrolet Camaro, Pontiac Firebird Key Features Powertrain Highlight: Renowned Mazda Wankel (Rotary) Engine Handling: Balanced chassis, sophisticated suspension system Design Era: Distinctive 1980s Japanese sports car styling Manual Value Proposition Completeness: Most comprehensive digital resource available for this model year range. 📋 Manual Details Coverage Areas Years Covered: 1989, 1990, 1991 Regions Covered: Global (USA, Japan, Europe, Australia) Page Count Estimated Pages: Approx. 2000+ (as a comprehensive compilation) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Powertrain: 13B-T Rotary Engine (Turbocharged), 13B Rotary Engine (Naturally Aspirated), Transmission (5-speed Manual, 4-speed Automatic), Driveline Chassis: Suspension (Front/Rear), Steering, Brakes (Front/Rear Disc), Wheels, Tires Electrical: Ignition System, Fuel System (EFI), Cooling System, HVAC, Lighting, Instrumentation, Audio System, Power Accessories, ECU, Wiring Diagrams Body: Exterior Panels, Interior Trim, Doors, Glass, Seats, Body Sealing Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement (rotary specific), fluid checks and changes Repair: Engine overhaul and rebuild (rotary apex seal inspection/replacement), transmission repair, brake system repair, suspension component replacement, electrical component diagnosis and repair Troubleshooting: Diagnostic flowcharts, common fault diagnosis, symptom-based troubleshooting Technical Specifications: Torque specifications, clearances, tolerances, electrical resistance values Technical Depth Depth: Comprehensive (from basic maintenance to full engine rebuilds and complex electrical diagnostics) 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (OCR optimized) Printability: Printable pages Print Quality Image Resolution: High resolution (clear diagrams and illustrations) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 13B-T (Turbocharged), 13B (Naturally Aspirated) Engine Type: Rotary (Wankel) Displacement: 1.3 Liters (Dual Rotor, approx. 654cc per rotor, often marketed as 2.6L equivalent) Performance Horsepower Turbo: Approx. 200-210 hp (depending on market and year) Torque Turbo: Approx. 195-200 lb-ft Horsepower Naturally Aspirated: Approx. 160-165 hp Torque Naturally Aspirated: Approx. 145-150 lb-ft Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Bosch or Hitachi components Fuel Type: Unleaded Gasoline (Premium Recommended) Cooling System Type: Liquid-cooled (Water Pump driven by rotor housing) Lubrication Oil Type: API SG/SH Rated Synthetic or High-Quality Conventional Oil (Viscosity 10W-30 or 10W-40) Oil Capacity With Filter: Approx. 5.0 US quarts (4.7 Liters) Rotary Specifics Apex Seals: Critical wear component, requiring proper lubrication and coolant levels. Oil Metering: Separate oil injection system for lubrication of apex seals and oil control rings. 🔧 Transmission Standard Type: 5-speed Manual Transmission (Type R) Optional Type: 4-speed Automatic Transmission (H4A-EL) Features Limited Slip Differential: Optional on Turbo models (e.g., Torsen or viscous coupling LSD) Fluid Specifications Manual Transmission Fluid: GL-4 or GL-5 Gear Oil (e.g., SAE 75W-90) Automatic Transmission Fluid: Dexron II or equivalent 📐 Dimensions Exterior Length: Approx. 4375 mm (172.2 inches) Width: Approx. 1715 mm (67.5 inches) Height: Approx. 1255 mm (49.4 inches) Wheelbase: Approx. 2430 mm (95.7 inches) Weights Curb Weight Turbo Manual: Approx. 1280 kg (2822 lbs) Curb Weight Naturally Aspirated Manual: Approx. 1190 kg (2624 lbs) 🛡️ Safety Features Ratings Federal Motor Vehicle Safety Standards: Compliant with FMVSS standards for its production era. Active Features Braking System: Four-wheel disc brakes (Ventilated front, solid rear) Anti Lock Braking System: Optional ABS on Turbo models Passive Features Seatbelts: Three-point inertia-reel seatbelts Airbags: Driver's side airbag (optional or standard depending on market/trim late in production) 💡 Technology Features Infotainment Audio System: Factory AM/FM Stereo Cassette Player with optional CD player (market dependent). Climate Control: Manual or automatic climate control systems available on higher trims. Driver Assistance Cruise Control: Standard on most Turbo models. Connectivity Telematics: Not applicable for this era. