The 1996 RX-7 (chassis code FD3S) represents the pinnacle of the third generation of this iconic Japanese sports car. Renowned for its exceptional handling, lightweight construction, and sophisticated rotary engine technology, the RX-7 is powered by a 1308cc (80 cu in) 13B-REW twin-sequential turbocharged rotary engine producing 255 PS and 217 lb-ft of torque. This enthusiast-focused vehicle, celebrated for its 50/50 weight distribution and advanced suspension geometry, was a consistent recipient of automotive awards and is recognized as one of the best-handling cars of its era, competing with esteemed models like the Nissan 300ZX and Toyota Supra. This comprehensive service and repair manual provides in-depth, factory-level technical detail for the 1996 RX-7. It covers all major mechanical, electrical, and body systems, including detailed procedures for the rotary engine's lubrication, cooling, and fuel injection systems, as well as the R581 5-speed manual transmission, suspension, brakes, and electrical components. The manual also offers extensive troubleshooting guides, maintenance schedules, and rebuilding procedures, making it an indispensable resource for owners, mechanics, and technicians aiming to maintain, repair, or restore this high-performance vehicle. 🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 1996 Generation Generation Code: FD3S (Third Generation) Codes Chassis Code: FD3S Engine Code: 13B-REW 👋 Introduction Market Position Positioning: Iconic Japanese sports car, renowned for its rotary engine and exceptional handling. Positioned as a high-performance, enthusiast-focused vehicle. Competitive Analysis Competitors 1996: Nissan 300ZX (Z32), Toyota Supra (JZA80), Mitsubishi 3000GT VR-4, Porsche 968. Key Features Distinctive Features: Lightweight chassis, 50/50 weight distribution, twin-sequential turbocharging, advanced rotary engine technology, sophisticated suspension geometry. Target Audience Audience: Enthusiasts, mechanics, restorers, and owners seeking to maintain, repair, or optimize their 1996 Mazda RX-7. 📋 Manual Details Coverage Areas Engine Coverage: Rotary engine, 13B-REW, twin-turbocharged, apex seals, rotor housing, eccentric shaft, lubrication system, cooling system, fuel injection, ignition system, emissions control. Transmission Coverage: R581 5-speed manual transmission, clutch system, driveline, driveshaft, differential, axle shafts. Chassis And Suspension Coverage: Front suspension (double wishbone), rear suspension (multi-link), steering system, power steering, springs, shock absorbers, bushings, anti-roll bars. Brake System Coverage: Front disc brakes (ventilated), rear disc brakes, ABS system, brake fluid, master cylinder, calipers, rotors. Electrical System Coverage: 12V battery, alternator, starter motor, lighting system (headlights, taillights, interior), wiring diagrams, fuses, relays, ECU (Engine Control Unit), diagnostic trouble codes (DTCs). Body And Interior Coverage: Body panels, doors, hood, trunk, bumpers, glass, seats, dashboard, interior trim, HVAC system, airbags. Troubleshooting Coverage: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, repair steps for specific problems. Page Count Estimated Page Count: 1500+ Manual Type Type: Full Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered All Systems: Comprehensive coverage of all major mechanical, electrical, and body systems. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, spark plug replacement (if applicable to rotary), fluid checks and top-offs. Repair Procedures: Engine rebuild (apex seal replacement, rotor housing resurfacing), transmission overhaul, suspension component replacement, brake caliper rebuilding, electrical component diagnostics and replacement. Rebuilding Procedures: Detailed steps for rebuilding the 13B-REW engine, transmission, differential, and major sub-assemblies. Restoration Procedures: Guidance on restoring various components, bodywork repair, interior refurbishment. Diagnostic Procedures: Troubleshooting common issues like starting problems, misfires, overheating, turbocharger issues, ABS faults, and electrical gremlins. Technical Depth Depth: In-depth, factory-level technical detail suitable for professional mechanics and experienced DIY enthusiasts. Includes torque specifications, clearance measurements, and detailed exploded diagrams. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchable Text: Yes, typically searchable by keywords. Print Quality Quality: High resolution, suitable for printing individual pages or the entire manual. Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Rotary (Wankel) Engine Code: 13B-REW Aspiration: Twin-turbocharged (Sequential) Displacement Cc: 1308 Displacement Cu In: 80 Performance Horsepower Ps: 255 PS @ 6500 RPM Torque Lb Ft: 217 lb-ft @ 5000 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Premium Gasoline (91 octane or higher recommended) Lubrication System Oil Type Recommendation: API SG or SH, SAE 10W-30 or 10W-40 (refer to manual for specific conditions) Cooling System Coolant Type: Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water) Rotary Specifics Apex Seal Material: Ferro-ceramic (later models, critical for longevity) Oil Metering System: Separate oil injection system for apex seals and lubrication. 🔧 Transmission Standard Type: R581 5-Speed Manual Transmission Optional Type: None for 1996 model year in most markets. Features Gear Ratios Final Drive: Typically 4.300:1 final drive ratio (check specific market configuration) Fluid Specification Gear Oil Type: GL-5 75W-90 or 80W-90 Synthetic Gear Oil (refer to manual for precise specification) Clutch System Type: Hydraulic, single dry plate. 📐 Dimensions Exterior Length Mm: 4275 mm Width Mm: 1750 mm Height Mm: 1230 mm Wheelbase Mm: 2505 mm Weights Curb Weight Kg: 1310 kg Gross Vehicle Weight...