This file is available for free download at http://www. iluvmyrx7.com This file was not scanned to deprive Mazda of any money - it was scanned due to the rareness of the original manuals and the overwhelming need of the RX-7 owner to have this information so that they can accurately troubleshoot problems, Perhaps if Mazda's dealerships could support the Rotary Engine it wouldn’t be so necessary for the owners to do so. Many thanks to Lenny Terris for scanning this.‘alarm conditions. LUBRICATION SYSTEM INDEX ‘OUTLINE ‘SPECIFICATIONS TROUBLESHOOTING GUidE OIL. PRESSURE PREPARATION « INSPECTION .... ENGINE OL INSPECTION .. REPLACEMENT OIL FILTER ....... REPLACEMENT OIL COOLER .. REMOVAL INSTALLATION OILPAN + PREPARATION - REMOVAL / INSTALLATION « ll, PRESSURE CONTROL VALVE REMOVAL INSTALLATION « METERING OIL PUMP PREPARATION ... INSPECTION .. mL PUNP DISASSENE INSPECTION Bofore beginning any service procedure, refer to the 1994 RX-7 Body Electrical Troubleshooting Manual; see section S for air bag ‘system service warnings and section J1 for audio antitheft systemD INDEX ( ENGINE 0% SPECIFICATION k- /) Rgsaseseee ~ Sees TTT ara erm a ESBS es ~@ 1.01 fiter 8.0i1pan Flaplacement .........2+.0+++ page D-7 Flomoval/ Installation ........- page D-10 2.0ll cooler 4. Metering ofl pump Flomoval/ Installation page 0-8 Inspection coves page D-14OUTLINE OUTLINE SPECIFICATIONS eet 138 Tube aa rasa i a crpee mea : toe nae — aa Be TEE, Coacaaa pee palate cana ie a a a co = a = Sater Ft one to eat a uenc ner aaa aa abt aT is to oe ee Se a aaa panaa TS aaa Westoyeaee) Lua met ea: ea Gc —T aaa 260838 oes [OETRTIN rer ies Faas Tae ta mon [Sonat arene Sai isa SN COTTA Recommended SAE Viscost = a a wenn mm fe Se econ enattampeshive angele sascontng el charge CFD ‘TROUBLESHOOTING GUIDE ‘TROUBLESHOOTING GUIDE = aa 5 as anes ae = = = ro Yee = = (eet = Eg Brae = : Tas $e = eesaeaae = 3 Ena aa : rT mon — | ie Se & Songuaal stir erstenioross apace oe ies ee = ar a = & anne Brame | % ee creer = es Seeginonaie., = a nee Bian, | See cores Exeme | = ianas Seer ae Reese | os ae a aS Sense aati! Seas at ee eect See ieee? an ee oa ioe —_fawaesaenone nee fre 2a Ot pressure cones or when egies col bce csi shat byes ah operatesOIL PRESSURE D OIL PRESSURE Warning * Continuous exposure with USED engine oll has caused skin cancer in laboratory mice. Protect ‘your skin by washing with soap and water Immediately after this work. PREPARATION ssT recta! sae obs renee INSPECTION 1. Disconneet the connector and remove the cil pressure sensor, 2. Insta tho SST. 3. Star the engine and letit warm upto operating tempera- ‘ure. 4, Runthe engine at 9,000 rpm and note the gauge reading. (Oil pressure: 340 kPa {3.5 kgt-cm?, 50 psi) min 5. Ifthe pressure snot as specified, check forthe cause and. tepair. (Rafer to Troubleshoobng Guide) 6. Remove the SST. 7. Apply sealant to tho ofl pressure sensor threads, Do not ‘allow sealant in the prossure sensor hol. 8. instal the ol pressure sensor. Tightening torque: TI-ASNem{1.1-1.6kgt-m, 8-11 ft-Ibt) 8. Connect the sensor connecter. D5| eo ENGINE OIL. ENGINE OIL INSPECTION 1.Be sure the vohicie is on lovel ground. 2! Warm up the engine onormal operating tamporature and, stop. 8. Watt or five minutos, ‘4. Remove the dipstick and check the ollevel and condition. '5.Add or roplace oll as necessary Note ‘The distance botwoen the LandF marks on the dipstick represents 1.7 L{1.8 US qi 1.5 mp REPLACEMENT ‘© When the engine and the oll are hot, they can badly ‘burn. Don't Burn yourself with elther. 