The 1999 Mazda RX-7 (chassis code FD3S) is a celebrated JDM icon, distinguished by its innovative 13B-REW rotary engine featuring sequential twin-turbocharging. This rear-wheel-drive sports car, produced by Mazda, a company with a rich heritage in rotary engine development, offers exceptional handling and a unique driving experience. Its lightweight construction and advanced chassis contribute to its performance, making it a standout in the sports car market of its era. The RX-7 has earned accolades, including appearances on Car and Driver's 'Ten Best' list, solidifying its status as an iconic vehicle with a dedicated enthusiast following. This comprehensive English-language service manual provides in-depth technical information for the repair, maintenance, and restoration of the 1999 Mazda RX-7. It covers all major systems, including the rotary engine, fuel, intake, exhaust, cooling, lubrication, ignition, electrical, transmission, brakes, steering, suspension, body, and interior. Detailed procedures for routine maintenance, component replacement, troubleshooting, and diagnostics are included, offering essential guidance for owners and professional technicians alike. The manual's extensive coverage ensures that users can effectively maintain the performance and longevity of this sophisticated rotary-powered sports car. 🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 1999 Codes Chassis Code: FD3S Engine Code: 13B-REW 👋 Introduction Market Position Positioning: The Mazda RX-7 (FD) is a legendary JDM icon, celebrated for its groundbreaking twin-rotor rotary engine, sophisticated chassis, and striking design. It occupied a niche in the sports car market, competing with cars like the Nissan 300ZX, Toyota Supra, and Mitsubishi 3000GT. Competitive Analysis Competitors: Nissan 300ZX (Z32), Toyota Supra (Mk. IV), Mitsubishi 3000GT VR-4, Porsche 968, Chevrolet Corvette. Key Features Unique Selling Points: Naturally aspirated rotary engine (13B-REW) with sequential twin-turbocharging, lightweight construction, exceptional handling and balance, iconic styling, rear-wheel drive. This manual provides the in-depth knowledge required to maintain and repair this complex and performance-oriented vehicle. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair, maintenance, rebuild, refurbish, and restoration of the 1999 Mazda RX-7. Page Count Estimated Page Count: Extensive, likely over 1000 pages based on typical full service manuals for performance vehicles. Manual Type Type: Full Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine System: Rotary engine (13B-REW), including theory of operation, disassembly, assembly, inspection, troubleshooting, and component replacement for apex seals, rotor housings, rotors, eccentric shaft, oil metering, cooling, lubrication, and ignition systems. Fuel System: Fuel injection system (sequential twin-turbo), fuel pump, fuel injectors, fuel pressure regulator, fuel lines, evaporative emissions control (EVAP). Exhaust System: Catalytic converter, mufflers, exhaust manifold, oxygen sensors, emission control components. Intake System Intake: Air intake system, air filter, mass airflow sensor (MAF), intake manifold, intercooler system, twin-turbocharger operation and diagnosis. Cooling System Cooling: Radiator, cooling fans, coolant hoses, thermostat, water pump, coolant flow, temperature sensor. Lubrication System Lubrication: Engine oil sump, oil pump, oil filter, oil cooler, oil metering system (premix or separate injection). Ignition System Ignition: Ignition coils, spark plugs, ignition timing, ECU control of ignition. Electrical System Electrical: Wiring diagrams, battery, alternator, starter motor, fuses, relays, lighting systems, horn, wipers, power windows, power locks, instrument cluster, dashboard warning lights. Transmission System Transmission: Manual transmission (R154 or similar, if applicable to specific FD market or variant), clutch system, clutch hydraulics, flywheel, driveshaft, differential, axle shafts, gearbox overhaul and repair. Brakes System Brakes: Front and rear disc brakes, ABS system, brake calipers, brake rotors, brake pads, brake lines, brake fluid specifications, parking brake, bleeding procedure. Steering System Steering: Power steering system, steering rack, steering column, steering wheel, tie rods, power steering fluid. Suspension System Suspension: Front and rear suspension (double wishbone), shock absorbers, springs, anti-roll bars, bushings, ball joints, wheel alignment specifications. Body And Frame Body: Chassis structure, body panels, doors, hood, trunk, bumpers, glass, seals, rust prevention and repair, paint codes. Interior Interior: Seating systems, dashboard, instrument panel, center console, door panels, headliner, seat belts, airbag system (if equipped). Climate Control HVAC: Air conditioning system, heater core, blower motor, evaporator, condenser, refrigerant type and capacity, climate control unit. Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical diagnostic procedures, component testing. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, air filter replacement, belt inspection and replacement. Engine Rebuild: Complete engine disassembly, cleaning, inspection, measurement, part replacement (apex seals, O-rings, gaskets), and reassembly procedures for the 13B-REW rotary engine. Turbocharger Service: Inspection, repair, and replacement of the sequential twin-turbocharger system. Transmission Overhaul: Step-by-step instructions for disassembling, inspecting, and reassembling the manual transmission. Brake System Repair: Brake pad and rotor replacement, caliper service, bleeding the brake system, ABS component diagnosis. Suspension Component Replacement: Replacement of shock absorbers, springs, bushings, and ball joints. Electrical Diagnostics: Tracing electrical faults using wiring diagrams, testing components, and repairing wiring harnesses. Body Panel Alignment: Adjustments and replacement of body panels for proper fit and finish. Interior Trim Removal: Instructions for...