1989 Mazda RX-7 (2nd gen) Service and Repair Manual
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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 1989 Codes Chassis Code: FC3S Generation Designation: Second Generation (FC) 👋 Introduction Market Position Market Segment: Sports Car, Rear-Wheel Drive Coupe Design Philosophy: Focus on lightweight design, balanced handling, and innovative rotary engine technology. Competitive Analysis Primary Competitors: Nissan 300ZX (Z31), Toyota Supra (MkII/MkIII), Porsche 944, Chevrolet Camaro/Pontiac Firebird Key Features Rotary Engine: The signature Wankel rotary engine, offering a unique power delivery and high-revving character. Handling: Renowned for its balanced chassis, sophisticated suspension, and predictable handling characteristics. Styling: Sleek, aerodynamic design with pop-up headlights, a hallmark of 1980s sports cars. 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Information Type: Vehicle Specific (not generic) Target Audience: Dealership Technicians, Professional Mechanics, Enthusiasts Page Count Estimated Page Count: Over 1500 pages (typical for comprehensive factory service manuals of this era) Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Printed Book (Original Factory Publication) Print Quality: High-quality original factory printing with clear diagrams and text. Binding Type: Original factory binding (typically hardcover or sturdy softcover with professional binding). Paper Type: Durable, high-quality paper designed for workshop use. 📖 Manual Coverage Systems Covered Engine Systems: Rotary Engine (13B), Lubrication, Cooling, Fuel Injection, Ignition, Emissions Control Drivetrain: Manual Transmission, Automatic Transmission, Clutch, Driveshaft, Differential, Axles Suspension Steering: Front Suspension (MacPherson Strut), Rear Suspension (Independent Multi-link), Power Steering System, Steering Gear Brakes: Front Disc Brakes, Rear Disc Brakes, Anti-lock Braking System (ABS), Parking Brake Electrical Electronics: Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Fuses, Relays, ECU (Engine Control Unit), Immobilizer (if equipped), Audio System Body Chassis: Body Construction, Exterior Trim, Interior Trim, Doors, Hood, Trunk, Seats, Glass HVAC: Air Conditioning System, Heater System, Ventilation Procedures Included Maintenance Procedures: Scheduled Maintenance, Oil Changes, Filter Replacements, Tune-ups, Fluid Level Checks and Replacements Repair Procedures: Engine Overhaul/Rebuild (Rotary Specific), Transmission Overhaul, Brake Caliper Rebuild, Suspension Component Replacement, Electrical Component Diagnosis and Repair, Body Panel Repair Troubleshooting: Diagnostic Flowcharts, Symptom-based Troubleshooting Guides, Error Code Explanations (for ECU) Diagnostics: Wiring Diagrams, Component Testing Procedures, Specifications for Measurement Special Tools: Identification and usage of specialized Mazda tools required for specific repairs Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and assembly instructions. ⚙️ Engine Specifications Primary Engine Engine Type: Rotary (Wankel) Engine Code: 13B Configuration: Naturally Aspirated (NA) and Turbocharged (Turbo) Displacement: 1.3 Liters (654cc x 2 rotors) Performance Horsepower Na: Approx. 145-160 hp (depending on specific market and minor revisions) Torque Na: Approx. 130-140 lb-ft Horsepower Turbo: Approx. 200 hp (Turbo II model) Torque Turbo: Approx. 200-210 lb-ft (Turbo II model) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Recommended Fuel: Unleaded Gasoline (Octane rating specified in manual, typically 91+ for optimal performance) Cooling System Cooling Type: Liquid-cooled Lubrication System Lubrication Type: Oil sump with oil injection system for apex seals. Oil Type Specification: API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for specific ambient temperature ranges). Rotary Specifics Apex Seals: Critical wear components requiring specific lubrication and maintenance. Oil Metering Pump: Responsible for injecting lubricating oil into the combustion chambers. 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission Features Clutch Type: Hydraulically Actuated, Single Dry Plate (Manual) Transmission Fluid Manual: API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (refer to manual for specific viscosity recommendations based on temperature). Transmission Fluid Automatic: Dexron III or equivalent ATF (Automatic Transmission Fluid) 📐 Dimensions Exterior Length: Approx. 172.0 inches (4369 mm) Width: Approx. 68.7 inches (1745 mm) Height: Approx. 49.8 inches (1265 mm) Wheelbase: Approx. 95.7 inches (2430 mm) Weights Curb Weight: Approx. 2800-3100 lbs (1270-1406 kg) depending on trim and options Gross Vehicle Weight Rating: Refer to vehicle's compliance plate (typically around 3700 lbs) Cargo Trunk Capacity: Limited, typical for a sports coupe. Specific volume not readily available but functional for weekend luggage. 🛡️ Safety Features Ratings NHTSA Ratings: As an older vehicle, specific NHTSA ratings from that era may be limited or unavailable in modern databases. The structure was designed for sporty performance. Active Features ABS: Available on higher trims and Turbo models (Anti-lock Braking System) Passive Features Seatbelts: 3-point inertia reel seatbelts Airbags: Driver-side airbag may have been optional or standard on later 1989 models, but not universally equipped as in modern vehicles. Body Structure: Reinforced chassis and crumple zones typical for the period. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, often with multiple speakers. Optional premium sound systems available. Instrumentation: Comprehensive analog gauges including speedometer, tachometer, oil pressure, water temperature, and voltage meter. Turbo models feature boost gauge. Driver Assistance Cruise Control: Available on most models. Connectivity Connectivity Features: Limited by era; primarily focused...