1. Warm up the engine to the normal operating temperature ‘and stop it 2, Remove the ol filer cap andthe oi drain plug 53. Drain the oll into a containor 4. Install @ new gasket and the drain plug. Tightening torque: ‘30-41 Nem {3.0-4.2kgt+m,22-30ft-Ibf} 65. Refillthe engine withthe specttiod type and amount ofen- gine ol il capacity: D-6 isa monn [Nae marae sansa ea = 4 Rate ala a Rane Se ype na £8, Racheck the ol level and add olf necessaryOWL FILTER D OIL FILTER REPLACEMENT 1 Remove the ol titer by using the ol fiter wrench, 2. Using a clean rag, wipe the mounting surface of the en- gino. 8. Anply a small amountof clean engine olltothe rubber seal of the now fit 4. instal the ol fitar and tighten it unt the rubber seal con- ‘tacts tho base, and then tighten the filter an additional 1-1/6 tums by hand. nd inspect for leaks around the fiter 6. Stop the engine and check te ol level add oll if neces sary. Note © Tho factory installed ol iter and the service part ter are diferent Service oll iter capacity: 0.47 L {0.18 US qt, 0.15 Imp qt} o7D OL COOLER OIL COOLER REMOVAL / INSTALLATION 1 rn tive battry cablo. 2. Remove inthe ordor shown in the figure. 3. stalin the reverse order of removal Note (in case of two oll cooler are equipped) LH oll cooler is shown. Remove install FH ol cooler in same procedure. ® 1. Light bezel 4.0 cooler 2. Brake pipe air duct lomoval Note sss page D-9 3 Oll cooler hoses 5. Air duct (ol cooler) lemoval Noto... page D-8 D-8OIL COOLER, OIL PAN Steps After Installation Fill the engine with tho spocifid amount and type of engine ol (Reet to page D-6.) Removal Noto ‘Oil cooler hose: Rlomove the. ing a dain pan to catch th ol il cooler 1, Remove the light bezel, 21 Remove the mounting bracket nuts 3 Remove the ol cooler. ip and disconnect the oil cooler hoso, us- D OIL PAN PREPARATION a eonrso = eee ces ae lie su |* none 5 t ae Thun D9D OL PAN REMOVAL / INSTALLATION {Disconnect he negative Bator cabo. 2’ Romove th uncoreover 3. Drain the eng 4 Remove in he order shown inthe gu, rtetng to Removal Note. 5: instal in tho roveree order of removal, refering ‘Installation Note. sosusler. wi) tts 41. Undercover ‘5. Crossmombor 2 Rlomoval Note .......-.+++++ page D-11 ‘8: Engine mount bracket 6.0llpan Flemovel NOIO = ..-...-+-2++~ page D-tt Romoval Noto ....-. ppago D-11 4. Stooring gear box Installation Note IT page 0-12OIL PAN D Removal Note Engine mount bracket 1-Ascamblo the SST and connect the hook tothe front en- ‘ine hange 2. Remove the engine mounting nuts. '3. Tum the bot of the SST clockwise to lithe engine. Crossmembor 1.Remove the power steering oil hose bracket from the ‘crosemember. 2. Remove the bolts and nuts (arrows) and the crossmem- ber il pan 1. Flamove the engine mount brackets from the engine. 2’ Disconnect the ol level eanear connector and ramave it fom the hamess bracket 8, Remove the oll pan mounting bok, Caution # Pry tools can easily scratch the oll pan contact sur- faces. Prying ofthe oll pan can also easily bend the oll pan flange. Refer to the following instructions betore removing the oll pan. 4 Insorta screwdriver only betweon the points shown inthe, figure to pry the of pan loose,D OIL PAN Installation Note ll pan 4. Remove al forsign matorial from the oil pan contact sur- facas, Caution ‘Ifthe bolts are reused, remove the old sealant from the bolt threads. Tightening bolts with old sealant ‘on them may cause cracking inside the bolt holes. 2, Apply slicone soslant tothe contact surtaces ofthe oil ian and the engin sido ofthe new gasket. neta th ol pan within five minutes of applying the seat- ant Tightening torque: 8,9-11.7 Nem{90-120 kgf-cm, 79-104 in-Ibf} ‘Steps After Installation ll the engine with the spectied amount and type of engine ol. (Refer to page D-6.) D-12OIL PRESSURE CONTROL VALVE D OIL PRESSURE CONTROL VALVE ee Ce en fencae™= z nesnaee eee — INSPECTION = 1. Check each part for damage and scoring. Replace ifnec- ‘ossary. ‘2. Measure the tree length ofthe spring, and itnecessary, replace it Free length: 73.0 mm (2.87 in) D-13D METERING OIL PUMP METERING OIL PUMP PREPARATION sst sovoseans fe soto om 2 ee serDagrosis (es Sieerng Spon seecer Stet Gece ee] | Seon Sipamp sytem -Matfunctions related tothe metering oll pump may be described as electrical component problems and me ‘chanical component probioms. Electrical Component Related Problem 1. Check for sarvice codes by using ho SST. (Refer to soction F.) 2 service code No. 20, 26,27 or 37 appears, check