1989 1990 1991 Mazda RX7 Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Model Code: FC3S (Type II Turbo), FC3C (Convertible), SA22C (Early models, though manual specifies FC generation) Generation: Second Generation (FC) Production Years Covered: 1989, 1990, 1991 Codes Manual Part Number Typical: Likely multiple, often indicated by body style or engine type (e.g., S2W, S2U for specific models/regions) 👋 Introduction Market Position Positioning: The Mazda RX-7 (FC) was a quintessential Japanese sports coupe of its era, positioned as a stylish, performance-oriented, and technologically advanced vehicle, directly competing with cars like the Toyota Supra, Nissan 300ZX, and Chevrolet Camaro/Pontiac Firebird. Competitive Analysis Key Competitors: Toyota Supra MkIII (A70), Nissan 300ZX (Z32), Mitsubishi Starion/Chrysler Conquest, Porsche 944. Key Features Distinctive Attributes: The rotary engine's unique power delivery, lightweight chassis, near 50/50 weight distribution, pop-up headlights, and stylish aerodynamic design were its defining characteristics. Manual Value Proposition Value For Owners: This manual is indispensable for RX-7 owners seeking to maintain, diagnose, and repair their vehicles with factory-correct procedures and specifications, crucial for preserving the unique rotary engine's longevity and performance. 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive service and repair for all major systems of the 1989-1991 Mazda RX-7 (FC generation). Engine Coverage: Rotary engine (13B) maintenance, diagnosis, overhaul, and component repair, including fuel injection and ignition systems. Transmission Coverage: Manual and automatic transmission repair, overhaul, clutch service, and driveshaft components. Chassis Coverage: Suspension (front struts, rear multi-link), steering system (power steering), brake system (ABS diagnosis for applicable models), and wheel/tire specifications. Electrical Coverage: Complete wiring diagrams, diagnostic procedures for engine control, lighting, accessories, instrument cluster, and power windows/locks. Body Coverage: Exterior panel repair, interior trim removal and installation, glass replacement, and body hardware adjustments. Page Count Estimated Page Count: ~1500-2000+ pages (typically a multi-volume set or a very thick single volume). Manual Type Type: Factory Service Manual (FSM) / Repair Manual. Language Language: English. Format Format: Likely a physical printed manual. If digital, typically PDF. 📖 Manual Coverage Systems Covered Engine Management: Fuel injection (Bosch L-Jetronic or similar ECU controlled), ignition system (distributorless ignition system for later models, or distributor), emissions control systems (air pump, catalytic converter). Cooling System: Radiator, water pump, thermostat, coolant flow paths, cooling fan operation. Rotary Specific: Apex seal inspection and replacement, rotor housing clearance, eccentric shaft checks, oil metering system (SAS/JMS). Suspension And Steering: Front MacPherson strut, rear independent multi-link, anti-roll bars, power steering pump and rack, steering angle sensor (if equipped). Braking System: Front and rear disc brakes, ABS (Anti-lock Braking System) troubleshooting and component identification, brake fluid specifications. Electrical Systems: Battery, alternator, starter motor, lighting circuits (headlights, taillights, interior), horn, wipers, power accessories, fuse and relay locations. Climate Control: Air conditioning system (R134a or R12 refrigerant type depending on production date/region), heater core, blower motor, HVAC controls. Lubrication System Engine Oil System: Oil pump, oil filter location, oil pressure specifications, oil cooler operation. Procedures Included Routine Maintenance: Oil and filter changes, spark plug replacement, air filter replacement, coolant flush, brake pad inspection/replacement, belt tensioning. Engine Overhaul: Complete engine teardown, component measurement (rotor housing wear, apex seal groove depth), reassembly, and torque specifications. Troubleshooting: Diagnostic flowcharts for common drivability issues, starting problems, electrical faults, and system malfunctions. Component Replacement: Step-by-step instructions for replacing parts such as starter motor, alternator, fuel pump, water pump, clutch, brake calipers, shock absorbers, and radiators. Diagnostic Procedures: Use of diagnostic tools (e.g., timing light, multimeter), interpreting sensor data, checking for vacuum leaks, and understanding ECU diagnostic codes (if applicable). Emission Control Service: Service of air injection systems, EGR valve (if equipped), and catalytic converter troubleshooting. Technical Depth Depth Level: Expert-level diagnostic and repair procedures suitable for professional mechanics and experienced DIY enthusiasts. Specific Procedures: Detailed steps for setting ignition timing, adjusting idle speed control, rebuilding fuel injectors, and torque specifications for all critical fasteners. Diagnostic Charts: Extensive troubleshooting flowcharts based on symptoms, providing systematic diagnosis. Wiring Diagrams: Comprehensive and high-resolution wiring schematics for all vehicle systems, color-coded and clearly labeled. 📊 Manual Specifications File Format Digital Format: If digital, typically PDF. Searchable text and clear image rendering are critical. Print Quality Print Quality: High-quality paper stock, clear black and white text, and legible diagrams/illustrations. Professional binding is essential for durability. Binding Type Binding Type: Professional bookbinding (e.g., spiral bound, perfect bound, or multi-ring binder) to withstand frequent use in a workshop environment. Paper Type Paper Type: Durable, non-glossy paper suitable for workshop conditions, resistant to grease and smudging. ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated and Turbocharged Rotary (Wankel). Engine Code: 13B Rotor Housing: 1.3L (654cc x 2 rotors), often advertised as 2.6L equivalent displacement. Compression Ratio: Naturally Aspirated: 9.7:1, Turbocharged: 8.5:1 (approximate). Performance Horsepower Na: 160 hp @ 6500 rpm (approximate, varies by market). Horsepower Turbo: 200 hp @ 6500 rpm (Turbo II, TII). Torque Na: 145 lb-ft @ 3500...