Wiring Diagrams, Component Testing Procedures, Specifications for Measurement
Special Tools:
Identification and usage of specialized Mazda tools required for specific repairs
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and assembly instructions.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotary (Wankel)
Engine Code:
13B
Configuration:
Naturally Aspirated (NA) and Turbocharged (Turbo)
Displacement:
1.3 Liters (654cc x 2 rotors)
Performance
Horsepower Na:
Approx. 145-160 hp (depending on specific market and minor revisions)
Torque Na:
Approx. 130-140 lb-ft
Horsepower Turbo:
Approx. 200 hp (Turbo II model)
Torque Turbo:
Approx. 200-210 lb-ft (Turbo II model)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Unleaded Gasoline (Octane rating specified in manual, typically 91+ for optimal performance)
Cooling System
Cooling Type:
Liquid-cooled
Lubrication System
Lubrication Type:
Oil sump with oil injection system for apex seals.
Oil Type Specification:
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for specific ambient temperature ranges).
Rotary Specifics
Apex Seals:
Critical wear components requiring specific lubrication and maintenance.
Oil Metering Pump:
Responsible for injecting lubricating oil into the combustion chambers.
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission
Features
Clutch Type:
Hydraulically Actuated, Single Dry Plate (Manual)
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (refer to manual for specific viscosity recommendations based on temperature).
Transmission Fluid Automatic:
Dexron III or equivalent ATF (Automatic Transmission Fluid)
📐 Dimensions
Exterior
Length:
Approx. 172.0 inches (4369 mm)
Width:
Approx. 68.7 inches (1745 mm)
Height:
Approx. 49.8 inches (1265 mm)
Wheelbase:
Approx. 95.7 inches (2430 mm)
Weights
Curb Weight:
Approx. 2800-3100 lbs (1270-1406 kg) depending on trim and options
Gross Vehicle Weight Rating:
Refer to vehicle's compliance plate (typically around 3700 lbs)
Cargo
Trunk Capacity:
Limited, typical for a sports coupe. Specific volume not readily available but functional for weekend luggage.
🛡️ Safety Features
Ratings
NHTSA Ratings:
As an older vehicle, specific NHTSA ratings from that era may be limited or unavailable in modern databases. The structure was designed for sporty performance.
Active Features
ABS:
Available on higher trims and Turbo models (Anti-lock Braking System)
Passive Features
Seatbelts:
3-point inertia reel seatbelts
Airbags:
Driver-side airbag may have been optional or standard on later 1989 models, but not universally equipped as in modern vehicles.
Body Structure:
Reinforced chassis and crumple zones typical for the period.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, often with multiple speakers. Optional premium sound systems available.
Instrumentation:
Comprehensive analog gauges including speedometer, tachometer, oil pressure, water temperature, and voltage meter. Turbo models feature boost gauge.
Driver Assistance
Cruise Control:
Available on most models.
Connectivity
Connectivity Features:
Limited by era; primarily focused on basic vehicle operation and entertainment. No advanced connectivity or smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, whichever comes first. High-performance rotary engines may benefit from more frequent changes.
Spark Plug Replacement:
Refer to manual; typically around 30,000 miles for standard plugs. Rotary engines often use specific long-life plugs.
Coolant Flush:
Every 2-3 years or 30,000 miles.
Timing Belt Or Chain:
Not applicable; rotary engines do not have timing belts or chains in the conventional sense.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (refer to manual for exact specification).
Power Steering Fluid:
Dexron II or equivalent power steering fluid.
Coolant:
50/50 mix of ethylene glycol antifreeze and distilled water.
Known Issues
Apex Seal Wear:
Degradation of apex seals leading to compression loss, rough idle, and reduced power. Regular proper maintenance is key.
Carbon Buildup:
Accumulation of carbon in the rotor housings and exhaust ports, potentially affecting performance and emissions. Requires periodic cleaning.
Oil Consumption:
Rotary engines naturally consume a small amount of oil for lubrication. Excessive consumption indicates potential seal wear.
O2 Sensor Failure:
Common on many vehicles of this era, affecting fuel mixture and emissions.
Vacuum Lines:
Aging rubber vacuum lines can crack and leak, leading to vacuum leaks and drivability issues.
📚 Vehicle History
Brand Heritage
Mazda Rotary Legacy:
Mazda's long and dedicated history with the Wankel rotary engine, starting with the Cosmo Sport and continuing with the RX series.
Model Evolution
Fc Generation:
Introduced in 1985, the FC RX-7 was a significant departure from the first generation (SA/FB), featuring a more modern and aerodynamic design influenced by the Porsche 944.
1989 Updates:
Minor cosmetic updates and potential refinements to the engine and suspension were common for the late FC generation.
Production
Production Years Fc:
1985-1992
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
The RX-7 (FC generation) was named to Car and Driver's Ten Best list multiple times during its production run.
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