Mazda RX-7 1991-1993 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Generation: FC (Second Generation) Model Years Covered: 1991, 1992, 1993 Codes Chassis Code: FC3S 👋 Introduction Market Position Description: The Mazda RX-7 FC generation represents a blend of sports car performance and accessible luxury, competing in the affordable sports coupe segment against rivals like the Nissan 300ZX (Z31), Toyota Supra (MkII/MkIII), and Mitsubishi Starion/Chrysler Conquest. Competitive Analysis Key Differentiator: Its signature rotary engine provides a unique driving experience, high-revving power delivery, and a distinctive engine note, setting it apart from conventional piston engines. Key Features Rotary Engine: The 13B rotary engine is the heart of the RX-7, known for its smooth operation, compact size, and high power-to-weight ratio, particularly in its turbocharged form. Handling: Lightweight construction, rear-wheel drive, and a well-balanced chassis contribute to excellent handling dynamics and driver engagement. Design: The FC RX-7 features a distinctive aerodynamic design with pop-up headlights, a sleek profile, and a driver-focused interior. 📋 Manual Details Coverage Areas Engine Mechanical: Complete teardown and reassembly, rotary engine specific components (apex seals, rotor housing, eccentric shaft), timing, diagnostics. Engine Lubrication System: Oil pump, oil cooler, oil filter, lubrication passages, oil pressure checks. Engine Cooling System: Radiator, water pump, thermostat, cooling fan operation, coolant specifications, pressure testing. Engine Control System: ECU (Engine Control Unit) diagnostics, sensor identification and testing (TPS, MAF, O2, crank angle), fuel injection strategy, ignition timing control. Fuel System: Fuel pump, fuel injectors, fuel pressure regulator, fuel filter replacement, fuel tank service, EFI system diagnostics. Exhaust System: Exhaust manifold, catalytic converter, muffler, exhaust sensors (pre-cat O2), leak detection. Accelerator Control System: Throttle body, accelerator cable adjustment, cruise control integration. Clutch: Clutch disc, pressure plate, release bearing, clutch master cylinder, clutch slave cylinder, hydraulic system bleeding. Manual Transmission: Gearbox disassembly and reassembly, gear ratios, shift linkage adjustment, transmission fluid specifications. Automatic Transmission: ATF specifications, torque converter, valve body operation, transmission control unit, diagnostic procedures. Propeller Shaft: Driveshaft U-joints, balancing, installation. Rear Final Drive: Differential assembly, gear ratios, axle shafts, seals, fluid specifications. Front Axle: CV joints, wheel bearings, hub assembly. Rear Axle: Independent rear suspension components, axle shafts, seals. Front Suspension: MacPherson struts, control arms, ball joints, sway bar, alignment specifications. Rear Suspension: Trailing arms, shock absorbers, springs, alignment specifications. Brake System: Disc brakes (front and rear), brake calipers, pads, rotors, brake fluid specifications, bleeding procedures, ABS system diagnostics. Parking Brake System: Parking brake mechanism, cables, adjustments. Brake Control System: ABS (Anti-lock Braking System) components, hydraulic modulator, wheel speed sensors, diagnostic codes. Steering Control System: Power steering pump, steering rack, tie rods, steering wheel alignment. Seat Belts: Seat belt retractors, pretensioners, inspection and replacement. Supplemental Restraint System Srs: Airbag module locations, SRS warning light diagnostics, airbag sensor calibration, replacement procedures. Body Lock Security System: Door locks, ignition switch, central locking, alarm system. Glasses Window System Mirrors: Window regulators (manual and power), door glass replacement, mirror adjustment and replacement. Exterior Interior: Body panel removal and installation, trim pieces, bumper repair, interior panel removal. Instrument Panel: Gauge cluster removal and repair, warning lights, dimmer switch. Seat: Seat removal, adjustment mechanisms, seat track maintenance. Automatic Air Conditioner: Refrigerant types, compressor, condenser, evaporator, HVAC controls, leak detection, charging procedures. Starting Charging System: Starter motor, alternator, battery maintenance, wiring diagrams, voltage and current checks. Lighting System: Headlights, taillights, turn signals, interior lighting, bulb types, fuse locations, wiring diagrams. Driver Information System: Trip computer, fuel economy display, warning indicators. Wiper Washer Horn: Wiper motor, linkages, washer pump, fluid reservoir, horn operation. Body Control System: Door actuators, power window motors, central locking control unit. Lan System: Limited coverage, likely for diagnostic communication between modules. Audio Visual Navigation Telephone System: Radio, speaker replacement, antenna, basic navigation and telephone system principles (if equipped). Auto Cruise Control System: Cruise control module, steering wheel buttons, actuator operation, diagnostics. Power Supply Ground Circuit Elements: Detailed wiring diagrams, fuse box layouts, relay functions, grounding points. Maintenance: Scheduled maintenance intervals, fluid change recommendations, lubrication points, filter replacement. Alphabetical Index: Facilitates quick lookup of specific topics and components. Page Count Estimated Pages: 1500-2500 (typical for comprehensive service manuals) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format File Format: PDF Delivery Method: Digital Download (.rar/.zip) Downloadable: Yes Printable: Yes 📖 Manual Coverage Systems Covered Engine Type: Rotary (13B-2) - Naturally Aspirated and Turbocharged variants. Powertrain: Engine, Clutch, Manual Transmission, Automatic Transmission, Driveshaft, Differential, Axles. Chassis: Suspension (Front and Rear), Steering, Brakes (including ABS), Wheels, Tires. Electrical: Starting and Charging, Lighting, Ignition, ECU control, SRS, Audio, HVAC controls, Power windows/locks, Cruise control, Wiper/Washer/Horn. Body: Exterior panels, interior trim, glass, locks, security, seats, instrument panel. Procedures Included Diagnostic Procedures: Troubleshooting flowcharts, error code interpretation, component testing using multimeter and specialized tools. Repair Procedures: Step-by-step guides for component removal, installation, adjustment, and repair, including engine rebuilds and major system overhauls. Maintenance...