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Tags: 1989 1990 1991 Amplifiers Audio Equipment Audio Note Car Electronics Mazda RX7

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Model Code:

FC3S (Type II Turbo), FC3C (Convertible), SA22C (Early models, though manual specifies FC generation)

Generation:

Second Generation (FC)

Production Years Covered:

1989, 1990, 1991

Codes

Manual Part Number Typical:

Likely multiple, often indicated by body style or engine type (e.g., S2W, S2U for specific models/regions)

👋 Introduction

Market Position

Positioning:

The Mazda RX-7 (FC) was a quintessential Japanese sports coupe of its era, positioned as a stylish, performance-oriented, and technologically advanced vehicle, directly competing with cars like the Toyota Supra, Nissan 300ZX, and Chevrolet Camaro/Pontiac Firebird.

Competitive Analysis

Key Competitors:

Toyota Supra MkIII (A70), Nissan 300ZX (Z32), Mitsubishi Starion/Chrysler Conquest, Porsche 944.

Key Features

Distinctive Attributes:

The rotary engine's unique power delivery, lightweight chassis, near 50/50 weight distribution, pop-up headlights, and stylish aerodynamic design were its defining characteristics.

Manual Value Proposition

Value For Owners:

This manual is indispensable for RX-7 owners seeking to maintain, diagnose, and repair their vehicles with factory-correct procedures and specifications, crucial for preserving the unique rotary engine's longevity and performance.

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive service and repair for all major systems of the 1989-1991 Mazda RX-7 (FC generation).

Engine Coverage:

Rotary engine (13B) maintenance, diagnosis, overhaul, and component repair, including fuel injection and ignition systems.

Transmission Coverage:

Manual and automatic transmission repair, overhaul, clutch service, and driveshaft components.

Chassis Coverage:

Suspension (front struts, rear multi-link), steering system (power steering), brake system (ABS diagnosis for applicable models), and wheel/tire specifications.

Electrical Coverage:

Complete wiring diagrams, diagnostic procedures for engine control, lighting, accessories, instrument cluster, and power windows/locks.

Body Coverage:

Exterior panel repair, interior trim removal and installation, glass replacement, and body hardware adjustments.

Page Count

Estimated Page Count:

~1500-2000+ pages (typically a multi-volume set or a very thick single volume).

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual.

Language

Language:

English.

Format

Format:

Likely a physical printed manual. If digital, typically PDF.

