Mazda RX-7 1989 1.3L 202-215 hp (151-160 kW) Service Repair Manual
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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Generation: FC3S (Second Generation) Model Year: 1989 Codes Chassis Code: FC3S Engine Code: 13B 👋 Introduction Market Position Vehicle Segment: Sports Car / Grand Tourer Target Audience: Enthusiasts, Owners, Professional Mechanics Competitive Analysis Key Competitors Era: Nissan 300ZX (Z32), Toyota Supra (Mk3), Porsche 944, Chevrolet Camaro/Pontiac Firebird Key Features Unique Selling Proposition: Rotary engine technology, balanced chassis, distinctive styling, and performance focus. 📋 Manual Details Coverage Areas Primary Coverage: Factory Service Repair Secondary Coverage: Maintenance, Diagnostics, Troubleshooting, Repair, Overhaul Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for comprehensive factory manuals of this era) Manual Type Type: Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (rotary), Fuel System, Ignition System, Exhaust System, Transmission (manual & automatic), Drivetrain (rear-wheel drive) Chassis: Suspension (front & rear), Steering, Brakes (front & rear disc), Wheels & Tires Electrical: Wiring Diagrams, Lighting, Instrumentation, Audio System, ECU & Sensors, Power Accessories Body: Exterior Body Panels, Interior Trim, Doors, Windows, Seats, HVAC System Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug/Igniter Service, Coolant Flush, Brake Fluid Flush Troubleshooting: Diagnostic Flowcharts, Symptom-Based Troubleshooting, Fault Code Interpretation (where applicable) Repair: Engine Overhaul, Transmission Rebuild, Brake Caliper Replacement, Suspension Component Replacement, Electrical Component Repair Diagnostics: Component Testing, Sensor Signal Analysis, Actuator Checks, Pressure Testing Technical Depth Depth: Comprehensive; Covers basic to advanced repairs, including complete engine and transmission rebuilds, detailed electrical diagnostics, and chassis component overhauls. 📊 Manual Specifications File Format File Quality: High-resolution scans with searchable text, allowing for easy navigation and printing. Print Quality Page Layout: Clear text and high-quality diagrams, schematics, and illustrations. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Rotary (Wankel) Displacement: 1.3L (654cc x 2 rotors) Engine Configuration: Twin-Rotor, Naturally Aspirated/Turbocharged (specific to the 202-215 hp variant) Aspiration: Turbocharged (likely sequential turbocharging for later models/performance variants) Performance Horsepower: 202-215 hp (151-160 kW) Torque: Approximately 200-220 lb-ft (271-298 Nm) - varies by specific model tune. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Premium Recommended) Technical Features Cooling System: Water-cooled rotary engine with external oil cooler (often integrated into the radiator assembly). Lubrication System: Wet sump with dedicated oil cooler, requires specific rotary engine oil. 🔧 Transmission Standard Transmission Type: 5-Speed Manual Optional Transmission Type: 4-Speed Automatic (less common in performance variants) Features Drivetrain: Rear-Wheel Drive (RWD) Clutch: Hydraulically Actuated Single Dry Plate Clutch 📐 Dimensions Exterior Length: Approx. 4315 mm (169.9 in) Width: Approx. 1700 mm (66.9 in) Height: Approx. 1270 mm (50.0 in) Wheelbase: Approx. 2430 mm (95.7 in) Weights Curb Weight: Approx. 1280-1350 kg (2822-2976 lbs) depending on trim and options Gross Vehicle Weight Rating: N/A (Typically not explicitly stated for sports cars of this era, but implied by chassis strength) 🛡️ Safety Features Ratings Crash Test Ratings: No official comprehensive ratings available from modern agencies for this era of vehicle. Focus on passive safety features. Active Features Braking System: 4-Wheel Disc Brakes (Ventilated Front, Solid Rear), optional ABS Parking Brake: Mechanical, Hand-operated, acting on rear wheels Passive Features Seatbelts: 3-point Inertia Reel Seatbelts (Front) Body Structure: Reinforced chassis and safety cage structure Steering Column: Collapsible Steering Column 💡 Technology Features Infotainment Audio System: Factory AM/FM Stereo with Cassette Player, optional CD player, likely 4-6 speaker system. Climate Control: Manual or optional Automatic Climate Control (ACC) with A/C and heater. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) on some models. Connectivity Connectivity Features: No modern connectivity features like Bluetooth or USB. Primarily analog systems. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first. Rotary engines are oil-hungry. Spark Plug Replacement: Refer to manual for specific interval, but often 30,000-60,000 miles. Use of correct spark plugs is critical. Timing Belt Equivalent: Rotary engines do not have timing belts; they use a timing chain and chain tensioner system. Fluid Specifications Engine Oil Type: Mazda recommends specific API SG/SH or higher oils, often with a 10W-30 or 10W-40 viscosity. Crucially, requires specific rotary-specific additive packages or careful selection to manage apex seal lubrication. Engine Oil Capacity: Approx. 5.5 - 6.0 liters (5.8 - 6.3 US quarts) with filter change. Coolant Type: Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water. Mazda Long Life Coolant or equivalent. Transmission Fluid Manual: API GL-4 or GL-5 gear oil, viscosity typically 75W-90. Transmission Fluid Automatic: Mazda ATF Type T-IV or equivalent. Brake Fluid: DOT 3 or DOT 4 brake fluid. Known Issues Apex Seals: Wear and failure of apex seals is a common issue with rotary engines, leading to compression loss and poor performance. Proper maintenance and avoiding overheating are critical. Oil Consumption: Rotary engines inherently consume some oil...