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Sku: 350714

Collections: ALL Mazda

Availability: In stock

Tags: 1991 1992 1993 Car Cars Mazda RX Models RX-7

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Generation:

FC (Second Generation)

Model Years Covered:

1991, 1992, 1993

Codes

Chassis Code:

👋 Introduction

Market Position

Description:

The Mazda RX-7 FC generation represents a blend of sports car performance and accessible luxury, competing in the affordable sports coupe segment against rivals like the Nissan 300ZX (Z31), Toyota Supra (MkII/MkIII), and Mitsubishi Starion/Chrysler Conquest.

Competitive Analysis

Key Differentiator:

Its signature rotary engine provides a unique driving experience, high-revving power delivery, and a distinctive engine note, setting it apart from conventional piston engines.

Key Features

Rotary Engine:

The 13B rotary engine is the heart of the RX-7, known for its smooth operation, compact size, and high power-to-weight ratio, particularly in its turbocharged form.

Handling:

Lightweight construction, rear-wheel drive, and a well-balanced chassis contribute to excellent handling dynamics and driver engagement.

Design:

The FC RX-7 features a distinctive aerodynamic design with pop-up headlights, a sleek profile, and a driver-focused interior.

📋 Manual Details

Coverage Areas

Engine Mechanical:

Complete teardown and reassembly, rotary engine specific components (apex seals, rotor housing, eccentric shaft), timing, diagnostics.

Engine Lubrication System:

Oil pump, oil cooler, oil filter, lubrication passages, oil pressure checks.

Engine Cooling System:

Radiator, water pump, thermostat, cooling fan operation, coolant specifications, pressure testing.

Engine Control System:

ECU (Engine Control Unit) diagnostics, sensor identification and testing (TPS, MAF, O2, crank angle), fuel injection strategy, ignition timing control.

Fuel System:

Fuel pump, fuel injectors, fuel pressure regulator, fuel filter replacement, fuel tank service, EFI system diagnostics.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust sensors (pre-cat O2), leak detection.

Accelerator Control System:

Throttle body, accelerator cable adjustment, cruise control integration.

Clutch:

Clutch disc, pressure plate, release bearing, clutch master cylinder, clutch slave cylinder, hydraulic system bleeding.

Manual Transmission:

Gearbox disassembly and reassembly, gear ratios, shift linkage adjustment, transmission fluid specifications.

Automatic Transmission:

ATF specifications, torque converter, valve body operation, transmission control unit, diagnostic procedures.

Propeller Shaft:

Driveshaft U-joints, balancing, installation.

Rear Final Drive:

Differential assembly, gear ratios, axle shafts, seals, fluid specifications.

Front Axle:

CV joints, wheel bearings, hub assembly.

Rear Axle:

Independent rear suspension components, axle shafts, seals.

Front Suspension:

MacPherson struts, control arms, ball joints, sway bar, alignment specifications.

Rear Suspension:

Trailing arms, shock absorbers, springs, alignment specifications.

Brake System:

Disc brakes (front and rear), brake calipers, pads, rotors, brake fluid specifications, bleeding procedures, ABS system diagnostics.

Parking Brake System:

Parking brake mechanism, cables, adjustments.

Brake Control System:

ABS (Anti-lock Braking System) components, hydraulic modulator, wheel speed sensors, diagnostic codes.

Steering Control System:

Power steering pump, steering rack, tie rods, steering wheel alignment.

Seat Belts:

Seat belt retractors, pretensioners, inspection and replacement.

