1987 Mazda RX-7 (2nd gen) Service and Repair Manual
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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation Generation Designation: Second Generation (FC) Codes Chassis Code: FC3S Engine Code: 13B 👋 Introduction Market Position Positioning: High-performance sports coupe, known for its unique rotary engine and balanced chassis Competitive Analysis Competitors: Toyota Supra, Nissan 300ZX, Chevrolet Camaro, Pontiac Firebird, Porsche 944 Key Features Design: Sleek, aerodynamic 'boxy' design characteristic of the 1980s, often compared to European sports cars Engine Type: Naturally aspirated and turbocharged rotary engine configurations Handling: Emphasis on balanced weight distribution and agile handling due to the compact rotary engine Trim Levels: Base models, GT, GXL, Turbo, Turbo II 📋 Manual Details Coverage Areas Primary Coverage: All models and all repairs A-Z Page Count Estimated Page Count: 1000+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Printed 📖 Manual Coverage Systems Covered Engine: Rotary Wankel engine (13B), including teardown, assembly, troubleshooting, and specifications Fuel System: Fuel injection (EFI), fuel pump, injectors, fuel pressure regulator, fuel tank, and lines Cooling System: Radiator, water pump, thermostat, hoses, cooling fan operation Ignition System: Ignition timing, spark plugs, ignition coils, distributor (if applicable), ECU control Transmission: Manual transmission (MT) and automatic transmission (AT) service, overhaul, and adjustment Drivetrain: Driveshafts, differential, axle shafts, wheel bearings Suspension: Front and rear suspension, struts, springs, control arms, bushings, alignment specifications Steering: Power steering system, steering rack, steering column, tie rods Brakes: Disc brakes (front and rear), ABS system (if equipped), brake pads, rotors, calipers, brake lines, parking brake Electrical System: Battery, alternator, starter motor, lighting system, fuses, relays, wiring diagrams, ECU, sensors HVAC: Air conditioning system, heater, ventilation, blower motor, controls Bodywork: Body panel removal and installation, glass, trim, doors, hood, trunk, interior components Chassis: Frame and structural components, torque specifications for fasteners Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug service, fluid checks and replacements Troubleshooting: Diagnostic procedures, common fault identification, symptom-based troubleshooting charts Repair: Detailed step-by-step repair instructions for all major and minor components Overhaul: Complete engine and transmission overhaul procedures Rebuilding: Component rebuilding guidance Diagnostics: Electrical system diagnostics, sensor testing, ECU troubleshooting Adjustments: Engine timing, idle speed, clutch adjustment, parking brake adjustment Technical Depth Depth Level: Comprehensive, covering basic maintenance to full engine rebuilds and complex diagnostics 📊 Manual Specifications File Format File Type: N/A (Printed Manual) Print Quality Print Quality: High-quality reproduction of original factory documentation Binding Type Binding: Stapled or perfect bound (typical for service manuals) Paper Type Paper Quality: Durable, high-quality paper designed for workshop use ⚙️ Engine Specifications Primary Engine Engine Type: Mazda 13B Rotary (Wankel) Displacement: 1.3 L (79.3 cu in) Performance Naturally Aspirated Hp: 145-160 hp (approx., depending on market and trim) Turbocharged Hp: 182-200 hp (Turbo and Turbo II models, approx.) Torque: Varies by model, typically 150-180 lb-ft (approx.) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Octane rating important for rotary engines) Rotary Specifics Apex Seals: Critical wear component, manual details inspection and replacement Oil Injection: Separate oil metering system for apex seals, manual covers maintenance 🔧 Transmission Standard Type: 5-speed manual transmission Optional Type: 4-speed automatic transmission Features Clutch: Hydraulic clutch actuation 📐 Dimensions Exterior Length: 169.1 in (4300 mm) Width: 69.1 in (1755 mm) Height: 49.4 in (1255 mm) Wheelbase: 95.7 in (2430 mm) Weights Curb Weight: Approx. 2,700 - 3,000 lbs (1225 - 1360 kg), varies by model 🛡️ Safety Features Ratings NHTSA Ratings: N/A for this era, but designed to meet safety standards of the time Active Features ABS: Anti-lock Braking System (ABS) available on some models, particularly Turbo II Passive Features Seatbelts: 3-point retractable seatbelts Body Structure: Reinforced safety cage construction 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional premium sound systems. Driver Assistance Cruise Control: Standard on most models. Connectivity N/A: No modern connectivity features like Bluetooth or USB. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 miles or 6 months (consult manual for exact specs based on driving conditions). Spark Plug Replacement: Specific interval for rotary spark plugs, consult manual. Timing Belt Replacement: N/A (Rotary engines do not have timing belts; they use a timing chain or gears). Fluid Specifications Engine Oil: API SG/SH, Viscosity 10W-30 or 10W-40 recommended. Crucial to use quality oil. (Verify with manual for specific grades). Coolant: Mazda specific coolant or equivalent ethylene glycol-based coolant, typically 50/50 mix with distilled water. Transmission Fluid Mt: API GL-4 or GL-5 gear oil, SAE 75W-90 recommended. (Verify with manual). Transmission Fluid At: Dexron II or equivalent automatic transmission fluid. (Verify with manual). Brake Fluid: DOT 3 or DOT 4 brake fluid. Power Steering Fluid: Dexron II or equivalent power steering fluid. Known Issues Apex Seals: Wear of apex seals leading to loss of compression and starting issues is a common rotary concern. Maintenance and proper operation are key. Carbon Buildup:...