Mazda RX-7 Service & Repair Manual (1986 1987 1988)-PDF
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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: FC (Second Generation) Production Years Covered: 1986, 1987, 1988 👋 Introduction Market Position Vehicle Segment: Sports car, Personal luxury car Target Audience: Enthusiasts, owners seeking to perform their own maintenance and repairs Competitive Analysis Key Competitors: Nissan 300ZX, Toyota Supra, Chevrolet Camaro, Pontiac Firebird Key Features Vehicle Highlights: Rotary engine, rear-wheel drive, balanced chassis, sporty handling, distinctive styling Manual Value Proposition Manual Benefit: Enables DIY repairs, enhances vehicle understanding, aids in troubleshooting, preserves vehicle value 📋 Manual Details Coverage Areas Manual Type: Complete Official Service and Repair Manual Language: English Format: PDF Coverage Scope: All models and all engines for the specified years 📖 Manual Coverage Systems Covered Engine Mechanical: Rotary engine (13B) internal components, rebuild procedures, timing, lubrication, cooling, intake, exhaust Engine Management: Fuel injection system (EFI), ignition system, sensors, actuators, ECU diagnosis and troubleshooting Transmission: Manual (5-speed) and Automatic transmission overhaul, diagnosis, and repair Drivetrain: Clutch, driveshaft, differential, axles, wheel bearings Suspension: Front and rear suspension components, alignment specifications, shock absorbers, springs, bushings Steering: Power steering system, steering rack, tie rods, steering column Brakes: Front and rear disc brakes, ABS system (if equipped), brake fluid specifications, caliper and rotor service Electrical System: Battery, charging system, starter, lighting, horn, wipers, power windows, mirrors, audio system wiring diagrams HVAC: Heating, ventilation, and air conditioning system diagnosis and service Body And Chassis: Body panel removal and installation, interior trim, glass replacement, chassis components Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement (rotary equivalent), belt inspections Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, fault code interpretation Major Repairs: Engine overhaul, transmission rebuild, suspension component replacement, brake system service Component Rebuilds: Detailed instructions for rebuilding specific components like the alternator, starter, fuel injectors, etc. Wiring Diagrams: Comprehensive electrical system wiring schematics for all major systems Technical Depth Depth Level: Factory-level repair and diagnostic information Diagnostic Tools: Information on required specialized tools and diagnostic equipment Specifications Data: Torque values, clearances, fluid capacities, electrical resistances, pressure readings 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (depending on original source scan quality) Printability: Printable pages for workshop use Digital Quality: Comprehensive, high-detail digital reproduction of original factory manual content Print Quality Source Material: Official Mazda factory service manual Resolution: High-resolution scans for clarity of text and diagrams Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Rotary (Wankel) Engine Code: 13B Rotor Displacement: 654cc per rotor (1308cc total displacement equivalent) Aspirated Variant Power: Approximately 145-160 hp (depending on market and specific model year) Turbocharged Variant Power: Approximately 182-200 hp (for Turbo II models) Turbocharged Variant Torque: Approximately 183-200 lb-ft (for Turbo II models) Performance Redline: Typically around 7000-7500 RPM Special Characteristics: Smooth operation, high-revving nature, unique sound, compact size Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Octane Rating: Premium unleaded (91+ octane recommended, especially for turbocharged models) Maintenance Considerations Apex Seals: Critical wear item requiring careful monitoring and potential replacement Oil Consumption: Rotary engines consume a small amount of oil as part of their lubrication system; this is normal and needs monitoring. 🔧 Transmission Standard Type Std: 5-speed manual transaxle Optional Type Opt: 4-speed automatic transaxle Features Drivetrain Layout: Rear-wheel drive (RWD) Clutch Type: Hydraulically actuated single-plate dry clutch Fluid Specifications Manual Transmission Fluid: GL-5 75W-90 gear oil (Mazda recommends specific grades, check manual for exact spec) Automatic Transmission Fluid: Dexron II or equivalent (Mazda specifies type, consult manual) 📐 Dimensions Exterior Wheelbase: Approximately 95.7 inches (2430 mm) Length: Approximately 168.7 inches (4285 mm) Width: Approximately 67.7 inches (1720 mm) Height: Approximately 49.2 inches (1250 mm) Weights Curb Weight: Approximately 2800-3100 lbs (1270-1406 kg) depending on trim and equipment 🛡️ Safety Features Ratings Crash Test Data: Limited public crash test data available for this era, but known for robust chassis construction for its time. Active Features Braking System: Front and rear disc brakes; ABS available on some higher trims/models Suspension Tuning: Designed for excellent handling and stability Passive Features Seat Belts: 3-point seat belts Body Structure: Reinforced safety cell structure 💡 Technology Features Infotainment Audio System: Factory-equipped radio with cassette player, often with optional graphic equalizer or CD player on higher trims. Dashboard Features: Analog gauges, including tachometer, speedometer, oil pressure, water temperature, and voltage meter. Driver Assistance ABS: Anti-lock Braking System available as an option or standard on certain models/trims. Limited Slip Differential: Optional on some models for improved traction. Connectivity Connectivity Features: Basic analog connectivity; no modern smartphone integration or Bluetooth. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 6 months (depending on driving conditions and oil used). Spark Plug Replacement: Check and replace as per manual recommendations; often requires specific platinum or iridium plugs...