📖 Manual Coverage

Systems Covered

Engine Management:

Fuel injection (Bosch L-Jetronic or similar ECU controlled), ignition system (distributorless ignition system for later models, or distributor), emissions control systems (air pump, catalytic converter).

Cooling System:

Radiator, water pump, thermostat, coolant flow paths, cooling fan operation.

Rotary Specific:

Apex seal inspection and replacement, rotor housing clearance, eccentric shaft checks, oil metering system (SAS/JMS).

Suspension And Steering:

Front MacPherson strut, rear independent multi-link, anti-roll bars, power steering pump and rack, steering angle sensor (if equipped).

Braking System:

Front and rear disc brakes, ABS (Anti-lock Braking System) troubleshooting and component identification, brake fluid specifications.

Electrical Systems:

Battery, alternator, starter motor, lighting circuits (headlights, taillights, interior), horn, wipers, power accessories, fuse and relay locations.

Climate Control:

Air conditioning system (R134a or R12 refrigerant type depending on production date/region), heater core, blower motor, HVAC controls.

Lubrication System

Engine Oil System:

Oil pump, oil filter location, oil pressure specifications, oil cooler operation.

Procedures Included

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter replacement, coolant flush, brake pad inspection/replacement, belt tensioning.

Engine Overhaul:

Complete engine teardown, component measurement (rotor housing wear, apex seal groove depth), reassembly, and torque specifications.

Troubleshooting:

Diagnostic flowcharts for common drivability issues, starting problems, electrical faults, and system malfunctions.

Component Replacement:

Step-by-step instructions for replacing parts such as starter motor, alternator, fuel pump, water pump, clutch, brake calipers, shock absorbers, and radiators.

Diagnostic Procedures:

Use of diagnostic tools (e.g., timing light, multimeter), interpreting sensor data, checking for vacuum leaks, and understanding ECU diagnostic codes (if applicable).

Emission Control Service:

Service of air injection systems, EGR valve (if equipped), and catalytic converter troubleshooting.

Technical Depth

Depth Level:

Expert-level diagnostic and repair procedures suitable for professional mechanics and experienced DIY enthusiasts.

Specific Procedures:

Detailed steps for setting ignition timing, adjusting idle speed control, rebuilding fuel injectors, and torque specifications for all critical fasteners.

Diagnostic Charts:

Extensive troubleshooting flowcharts based on symptoms, providing systematic diagnosis.

Wiring Diagrams:

Comprehensive and high-resolution wiring schematics for all vehicle systems, color-coded and clearly labeled.

📊 Manual Specifications

File Format

Digital Format:

If digital, typically PDF. Searchable text and clear image rendering are critical.

Print Quality

Print Quality:

High-quality paper stock, clear black and white text, and legible diagrams/illustrations. Professional binding is essential for durability.

Binding Type

Binding Type:

Professional bookbinding (e.g., spiral bound, perfect bound, or multi-ring binder) to withstand frequent use in a workshop environment.

Paper Type

Paper Type:

Durable, non-glossy paper suitable for workshop conditions, resistant to grease and smudging.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated and Turbocharged Rotary (Wankel).

Engine Code:

Rotor Housing:

1.3L (654cc x 2 rotors), often advertised as 2.6L equivalent displacement.

Compression Ratio:

Naturally Aspirated: 9.7:1, Turbocharged: 8.5:1 (approximate).

Performance

Horsepower Na:

160 hp @ 6500 rpm (approximate, varies by market).

Horsepower Turbo:

200 hp @ 6500 rpm (Turbo II, TII).

Torque Na:

145 lb-ft @ 3500 rpm (approximate).

Torque Turbo:

195 lb-ft @ 3500 rpm (Turbo II, TII).

Fuel System

Fuel Delivery:

Fuel Injection (Bosch L-Jetronic or similar electronic fuel injection system).

Fuel Type:

Unleaded gasoline, 87 octane minimum, 91 octane recommended for turbocharged models.

Engine Oil

Oil Type Recommendation:

API SG or higher, SAE 10W-30 or 10W-40. For rotary engines, it's critical to use oil that mixes with fuel or is injected by the SAS system for apex seal lubrication.

