Mazda RX-7 FD 1992-2002 Workshop Manual

This comprehensive workshop manual provides in-depth technical information, maintenance procedures, and repair instructions for the Mazda RX-7 FD 1992-2002. Covering both stock and modified versions, it includes detailed guides on the 13B-REW rotary engine, twin-turbo system, suspension, electrical wiring, and drivetrain. With step-by-step instructions, wiring diagrams, and troubleshooting tips, this manual is essential for mechanics, restorers, and RX-7 enthusiasts looking to maintain or enhance their vehicle’s performance.

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1. Engine (13B-REW) - main problems

🚨 Apex Seals

Wear out after 80-120 thousand km.

Symptoms: loss of compression, difficult cold start, unstable engine operation.

✅ Maintenance: Use high-quality oil, regularly check compression.

🚨 Engine overheating

Due to insufficient efficiency of the cooling system.

May lead to deformation of the rotor housing and destruction of seals.

✅ Maintenance:

Install a more efficient radiator and oil cooler.

Check the coolant level.

🚨 Excessive oil consumption

13B-REW burns oil by design (1 liter per 1000-1500 km).

Low oil level = engine failure.

✅ Maintenance:

Check the oil level every 1000 km.

Use mineral oil 10W-40 or 15W-50 (synthetics are not recommended).

🚨 Sequential Twin-Turbo System

The turbos work alternately, but over time the vacuum lines fail.

Symptoms: loss of power, detonation, dips during acceleration.

✅ Maintenance:

Check the vacuum lines.

Regularly clean the intercooler and intake tract.

Possibly replace the system with a single-turbo (if reliability is needed).

2. Cooling and coolant system

🚨 Thermostat and water pump malfunctions

Over time, they may fail, which will lead to overheating.

✅ Maintenance:

Check the condition of the water pump.

Replace the coolant every 2 years.

🚨 Jammed radiator fan

If it does not work, the engine may overheat.

✅ Maintenance:

Check the operation of the fan and relay.

3. Electrics and wiring

🚨 Faulty sensors (TPS, MAF, temperature sensor)

Failure causes unstable engine operation.

✅ Maintenance:

Check the sensors if problems with idle or dynamics appear.

🚨 Generator problems

The RX-7 FD generator is weak and may not cope with additional loads.

✅ Maintenance:

Check the battery charge.

It is possible to install a reinforced generator.

4. Transaxle and Transmission

🚨 Wear of synchronizers

Especially in 3rd and 4th gear during aggressive driving.

✅ Maintenance:

Use high-quality transmission oil (MT-90 or similar).

🚨 Increased clutch wear

The factory clutch is weak for tuning.

✅ Maintenance:

Check the fluid level in the hydraulic drive.

When tuning, install a reinforced clutch.

5. Suspension and steering

🚨 Wear of silent blocks and ball joints

Multi-link suspension, expensive to repair.

✅ Maintenance:

Check the condition every 20-30 thousand km.

Use polyurethane silent blocks (for durability).

🚨 Leaks in the steering system

The power steering starts to leak over time, especially in cold climates.

✅ Maintenance:

Check the power steering fluid level.

Use high-quality ATF oil.

6. Body and corrosion

🚨 Rust on arches, sills and bottom

RX-7 has weak anti-corrosion protection.

✅ Maintenance:

Do anti-corrosion treatment every 2-3 years.

Monitor the condition of the drainage holes.

✅ Oil (10W-40 / 15W-50) - check every 1000 km.

✅ Coolant - change every 2 years.

✅ Spark plugs (BUR9EQ / BUR7EQ) - change every 15-20 thousand km.

✅ Turbine vacuum lines - check every 10 thousand km.

✅ Condition of apex seals - check compression every 20-30 thousand km.

✅ Suspension and steering - diagnostics every 20 thousand km.

✅ Anti-corrosion treatment - every 2-3 years.