the metering oll pump following the diagnosis chart below. Diagnosis Chart ‘Bo Nnirgalipap poion snes) | § Opener a can poionsre’ arg Pato apecon® © Chang Borst n ning swoon pore corel itaco6) ‘a aden sora 1 Dae coool ost ener cr powerian conta role Bi Wing ipompcorTaond | ® Oper rican wena bteonpoweian cone’ | Pass repecioa 7 ose ard saprig mater ‘moos o excel angst perpen ashen sean cot moti vege Fiieng ap canlepaan) | © Opn ra cveu mig betwee power roaue enseprg mee 1 tee comectovl maeng l puoorpowarsin com Soran rte rsd swarm Snel nev 3am pane ate i) 7 vata eg Tasos Control Module Terminal zTyaieTel ivf fwaslatwinfw fata eg i sal | Ey ee p14METERING OIL PUMP INSPECTION 1 Metering oll pump contro system Sepp moor eaistnce Tease ica a a alorg ar (Benda mstbe Ret) ievtagh a we? fee SSE Pe ernst-se| Opm_| 18-0 0 SBreSr St | TeAHT | Coen Ropace nara ooo = . aie [uiana ancora menses | yo (earoreaugnen —] Pepa eps wa ree Panera air noe ein akag IAG Raa) z “Top pytor wich OW nbataypuebvevetpenseadatorral a AIA | yy me no, Rains poserran coe nase sma done aspen Powortanconval medals emia aage postion sao TU itor enh OW approx 1-427 aad ral 2A | no, | le aspron 1 Vind aia? rs | no, | Race meting ot rump jes Dose ratageinseastom anor 1 Witwnatenio app 1 WVwhanacse- | NO | ring nd scr rg T= Postion sere opraon a origin ear wperesecie BCT adler p45D METERING OIL PUMP 2.Metoring cil pump positon sonsor Terese etree mina Vg and Es apoio? ‘ lotstarc ttl (Vo) ard YoY) a pce? Pesitances04-1240 || | i hare cena betwen pion ssa ord poreian anol maaan = | Ve (OR _— | no, [Repararape wit tness J YS) ar EIoRe) © T= Tames hor art Tse sot or rand baat Vo and A et waghaaat? Tepato aac wna Ree Te Consol ant tara valage ( “Tunignlon wih ON eta approx 1-42V eda awn? | wo, [Reaace maha nano argananerycmatancioraby deanery reptvebstey ete tr20%e | ves Raascoponenan nNOS Poston sensor epson —_ ane aor cnn caning napa ay abeTo Oe ismipengin un covet tepersirereatee 00 (76 atte | YER [ Rover mee ct pee ‘oe rs cnde No. 20 pen? ‘Mechanical Component Related Problem | Excassive oll consumption may be caused by a metoring oll pump malfunction. Before replacing the matoring oll pump, refer to Oil leakage" inthe Troubleshooting Guide (page D~4) and perform the electical component inspection (pages D-15 and D-16). D-16METERING OIL PUMP, OIL PUMP D Oil nozzle 1, Remove the ollnozzk tak manifol, 2. Veily that ai passesin only one direction as shown. Ifnot 50, roplace the ol nozzle from the rotor housing and the in- Ol PUMP DISASSEMBLY / ASSEMBLY 1, Disassombla in the order shown inthe figure. 2. Assemble inthe ravorsa order of disassombly refering to Assembly Note. 1. Snap ring 5. Screw 9. Front inner rotor 2. Rear outer rotor “Assombly Noto ‘Assombly Note ‘Assombly Noto coe Page D-19 Noeee Page D-18 s..-- pageD-18 §. Body 10.Key 8, Rear inner rotor 7. Genter plato 11. Shaft ‘Assembly Noto 8. Front outer rotor rrvseisrses pAgeD=18 Assembly Noto 4. Key age D-18 D-A7D-18 Ol PUMP INSPECTION 1. Inspect the ol pump parts for wear and damage. Ropiace as necessary. 2. Measure the clearance between the lobes of rotors by us: ing a fosir ga Standard clearance: (0.03-0.12 mm {0.0012-0.0047 in} Maximum: 0.15 mm {0.0059 In} 3. Measure the clearance between the outer rotor and the ‘pump bod}. ‘Standard clearan (0.20-0.25 mm {0.0078-0.098 in} Maximum: 0.30 mm {0.0118 in} 4. Inspect the side clearance of the rotors. (1) Using a straightedge and efeelor gauge, measure the depth of the rotor inthe pump body. (@) Measure the depth ofthe rotor siding surface fromthe pump mounting surface, (8) Ad these two dopth to obtain the side coaranco. (@) Itnot as specified, grind or replace the pump body. Standard end clearance: 0.03-0.125 mm (0.0012-0.0049 in} ‘Maximum: 0.15 mm (0.0069 In} ‘Assembly Noto ‘Outer rotor and inner rotor Install the front and rear outer and innar rotors so that the tally marks on the rotors face the front housing,om PUMP D ‘Sorew TE rovent tho seow tom osening, stake alto eta