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Mazda RX7 RX-7 1998 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: RX-7 Year: 1998 Generation Generation Code: FD Generation Designation: Third Generation (FD3S) Codes Chassis Code: FD3S 👋 Introduction Market Position Positioning: The 1998...
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Sku: 80698
Mazda RX7 RX-7 1998 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Year:
1998
Generation
Generation Code:
FD
Generation Designation:
Third Generation (FD3S)
Codes
Chassis Code:
FD3S
👋 Introduction
Market Position
Positioning:
The 1998 Mazda RX-7 (FD) is a legendary Japanese sports car, renowned for its distinctive styling, lightweight chassis, and unique twin-rotor rotary engine. It competed against performance icons like the Nissan 300ZX, Toyota Supra, and Porsche 911, offering a purer, more driver-focused experience.
Competitive Analysis
Competitors:
Nissan 300ZX (Z32), Toyota Supra (JZA80), Mitsubishi 3000GT VR-4, Chevrolet Corvette (C5), Porsche 911 (996).
Key Features
Distinctive Features:
Twin-rotor 13B-REW rotary engine with sequential turbocharging, lightweight construction, near 50/50 weight distribution, sophisticated suspension design, iconic 'Kodo' design language.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service, repair, maintenance, troubleshooting, and rebuilding of the 1998 Mazda RX-7 (FD chassis).
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Full Service & Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Rotary engine (13B-REW), lubrication system, cooling system, fuel injection, ignition system, emission control systems.
Transmission:
5-speed manual transmission, clutch system, drivetrain, driveshafts, differentials.
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), brake system hydraulics, parking brake.
Suspension:
Front and rear independent suspension, shock absorbers, springs, control arms, bushings, steering system.
Electrical:
Battery, charging system, starting system, lighting system, ignition switch, fuse box, relays, wiring diagrams, ECUs (Engine Control Units).
Body:
Body panels, doors, hood, trunk, interior trim, exterior trim, glass, seals, structural components.
Climate Control:
Air conditioning system, heater, ventilation, HVAC controls.
Wheels Tires:
Wheel specifications, tire pressure, mounting, and balancing.
Procedures Included
Maintenance:
Routine maintenance, fluid changes (oil, coolant, brake fluid), filter replacements, spark plug service, timing belt (if applicable), drive belt inspection and replacement.
Repair:
Engine repair and overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical component diagnosis and repair, body panel repair.
Troubleshooting:
Diagnostic procedures for common issues, fault code interpretation, symptom-based troubleshooting guides.
Rebuilding:
Detailed instructions for engine apex seal replacement, rotor housing lapping, and other rotary-specific rebuild procedures.
Installation:
Component replacement and installation procedures for all major systems.
Technical Depth
Depth:
In-depth technical information, including detailed diagrams, torque specifications, diagnostic flowcharts, and component specifications, suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely searchable text-based PDF for easy navigation and information retrieval.
Print Quality
Print Readability:
Designed for clear viewing on screen and suitable for printing individual pages or sections.
Binding Type
Binding:
N/A (Digital PDF download)
Paper Type
Paper:
N/A (Digital PDF download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
13B-REW
Engine Type:
Rotary (Wankel)
Configuration:
Twin Rotor, Naturally Aspirated (initially), Sequential Twin-Turbocharged
Displacement:
1308 cc (654 cc x 2 rotors)
Performance
Horsepower Ps:
255 PS (188 kW; 252 hp)
Horsepower Hp:
252 hp @ 6500 rpm
Torque Lb-Ft:
217 lb-ft @ 5000 rpm
Redline:
8000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Premium Gasoline (91 octane or higher recommended)
Turbocharging:
Sequential twin-turbocharging system (smaller turbo for low-end response, larger turbo for high-end power).
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (RWD)
Optional
Type:
None offered for the 1998 model year in most markets.