Oil Capacity:

5.3 US quarts (5.0 liters) with filter change.

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission.

Optional

Optional Transmission:

4-speed automatic transmission.

Features

Clutch Type:

Hydraulically operated, single dry plate clutch.

Fluid Specs

Manual Transmission Fluid:

API GL-4 or GL-5 SAE 75W-90 synthetic gear oil recommended.

Automatic Transmission Fluid:

Dexron III or equivalent ATF.

📐 Dimensions

Exterior

Length:

175.2 inches (4450 mm) (Coupe/GT-S).

Width:

69.1 inches (1755 mm).

Height:

50.2 inches (1275 mm) (Coupe).

Wheelbase:

95.7 inches (2430 mm).

Weights

Curb Weight:

~2900-3100 lbs (1315-1406 kg), depending on trim and options.

🛡️ Safety Features

Ratings

NHTSA Ratings:

Specific NHTSA ratings for these years are not readily available, but generally considered safe for its era. Focus was on handling and braking.

Active Features

Optional Anti-lock Braking System (ABS) available on some models.

Traction Control:

Not typically available on this generation.

Passive Features

Airbags:

Driver's side airbag standard from late 1989/1990 models onwards. Passenger airbag not standard.

Seatbelts:

3-point front seat belts with pretensioners.

Chassis Design:

Reinforced chassis and crumple zones for the period.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette stereo systems, often with premium speaker options. CD players were rare or aftermarket.

Climate Control Interface:

Manual or automatic climate control systems with rotary dials or buttons.

Driver Assistance

Cruise Control:

Standard on most models.

Power Features:

Power windows, power door locks, power mirrors were common options.

Connectivity

OBD Ii:

Not applicable. Diagnostic systems rely on basic fault codes and multimeter readings, as OBD-II was not standard until the mid-1990s.

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first. Rotary engines require more frequent changes.

Spark Plugs:

Typically every 30,000 miles (48,000 km). Specific platinum or iridium plugs are recommended.

Timing Belt:

Not applicable (rotary engines do not have timing belts or chains for valve timing).

Coolant Flush:

Every 2-3 years or 30,000 miles (48,000 km).

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

Dexron II or equivalent ATF.

Known Issues

Apex Seals:

Wear and failure of apex seals due to improper lubrication or overheating are common. Regular apex seal lubrication is critical.

Oil Metering System:

Failure of the oil metering system (SAS/JMS) can lead to premature apex seal wear. Routine checks are vital.

Rotary Specific Maintenance:

Carbon buildup in the exhaust port and rotor housings can occur, often requiring periodic de-carbonization.

Cooling System Reliability:

Overheating can be an issue, especially for turbocharged models, due to the engine's compact design and heat generation. Ensuring the cooling system is in optimal condition is paramount.

Fuel System Clogging:

Aging fuel injectors and fuel pumps can lead to performance issues or difficulty starting.

📚 Vehicle History

Brand Heritage

Mazda Rotary:

Mazda's long and storied history with the Wankel rotary engine, beginning with the Cosmo Sport and continuing through iconic models like the RX-7 and RX-8.

Model Evolution

First Generation:

SA22C (1978-1985): Introduced the RX-7 lineage with a focus on lightweight sportiness.

Second Generation Fc:

FC3S/FC3C (1985-1992): Redesigned with a more sophisticated chassis, advanced suspension, and more powerful turbocharging options. This generation is characterized by its 'Savanna RX-7' badging in Japan.

Third Generation:

FD3S (1992-2002): Further evolution of rotary power and chassis dynamics, often considered the pinnacle of the RX-7 lineage.

Production

Manufacturing Location:

Japan.

Sales Peak:

The FC generation saw strong sales in its early years, benefiting from Mazda's reputation for reliable and sporting vehicles.

🏆 Awards & Recognition

Recognitions

Car And Driver:

Car and Driver's 'Ten Best' list multiple times during its production run for its performance and handling.

Road And Track:

Frequently praised by automotive journalists for its driving dynamics and innovative rotary engine technology.

Ratings

Jdp Power:

Specific J.D. Power ratings for this generation are not a primary focus for this model's appeal, which is more driven by enthusiast and performance credentials.