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles (8,000 km) or 6 months, whichever comes first (for synthetic oil). Spark Plug Inspection: Crucial for rotary engines; inspect and potentially replace every 15,000-30,000 miles (24,000-48,000 km) based on condition and usage. Manual will detail specific plug types and gaps. Coolant Flush: Every 24,000 miles (38,000 km) or 24 months. Fluid Specifications Brake Fluid: DOT 3 or DOT 4 Coolant: Mazda Long Life Coolant or equivalent (50/50 mix with distilled water) Known Issues Rotary Engine Apex Seals: Wear and failure of apex seals can lead to loss of compression and engine damage. Proper maintenance is key. Oil Consumption: Rotary engines inherently consume oil as part of their lubrication system. Monitor oil levels diligently. Turbocharger Reliability: Early turbochargers can be prone to wear; proper warm-up and cool-down procedures are vital. Vacuum Lines: Aging rubber vacuum lines can crack and leak, affecting engine performance and idle quality. Cooling System: Radiator leaks...
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Sku: 295166
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1989-1991 Mazda RX-7 RX7 Workshop Service Repair Manual 1989 1990 1991
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Model Code:
FC3S
Generation:
Second Generation
Codes
Chassis Codes:
FC3S (Rotary Turbo), FC3S (Naturally Aspirated)
👋 Introduction
Market Position
Segment:
Sports Car, Grand Tourer
Target Audience:
Enthusiasts, DIY Mechanics, Professional Technicians
Competitive Analysis
Key Competitors:
Nissan 300ZX (Z32), Toyota Supra (Mk3), Porsche 944, Chevrolet Camaro, Pontiac Firebird
Key Features
Powertrain Highlight:
Renowned Mazda Wankel (Rotary) Engine
Handling:
Balanced chassis, sophisticated suspension system
Design Era:
Distinctive 1980s Japanese sports car styling
Manual Value Proposition
Completeness:
Most comprehensive digital resource available for this model year range.
📋 Manual Details
Coverage Areas
Years Covered:
1989, 1990, 1991
Regions Covered:
Global (USA, Japan, Europe, Australia)
Page Count
Estimated Pages:
Approx. 2000+ (as a comprehensive compilation)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
13B-T Rotary Engine (Turbocharged), 13B Rotary Engine (Naturally Aspirated), Transmission (5-speed Manual, 4-speed Automatic), Driveline
Chassis:
Suspension (Front/Rear), Steering, Brakes (Front/Rear Disc), Wheels, Tires
Electrical:
Ignition System, Fuel System (EFI), Cooling System, HVAC, Lighting, Instrumentation, Audio System, Power Accessories, ECU, Wiring Diagrams
Body:
Exterior Panels, Interior Trim, Doors, Glass, Seats, Body Sealing
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement (rotary specific), fluid checks and changes
Repair:
Engine overhaul and rebuild (rotary apex seal inspection/replacement), transmission repair, brake system repair, suspension component replacement, electrical component diagnosis and repair
Troubleshooting:
Diagnostic flowcharts, common fault diagnosis, symptom-based troubleshooting
Technical Specifications:
Torque specifications, clearances, tolerances, electrical resistance values
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and complex electrical diagnostics)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text (OCR optimized)
Printability:
Printable pages
Print Quality
Image Resolution:
High resolution (clear diagrams and illustrations)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
13B-T (Turbocharged), 13B (Naturally Aspirated)
Engine Type:
Rotary (Wankel)
Displacement:
1.3 Liters (Dual Rotor, approx. 654cc per rotor, often marketed as 2.6L equivalent)
Performance
Horsepower Turbo:
Approx. 200-210 hp (depending on market and year)
Torque Turbo:
Approx. 195-200 lb-ft
Horsepower Naturally Aspirated:
Approx. 160-165 hp
Torque Naturally Aspirated:
Approx. 145-150 lb-ft
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch or Hitachi components
Fuel Type:
Unleaded Gasoline (Premium Recommended)
Cooling System
Type:
Liquid-cooled (Water Pump driven by rotor housing)
Lubrication
Oil Type:
API SG/SH Rated Synthetic or High-Quality Conventional Oil (Viscosity 10W-30 or 10W-40)
Oil Capacity With Filter:
Approx. 5.0 US quarts (4.7 Liters)
Rotary Specifics
Apex Seals:
Critical wear component, requiring proper lubrication and coolant levels.