Supplemental Restraint System Srs:

Airbag module locations, SRS warning light diagnostics, airbag sensor calibration, replacement procedures.

Body Lock Security System:

Door locks, ignition switch, central locking, alarm system.

Glasses Window System Mirrors:

Window regulators (manual and power), door glass replacement, mirror adjustment and replacement.

Exterior Interior:

Body panel removal and installation, trim pieces, bumper repair, interior panel removal.

Instrument Panel:

Gauge cluster removal and repair, warning lights, dimmer switch.

Seat:

Seat removal, adjustment mechanisms, seat track maintenance.

Automatic Air Conditioner:

Refrigerant types, compressor, condenser, evaporator, HVAC controls, leak detection, charging procedures.

Starting Charging System:

Starter motor, alternator, battery maintenance, wiring diagrams, voltage and current checks.

Lighting System:

Headlights, taillights, turn signals, interior lighting, bulb types, fuse locations, wiring diagrams.

Driver Information System:

Trip computer, fuel economy display, warning indicators.

Wiper Washer Horn:

Wiper motor, linkages, washer pump, fluid reservoir, horn operation.

Body Control System:

Door actuators, power window motors, central locking control unit.

Lan System:

Limited coverage, likely for diagnostic communication between modules.

Audio Visual Navigation Telephone System:

Radio, speaker replacement, antenna, basic navigation and telephone system principles (if equipped).

Auto Cruise Control System:

Cruise control module, steering wheel buttons, actuator operation, diagnostics.

Power Supply Ground Circuit Elements:

Detailed wiring diagrams, fuse box layouts, relay functions, grounding points.

Maintenance:

Scheduled maintenance intervals, fluid change recommendations, lubrication points, filter replacement.

Alphabetical Index:

Facilitates quick lookup of specific topics and components.

Page Count

Estimated Pages:

1500-2500 (typical for comprehensive service manuals)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

File Format:

Delivery Method:

Digital Download (.rar/.zip)

Downloadable:

Printable:

📖 Manual Coverage

Systems Covered

Engine Type:

Rotary (13B-2) - Naturally Aspirated and Turbocharged variants.

Powertrain:

Engine, Clutch, Manual Transmission, Automatic Transmission, Driveshaft, Differential, Axles.

Chassis:

Suspension (Front and Rear), Steering, Brakes (including ABS), Wheels, Tires.

Electrical:

Starting and Charging, Lighting, Ignition, ECU control, SRS, Audio, HVAC controls, Power windows/locks, Cruise control, Wiper/Washer/Horn.

Body:

Exterior panels, interior trim, glass, locks, security, seats, instrument panel.

Procedures Included

Diagnostic Procedures:

Troubleshooting flowcharts, error code interpretation, component testing using multimeter and specialized tools.

Repair Procedures:

Step-by-step guides for component removal, installation, adjustment, and repair, including engine rebuilds and major system overhauls.

Maintenance Procedures:

Routine service, fluid changes, filter replacements, lubrication, belt tensioning.

Specification Data:

Torque specifications, clearances, fluid capacities, electrical component resistance/voltage values, alignment angles.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repairs.

📊 Manual Specifications

File Format

PDF Quality:

High resolution, designed for clarity and readability, often scanned from original factory publications.

Searchable Text:

Likely searchable if OCR (Optical Character Recognition) has been applied to the PDF.

Print Quality

Printability:

Designed to be printed for workshop use, often organized into printable sections.

Binding Type

Binding For Printed Version:

Not applicable for digital download, but original manuals were typically coil-bound or perfect-bound for durability.

Paper Type

Paper Type For Printed Version:

Not applicable for digital download, but original manuals used heavy-duty paper for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Code:

13B-2

Engine Type:

Rotary, Wankel

Displacement:

1.3 Liters (654cc x 2 rotor)

Performance

Naturally Aspirated Horsepower:

Approx. 160 hp @ 6500 rpm (for 1991-1993 models with 13B-2 NA)

Turbocharged Horsepower:

Approx. 200 hp @ 6500 rpm (for 1991-1993 models with Turbo II)

Naturally Aspirated Torque:

Approx. 145 lb-ft @ 4000 rpm (for 1991-1993 models with 13B-2 NA)

Turbocharged Torque:

Approx. 197 lb-ft @ 3500 rpm (for 1991-1993 models with Turbo II)

Fuel System

Fuel Injection Type:

Electronic Fuel Injection (EFI), sequential port injection.

Fuel Type:

Unleaded Gasoline (Octane rating recommendation typically 91+)

🔧 Transmission

Standard

Transmission Type Na:

5-Speed Manual Transmission

Optional

Transmission Type Turbo:

4-Speed Automatic Transmission

Features

Manual Gear Ratios:

Specific ratios available in manual (e.g., 1st: 3.483, 2nd: 2.015, 3rd: 1.310, 4th: 1.000, 5th: 0.795, Reverse: 3.115 - subject to minor variation across model years).

