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1994 Mazda RX7 Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 1994 Chassis Code: FD3S Codes Engine Code: 13B-REW 👋 Introduction Market Position Positioning: Iconic JDM sports car, celebrated for its rotary engine and performance Competitive Analysis Competitors 1994: Nissan 300ZX (Z32), Toyota Supra (Mk IV), Mitsubishi 3000GT VR-4 Key Features Engine Technology: Sequential Twin Turbo Rotary Engine (13B-REW) - unique high-revving power delivery Chassis Design: Lightweight, balanced chassis with near 50/50 weight distribution Aerodynamics: Sleek, aerodynamic body designed for high-speed stability 📋 Manual Details Coverage Areas Primary Coverage: Complete Repair & Service Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Electrical Schematics, Bodywork Page Count Approximate Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Printed Book 📖 Manual Coverage Systems Covered Engine Mechanical: Rotary Engine (13B-REW), Apex Seals, Rotors, Housing, Lubrication System, Cooling System, Ignition System, Fuel System (Sequential Twin Turbo) Engine Management: ECU, Sensors (MAP, TPS, Knock, O2), Actuators, Emissions Control Transmission: R154 5-Speed Manual Transmission, Clutch System, Driveshaft, Differential Brakes: Front Ventilated Discs, Rear Discs, ABS System, Hydraulic Lines, Parking Brake Suspension Steering: Double Wishbone Front/Rear, Power Steering System, Bushings, Dampers, Springs, Control Arms Electrical: Wiring Harnesses, Fuses, Relays, Lighting, Instrumentation, Starter, Alternator, Battery Body Chassis: Frame Structure, Exterior Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim HVAC: Air Conditioning, Heating, Ventilation, Blower Motor, Refrigerant System Fuel System: Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Lines, Fuel Filter Cooling System: Radiator, Fan, Water Pump, Hoses, Thermostat Procedures Included Routine Maintenance: Oil Changes, Filter Replacements, Spark Plug Checks, Fluid Level Checks, Belt Adjustments Engine Repair: Engine Overhaul, Apex Seal Replacement, Turbocharger Rebuild, Compression Testing Transmission Repair: Clutch Replacement, Gearbox Disassembly & Reassembly, Differential Service Brake Service: Brake Pad & Rotor Replacement, Caliper Rebuilding, Brake Fluid Flush, ABS Bleeding Suspension Steering Repair: Shock Absorber Replacement, Bushing Replacement, Power Steering Pump/Rack Service Electrical Diagnostics: Wiring Diagram Interpretation, Troubleshooting Faulty Circuits, Component Testing Bodywork Repair: Panel Replacement, Dent Repair, Door Alignment, Seam Sealing Troubleshooting Guides: Symptom-Based Diagnostics, Common Faults & Solutions Technical Depth Depth: Comprehensive (from basic maintenance to full engine rebuilds and complex electrical diagnostics) Detail Level: Detailed step-by-step instructions with torque specifications, clearances, and diagnostic values Diagnostic Tools: Includes procedures for using specialized Mazda diagnostic tools (e.g., oscilloscope, fuel pressure gauge) 📊 Manual Specifications File Format Print Quality: High-quality, durable paper suitable for workshop use Print Quality Durability: Designed for longevity in automotive repair environments Binding Type Binding: Professional perfect binding or saddle-stitched, allowing pages to lay relatively flat Paper Type Paper Stock: Matte finish, often coated paper to resist grease and dirt ⚙️ Engine Specifications Primary Engine Engine Type: Rotary (Wankel) Engine Configuration: Twin-Rotor, Twin-Turbocharged Displacement: 1308cc (effective) Bore X Stroke: 100 mm x 65 mm (per rotor) Performance Horsepower Hp: 255 hp @ 6500 RPM Torque Lb Ft: 217 lb-ft @ 5000 RPM Redline: 7500 RPM Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (EFI) Fuel Type: Unleaded Premium Unleaded Gasoline (91 Octane or higher recommended) Turbocharging Turbo System: Sequential Twin Turbochargers (Hitachi HT07-43) 🔧 Transmission Standard Type: Mazda R154 5-Speed Manual Gear Ratios 1St: 3.250 Gear Ratios 2Nd: 1.988 Gear Ratios 3Rd: 1.323 Gear Ratios 4Th: 1.000 Gear Ratios 5Th: 0.782 Final Drive Ratio: 4.300 Optional Type: None (Manual transmission only for US/JP market 1994 model) Features Clutch Type: Hydraulic Actuated, Single Dry Plate 📐 Dimensions Exterior Length: 166.9 inches (4239 mm) Width: 69.1 inches (1755 mm) Height: 47.8 inches (1214 mm) Wheelbase: 95.5 inches (2425 mm) Front Track: 58.7 inches (1490 mm) Rear Track: 58.5 inches (1485 mm) Weights Curb Weight: 3009 lbs (1365 kg) Gross Vehicle Weight Rating: N/A (Typically not specified for sports cars) Cargo Trunk Capacity: Approx. 5.7 cu ft Wheels Tires Standard Wheel Size: 16 x 7.0 inches (Front), 16 x 8.0 inches (Rear) Standard Tire Size: 225/50R16 (Front), 245/45R16 (Rear) Bolt Pattern: 5 x 114.3 mm (5 x 4.5 inches) 🛡️ Safety Features Ratings NHTSA Frontal Impact: Not rated or tested under current methodologies IIHS Side Impact: Not rated or tested under current methodologies Active Features ABS: Yes, 4-wheel Anti-lock Braking System Traction Control: Optional (may be limited to specific markets or later production years) Passive Features Airbags: Driver and Passenger airbags standard Seatbelts: 3-point inertia-reel seatbelts with pretensioners Body Structure: Reinforced safety cell, crumple zones 💡 Technology Features Infotainment Audio System: Factory fitted cassette player with AM/FM radio, optional CD player Display: Analog gauges for speed, RPM, boost, oil pressure, temperature. Digital clock. Driver Assistance Cruise Control: Standard on most models Instrumentation: Full analog cluster with tachometer and prominent boost gauge. Connectivity Connectivity Features: None (pre-dates modern connectivity standards) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles (depending on driving conditions, synthetic oil recommended) Air Filter Replacement: Every 15,000 miles or as needed Spark Plug Replacement: Every 30,000 miles (specific rotary spark plugs) Coolant Flush: Every...