Oil Metering:
Separate oil injection system for lubrication of apex seals and oil control rings.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (Type R)
Optional
Type:
4-speed Automatic Transmission (H4A-EL)
Features
Limited Slip Differential:
Optional on Turbo models (e.g., Torsen or viscous coupling LSD)
Fluid Specifications
Manual Transmission Fluid:
GL-4 or GL-5 Gear Oil (e.g., SAE 75W-90)
Automatic Transmission Fluid:
Dexron II or equivalent
📐 Dimensions
Exterior
Length:
Approx. 4375 mm (172.2 inches)
Width:
Approx. 1715 mm (67.5 inches)
Height:
Approx. 1255 mm (49.4 inches)
Wheelbase:
Approx. 2430 mm (95.7 inches)
Weights
Curb Weight Turbo Manual:
Approx. 1280 kg (2822 lbs)
Curb Weight Naturally Aspirated Manual:
Approx. 1190 kg (2624 lbs)
🛡️ Safety Features
Ratings
Federal Motor Vehicle Safety Standards:
Compliant with FMVSS standards for its production era.
Active Features
Braking System:
Four-wheel disc brakes (Ventilated front, solid rear)
Anti Lock Braking System:
Optional ABS on Turbo models
Passive Features
Seatbelts:
Three-point inertia-reel seatbelts
Airbags:
Driver's side airbag (optional or standard depending on market/trim late in production)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Stereo Cassette Player with optional CD player (market dependent).
Climate Control:
Manual or automatic climate control systems available on higher trims.
Driver Assistance
Cruise Control:
Standard on most Turbo models.
Connectivity
Telematics:
Not applicable for this era.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (for synthetic oil).
Spark Plug Inspection:
Crucial for rotary engines; inspect and potentially replace every 15,000-30,000 miles (24,000-48,000 km) based on condition and usage. Manual will detail specific plug types and gaps.
Coolant Flush:
Every 24,000 miles (38,000 km) or 24 months.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4
Coolant:
Mazda Long Life Coolant or equivalent (50/50 mix with distilled water)
Known Issues
Rotary Engine Apex Seals:
Wear and failure of apex seals can lead to loss of compression and engine damage. Proper maintenance is key.
Oil Consumption:
Rotary engines inherently consume oil as part of their lubrication system. Monitor oil levels diligently.
Turbocharger Reliability:
Early turbochargers can be prone to wear; proper warm-up and cool-down procedures are vital.
Vacuum Lines:
Aging rubber vacuum lines can crack and leak, affecting engine performance and idle quality.
Cooling System:
Radiator leaks and coolant flow issues can lead to overheating, especially critical for rotary engines.
📚 Vehicle History
Brand Heritage
Mazda Rotary Legacy:
Mazda's pioneering work with the Wankel engine, starting with the Cosmo.
Model Evolution
Fc Generation Launch:
Introduced in 1985 as a successor to the SA22C (First Generation RX-7).
Facelift:
Received a significant facelift for the 1989 model year, improving aerodynamics and introducing new features.
Production
Production Years:
1985-1992
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
Mazda RX-7 (FC generation) was a repeat recipient of Car and Driver's Ten Best list.
Motor Trend Car Of The Year:
Not a direct winner, but competitive in its segment.
Ratings
Automotive Journalism Reviews:
Consistently praised for its performance, handling, and unique rotary engine.
Certifications
Epa Fuel Economy:
Varies by model and transmission, generally in the range of 16-18 MPG City / 20-22 MPG Highway.
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