Automatic Transmission Model:

Typically a Jatco 4-speed automatic.

📐 Dimensions

Exterior

Length:

Approx. 169.5 inches (4305 mm)

Width:

Approx. 66.7 inches (1695 mm)

Height:

Approx. 49.2 inches (1250 mm)

Wheelbase:

Approx. 95.7 inches (2430 mm)

Weights

Curb Weight Na:

Approx. 2800-3000 lbs (1270-1360 kg)

Curb Weight Turbo:

Approx. 3000-3200 lbs (1360-1450 kg)

Gross Vehicle Weight Rating Gvwr:

Typically around 3700-3800 lbs (1680-1725 kg)

🛡️ Safety Features

Ratings

NHTSA Crash Test Results:

No specific standardized ratings readily available for this era; manufacturer testing and internal data would be primary sources.

Active Features

Anti-lock Braking System (ABS) standard on most models or as an option.

Traction Control:

Optional on some Turbo models.

Passive Features

Airbags:

Driver's side airbag standard for these years. Passenger airbag generally not standard or available.

Seat Belts:

3-point inertia reel seat belts with pretensioners.

Rollover Protection:

Reinforced A-pillars and roof structure.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player, often with optional equalizer and speaker upgrades. CD players were not standard in this era for most models.

Driver Assistance

Anti-lock Braking System was a significant technological feature for its time, improving braking stability.

Cruise Control:

Electronically controlled cruise control system, improving highway driving comfort.

Connectivity

Connectivity Features:

Limited by modern standards; primarily focused on basic car systems. No integrated Bluetooth or smartphone connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles (5,000-8,000 km) or 6 months, using high-quality synthetic oil recommended for rotary engines.

Spark Plug Replacement:

Rotary engines use two spark plugs per rotor. Replacement intervals vary, but generally around 20,000-30,000 miles. Specific types (e.g., platinum or iridium) recommended.

Air Filter Replacement:

Every 15,000-30,000 miles, or sooner if driving in dusty conditions.

Timing Belt Interval:

Not applicable (rotary engines do not have timing belts).

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 10W-30 or 10W-40 (synthetic recommended for rotary engines). Consult manual for specific weight and API classification for extreme temperatures.

Coolant Type:

Mazda recommends a 50/50 mixture of Mazda Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze) and distilled water.

Transmission Fluid Manual:

API GL-4, SAE 75W-90 gear oil.

Transmission Fluid Automatic:

Dexron III (or equivalent ATF).

Differential Fluid Type:

API GL-5, SAE 80W-90 gear oil.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Rotary Engine Apex Seals:

Apex seal wear is a common concern with rotary engines, leading to loss of compression. Regular maintenance, proper oiling, and avoiding prolonged idling or lugging the engine can extend their life. Compression testing is crucial.

Oil Metering System:

The oil metering system injects oil into the engine for lubrication of apex seals. Blockages or failures can lead to premature wear. Ensuring the oil lines are clear is important.

Turbocharger Reliability:

Turbochargers, especially on older vehicles, can experience bearing wear or seal failures. Proper warm-up and cool-down procedures are essential.

Susceptibility To Overheating:

Rotary engines generate a lot of heat. Ensuring the cooling system is in top condition, including radiator, water pump, and thermostat, is critical.

Vacuum Lines And Emissions Components:

Many vacuum lines and emission control components can degrade over time, leading to vacuum leaks and engine performance issues. Thorough inspection and replacement are often needed.

📚 Vehicle History

Brand Heritage

Mazda Rotary Legacy:

Mazda's pioneering work with the Wankel rotary engine, beginning with the Cosmo Sport and continuing through the RX series, established its reputation for innovative engine technology.

Model Evolution

Fc Generation Introduction:

The FC generation, introduced in 1985, replaced the SA22C RX-7. It featured a more aerodynamic design, independent rear suspension, and the introduction of the powerful 13B rotary engine. The 1991-1993 models represent the final facelift of this generation, often referred to as Series 5 or late FC.

Turbo Ii Introduction:

The Turbo II variant, introduced in 1986, significantly boosted performance with a turbocharged and intercooled 13B engine.

Production

Production Years Fc:

1985-1992 (though some markets received them into early 1993).

Manufacturing Location:

Mazda's Hofu Plant, Yamaguchi Prefecture, Japan.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The RX-7 (FC generation) was recognized by Car and Driver as one of the Ten Best cars in America in 1986 and 1987, highlighting its performance and handling.

Iconic Sports Car Status:

Widely regarded as a modern classic and an icon of Japanese sports car engineering, particularly for its rotary engine and driving dynamics.