Premium unleaded (91+ octane recommended, especially for turbocharged models)
Maintenance Considerations
Apex Seals:
Critical wear item requiring careful monitoring and potential replacement
Oil Consumption:
Rotary engines consume a small amount of oil as part of their lubrication system; this is normal and needs monitoring.
🔧 Transmission
Standard
Type Std:
5-speed manual transaxle
Optional
Type Opt:
4-speed automatic transaxle
Features
Drivetrain Layout:
Rear-wheel drive (RWD)
Clutch Type:
Hydraulically actuated single-plate dry clutch
Fluid Specifications
Manual Transmission Fluid:
GL-5 75W-90 gear oil (Mazda recommends specific grades, check manual for exact spec)
Automatic Transmission Fluid:
Dexron II or equivalent (Mazda specifies type, consult manual)
📐 Dimensions
Exterior
Wheelbase:
Approximately 95.7 inches (2430 mm)
Length:
Approximately 168.7 inches (4285 mm)
Width:
Approximately 67.7 inches (1720 mm)
Height:
Approximately 49.2 inches (1250 mm)
Weights
Curb Weight:
Approximately 2800-3100 lbs (1270-1406 kg) depending on trim and equipment
🛡️ Safety Features
Ratings
Crash Test Data:
Limited public crash test data available for this era, but known for robust chassis construction for its time.
Active Features
Braking System:
Front and rear disc brakes; ABS available on some higher trims/models
Suspension Tuning:
Designed for excellent handling and stability
Passive Features
Seat Belts:
3-point seat belts
Body Structure:
Reinforced safety cell structure
💡 Technology Features
Infotainment
Audio System:
Factory-equipped radio with cassette player, often with optional graphic equalizer or CD player on higher trims.
Dashboard Features:
Analog gauges, including tachometer, speedometer, oil pressure, water temperature, and voltage meter.
Driver Assistance
ABS:
Anti-lock Braking System available as an option or standard on certain models/trims.
Limited Slip Differential:
Optional on some models for improved traction.
Connectivity
Connectivity Features:
Basic analog connectivity; no modern smartphone integration or Bluetooth.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months (depending on driving conditions and oil used).
Spark Plug Replacement:
Check and replace as per manual recommendations; often requires specific platinum or iridium plugs for rotary engines, with a periodic change of the leading and trailing plugs.
Coolant Flush:
Every 2-3 years or 30,000 miles.
Timing Belt Replacement:
N/A (Rotary engines do not have timing belts; they use a chain or gears internally for rotor timing, which is part of engine rebuild).
Fluid Specifications
Engine Oil Type:
API SG or higher, viscosity 10W-30 or 10W-40 recommended (check manual for specific OEM recommendations).
Engine Oil Capacity:
Approximately 5.1 quarts (4.8 L) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Mazda FL22 or equivalent).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Apex Seal Wear:
Premature wear or failure leading to loss of compression and starting issues.
Oil Seals:
Rotary oil seals (especially front and rear main seals) can degrade over time, leading to oil leaks or internal oil consumption.
Cooling System:
Overheating due to inefficient radiator or coolant leaks; specific rotary cooling system design can be sensitive.
Turbocharger Reliability:
Early turbo models can be susceptible to turbocharger failure if not properly maintained or if pushed too hard without proper warm-up/cool-down.
Ignition System:
Degradation of ignition coils, wires, or distributors can lead to misfires and poor performance.
📚 Vehicle History
Brand Heritage
Mazda Rotary Legacy:
Mazda's pioneering and continued development of the Wankel rotary engine, starting with the Cosmo.
Model Evolution
Rx-7 Generations:
The FC generation (1986-1992) followed the FB (SA/FB) and preceded the highly acclaimed FD generation.
Fc Development:
Styled partly by Satoru Tomonaga and designed with input from Porsche consultants, featuring a more sophisticated and aerodynamic design than its predecessor.
Production
Manufacturing Plant:
Mazda Hiroshima Plant, Japan
Sales Performance:
Popular sports car globally, particularly in the late 1980s and early 1990s, contributing to Mazda's performance image.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The FC RX-7 was named to Car and Driver's Ten Best list in 1986 and 1987.
Motor Trend Import Car Of The Year:
While the first generation RX-7 won this award, the FC continued to build Mazda's reputation for sporty, well-engineered vehicles.
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