Features
Clutch:
Hydraulically actuated clutch
Final Drive Ratio:
4.30:1 (typical)
📐 Dimensions
Exterior
Length:
166.9 inches (4239 mm)
Width:
69.1 inches (1755 mm)
Height:
48.2 inches (1224 mm)
Wheelbase:
95.2 inches (2418 mm)
Ground Clearance:
4.7 inches (119 mm)
Weights
Curb Weight:
approx. 2900-3000 lbs (1315-1361 kg) depending on trim and options
🛡️ Safety Features
Ratings
NHTSA Driver Frontal:
Not explicitly rated or commonly published for this era of specialized sports car.
IIHS Crash Test:
Not typically tested by IIHS in the same manner as mainstream vehicles.
Active Features
ABS:
Standard Anti-lock Braking System
Passive Features
Airbags:
Driver and Passenger front airbags
Seatbelts:
3-point inertia-reel seatbelts
Structure:
Reinforced safety cell, front and rear crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player and cassette deck, speakers typically located in doors and rear deck.
Climate Control Type:
Manual or automatic climate control (depending on trim level), featuring A/C and heater.
Driver Assistance
ABS:
Standard Anti-lock Braking System provides enhanced control during braking.
Traction Control:
Optional or standard on certain models, providing enhanced stability and grip.
Connectivity
Bluetooth:
Not available on the 1998 model. Aftermarket solutions are common.
Navigation:
Not available from the factory. Aftermarket navigation systems are a popular upgrade.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first. Frequent oil changes are crucial for rotary engines.
Spark Plug Replacement:
Recommended every 15,000-30,000 miles (24,000-48,000 km) for specific rotary spark plugs. The 13B-REW uses two plugs per rotor.
Coolant Change:
Every 2 years or 30,000 miles (48,000 km).
Fluid Specifications
Engine Oil:
API SG or SH, SAE 10W-30 or 10W-40. High-quality synthetic oil is highly recommended for rotary engines. Check owner's manual for specific viscosity based on climate.
Coolant:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water. Mazda Genuine FL22 coolant or equivalent. Capacity: Approx. 7.9 US quarts (7.5 Liters).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid:
API GL-4, SAE 75W-90 gear oil. Capacity: Approx. 2.1 US quarts (2.0 Liters).
Differential Fluid:
API GL-5, SAE 80W-90 gear oil. Capacity: Approx. 1.2 US quarts (1.1 Liters).
Known Issues
Apex Seals:
Wear and failure of apex seals is a common concern for high-mileage rotary engines, leading to loss of compression. Regular maintenance and proper break-in procedures are crucial.
Oil Consumption:
Rotary engines naturally consume oil as part of their lubrication system. This manual will detail the correct amount and how to monitor it.
Cooling System:
Overheating can be an issue if the cooling system is not meticulously maintained, due to the concentrated heat of the rotary design. Thorough inspection of radiators, hoses, and water pump is vital.
Fuel Injectors:
Clogging or failure of fuel injectors can impact performance and engine health.
Emission Controls:
The sequential turbo system and associated emission control components (e.g., air pump, EGR) can require specialized troubleshooting and maintenance.
📚 Vehicle History
Brand Heritage
Mazda Rotary Heritage:
Mazda has a long and iconic history with the rotary engine, beginning with the Cosmo in the late 1960s. The RX-7 lineage represents the pinnacle of Mazda's rotary development for production sports cars.
Model Evolution
Generations:
First Generation (SA/FB: 1978–1985), Second Generation (FC: 1985–1992), Third Generation (FD: 1991–2002). The 1998 model falls within the final, most refined generation (FD).
Production
Production Years Fd:
1991-2002
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Car and Driver magazine listed the RX-7 on its '10Best' list for multiple years, recognizing its performance and handling capabilities.
Motortrend Car Of The Year:
While not winning Car of the Year, the RX-7 consistently received praise and accolades from automotive journalists for its engineering and driving dynamics.
Iconic Sports Car Status:
Widely considered one of the most iconic Japanese sports cars of the 1990s, celebrated for its unique rotary engine and driving experience.
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