The 1989 Mazda RX-7, designated FC3S (S5), represents a significant entry in the sports coupe segment, celebrated for its innovative rotary engine and exceptional handling. This performance-oriented vehicle, powered by a twin-turbocharged 13B rotary engine, offered a unique, smooth power delivery and a high-revving character that set it apart from competitors. Its design, featuring iconic pop-up headlights and a sleek aerodynamic profile, combined with a near-perfect 50/50 weight distribution and a sophisticated suspension system, contributed to its renowned agility and driver engagement, earning it frequent accolades in the automotive press. This comprehensive workshop service repair manual provides in-depth technical information and procedures for the 1989 Mazda RX-7. It covers all major systems, including the 13B rotary engine, turbocharger, transmission, brakes, suspension, and electrical systems, with expert-level detail suitable for complete overhauls and advanced diagnostics. The manual includes scheduled maintenance guidelines, systematic troubleshooting steps, and detailed repair instructions for components such as engine seals, turbochargers, and brake systems, ensuring owners and technicians have the resources needed to maintain and restore this performance vehicle. 🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 1989 Generation: FC3S (S5) Codes Chassis Code: FC3S Engine Code: 13B 👋 Introduction Market Position Segment: Sports Coupe, Performance Car Competitors 1989: Nissan 300ZX (Z32), Toyota Supra (Mk III), Porsche 944, Chevrolet Camaro. Competitive Analysis Unique Selling Proposition: The RX-7's rotary engine offered a unique, smooth power delivery and high-revving character unmatched by piston engines in its class, combined with excellent handling. Key Features Engine Type: Rotary (Wankel) Twin-Turbocharged Handling: Renowned for its balanced chassis, near 50/50 weight distribution, and sophisticated suspension for its era. Design: Iconic 'wind-up window' sports car design, pop-up headlights, sleek aerodynamic profile. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Page Count Estimated Pages: 1500+ Manual Type Type: Comprehensive Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Full coverage of 13B rotary engine, including assembly, disassembly, seals, apex seals, rotors, housings, and porting. Engine Management: Ignition system, fuel injection, ECU diagnosis, sensor testing (MAP, TPS, O2), emissions control systems. Turbocharger System: Detailed information on the twin-entry turbocharger system, intercooler, wastegate operation, boost control, and common failure points. Transmission: Manual transmission (Type R154 equivalent often fitted, though factory manual gearbox details are key), clutch system, driveshaft, differential. Brakes: Front and rear disc brake systems, ABS (if equipped), hydraulic circuits, master cylinder, caliper overhaul, pad and rotor replacement. Suspension Steering: Front MacPherson strut, rear independent multi-link suspension. Bushings, ball joints, shock absorbers, steering rack, power steering system. Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting, power windows, mirrors, audio system, fuse/relay locations, diagnostic connectors. HVAC: Heating, ventilation, and air conditioning system diagnosis, refrigerant handling, component replacement. Body Chassis: Body panel removal and installation, door mechanisms, glass replacement, interior trim, structural components. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug (rotary specific) replacement, coolant checks, brake fluid flush, timing belt (auxiliary belt) inspection. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault code interpretation, wiring harness troubleshooting. Engine Rebuild: Detailed steps for complete engine teardown, inspection, component replacement (rotors, seals, housings), and reassembly. Transmission Repair: Gearbox overhaul, bearing replacement, seal replacement, clutch assembly installation and adjustment. Brake Service: Disc pad and rotor replacement, caliper overhaul, brake line replacement, bleeding procedures, ABS component testing. Suspension Work: Strut replacement, shock absorber replacement, bushing replacement, alignment procedures. Electrical Diagnostics: Testing sensors, actuators, wiring continuity, component voltage checks using multimeters and oscilloscopes. Turbo Maintenance: Turbocharger inspection, wastegate adjustment, intercooler cleaning, boost leak testing. Body Repair: Panel alignment, dent repair, rust prevention, interior trim removal for access. Technical Depth Depth: Expert level. Covers complete overhaul, rebuilding, advanced diagnostics, and performance tuning considerations for the 13B rotary engine and associated systems. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text content for quick information retrieval. Print Quality Resolution: High-resolution scans, ensuring clarity of diagrams and text. Readability: Designed for clear on-screen reading and can be printed. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Mazda 13B Rotary (Wankel) Configuration: Twin-Rotor, Naturally Aspirated (non-turbo variants exist, but this manual covers the turbo model) Displacement: 1.3L (654cc per rotor x 2 = 1308cc equivalent) Aspiration: Twin-Turbocharged (Sequential Turbocharging System) Performance Horsepower Hp: 202-215 hp Horsepower Kw: 151-160 kW Torque Ft Lb: 190-200 lb-ft (approximate) Redline: 7500 RPM (approximate) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Premium Gasoline (91+ Octane Recommended) Ignition System: Distributorless Ignition System (DIS) or Distributor-based depending on exact market/spec. Lubrication Oil Type Recommendation: API SG or SH, SAE 10W-30 or 10W-40 (rotary specific oils may be beneficial, consult manual) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Type: 4-Speed Automatic Transmission (less common on...