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1994 Mazda RX7 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Year:
1994
Chassis Code:
FD3S
Codes
Engine Code:
13B-REW
👋 Introduction
Market Position
Positioning:
Iconic JDM sports car, celebrated for its rotary engine and performance
Competitive Analysis
Competitors 1994:
Nissan 300ZX (Z32), Toyota Supra (Mk IV), Mitsubishi 3000GT VR-4
Key Features
Engine Technology:
Sequential Twin Turbo Rotary Engine (13B-REW) - unique high-revving power delivery
Chassis Design:
Lightweight, balanced chassis with near 50/50 weight distribution
Aerodynamics:
Sleek, aerodynamic body designed for high-speed stability
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Repair & Service
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Electrical Schematics, Bodywork
Page Count
Approximate Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Printed Book
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Rotary Engine (13B-REW), Apex Seals, Rotors, Housing, Lubrication System, Cooling System, Ignition System, Fuel System (Sequential Twin Turbo)
Engine Management:
ECU, Sensors (MAP, TPS, Knock, O2), Actuators, Emissions Control
Transmission:
R154 5-Speed Manual Transmission, Clutch System, Driveshaft, Differential
Brakes:
Front Ventilated Discs, Rear Discs, ABS System, Hydraulic Lines, Parking Brake
Suspension Steering:
Double Wishbone Front/Rear, Power Steering System, Bushings, Dampers, Springs, Control Arms
Electrical:
Wiring Harnesses, Fuses, Relays, Lighting, Instrumentation, Starter, Alternator, Battery
Body Chassis:
Frame Structure, Exterior Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim
HVAC:
Air Conditioning, Heating, Ventilation, Blower Motor, Refrigerant System
Fuel System:
Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Lines, Fuel Filter
Cooling System:
Radiator, Fan, Water Pump, Hoses, Thermostat
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Spark Plug Checks, Fluid Level Checks, Belt Adjustments
Engine Repair:
Engine Overhaul, Apex Seal Replacement, Turbocharger Rebuild, Compression Testing
Transmission Repair:
Clutch Replacement, Gearbox Disassembly & Reassembly, Differential Service
Brake Service:
Brake Pad & Rotor Replacement, Caliper Rebuilding, Brake Fluid Flush, ABS Bleeding
Suspension Steering Repair:
Shock Absorber Replacement, Bushing Replacement, Power Steering Pump/Rack Service
Electrical Diagnostics:
Wiring Diagram Interpretation, Troubleshooting Faulty Circuits, Component Testing
Bodywork Repair:
Panel Replacement, Dent Repair, Door Alignment, Seam Sealing
Troubleshooting Guides:
Symptom-Based Diagnostics, Common Faults & Solutions
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and complex electrical diagnostics)
Detail Level:
Detailed step-by-step instructions with torque specifications, clearances, and diagnostic values
Diagnostic Tools:
Includes procedures for using specialized Mazda diagnostic tools (e.g., oscilloscope, fuel pressure gauge)
📊 Manual Specifications
File Format
Print Quality:
High-quality, durable paper suitable for workshop use
Print Quality
Durability:
Designed for longevity in automotive repair environments
Binding Type
Binding:
Professional perfect binding or saddle-stitched, allowing pages to lay relatively flat
Paper Type
Paper Stock:
Matte finish, often coated paper to resist grease and dirt
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotary (Wankel)
Engine Configuration:
Twin-Rotor, Twin-Turbocharged
Displacement:
1308cc (effective)
Bore X Stroke:
100 mm x 65 mm (per rotor)
Performance
Horsepower Hp:
255 hp @ 6500 RPM
Torque Lb Ft:
217 lb-ft @ 5000 RPM
Redline:
7500 RPM
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Premium Unleaded Gasoline (91 Octane or higher recommended)
Turbocharging
Turbo System:
Sequential Twin Turbochargers (Hitachi HT07-43)
🔧 Transmission
Standard
Type:
Mazda R154 5-Speed Manual
Gear Ratios 1St:
3.250
Gear Ratios 2Nd:
1.988
Gear Ratios 3Rd:
1.323
Gear Ratios 4Th:
1.000
Gear Ratios 5Th:
0.782
Final Drive Ratio:
4.300
Optional
Type:
None (Manual transmission only for US/JP market 1994 model)
Features
Clutch Type:
Hydraulic Actuated, Single Dry Plate
📐 Dimensions
Exterior
Length:
166.9 inches (4239 mm)
Width:
69.1 inches (1755 mm)
Height:
47.8 inches (1214 mm)
Wheelbase:
95.5 inches (2425 mm)
Front Track:
58.7 inches (1490 mm)
Rear Track:
58.5 inches (1485 mm)
Weights
Curb Weight:
3009 lbs (1365 kg)
Gross Vehicle Weight Rating:
N/A (Typically not specified for sports cars)
Cargo
Trunk Capacity:
Approx. 5.7 cu ft
Wheels Tires
Standard Wheel Size:
16 x 7.0 inches (Front), 16 x 8.0 inches (Rear)
Standard Tire Size:
225/50R16 (Front), 245/45R16 (Rear)
Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
Not rated or tested under current methodologies
IIHS Side Impact:
Not rated or tested under current methodologies
Active Features
ABS:
Yes, 4-wheel Anti-lock Braking System
Traction Control:
Optional (may be limited to specific markets or later production years)
Passive Features
Airbags:
Driver and Passenger airbags standard
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Body Structure:
Reinforced safety cell, crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory fitted cassette player with AM/FM radio, optional CD player
Display:
Analog gauges for speed, RPM, boost, oil pressure, temperature. Digital clock.
Driver Assistance
Cruise Control:
Standard on most models
Instrumentation:
Full analog cluster with tachometer and prominent boost gauge.
Connectivity
Connectivity Features:
None (pre-dates modern connectivity standards)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (depending on driving conditions, synthetic oil recommended)
Air Filter Replacement:
Every 15,000 miles or as needed
Spark Plug Replacement:
Every 30,000 miles (specific rotary spark plugs)
Coolant Flush:
Every 2 years or 30,000 miles
Transmission Fluid Change:
Every 30,000-60,000 miles (specific Mazda gear oil)
Brake Fluid Flush:
Every 2 years or 24,000 miles
Fluid Specifications
Engine Oil:
API SG or SH, SAE 10W-30 or 10W-40 (Synthetic recommended for rotary)
Engine Oil Capacity:
4.4 US quarts (4.2 L) with filter
Coolant:
Mazda FL22 Antifreeze/Coolant or equivalent (50/50 mix)
Transmission Fluid:
Mazda GL-4 75W-90 Synthetic Gear Oil
Differential Fluid:
Mazda GL-5 75W-90 or 80W-90 Gear Oil
Power Steering Fluid:
Dexron III ATF or equivalent
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Rotary Engine:
Apex seal wear, oil seal failure, carbon buildup in housings, prone to overheating if cooling system is neglected.
Sequential Turbos:
Failure of the secondary turbo or associated solenoids, vacuum line issues.
Fuel System:
Clogged primary injectors, vacuum leaks affecting fuel pressure.
Electrical:
Corrosion on grounds, faulty ignition coils, intermittent electrical gremlins.
Cooling System:
Leaking radiator end tanks, failing water pump, blocked oil coolers.
Part Numbers
Oil Filter Example:
Mazda: B6Y1-14-302, Fram: PH3593, Wix: 51515
Air Filter Example:
Mazda: N3A1-13-215, Wix: WA10020
Spark Plug Example:
NGK: R7437-9 (example, specific plugs vary)
📚 Vehicle History
Brand Heritage
Brand Focus:
Mazda is known for its innovative engineering, particularly its development and popularization of the rotary engine.
Model Evolution
Rx7 Generations:
First Gen (SA/FB), Second Gen (FC), Third Gen (FD)
Fd Introduction Year:
1992 (Japan), 1993 (North America)
Fd Design Philosophy:
Lightweight sports car, advanced aerodynamics, and refined rotary performance.
Production
Production Period Fd:
1992-2002
Manufacturing Location:
Hiroshima, Japan
Key Market Impact:
Highly influential in the sports car market, particularly for its rotary engine technology.
🏆 Awards & Recognition
Recognitions
Car And Driver:
Car and Driver's Ten Best list multiple times (including for the FD generation)
Motor Trend:
Often lauded in period reviews for its handling and performance.
Certifications
Epa Fuel Economy:
Approx. 15 MPG City / 20 MPG Highway (varies with driving)
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