Component Testing, Sensor Signal Analysis, Actuator Checks, Pressure Testing
Technical Depth
Depth:
Comprehensive; Covers basic to advanced repairs, including complete engine and transmission rebuilds, detailed electrical diagnostics, and chassis component overhauls.
📊 Manual Specifications
File Format
File Quality:
High-resolution scans with searchable text, allowing for easy navigation and printing.
Print Quality
Page Layout:
Clear text and high-quality diagrams, schematics, and illustrations.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotary (Wankel)
Displacement:
1.3L (654cc x 2 rotors)
Engine Configuration:
Twin-Rotor, Naturally Aspirated/Turbocharged (specific to the 202-215 hp variant)
Aspiration:
Turbocharged (likely sequential turbocharging for later models/performance variants)
Performance
Horsepower:
202-215 hp (151-160 kW)
Torque:
Approximately 200-220 lb-ft (271-298 Nm) - varies by specific model tune.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Premium Recommended)
Technical Features
Cooling System:
Water-cooled rotary engine with external oil cooler (often integrated into the radiator assembly).
Lubrication System:
Wet sump with dedicated oil cooler, requires specific rotary engine oil.
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Optional
Transmission Type:
4-Speed Automatic (less common in performance variants)
Features
Drivetrain:
Rear-Wheel Drive (RWD)
Clutch:
Hydraulically Actuated Single Dry Plate Clutch
📐 Dimensions
Exterior
Length:
Approx. 4315 mm (169.9 in)
Width:
Approx. 1700 mm (66.9 in)
Height:
Approx. 1270 mm (50.0 in)
Wheelbase:
Approx. 2430 mm (95.7 in)
Weights
Curb Weight:
Approx. 1280-1350 kg (2822-2976 lbs) depending on trim and options
Gross Vehicle Weight Rating:
N/A (Typically not explicitly stated for sports cars of this era, but implied by chassis strength)
🛡️ Safety Features
Ratings
Crash Test Ratings:
No official comprehensive ratings available from modern agencies for this era of vehicle. Focus on passive safety features.
Factory AM/FM Stereo with Cassette Player, optional CD player, likely 4-6 speaker system.
Climate Control:
Manual or optional Automatic Climate Control (ACC) with A/C and heater.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) on some models.
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth or USB. Primarily analog systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first. Rotary engines are oil-hungry.
Spark Plug Replacement:
Refer to manual for specific interval, but often 30,000-60,000 miles. Use of correct spark plugs is critical.
Timing Belt Equivalent:
Rotary engines do not have timing belts; they use a timing chain and chain tensioner system.
Fluid Specifications
Engine Oil Type:
Mazda recommends specific API SG/SH or higher oils, often with a 10W-30 or 10W-40 viscosity. Crucially, requires specific rotary-specific additive packages or careful selection to manage apex seal lubrication.
Engine Oil Capacity:
Approx. 5.5 - 6.0 liters (5.8 - 6.3 US quarts) with filter change.
Coolant Type:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water. Mazda Long Life Coolant or equivalent.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, viscosity typically 75W-90.
Transmission Fluid Automatic:
Mazda ATF Type T-IV or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Apex Seals:
Wear and failure of apex seals is a common issue with rotary engines, leading to compression loss and poor performance. Proper maintenance and avoiding overheating are critical.
Oil Consumption:
Rotary engines inherently consume some oil as part of their lubrication system. Excessive consumption can indicate seal wear.
Cooling System Issues:
Overheating due to radiator blockages, pump failure, or coolant leaks can severely damage the engine.
Sidel Seal Wear:
Similar to apex seals, sidel seals can wear, impacting compression.
📚 Vehicle History
Brand Heritage
Mazda Rotary Legacy:
Mazda's commitment to rotary engine technology, dating back to the Cosmo and RX series.
Model Evolution
Rx-7 Generations:
First Generation (SA/FB), Second Generation (FC/FC3S), Third Generation (FD/FD3S)
Fc Generation Introduction:
Introduced for the 1986 model year, evolving into the 'S5' generation for 1989.
Production
Production Years:
FC Generation: 1985-1992
Manufacturing Location:
Hiroshima, Japan
🏆 Awards & Recognition
Recognitions
Carmagazine Awards:
Often lauded by automotive press for its handling and unique rotary powertrain.
Ratings
Handling Reputation:
Consistently praised for its excellent balance, responsive steering, and predictable handling characteristics, making it a favorite on race tracks and winding roads.